biogas/agriculture brochure

Product Solutions for your Success!

L I Q U I D M A N U R E T E C H N O L O G Y

A N A E R O B I C D I G E S T I O N T E C H N O L O G Y

The Boerger Product Solutions_US_Boerger 22.01.13 10:03 Seite 1

In the beginning of the 1990s we gained traction in the agricultural market

place with our newly designed rotary lobe pump. Important technical

characteristics determined our success. For example our MIP-Design

(Maintenance In Place), enabling fast and easy access and / or

replacement of all product wetted parts, including our patented rotor tips.

With the new era of anaerobic digestion plants in Europe, now also a

global phenomenon, our rotary lobe pumps gained a high reputation in

this field. The installation of highly profitable anaerobic digestion plants

began with the arrival of energy crop based systems. New problems

developed with dry cellulosic material built up in fermentation and

storage tanks. All elastomer based rotary positive displacement pumps

including the rotary lobe technology experienced high wear rates caused

by the extremely abrasive material. The goal was to develop a modified

rotor technology for this fibrous application.

Many end users might have thought, typical Börger: problem identified,

problem solved - in an amazingly simple and exclusive way. The Premium Rotor,

which had already been invented for magma applications in sugar mills, was the inspiration for both, the elastomeric

Optimum Rotor, and the new Premium Profile Rotor. As the name suggests, profiles have been incorporated into the rotor.

The milled grooves ensure that the pumped fluid with fibrous media itself becomes part of the rotor surface, ensuring an

improved sealing line between suction and discharge side of the pump unit. The fibrous parts of the fluid are basically

used as sacrificial wear items. In contrast, the Premium Profile Rotor itself shows only limited abrasion problems, even in

long term use. The Börger Rotary Lobe Pump with the Premium Profile Rotor is already well established in the anaerobic

digestion market as the biogas pump, and has gained a significant market share.

We offer customer based solutions with Börger Biogas Pumps and have

proven that the cost effective, modular design of our Rotary Lobe

Pumps is well suited for difficult applications in anaerobic

digestion plants. They run and run and run….

Recently, in one of the largest biogas plants

worldwide, Börger successfully replaced

previously installed rotary lobe pumps

of another supplier with our Biogas

Pumps featuring the Premium

Profile Rotor.

The Börger Biogas Rotary Lobe PumpSimple, Robust, Durable and Cost Effective

R O T A R Y L O B E P U M P S

Detail of Premium Profile Rotor


Powerful Biogas Pump for Continuous Operation:Unrivalled Ease of Maintenance

A Solid Pump with a well thought out Modular Design

The timing gear assembly represents a cantilevered shaft design.

The gear unit is a sealed component housed in a one piece Block

Casing. The gear wheels with a high safety factor and the oversized

bearings combined with the heavy duty gear casing complete the

robust timing gear platform of the Börger Rotary Lobe Pump. The

intermediate chamber incorporates a clear separation between

timing gear and pump casing. This integrated, high volume and

lubricant filled quench and control chamber provides a high degree

of safety and is supplied by Börger as a standard. The proven, cost

effective single acting mechanical seals are cooled and lubricated

by the quench chamber. Internal access is simple through removal

of one central screw based on our MIP Design. Replaceable

protection plates eliminate the Börger Block Pump Casing as a

wear part.

Unique and Versatile

The modular Börger platform with the MIP concept utilizes a variety of different rotor types.

The Börger patented rotor tip is still the classic popular design for elastomer coated rotors.

Also entirely coated rotors, the Optimum Rotor with large sealing lines and the Premium

Profile Rotor are often used in anaerobic digestion plants. Börger Rotary Lobe Pumps are

constructed following our MIP-Design criteria. MIP (Maintenance In Place) ensures maximum

maintenance friendliness. All wetted parts can quickly be maintained and replaced when

necessary by your own staff – without the removal of pipe or

drive system. Quick, Easy and Cost Effective.

An excerpt of the Börger rotor variety

Reversible Flow Direction

Rotary Lobe Pumps are self-priming, valveless positive displacement pumps. The screw

rotors produce a gentle, low pulsative flow. Since the pump unit is symmetrical, the fluid

flow is reversible by change of rotation direction. Therefore, Börger Rotary Lobe Pumps

are perfectly suited for filling and emptying applications.


