TEKA. COMMISSION OF MOTORIZATION AND ENERGETICS IN AGRICULTURE – 2015, Vol. 15, No.
1, 89–94
Design of Digester Biogas Tank
Part 3: 3D Digester Biogas Tank Model
Karol Tucki, Marek Klimkiewicz, Piotr Piątkowski
Department of Production Management and Engineering, Warsaw University of Life Sciences – SGGW
Received January 09.2015; accepted February 19.2015
Summary. The paper presents the 3D design process of digester projects may be saved in different locations, e.g. the hard
biogas tank using modern engineering software.The biogas tank drive or a server. Information on access paths to individual
shell, bottom of the tank and its roof were designed. The welded files of a project are located in a text file with .ipt extension
and bolted connections available in the library of program were which is a project file. Creation of a project file is the be-
used to join the construction elements. ginning of work in the program [3].
Key words: project, digester biogas tank, 3d model. When selecting the “parts” work mode it is possible to
make 2d sketches, which can be created using functions sim-
ilar to the ones utilized by the most popular program of the
INTRODUCTION Autodesk program – Autocad. The logic of part design is
different than in Autocad. When creating a sketch, the con-
The development of computer equipment and 3d design structor tries to give it the shape of the recreated part and next
processes allow engineers to design more quickly and to provides it with a series of detailed nodes and dimensions.
optimize their work. 3d modelling programs allow for the The 2d sketches may be edited many times and transformed
growth of innovativeness in numerous technical disciplines into 3d models. The created parts may be subjected to stress
[2, 9]. analysis and transformed into, e.g. metal sheet construction.
The market offers many CAD-like programs. One of The next work mode is creation of assemblies, which are used
such is the Autodesk Inventor 2014. It serves to construct to connect parts into more complex units. This mode allows
different 3d models. The activity of the user focuses most- the constructor to connect the individually designed parts.
ly on the creation of a 3d model, that reflects the future The “assembly” file allows for dynamic simulations, stress
construction. The program allows for creation of layout analysis, beam analysis, connecting of parts with cables and
drawings, working drawings, offer drawings and reference wiring harnesses, pipes, connecting elements via welding,
drawings. The changes introduced in the model are automati- screws and bolts. This mode also contains tools that facilitate
cally included in the 2d drawings. This allows for innovative creation of elements such as rollers, transmissions or bearings.
adapting design works and creation of prioritized models, The next mode is the “drawing” mode which allows for the
which are reflected in the history tree of the object viewer. creation of 2d drawings in a similar manner to Autocad and
The method for prioritisation is FMB (Flacture – Based – for projection, description and dimension of 3d elements onto
Modeling). The software provides a library of materials a 2d surface. The program also supports a “presentation”
and parts that may be used in creation of own projects. The mode that is used to present the construction of assemblies or
program also allows for creation of own part libraries and to components. The “drawing” mode also allows for the creation
define materials that can be later used in different projects. of animations that present operation of devices [3].
The Autodesk Inwentor allows engineers to create intelligent
components such as, e.g. constructions from sections, pipes,
electric cables. The program uses four basic work modes: DESIGNING OF THE SHELL AND THE BOTTOM
part, assembly, drawing and presentation [3]. OF THE FERMENTATION CHAMBER
Designing of every device, machine, construction is
done via a separate project. Files containing parts, com- The individual rings of the shell (Fig. 1) of the cham-
ponent drawings, libraries, etc., which serve as parts of the ber were created in the “part” mode. At the beginning, the
90 KAROL TUCKI, MAREK KLIMKIEWICZ, PIOTR PIĄTKOWSKI
2d sketch of the ring was created. Next, the sketch was
transformed into a 3d model using a linear extension func-
tion [4]. This way the ring achieved the required height.
The tank’s rings were bevelled in order to prepare place
for the weld [10].
Fig. 1. The shell’s ring with visible groove for the weld [own
elaboration]
The bottom ring was created following the same method
as the shell’s rings – it was provided with an internal diam- Fig. 4. Cross-section of the angle section 100x100x7; a – angle
eter, height and thickness (Fig. 2). section sketch, b – rotation of the sketch by 360̊ [own elabo-
ration]
DESIGNING OF THE DOME OF THE
FERMENTATION CHAMBER
Between the applied internal and external membrane
there was a seal of foamed EPDM rubber [1]. The 3d model
was created in the same way as the shell elements of the
tank (Fig. 5).
