Progressive biogas production - Vogelsang

ENGINEERED TO WORK
Engineered FOR MORE EFFICIENCY to work AND ECONOMY
Progressive
biogas production
Equipment and systems for pumping,
grinding and biomass feeding
Industry
Waste water
Biogas
Railway
Agriculture

Biogas | Product Overview
Vogelsang: simply more biogas
Reliable components for specialized tasks
Innovative solutions for progressive technologies are
central to our corporate philosophy. We have partnered
with biogas plant pioneers from the very beginning to
conduct intense research in the field. In the interest
of more efficient and economical operation of biogas
plants, we offer plant operators special components
and systems that simplify handling and increase yield.
RotaCut® A wet macerator and heavy
material separator in one. Reliably
separates foreign objects such as stones
and metal parts; macerates fibers and
coarse materials in defined liquid media,
thus ensuring more homogeneous and
flowable suspensions.
BioCut® The original Vogelsang rotary
lobe pump combined with an upstream
RotaCut wet macerator is specially
designed for the biogas sector. Optimizes
liquid introduction with economical
pumps and perfect maceration. Fibrous
matter is discharged into the RotaCut
where it is reliably macerated.
BioCrack® The electrokinetic
disintegration process that lowers
operating costs and increases efficiency
by means of higher gas yields and
reduced biomass consumption.
Take advantage of our knowledge
We develop and continuously improve biogas plant components that demonstrate their
high performance at installations throughout the world. Research, ongoing development
and innovative features are key to achieving maximum efficiency and economy in
biogas production.
Efficient biogas production
The performance of a biogas plant depends largely on the efficiency of its individual
components. Every one of our products does its part. A combination of our individual
components creates a more effective overall system. As a result, we are able to offer reliable
products and efficient solutions – tailored to your specific requirements – for pumping,
macerating and feeding, as well as for preparing cosubstrates and biosuspensions.
Vogelsang rotary lobe pumps Thanks to
their excellent properties – compact
design, self-priming, easy to service and
maintain – Vogelsang pumps are the
economical solution for many different
pumping tasks.
XRipper Allows the efficient fermentation
of fruit, vegetables and a variety of organic
waste. The powerful twin-shaft grinder
economically prepares large and coarse
solids in liquid or dry media.
QuickMix II and EnergyJet
Solid matter feeders – economical
digester feeding with mashed substrate.
Their optimal feeding increases
the gas yield and reduces the
energy required for mixing,
stirring and pumping.
3

Biogas | Pumps
The economical solution for a variety of conveying tasks
The heart of a high-performance biogas plant
Rotary lobe pumps –
perfect quality and
performance
We invented and perfected them. Now they
are the global benchmark for reliable pumping
technology in many sectors.
Where sophisticated, rugged and powerful pumping technology
is required, rotary lobe pumps from Vogelsang are the equipment
of choice. Thanks to our strategy of continued development,
these pumps are fully loaded with innovative features that make
them highly efficient and easy to maintain. This is a decisive
advantage when it comes to creating economical solutions for
biogas plants.
The principle
Vogelsang rotary lobe pumps feature elastomer-coated lobes.
These non-contacting, rotating, positive displacement pumps
have become an indispensable component in biogas plants.
Vogelsang rotary lobe pumps are an economical solution for the
many conveying tasks in biogas plants due to their pulsationfree
HiFlo® rotary lobes, their high tolerance for foreign matter
and dry running, and their speed-proportional capacity.
Versatile
There are virtually no limits to the
applications of Vogelsang pumps. They
can even handle abrasive media such
as sandy manure and highly viscous
biosuspensions with high fiber and solid
particle content. The Vogelsang rotary
lobe pump handles (almost) anything.
Practical and economical
Vogelsang pumps are easy to operate,
maintain and service. This minimizes
downtime, ensures high availability and,
above all, reduces operating costs.
Compact and space-saving
These compact pumps can be conveniently
integrated into any system – even in tight
spaces. Retrofitting a Vogelsang pump is
generally a simple matter.
Easy to service
A QuickService design makes these
pumps particularly convenient to maintain:
simply open the cover plate to gain access
to the pump chamber. Since there is no need
to dismantle pipework and disassemble the
pump first, wearing parts can be quickly
replaced.
Q – QuickService pumps: The wearing
plates, lobes and seal can be replaced
on-site without removing the pump.
This saves money and ensures very high
availability.
QD – QuickService pumps with a
third bearing in the cover plate provide
high stability, even at high pressures.
