Biogas is a clean and efficient renewable energy source, and promoting biogas engineering is one of the important methods to achieve green energy utilization and mitigate climate change. Recently, Nord Drive has partnered with PRG, one of the world's leading mixing technology suppliers, to provide driving solutions for a super large biomethane factory in Europe.
Superb driving force
Connect a 5-meter diameter mixing paddle to a 22 meter long mixing shaft
Reliable and stable operational capability
Can provide maximum reliability for year-round, all-weather, fault free and smooth operation
Explosion proof level in compliance with ATEX directive
Considering the flammable and explosive properties of methane gas, the driver also needs to have explosion-proof performance that meets the requirements of the ATEX directive
Recently, Frizoit in Lower Saxony, Germany, is building a super large biogas plant that includes 40 fermentation tanks with a width and height of 24 meters each. It is expected to process one million tons of feces and fecal liquid in the region every year. To ensure reliable operation, it is necessary to continuously stir the biomass in fermentation tanks (each with a capacity of up to 9500 m3). And the size of the mixer used in the project is also amazing: a special mixing blade with a diameter of 5 meters is connected to a 22 meter long mixing shaft; The mixer itself weighs 7.5 tons, without a gearbox.
The oversized size of the device places extremely high demands on the drive, such as:
Provide maximum reliability for smooth operation 24/7 without any faults throughout the year;
Minimize maintenance requirements to the greatest extent possible;
Durable and sturdy design that meets long-term exposure to various climatic conditions.
In addition, considering the flammable characteristics of methane gas, the driver also needs to have explosion-proof performance that meets the requirements of the ATEX directive.
After multiple screenings, PRG adopted Nord's MAXXDRIVE in its mixer ® Series industrial gearbox. These gearboxes have been meticulously designed to maximize load capacity and operational reliability, providing an output torque of 15 to 282 kNm, allowing for long-term reliable operation even in extreme conditions such as biomethane factories. They also adopt an integrated UNICASE casing, which reduces the joint surface of the casing, thereby ensuring the machining accuracy, load-bearing stiffness, and strength of the casing. The bearings also provide a longer service life than gearboxes manufactured by splicing.
The gearbox adopts customized design, with low operating noise. The large low friction rolling bearings used ensure ultra-high radial and axial load capacity, and high-precision axis alignment reduces working noise, achieving long-term reliable operation. Nord's engineers work closely with PRG experts to tailor driving solutions for customers, meeting their personalized application needs.
In addition, Nord has specifically developed SAFOMI-IEC motor interfaces for mixer drives, combining the functions of standard IEC motor interfaces with those of oil expansion tanks, further improving operational reliability. This design does not require a fuel tank or hose, and more importantly, does not require a gearbox input shaft oil seal (which, due to the high speed of the input shaft, causes fast lip line speed and is prone to wear), thereby reducing maintenance workload and extending service life.
Through multiple optimizations, the interval between its first oil change has been extended to 20000 working hours, equivalent to two years of operation time.