applied

sciences
Article
Enhancing Biogas Plant Efficiency for the Production of Electrical
and Thermal Energy
Ljubisa Josimović 1 , Slavica Prvulović 2 , Luka Djordjević 2, * , Ivana Bicok 2 , Mihalj Bakator 2 ,
Velibor Premčevski 2 , Uroš Šarenac 2 and Dalibor Šeljmeši 2

1 College of Textile Engineering, Textile High School of Professional Studies, Vilema Pusmana 17,
16000 Leskovac, Serbia; [email protected]
2 Technical Faculty “Mihajlo Pupin”, University of Novi Sad, Djure Djakovića, 23000 Zrenjanin, Serbia;
[email protected] (S.P.); [email protected] (I.B.); [email protected] (M.B.);
[email protected] (V.P.); [email protected] (U.Š.); [email protected] (D.Š.)
* Correspondence: [email protected]

Featured Application: Featured Application: This research offers a practical methodology for
designing biogas plants, improving renewable energy production, and promoting sustainable
agricultural practices.

Abstract: This paper aims to enhance the efficiency of biogas plants for the production of electrical
and thermal energy by optimizing substrate selection and digester heating techniques. The study
presents a comprehensive project of a biogas plant, including all necessary installations and a detailed
methodology for equipment selection. Specific substrates used include animal flour, corn silage, and
molasses, each chosen for their high dry matter content and biogas production efficiency. The digester
heating technique was analyzed to maintain optimal fermentation temperatures, ensuring a stable and
efficient biogas production process. The projected daily biogas production is estimated to be 5688 m3 .
The analysis shows that maintaining a constant digester temperature significantly improves biogas
yield. Seasonal variations in thermal energy requirements were identified, highlighting the need
Citation: Josimović, L.; Prvulović, S.;
for effective insulation and heating mechanisms, particularly during colder months. Additionally,
Djordjević, L.; Bicok, I.; Bakator, M.; the implementation of advanced heating techniques demonstrated a reduction in overall energy
Premčevski, V.; Šarenac, U.; Šeljmeši, consumption for maintaining the desired digester temperature. This research provides valuable
D. Enhancing Biogas Plant Efficiency insights for the design and operation of efficient biogas plants. By optimizing substrate mixtures
for the Production of Electrical and and digester heating, the study contributes to sustainable energy production, reduced greenhouse
Thermal Energy. Appl. Sci. 2024, 14, gas emissions, and enhanced biogas plant efficiency, supporting both environmental protection and
5858. https://doi.org/10.3390/ economic development.
app14135858

Academic Editor: Francisco Keywords: biogas plant; biogas; electricity; heat energy; RES; sustainable energy
Jesús Fernández Morales

Received: 6 June 2024

Revised: 23 June 2024
1. Introduction
Accepted: 27 June 2024
Published: 4 July 2024
In response to the depletion of conventional energy sources and the rising demand for
energy, efforts are increasingly being made to enhance the availability of renewable energy
through the use of biogas produced via anaerobic fermentation [1,2]. The production of
renewable energy from biogas is a beneficial technology, contributing, among other things,
Copyright: © 2024 by the authors. to the mitigation of greenhouse gas emissions, inactivation of pathogens, nutrient reuse,
Licensee MDPI, Basel, Switzerland. and regional/local economic development [3–5].
This article is an open access article The production of biogas is achieved by fermentation of organic substances, in fer-
distributed under the terms and menters or digesters, through the anaerobic digestion from methanogenic bacteria [6,7].
conditions of the Creative Commons Raw materials for biogas production can include animal manure, green mass (plants), corn
Attribution (CC BY) license (https:// silage, expired food products (if they are hygienically safe), rotten seeds, turnip noodles,
creativecommons.org/licenses/by/
molasses, fruit pulp, vegetable and fruit processing residues, seeds, bark, fallen fruit, food
4.0/).

Appl. Sci. 2024, 14, 5858. https://doi.org/10.3390/app14135858 https://www.mdpi.com/journal/applsci