A choice of pumps
The Vogelsang VX rotary lobe pumps
are available in four series. Every pump
is configured according to specified
requirements and applications.
The interior coating, lobe material
and drive type are all customised to
your particular biogas plant.
Flexible drives
The pump can be driven by diesel engines
or hydraulic and electric motors – either
with a geared motor or more compactly
with a piggy-back electric motor and
belt drive. All pumps can be equipped
with variable frequency drives for
more control and optimization of their
operational characteristics.
Shaft guarantee
Large cross-sections and no shoulders:
Vogelsang pumps have break-resistant
shafts. The VX series come with a 5-year
warranty against internal shaft breakage*.
* When used as intended, as specified in our
warranty terms and conditions.
Advantages of Vogelsang
pumps at a glance
• Minimal space requirements due
to compact design
• Usable in a wide variety of
applications and easy to operate due
to reversibility of flow, self-priming
capabilities and high tolerance of
dry running
• High tolerance of foreign material
due to the innovative Injection A
technology
• Economical operation due to
high efficiency and pulsation-free
HiFlo® lobes
• Easy service and maintenance,
resulting in high availability and
low downtimes
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5

Biogas | Pumps
Cutting-edge technology in standard models and special designs
Sealing technology for
professionals
For years, cartridge seals have been a
standard in all VX pumps. All components
are contained in a fully preassembled
unit. Special units are available for the
diverse requirements in biogas plants.
Injection A
In conventional rotary lobe pumps,
foreign materials and solids are drawn
in by vortex suction. This often causes
damage by foreign matter and greater
wear on the lobe tips.
Advanced technology from Vogelsang:
Our innovative InjectionSystem injects
foreign material directly into the cavities
that open between the lobes. This reduces
collisions with the lobe tips. In addition,
the internal seal of the pump is improved.
Using the flexible Injection modules the
flow direction can be altered on site.
Control technology
The performance and efficiency of
Vogelsang rotary lobe pumps is greatly
enhanced by their advanced control
technology. The Performance Control
Unit (PCU) continuously monitors and
intelligently coordinates pressure, current
consumption and (optionally) rotating
speeds. Thus, it automatically detects
the load and makes the necessary control
adjustments to keep the pump running at
optimum levels.
Quality management
Quality control is guaranteed at Vogelsang.
Every pump is tested before leaving the
factory. Acting on the principle of
“Those who stop seeking improvement
lose their edge”, we constantly sharpen
our quality management system
and regularly certify according to
DIN EN ISO 9001:2008.
Special designs
Our in-house specialists develop custom
equipment upon request.
Some examples are:
• Multi-chamber pumps
• Two-stage pumps
• Combination drives
• Pumps with an integrated
cutting assembly
• Radial wear plates
Advantages of Injection A
at a glance
• Considerably higher resistance
to foreign materials and solids
• Improved pump efficiency and
suction characteristics, even at
low rotational speeds
• Reduced operating costs and
significantly longer service lives
(up to 2.5 times longer in field trials)
Advantages of Cartridge
sealing at a glance
• Quick and simple seal replacement
• High availability and operational
reliability thanks to safety
performance
• 100 percent proven seal, automatically
activated during assembly
Technical data
Type Marathon Displacement
Max. pressure Max. capacity* Max. speed Max. shaft deflection
volume
Q QD Marathon Q - Version QD-Version
l/rev bar bar bar m 3 /h l/min min -1 mm/bar mm/bar
Series VX 136
70 140 (70/70) 1.27 10 12 16 61 1016 800 0.01 0.002
105 210 (105/105) 1.90 10 12 16 91 1520 800 0.03 0.004
140 280 (140/140) 2.53 8 12 14 121 2024 800 0.05 0.007
210 420 (210/210) 3.80 5 10 12 182 3040 800 0.16 0.016
280 5.06 8 243 4048 800 0.031
420 7.59 6 364 6072 800 0.090
Series VX 186
92 184 (92/92) 3.56 10 16 128 2136 600 0.01
130 260 (130/130) 5.03 10 12 16 181 3018 600 0.02 0.003
184 368 (184/184) 7.12 8 12 14 256 4272 600 0.05 0.008
260 520 (260/260) 10.06 5 10 12 362 6036 600 0.12 0.012
368 14.24 3 8 513 8544 600 0.33 0.028
390 15.09 3 7 543 9054 600 0.40 0.028
520 20.12 6 724 12072 600 0.069
736 28.48 3 1025 17088 600 0.191
Series VX 215
226 15.47 5 8 501 8354 540 0.10 0.010
320 21.88 2.5 7 708 11815 540 0.29 0.026
452 30.94 5 1002 16708 540 0.063
640 43.76 3 1417 23630 540 0.161
Series VX 230
226 13.45 8 12 436 7263 540 0.05 0.006
320 19.04 5 10 617 10282 540 0.13 0.012
452 26.90 10 872 14526 540 0.029
640 38.08 6 1234 20563 540 0.073
* maximum theoretical capacity. Normally real capacity is lower, depends on pressure difference and viscosity of the media, as well as pump installation situation.
