A perennial problem with anaerobic digesters is the tendency to produce ammonia, which can introduce complications when it comes to finding a suitable destination for digestate. Scout Mata and Katie Hetrick discuss nutrient recovery initiatives being undertaken at the University of California (Davis) with an anaerobic digestion facility called the Renewable Energy Anaerobic Digester, or READ.

A typical day at READ involves processing 20 tons of food and grease-trap waste from local grocery stores and campus dining rooms – waste that would otherwise end up in landfill. Trucks deliver food waste in plastic garbage bags, which are then separated by depackagers into an organic fraction (food) and contaminants (mostly plastic). The organics are liquified into a slurry and added to the digester.

The process generates ammonia in concentrations that are too high for disposal and processing at the campus’s wastewater treatment plant, yet too low to be valuable as fertilizer. Proper disposal of this ammonia-rich digestate can be costly.

“We ultimately had to pay a farmer to remove and use it,” said Joe Yonkoski, UC Davis Facilities Management superintendent of thermal infrastructure and biodigester supervisor. “This cost represented a significant portion of READ’s operating costs.”

To address this challenge, Facilities Management collaborated with Harold Leverenz, then a postdoctoral researcher in the UC Davis Department of Civil and Environmental Engineering. In his spare time, Dr. Leverenz conducted research in his garage with Rus Adams, to evaluate strategies for separating and concentrating the ammonia from waste streams, including urine, the digestate from READ and other sources. They produced research prototypes of nutrient recovery technologies which were installed on campus for testing at UC Davis’ wastewater treatment plant. The team also founded Advanced Environmental Methods LLC, or AEM, to explore the commercial aspects of nutrient recovery projects, and tackle some of the problems.

“I’ve been interested in helping solve the problem of nutrient pollution through nutrient recycling since my time as an undergraduate in biosystems engineering at Michigan State University,” said Leverenz, who still conducts research for UC Davis Civil and Environmental Engineering and also designs constructed wetlands and other natural treatment systems as an engineer at Biohabitats, Inc.

“We could be capturing nutrients from waste streams for beneficial use in crop production and create a closed-loop system instead of discharging these fertilizers into our waterways or putting it into the air or landfills.”

This collaboration led to an auspicious partnership between AEM and Facilities Management who together led the design of this one-of-a-kind ammonia distillation system, the Chemdist Group who fabricated it, and California Safe Soil, a fertilizer and pet nutrition product manufacturer.

The system processes the ammonia-rich digestate, separating it into nearly ammonia-free digestate and concentrated ammonia. The ammonia-free digestate can be processed at the campus’s wastewater treatment plant, or by other means, locally without adding excess nutrients to inland waters. The concentrated ammonia product has now become a valuable commodity purchased by California Safe Soil as an ingredient in the formulation of a certified organic fertilizer.

“The new ammonia extraction system not only eliminates a major operating cost, it’s environmentally responsible, generates revenue, and helps support the operation of READ,” said Yonkoski. “It’s taken years of hard work and collaboration so we’re excited that it’s up and running.”

Fossil-free solution
With this update, UC Davis addresses a significant challenge for anaerobic digester facilities worldwide. READ’s novel ammonia extraction system can remove 90-97% of ammonia from the digestate without the use of fossil energy sources – resulting in a low-carbon or “green” ammonium fertilizer. With more efficient and sustainable digestate recycling, the facility’s capacity to process food waste can increase from 20 tons per day to 50 tons per day, further reducing landfill waste.

The system also aligns with California’s SB 1383 objectives by reducing greenhouse gas emissions and enhancing the economic viability of anaerobic digestion. To this end, research is ongoing at READ to advance the biorefinery concept, where our urban waste streams are processed for the recovery of various products, including organic acids, nutrients, energy, and water. As demand grows for “green” waste management solutions, UC Davis serves as a model for institutions worldwide, while READ’s progress highlights the importance of continued research and collaboration in achieving sustainable solutions.

While the ammonia distillation column has enhanced digestate management, the Facilities Management group said they are eager to make further improvements. Help towards this end has so far been forthcoming in the shape of a CalRecycle grant.

The Anaerobic Digestion and Bioresources Association (ADBA) has announced the winners of this year’s AD and Biogas Industry Awards, celebrating outstanding achievements and innovations in the global anaerobic digestion (AD) and biogas sectors. Co-organised by ADBA in partnership with World Biogas Association (WBA), the awards ceremony, held 10 July 2024 at the NCC in Birmingham, UK, recognised the exceptional international contributions of individuals, companies and projects that have demonstrated excellence and leadership in advancing the biogas industry.