Appl. Sci. 2024, 14, 5858 2 of 14

scraps, residues from the beer industry, residues from milk and cheese production, residues
from oil production, etc. [6,8–10].
The advantages of biogas plants are the following:
• Biogas plants are very efficient in decomposing or fermenting waste. Instead of
consuming energy, they produce it, and that is the reason they are different from all
other systems [11,12];
• In addition to the environmental benefits, the main advantages of biogas plants are
the production of biogas and production of biofertilizers [13,14];
• Additional benefits include production of electricity and heat, production of biomethane,
and savings on the capital costs of waste management systems, during the construction
of new facilities [15–18];
• Biogas production prevents methane emissions into the atmosphere, which is the best
way to reduce global warming. When we talk about a biogas plant, first of all we
are referring to a gas with a large amount of methane in it, which is produced by
fermentation of various organic substances [8,19,20].
In addition to addressing energy scarcity, the use of biogas technology significantly
contributes to environmental protection and sustainable development [21]. Biogas produc-
tion from organic waste materials not only provides a renewable energy source but also
mitigates the environmental impact associated with conventional waste disposal methods.
The anaerobic digestion process employed in biogas plants reduces the volume of waste,
lowers greenhouse gas emissions, and decreases the reliance on fossil fuels [22,23].
A critical aspect of biogas plant operation is the management of the fermentation pro-
cess [24,25]. This involves maintaining optimal conditions for the anaerobic microorganisms
responsible for breaking down organic matter. Temperature control is particularly impor-
tant, as it affects the metabolic activity of methanogens. The digester heating technique
analyzed in this study ensures a stable and efficient fermentation process, contributing to
consistent biogas yields.
The economic benefits of biogas production are also noteworthy. By converting waste
into energy and other useful byproducts, biogas plants can generate revenue and reduce
waste management costs [26,27]. This can be particularly beneficial for rural communities,
where biogas plants can create local jobs and support economic development. Additionally,
the production of renewable energy from biogas can reduce energy costs and enhance en-
ergy security, especially in areas with limited access to conventional energy sources [28–30].
The implementation of biogas technology also aligns with global efforts to combat
climate change. By capturing methane emissions from organic waste, biogas plants help
reduce overall greenhouse gas emissions, contributing to climate mitigation goals. Fur-
thermore, the use of biogas as a renewable energy source supports the transition to a
low-carbon economy, reducing dependence on fossil fuels and promoting sustainable
energy practices [31–33].
In this context, the development and optimization of biogas plants are crucial for
maximizing their environmental and economic benefits [34,35]. This study aims to pro-
vide a detailed analysis of the biogas production process, including feedstock selection,
fermentation management, and energy utilization. The findings of this research will offer
valuable insights for the design and operation of efficient biogas plants, contributing to the
advancement of renewable energy technologies.
Overall, the integration of biogas technology into energy and waste management
systems represents a promising approach to addressing some of the most pressing envi-
ronmental and economic challenges of our time. By harnessing the power of anaerobic
digestion, biogas plants can transform waste into a valuable resource, supporting sustain-
able development and enhancing the resilience of energy systems [36–38].
Numerous studies have investigated various aspects of biogas production and opti-
mization, contributing valuable insights to the field. Cinar et al. examined the potential
of biogas production from aquatic biomass, providing insights into the scalability and
efficiency of using algae and seaweed as substrates [39]. In the paper [40], the authors inves-
 Appl. Sci. 2024, 14, 5858 3 of 14

tigated the impact of pretreatment methods on biogas yield from lignocellulosic biomass.
They demonstrated that certain pretreatment techniques can significantly enhance biogas
production by improving substrate digestibility.
In the paper [41], Tao and You focused on the life cycle assessment of biogas production
from dairy manure, evaluating the environmental impacts and potential benefits of using
dairy manure as a feedstock. Imeni et al. examined the biogas production from co-digestion
of dairy manure and crop residues, evaluating performance and economic feasibility [42].
In the paper [43], the authors analyzed the anaerobic co-digestion of food waste and yard
waste for enhanced biogas production, using experimental and kinetic modeling.
Our study stands out in the field of biogas production through its comprehensive
approach to integrating theoretical knowledge with practical applications in biogas plant
design. By focusing on substrate selection, fermenter heating techniques, and process
optimization, we offer a detailed methodology that encompasses the entire process—from
substrate selection to energy utilization and environmental impact assessment. This ap-
proach bridges the gap between technological aspects and the economic and environmental
benefits, providing valuable operational and environmental insights for efficient and sus-
tainable biogas production.
The study’s novelty lies in its holistic and integrative approach, combining theoretical
insights with practical applications to optimize biogas production. This includes innovative
techniques for digester heating and a detailed analysis of substrate combinations that have
not been extensively studied together.

2. Materials and Methods

The basic process of biogas plants is usually carried out in the following stages [8]:
1. Preparation of raw material for processing;
2. Anaerobic digestion;
3. Storage, transport, and use of boiled liquid;
4. Storage, purification, and use of biogas.
The purpose of a continuous-flow biogas plant above all represents the production, treat-
ment, storage, and use of biogas, and as a result, electricity and heat are generated [17,44,45].
Sci. 2024, 14, x FOR PEER REVIEW 4 of 15
Figure 1 shows the continuous-flow plant scheme, and Table 1 shows the yields of
biogas from manure [46].

Figure 1. Scheme of a continuous-flow plant.

Figure 1. Scheme of a continuous-flow plant.

Table 1. Yields of biogas from manure of domestic animals.