We can establish the correct size for a pump for a specific application using our computer-aided sizing program.
7
6

Biogas | RotaCut
Rugged, solid and ideal for initial substrate preparation
RotaCut® inline macerator
The perfect solution for homogeneous suspensions and reliable processes
Functional principle
The medium flows steadily through the RotaCut macerator.
Gravity separates heavy objects such as stones and metal pieces,
which can be effortlessly removed through a cleaning port. All
floating and suspended substances within the medium – fibres,
hair, bones, wood, tangles, whole plant silage or grass – are
transported to the cutting screen by the liquid current and
chopped by rotating, self-sharpening blades. The
medium is simultaneously homogenized.
Wide range of applications
The RotaCut plays an important part in boosting plant
efficiency by ensuring that biogas plants can operate reliably
and economically. The RotaCut is used for a wide range of
applications within the biogas plant – including liquid feeding,
digester agitation, slurry transfer to the post-digester, material
recirculation, as well as in locations upstream from the separation
unit and from the external heat exchanger. This versatility ensures
cost-effective operation of the facility.
RotaCut advantages at a glance
• Reliable maceration of fibrous and coarse materials
• Protection of all downstream plant components against
foreign objects
• Homogeneous and flowable substrate, leading to lower
agitation and pumping power requirements
• Greater cosubstrate surface area, resulting in higher
gas yield
ACC® – Automatic Cut Control
Automatic Cut Control provides consistently
high cutting performance in the
RotaCut. It automatically adjusts the
blades and keeps the contact pressure
at a constant level – as high as necessary
and as low as possible. This increases
blade service life and eliminates the need
for manual maintenance. The operator is
informed by a signal indicator when the
blades have reached the end of their
service life.
ACC plus: always informed
The RotaCut can be monitored online
using the ACC plus which is optionally
available for the RCQ and RCX series.
Either an external display or the control
system graphically shows the condition
of the blades at all times and informs
you when the blades need to be changed,
enabling you to plan replacement part
orders and maintenance well in advance.
ACC systems are key to increased
efficiency and automated operation
during continuous use.
Performance Control Unit (PCU):
efficiency through intelligence
When multiple pumps and macerators
are combined into a single unit, the
PCU monitors the processes and other
parameters for each machine. It ensures
optimal communication between the
machines and continuously monitors
their load, controlling each in such a way
that the unit as a whole delivers optimal
results.
The PCU recognises problems early and
automatically eliminates them at the
start. All parameters can be transferred
to a central control system for remote
monitoring.
ACC advantages at a glance
• No manual blade adjustment
required; fully automatic,
uninterrupted operation
• Contact pressure can be readily
adjusted to the medium –
without interrupting operation
• Low operating costs thanks to
minimum wear and low current
consumption
• Optimal results due to consistently
high cutting performance and
constant grinding levels
PCU advantages at a glance
• Reduced maintenance due to
autonomous operation
• Efficient operation due to fully
automatic and situationdependent
control of operating
parameters
• Longer service life reduces
operating costs
• Automatic fault elimination
9

Biogas | RotaCut | XRipper
XRipper
The robust two-shaft
grinder
Effortless grinding of vegetables, fruit and organic waste
Type designation RC3000 RC5000 RCQ-33pro RC10000 RCQ-43pro RCX-48 RCX-58
Motor type
Geared motor x x x x x x x
Hydraulic motor x x x x
Optional speed min -1 76 - 326 66 - 330 115 - 292 66 - 319 115 - 292 114 - 311 94 - 276
Optional motor power kW 1.5 - 4.0 1.5 - 7.5 5.5 - 7.5 2.2 - 7.5 5.5 - 7.5 5.5 - 11.0 7.5 - 15.0
Maximum flow rate m 3 /h 180 300 300 600 600 600 750
Type overview
Separator tank type
Inline
Inline
Inline
RCX
RCX
Cyclone
MXL
Cyclone
MXL
MXL
Cyclone
MXL
MX
Compact
Compact XL
Compact
Compact XL
Compact
Compact XL
Compact
Compact XL
One grinder does it all
The robust XRipper with its reliable
two-shaft design reduces voluminous
solids such as fruit and vegetables, as
well as catering and food industry waste.
