effective mixing to reduce energy consumption in a digester
TRANSCRIPT
Effective Mixing to reduce Energy consumption in a digester
Qingdao - May 18. 2011Dr. Eilert BalssenManager Agriculture and Biogas
Effective mixing – Dr. Eilert Balssen June 14, 2011 2
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana” survey
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 3
Fluid Technology – Global Presence
“Think Global Act Local”
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Mid-East/Africa6 Locations
South America11 Locations
140 Countries 310 Locations 43 Production Facilities 40 Service Centers >2,500 Distributors
ITT Fluid Technology ITT Water & Wastewater
Effective mixing – Dr. Eilert Balssen June 14, 2011 4
ITT Water & Wastewater around the world
HQMain plantManufacturing plantDistributorsSales companies
ITT Fluid Technology ITT Water & Wastewater
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1928First telephone
switchboard in
Shanghai
1983Establishment of
communication
products
manufacturing
enterprises
1996
Flygt Shanghai Sales
Office
ITT Industries (China)
Investment Co., Ltd.
2001The
introduction
of Six Sigma
tools
1999Acquisition of STX’s
three enterprises in
Nantong, Xiamen and
Tianjin
1997
1998Shanghai Goulds
Pumps Plant
CableComShenzhen JV
2002FHD
production
base in
Shenyang
Acquisition of
Goulds Pumps
and
Its Nanjing
Plant
2000Acquisition of MMI
and Its plants in
Tianjin
2003Sanitaire Shenyang
production
base
1994Zhenjiang Cannon
Joint Venture
Shenyang Flygt JV
2004Acquisition
of Shanghai
HengTong
Acquisition of
WEDECO
ITT’s Footprint in China
2007Establishment of
the Nanjing FT
Plant
Establishment of
the Wuxi Plant
Expansion of
Shenyang Plant
2008Establishment
of FT IFE
organization
2006Switches
Divestiture
Effective mixing – Dr. Eilert Balssen June 14, 2011 6
Overview of ITT China
• Six manufacturing enterprises in six cities • Three management centers in Beijing, Shanghai and
Hong Kong• Asia global sourcing center in Shanghai • A total investment of $250 million • 2000 employees
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ITT Fluid Technology
建筑服务Building Services
污水废水治理Waste Water
Treatment
水处理Water
生物制药BioPharm
采矿和矿物处理Mining and
Mineral Processing
化工和石化Chemical and Petrochemical
油类和气体Oil and Gas
纸浆造纸Pulp and Paper
能源Power
Everything But The Pipes
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ITT Water & Wastewater Shenyang Plant
•Established in Mar 1995
•Location: Shenyang New Development Zone
•Registered Capital: USD 11 million•ISO9000 Management system was certificated in 2003• Production: water & wastewater pumps, like G&G, Steady Pump, etc.
•Employee No. at present :173
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Biogas Plant
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Flow limits
The friction has to be overtaken to move the particles
F F
V
shear stress(F/A)
y
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Shear stress
4
2
6
8
DM content (%)
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Flow limits – Viskosity
mixed organic material belongs to the structural viscose or non-Newtonian fluids
The viscosity is changing during mixing
The Viscosity is the important value but you can not measure it!
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Flow limits - DM-content %
The limit can be measured experimentally only, because:
You never know the substrate in advance
You can reach the limit under 10 % or over 15 % depending on the material
Generally fresh material like corn silage is more difficult to mix then „predigested“ material like manure
The DM is the best measurable value for orientation
Effective mixing – Dr. Eilert Balssen June 14, 2011 14
Flow limits – Thrust based mixing
The flow limit is reached if the media flowing the „short way“ back to the propeller
We call that „short cut“
Outside this limit you can mix only with a kneading technique
Effective mixing – Dr. Eilert Balssen June 14, 2011 15
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana” survey
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 16
•Marine propeller•SS or duplex SS blades
•Double acting mech. seal
•No reducer
•Class H insulation
•WL70° rating
•Up to 25 kW
Submersible Mixers For Biogas
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ITT Flygt Standard
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The ITT standard is related to Flygt mixers 4600 series up to 25 kW
The selection is based on the thrust!
Traditionally it is calculated in installed power in W/m³digester volume
Our recommendation: minimum 20 W/m³
Nowadays we show it in thrust per volume
ITT Flygt Standard
Effective mixing – Dr. Eilert Balssen June 14, 2011 19
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana” survey
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 20
Volume load (kg DM / m³ x d) digester volume. DM and not organic DM!
Energy consumption- by volume (Wh/m³ x d)- by volume load (Wh/kg x d)
Calculation factor for different materials:- corn silage as “base material” has the factor 1- manure as “pre-digested material has 0,5 - Gras silage and other heavy material has 2
retention time (digester volume m³/daily load m³) = days
Key data
Effective mixing – Dr. Eilert Balssen June 14, 2011 21
high grass inputhigh manure inputlow retention time
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
90,00
15 30 5 25 13 8 22 7 11 9 29 6 1 4 3 28 27 21 10 2 16 17 18 23 14 24 20 26 19 12
Faulr.gew.kg/m³d inst.LeistungW/m³ Verbr.Wh/m³d/10 Verbr.Wh/kgTMd
Energie consumption of 30 plants
high manure input low retention time
Plant [No.]
