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In a biogas project, process selection and design are vital to the plant performance and reliability. Only an advance concept for automation and process control makes biogas production efficient and safe .Today the average availability of a biogas plants is approximately 65%. This is far below the profitable level of 80%. An advance concept for automation and process control only can make biogas production efficient and safe in the long run. With automation and process control we can efficiently handle dangerous situations in the Biogas fermentation process.

Unfortunately, many Biogas plants are still working on a rather low level measuring and process control systems due to the price constrain during the construction phase. As a consequence, the chances of missing efficiency level of greater than 80% is practically zero. To add to it, the technically weak installations in hazardous areas are prone to fail which could be a serious hazard.

Didask Bioenergy provides all relevant control systems, whereby the investor and the operator of the Biogas plant find themselves in a win-win situation. Our knowledge and experience in Biogas production and in engineering safety relevant measurement systems ensures high-yield plant operation.

A biogas plant is a complex installation with close interrelationships between all associated parts of the plant. Due to this, a centrally computerized monitoring and controlling system is an essential part of the overall plant operation, aiming to guarantee success, avoid failures and enhance productivity. Standardization and further development of the AD process technologies is only possible with regular monitoring and documentation of relevant data. Monitoring and documentation is also necessary for process stability, so as to be able to recognize deviations from standard values and permit early intervention and implementation of corrective measures. The monitoring process includes the analysis of chemical and physical parameters. Regular laboratory tests are required to optimize the biochemical process and to avoid inhibition or collapse of biogas production.

Didask Bioenergy plants can be automated according to the choice and requirement of the investor.Some of the parameters that are monitored, as a minimum requirement are the type and quantity of inserted feedstock, Process temperature, pH value, Gas quantity and composition, fatty acids content, Filling level. This monitoring process would be installed in the construction phase of the biogas plant. The control of biogas plants is increasingly automated through use of specific computer based process control systems. A wireless remote controlling system is possible for the plant management.

The State of art automated control systems are made use of at Didask Bioenergy for the Feedstock feeding, Sanitation, Digester heating, Sediment removal, stirring intensity and frequency, Feedstock transport through the plant by conveyor systems, Solids and liquids separation, Desulphurization, Electric and heat output management.

The type of controlling and monitoring equipment varies from simple timers up to the visualization of CAD supported controlling with a remote alarm system. However, in practice, the measurement and technical control equipment used in agricultural biogas plants are often very simple due to financial constrains.

The Separator

In Didask Bioenergy plants, the Separator is used for separation of digested biomass into solid and liquid fractions and is included into the basic equipment of the biogas plant. Separator components are made of corrosion- and abrasion-resistant steel. The digestate is either gravity fed or is fed to the loading chamber by means of pumps through a supply branch pipe. This can be automated as per the investor’s requirement. From the loading chamber digestate is fed to the separator by the use of a varied pitch auger made of abrasion-resistant steel. Separation chamber is a cylindrical sieve also made of abrasion-resistant steel. Liquid and solid fractions are separated by means of pressure and filtration in the separator. The liquid fraction is poured out through an emptying fixture secured to the accumulator tank. Solid fraction with the help of an unloading batching system leaves the separator and is accumulated in a bin and fed further on.

Volume of feedstock input

The volume of feedstock which can be inserted in the digester can be determined using flow measurement instruments called flow meters. The flow meters are robust and are not affected if they become soiled. Generally, inductive and capacitive flow meters are used, but instruments using ultrasound and thermal conductivity measurements can also be provided. Flow- meters which have mechanical parts are less suitable for biogas plants and are avoided. For solid feedstock input like maize silage, appropriate weighting equipment using load cells are used which allows adjusting the dosage of solids. This can be fixed on the conveyor, providing ease in operation.

Digester level determination

Monitoring of the levels in digesters and in storage containers is done using ultrasound or radar techniques, which measure the hydrostatic pressure on the floor of the digester or the distance to the surface of the liquid.

Gas reservoirs level determination

Measuring the levels of gas in the reservoirs is important for operation of CHP plants. If the pressure of the biogas available is too little, the CHP plant will be automatically switched off and restarted when the level is beyond the minimum permitted for CHP operation. Measurement of level is usually done by pressure sensors.

Process temperature

The temperature inside the digester should be constant and hence is permanently monitored. There are several measuring points inside the digester for temperature monitoring of the whole process. The measured values are sent to an automated data logger and can be visualized by an operator on a computer in a remote location. This data input also enables automatic control of the heating cycle.

pH-value Monitoring

The pH-value of the substrate provides important information about the performance of the AD process thus providing vital information about the gas production. Measurement of pH is done on a sample from the digester content, which is taken at regular intervals. The pH is measured using pH-meters.

Volatile fatty acids (VFA) Monitoring

The monitoring of VFA facilitates evaluation and optimization of the AD process. The measurements concern the spectrum and the concentration of fatty acids. Continuous measurement is difficult to be done on site, due to difficulty of analysis methods. A correct evaluation of the actual process biology is difficult even in laboratory, due to the duration between taking the sample and performing the analysis in the laboratory. In addition to VFA monitoring, the concentration of chemical oxygen demand can be monitored continuously which provides another parameter in the fatty acid analysis.

Biogas Quantity Monitoring

The biogas quantity in Didask Bioenergy plants is measured by gas meters. Measurement of gas production i.e. gas quantity is an important tool to assess process efficiency of the plant. Variations of gas production can indicate process disturbances and require adequate adjustment measures. The gas meters are usually installed directly in the gas lines. The measured biogas quantities are recorded for assessing gas production patterns and trends and the overall performance of the biogas plant.

Biogas Composition Monitoring

The composition of biogas can be continuously monitored by gas analysis and the use of appropriate measurement devices. The results can be used for controlling the AD process and for the subsequent processes such as gas cleaning.
Determination of gas composition is done using sensors based on heat decalescence, heat transmission, infrared radiation absorption, chemisorptions and electro-chemical sensing. Infrared sensors are suitable for determination of methane and carbon dioxide concentrations. Electro-chemical sensors are used to determine the hydrogen, oxygen and hydrogen sulphide contents level.
Measurement of gas composition can be done manually or automatically. The manual measurement devices provide information about the actual gas composition, but the subsequent integration of data in a computerized plant control system is difficult. Hence, automatic gas composition measurements are preferred and are more popular.
The automation level can be adjusted and utilized as per the choice of the Investor, depending upon the financial ability and specific needs of the operator.


To make the world a better place to live in by the development of economic, efficient and environmental friendly energy technology solutions.


To create environmental sustainability and energy independence through the growth of the biogas industry thus reducing the dependence n fossil fuels.


Biogas is the one of the only technologically fully established

renewable energy source that is capable of producing heat, steam, electricity, vehicle fuel and other valuable byproducts. It is, in the true sense of the word, a dynamic energy source. Biogas has become a fuel to be looked forward to. This growth has begun over the last two decades.

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