Contractor Peter Wyss from Ittingen (CH) has been using slurry, manure and organic waste in a highly innovative way for over 20 years. The biogas produced is used to run two combined heat and power units (CHP), generating a total of 750 kW of electricity and thermal energy. The reliable operation of the units is ensured by EVOLUBE ULTRA SAE 40, which is specially formulated for biogas.

Mr Wyss, or perhaps you’d prefer Pesche, what role does biogas-based energy production play in operations?

Quite a big one! But it’s only part of the whole recycling process. We’ve made a virtue out of necessity. We dispose of large quantities of slurry, manure and organic waste from the agricultural and food industry. Due to the odours emitted, we came up with the idea of making biogas production part of the recycling process. This put an end to the stench and gave us a valuable substitute for natural gas.

How is biogas produced?

To put it simply, we first grind the material and optimise the mixture. It then goes into one of our two fermenters, where anaerobic fermentation (without oxygen) takes place through microorganisms. This produces a mixture of methane (CH4) and carbon dioxide (CO2). The most important thing is to clean the gas – by dehumidifying, desulphurising and filtering – before it’s fed into the combined heat and power units. The quality of the gas is continuously examined.

What do you particularly like about the technology?

That full use is made of a raw material that the general public just sees as muck (laughs). We use this to generate biogas that can be stored and then utilised when energy is in demand. The nutrient-rich fermentation residue is separated into liquid and particles using our own technology. These contain a lot of nitrogen and are therefore high-quality fertilisers.

How is the unit maintained?

For contract operations, we employ five mechanics who also maintain the CHP units. Endoscopic assessments of the combustion chambers and certain maintenance work are carried out by experts. Lubrication issues are solved with the help of MOTOREX.

Why MOTOREX?

Gas engines place specific demands on motor oil. The smaller CHP unit is powered by a V8 turbo engine with an impressive 139,000 hours of operation. It has only been serviced twice since it was commissioned in 2008. We’ve been lubricating it with EVOLUBE ULTRA SAE 40 for several years now. This gas motor oil demonstrates high oxidation stability and low volatility, and it neutralises the effects of harsh combustion gases. With the help of oil analyses, we can make full use of the life cycle of the some 200 litres of motor oil and optimise the service life.

What is the proportion of the cost of lubricants in relation to the total cost?

I don’t have an exact figure, but the costs are low. The overall package from MOTOREX pays off. Besides high-quality products, their expert advice and rapid oil analyses during ongoing operations are crucial for us.

What aspects are important to you as a contractor?

Operational reliability for sure. We’re not only Swissgrid’s systems provider, we also supply over 350 households in the area with heat. At the same time, we recycle almost 40,000 tonnes of biomass a year, thus contributing to a reduction in CO2. This is a prime example of a closed-loop process, and one I’m very proud of.

 

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