The XRipper enlarges the surface area
and thereby accelerates fermentation.
At the same time, it protects biogas
plants against damage and costly repairs.
Service-friendly construction
The monolithic Ripper rotors made of
special steel are mounted on generously
sized shafts. The rotors are made from
a single block. This and the robust QD
design that features bearings on both ends
guarantee outstanding functionality and
stability. The QuickService concept allows
for fast, on-site service and maintenance.
How it works
The XRipper reduce solids, cuts long-fiber
materials with its sharp tips and edges,
and grinds coarse and brittle substances.
The resulting particle size is adjusted by
modifying the width and contour of the
ripper blades.
Advantages of the XRipper
• Long service life due to
rugged design
• High availability due to rapid
service and maintenance
• Economical preparation of
voluminous and coarse cosubstrates
• Faster decomposition and higher
gas yield due to cosubstrate
preparation that is ideally suited
for digesters
RC5000 Compact RCQ-33G
RC10000 Compact XL RCX-58G
Technical Data
Type
Max. pressure
bar
Blade widths
mm
Max. operating torque
Nm
Max. throughput
m 3 /h
Throughput refers
to medium
XRS100-64Q 9 8 300 40 Water
XRS100-90Q 7 8 300 55 Water
XRS136-140Q 8 10|14 1200 110 Water
XRS136-140QD 12 10|14 1200 110 Water
XRS186-130Q 10 11|16|32 2400 170 Water
XRS186-130QD 12 11|16|32 2400 170 Water
XRS186-260Q 5 11|16|32 2400 340 Water
XRS186-260QD 10 11|16|32 2400 340 Water
XRS186-520QD 6 11|16|32 2400 680 Water
XRS186-780QD 3 11|16|32 2400 1020 Water
XRL186-260QD – 11|16|32 2400 20 Easy to reduce solids
XRL186-520QD – 11|16|32 2400 40 Easy to reduce solids
XRL186-780QD – 11|16|32 2400 60 Easy to reduce solids
10 11

Biogas | BioCut
Powerful components – perfectly combined and coordinated
BioCut®
Developed specifically for biogas plants,
BioCut is the powerful combination of a
Vogelsang rotary lobe pump and
an upstream RotaCut
inline macerator
Performance
Thorough maceration and uniform
blending of the liquid phase and
cosubstrate into a homogeneous
biosubstrate substantially increases
the efficiency of biogas production.
Vogelsang has developed a compact
unit specifically for this purpose.
By combining a robust rotary lobe
pump and a powerful macerator into
a single unit, BioCut can prepare
superior quality biosuspensions. It
can simultaneously feed one or more
digesters under automatic control and
handle additional pumping tasks in the
biogas plant when needed.
Design
The system combines a self-priming rotary lobe pump and a special version of the
proven RotaCut. As a central pump station, the BioCut can also handle other pumping
tasks within the system. These include emptying distributed storage pits and feeding
remote storage.
Principle
In most cases, the BioCut draws the biosuspension out of a mashing pit where liquid
manure and cosubstrate have been mixed. The heavy material separator protects the
system against foreign bodies and prevents damage to downstream components.
The RotaCut cutting assembly grinds long fibers to prevent tangling. The cutting screen
geometry and the blade rotor speed can be adjusted to vary the degree of maceration
and the desired throughput. If needed, the cosubstrate can be macerated numerous
times and homogenized more thoroughly by means of repumping or bypass operation.
BioCut advantages
at a glance
• Dosing, mashing and maceration
with a single system
• Fully automatic feeding of
the digester
• Blending of many different types
of cosubstrate
• Excellent maceration results
• High gas yield
• Usable as a central pump station
BioCut combinations
Model Rated capacity Max. pressure Nominal speed Installed electric motor power
Pump
RotaCut
m 3 /h bar min -1 kW kW
BioCut VX136-105Q/RCQ-26G 25 3 300 7.5 4.0
BioCut VX136-105Q/RCQ-33Gpro 30 4 360 7.5 5.5
BioCut VX136-140Q/RCQ-33Gpro 42 4 387 11.0 5.5
BioCut VX186-130Q/RCQ-43Gpro 98 3 410 22.0 7.5
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Biogas | QuickMix II
The turbocharger for biogas plants
QuickMix II
The QuickMix II is based on an entirely new concept. It combines our proven components in
a single unit to increase gas yield and significantly reduce the plant‘s energy requirements.
