1.

ANAEROBIC DIGESTER MIXING

Mixing does not mean simply stirring the substrate. The mixing of the digester has to be
sensitively adjusted to give the microbes the best possible environment for the least
whole life cost.

One of the most important factors of a successful anaerobic digestion plant is the mixing. This
applies not only to the digester but also to the inlet tanks, blending tanks, separation systems,
digesters themselves and post digestion storage. The requirements for each of these stages are
different but effective mixing is essential. So what is ‘effective mixing’? Design engineers
would define it as achieving the optimised contact between the substrates for the minimum
whole life cost. Guidance on what this means in reality can be obtained from the manufacturers
that have been in the business for a long time. They can provide advice on what system will be
most appropriate for your project, but they will, of course, be keen to offer their own products.
The following guidance is intended to provide the reader with sufficient understanding to deal
knowledgably with the mixing needs of their project. For simplicity, the guidance concentrates
on the needs of the anaerobic digestion tank itself as this is the key and most sensitive
component in the system.

Mixing in the digester is critical as it fulfils the functions of;

• Bringing the feedstock and microbes into the intimate contact they need to successfully
digest

• Avoiding stratification

• Avoiding excessive build up of heavy deposits at the bottom of the digester

• Minimising the production of crusts and foams on the top of the digesting sludge

The successful completion of these functions results in the maximised gas production and
quality of digestate. As these are the primary benefits of digestion, it is clear that mixing is a
key component of the digestion plant.

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The mixing systems in most common usage are;

1. Long shafted paddle type

2. Jet mixing

3. Gas mixing

4. Submersible mixers

5. Wall mounted mixers

Each of these is discussed with their pros and cons in the sections below.

1.1 Long shafted paddle type mixers

There are two versions available: either side entry with the shaft going from the side towards the
centre of the tank, or top entry. Side entry mixers are only suitable for relatively small digesters
with a maximum of around 6 metres depth. Top entry mixers are mostly used when tank height
is considerable compared to tank diameter. Normal operation for both types would be
intermittent, i.e fixed periods of several minutes every hour equally spaced throughout the day.

Advantages - normally a reasonably low power consumption motor is used which is mounted
externally giving easy access. No regular servicing is required apart from the normal greasing,
etc. They are all slow speed, large bladed units that hence minimises the risk of mechanical
failure.

Disadvantages - Stratification on some substrates may occur, causing the units to operate
continuously or the substrate to be diluted to compensate. This has cost and efficiency impacts.
Costly to install because of the entry to the tank as it has to remain gas/liquid tight for the life of
the digester. If the unit fails then total shutdown is required to remove the unit or carry out
repairs.

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1.2 Jet mixing

A jet mixing system comprises one or more (depending on the tank size) externally mounted
pump units which deliver a recirculated flow into a series of nozzles within the tank. The
operation is again intermittent with varied pump unit selection to optimise wear rates.

Advantages - The pump unit is mounted externally so regular service is facilitated.

Disadvantages – The jets may become blocked over time which will degrade mixing
performance and increase power costs. The jets may only be unblocked by draining down the
digester – a major expense. Power consumption may be higher than other systems.

1.3 Gas mixing

Gas mixing involves recirculating a fraction of the digester gas through the digesting sludge via
a compressor and a series of pipes and nozzles. Again, operation is normally intermittent and
may also be controlled by using variable speed drives.

Advantages - The motors are mounted externally as is most of the pipework, easing the
maintenance requirements. With some systems, a separate mixing chamber is provided which is
accessible from the outside of the tank for maintenance.

Disadvantages - initial purchase cost is slightly more expensive than other systems, but whole
life costs are usually the lowest.

1.4 Submersible mixers

These are similar to the ubiquitous submersible pumps except that the pump head is replaced by
a normally quite slow running propeller. The unit is mounted on guide rails through the roof of
the tank. They can be electrically or hydraulically powered and are usually operated
continuously.

Advantages - Possibly the lowest cost solution in terms of initial purchase cost. The system
offers very efficient and controllable mixing with the possibility of raising and lowering mixer.
Some systems are available with a gas tight chamber at the top of the guide rail which allows
the submersible mixer to be removed without the total loss of gas production. Most are installed

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in a way that the angle of direction can be adjusted to suit the tank design. The service shaft can
also act as a gas over pressure and under pressure relief valve on some systems.

Disadvantages - Regular servicing must be completed to prevent breakdowns. Seals can be a

weakness on these units.

1.5 Wall mounted mixers

These are mounted on the wall of the digester with a short shaft and high speed impeller.

Advantages - All the major components are mounted externally with automatic oilers and grease
applicators. The submerged end of the unit requires only a limited amount of maintenance
which is normally completed during the planned digester shut down of every two to three years.
No entry into the tank is required at any time as the whole unit is removed by a very simple
guide system. The units may be operated intermittently and/or in conjunction with a variable
speed drive.

Disadvantages - As the mixer position is fixed, there is no room for adjustment and the position
needs to be correct for the mixer to operate efficiently. A manufacturer with many years
experience with these systems can provide the best advice.

1.6 General Advice from a Supplier of Mixers

“Different manufactures will no doubt have there own ideas on mixing and what power is
required, most will go for the lowest power requirement as it relates to initial purchase price.
This is possibly not the way forward and could turn out to be a costly mistake especially when
lifetime costs are considered. Some will calculate on W/m³ (watts per cubic meter of tank
volume), some will base the calculations on previous contracts and a “it worked at their site so it
should work on yours,” type of approach, which may work, but what if it doesn’t? Would they
agree to remove the equipment, pay you for down time and loss of revenue? Check before you
agree to the signing of the contract. Some will approach armed with little magic sticks that you
plug in to the side of your computer, and I promise you that you will be amazed at all the
colours and you will be convinced that this really is technical stuff. But wait, it has been proven
time and time again that this system of unit selection is not as thorough as it makes you believe.
If the manufacturer supplies the data then it’s very possible that it will be correct, but in a lot of
cases this data is supplied by a third party who conducted the trials. These specialists are very

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good at what they do, but there are so many instances where the wrong data has been inputted
purely because the companies are not mechanically minded and do not understand propeller
technology. It takes years to develop a portfolio of propeller and mixing data using different
mediums and especially with the industry as it is now, there will never be two plants that have
the same medium entering their digesters.

According to Washington University, St Louis, as high as 76% of any digesters that fail in the
USA, failed because of incorrect mixer technology. Possibly they were not serviced, but in most
cases they would have been undersized due to cost and winning the order! In all cases, it is
advisable to get references from existing users of mixing equipment which is ‘relevant’ to your
proposed works and take the time to visit these people and talk with them, regardless of where
they are.”

With thanks to Hugh Vaughan of Landia

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