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Product Line Up
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Biogas Systems
Biogas technology
MT-Energie’s biotechnology is based off of a two part, continuously running
system. Because of this three tanks are needed: a 1st digester, 2nd digester
and storage tank.
The main difference between our system and a classical two step process is
that the first digester and second digester are run under the same
conditions. The atmosphere in the digester is almost oxygen free. The
substrate has a constant temperature in the mesophilic range (40-42°C or
104-107°F) and a neutral pH range (6.7-7.5).
The advantage of this system is the maximization of gas production. In the
second step an additional 20% of the gas is extracted.
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Biogas – the multi-use resource
 Biogas
is a mixture of gases that is produced through the microbial digestion of
organic substance in the absence of oxygen. It consists of 50 to 70% methane
and 30 to 50% carbon dioxide. Furthermore biogas also contains trace gases
such as nitrogen, ammonia and hydrogen sulphide.
Combined heat and power plants (CHP) transform high-quality biogas into
electricity and heat. The operator can produce electricity to send out into
the electricity grid or use it for his/her own purposes.
Stables, houses, industrial and trade structures, and other buildings can be
heated with the heat produced from the CHP. With mounting energy prices,
biogas will be increasingly used to directly heat boilers.
The substances that are suitable for the biogas plant include renewable
materials such as corn and sunflowers. Also, solid and liquid manure have
been widely used for biogas production. In particular, biogas offers a great
deal for large dairy farms, which can easily use the readily available
liquid manure to create energy. The manure can be pumped directly from its
collection point into the biogas plant.
The environmentally harmful methane emissions from the manure are
drastically diminished after their use in the biogas plant. Organic wastes,
which have no more reuse possibilities what so ever, can be fed in. The only
important thing is that the organic material does not contain, or has as
little as possible, lignins (woody structured materials)
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Performances
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Turn-key systems
If you want to
produce biogas successfully and profitably, you will need an
experienced partner. Such as MT-Energie.
In our opinion, the planning and construction of biogas systems and
all subsequent support should be provided from a single source. This
is why we offer you a complete services package to safeguard
successful operation of a biogas system.
Project development - Project planning
Profitability analysis
- Biological input analysis
- Plant rating (tank size, input system, plant output)
- Financial aspects
- Profitability analysis (liquidity/profitability)
Technical analysis
- Site planning with a view to possible expansion
- Support with permit planning
- Support with planning gas and electricity feed aspects
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Project development
Feasibility
analysis and profitability analysis
We provide qualified advice already during the planning phase to
ensure that your biogas system will be tailor-made exactly to your
needs and situation. We draw up a feasibility analysis in advance to analyse the profitability
and liquidity of a biogas project.
Although we use tried-and-tested components from series production and
construct complete systems as far as possible, every single project always
demands an individual approach. Our experts inspect the situation on site
and analyse the operation process. While planning the project, we also give
consideration to possible future expansion.
Permit
It takes a lot of experience as well as time and paper to collate the
complete permit documents. We compile the permit application regardless of
whether an order is finally placed.
This reduces the time it takes from the initial idea through to actual
operation of your plant.
Our workforce includes a range of experts who are familiar with all the
official procedures and who all work closely together. Our architects,
technical draughtsmen and civil engineers put the documents together swiftly
and react flexibly to possible changes. The uniform structure of our biogas
systems also helps to accelerate the procedure.
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Project implementation
1. Constructing the digestion line
You receive a complete digestion line consisting of a two-stage
biogas system using MT components throughout, from the solids feeder
through to the residue storage tank. Oversized components and
buildings produce no yield but only cost money. By contrast, our
"slim" approach keeps the investment costs as low as possible. And
in spite of that, the systems can be expanded later on with a
manageable outlay.
2. CHP and transformer
The combined heat and power plant is not one of our own components.
But thanks to our many years of practical experience, we are very
well able to judge which CHP goes best with your biogas system.
Framework agreements with the suppliers safeguard our access to the
best units on the market.