Average Daily Average

The Propor- The Propor-
Inflow of Liq- Nitrogen
tion of Or- tion of Or- C:N Ratio in
uid Manure at Content
Species of Do- ganic Matter ganic Matter Organic Average Bio- Average Bio-
Average Or- in Or-
estic Animal Content in the Content in the Matter Con- gas Yield) gas Yield
ganic Matter ganic
Liquid Ma- Liquid Ma- tent
Content by Matter
Appl. Sci. 2024, 14, 5858 4 of 14

Table 1. Yields of biogas from manure of domestic animals.

Average Daily
Average
Inflow of Liquid The Proportion The Proportion
Nitrogen C:N Ratio in
A Species of Manure at of Organic of Organic
Content in Organic Average Biogas
Domestic Average Organic Matter Content Matter Content Average Biogas Yield
Organic Matter Yield)
Animal Matter Content in the Liquid in the Liquid
Matter Content
by Weight of Manure (gomc ) Manure (gomc )
Content
11%
[m3 /(kgorganic mattercontent [ƒbg (kgorganic mattercontent
[kg/day × LSU] [%] [kg/day × LSU] [%]
× day)] × day)]
Dairy cattle 45 10.5 4.7 1.7 ÷ 6.0 (17 ÷ 25):1 0.18 ÷ 0.33 0.846 ÷ 1.551
Cattle in
29 11 3.2 1.7 ÷ 6.0 (17 ÷ 25):1 0.16 ÷ 0.32 0.512 ÷ 1.024
fattening
Breeding cows 30 12 3.6 3.8 (6 ÷ 12):1 0.34 ÷ 0.55 1.224 ÷ 1.980
Pigs in fattening 26 11.54 3 3.8 (6 ÷ 12.5):1 0.30 ÷ 0.55 0.900 ÷ 1.650
The laying hens 58 11.03 6.4 6.0 ÷ 6.5 (7 ÷ 15):1 0.31 ÷ 0.62 1.984 ÷ 3.968
Broiler chicken 48 10.62 5.1 6.3 15:1 0.30 ÷ 0.56 1.530 ÷ 2.856
Sheep 28 11.07 3.1 3.8 33:1 0.09 ÷ 0.31 0.279 ÷ 0.961
Horses 32 10.94 3.5 2.3 25:1 0.20 ÷ 0.30 0.700 ÷ 1.051
Note: LSU—livestock unit.

Appl. Sci. 2024, 14, x FOR PEER REVIEW 5 of 15

Figure 2 shows the average daily inflow of liquid manure at average organic matter
content by weight of 11%.

Figure 2.
Figure 2. Average
Averagedaily
dailyinflow of liquid
inflow manure.
of liquid manure.

The
The research
researchininthis
thispaper
paperwill be be
will based on aon
based biogas plantplant
a biogas with awith
continuous flow forflow for a
a continuous
a power plant.
power plant.
The technological parts of the plant are the following facilities: manure storage tank,
The technological parts of the plant are the following facilities: manure storage tank,
pumping station, condensate pit, digester, lagoon, CHP unit in container, separator, gas
pumping station, condensate pit, digester, lagoon, CHP unit in container, separator, gas
torch and blower, and others (fluid pipes, gas pipes, etc.).
torchThe
andfollowing
blower, manure
and others (fluid
is used for pipes, gasplant:
the biogas pipes, etc.).
The following manure is used for the biogas plant:
• Animal flour with a dry matter content of 92–98%;
•• Animal flour
Corn silage with
with a dry
a dry matter
matter content
content of 92–98%;
of 30–35%;
•• Corn silage
Molasses withwith a matter
a dry dry matter content
content of 30–35%;
of 84–88%.
• Molasses
The with
projected a dry
daily matter
biogas contentisof5688
production 84–88%.
m3 per 41.4 t of substrate.
The projected daily biogas production is 5688 m3 per 41.4 t of substrate.
Biogas Plant Components
Biogas Plant
The Components
biogas plant consists of the following 13 installations, each playing a crucial role
in the production process:
The biogas plant consists of the following 13 installations, each playing a crucial role
• theManure
in storage
production tank: a facility for storing raw manure before processing;
process:
• Pumping station: used for transferring manure and other substrates to the digester;
•• Manure storage tank: a facility for storing raw manure before processing;
Condensate pit: collects and drains condensate formed during the biogas production
• Pumping station: used for transferring manure and other substrates to the digester;
process;
• Digester: the main unit where anaerobic digestion takes place;
• Lagoon: used for storing digested material (digestate) after the fermentation process;
• CHP unit (combined heat and power): generates electricity and heat from biogas;
• Separator: separates solid and liquid fractions of the digestate;
• Gas torch: burns excess biogas that cannot be used or stored;
Appl. Sci. 2024, 14, 5858 5 of 14

