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17 83 88
17 83 88
1, 83–88
Department of Production Management and Engineering, Warsaw University of Life Sciences – SGGW
Summary. The paper describes the design process of digester THE INITIAL DESIGN ASSUMPTIONS
biogas tanks.The analysed issues include:the construction as- OF THE DESIGNED BIOGAS PLANT
sumptions related to construction of the biogas tank shell, design
of the roof, the thermal insulation, the selectionof inlet and outlet The analyzed design of a digester biogas tank shall
pipes used for the substrate transport. be intended for a biogas plant located on the premises of
Key words: biogas, calculation, project. an agricultural farm dealing with cattle production. The
farm shall, instead of storing it in a tank, use the manure
in the proposed digester biogas tank and process it into
INTRODUCTION biogas. It was assumed that the farm owned 200 animals.
The substrate for biogas production is cattle slurry. The
Fermentation tank is the central part of any biogas plant. operation of the biogas plant will be based on a single-stage
It is there that the input material (substrate) is broken down technology, mesophilic (35°C) utilizing wet fermentation.
and biogas is produced. In order to create a design for a fer- The fermentation chamber was designed as a vertical one
mentation chamber a number of assumptions must be made with a biogas tank in the form of a roof membrane [3, 6].
including the type and quantity of substrates used and the Sometimes other design philosophies for biogas tanks are
installation type. On the basis of the above-mentioned data, utilized, e.g. gas cushions [4].
it is necessary to assess the efficiency of a biogas energy
plant [9, 10]. A number of additional assumptions must also CALCULATION OF ENERGY YIELD
be made in relation to the finishing elements of the tank.
The digester biogas tanks may be manufactured from sheet Calculations of the quantity of methane produced and
metal, ferro-concrete, plastics. They are mostly cylindrical the energy yields were realized using the designed calculator
in shape, may be submerged in soil, free-standing or placed (Fig. 1).
horizontally on foundations [2].
DETERMINATION OF plant
LOAD VOLUME Chamber’s Volume load – BR Hydraulic Retention
Fig. 1. Calculation of biogas yield in the designed [own elaboration] volume – [m3] [kg d.o.m./m3/d] Time – HTR [d]
IN THE FERMENTATION TANK
700 11,2 70
Determination of load volume in the fermentation tank 750 10,5 75
When choosing the size of the fermentation chamber the
aim is not to achieve a total decomposition of the organic 800 9,8 80
When choosing the size of the fermentation chamber the aim is not to achieve850 a total 9,2 85
material in order to maximize biogas production. This would
decomposition ofrequire
the organic
a verymaterial in order
long storage to maximize
of substrate in thebiogas
chamberproduction.
and 900
This would 8,7 90
therefore the need for extremely large tanks [7]. In order to 950 8,3 95
require a very long storage of substrate in the chamber and therefore the need for extremely
1000 7,9 100
verify the resultant volume of the fermentation chamber it
arge tanks [Myczko 2011]. to
is necessary Indetermine
order to its verify
volume the loadresultant volume
parameter, of theSorce:
which fermentation
own elaboration
informs what quantity of dry organic mass highest
(d.o.m.) biogas
should production is achieved for the volume read at the crossing point of BR and
chamber it is necessary to determine its volume load parameter, which informs what quantity
be fed for every square meter of the chamber’s HTR volume.
lines.This
The graphOn the basis
shows that of results presented
a threshold in the
value for table (Table
rector's volume 1) is 300 m3. Above this
there
of dry organic mass (d.o.m.) should be fed for every square meter of the chamber's volume.
parameter is also used in order to estimate the optimal bio- was created a graph (Fig. 2) which presents the relation between
value the volume load decreases and the retention time increases. For the analyzed project the
This parameter is gas alsoproduction
used in order[1, to
11]. It is calculated
estimate the optimal using the following
biogas the volume load
production [Curkowskii in. and the hydraulic retention time. The highest
highest 3
biogas production is achieved for the volume read at the crossing poi
equation (1). optimal value was biogas
assumed at 250 m
production is.achieved for the volume read at the cross-
2009, Scholwin 2006]. It is calculated using the following equation (1).
ing point of BR and HTRgraph
HTR lines. The lines.shows that a threshold
The graph shows thatvalue for rector's volume is 300 m
a thresh-
𝑚𝑚 ∙𝑠𝑠.𝑚𝑚.𝑜𝑜.
