Technical Requirements For Sealed Installation Of Biogas Fermentation Equipment In Pig Farms

Foundation Preparation and Structural Design for Biogas Fermentation Systems

The stability of biogas fermentation equipment depends on proper foundation construction. For large-scale digesters, excavate trenches with a minimum depth of 1.2 meters in soft soil areas to ensure load-bearing capacity. Compact the soil base using vibratory rollers to achieve 95% Proctor density before pouring concrete. Reinforce the foundation with steel mesh grids spaced 20 cm apart to prevent cracking under dynamic loads.

Structural design must account for thermal expansion. In regions with temperature variations exceeding 20°C annually, incorporate expansion joints every 8-10 meters along digesters. These joints should use compressible materials like neoprene to accommodate movement without compromising密封性能. For floating-drum digesters, anchor the gas holder securely to prevent tilting while maintaining flexibility for vertical movement.

Geotechnical surveys are critical before construction. Conduct soil bearing tests to determine appropriate foundation types. In clay-rich soils, use raft foundations to distribute loads evenly. For rocky terrain, adjust excavation methods to avoid blasting damage, which could create micro-fractures affecting密封 integrity.

Pipeline Installation and Connection Techniques

Pipeline systems require precise alignment and material selection. Use Schedule 40 PVC pipes for underground installations, ensuring joints are solvent-welded rather than glued. For above-ground systems, stainless steel pipes with flanged connections offer better durability. All pipelines should maintain a minimum slope of 1% toward digesters to prevent condensation buildup.

Flexible hose connections demand special attention. Install rubber hoses with built-in wire helixes between fixed and moving components, such as between digesters and gas holders. Secure these connections with stainless steel clamps rated for at least 1.5 times the operating pressure. Regularly inspect hoses for cracks or brittleness, replacing them every 3-5 years depending on usage.

Condensate management systems must integrate with pipelines. Install automatic condensate traps every 30 meters along horizontal runs and at low points in vertical drops. These traps should have clear drainage paths and be accessible for monthly maintenance. In cold climates, insulate pipelines and install trace heating cables to prevent freezing.

Sealing Methods for Digestion Chambers

Primary sealing of digestion chambers relies on multi-layer waterproofing. Apply a bituminous primer coat to concrete surfaces before installing EPDM rubber liners. Overlap liner sections by at least 30 cm and weld joints using hot-air guns, ensuring welds pass vacuum box tests at 25 kPa. For secondary containment, construct a concrete ring beam around the digester perimeter, filled with bentonite clay to create an impermeable barrier.

Gas collection systems require airtight seals at all penetration points. Use mechanical seals with double O-rings for shafts connecting mixers to digesters. For floating-drum systems, install gas-tight seals between the drum and water jacket using silicone-based compounds. Regularly inspect these seals for wear, replacing them when compression set exceeds 25%.

Access ports and inspection windows need specialized sealing. Install cast iron manholes with neoprene gaskets rated for biogas service. For observation windows, use laminated safety glass with butyl rubber frames. All seals should undergo pressure testing at 1.2 times the maximum operating pressure before commissioning.

Quality Control and Safety Protocols

Pressure testing protocols must follow industry standards. Conduct hydrostatic tests at 1.5 times the design pressure for 24 hours, observing for pressure drops exceeding 2% as failure criteria. For gas-tightness tests, use soap solution checks on all joints while maintaining 500 Pa positive pressure for 2 hours. Document all test results with photographic evidence of seal integrity.

Safety systems require redundant design. Install dual pressure relief valves set at 5% above maximum operating pressure, with one valve located at the digester top and another near the gas outlet. Equip all control panels with emergency stop buttons and audible alarms activated at 80% of relief valve settings. Conduct monthly functional tests of these safety devices.

Maintenance schedules should prioritize components. Inspect all seals quarterly using infrared thermography to detect leaks invisible to the naked eye. Replace gaskets showing permanent deformation or chemical degradation. Keep spare seals on-site, storing them in climate-controlled environments to prevent material aging.

Since 1999,Sinomuge(Muge) has been a leading manufacturer of livestock feeding systems in China, we specialize in producing silo and feed transport system, liquid feed intelligent feeding systems, intelligent feeding controllers, precision feeding systerm for sows and other automated pig farming equipment. We have established extensive partnerships with leading livestock groups worldwide, including MuYuan, Zhengbang Group, New Hope Group, and Twins Group,, providing integrated professional solutions from design and R&D to production and installation.Official website address：https://sinomuge.com/