• Condensate pit: collects and drains condensate formed during the biogas production process;
• Digester: the main unit where anaerobic digestion takes place;
• Lagoon: used for storing digested material (digestate) after the fermentation process;
• CHP unit (combined heat and power): generates electricity and heat from biogas;
• Separator: separates solid and liquid fractions of the digestate;
• Gas torch: burns excess biogas that cannot be used or stored;
• Blower: maintains the pressure of biogas within the system;
• Gas pipes: transport biogas from the digester to storage or the CHP unit;
• Fluid pipes: transport substrates and digestate between different units;
• Heaters: installed within the digester to maintain optimal temperature;
• Control unit: monitors and controls the entire biogas production process.
This detailed description of the components has been included to provide a clear
understanding of the biogas plant’s infrastructure. Biogas composition: methane CH4 ca.
Appl. Sci. 2024, 14, x FOR PEER REVIEW 50–55%, carbon dioxide CO2 approx. 45–50%, nitrogen N2 ca. 0–3%, hydrogen
6 of 15H2 ca. 0–1%,
oxygen O2 approx. 0–1%, hydrogen sulfide H2 S ca. 0–2%.

3. Results and Discussion

3. Results and Discussion
The technological process of biogas production and utilization in a biogas plant begins
The technological process of biogas production and utilization in a biogas plant be-
gins withthe
with thepreparation
preparation of of raw
rawmaterials.
materials.This This includes
includes the the dilution
dilution of substrates
of substrates with with water
water and the addition of necessary additives. The substrates are then subjected to anaer-to anaerobic
and the addition of necessary additives. The substrates are then subjected
obicfermentation
fermentation to producebiogas
to produce biogas and
and anaerobically
anaerobically digested
digested liquid.liquid.
The digested liquid is directed to a reception area and subsequently treatedtreated
The digested liquid is directed to a reception area and subsequently to be to be used
usedor disposed
or disposed of in various ways, such as for fertilizer, aerobic treatment, environmental
in various ways, such as for fertilizer, aerobic treatment, environmen-
tal disposal,
disposal,ororasasanimal
animalfeed. Simultaneously,
feed. Simultaneously, the produced biogasbiogas
the produced is collected, purified,purified, and
is collected,
andeither
eitherutilized
utilized or
or combusted
combusted to generate thermal and electrical energy.
to generate thermal and electrical energy. The The system
system includes
includes recirculation pathways for clarified liquid and sludge to maintain
recirculation pathways for clarified liquid and sludge to maintain efficiency efficiency andand optimize
optimize resource
resource usage. usage.
Figure 3 provides a clear and comprehensive overview of this process, illustrating
Figure 3 provides a clear and comprehensive overview of this process, illustrating the
the flow of materials and energy within the biogas plant.
flow of materials and energy within the biogas plant.

Figure
Figure 3. Block
3. Block diagram
diagram of the technological
of the technological process
process for biogasfor biogas production
production and utilization.
and utilization.

3.1. Substrate Flow

Corn silage and livestock flour will be taken with the loader from the silage ware-
house and dosed into a manure storage tank. Liquid bovine manure and molasses will be
dosed by tanks at the connection at the manure storage tank.
In this case, the following quantities of raw materials are added daily to the manure
Appl. Sci. 2024, 14, 5858 6 of 14

3.1. Substrate Flow

Corn silage and livestock flour will be taken with the loader from the silage warehouse
and dosed into a manure storage tank. Liquid bovine manure and molasses will be dosed
by tanks at the connection at the manure storage tank.
In this case, the following quantities of raw materials are added daily to the manure
storage tank: 11.8 [t/d] fodder flour, 11.8 [t/d] molasses, 5.5 [t/d] corn silage, and 12.3 [t/d]
beef fertilizer with fodder residues.
That solid portion of the feedstock will be mixed in a dosage pit of 1 to 11% of dry
weight (separation fluid and/or recirculate), then the mixed mass will be dosed through a
tube and pumping station into a digester, which will contain up to 8% of dry matter.
A central pump is provided at the pumping station.
Processes performed by the central pump:
• Pumping a mixture of raw materials with a proportion of up to 11% dry matter, for
dosing into a digester.
The liquid pipes provided are the following:
• PE100 DA225 mm PN10;
• DN200 V2A (204 × 2.0).
With the help of the heaters installed inside the digester on the wall, the liquids will
keep the temperature constant at 40.5 ◦ C. The theoretical time limit of fermentation is
60 days. From the dosing pit, the digester will be dosed daily with a fresh raw material.
In the digester, the feedstock is further fermented. After that, the decomposed material
from the digester is being pumped to a separation, which separates the solid and liquid
portion of the fermentation feedstock.

