Components

Schmack Biogas > Components

Components

Biogas substrates require special treatment during storage, processing, introduction and mixing. Schmack has been developing and manufacturing its own components to a high quality standard for many years. We also supply and fit components from other manufacturers. We would be happy to advise you.

Flex-Silo mobile silo concept

Our innovative mobile silo concept made up of system modules protects the groundwater from silage effluent. The Flex-Silo is patented and in 2016 was presented with the Biogas Innovation Award from the German agricultural industry.

Flex-Silo – easy to assemble, cost effective & robust

Most operators of biogas plants are familiar with the problem – with conventional silos, it’s impossible to keep the joints leak-tight forever. As a consequence, the silo systems need be replaced and repaired in a constant cycle. This is expensive and time consuming.

In response, Schmack Biogas has developed a wholly new silo concept, the Flex-Silo. The silo walls comprise multiple staggered structural elements. The casing around the system modules is made of HDPE to make it resistant to corrosion and UV rays. The silo blocks are filled with concrete. This gives the silo stability, rendering a foundation and connecting elements unnecessary.

Silage effluent and waste water are discharged separately from rainwater. They pass through the drainage openings in the silo blocks into the corrosion-resistant plastic waste water collector, and are routed from there directly to the biogas plant or the substrate store. The rainwater drain (suspended gutter) is located above the silage effluent drain, which prevents contamination of the rainwater.

Take advantage of these benefits

  • Simple construction on closed black surface in the silo area
  • Compliance with existing water protection regulations
  • Waste water and rainwater at different levels, so no contamination of rainwater
  • No clogging of floor drains, no changeover valves, so low-maintenance and user friendly
  • No unprotected concrete in the acidic silage effluent
  • Individual elements can be replaced with ease in the event of damage
  • Can also be adapted to difficult plots of lands thanks to corner design with free angle specifications

Pressestimmen

SiloDrain drainage system

SiloDrain is a drainage system that collects rainwater from covered silage areas and discharges it as clean rainwater. The separation of rainwater reduces spreading costs.

SiloDrain – silo system for water separation

Our innovative drainage system collects rainwater from the covered silo areas and discharges it as clean rainwater into receiving waters or seepage systems. The system prohibits connection of the rainwater to the silage effluent in the mobile silo, thus ruling out any contamination of the rainwater.

State of the art before SiloDrain

Silage effluent has a pH value of up to pH 2 and must be disposed of properly, which is very costly. In standard mobile silos, it collects in drainage channels or gullies via a central incline and is discharged from there into an intermediate storage facility via pipe systems. If rainwater then runs over the cover panel of the mobile silo, it mixes with the silage effluent, thus multiplying the volume of the liquid to be disposed of. This increases costs and creates more work!

Separate rainwater and reduce spreading costs with SiloDrain

The rainwater is collected via the drainage system of the covered silo areas and can be transferred to the public storm sewer as dischargeable rainwater or allowed to seep away on the premises.

Since the digestate, silage effluent and surface water are always separated, SiloDrain conserves storage capacity while reducing spreading costs.

Design and function

SiloDrain comprises a PVC fabric sheet with integral pressure stable PE drainage pipes, which are attached to the silo wall. These function as both a drain to discharge the rainwater itself and as spacers between the wall of the mobile silo and the silage stock, to allow the rainwater to flow into the drain. After ensilage, the drainage film is placed on the underlay film and overlapped with the cover film.

SiloDrain can be installed on virtually any mobile silo wall. The system is installed with an appropriate incline to the walls of the mobile silo. The height of the system setup at the wall compensates for unevenness as well as varying settlement of the silage up to a height of around one metre. Accumulating water can be discharged from the silo in any direction. Additionally, SiloDrain offers additional concrete protection, as no silage effluent can attack or damage the installation.

Materials

  • PVC
  • 730 g/m²
  • Fabric-reinforced
  • Resistant to silage effluent and UV rays

Benefits at a glance

  • Simple design for retrofitting in existing mobile silo systems
  • Waste water and rainwater at different levels, so no rainwater contamination
  • Lower fermentation residue storage volume required, leading to a reduction in spreading costs (no storage of contaminated rainwater)
  • Durable design
  • Optimal ensilage – no rainwater in the silo
  • Optimale Silierung – kein Regenwasser im Silo

PASCO charger technology

The charger technology of the PASCO series, developed in-house, enables flexible processing of all solid matter variants, including grass, maize and solid manure – with very low inherent power consumption. All models are designed to industry standard and utilise high quality, robust and durable materials that will give the operator many years of seamless plant operation.

PASCO 8/12
Flexible supply system – even for difficult substrates

The PASCO 8/12 supply system is a robust dosing station made of steel. The PASCO 8/12 is specially designed to handle difficult substrates, such as larger quantities of solid manure, grass and other regenerative raw materials.

The basic version of the PASCO has a capacity of approx. 8 m³ and can be easily extended to 12 m³ with an extension kit. Side entry (below the fill level) or a solution involving vertical conveying technology can be implemented depending on local and plant-specific conditions.

Take advantage of these benefits:

  • Robust and high quality dosing station
  • Flexible in use for different quantities and raw materials
  • Liquid-tight sump tray
  • Free selection of discharging and conveying technology
  • Low-maintenance operation

PASCO 16/20/30
Robust dosing station of industrial quality

The PASCO 16/20/30 supply system comprises a dosing station plus conveyor device individually matched to specific requirements. The PASCO 16/20/30 has been specially designed to supply regenerative raw materials and similar feedstocks into biogas digesters and can reliably process difficult substrates such as larger quantities of solid manure and grass.

