Innovative and self-sufficient: a micro-biogas plant in Poland sets new standards

A 50 kW micro-biogas plant designed to industrial standards was set up on a dairy farm with around 300 cows. The plant, designed and built by Integrotech sp. z o.o., has a unique technical feature: while most agricultural biogas plants shut down automatically in the case of a power grid failure, this one can continue to operate completely autonomously off grid.

“We aim to educate the market and investors on the expectations they should have towards biogas plant contractors, ensuring that such installations serve not only as distributed sources but also as stable and autonomous energy systems – an aspect of particular importance in Poland given the increasing geopolitical challenges”, explains Piotr Łuczak, CEO of Integrotech sp. z o.o.

Highest quality standards

Integrotech opted for the highest quality and reliability in all components and suppliers and relied on SUMA to provide the agitation technology. The SUMA GIANTMIX FR 4 SP long axis agitator is used in the 630 m³ fermenter. It was precisely designed to meet the requirements of the tank using CFD flow simulation. Thanks to its high adjustability vertically up to +/- 30° and horizontally up to +/- 25°, it homogenizes the substrate ideally and prevents both floating and sinking layers. In addition, the GIANTMIX Z3 HY stationary was installed in a fixed position. The permanently installed tractor-driven agitator can be operated via the PTO shaft of agricultural machinery, thus providing additional backup for the operation of the biogas plant, as requested by the operator.

“Integrotech originates from the gas energy sector, where very high standards of design, construction, and operation apply. Therefore, our objective was to transfer these standards to the agricultural biogas market. Therefore, our engineers selected equipment and system solutions based on quality, operational flexibility, ease of maintenance, and overall lifetime costs. Within this design approach, SUMA agitators proved to be the optimal choice, as confirmed by the plant’s operational performance to date”, adds Piotr Łuczak.

Digitally controlled plant operation

The entire plant is controlled by an automated system developed by Integrotech: all operating parameters, from process temperature and fill levels to gas quality, can be monitored via an app.

The plant impressed from the outset: with an availability of around 95 percent, the micro-biogas plant is one of the most powerful in its class. Between 20-35 percent of the electrical energy generated is used for process purposes and for the farm and household consumption. In addition, the plant’s residual heat is used to heat the farm buildings and the farmer’s home and to stabilize the fermenter temperature, even under harsh winter conditions with temperatures as low as -18 °C. The remaining share of electrical power (65-80 percent) is fed into the public grid. The digestate produced is used as a nutrient-rich agricultural fertilizer.

“As with all components, our customer opted for the highest quality in choosing the SUMA long axis agitator, thereby benefiting from stable operation, easy maintenance, and high efficiency. It is no coincidence that this micro-biogas plant is recognized as a flagship project in Poland and was deservedly awarded gold at this year’s Ferma, an important agricultural fair focusing on livestock farming in Poland. I am very pleased that we were able to support the project,” says Mirosława Dyjak-Wojciechowska, Managing Director of SUMA Polska.

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