3.2. Biogas Flow

Biogas is generated in a digester where a biogas storage facility with a capacity
of 1842 m3 will be installed. The storage purpose is a compensation between biogas
production and biogas consumption at the power plant (e.g., CHP servicing). The biogas
will be taken from the storage through the biogas pipes, condensate pits, and biogas fittings
with blowers that will compress the biogas to approx. 120 mbar and transfer it through
the control unit to the CHP unit. The calculated flow rate for compressor 1 is approx.
240 m3 /h.
Gas tubes provided:
• Material: PEHD PE 100 DA 225 PN 6–GAS;
• Material: 1.4571 DN150 (154 × 2.0) and DN 200 (204 × 2.0).

3.3. The Flow of the System of the Heating

For the needs of the maintaining of the constant temperature of the digester during
the process of fermentation, the heat which is produced by the biogas motor during the
combustion of the biogas, in other words, during the production of the electricity, is used.
For that purpose, the board heat exchanger whose task is to take as big a quantity of
the heat from the SUS motor as possible, and to give it, further, to the next cycle of the
system of the heating, is installed. When there is no need for the heating of the digester, the
so-called “emergency cooler” is turned on. It takes out the heat from the motor in order for
it not to be overheated. The working regime is 90–70 ◦ C [47].
By means of the centrifugal pump, the heated water from the exchanger of the heat is
taken out in the next cycle towards the divider of the heat. The cycle of the hot water from
the divider and the busbar towards the digester has a temperature regime of 40–60 ◦ C.
All underground powerlines are insulated with polyurethane foam and protected
while they are insulated by the mineral wool in the open in the lining of the Al sheet metal.
The liquid will be heated and constantly kept under a temperature of 40.5 ◦ C by installed
heaters inside of the reservoirs on the wall. There are the measurers of the temperature on
the outer part of the digester and outside the Ex zone. The sensor is pulled in one small
Appl. Sci. 2024, 14, 5858 7 of 14

pipe which is installed on the digester and is technically packed, and which lies in the space
inside the digester. For reaching the process temperature of 60–45 ◦ C, the pipes for the
heating of the stainless steel DN100 will be installed on the internal walls of the digester.
The source of the thermal energy will be the waste heating of the CHP units [47].

3.4. The Objects and the Equipment

3.4.1. The Mixing Hole
For the needs of the device, the mixing hole has been made, which integrates and homog-
enizes the daily quantity of the substratum which is needed into the mixture/composition
with a given parameter of 11% of the dry matter.
The mixing hole also supplies and doses the digester during the whole day with a
certain amount of the produced mixture.
Because of the lack of stable dung for mixing, the recirculation of the liquid matter
from the digester will be carried out. For reaching the ideal mixture with 11% of the dry
matter, water is added, if it is needed.

3.4.2. The Digester

The digester which is made on the biogas device is round, made of armored concrete,
and covered with the membrane—the storage for the gas. The walls are covered with
trapezium sheet metal, with a thickness of insulation of 80 mm.
The capacity of the digester with the fixed level of the substrata contains approximately
4.456 m3 of the useful volume.
Inside of the digester two long posts in the form of the mixers and two deluged mixers
are installed. The mixers will be fixed on the ground and on the walls of the digester. The
mixers are located under the solid and constant level of the liquid of the raw material
at 1 m.
The given raw materials from the mixing hole are transported into the central pump
station, which further transports them into the digester [48].

3.4.3. The Pump Station with the Equipment

The pump station is located immediately next to the mixing hole and serves as protec-
tion from outer weather conditions for the pumps, sensors, and electrical equipment, so
the devices for measuring and valves can be inside, protected from freezing.

3.4.4. The Devices for Measuring

Temperature gauges are located on the outer part of the digester and outside the Ex
zone. The sensor is pulled into one technical jointing which is installed on the digester, and
which lies in the space inside the digester. The measurer of the level is located in the low
position, near the ground from the outer part of the digester (the internal part of the sensor
is protected to zone 0).
The measurers are installed on one steel flange from the outer part of the digester.

3.4.5. The Lagoon

The lagoon which is built for the purpose of the biogas device is approximately
7.500 m3 of the useful volume. It is dug into the ground, with a foil floor for the protection
of pouring out, in other words, of the penetration of the liquid phase into the ground.

3.4.6. The Storage of the Gas

The production and the consumption of the gas is not always simultaneous. The biogas
which is made in the digester will be accumulated in the storage for the biogas [49,50]. The
storage of the gas meets the following criteria: the absence of leaking of the gas, higher
pressure, and constant temperature. The high roof with the membrane which provides the
absence of leaking of the gas is put onto the digester. As storage material, the membrane
Appl. Sci. 2024, 14, 5858 8 of 14

with the foil with a high degree of firmness from tearing and increasing resistance to the
gas is used.
The outer membrane keeps the shape of a semi-circle thanks to the blow-pipe of the air.
The outer air between the internal and outer membrane is blown in such a way that
a pressure of 3 mbar, on average, is constantly kept. With the increasing of the internal
membrane from the pressure because of the production of the gas in the gas space, the excess
air between the outer and internal membrane comes out through the exhaust valve [48].
The characteristics of the storage of the biogas and materials are described in Table 2.

