How Hard Is It to Replace an 800m³ Biogas Storage Tank? – Custom Shape + Above-Mixer Installation + Precision Openings
“An 800m³ custom-shaped gas holder, mounted directly above a side mixer, with two precision openings required on the hemispherical body – how do you replace that?”
1. Double Membrane Gas Holder Replacement Background: Aging Biogas Storage – Safety Risks & Replacement Needs
A waste treatment facility in Jinan, Shandong Province, China, had an 800m³ digester-mounted double membrane gas holder that had been in service for many years.
As an aging asset, it posed increasing risks to the plant’s biogas system reliability. The owner decided to fully dismantle the existing unit and install a new 800m³ digester-mounted double membrane gas holder.
The new system restored the plant’s biogas storage, pressure regulation, and peak-shaving capabilities for normal production operations.
2. Double Membrane Gas Holder Replacement Core Challenges: Above-Mixer Space Constraints, Non-Standard Structure & High-Precision Openings
This replacement project was a custom engineering endeavor, far more complex than standard gas holder installations.
Unlike conventional hemispherical gas holders, this unit features a non-standard shape and is mounted directly on top of the anaerobic digester. However, the digester is equipped with an internally mounted side mixer, and the gas holder sits directly above the mixer.
This created extremely confined working conditions—both dismantling and installation had to be carried out in a highly restricted space, presenting significant design and execution challenges.
Adding to the complexity, the project demanded exceptional design precision. According to the original design requirements, two maintenance access hatches had to be precisely integrated into the hemispherical gas holder body—one on each side—to serve as dedicated entry points for future digester maintenance.
This imposed stringent requirements on structural design accuracy, opening dimension tolerance, and overall gas-tightness.
3. Double Membrane Gas Holder Replacement Technical Solution: Custom 3D Modelling, Precision Construction & Equipment Protection
To address these challenges, the project utilized high-quality membrane materials from leading international suppliers, with custom 3D modeling and design precisely matched to the on-site equipment parameters.
Prior to construction, multiple senior engineers from Haiyue conducted thorough on-site surveys to verify every component requiring replacement—including aging control systems and auxiliary equipment—and developed a detailed, project-specific construction plan.
During installation, because the gas holder is positioned directly above the mixing equipment, the team had to precisely disconnect the mixer’s hydraulic and electrical lines. Every step was executed with precision and strict adherence to procedure to eliminate risks of equipment damage or electrical faults.
4. Double Membrane Gas Holder Replacement Project Delivery: Senior Engineers on Site, Multi-Point Coordination
Throughout the project, a team of experienced senior engineers provided on-site supervision and technical support.
They managed the full range of critical challenges—custom opening design for the non-standard gas holder body, precise equipment matching, mixer protection, and careful disconnection and reconnection of all lines.
The custom-designed gas holder was successfully installed in these complex conditions, and the retrofitted system now operates in full compliance with safety standards, delivering reliable and stable performance.
From safety assessment of aging gas holders to demolition planning, from custom structural modelling to precision installation above a mixer – every step demands deep engineering expertise and on-site problem-solving capability.
This 800m³ digester-mounted double membrane gas holder replacement project involved multiple technical challenges: custom-shaped gas holder design, confined-space operation, installation above a side mixer, and high-precision openings with gas-tight sealing.
Haiyue’s team delivered a complete design-to-delivery solution under these complex conditions, backed by senior on-site engineering supervision and rigorous quality control.
If you are facing a similar challenge – replacing an aging gas holder, retrofitting a biogas storage system, or dealing with unique installation constraints – please reach out to us.
With over a decade of experience in double membrane gas holder R&D, manufacturing, and installation, Haiyue provides one-stop solutions including custom design, on-site survey, demolition and replacement, and commissioning.