[kg/
m³]
-[W
/m³]
-[W
h/m
³/10]
-[W
h/kg
DM
]
Volume load (kgDM/m³d) inst. power (W/m³) Energy cons. by vol. (Wh/m³d)
Energy cons. by vol. load (Wh/kgd)
Effective mixing – Dr. Eilert Balssen June 14, 2011 22
Results:
Thrust reserve is reducing the energy consumption especially with high volume load
manure decrease the demanded thrust
high manure content increase the digester volume and the energy consumption
grass, grain and poultry manure increase the demanded thrust
Energie consumption of 30 plants
Effective mixing – Dr. Eilert Balssen June 14, 2011 23
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana survey”
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 24
Mixer in Biogas Plants
Effective mixing – Dr. Eilert Balssen June 14, 2011 25
Digester:
diameter 25 m / filling height 5,5 m
Installation A: 4 x 13 kW
Installation B: 2 x 13 kW
2 x 5,7 kW, 42 UPM ø 2,5 m
Results from Banana research
Effective mixing – Dr. Eilert Balssen June 14, 2011 26
Results from Banana research
30
higher gas production!
Wh/kg
A
Wh/m³d
kg DM/m³d
W/m³
energy consumption
volume load
Installed power
reduction %B
52
43
30
9,4
73
7,7
15,0
19,8
129
6,5
21,4
energy consumption
Effective mixing – Dr. Eilert Balssen June 14, 2011 27
The basis for both test should be comparable
but they have been much more difficult for banana
with the high load we got very good results
the combination of high thrust/energy banana and compact mixer for crust mixing is the best
banana and compact mixer are relative easy to maintain
low risk of losses during maintenance
Results from Banana research
Effective mixing – Dr. Eilert Balssen June 14, 2011 28
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana survey”
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 29
Dimensioning of mixers
all you need to get a tank mixed is:
thrust !!!
Effective mixing – Dr. Eilert Balssen June 14, 2011 30
Dimensioning of mixers
The specification of all Flygt mixers are based on the thrust
The needed thrust is depending on the tank size and the medium (viscosity)
The dimensioning of Flygt mixers takes place with the help of the software program MIDS.
Our selection charts show the needed mixers in relation to the tank size
Effective mixing – Dr. Eilert Balssen June 14, 2011 31
Mixer selection chart
Effective mixing – Dr. Eilert Balssen June 14, 2011 32
Mixer selection chart
Effective mixing – Dr. Eilert Balssen June 14, 2011 33
Mixer selection chart
Effective mixing – Dr. Eilert Balssen June 14, 2011 34
Installation
Effective mixing – Dr. Eilert Balssen June 14, 2011 35
Installation
Effective mixing – Dr. Eilert Balssen June 14, 2011 36
Installation
Effective mixing – Dr. Eilert Balssen June 14, 2011 37
Installation
Effective mixing – Dr. Eilert Balssen June 14, 2011 38
Installation
Effective mixing – Dr. Eilert Balssen June 14, 2011 39
Banana in Biogas Plants
Effective mixing – Dr. Eilert Balssen June 14, 2011 40
Introduction - basics
ITT Flygt Standard
Results from the survey with compact mixers
Results of the slow running “Banana” survey
Dimensioning of mixers
New Mid Size and Top Entry Mixers
Effective Mixing to reduce Energy consumption in a digester
Effective mixing – Dr. Eilert Balssen June 14, 2011 41
New mixer generation
The development of a new mid size mixer which is an option to compact mixers
Nearly half energy needed7.5 kW instead 13 kW
11 kW instead 18.5 kW
Propeller Banana 1,4 m
78 rpm 11kW
67 rpm 7.5 kW
Weight 315/285 kg
Effective mixing – Dr. Eilert Balssen June 14, 2011 42
New mid size mixer 4460 2-pole
Effective mixing – Dr. Eilert Balssen June 14, 2011 43
4460 Mid Size 2-pole
44
Introducing the Flygt TEA’s
Digesters to 2000m3
Digesters to 5000m3
SY4860
SY4870
TEA’s for a range of applications
Biological treatment Digesters Sludge tanks and more…
Treatment
SY4850
45
Why Top Entry Agitators?
low Power consumption Life Cycle Cost (LCC)
All wetted parts of high alloy steel (4860/4870)
Good process results Maximum uptime
Effective mixing – Dr. Eilert Balssen June 14, 2011 46
SY4850 Agitators
Standard execution With two Flygt Banana impellers and bottom support
With two 3-bladed hydrofoils and with bottom support
47
ITT Water and Wastewater Mixing Solutions
For the optimal solution to your mixing needs!
Effective mixing – Dr. Eilert Balssen June 14, 2011 48
Thank you for your attention