Table 2. The characteristics of the membrane for the storage.

The Internal Membrane

Material PELD
Thickness 0.8 mm
Weight 750 g/m2
Tautness/firmness 650 N/cm
Surface resistance <3 × 109 Ohm
The resistance of leaking <3 × 109 Ohm
The permeability of the gas (methane) 260 cm3 /m2 × d × 1 bar
The resistance to the temperature −30 ◦ C ± 70 ◦ C
The Outer Membrane
Material double PVC—covered with polyester cloth
Weight 670 g/m2
Tautness/firmness 3000 N/cm
Surface resistance <3 × 109 Ohm
The resistance of leaking <3 × 108 Ohm
The permeability of the gas (methane) 260 cm3 /m2 × d × 1 bar
The resistance to the temperature −30 ◦ C ± 70 ◦ C

3.4.7. The Valve for the Protection of the Storage on High Pressure and Low Pressure
The digester is equipped with a safety valve for the high/low pressure. The valve
for the high/low pressure is a safety device, which stops the excessive pressure of the
gas in the storage. The valve for the high/low pressure is adjusted for a high pressure of
3.5 mbar and for a low pressure of 1 mbar. For the gas flows until 300 m3 /h, there is a loss
of pressure in the fuse of a pressure of 1 mbar.

3.4.8. The Gas Power Line and the Parts of the Gas Power Line
The pipeline, in other words, the flow of the biogas, consists of different gas power lines,
important equipment, the storage of the gas, and the preparation of the gas (desulfurization).
Agricultural biogas devices work exclusively under a low pressure (until 200 mbar).
The usual working high pressure is from 2.5 until 3.5 mbar. The transport of the gas is
carried out by way of the high pressure which is made from bacteria in the digester and
from the low suction pressure of the compressor in the bloc’s internal combustion engine.
The pipes and the flow of the biogas are carried out with a fall of at least 1.5% towards
the condensation hole. The main spot for the taking of the gas will be from the digester
from the outer side of the wall, which is marked by the jointing and, in this way, it is safe.
The pipe is led along the wall towards the ground until it comes into the ground. The
transition from the stainless steel onto the PEHD pipe is carried out only in the ground
part. The underground gas power line will also be implemented with a minimal fall of 1.5%
towards the condensation hole. The gas power lines are marked with yellow arrows with
the notice “Attention, biogas”.
The gas parts of the biogas device are resistant to the substratum and corrosion.
The blow-pipe for the biogas increases the pressure of the biogas to, approximately,
120 mbar, for the suitable combustion to be enabled in the CHP unit. The motor of the
Appl. Sci. 2024, 14, 5858 9 of 14

compressor for the biogas will be controlled through the frequency, in order for the quantity
of the gas and the pressure of the gas to be regulated.
Appl. Sci. 2024, 14, x FOR PEER REVIEW Figure 4 shows the situation plan of the biogas plant with installations, and Figure
10 of 15
5
Appl. Sci. 2024, 14, x FOR PEER REVIEW 10 of 15
shows the biogas power plant on-site in the production process.

Figure 4.
Figure 4. Situation plan of
Situation plan of the
the biogas
biogas plant
plant with
with installations.
installations.
Figure 4. Situation plan of the biogas plant with installations.

Figure 5. Biogas power plant on-site in the production process.

Figure5.5.Biogas
Figure Biogaspower
powerplant
planton-site
on-sitein
inthe
theproduction
productionprocess.
process.
3.5. Digester Heating Technique
3.5.
3.5.Digester
DigesterHeating
HeatingTechnique
Technique
The digester is the heart of a biogas plant and the process of anaerobic fermentation
The
The digester is theheart
digester is the heartofofaabiogas
biogasplant
plantand
andthe
theprocess
processof
ofanaerobic
anaerobicfermentation
fermentation
takes
takes place in it.
takesplace
placeininit.
it.
The digester built on the biogas plant is circular in shape, made of reinforced concrete
The digester built on the biogas plant is circular in shape, made of reinforced concrete
and covered with a membrane for the storage of gas [50]. The walls are lined with trape-
and covered with a membrane for the storage of gas [50]. The walls are lined with trape-
zoidal sheet metal, with an insulation thickness of 80 mm.
zoidal sheet metal, with an insulation thickness of 80 mm.
The capacity of the digester with a fixed substrate level contains about 4456 m³ of
The capacity of the digester with a fixed substrate level contains about 4456 m³ of
useful volume.
useful volume.
Appl. Sci. 2024, 14, 5858 10 of 14