Overview of construction and applications of Börger Rotary Lobe Pumps

Rotary Lobe Pump on

3-Point-Hitch-Frame.

Driven by PTO shaft.

Submerged or semi-

submerged design –

another customized

solution for special

applications.

Rotary Lobe Pump shaft to

shaft design with geared

motor (standard).

Pump with a directly flanged,

compact hydraulic motor.

Tanker Truck Pumps up to

4,500 gpm (17,000 litre/min.)

available.

For limited space – the

overhead design.

Rotary Lobe Pump with auger feed unit. The

conveying capacity of the system is influenced by

the viscosity and solid content of the medium.

Customized Mobile Pump Systems

Rotary Lobe Pumps as complete aggregate, e.g.

as trailer mount with electric or diesel motor.

Space and weight saving

design for tanker trucks.

Hand cart –

for various applications

Model Range from 4.4 – 4,400 usgpm (1 – 1,000 m³/h)AL PL CL FL EL XL

50 100 260 518 1000 1760

25 200 390 776 1550 2650

75 300 520 1036 3050 3530


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S T A I N L E S S S T E E L T A N K S

Tanks made from stainless steel

Börger tanks are made from stainless steel and offer a wide range of application. Börger Stainless Steel Tanks are heavily

utilized in the Biogas Industry as primary and secondary digesters and as equalization or storage tanks. The tanks are fixed

to a concrete foundation using anchor bolts with sealing compound. The Börger Stainless Steel Tanks can be customized to

meet specific needs with capacities ranging from 8,000 to 1,300,000 gal (30 to 5,000 m³). The tank builds high and narrow or

low and wide, depending on your requirements. Börger tanks can be designed for growth, if more storage space is required

in the future, ring segments may be added at any time. The high-quality tanks can also be dismantled and rebuilt elsewhere

making your storage tank a true asset.

Reinforcedfoundation

The inner surfaceof the segment

Sealing compound

The flat faced horizontal segments of thetank are connected with a special U-pro-files. This construction provides a stabili-zing and reinforcing effect on the boltedtank wall.

or

The tank is enhancedat the top with astabilizing profile.

The foot mounting is fixed and sealedto the concrete foundation.

Anchor bolts

Features:

• maintenance free

• gas tight

• versatile use

• easy to transport

• simple to install

• can be extended and removed

• variety of accessories

• various tank sizes

Applications:

• liquid storage

• anaerobic digester

• sludge storage

• equalization tank

• aeration tank

• fermentation tank

• fire water storage

• sewage storage

• liquid fertilizer

• liquid manure

Tank Accessories:

• factory designed segments, tank

connections and flanges, tank access,

manways etc.

• ladders with safety cage, stairways and

platforms for safe access

• tank covers made of stainless steel,

GRP, trapezoidal sheet or ceiling foil

• tank insulation


The Börger Concept –

Competent and Reliable Solutions

Powerfeed Solids Systems are designed as robust and reliable

machines for moving high solid substrates and biomass into a

liquid stream under anaerobic conditions.

The Powerfeed SSE as well as the powerful Biogas Pump are the

central unit of the solids feeding system. Multiple tanks are

connected via customized manifolds to the recirculating Biogas

Pump / Powerfeed SSE System. The Powerfeed Technology is

strategically positioned in the pressurized pipe system and feeds

the substrates into the liquid stream under anaerobic conditions.

The manifold settings control the substrate feed into the targeted

digester and need for agitation is reduced due to the homogeneous

condition of the liquid / solid mixture.

The Powerfeed SSE includes a compression zone that reaches into

the pressurized liquid stream. The length of the compression zone

can be modified with adjustable auger flighting. The Powerfeed SSE

handling increases the surface area of the substrates and

minimizes air pockets, reducing the risk of swim layers forming in

the digester.

The features of the Powerfeed SSE technology include low

operational speeds with less abrasion, a reliable seal to the liquid

stream formed by the adjustable compression zone and the

elimination of elastomeric wear components. Simplicity at its best.