𝐵𝐵𝑅𝑅 = 𝑉𝑉 , (1) (1) old value for
valuerector’s volume
the volume load is 300 mand
decreases 3
. Above this value
the retention the
time increases. For the analyz
𝑤𝑤𝑤𝑤𝑤𝑤.
volume load decreases
optimal andassumed
value was the retention
at 250 m3time
. increases. For
where: where: the analyzed project the optimal value was assumed at 250 m3.
𝐵𝐵𝑅𝑅 - volume load B [kg – volume load [kg d.o.m./m /d],
R d.o.m./m /d];
3 3
where: where: (𝛾𝛾𝑓𝑓𝑓𝑓 𝜌𝜌𝑛𝑛 +𝛾𝛾𝑓𝑓 𝜌𝜌𝑤𝑤 𝑦𝑦)𝛾𝛾𝑛𝑛 𝑟𝑟 Ta b l e 3 . Parameters of roof membranes [www.czystaenergia.pl]
𝑡𝑡𝑠𝑠,𝑒𝑒 = (5)
𝜌𝜌𝑛𝑛 - computational ρn –overpressure
computational in overpressure
𝑓𝑓𝑑𝑑𝑑𝑑in
the gas space
𝛼𝛼⊥the gas space of the tank
of the tank with a fixed roof or weight (own) Polyester – internal PVC – external
where: with a fixed roof or weight (own) of a floating roof di- Parameter load-bearing layer covering layer
of a floating roofvideddivided by tank’s
by the the tank's cross-section
cross-section areaarea
(with(with a tank
a tank withwithUnit
fixed roof with
weight 900 g/m2 900 g/m2
𝜌𝜌𝑛𝑛 - computational overpressure in the gas space of the tank with a fixed roof or weight (own)
hydrostatic test fixed
𝜌𝜌𝑛𝑛 =0),roof
withwith hydrostatic
exploitation test =0),𝜌𝜌with
conditions exploitation
𝑛𝑛 = 100 [kPa]; Maximal tearing
4700 N/5cm 4200 N/5cm
of a floating roof divided by
conditions = the
100tank's
[kPa],cross-section area (with a tank withstrength fixed roof with
y - distance from the upper edge of the shell (in case of a floating roof - from the maximal
hydrostatic ytest
– d𝜌𝜌istance from the upper edge of the shell (in case of Maximal puncture 4500 N/5cm
𝑛𝑛 =0), with exploitation conditions 𝜌𝜌𝑛𝑛 = 100 [kPa]; 4000 N/5cm
liquid level) to a floating
level: 100roof
mm–over fromthe
thebottom
maximal edge of alevel)
liquid dimensioned
to level: shell band, when it
strength
y - distance from the 100 upper edge the
mm over of the shelledge(in case of a floating roofshell- from
Gasthe maximal < 200 (cm3/(m2 d < 450 (cm3/(m2
permeability
is connected via groove weld or bottom 300 mm in case of a dimensioned
of a band connected via end-jointing
band, when it is connected via groove weld or 300 mm (Methane) bar) d bar)
liquid level) to level: 100 mm over the bottom edge of a dimensioned shell band, when it
[m]; in case of a band connected via end-jointing [m]; Fire rating DIN
B1
is connectedC1via groove weld
– corrosion allowance mm in case of a band connected 4102
or 300[PN-B-03210], via end-jointing
C1 - corrosion allowance [PN-B-03210];
[m];
𝛼𝛼⊥ - should be assumed 𝛼𝛼⊥ =1 [PN-B-03200];
C corrosion allowance [PN-B-03210];
𝛾𝛾𝑓𝑓1 -- load coefficient [PN-B-03210];
𝛼𝛼⊥ - should be assumed 𝛼𝛼⊥ =1 [PN-B-03200];
𝛾𝛾fn - pressure load coefficient in the gas area of the tank with overpressure [PN-B-03210];
𝛾𝛾𝑓𝑓 - load coefficient [PN-B-03210];
𝛾𝛾n - destruction consequence coefficient for hazardous and flammable liquids [PN-B-03210];
86 KAROL TUCKI, MAREK KLIMKIEWICZ, PIOTR PIĄTKOWSKI
A - pipe's cross-section area [m2];
V - substrate flow speed [m/s], [Gradziuk 2003].
