Methanisation is an increasingly used process to transform organic matter into biogas and digestate. A well-maintained methaniser can operate optimally for many years, ensuring stable biogas production while reducing the risk of breakdowns and high repair costs. To help you get the most out of your installation, here is a guide to best maintenance practices for methanisers.

---

1. Establish a Regular Maintenance Plan

Regular maintenance is crucial to prevent problems and keep the methane digester in good working order. Here are the key steps to include in your maintenance plan:

• Inspection Visits : Schedule regular inspections, at least quarterly. This helps detect early signs of wear or malfunction.
• Preventive maintenance : Identify sensitive components and plan their replacement before they wear out completely. This strategy helps avoid unplanned breakdowns.
• Cleaning Equipment : Residue can build up over time. Cleaning sensitive components, such as pumps and lines, ensures proper material flow and prevents clogs.

---

2. Monitor Warning Signals

Methane digesters often emit warning signs before they break down. Monitoring these indicators is essential for rapid intervention:

• Abnormal Vibrations : Unusual vibrations may indicate an imbalance in the mixers or worn bearings.
• Unusually low gas emissions : A sudden drop in biogas production may be a sign of a problem with the digester bacteria or clogged ducts.
• Abnormal Odors : A stronger or unusual odor may indicate a leak problem or a malfunction in the containment system.

---

3. Control Biological Parameters

The methanization process relies on complex biological activity. It is therefore important to regularly monitor the biological parameters to maintain the efficiency of the digester.

• pH : Too low or too high a pH can inhibit the activity of methanogenic bacteria. Be sure to maintain a stable pH, usually between 6.8 and 7.5.
• Temperature : Methane-producing bacteria are sensitive to temperature variations. Maintain a stable temperature in the digester to avoid a drop in production.
• Agitation : Regular agitation of the contents of the methanizer ensures homogeneity of the substrate, thus optimizing biogas production.

---

4. Check for Watertightness and Safety

Sealing is a crucial element to prevent biogas leaks and ensure the safety of the installation. Best practices include:

• Seal Inspection : Replace worn seals and valves to prevent leaks. This is especially important for biogas storage tanks.
• Safety checks : Test gas detectors regularly to prevent any risk of explosion or incident.
• Safety Equipment : Ensure that all personnel are trained to respond to a leak and that protective equipment is easily accessible.

---

5. Use Quality Replacement Parts

Investing in quality spare parts is essential for the durability of your methanizer. Choose spare parts that are suitable for your methanizer model, and favor parts from recognized manufacturers to ensure better longevity.

• Plan for critical parts inventory : Having frequently used parts (such as bearings, seals, and pumps) in stock helps reduce downtime in the event of a breakdown.
• Prefer specialized suppliers : Working with reliable suppliers who understand the specificities of methanizers guarantees perfect compatibility and better performance of the parts.

---

6. Document All Interventions

Finally, good documentation of maintenance interventions allows you to track the history of the installation and identify trends or components at risk. Keeping a maintenance log is useful for:

• Identify recurring weaknesses : Some parts may show signs of wear more frequently than others. A log helps detect these patterns and anticipate repairs.
• Plan improvements : With intervention reports, you can evaluate the performance of the installation and make informed decisions for future investments.
• Improve inventory management : Accurate tracking of replaced parts makes it easier to replenish the parts needed for future interventions.

---

Conclusion

Preventive maintenance is essential to ensure the reliability and durability of your methane digester. By following these best practices, you reduce the risk of breakdowns, increase productivity and ensure optimal operation of your installation in the long term. By integrating these steps into your maintenance routine, you invest in the sustainability of your installation and participate in the production of renewable energy in an efficient and safe manner.

For information on spare parts and maintenance services, Methappro offers a complete range of equipment and tailor-made solutions.