A uniform mixture of solid and liquid
input materials and avoidance of
clumping are important preconditions
for optimal fermentation. The QuickMix II
meets these preconditions by employing
a unique twin-shaft design that produces
an optimal cosubstrate mash.
Design and functional principle
The QuickMix II consists of twin auger
and a Vogelsang rotary lobe pump. Solid
material is fed to the twin auger by a
suitable feeding system. At the same time,
a liquid phase is added to the QuickMix II
from one side. The ripping teeth of the
twin auger prepare voluminous solid
matter and thoroughly blend it with the
liquid phase to create a homogeneous
QuickMix
Co-ferments
Feeder pump
suspension. In this way, QuickMix II
creates the conditions necessary for
optimal fermentation of solids in the
digester.
The slurry consistency can be adjusted
to individual requirements by regulating
the quantity of the liquid phase. Finally,
the twin auger feed the suspension to
the pump chamber. The capacity control
makes it possible to rinse the line at the
end of the procedure, which eliminates
the need for an additional rinse pump.
Range of applications
The QuickMix II is the ideal solution
wherever suspensions need to be
mashed and conveyed, such as in solid
matter or digester feeding.
QuickMix properties
Compact and maintenancefriendly
design
The QuickMix II is compact and
extremely easy to service and maintain.
Due to the QuickService design, all
maintenance tasks in the pump chamber –
including the replacement of wearing
parts – can take place on-site without
disassembling the unit. When necessary,
the screw conveyors can also be
replaced. The QD bearings on either
side of the unit prevent the screws from
rubbing and guarantee high output
and a long service life, resulting in
maximum availability and reliability.
Thorough mixing of the cosubstrates
with the liquid phase produces a readily
fermentable mash.
The advantages – tested by the EU
Tests show that gas yield is increased
by up to 8 percent* while energy
consumption for the pumps and agitators
is reduced by up to 40 percent*.
QuickMix II advantages
at a glance
• Up to 8 percent more biogas*
• Up to 40 percent less energy
consumption for mixing*
• Capable of handling a variety of
cosubstrates
• Breaks up and dissolves coarse and
fibrous matter
• Homogeneous mixing of dry matter
and liquids
• Infinitely variable dosing of solid
material allows for the optimal
adjustment of dry substance content
• pH-neutral mashing
• Minimal odor and gas emissions
• Several digesters can be fed using
just one QuickMix II
Calculate your efficiency advantages
at www.biogas-profit-calculator.com
Series & model Rated capacity Displacement volume Flange size Max. pressure Max. speed
m 3 /h l/rev mm in bar min -1
VX186-92QD 20 - 64 3.56 150 6 8 400
VX186-130QD 30 - 90 5.03 200 8 6 400
VX186-184QD 40 - 128 7.12 250 10 4 400
* Results from the EU-AGRO BIOGAS research project.
14 15

Biogas | EnergyJet
EnergyJet®
The efficient solution
for trouble-free digester
feeding with corn silage,
grass silage, GPS or dung
in a mashed form
Introduce renewable resources in a reliable and uncomplicated way
Performance
Renewable resources often contain stones, metal parts and sand.
This causes system malfunctions and damage to conventional
systems, and also increases wear. EnergyJet is unaffected by
foreign matter due to its large free ball passage. Thanks to its
protective plating at key positions, the solid design also provides
long-term resistance to abrasive media. With entry rates of up
to 25 tons of solid matter per hour (corn silage) this is the basis
for economical feeding of biogas plants with renewable resources.
The optionally available sensors and control technology offer twice
the safety and allow for fully-automatic operation.
Construction and operation
Separating, sealing and mashing are the three steps that make the
EnergyJet unique. Solid matter is fed into the system by the upper,
trough-shaped inlet in the EnergyJet. As for the EnergyJet CS, this
process is taken care of by a feed screw which adds the matter
from the side. Supported by bearings on both sides, the slowly
rotating stainless-steel screw then conveys the cosubstrates continuously
into the separation part of the EnergyJet. Here, excess
moisture is removed from wet solid matter and an unbreakable
plug is then formed. At the same time, a liquid suspension (for
example, liquid manure or recirculated material) flows at a rapid
speed directly into the sealed mashing housing, which prevents
gas emissions. The rotating mashing screw mixes solid matter
and the fluid stream into a homogeneous suspension, which is
then fed into the digester. The foreign matter contained in the
cosubstrates does not have to pass through any pump chambers.