Both membranes will be attached to the angle section A – pipe’s cross-section area [m2],
topping the tank, between the internal membrane and the V – substrate flow speed [m/s], [5].
applied angle section there will be a seal of foamed DailyEPDM
substrate flow Daily substrate
Q was flowusing
calculated Q wasequation
calculated using equation (8):
(8):
rubber [www.essentracomponents.pl]. The capacity of the
𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀
gas membrane should be from ¼ to 2 daily biogas yields. Q = 𝑞𝑞 , (8) (8)
The project assumes that the biogas tank with the part of the
fermentation chamber not filled with substrate where: will be able where:
to hold ½ of a daily biogas production. Annual production of M
Msub - substrate mass – substrate mass stream [kg/d],
sub stream [kg/d];
biogas read from the calculator is about 87 178.18 m3/y and q – density of 3substrate [kg/m3].
q - density of substrate [kg/m ].
the operating
of the biogas plant time ofa the
is 8000 hours biogas
year, plant is333
i.e. about 8000 hours
days. a year,
The On the
dailyi.e.production basis of calculations the value of Q was achieved
of biogas
about 333 days. The
3 daily production of biogas will therefore at 10 [m3/d], i.e. 0.00016 [m3/s]. When substituting and trans-
will therefore be about 262 m3 . According to the literature sources [Szlachta 2006] biogas
be about 262 m . According to the literature sources On [12]
the basis
bio- offorming
calculations
equationthe(7),
value of Q was
the target pipe’sachieved [m3/d],
at 10area
cross-section was i.e. 0.00016 [m
3
powłokowych według Eurokodów. ZK2014 – Kon- 15. PN-B-03210: 1997 Konstrukcje stalowe. Zbiorniki wal-
strukcjemetalowe/Metal Structures, Kielce-Suched- cowe pionowe na ciecze. Projektowanieiwykonanie.
niów, Poland, 1-4. 16. www.askotech.com.pl/produkt_08_122.html -katalog rur.
9. Roszkowski A., 2006.: Agriculture and fuels of the fu- 17. www.czystaenergia.pl/pdf/biogazexpo2013/14a.pdf.
ture, TEKA Kom. Mot. Energ. Roln., Vol. 6, 131-134.
10. Schenkel Y., Crehay R., Delaunois C., Schummer J., PROJEKTOWANIE ZBIORNIKA KOMORY
2003.: The agricultural sector and bioenergy production. BIOGAZOWEJ
TEKA Kom. Mot. Energ. Roln, Lublin, Vol. 3, 228-235. CZ. 2.: PROCES PROJEKTOWANIA KOMORY
11. Scholwin F. i inni, 2006: Biogaz – Produkcja i wyko- FERMENTACYJNEJ
rzystanie, InstitutfürEnergetikumwelt GmbH, 1-176.
12. Szlachta J., 2006: Możliwości pozyskania biogazu rol- Streszczenie. Opisano proces wyznaczania parametrów geo-
niczego jako odnawialnego źródła energii, 1-32. metrycznych komór biogazowych. Przeanalizowano założenia
konstrukcyjne odnoszące się do budowy płaszcza zbiornika bio-
13. Ziółko J., Włodarczyk W., Mendera Z., Włodar-
gazowego, rozwiązanie konstrukcji dachowej projektowanego
czyk S., 1995: Stalowe konstrukcje specjalne. Arkady,
zbiornika, izolację termiczną zbiornika oraz dobór przewodów
Warszawa. doprowadzającego i odprowadzającego substrat wykorzystywa-
14. Ziółko J., 1986: Zbiorniki metalowe na ciecze i gazy. ny do produkcji biogazu.
Arkady, Warszawa. Słowa kluczowe: biogaz, obliczenia, projekt.