Fig. 2. Bottom ring [own elaboration]
The bottom was created by sketching a circle and using
the linear extension function to provide it with the required
thickness (Fig. 3).
Fig. 5. 3d model of the EPDM seal [own elaboration]
Next, the internal membrane was designed (Fig. 6)
Fig. 3. Middle part of the tank’s bottom [own elaboration] and the external membrane by creating proper sketches
that were transformed into 3d models by turning them [4].
The next element to design was the angle section that This operation for the internal membrane was presented
tops the tank, on the basis of the norm PN-B-03210. First, in Figure 6.
the sketch of the angle section was created (Fig. 4a), next
it was turned by 360 ̊ (Fig. 4b) and then it was cut using
a separate plane and the remaining edges were bevelled [7].
DESIGN OF DIGESTER BIOGAS TANK 91
In order to protect against weather conditions the tank
will be covered with trapezoidal sheet metal FLOLINE 40.
When creating the cover element it was required to create
a sketch of the sheet metal element and next multiply it and
provide it with the required thickness [8]. The sketch was cut
to proper length and turned 360 ,̊ which resulted in a simpli-
fied model of trapezoidal sheet metal (Fig. 9).
Fig. 6. Turning of a profile in order to design the internal mem-
brane [own elaboration]
Both membranes will be held down by a ring adhering
to the angle section topping the tank. The edges of the ring
were rounded (Fig. 7) in order to avoid cutting of the moving
membranes.
Fig. 9. Turning of the trapezoidal sheet metal model in order to
create a 3d model [own elaboration]
CONNECTING INDIVIDUAL PARTS INTO THE
FERMENTATION CHAMBER ASSEMBLY
Individual elements of the tank such as: shell rings, angle
section topping the tank, the bottom, bottom ring, middle
bottom part were connected using the concentric connection
functions (Fig. 10a). The angle section topping the tank was
moved up to connect it via a fillet weld to the shell ring. Next
every element was marked as “fixed”.
Fig. 7. The process of rounding of edges of the ring holding The elements of the roof: the internal membrane, the ex-
down the membranes [own elaboration] ternal membrane, the seal and the ring holding down the mem-
branes were also joined in a concentric manner (Fig. 10b).
DESIGNING OF THERMAL INSULATION: LAYERS
OF MINERAL WOOL AND TANK’S COVER FROM
TRAPEZOIDAL SHEET METAL
In order to protect the tank from weather conditions and
to maintain the mesophilic temperature, the tank is insulated
with mineral wool. Mineral wool model (Fig. 8) was creat-
ed as a circle segment. The element was designed in such
a way as to allow for placing it between sections that will
be generated during the next design stage.
Fig. 8. Creation of the mineral wool element [own elaboration] Fig. 10. Concentric connection of: a – tank’s rings, b – ring
pressing down on the membranes [own elaboration]
92 KAROL TUCKI, MAREK KLIMKIEWICZ, PIOTR PIĄTKOWSKI
During the next stage the ring pressing down on the In the next stages the issue for consideration was the
membranes was connected to the angle section with a screw strengthening of the stability of the construction and the
with a hexagonal head M14x1.5x60, selected on the ba- connection between the tank and the trapezoidal metal sheet
sis of norm ISO 8765 (two-sided with spacers 14-140 HV covering [6].
from norm ISO 7089) and with nuts M14x1.5 from norm In order to connect the trapezoidal sheet metal different
ISO 8674. The connection was realized by the sketching sections or wooden battens can be used. Their spacing is
of a point in the middle of the upper surface of the upper based on calculations concerning the circumference of the
ring, the point that was next multiplied on a circle, which tank. The Autodesk Inventor has an option for automatic
resulted in 60 points. These were used as reference points placement of sections. When using this function, two points
for the screws placement (Fig. 11). must be indicated between which the section is to be placed.
On the surface of the ring holding down the membranes
a point was drawn that was then projected on the bottom
ring. Next, from the level of the bottom ring a plane was
created that was moved away from the top surface of the
ring. This way the two points were created required for the
placement of sections. From the available sections a CH
channel section 100x10 was chosen (Fig. 14). The section
will provide space to place mineral wool between the tank’s
shell and the sheet metal that will be connected to it.