The digester built on the biogas plant is circular in shape, made of reinforced con-
crete and covered with a membrane for the storage of gas [50]. The walls are lined with
trapezoidal sheet metal, with an insulation thickness of 80 mm.
The capacity of the digester with a fixed substrate level contains about 4456 m3 of
useful volume.
Two long-beam and two submersible mixers are installed inside the digester. The
stirrer will be attached to the floor and walls of the digester.
The raw materials are transported from the mixing pit to the central pumping station,
which is further transported to the digester [51–53].
Heating and maintaining a constant temperature of 35 ◦ C for the mesophilic process
and 55 ◦ C for the thermophilic process is crucial and extremely important for the efficiency
of anaerobic digestion.
To maintain the temperature of the substrate in the digester, heating inside it must be
provided. Factors affecting substrate heat loss are the following:
• Occurrence of heat loss through the digester mantle;
• Heat loss due to the dosing of the substrate at a lower temperature than expected.
The mentioned factors of heat loss that occur in the substrate are possible; the substrate
is heated to the set temperature by applying the heating technique in order to achieve an
efficient process of anaerobic digestion.
The digester heating system consists of horizontal plastic pipes made of cross-linked
polyethylene that run along the outer circular wall of the digester, approx. 16 rows of pipes.
Hot water for heating the digester is provided from a heat exchanger installed inside the
“CHP” plant. The temperature of the water for heating the digester is about 40 ◦ C and the
estimated maximum heating capacity of the digester of this system is about 140 kW.
The necessary amount of thermal energy for the heating of the substratum Qps is
calculated as follows:
Q ps = ms ·c ps ·∆t (1)
where ms represents the flow of the mass of the substratum, cps represents the specific
thermal conductivity of the substratum, and ∆t represents the difference between the
temperature of the substrate in the digester and the entry raw material.
Note: The balance is changed by the seasons and the months. The average monthly
temperature is taken.
Table 3 and Figure 6 show the thermal energy which is needed for the warming up of
the digester.
Key observations from Table 3 indicate that the entry temperature varies throughout
the year, with the lowest values during the winter months (5.0 ◦ C in January) and the
highest values during the summer months (17.0 ◦ C in July and August). Correspond-
ingly, the temperature difference is highest in January (35.5 ◦ C) and lowest in July and
August (23.5 ◦ C). Consequently, the necessary thermal energy (kW) is highest in January
(87.5 kW) and lowest in July and August (57.9 kW). The monthly thermal energy require-
ment (kWh/month) follows the same trend, being highest in January (65,097 kWh) and
lowest in August (43,092 kWh).
Figure 6 visually represents the data provided in Table 3. It shows the monthly
variation in the thermal energy required to heat the digester. The x-axis represents the
months of the year from January to December, while the y-axis represents the thermal
energy required in kWh/month. The graph highlights a peak in thermal energy requirement
during the colder months (January) and a trough during the warmer months (July and
August). This visual representation facilitates quick identification of the months with the
highest and lowest energy requirements, aiding in easier planning and resource allocation
for maintaining optimal digester temperatures throughout the year.
 Appl. Sci. 2024, 14, 5858 11 of 14

Table 3. The thermal energy which is needed for the warming up of the digester.

Entry The Temperature The Difference of Necessary Thermal Necessary Thermal

Month d/m Temperature of the Digester the Temperatures Energy Energy
◦C ◦C ◦C kW kWh/m
January 31 5.0 40.5 35.5 87.5 65.097
February 28 6.0 40.5 34.5 85.0 57.141
March 31 8.0 40.5 32.5 80.1 59.596
April 30 10.0 40.5 30.5 75.2 54.124
May 31 12.0 40.5 28.5 70.2 52.261
June 30 15.0 40.5 25.5 62.8 45.251
July 31 17.0 40.5 23.5 57.9 43.092
August 31 17.0 40.5 23.5 57.9 43.092
September 30 14.0 40.5 26.5 65.3 47.026
October 31 12.0 40.5 28.5 70.2 52.261
November 30 8.0 40.5 32.5 80.1 57.673
December 31 6.0 40.5 34.5 85.0 63.263
Sum 877.2 639.878
Average 73.1 53.323
Maximum 87.5 65.097
Appl. Sci. 2024, 14, x FOR PEER REVIEW 12 of 15
Minimum 57.9 43.092

Figure
Figure 6. The
6. The thermal
thermal energy
energy which
which is needed
is needed forfor
thethe warming
warming upup of the
of the primary
primary digester.
digester.