The previously deposited separation fluid is fed into the system.
The fluid allows for effective regulation of system performance.
Applications and advantages
The EnergyJet is specifically designed to introduce renewable
resources and fibrous solid matter such as:
• Corn silage • Grass silage • GPS • Dung
The integrated separation ensures safe plug formation and sealing
– even at high back-pressure. EnergyJet creates an unbreakable
plug regardless of fluctuations in dry matter content levels
and varying characteristics of the co-substrates. Rotating screw
blades and the fluid flow, which is directed to the center of the
deflector plate by the jetting channel, dissolve the solid matter
and mix it into a well-mashed suspension. This particular process
is further enhanced with a RotaCut. Long fiber particles, found in
large quantities in dung and grass, are macerated, clumps are broken
up, and the organic suspension is homogenized in a digestercompatible
manner. This allows for high gas yields and reduced
energy requirements. The RotaCut also separates out foreign
matter such as stones and metal parts, which prevents damage
to downstream units and the accumulation of foreign matter in
Characteristics of the EnergyJet
the digester. Coarse matter is sufficiently macerated and not a
problem – the system runs smoothly. Furthermore, the EnergyJet
is constructed according to the well-known QuickService concept.
All moving parts are quickly and simply exchanged. The cover is
easily removed for complete access to the work area. The screw
blades, bearing bushing and the high-wear screw parts can be
exchanged as needed in a few manual steps.
Advantages of the EnergyJet at a glance
The advantages of fluid and dry solid matter feeding are
combined.
• Resistant to foreign matter and durable like a solid
matter screw
• Feeding with a homogeneous, well-mashed organic
suspension like a wet feeder
• Reduced energy requirements and increased gas yield
EJ30-100 up to 8 7.5-15 4 6 75 Trough Width: 1000
* Maximum insertion rate for corn silage.
16 17
Type
Insertion rate*
t/h
Drive power
kW
Max. operating pressure
bar
Peak pressure
bar
Max. free passage
mm
Inlet type
EJ40-CS up to 25 11-30 4 6 100 Side flange ø 418
EJ40-100 up to 25 11-30 4 6 100 Trough Width: 1000
EJ40-300 up to 20 11-30 4 6 100 Trough Width: 3000
Size
mm

Biogas | BioCrack
More power for your biogas plant
BioCrack®
The electrokinetic disintegration process
for increased efficiency in biogas plants
Internal electrode
BioCrack housing
Electrode head
Sectional drawing of the BioCrack module
BioCrack enhances the exposure of the
nutrients contained in the biosuspension
to the bacteria within the digester. During
the electrokinetic disintegration process,
a high-voltage field is generated in the
module to break up agglomerations
(aggregates/colloids) of dead organic
matter and bacteria.
This considerably increases the availability
of nutrients for the fermenting bacteria.
The result is a higher gas yield and
improved utilisation of substrates.
Clear advantages
Up to 18 percent more biogas:
Even after retrofitting, this higher yield
pays off after just a short period.
Minimum energy costs:
The BioCrack has extremely low power
requirements, only 35 W per module.
Low investment costs:
A BioCrack system is considerably less
expensive than other disintegration
methods.
Up to 30 percent lower energy consumption:
The digesters require less mixing and pumping power.
Suitable for all biogas plants – simple and flexible retrofitting:
The BioCrack system modules can be installed vertically,
horizontally or at an angle.
Highly active fermentation substrate:
The biomass is more rapidly decomposed and the digester
volume is utilised better. This markedly increases biogas yield.
No regular maintenance, no moving parts – always ready to go:
The reason why: BioCrack has no moving parts, which saves you
significant money and reduces your stress!
Uses of the BioCrack in biogas plants
• Digester feeding with liquids
• Use of recirculated material for mixing
• Separate digester agitation
• External digester heating
• Use at the central pump station
BioCrack and RotaCut – an unbeatable team
The combination of the BioCrack and RotaCut makes this
system a success. The RotaCut initially prepares the substrate by
increasing the surface area of its material. Greater surface area
increases the effectiveness of the BioCrack, while simultaneously
protecting the internal electrodes of the BioCrack modules
against foreign bodies. Together with a Vogelsang rotary lobe
pump, this team is an unbeatable combination.