The award winners, judged by an expert panel representing the global biogas sector, exemplify the innovation, dedication and progress driving the global shift towards sustainable circular economy solutions to waste and energy issues.

WBA Chief Executive Charlotte Morton OBE said, “I heartily congratulate the winners of the 2024 AD and Biogas Industry Awards, who stood out among an extraordinary competition. The exceptional standard of this year’s shortlisted nominees highlights the remarkable innovation and dedication within the sector. Each nominee has demonstrated pioneering advancements, operational excellence and a commitment to sustainability, setting new benchmarks in the biogas industry. Their contributions underscore the dynamic progress and potential of AD and biogas technologies in addressing global energy and environmental challenges. This year’s shortlist not only reflects the industry’s current achievements but also its promising future.”

During the ceremony, host Chris Hines MBE, sustainability pioneer and co-founder of Surfers Against Sewage, spoke about his decades campaigning for sustainable waste water management and praised the AD and biogas industry for creating sustainable solutions, supporting healthy rivers and seas. Chris’ message resonated strongly with fellow guest speaker, and avid surfer, the 11-year-old Child Prime Minister of the UK Children’s Parliament, Clark Dearson, who spoke passionately about his own love of the sea and the inspiring power that solutions like AD and biogas have on overcoming the environmental despair felt by many children – and motivating the next generations.

The ceremony was attended by global industry leaders and policy makers with a delegation from India including Mr Pankaj Jain, Secretary of the Ministry of Petroleum and Natural Gas, Government of India, and the Chairman of the Indian Oil Corporation Mr Shrikant Madhav Vaidya, both major advocates for biogas’ great potential to decarbonise the global economy and cut harmful methane emissions. They were joined by representatives from the United Nation Industrial Development Organisation (UNIDO), C40 Cities and the Global Methane Hub along with Shell Energy, Future Biogas and Hexagon Agility – the award sponsors.

The AD and Biogas Industry Awards 2024 Winners and Highly Commended:

1. Health and Safety

Winner: Marches Biogas Ltd

Highly Commended: Dwr Cymru Welsh Water (DCWW)

2. Women in Biogas

Sponsored by Shell Energy

Winner: Katrin Pütz – (B)energy
Highly Commended: Alexi Dragonetti – Agrivert; Christine Mapp – Eco Verde Energy (EVE); Deanna Martin – Deanna Martin Biogas; Helen Edwards – Ceres Energy Limited; Mantopi Martina de Porres Lebofa – Lesotho Council of NGOs (LCN)

3. AD Hero of the Year

Sponsored by Future Biogas

Winner: Christopher Kellner

4. Best Anaerobic Digestion/Biogas Support

Winner: Marches Biogas Ltd

5. The Net Zero Circular Solutions

Sponsored by Hexagon Agility

Winner: Madrid City Council’s Anaerobic Digestion Complex –  Ayuntamiento de Madrid, Parque Tecnológico de Valdemingómez (Madrid City Council-Valdemingómez Technology Park)

6. Education Campaign of the Year

Winner: Advancing CBG and Biomethane Projects – Dr Rahul Jain – Centre for Science and Environment (CSE)
Highly Commended: Biogas and Gases Technologies – TIND-BGASTECH

7. Best Biogas Plant Below 1MWe Equivalent

Winner: Fylde Fresh and Fabulous AD facility – Fylde Fresh and Fabulous
Highly Commended: Gorakhpur Biogas Plant, Uttar Pradesh – Indian Oil Corporation Ltd

8. Best Biogas Plant Above 1MWe Equivalent

Winner: Cocal Energia S.A. – Cocal and Geo Biogas & Carbon
Highly Commended: Edina and Biotech4 – Holme Bioenergy; Geo Tamboara – Geo Biogas & Carbon

9. Micro AD Initiative

Winner: O Biodigestor Sertanejo (The Brushland Biodigester) – Diaconia

Highly Commended:  Biolectric Small On-farm AD – Biolectric; Portable biogas plants in Yemen – BioTreasure

10. AD Rising Star

Winners: David Payne – Zebra EM / Khanittha Monthaklin – Viridor (Process optimisation with SLR Consulting)

Highly Commended: Kevin Kirubakaran – Olleco

11. Research and Innovation

Winner: Electrochaea´s Biomethanation Technology – Electrochaea

Highly Commended: Transforming Sustainability: The SMASH Project’s Outstanding Contribution to AD Biogas Innovation – Ixora Energy

This post includes sponsored content produced in collaboration with Gen-C.

