How we build
Our modular approach blends cutting-edge tech with experience, ensuring profitable solutions and fostering enduring partnerships.
![reactor tanks from above](https://bigadan-web.imgix.net/images/General/reaktortanke.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=500&q=90&w=400&s=b5c8e18d7563f586235da5f0b14a44d1 400w, https://bigadan-web.imgix.net/images/General/reaktortanke.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=750&q=90&w=600&s=c0fc2dbd45d5033eae81e266250255fc 600w, https://bigadan-web.imgix.net/images/General/reaktortanke.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1000&q=90&w=800&s=07ded61bdabc6f67b7e8d2677527d5f0 800w, https://bigadan-web.imgix.net/images/General/reaktortanke.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1250&q=90&w=1000&s=b3d335f13e125db481ae1fa73a3f1e42 1000w, https://bigadan-web.imgix.net/images/General/reaktortanke.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1500&q=90&w=1200&s=24a76793e80df98027915ecafedbc6a6 1200w)
A proven and modular concept
The Bigadan concept ensures that we construct some of the world’s most modern plants, all while it keeps our oldest biogas plants operational today — thanks to continual expansions and modernizations for optimized biogas yields. The modular approach ensures swift construction and provides the flexibility for future expansions.
![tanks](https://bigadan-web.imgix.net/images/General/5K4A4259.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=400&q=90&w=600&s=9af28bab1f79a8fe0bf388bf1d72e805 600w, https://bigadan-web.imgix.net/images/General/5K4A4259.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=533&q=90&w=800&s=3ec4c4fa27bf3fd528a1fcc137d2cda5 800w, https://bigadan-web.imgix.net/images/General/5K4A4259.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=667&q=90&w=1000&s=8ee49c95688b5777e637b93601eb2ce3 1000w, https://bigadan-web.imgix.net/images/General/5K4A4259.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=800&q=90&w=1200&s=1389f0d89bfc171e7cefe085aabed0ef 1200w)
![tanks on a biogas plant](https://bigadan-web.imgix.net/images/General/5K4A3976.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=400&q=90&w=600&s=7ef74c372cbc1aaff75c5e78e3ce86ec 600w, https://bigadan-web.imgix.net/images/General/5K4A3976.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=533&q=90&w=800&s=5d11c7d92373b893741698ae54e58fc9 800w, https://bigadan-web.imgix.net/images/General/5K4A3976.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=667&q=90&w=1000&s=1577dc74ddabc038ed26b16d4876656f 1000w, https://bigadan-web.imgix.net/images/General/5K4A3976.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=800&q=90&w=1200&s=61a187e47837d79a8d4f6987b1a9862c 1200w)
We operate within three concepts
Agriculture
We’re working directly with farmers and associates in the agricultural field to create circular biogas ecosystems and improved utilisation of nutrients-rich fertiliser.
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
Our metropolis concept is directed at large cities and helps them create, ensure and nurture efficient waste treatment for the local production of circular energy for the entire power grid.
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
We create local ecosystems in close partnership with leading companies on a global scale. The aim is to make use of their organic waste and lower their carbon footprint.
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.
![pipes](https://bigadan-web.imgix.net/images/General/5K4A4267.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=500&q=90&w=400&s=a7d994ffe13efeeb8bb4b702499b2de7 400w, https://bigadan-web.imgix.net/images/General/5K4A4267.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=750&q=90&w=600&s=f58010393ffade6f6b9a1e27e9180271 600w, https://bigadan-web.imgix.net/images/General/5K4A4267.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1000&q=90&w=800&s=a77c4cc53e1600e5d767574d44c570e6 800w, https://bigadan-web.imgix.net/images/General/5K4A4267.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1250&q=90&w=1000&s=7bfd6ca2c0419ad233ad7d73a2fcd8b5 1000w, https://bigadan-web.imgix.net/images/General/5K4A4267.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1500&q=90&w=1200&s=f112e117ca9cc67e6eb468cec80fb123 1200w)
Plant highlights
Standardized for plants ranging from 250-2500 t/day, Bigadan's design incorporates:
- Advanced reception with fine-tuning and pre-sorting equipment.
- EU-compliant pasteurization stages.
- Efficient heat exchange systems for reliable process heating and recovery.
- Corrosion-resistant tank designs up to 9,500 m³.
- Modular technical units.
- Biological gas and odor purification.
- Efficient separation techniques.
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
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
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
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.
![Employee in a lab](https://bigadan-web.imgix.net/images/General/5K4A3875.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=267&q=90&w=400&s=4c2281a6c489e6859e55072241d4307b 400w, https://bigadan-web.imgix.net/images/General/5K4A3875.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=400&q=90&w=600&s=e605793aa4a47f1b32b812325fd2a632 600w, https://bigadan-web.imgix.net/images/General/5K4A3875.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=533&q=90&w=800&s=914d28972b35f0f099a42c8d7115193d 800w, https://bigadan-web.imgix.net/images/General/5K4A3875.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=667&q=90&w=1000&s=ea13af8e433d4e90c70fffb523a31282 1000w, https://bigadan-web.imgix.net/images/General/5K4A3875.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=800&q=90&w=1200&s=9e4e63c15604e707af4e8ec1526c8691 1200w)
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