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Report State-of-the-art technology in rural Germany If you think that exceptional things take place only in exceptional locations, think again. In the village of Trechwitz, a rural area not far from the city of Potsdam in Germany, one of the most modern biogas plants in Europe is in operation because of the vast energy potential from manure. The successful development of these modern biogas plants started a few years ago, when the local farmers Hergen Wessels and his son Timo Wessels wanted to have a biogas plant for their own farm and realized that there was no technology designed to fit their plans. Therefore, they started to develop their own concept adapted specifically to their farm. The success that followed led Hergen Wes- sels and his son Timo to organize a group of companies to develop, operate and maintain biogas plants. At present, there are approx. 80 employees working in the different areas. The first plant completed by these companies was in 2008, at Timo Wessels’ farm. The plant in Trechwitz was built to capital- ize on the manure and slurry generated by a number of agricultural operations in and around the village. Among these operations are Wessels’ own cow barns in Damsdorf, a riding stable in Trechwitz and a chicken farm in Damsdorf. Another cow barn will be added on the site of the biogas plant itself, holding 120 cattle. When the biogas plant started operating in January 2012, corn and sugar beets were used in addition to manure and slurry. Facility Manager Radko Doldzhev explains: “By now, we operate the plant completely without additional plant mass. Every day, we process 45 tons of manure and slurry. The logging of the supplied material is done automatically: the trucks drive up to the remote-controlled weighing machine and the data is immediately logged in the computer. We generate about 500 kilowatt-hours of power per hour. Since the plant has a total capacity of 800 kilowatt-hours, there is still potential to generate more electricity.” The biogas plant in Trechwitz is being operated with manure and slurry. 18 Güntner heatXchange 18 From left to right: Facility manager Radko Doldzhev, Gerd Knospe (etalon), Rob Emrich (ElectraTherm) in front of the Green Machine Power generation using an ORC plant So, what is so special about this biogas plant? After all, there are already hundreds of them throughout Europe. From the beginning, Timo Wessels put a strong focus on operating the plant with maxi- mum energy efficiency. In cooperation with the company etalon GmbH from Potsdam, specialists in detecting and realizing energy saving potential, and the company ElectraTherm from Reno, Nevada, they put into operation a whole new concept of an ORC plant. ORC stands for Organic Rankine Cycle and denotes a procedure to drive steam turbines with a working fluid other than steam. This process is used to generate electricity with the help of combined heat and power generation, e. g. in biogas plants. New technology by ElectraTherm ElectraTherm has developed a compact ORC machine called the Green Machine that is able to generate electricity from low-temper- ature waste heat by using an organic working fluid. In order to achieve this, patented and patent-pending technology is used. Rob Emrich, Vice President of Sales at ElectraTherm, says: “We put about seven years of development work into this machine, and we are quite proud of it. The small-scale ORC market is still fairly new and this project is an excellent demonstration of our proven technology. This plant is only the fifth in all of Europe that is equipped with a Green Machine to date.” On top of the machine room, there are two drycoolers of the GFH series; a unit with one fan serving as oil-mixture cooler and a unit with four fans serving as emergency cooler. Before the Green Machine was installed, the entire waste heat of the motor was dissipated into the ambient air by the GFH drycooler with four fans. Since the installation of the Green Machine that uses the waste heat to generate electrical energy, this emergency cooler is only used during maintenance work on the block heating station. A special condenser for the energy industry The working fluid used in the ORC process of the Green Machine is being cooled by a condenser of the Güntner series GVD which has been developed especially for the needs of the energy industry. This V-shape coil con- denser has a very small footprint compared to its power density and can be adapted to any application due to its modular design. There are eight basic models with a high flexibility of fin and tube geometries and a large variety of heat exchanger coils allowing for the design of the optimally suited unit. Additionally, the units are delivered ready for operation, so that no installation of individual components on site is necessary. And despite their impressive size, the units are suited for transportation by truck. The plant was designed for an output of 800 kW. Especially when operating at full load, there is the potential to install a district heat- ing system to cover the needs of part of the village. The already existing plant in Damsdorf, consisting of three block heating stations with a total capacity of 1.9 MW, is part of such a district heating system. In total, 26 houses, a local school with a gym and a local storage building are heated with energy generated by this plant. Unit on the left: The Güntner GFH drycooler serves as oil-mixture cooler; unit on the right: The Güntner GFH drycooler serves as emergency cooler that can be used e. g. during maintenance work on the block heating station. The Güntner condenser GVD, specifically developed for the energy industry, cools the working fluid used in the ORC process. 19 ElectraTherm Inc. The company ElectraTherm Inc., headquartered in Reno, Nevada, was founded in 2005 and is a leader in small-scale waste heat recovery. www.electratherm.com etalon GmbH The company Etalon GmbH, headquar- tered in Potsdam, has been helping clients since 1997 to find the perfect energy saving solution for their ventures. This includes investment in innovation, energy management and the optimization of building technology. www.etalon-energie.dePDF Image | heat X Change
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