Reliable Biogas Dehumidification for equipment safety (Oman)
Biogas generated from dairy waste and similar feedstocks often contains high levels of moisture, which can lead to corrosion, reduced combustion efficiency, and equipment failure in downstream systems. To address these operational risks, CRA partnered with Lalbuksh Voltas Engineering Services & Trading L.L.C. to deliver a fully engineered biogas dehumidification system for the Mazoon Dairy project in Oman. The system was designed to reliably remove condensate and humidity from raw biogas before compression and utilization, ensuring consistent gas quality for energy recovery applications. Engineered for harsh desert conditions, the dehumidifier operates seamlessly under variable flow and temperature profiles, ensuring both safety and long-term system reliability.
The project presented several unique challenges
- Variable Gas Conditions: The biogas composition and flow rates fluctuated throughout the day, demanding a robust control system capable of maintaining steady outlet gas dryness.
- High Ambient Temperatures: Operating in Oman's desert climate required specialized cooling and heat management to prevent thermal overload and system inefficiency.
- Continuous Operation Requirements: As the biogas was routed to downstream utilization units, system downtime was not an option—requiring redundancy, automation, and minimal maintenance design.
- Integration Constraints: The unit had to be skid-mounted and fully compatible with existing gas compression and purification systems.
robust mechanical design to ensure consistent, efficient moisture removal
CRA engineered and supplied a refrigeration-based biogas dehumidifier rated at 400 Nm³/hr, designed for inlet pressures of 15–20 mbar. The system featured advanced automation and robust mechanical design to ensure consistent, efficient moisture removal:
Engineering & Design
- Fully enclosed skid-mounted configuration with weatherproofing for outdoor installation.
- Automatic condensate drainage using level-sensing controls for uninterrupted operation.
- Integration with temperature and humidity monitoring systems to maintain optimal dew point.
- Use of stainless steel and anti-corrosive materials for all wetted parts, enhancing field life.
Fabrication & Assembly
- In-house design and assembly of the chiller, heat exchanger, control panel, and condensate management system.
- Custom insulation and thermal design for efficient heat exchange under high ambient conditions.
- Factory testing of all components for performance validation prior to dispatch.
Installation & Commissioning
- On-site mechanical and electrical integration with Mazoon Dairy’s biogas compression and purification skids.
- Live performance testing and control tuning for consistent dehumidification across varying gas loads.
- Operator training and documentation for long-term operation and maintenance.
Delivery of high-quality biogas, protecting equipments.
- Consistent delivery of dry, high-quality biogas, protecting compressors, burners, and purification systems.
- Automated, low-maintenance operation with built-in fault monitoring and condensate management.
- Stable performance under extreme desert conditions, demonstrating robust system design and reliability.
- Seamless integration into the overall biogas utilization chain, ensuring efficient downstream processing.
- Compliance with environmental and safety standards, supporting sustainable dairy waste-to-energy operations.
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