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Eggersmann Recylingtechnology

BEKON Plug-Flow Fermenter

Continuous Process

Continuous fermentation is a robust process in which particularly large quantities of biogas are constantly produced. Pre-shredded biomass is fed into the digester by means of a feeding screw, where it decomposes into a liquid slurry under anaerobic conditions. 

The Process

As only the process water contained in the biomass is used for liquefaction in this process, it is a dry fermentation process – for wet fermentation, additional water must be added. In the fermenter, the material is regularly mixed by paddle agitators , thereby stimulating the exchange of substances and the release of gas. Mixing mainly takes place vertically in order to avoid the formation of layers of sinking and floating components. The substrate is optimally homogenised by the paddle agitators and uniform fermentation is achieved. The finished fermented substrate is discharged using a digestate pumping system. Exactly as much fresh biomass is added to one end of the elongated fermenter as fermentation residue is removed from the other end. As a result, the substrate automatically moves from the input to the output, creating a continuous fermentation process with a particularly high biogas yield.  

A. · Digester unit · B. Dewatering hall · 1. Gas-tight feeding screw · 2. Paddle agitators · 3. Agitator drives (outside) · 4. Substrate level · 5. Headspace · 6. Gas venting connection · 7. Discharge piping · 8. Digistate pumping system · 9. Dewatering presses

Advantages of the process

The process offers the following advantages:

  • Highest biogas production
  • Highest economic efficiency 
  • High degree of automation 
  • High safety standard
  • Highest plant availability
  • Simple operation
  • Base load-capable energy generation
  • Low energy requirement

Gas-tight Feeding Screw

  • Automated material infeed

Paddle Agitators

  • Low energy consumption 

Digistate Pumping System

  • Automated material extraction

Compost and Liquid Fertiliser

The continuous process produces pumpable fermentation residues, which can be dewatered or directly composted with sufficient waste or structural material, depending on the system concept. After dewatering, the liquid part can be utilised agriculturally as liquid fertiliser, while the solid part or the underwatered digestate is used to make compost. We recommend using the digestate mixer (BRT HARTNER DM) to produce a homogeneous and structured mixture for composting. Biogas, liquid fertiliser and compost – the full potential of biomass can be unfolded through continuous fermentation.

Customised Solutions

Similar to discontinuous fermentation, the continuous process also allows the creation of customised solutions according to the required plant capacity. This means that the fermenter size can be adapted to the substrate quantity. Fermenters with a capacity of 25,000 to 50,000 tonnes per year are reasonable – beyond this, the construction of additional fermenters parallel to the first is recommended. This means that there are no limits to the plant capacity. New fermenters can be added in the event of an increased volume.

Plant Structure

1. Central Logistics Hub · 2. Storage Bay · 3. Loading Crane · 4. Dosing Bunker · 5. Conveyer Belts · 6. Covered Maintenance Corridor · 7. Digester Unit · 8. Feeding Screew · 9. Drive with Torque Arm · 10. Paddle Agitator · 11. Sampling Nozzle with Temperature Sensor · 12. Manhole · 13. Gas Venting Connection · 14. Dewatering Hall · 15. Digistate Pumping System · 16. Dewatering Presses · 17. Decanter · 18. Material Discharge for Composting