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Sunflower Field

Grüne Energie Beckum

A repowering action...

The biogas plant from the company Lipp was commissioned n 2004 by NBS Bioenergie. The plant is in a industrial area in the outskirts of Beckum, where there is no supply of natural gas existing.

Two digesters with a volume of 1.200 m³ each, a digestate storing tank with 2.250 m³, a Ligavator (storage for flour from cereals) and a 400 m³ liquid manure storing tank were built. The electrical installed power is 1.062 kWel (717 kW gas motor from Deutz and a pilot injection motor with 345 kW from MAN). The original operation permit for 700 kWel was issued according to the feeding og cereals, renewable raw materials and liquid manure.

1st Substrate concept:
Liquid manure: 2850t/a
Renewable Raw Materials:  3670t/a

The profitability calculations were at the time done with cereal prices between 90-110 €/t. Shortly after the production began, as the substrate prices increased considerably the profitability of the plant was gone. In September 2009 the permit was changed and issued for the feeding of sugar beets (1,43 MWel).

2nd Substrate concept:
Sugar beets: 28.000t/a

A new digestate storage tank with a volume of 6000 m³, where the beets could be stored during the season, a new feeding system with a moving floor and a beet shredder, a scale, asphalt coating of the access roads, as well as a vacuum evaporator for the produced digestate were constructed.

A stable load of 50% was never achieved during the sugar beet monofermentation. The plant was finally disconnected of the grid in May 2011 after a production phase of around 1,5 years. Due to the problems with the monofermentation of sugar beets, the plant never reached a lucrative production.

Further Planning:

Both substrate concepts are allowed. In order to ensure a profitable operation of the plant, it should run with liquid manure/renewable raw material in the future. If the 3670 t/a renewable raw resources were maize instead of cereal, then the electrical output would be of only 350 kW or it could be run with a full load of around 717 kW, but then the substrate mixture will only last for 6 months. 

a. Substrate Concept:
For the successful operation it is necessary the increase of the renewable raw materials amount (see Step 2).

b. Substrate Efficiency
Further on, it is necessary to install a preparation step (hydrolysis) in order to be able to treat the renewable raw resources efficiently and obtain the highest gas yield possible. The hydrolysis decomposes stodgy substances, and this way it is possible to achieve more biogas in the next fermentation steps. It is possible to get an increase of around 15% in the produced energy (see Step 2).

c. Energy Efficiency:
Balancing energy and decentralised energy trading are becoming more important. Biogas can be stored.
Biogas plants can, together with local energy distributors, supply electricity as the need arises.  Gas-storing roofs will be designed for almost 12 hours of storing capacity, allowing the commercialization of electricity in the area of Beckum during peak-periods. An extra 717 kW CHP unit would be installed together with the already existing 717 kW and 345 kW CHP units. However, the yearly average output of the biogas plant, which is 717 kW, would never be exceeded. There is no need to feed more tons of substrate as what it is today fed. 
Due to the rearrangement of the permit which took place in September 2009, it is already allowed to run 2 x 717 kW.

Next steps:
1st step:
Notification in accordance with §15 for the recommissioning of the plant after the refurbishment of the existing technology and the soil embankment of the site according to the permit. The substrate feeding takes place over a liquid-solid feeding system (Vogelsang - EnergyJet) and the 2nd digester is also used.

This step is already completed! July 2014

2nd step:
Application for a modification in the permit for the additional installation of two hydrolysis tanks with a volume of 200m3 each, a gastight digestate storing tank and an increase of the substrate amount to: liquid manure approx. 6000t/a and renewable raw materials approx. 10.000t/a (Total 16.000t/a)

With these measures, it would still be possible to reduce the total amount to about a 50% of the amount which is stated in the permit from 2009. These amounts will be necessary to ensure an average output of 717 kW for the biogas plant.

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ARCHEA Unternehmensgruppe
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31840 Hessisch Oldendorf
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