Less air entrainementLess agitationLess power consumption

Features at a Glance:· One central feeding system for multiple tanks

· Independent of individual tank heights

· Odorless and gas tight system

· Less moving parts

· Simple and compact feeding unit

· Precise substrate feed minimizes agitation needs

· Adjustable compression zone

· Simplified controls

P O W E R F E E D S S E

Powerfeed SSE

· Designed with robust and thick-walled

stainless steel components

· The basic elements are accessible

through the quick release cover

· The compression zone can be adjusted

to accommodate different feed stocks

· A central retaining disc allows access

to the main components


The Biogas Pump· Durability

· Premium Profile Rotor

Pressure Side

Manifold

Powerfeed SSE

TechnologySuction Side Manifold

Substrate Storage


(1)(2)

(3)

(4)(5)

(6)(7)

(8)

(9)

(10.3) (10.2) (10.1)

(10.4)

(9.2) (9.2)

(10)

(10) Dewatering and Discharging with the Multi-Disc

The rotating, spring adjustable Multi-Disc (10.1) is mounted to

the rotating auger as the discharge unit for the Bioselect BP.

The Multi-Disc is adjusted via a setting screw (10.3) to a

compressible, centrally mounted spring (10.2). The Mutely-Disc

presses towards the fibrous material conveyed by the auger. If

the axial thrust is higher than the spring load, a discharge slot

(10.4) is created and the dewatered material, which has been

loosened by the rotating Multi-Disc, exits the Bioselect BP.

(9) Thickening and Transferring with the Rotary Lobe Pump

The Börger Rotary Lobe Pump is connected as the discharge unit to the

Bioselect BT, forming a closed, piped-in system. The pump has two

functions, forming a seal to control the thickening level and transferring the

material downstream for further processing. The solids content can be

adjusted by pump speed variation via a VFD in the control panel. The control

panel also monitors the safe operation of the Bioselect BT including the feed

pump and the separation unit.

The Bioselect – Solid Liquid SeparationThe Special Separator

The Börger Bioselect is a closed loop, leak-proof machine for thickening (BT) or dewatering (BP) applications. The wedge wire filter

and the auger unit are toleranced precisely to minimize wear on the filter. The patented auger design incorporates grooves in the

outer perimeter of the flighting. Fibrous material accumulates in the grooves and creates a soft and continuous surface between the

auger and the filter, thus enabling an increased clearance between them. The result: Effective liquid solid separation with minimized

wear characteristics.

· Closed and leak-proof system

· The Patented auger groove design minimizes filter wear

· The post filter press channel enhances separation

B I O S E L E C T

Operating PrincipleLiquid substances such as manure,

digestates or other fibrous substances

find their way from the entrance (1)

into the closed filter chamber of the

Bioselect (2). The outer casing is

separated from the auger unit by a

sealed filter (3). The auger unit (4) is

connected to the geared motor (5). The

solid laden fluid is fed into the inside of

the filter unit. The liquid centrate is

forced through the filter into the outer

cylinder of the Bioselect (6). The solid

contents remain inside the filter. The

rotating auger unit (4) conveys the

solids into the press-channel (7), where

post-drainage takes place up to the

flange connection (8), Although the

Bioselect BP and BT have different end

results, the separation concept of both

machines are identical. The auger is

designed so that pressure is generated

against the discharge unit (9) or (10).

Each discharge unit creates an

adjustable counter pressure, this way

the thickening or dewatering level can

be precisely defined and adjusted.


Illustration of Press Channel Design

Bioselect BTThe Bioselect BT is a combination of a separation unit with two rotary lobe pumps. Innovative control solutions between these

three main components and monitoring devices allow for an effective and safe operation of the Bioselect BT.

The geared motor of the Bioselect auger is amperage load controlled. The feed pump conveys sufficient flow to the separation unit.

The discharge pump determines the level of thickening. For example, slurry with a 4 % solid content can be thickened to a 10 %

solid concentration for improved liquid transfer via tanker truck or for digester feed with higher solid content. Liquid manure as

well as other substrates can also be thickened to 22 % DS content, without any mechanical modifications to the machine.