Take advantage of these benefits:

  • Robust and high quality dosing station
  • Flexible in use for different quantities and raw materials
  • Liquid-tight sump tray
  • Free selection of discharging and conveying technology
  • Low-maintenance operation

PASCO 60/80/100
Industrial charger technology for biogas plants

The PASCO 60/80/100 supply system comprises a push floor dosing station plus conveyor device individually matched to specific requirements. The dosing station in the PASCO 60/80/100 has been specially designed to supply regenerative raw materials and similar feedstocks into biogas digesters and is characterised by its high degree of flexibility when it comes to processing difficult substrates such as larger quantities of solid manure and grass.

Vertical conveying technology and liquid charging are available as variants for supplying the digester.

Take advantage of these benefits:

  • Robust and high quality dosing station
  • Flexible in use for different quantities and raw materials
  • Liquid-tight PE sump tray
  • Free selection of discharging and conveying technology
  • Low-maintenance operation
  • Extremely low inherent power consumption

Fermentation

A reliable agitator is the engine of every biogas plant. It helps to ensures that the substrate is evenly mixed. Proper mixing prevents settling and floating, and stirs out the gases. Our agitators ensure optimal and gentle mixing of the microorganisms in the substrate. When compared to conventional agitators, they have a robust and low-maintenance design, and consume very little power.

Perfect mixing

Schmack Biogas agitators are robust and durable, and help to ensure seamless operation of your biogas plant.

Remex® paddle agitator – durable and gentle in handling microorganisms

A reliable and robust agitator is the engine of every biogas plant. It helps to ensures that the substrate is evenly mixed. Proper mixing prevents settling and floating, and stirs out the gases.

The continuously operating Remex® paddle agitator is particularly suitable for regenerative raw materials. The slow and steady agitation process is gentle on microorganisms to ensure optimal fermentation. A particular advantage is the very low power consumption. This enables continuous operation of the agitators and prevents floating layers.

Maintenance work can be conveniently carried out at any time. All electrical parts as well as the drive motor and the gear unit in the agitator are located outside the digester for ease of access.

Take advantage of these benefits

  • Very low inherent power consumption
  • Extremely robust and durable
  • Self-lubricating polyamide bearing
  • Horizontal and vertical mixing
  • External motor
  • Low failure rate
  • Low maintenance

REMEX® SF agitator – self-supporting paddle agitator for steel tanks

The REMEX® SF is an evolution of the successful REMEX® agitator for mixing regenerative raw materials and liquid manure.

It is now possible to carry out straightforward installation or retrofitting of a large wing agitator in a steel tank – without the need for external support structures or concrete foundations.

An intelligently designed, internal mounting frame transfers the entire torque from the agitator to the internal tank floor. A reinforced sealing flange frame on the tank wall prevents substrate or biogas from leaking out. Loads on the tank wall are ruled out.

The height of the REMEX® SF can be continuously adjusted during installation. It can be used with varying fill levels (e.g. in the fermentation residue store). Seals and drive units requiring maintenance are mounted outside the digester for ease of access.

Take advantage of these benefits

  • Use with varying filling levels
  • Easy retrofitting
  • Without external support structures or concrete foundations
  • Continuous height adjustment in installation
  • Seals and drive units on the outside

Prw-s agitator – successfully installed more than 500 times in biogas plants

The low-maintenance agitator is mounted on the outside of the concrete ceiling. The drive unit is therefore on the outside of the digester and is freely accessible if maintenance is required. The agitator can be accurately adjusted to the speed and power consumption while your biogas plant is operational.

The paddle agitator is ideal for mixing fermentation substrates and liquid manure. The constant and gentle mixing of the microorganisms prevents settling and floating to the fullest extent possible, and reliably stirs out the biogas.

Take advantage of these benefits:

  • Maintenance-free base position
  • High agitator capacity
  • Robust and durable material
  • Continuously adjustable speed control
  • ATEX approval (zone 2)
  • Inverter controlled

Pump and substrate technology

Schmack Biogas supplies the pump and substrate technology according to the viscosity of the substrate, the dry matter content and the type of plant. This enables maximum flexibility through customised solutions. High quality, robust, tried & tested components from renowned manufacturers ensure the requisite level of safety and performance, e.g. when filling or pumping out tanks.

Gas tank

Is your plant still gas-tight? Gas-tight covers and membrane roofs age. Ultimately, leaks can occur. It is important to take precautions – replace them promptly – and ensure that your plant can achieve its full yield!

Gas utilisation

Combined heat and power unit (CHP), activated carbon and gas cooling

Individual, independent advice from our experts – The CHP unit is the heart of your biogas plant. We provide information and advice on CHP unit manufacturers and the associated peripheral equipment, such as activated carbon and gas conditioning, including integration into the overall system. You can consult our experts and jointly identify the right performance class for your biogas plant, carefully tailored to your needs.

Fertiliser management

Expertise and precise methods are needed to ensure that fertiliser utilisation is compliant with the German Fertilisers Regulation (DüV). We are specialists when it comes to reliable analytics and determine the relevant parameters of your fermentation residues in our laboratory. We have carefully considered concepts for fermentation residue processing and optimal storage to help support your compliance with the German Fertilisers Regulation (DüV). This way, you can reduce spreading quantities, separate the nitrogen and convert the organic nitrogen into mineral nitrogen. For sewage plants, we develop bespoke concepts for sewage sludge drying including a thermal concept for optimum use of waste heat.

Take advantage of these benefits:

  • Reduction in spreading quantities
  • Separation of nitrogen
  • Conversion of organic nitrogen into mineral nitrogen