3. Initial commissioning
- Computer-aided system control
- Safety on a gas-producing system
- Biological principles of the digestion process for various
different substrates
- Start-up procedure
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MT-Aftersales-Service
1. Biological process support
The basic prerequisite for optimum operation of a biogas system is a
stable digestion process. Here MT-ENERGIE offers the service of biological process
support based on the experience gained in looking after 300 biogas systems.
Our laboratory with its analysis procedures is capable of detecting the
early stages of possible problems in the process and helps to avoid major
difficulties by permitting specific intervention. In addition, on-going
biological process support makes a contribution to clear improvements in gas
yield and thus also in the profitability of your biogas system.
2. Maintenance and service
After a plant has been successfully commissioned, we still maintain close
contact with the operators. Our service staff help you to observe the
maintenance intervals, and are available to you 24/7 via a telephone hotline
and also personally on site.
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Farm based biogas plants
In order to enable small farms to reduce greenhouse gas
emissions for a reasonable cost, MT-Energie has developed a single-stage
biogas plant (up to 500kW) that is specially designed to use solid and
liquid manure (slurry) as the input feedstock. Since liquid manure breaks
down far more rapidly than materials such as maize silage, our one-stage
biogas plant makes for a far more attractive concept from an economic
standpoint. Owing to the use of a high proportion of liquid manure, the
substrate from the fermenter contains only minute residual gas potential –
and thus there is no reason to invest in a post-fermentation system.
Existing outdoor slurry storage tanks can be integrated into biogas plants
as post-fermentation systems. The fermenter empties itself out periodically
via an overflow element. A helical rotor pump is installed to reduce the
fluid level in the event the system needs to be serviced.
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Crude biogas plants
Biogas plants whose input mainly consists of silage
derived from maize, whole plants or grass generally use a continuously
operating two-stage decomposition process that is far slower than the
process used in a one-stage slurry based plant.
The biomass can remain in the two-stage system for a longer time, thanks to
an integrated post-fermenting unit whose environmental conditions for the
bacteria are the same as those in the fermenter.
This, in turn, enables us to ensure that a maximum amount of gas is produced
from input materials that take longer to break down, since up to 20 percent
of the possible gas yield is generated during this second stage. For maximum
efficiency, two-stage plants are generally the better choice for plants
greater than 500 kW.
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Biowaste biogas plants
Anaerobic digestion of biowastes is capable of conferring
multiple environmental and socio-economic benefits. As society faces
bio-waste as a resource, biowastes are diverted from landfills. Throughout
digestion, not only is biogas generated, but biowaste is also transformed to
digestate which contains significant fertiliser value. Therefore, anaerobic
digestion offers the unique possibility of reduced emissions, renewable
energy generation
and biowaste recovery by closing the natural biological circle and
converting waste into high quality fertiliser.
Biowastes can come from innumerable sources such as households or the food
processing, slaughterhouse or catering industries. Therefore, biowaste
biogas plants are individually planned according to legal requirements.
Waste reception, storage, milling and hygenisation are designed on the base
of the expected volume and characteristics of the input. Pre-treated waste
is then digested in a two-stage biogas plant.
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MT Components
Professional solutions for biogas systems –
developed by MT-Energie
You can rely on our designing and system planning engineers: they have many
years of experience in developing components for biogas systems.
Furthermore, they pay special attention to what practical users say. Regular
contact with our customers results in an on-going flow of highly varied
practical experience that is ploughed back directly into the development
process. This combination has resulted in numerous successful components and
detailed concepts which have become accepted branch standard today.
Our aim is to make the processes as simple, efficient and safe as possible.
The key components which we have developed in our company and coordinated
exactly to each other, play a major role in the success of our systems that
operate with above-average economic efficiency.
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MT-Alligator
The new MT-Alligator and MT-Alligator plus solids feeding
systems enable the supply of difficult substrates into the biogas plant. In
the dosing tank the solids are transported to the screws by a hydraulic,
sensor-monitored push floor system.