Bioselect BPThe Bioselect BP with Multi-Disc discharge unit is available as a stand alone screw press separation unit. It can also be offered as

a completely automated system with feed pump and control panel. The dewatering rate is modified with one simple step by

adjusting the setting screw of the Multi-Disc spring. With the automated system, no static suction head with riser pipes has to be

created at the inlet of the screw press.

Advantages· Totally odorless operation

· Thickening rate is easily adjustable

· The feed pump discharges the thin phase centrate

· Turn-key, compact machine

· Closed loop system allows for one machine to feed multiple tanks

· Wide range of flow and solid concentration

Advantages· Pumping of the thin phase centrate

in a closed system is possible

· Rotating, spring loaded Multi-Disc ensures consistent, granular dewatered material

· Simple installation and cost effective operation

· Rotary lobe pump can be connected to either the inlet flange or centrate outlet flange

· Wide range of flow and solid concentration


B

C

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B≥

A≥

C

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Safety equipment like valves etc. are not shown on drawings.

The Classic Operation

A pump supplies material through suction pipe A. The

control unit (C) regulates a steady and ideal workload

for the separator. The thin phase centrate in

discharge pipe B can be transferred by the

remaining, limited pressure of the feed pump, for

example into an underground storage.

Connecting a Pump to the Drain Pipe

For this operation, inlet pipe A requires a positive

head pressure into the separator. The control

panel (C) regulates the discharge flow depending

on the pump rate. This pump unit can discharge

the liquid phase against higher pressures, for

example to elevated tanks..

Classic Anerobic Digester

Dewatering out of a tank with constant suction

head on the Bioselect. In this case the liquid phase

is forwarded by a Börger Rotary Lobe Pump.

Capabilities of the Bioselect BP


C

A

B

Capabilities of the Bioselect BT

Separation with Discharge through Outside Wall

A short discharge pipe through an outside

wall will allow for accumulation of thickened

material in a controlled space.

Customized Solutions

The Bioselect in a customized, compact system.

The substrate enters through inlet A, the liquid

phase is transported through B with the re-

maining pressure of feed pump. The thickened

material is forwarded through C for further

treatment.

Mobile Version

Trailer mounted Börger Bioselect allows for

mobility and flexibility. Capability to change the

application or location. By connecting suction,

discharge and drain pipe plus power supply the

operator is ready to separate.


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Boerger, LLC | 2860 Water Tower Place, Chanhassen, MN 55317, USA | Toll Free 877-726-3743 | [email protected] | www.boerger.com

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Börger Macerating TechnologyThe highest variety in the Industry

MulticrusherThe Börger Multicrusher is an effective, widely applicable twin shaft grinderwith strong “Pull-In-Function” for solids and debris laden fluids. TheMulticrusher grinds and crushes foreign objects like stringent materials, wood,plastics, skins, textiles etc. to ensure trouble free operation of downstreamequipment. The relative rotation speed of the two shafts ensures an optimizedmacerating effect. The Multicrusher incorporates the same unique advantagesof the Börger MIP-Design as the Rotary Lobe Pump.

MultichopperThe Börger Multichopper is a single shaft grinder with central cutter plate andknife head for solids and debris laden fluids. The Multichopper macerates andconditions stringent material in homogenous sludge. The innovative design ofthe Multichopper with a central shaft clamp construction allows quick and easyreplacement of wear parts onsite according to Börger MIP-Design.

The macerating mechanism is also available as a kit.

RotorrakeThe Rotorrake is a robust, single-shaft inline macerator with integrated debriscollector. Blades are mounted on the carrier shaft. The stationary counterblades are kept blockage free by the rotating cutting blades.

The Rotorrake is available in different sizes (flow range of up to 800 m³/h / 3,500 gpm) and tackles chopping tasks where others have failed – for breakingup stringent and ragging material.

In the end… the thinking Pump

Difficult and inconsistent hydraulic conditions as well ascritical, viscous abrasive fluids – positive displacementpumps often have to perform under unconventional andunexpected scenarios. Our simple, intelligent controlsystems adjusts perfectly to these changing parameters.With the Bioselect, the pump either operates at apredetermined suction level or it targets an exact pre-setpressure range, depending on the pump set up in thedewatering system. The rotation speed of the pump unitadjusts automatically for optimal results.

M A C E R A T I N G T E C H N O L O G Y


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