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WHIRLER CENTRIFUGALS PVT. LTD.
GST : 24AAACW1729R1ZX

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Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant

Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant Specification

Production Capacity
Biogas: up to 100 m3/tonne feedstock/day

Motor Power
Typically 3-11 kW per feeder/mixer, modular

Frequency
50 Hz / 60 Hz

Efficiency (%)
Up to 85% organic matter reduction

Temperature Range
Ambient to 55 C (mesophilic and thermophilic operation)

Usage & Applications
Biogas generation, organic fertilizer production, renewable energy, agricultural waste valorisation

Automation Grade
Fully Automatic

Driven Type
Electric

Installation Guideline
On-site assembly, modular installation, includes commissioning and operator training

Speed
Fully automated with adjustable processing speed

Model No
Customizable as per client/order

Accessories
Solid/liquid mixer, process liquid tank, biogas scrubber, chiller/condenser, CHP unit, flaring system

Type
Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant

Material
Corrosion-resistant structural grade steel, industrial plastic, reinforced concrete (as per module requirement)

Computerized
Yes

Automatic Grade
Fully Automatic

Control System
PLC / SCADA-based automated control panel

Drive Type
Electric motor driven feeders, mixers, and liquid pumps

Voltage
380-480 V (three-phase)

Power
Custom configuration, typical 30 kW-500 kW based on plant size

Weight (kg)
Varies by design, typically 20,000 kg and above

Dimension (L*W*H)
Modular, customizable (e.g., 15m x 12m x 6m for 5 TPD system)

Color
Industrial grey/yellow or customizable

Capacity
From 1 TPD up to 500 TPD (Tons Per Day)

Features
Plug flow dry digestion, integrated biogas cleaning, full automation, energy recovery, solid digestate management

Surface Finish
Industrial grade epoxy paint, anti-corrosive coating

Machine Type
Plug Flow Scrubber-Integrated Anaerobic Digester

Power Consumption
1.5-4% of recoverable energy per tonne input

Operational Mode
24x7 continuous, requires minimal operator intervention

Digestion Type
Dry anaerobic (batch/continuous plug flow fermenter)

Digestate Management
Solid digestate output for composting/fertilizer

Biogas Cleaning
Integrated biological scrubber, chiller/condenser, CO2 removal/upgrading

Emission Management
Emergency flare for excess biogas

Liquid Recirculation
Process liquid/effluent recirculation with heating/mixing

Thermal Energy Output
Heat recovery for process and facility heating

Process Flow Colors
Yellow: Raw biogas, Brown: Solid manure/digestate, Blue: Process liquid/water, Green: Clean biogas, Red: Heat recovery

Sulfur Removal
Biological scrubber for H2S desulfurization

Safety Features
Gas leakage sensors, overpressure/temperature cutoffs

Feedstock Input
Animal manure, crop residues, organic agriculture waste (>15% TS)

Biogas Utilization
Upgraded biomethane for combined heat & power (CHP) or grid-injection

Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

About Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant

This **Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant** is a state-of-the-art waste-to-energy solution designed to process high-solids agricultural residues. Utilizing a robust horizontal plug flow reactor, the facility ensures the continuous, efficient decomposition of crop waste, straw, and manure.

A key feature of the plant is its integrated gas scrubbing system, which purifies raw biogas by removing impurities such as hydrogen sulfide, yielding high-quality biomethane. Engineered as a fully operational, ready-to-run (turnkey) system, it is optimized to maximize thermal energy output for direct heating or industrial applications. By transforming low-value agricultural waste into a reliable source of green heat, this plant offers agri-businesses an economically viable pathway to reduce waste management costs, lower carbon emissions, and advance circular agricultural practices.

Plug Flow Dry Digestion Technology

This system uses a plug flow dry anaerobic digestion process, allowing high solids organic feedstocks (animal manure, crop residues, etc.) to be efficiently converted into biogas. The dry batch or continuous operation ensures maximum flexibility and high organic matter reduction, achieving efficiencies of up to 85%. This design makes it ideal for farms and agro-industrial applications with diverse waste streams.

Integrated Biogas Cleaning & Upgrading

An integrated biological scrubber efficiently removes hydrogen sulfide (H2S) and other contaminants, while the chiller/condenser unit cools and dries the biogas. Additional CO2 removal and upgrading systems deliver high-purity biomethane suitable for grid injection or CHP units. This comprehensive cleaning ensures the biogas meets strict quality and safety standards.

Automated Operation & Robust Safety

Equipped with PLC/SCADA-based automated control panels, the plant operates continuously with minimal operator intervention. Electric motors drive the feeders, mixers, and pumps, while safety features-including gas leakage sensors and overpressure/temperature cutoffs-ensure safe and reliable operation around the clock. The modular design supports easy on-site installation and expansion.

FAQ's of Turnkey Thermal Energy Agricultural Residue Plug Flow Scrubber-Integrated Anaerobic Digester Plant:

Q: How does the plug flow dry anaerobic digestor process agricultural residue and animal manure?

A: The plug flow digestor uses dry anaerobic digestion to process agricultural residues, animal manure, and organic waste with more than 15% total solids. The feedstock moves through the fermenter in a continuous or batch plug flow, where microorganisms break down organic matter, producing biogas and solid digestate.

Q: What biogas cleaning technologies are integrated into the plant?

A: The plant includes a biological scrubber to remove hydrogen sulfide (H2S), a chiller/condenser for cooling and drying biogas, and a specialized system for CO2 removal and biomethane upgrading. The result is high-quality, clean biogas suitable for grid-injection or combined heat and power generation.

Q: When and where can this modular plant be installed?

A: The modular, customizable design enables installation at farms, agro-industrial sites, or any location generating agricultural/organic wastes. On-site assembly, commissioning, and operator training are provided, allowing rapid deployment and scalability to meet varying input capacities from 1 TPD to 500 TPD.

Q: What are the main benefits of using this integrated digester plant?

A: Key benefits include efficient renewable biogas generation, organic waste valorization, reduced environmental emissions, automated 24x7 operation, high organic reduction rates, production of high-value solid organic fertilizer, and energy recovery for use in facility heating or electricity generation.

Q: How is digestate managed and utilized after biogas production?

A: The solid digestate output from the digester is suitable for composting or direct use as an organic fertilizer, providing a valuable byproduct that supports sustainable agriculture and closes the nutrient loop.

Q: What safety features are incorporated into the system?

A: Comprehensive safety is ensured through gas leakage sensors, overpressure and temperature cutoffs, and an emergency flare system for controlled release of excess biogas. The plant is constructed from corrosion-resistant materials and features a robust industrial-grade protective coating for long-term reliability.

Q: What level of automation and operator intervention is required?

A: The fully automatic system is operated via a PLC/SCADA-based control panel. Most functions-including feeding, mixing, liquid recirculation, and process monitoring-are automated, requiring only minimal operator oversight, primarily for routine checks and performance monitoring.

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