The MT-Alligator is equipped with a double screw system and is therefore the
ideal solution for substrates which are moderately difficult to convey. The
MT-Alligator plus has a triple screw system and can therefore process
substrates which are difficult to convey.
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MT-Fortis
The well-proven MT-FortisŪ solids feeding system is
naturally still included in our range and features a number of perfected
details. This system has a single screw system and is particularly suitable
for substrates which are easy to transport such as corn silage.
The MT-Fortis solids feeding system serves to supply the biogas plant with
biomass such as silage or solid manure which cannot be pumped. The dosing
tank is a holding tank which can be easily filled with a suitable loading
vehicle. In the tank a hydraulic push floor transports the solids to the
screw system. This routes the solids to the digester. The system records and
documents all components and dosed quantities.
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MT-EasyLift
In practice the height of the submersible motor-driven
stirring device is adjusted by means of a manually-operated cable winch.
Operators adjust the mixers infrequently as this involves a great deal of
time and physical effort. In addition, it is difficult to assess the
difference in height and it is almost impossible to stipulate the set mixer
height exactly.
With the MT-EasyLift the height of the mixers can be modified simply and
quickly. This system, with its hydraulic drive and control lever operation,
does not require any physical effort, which makes work a lot easier. The
operator can adjust the height of the mixer by means of a scale mounted on
the lift and can position the mixer exactly in the tank.
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MT-GasManager
The MT-GasManager actively controls the flow of gas
between the tanks of a biogas plant. The system controls the supporting air
pressure between the weather protection foil and the gas collector foil. The
existing storage volume is more efficiently utilised, especially in
multi-tank systems, which has many advantages for plant operation.
The new system permits intelligent management for requirement-based storage
and distribution of biogas within the plant, enabling MT-Energie to set
global standards in biogas technology.
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MT-Mixator
The new MT-Mixator optimises the well-proven screw-based
MT solids feeding system. This new system ensures regular and efficient
biogas plant operation.
Recirculated material is flushed directly from the digester through a pipe
into the stuffing screw of the solids feeding system. At the same time, non-pumpable
substrates such as silage and solid manure are fed into the stuffing screw,
which then acts as a mixing screw.
Solids and recirculated material are then already mixed when fed into the
digester.
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MT Mixing Technology
The MT mixing equipment stirs the substrate in the tank
regularly and reliably. The special cable and gear unit protection system
ensures high operational reliability with low maintenance and servicing
costs. The angle and height of the mixers are infinitely adjustable from the
outside.
The MT cable protection system prevents cable damage resulting from
tractional forces which may occur, for example, due to floating layers. It
also prevents damages caused by mixer propellers or cable clips.
The simple and reliable MT gear unit protection system prevents penetration
of fermenting substrate into the mixer. Leaks are reliably detected.
Maintenance times can be selected as required, permitting long maintenance
intervals.
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MT Double Membrane Cover
Open, round tanks can be sealed gas-tight with the MT
double membrane cover. The overall system comprises two conically cut,
overlapping foils and a special foil clamping rail.
The outer membrane provides effective and durable protection against the
weather, the inner foil serves as a flexible gas collector. This membrane
moves up and down depending on the gas production – the collection volume
for the produced biogas therefore automatically increases or decreases.
An external supporting air blower creates a slight overpressure between the
two conical membrane. This keeps the weather protection membrane in form and
exerts a system pressure on the gas collector membrane. The gas filling
level can be easily read from an externally mounted indicator.
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Technical Service
We are your No.1 for servicing - And not just for MT
plants!
You can rely on us even after the start up phase of your biogas system. With
the help of remote monitoring we can track, constantly if necessary, the
changes of your biogas system. This allows for constructive cooperation
between system operators and our team here at A biogas plant is a complex
technical system, which cannot function properly without regular servicing.
Therefore MT-Energie places high priority on supporting plant operators
after the construction of their plant.