BioCrack advantages at a glance
• Up to 18 percent more biogas
• Up to 30 percent lower energy consumption
• Minimum energy costs
• Low investment costs
• Suitable for all biogas plants – simple and flexible retrofitting
• Highly active fermentation substrate
• No routine maintenance, no moving parts: always ready to go
Calculate your efficiency advantages now:
www.biogas-profit-calculator.com
BioCrack L
Power requirement per module 35 W
Maximum flow rate 40 m 3 /h
Maximum pressure
5 bar
Maximum module length 1950 mm
Minimum module width 325.5 mm
(U module)
Maximum module width 492 mm
(S module)
Electrical supply voltage 220 V, 50 Hz | 110 V, 60 Hz
Material
Stainless steel tube; inside
DN 150 (6 in), PE-coated
internal electrode
18 19

Biogas | Distribution technology
Invented by Vogelsang 30 years ago and still unmatched
Perfect distribution
technology
Dribble bar linkages, exact distributors and tank filling systems from Vogelsang
With the dribble bar linkage system from Vogelsang, liquid
organic fertiliser can be spread where other systems have long
reached their limits. It enables fertilisation of planted fields with
plant heights up to 80 centimetres. Ammonia emissions and their
undesirable side effects are considerably reduced with Vogelsang
equipment.
One system does it all
The dribble bar linkage is available in four model types. These
include high-performance standard solutions as well as special
solutions with working widths of up to 36 metres for tank trailers,
self-propelled vehicles and slurry hosing networks.
Functional and always compatible
Vogelsang dribble bar linkages always fit and can readily be
attached to almost any tank type. They can either be installed
permanently or using a detachable 4-point fitting. All spreaders
are carefully designed and reliable in use.
Sophisticated periphery
Apart from the dribble bar equipment, Vogelsang offers a full
range of components for modern slurry handling: RotaCut
foreign body protection, rotary lobe pumps, exact distributors
and complete mobile or stationary tank filling systems.
Certified quality
Vogelsang produces quality distribution technology products and
has proven itself a thousand times over under severe conditions
Advantages of dribble bar linkages
• Economical spreading of liquid manure/digester output
using high performance and reliable distribution equipment
• The best possible use of manure through precise, closeto-the-ground
spreading that is low in emissions
• Spreading on planted fields
• Vogelsang dribble bar linkages fit any tank; compatible
systems are available for every application and tank trailer
around the world. Vogelsang works
continuously with independent organisations
to test, further develop and improve
its spreading systems. It comes as no surprise
that Vogelsang has been the market
leader in the field of modern distribution
technology for over thirty years.
Systematic savings
Exact spreading with Vogelsang equipment
pays off. It achieves precise and uniform
distribution close to the ground, ensuring
a high level of nutrient utilisation. Low
ammonia evaporation, insensitivity to
wind and good precision guidance are essential
for effective fertilisation. Ultimately,
the benefits are reduced turf damage,
low feed contamination and considerable
reductions of chemical fertiliser costs.
Effective tank filling
Tank trailers can be filled efficiently and
quickly using Vogelsang equipment. Simple
pumps or complete tank filling systems,
permanently installed or mobile: decades
of experience have made Vogelsang a valuable
partner for anyone in need of efficient
and reliable tank filling equipment.
Delivery rates of up to 23 000 litres per
minute leave nothing to be desired.
Specifically geared toward easy handling,
Vogelsang equipment requires less setup
work and achieves shorter tank filling times.
Exact distribution systems
ExaCut and DosiMat are core elements of
the Vogelsang spreading system. Their task
is to uniformly distribute the slurry to the
hoses. We invented exact distribution and
developed distributors that are perfectly
matched with various spreading systems.
DosiMat
Liquid, organic fertiliser is conveyed
through a rotor powered by a hydraulic
motor and distributed to the hose outlets.
As the fertiliser flows through the system,
blades pass over the cutting screen and
macerate fibrous materials. This ensures
optimal average distribution across all
hoses.
ExaCut
With its compact design, the ExaCut
can be universally employed as a
central or decentral distributor
with a heavy material separator.
It can be readily integrated with
the side arms of a dribble bar
linkage or other spreading
system. This enables extreme working
widths of up to 36 metres. Vogelsang
offers suitable solutions for all types of
spreading systems.
