How we build
How we build
Our modular approach blends cutting-edge tech with experience, ensuring profitable solutions and fostering enduring partnerships.
We operate within three concepts
Agriculture
The main basis of our biogas plants is what we define as the agriculture concept – because it is fundamental to have the agricultural sector as a biomass supplier and digestate offtaker. The agriculture biogas plant consist of tanks and equipment from biomass reception to the digestate leaves the plant again, and treatment and utilization of the biogas.
Metropolis
The metropolitan concept, that builds on food waste biomasses, adds several other processes to the plant, for separation of the impurities such as plastic, glass, metal etc. from the biomass. The food waste will undergo a pre-sorting, before it is pumped to the first pre-storage tank and down the process a further separation of the heavy impurities. Finally, the digested biomass will be separated for the smallest impurities, before it is stored for leaving the plant.
Industry
The industrial concept of the biogas plant, is with biomasses arising from industrial waste of many kinds. E.g. slaughterhouse waste which often need a certain pre-treatment due to its many different consistencies. Solid industrial wastes from e.g. food production is also a typical biomass – this can often be handled with a solid intake system, as described in the agricultural section, but with modifications.
The key components we use
Our reception tanks has a capacity of up to 800 m³. They’re all designed for the management of primarily liquid biomass, but can also handle a certain proportion of solid biomass. The reception and pre-storage tanks together serve as storage units, especially for days when fresh biomass isn't delivered. Additionally, they come with large receiving hatches for direct tipping of solid biomass and boast efficient, adjustable agitators.
Additional info:
- Short construction time of 2-3 weeks under optimal conditions.
- Robust construction
- Effective and adjustable mixing
The solid intake system is arranged in a hall for reception and storage of the solid biomass where a front loader and/or portal crane “transports” the biomass to the intake system. The intake system consists of a feed mixer, which pre-mix the biomass, before it is fed to a combined shredder and liquid/solid mix pump that mixes the solids into a liquid stream, directly to the digester tanks.
Additional info:
- Flexible design
- Effective shredding
- Handling of foreign matters
This is used for the preprocessing of biomass that requires pasteurization. Biomass is heated to a minimum of 70°C for at least 60 minutes, in compliance with EU's by-product regulation no. 1069/2009. The system balances heat consumption through heat recovery between untreated and treated biomass. This approach not only mitigates odor issues but also leads to 10-20% increased gas production and enhanced dewatering of digested biomass.
Additional info:
- Heat regain of the 70° C pasteurized biomass
- Containment of odour
Our specially designed counterflow spiral heat exchangers are meant for heat recovery and the warming of all kinds of biomass. The design, unchanged for years, ensures a high flow capacity, large paths that reduce blockages, and efficient heat transfer.
Additional info:
- High capacity: 35-40 m³/h
- Limited pressure loss
- Excellent heat transfer with no blockage
- Minimal struvite deposition
- High level of stability
- Can be delivered in 6-meter modules
These are the main process tanks where biogas is produced by breaking down the organic materials in the biomass. They are maintained at a constant temperature between 39°C (mesophilic) and 52°C (thermophilic) and function both in primary and secondary digestion stages. The tanks are constructed with minimal crane use and can be set up in just 8-10 weeks under optimal conditions. Notably, the top of the tank is made of stainless steel to prevent corrosion, and it also features a top-mounted mixer developed and produced by Bigadan.
Additional info:
- The roof and upper section of the tank are made of stainless steel to prevent corrosion
- A small monitoring house on the side of the reactor allows for inspection of the biomass surface
- A top-mounted agitator ensures more efficient and energy-saving mixing of the biomass
The digested biomass is stored in these tanks before further processing or collection. These tanks typically come with a gas storage unit on top, ensuring that any residual gas potential in the biomass gets captured.
Additional info:
- Combined design is more cost-effective than building a separate gas storage.
- Collection of residual gas
- Side mounted agitators ensure easy service
The gas system works as a self-operating low-pressure system, pushing the gas by the pressure built up in the digester tanks towards the gas storages and the gas blowers.
Additional info:
- Largely self-operating; gas blowers are only used for increase of the pressure towards consumers and the emergency flares.
- Automatic load-control to consumers according to the gas storage filling
- Removal of the acidic H2S, either by water scrubbing and biological treatment, active carbon filters or by adding iron chloride to the biomass.
These specialized tanks store unique liquid biomass, usually of industrial origin, with a high gas potential. This allows for balancing the varying gas production over days and weeks, depending on the availability of standard biomass.
Additional info:
- Heated tank and pipes prevent the biomass from going viscous or solid
- Reliable external heating – no heating components inside the tank
- Acid resistant stainless steel allow many industrial biomasses
Bigadan's specialized system cleans the air from the reception and mixing tanks, as well as the reception hall and other odorous areas. Key features include:
- Effective removal of hydrogen sulfide through a dual filtration process.
- Utilizes a primary filter and a main filter with outstanding filtration properties.
- Achieves significant reduction of unpleasant odors by targeting hydrogen sulfide and other sulfur compounds.
Biogas typically contains 0.2-0.4% hydrogen sulfide, which has a corrosive effect on CHP engines. The most effective way to remove this is with a bio-scrubber, which purifies the gas. Bigadan offers comprehensive biogas filters for this purpose, boasting multiple benefits:
- It notably extends the lifespan of CHP engines by preventing corrosion.
- Ensures a high degree of operational reliability, reducing over 90% of hydrogen sulfide.
“We recently completed the construction of the largest shared facility in western New York. We decided to work with Bigadan; primarily because we trusted their proven technology more than others”
Robert Blythe
CEO, Synergy LLC, USA
Though our concept is proven, our close collaborations drive us to optimize biogas production continually. At our on-site test plants, we explore the potential of new biomasses. Drawing from our experience and our trusted suppliers, we ensure cost-effective quality while staying ahead in innovative designs.
Do you want to learn more?
Our dedicated team of sourcing experts are ready to inform you or help you move further in your journey. Reach out today and we’ll get back to you as soon as possible.