Our service team takes care of more than 500 biogas plants – not of all
which have been constructed by MT-Energie. There are also a large number of
operators of biogas plants, which have been delivered by other
manufacturers, who trust in our service competence.
Preventative servicing by MT-Energie allows scheduled maintenance to be
carried out and ensures high availability of your biogas plant. Our
customers seem to be very happy with our services: A survey, which was
carried out by top agrar magazine (issue March 2010) amongst operators of
biogas plants, showed MT-Energie to be the manufacturer with the highest
customer satisfaction ratings.
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MT Expert Teams
Control Technology
Efficiency is the core criterion for each biogas plant. Gas loss, in
particular, results in tangible yield reduction.
Is your plant gas-proof?
Our methane detector quickly and reliably detects leaking methane. This is a
decisive advantage of preventative leak detection.
Are you recognising today the faults of tomorrow?
The PROFIBUS analyser allows MT-Energie experts to detect faults of the
control system. Our specialist measuring devices for monitoring the grid
quality and pipeline status are able to localise potential faults at an
early stage.
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MT Service Packages
MT-Energie operates a flexible service concept, which
ranges from individually commissioned services to a full maintenance
contract. Customers can choose the required performances according to their
personal requirements and preferences.
Maintenance contracts by MT-Energie comprise three performance levels:
1. The MT basic contract includes a visual and functional check of the
biogas plant.
2. The MT partner contract includes the performances of the MT basic
contract plus spare parts, services and maintenance work.
3. The combined package contains the performances of the MT basic contract
or MT partner contract plus process biology support/consulting.
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Control Centre
Your contact in the event of an emergency
You can get hold of the MT-Energie service team at all times by contacting
our control centre. Therefore, in the event of an emergency, you will be
guaranteed optimum support at any time of day or night. Our Zeven-based
control centre is able to log onto your plant at any time. This way we can
call-up protocols and localise error messages. Via remote diagnosis, our
experts can give targeted control instructions for operating the plant so
that your biogas plant will be up and running as soon as possible. This
feature will save you both time and money.
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Process Biology
There are reasons that we put so much emphasis on the
realistic calculations of economic profitability before we truly take on a
project. One should always be kept in mind: a biogas plant is not the same
as a wind turbine or a solar collector.
The deciding factor as to whether a biogas system is a success is the
biology. The profitability is tightly coupled with the stability and
effectiveness of fermentation process, independent of what substrate is
used.
Our process biology specialized team, MT-GENIUS, advises the system
operators of over 300 systems. Because the basis of the biological process
is the same, we also test numerous systems that were not built by us.
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MT-Biomethan: the new perspective
Many biogas plants that turn gas into electrical power
on location work without an optimised heat concept that would substantially
increase the biogas plant’s total yield.
Not every biogas plant is located next to an industrial center with
potential heat consumers. In many cases, there is no way to utilise
generated heat for profit.
This means that biogas electrification directly on site is inefficient in
many cases. A more effective solution would be to turn the gas into
electrical power in such a way that both the electrical power and the heat
produced can be used to maximise efficiency. Since biogas consists of 50–60%
methane, and methane is the main component in natural gas, the natural gas
supply is an obvious candidate for transporting biogas. However, biogas
needs to be refined for it to meet the criteria set for natural gas.
There are virtually no limits to the opportunities for using high-purity
refined gas. There are already options available for using this high-value
energy carrier by feeding it into the public natural gas supply for firing
CHP plants at the ideal location.
- Centralised utilisation from decentralised generation will represent a
fundamental requirement on future energy carriers that biomethane already
fulfills.
- Around half of Germany’s energy is used as heat. Biomethane is an ideal
fuel for this purpose.
- Biomethane used as a fuel in converted vehicles represents the replacement
fuel of the future.
- Energy storage capabilities accomplished by liquefaction provides new
economic and ecological possibilities.
- CO2-neutral manufacturing and highly efficient utilisation of biomethane
will make a substantial contribution to climate protection.
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Visit the online stand of MT Biomethan on EXPO21XX
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