Advantages of the exact
distributors at a glance
• Exact dosing of the slurry onto
the outlets
• Superb cutting performance
ensures reliable maceration of
fibrous materials
• Very convenient to service and
maintain
• Precise spreading
21
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21

Biogas | Service
When it comes to service,
we leave nothing to chance
Whether commissioning, training, or full service with a maintenance
agreement and wearing parts service package, our tailored, comprehensive
services are always available to you. This way, we guarantee smooth
operation from the start.
Comprehensive services for smooth operation and a long service life
Support and supply from A to Z
Because we realize that close proximity to our customers is
essential for our joint success, we design our services to best
meet your needs. In Germany and in countries where we have
subsidiaries, Vogelsang service centers and contractual partners
maintain an active dialogue with our customers and provide
reliable support.
That means you get precisely the support you need in every
phase of our partnership. Our highly qualified staff makes it
possible – expert consultants and technicians who know your
Vogelsang machines inside and out.
We think ahead
Thinking ahead in your best interest begins with our extensive
and detailed product documentation. Spare parts are available
within a short period of time given our high degree of vertical
integration in production. In addition, you will always find an
authorized service partner in your area who can help with repairs
and replacement of wearing parts. The Vogelsang ServicePack
completes our range of services. Whether you need start-up
services, on-site training, training at the Vogelsang facility, full
service support with a maintenance contract, or a wearing parts
service package – we offer a support program tailored specifically
to your needs.
LifeGuard – leading through
innovation
Maintenance generally results in
downtime as well as expenditures for
personnel and spare parts. We have
therefore developed a concept to keep
service and repair times to a minimum:
LifeGuard – for maximum service life of
our products.
The service life of a Vogelsang machine is
determined by specific LifeGuard factors.
We take these factors into consideration
and offer you features that are relevant
for maximum productivity and service
life.
Many years of customer experience with
sewage treatment plants has shown
that when used in combination with
our performance control units (PCU),
LifeGuard produces optimal results while
ensuring a long and trouble-free service
life of your machine.
22 23

ENGINEERED TO WORK
Our company
Innovation and progress have been
hallmarks of Vogelsang for over 80 years
and have made us a leading global plant
engineering company. Time and time
again we have achieved significant
milestones of progress. Today, we develop,
manufacture and distribute some of the
most innovative and reliable machines
and systems for agriculture, municipalities
and industry.
With our overseas subsidiaries and service
centers, we are world-renowned for
advanced engineering and customerfriendly
solutions.
Our product range
We offer solutions for the following areas:
• Industrial sector
• Waste water treatment
• Biogas
• Railway waste water disposal
• Agriculture
We offer a broad range of products:
• Rotary lobe pumps
• Maceration technology
• Distributors
• Spreading technology
• Supply and disposal systems
• Complete solutions
We also offer customized solutions for
your specialized applications.
How to reach us
Vogelsang is present worldwide. Visit us
online for more information about our
company and wide range of services:
vogelsang.info
We are here to assist you and look forward
to speaking with you.
vogelsang.info
Hugo Vogelsang Maschinenbau GmbH
Holthöge 10–14 | 49632 Essen/Oldb., Germany
Phone: +49 5434 83-0 | Fax: +49 5434 83-10
info@vogelsang-gmbh.com
USA vogelsangusa.com | Great Britain vogelsang.co.uk
France vogelsang.fr | Italy vogelsang-srl.it
Poland vogelsang.pl | Romania vogelsang.ro
Czech Republic vogelsang-czech.cz | Spain vogelsang.es
Australia vogelsang.com.au | China vogelsang.com.cn
Denmark vogelsang-as.dk | Sweden vogelsang.se
Ireland vogelsang.ie | Finland vogelsang.fi
Mexico vogelsang.mx | Brazil vogelsang.com.br
Malaysia vogelsang.com.my | India vogelsangindia.com
South Korea vogelsang.co.kr | Russia vogelsang.ru
Germany – Eastern Branch Vogelsang Lutherstadt
Eisleben vogelsang-gmbh.com | Vogelsang International
vogelsang-international.com
Product availability, appearance, technical
specifications and details are subject to
continuous development. All information
presented here is therefore subject to change.
Copyright© 2014 Hugo Vogelsang Maschinenbau GmbH. In selected countries, Vogelsang®, HiFlo®, RotaCut®, ACC®, CFC®,
BioCrack®, XTill®, EnergyJet® and BioCut® are registered trademarks of Hugo Vogelsang Maschinenbau GmbH, Essen/Oldb., Germany.
All rights reserved including graphics and images. Biogas_EN_04207714_5000_MET0066 – Printed in Germany