Efficiency Increase by Real-Time Analysis
Real-time measurement with NIRS reports all relevant parameters continuously for process control in a biogas facility. This enables optimal feeding control, indicates critical fermenter conditions and makes it possible to perform complete remote monitoring and control of the plant. The increase in the total output of the plant depends on numerous coefficients. Each particular of these coefficients can determine the economic success or failure, and therefore each should receive attention from the plant operators. Each measure follows the principle of efficiency increase: more output from the same input or the same output from less input.
The notable improvements in economic performance by enhanced efficiency are exhibited in three typical examples from a biogas plant with 500kW output:
Dry Weight Content of the Silage
Within a silo the dry weight content typically varies about 10%. This fluctuation has substantial influence on the daily gas yield, but cannot be determined by conventional laboratory analysis. With real-time NIRS the dry weight content of silage can be measured continuously and used for controlling the plant in order to obtain an even gas yield and fermentation rate. The economic impact of this optimization can be up to €30,000 annually.
Residual Gas Potential
A conventionally operated plant obtains a very good efficiency value, leaving about 5-10% residual gas. In order to reach the technically-feasible 3%, continuous monitoring of the plant is necessary. Real-time NIRS measures the dry material in the fermenter and post-fermenter, which is directly related to the fermentation rate. A reduction in residual gas of 1% means a savings of approximately €15,000 annually. Additionally process risk is minimized by this monitoring.
Plant Standstill
Certain individual metabolites of the fermentation process can inhibit the process itself, and in some extreme cases, cause the process to cease. In such a case, a plant stoppage can mean a loss of €70,000 and several weeks’ production in a 500kW plant. By monitoring organic acids in real-time, NIRS can reduce the risk of such an incident.
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