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Two Shaft Gas Turbines Manufacturer,Supplier and Exporter in India

Product Code : SCL-CELE-13929

This experimental Biogas Plant is a sophisticated, laboratory-scale system designed to demonstrate and investigate the complete process of anaerobic degradation and biogas generation. Its two-stage configuration and integrated PLC control allow for comprehensive study of the parameters influencing biogas yield and quality.

The plant simulates an industrial biogas process using a two-stage (dual stage) method for optimized control over the degradation phases. It supports both continuous and discontinuous (batch) operation modes.

Stage	Reactor	Substrate Process	Key Control Parameters	Capacity
Stage 1	Stirred Tank Reactor 1	Hydrolysis and Acidification (Conversion of long-chain organic substances into short-chain organic substances).	Temperature and pH value are individually controlled.	Approx. 20L
Stage 2	Stirred Tank Reactor 2	Methane Formation (Last step of anaerobic degradation; generation of biogas, primarily methane and carbon dioxide).	Temperature and pH value are individually controlled.	Approx. 70L

Substrate Supply: A separate supply unit includes a 25L substrate tank with a stirring machine (maximum 200 revolutions per minute) and peristaltic feed pumps (maximum 25 L per hour flow rate).
Digestate Collection: A 25L digestate tank collects the final product.
pH Regulation: Two metering pumps (maximum 2.1 L per hour each) are provided for precise addition of acid and caustic to control the pH in both reactors.
Temperature Control: A dedicated heating water circuit (with a tank, heater, temperature controller, and pump - maximum 480 L per hour flow rate) manages the thermal environment of the reactors.

Instrumentation and Data Analysis

The plant is fully instrumented for extensive biogas and process analysis, with a central control system for operation and data logging.

Control and Monitoring

System Control: Controlled by a PLC (Programmable Logic Controller).
Operation: Via a touch screen interface.
Data Acquisition: Measured values are transmitted to a PC via USB (Optional software for Windows 7, 8.1, 10).

Biogas Analysis Specifications

Parameter	Sensor Type	Measuring Range
Biogas Quality	Sensors	Methane content: 0 to 100 percent
		Carbon dioxide content: 0 to 100 percent
Biogas Flow	Flow Meter	0 to 30 NL per hour (Normal Liters per hour)
Biogas Treatment	Drying Column	Biogas is dried with silica gel to measure Humidity (0 to 100 percent range).
Process Control	Sensors	pH value: 2x 1 to 14 (in each reactor)
		Temperature (reactors and biogas): 3x 0 to 100 deg C

Core Experiment Capabilities

The system allows students to conduct practical experiments on process optimization and performance evaluation of biogas technology:

Operating State Stability: Achieving and maintaining a stable operating state in both single-stage and dual-stage configurations.
Parameter Influence Studies: Investigating how key factors impact biogas generation:

Temperature
Substrate type (e.g., maize, potatoes)
Volumetric loading
pH value

Operation Mode Comparison: Analyzing the influence of different modes on biogas yield:

Single stage versus dual stage
With and without post-fermentation (by utilizing the digestate tank)
Continuous versus discontinuous (batch) operation

Performance Determination: Quantifying key output parameters based on operating conditions:

Biogas yield
Biogas flow rate
Biogas quality (Methane and Carbon Dioxide content)

The system's core is a gas generator connected to a power turbine on a separate shaft, enabling the study of two-shaft performance characteristic of vehicle, ship, or generator drives.

1. Gas Generator (High Pressure Turbine)

Components: Radial compressor, tubular combustion chamber, and a radial turbine mounted on a single shaft (Turbine 1).
Speed Range: 70,000 to 90,000 revolutions per minute (Maximum speed limit is 92,500 revolutions per minute).
Fuel: Propane gas, with a maximum consumption of 20 kg per hour.
Performance: Maximum compression ratio of 2:1.
Starting: A computer-controlled start-up fan is used for starting and gas sweep.

2. Operation Modes (Two-Shaft vs. Jet Engine)

Mode	Arrangement	Energy Conversion	Key Measurement
Power Turbine	Two-shaft arrangement	Exhaust gas energy is converted into mechanical energy by the free-running power turbine (Turbine 2).	Electrical power output (0 to 200 Watts) from the asynchronous generator/motor.
Jet Engine	Single-shaft arrangement	Exhaust gas is accelerated and transformed into thrust via a propelling nozzle.	Thrust measurement (force sensor) from 0 to 50 N.

3. Power Generation & Load

Power Turbine Speed: 15,000 to 25,000 revolutions per minute (Maximum 42,600 rev per minute
Generator: Asynchronous motor with a frequency converter acts as a generator.
Load: Generated electrical energy is converted into heat using four 600W braking resistors.²

Sensors and Instrumentation

The system is extensively instrumented with sensors and a PLC (Programmable Logic Controller) for precise, real-time data acquisition via USB and the optional 'Sci-Cal' software.³

Parameter	Type/Quantity	Measurement Range
Temperature	8 “K” type sensors (0.1 deg C resolution)	0 to 1100 deg C (Gas path and oil circuit)
Speed	2 sensors (for each turbine shaft)	0 to 200,000 revolutions per minute
Pressure	5 Pressure sensors 02	Measures fuel, combustion chamber, compressor inlet/outlet, and turbine outlet.
Air/Gas Flow	2 Flow sensors	Inlet/Outlet Air/Gases: 0 to 3000 cubic meters per hour
Thrust Force	Load cell/Force sensor	0 to 50 N (Newtons)
Lubrication System	Gear pump, filtration, heat exchangers	Comprehensive monitoring of the essential oil cooling and filtration loop.

Core Experiment Capabilities

The laboratory unit facilitates critical experiments for understanding thermal machines and propulsion:

System Performance: Investigation of the function and typical behavior during operation of a gas turbine in both power turbine and jet engine modes.
Efficiency Analysis: Determining thermal, isentropic, and mechanical efficiencies across the components.
Key Metrics: Determining effective power, thrust measurement, specific fuel consumption, and pressure losses and ratios across the compressor and turbine.
Characteristic Recording: Recording the characteristic curves (e.g., speed vs. power) of the power turbine.
Exhaust Emissions Analysis: Measuring key emission components in the exhaust gas, including CO2, CO, NO, NO2 (NOx), and SO2.