Fig. 11. Multiplication of reference points for screws using a cir-
cular array [own elaboration]
Screw joints were created in a threaded connection cre-
ator (Fig. 12). After the end of creation of the connection,
the program automatically placed the screw in the indicated
points (Fig. 13).
Fig. 14. Placement of the CH channel section 100x10 using
section placement generator [own elaboration]
The section is then turned in such a way that it touches
the tank’s ring with its side surface (Fig. 15).
Fig. 12. Generation of screw connection of the ring holding
down the membranes and the angle section at the top of the tank
[own elaboration]
Fig. 15. Tangential orientation of the section to the edge of the
tank [own elaboration]
Next it was required to attach the trapezoidal sheet metal
to the generated channel section. From the level of trape-
zoidal sheet metal there was created a plane as an element
Fig. 13. Generated screw connection of the ring holding down tangential to the element (sheet metal) and parallel to the
the membranes and the angle section at the top of the tank [own plane passing through the centre of the element [8]. Onto
elaboration] that plane there were projected the edges of the previously
placed section and the edges of the sheet metal in order to
DESIGN OF DIGESTER BIOGAS TANK 93
determine the connection point. In that point a circle was
sketched, which was pulled to the next plane using the “cut”
function. In this way a hole was created – a place for a screw.
Using the library of the program – „ConcentCenter ”
from norm ISO 1479, there was chosen a sheet metal screw
C ST 9.5x32-C (Fig. 16). In the next step the screw was
multiplied in a “linear array” along the surface of the section.
Fig. 18. Finished connection of trapezoidal sheet metal and sec-
tions [own elaboration]
Fig. 16. Selection of a screw from the program’s library [own
elaboration]
Using automatic connection and selecting the “rigid con-
nection” option the screws were placed in their intended
locations.
The section was multiplied in a circular array around the Fig. 19. Connection of trapezoidal sheet metal and section – top-
tank’s shell (Fig. 17). view [own elaboration]
Fig. 20. Creation of continuous fillet weld connecting the tank’s
Fig. 17. Multiplication of the channel section around the rings shell with the channel section [own elaboration]
of the tank [own elaboration]
Next, between the sections the mineral wool element was
In the next stage the screws were multiplied using the placed, using the “concentric placement tool”. The element
same principle as the sections. This way there was created was multiplied with “circular array” (Fig. 21).
a connection between the trapezoidal sheet metal with every
channel section placed around the tank’s shell (Fig. 18). The
top-view of the connection is given in Figure 19.
At the next stage of creation of the model of the fermen-
tation chamber there were created the welds between the
elements of the tank’s shell. The lowest ring was welded to
the peripheral ring of the bottom using a fillet weld from
both the inside of the tank and the outside [Ziółko 1995].
The top angle section was welded to the top ring with fillet
weld from the outside of the tank. The channel sections on
the circumference of the shell were welded to the shell using Fig. 21. Multiplication of the mineral wool element around the
fillet welds (Fig. 20). tank [own elaboration]
94 KAROL TUCKI, MAREK KLIMKIEWICZ, PIOTR PIĄTKOWSKI
At the end, the pipes were designed used for the feeding REFERENCES
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Fig. 23. Visualization of the designed fermentation chamber 15. PN-EN ISO 8674:2013-06: Nakrętki sześciokątne wyso-
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Modern engineering software makes it much easier
for constructors to create a complete technical documen- PROJEKTOWANIE ZBIORNIKA KOMORY
tation – starting from the concept and ending with de- BIOGAZOWEJ
tailed engineering analyses. This process was presented CZ. 3.: MODEL 3D KOMORY FERMENTACYJNEJ
using a digester biogas tank as a design example. Some
characteristics of the modern software include: checking Streszczenie. Opisano proces projektowania 3D komory biogazo-
correctness of the model in 3d option, automatic creation wej przy wykorzystaniu nowoczesnego oprogramowania inżynier-
of detail projections and ability to realize exhaustive stress skiego. Zaprojektowano płaszcz zbiornika biogazu, jego dno oraz
kopułę dachu komory. Do połączenia elementów wykorzystano
analyses, and ease of use.
połączenia spawane oraz śrubowe dostępne w bibliotece programu.
Słowa kluczowe: projekt, zbiornik komory biogazowej, model 3d.