The significant variation in thermal energy requirements underscores the need for
Key observations from Table 3 indicate that the entry temperature varies throughout
effective insulation and possibly additional heating mechanisms during colder months
the year, with the lowest values during the winter months (5.0 °C in January) and the
to maintain the digester at the desired temperature. Understanding these variations
highest values during the summer months (17.0 °C in July and August). Correspondingly,
allows for better energy management and cost planning, ensuring that sufficient resources
the temperature difference is highest in January (35.5 °C) and lowest in July and August
are allocated for heating during the winter months. Maintaining a constant digester
(23.5 °C). Consequently, the necessary thermal energy (kW) is highest in January (87.5
temperature is crucial for the efficiency of the anaerobic digestion process, and this analysis
kW) and lowest in July and August (57.9 kW). The monthly thermal energy requirement
ensures that the plant can operate efficiently year-round.
(kWh/month) follows the same trend, being highest in January (65,097 kWh) and lowest
Overall, the analysis of Table 3 and Figure 6 provides valuable insights into the seasonal
in August (43,092 kWh).
variations in thermal energy requirements for the digester. These insights are critical for
Figure 6 visually represents the data provided in Table 3. It shows the monthly vari-
optimizing the design and operation of the biogas plant, ultimately contributing to its
ation in the thermal energy required to heat the digester. The x-axis represents the months
overall efficiency and sustainability. The integration of optimized substrate selection and
of advanced
the year from January
digester to December,
heating techniques while
in ourthestudy
y-axis represents
has the thermalimprovement
led to a measurable energy re-
quired in kWh/month. The graph highlights a peak in thermal energy requirement
in biogas production efficiency and yield. This demonstrates the practical application during of
theour
colder months (January) and a trough during the warmer months (July and
methodology in enhancing biogas plant performance. Our approach bridges the gap August).
This visual theoretical
between representation facilitates
research quick identification
and practical implementation, of the months with
showcasing the benefits
tangible highest in
and lowest energy
operational requirements, aiding in easier planning and resource allocation for
efficiency.
maintaining optimal digester temperatures throughout the year.
The significant variation in thermal energy requirements underscores the need for
effective insulation and possibly additional heating mechanisms during colder months to
maintain the digester at the desired temperature. Understanding these variations allows
for better energy management and cost planning, ensuring that sufficient resources are
Appl. Sci. 2024, 14, 5858 12 of 14

4. Conclusions
This study investigates the efficiency of biogas plants for the production of electrical
and thermal energy through the optimization of substrate selection and fermenter heating
techniques. Utilizing specific substrates such as animal flour, corn silage, and molasses, the
research achieved a significant increase in biogas yield, projecting a daily production of
5688 m3 . The analysis demonstrated that maintaining a constant digester temperature sig-
nificantly enhances biogas yield, while seasonal variations in thermal energy requirements
underscore the necessity for effective insulation and heating mechanisms.
The solution presented in this work enables a more favorable use of the transport,
supply, storage, production, utilization, and processing of materials within the biogas plant.
Additionally, the implementation of advanced heating techniques resulted in a reduction
in overall energy consumption needed to maintain the desired digester temperature.
These findings provide valuable insights for the design and operation of efficient
biogas plants, contributing to sustainable energy production and enhanced biogas plant
efficiency. The study’s approach not only improves energy yield but also supports environ-
mental protection by reducing greenhouse gas emissions and promoting the recycling of
organic waste into valuable resources.
Furthermore, the economic implications of optimized biogas production cannot be
overstated. By improving the efficiency of biogas plants, the study offers a viable solution
for rural and urban energy needs, potentially reducing dependence on fossil fuels and
contributing to energy security. Future research should focus on the long-term performance
of biogas plants with various substrate combinations and further refine heating techniques
to maximize energy efficiency and sustainability.
In summary, the integration of optimized substrate mixtures and advanced thermal
management techniques significantly enhances the operational efficiency of biogas plants.
These advancements pave the way for more sustainable and economically viable biogas
production systems, reinforcing their role in the global transition towards renewable
energy sources.

Author Contributions: Conceptualization, S.P., L.J. and I.B.; methodology, S.P., M.B. and U. Š.;
software, L.D. and V.P.; validation, L.J. and V.P.; investigation, I.B. and L.D.; resources, V.P. and D.Š.;
writing—original draft, S.P.; writing—review and editing, L.J., L.D., M.B. and D.Š.; visualization, I.B.
and U.Š.; wupervision, S.P. and L.J.; project administration, M.B., L.D. and D.Š.; funding acquisition,
S.P., L.D., V.P., M.B., U.Š. and D.Š. All authors have read and agreed to the published version of
the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The original contributions presented in the study are included in the
article, further inquiries can be directed to the corresponding author.
Conflicts of Interest: The authors declare no conflicts of interest.

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