The Avocet Renewables’ anaerobic digestion (AD) plant at Coston Hall Farm, Barnham Broom near Norwich uses agricultural feedstocks such as energy crops to generate biomethane and electricity, which is exported to the grid, as well as heat, which is used locally on the farm for crop drying. The 500 kW V12 MAN E3262 engine was installed in 2017 to provide heat and generate electricity. Following a technical issue, Peterborough-based GenV Ltd were brought in to service and support the engine. However, issues such as a locked control panel meant that GenV were limited in their ability to optimise CHP performance, so turned to support partners Gen-C for help.

Limited by legacy controls

“The control system was old, and because it was locked to the original supplier we had no access to change key aspects of how the engine ran, and we couldn’t access anything remotely,” explains Warren Vessey, Managing Director at GenV. “After struggling for 18 months with failing engine performance, we performed a full R3 service and agreed with the client to undertake a number of upgrades, including a new open-access control system, with the help of our long-term partner, Gen-C.”

As well as replacing and upgrading the control panel, Yorkshire-based Gen-C were also commissioned to upgrade the engine in a bid to restore lost power output and improve reliability.

“The engine was underperforming – producing only around 400 kW – misfiring and vibrating badly, so the client was losing considerable revenue” says James Thompson, Managing Director of Gen-C. “The engine was also comprised of a mixture of equipment from varying brands, which is something we see quite often – the ignition controller, actuator, fuel mixer, pick-ups etc. were from different manufacturers, which was impacting performance.”

Streamlining CHP operation

James continues: “To improve overall performance, we upgraded the key components such as the mixer and throttle speed control. And because everything we install comes from one manufacturer (leading German brand Motortech), the client now has a single point of contact for all servicing and spares – as we are the sole Motortech agent for the UK. We simultaneously removed the old controllers and screen in the control panel and installed a new touch screen with our controllers and expansion cards.

“The new open-access control system means the AD operator, GenV and ourselves can all access the system remotely and make immediate changes as required, keeping downtime to a minimum. The system also features smart diagnostics, with alerts based on user-defined parameters, and is backed by our 12-months free remote technical support.”

Benefits of remote access

The most immediate benefit enjoyed by Avocet Renewables following the engine upgrade is that their CHP is once again running at full power, providing a 20% uplift in output. With the new components designed to last for at least the next ten years, the engine is also operating more smoothly which will improve reliability, cut downtime and reduce servicing requirements.

“The open protocol on the new control panel gives us full access to the engine via remote monitoring. That means I can see everything that’s happening and can assist the Coston Hall Farm site at any time, from wherever I am, making it far more efficient and easier to use,” stresses Warren Vessey.

“Another big advantage for the client is that they now have full flexibility and choice over who handles their maintenance contract. It’s an industry-known system with readily available parts and support, so anyone can access it. It’s user friendly and modifications or adjustments can be made from anywhere, which really helps to limit downtime.”

The upgrade was only completed in mid-June, but Mark Gill, Plant Manager at Coston Hall Farm, is already positive: “The system works well and is a lot speedier than the old control panel. It’s also much easier to operate and, most importantly, our CHP is operating at full power again.”

CHP support experts Gen-C will showcase their range of engine control and optimisation solutions at the World Biogas Expo in July. Covering four key areas – parts, controls, upgrades, and asset supply – Gen-C and its network of engine partners will be on hand to explain to biogas plant operators how to cut CHP downtime, increase operational efficiency and “take full control of their own engine”.

Instant restarts
“The theme of our stand this year is ‘Take Control’,” says James Thompson, Managing Director of Gen-C. “For too long, engine owners have been at the mercy of service providers, many of whom charge high fees to maintain and repair their CHPs yet demand long wait times for engineer callouts. The irony is that many engine interruptions are caused by minor changes in the gas composition and could be easily rectified by the plant operator themselves, if only they had the ability to access and restart their own engine. Our smart control panels allow them to do exactly that, effectively ‘unlocking’ the engine to give operators full remote control over their own asset – without the need for a service provider. We’re excited to demonstrate to plant owners the benefits that this game-changing technology can bring.”

Immediate spares
Alongside Gen-C’s smart control panel installations, which are delivered in conjunction with their technology partners Motortech and DSE, the company is also excited to promote its extensive range of engine parts and spares.

“Since Brexit, getting access to OEM parts at short notice has become increasingly difficult,” explains James. “But thanks to our partnerships with leading European manufacturers such as RS Motor and Motortech, we always have a wide range of engine spares in stock at our Yorkshire HQ, ready for immediate dispatch to our UK client base. We’ll be outlining to visitors to our stand the importance of having a quality UK distributor like Gen-C on speed dial to keep your engine running safely and smoothly.”

Smart upgrades
The firm also offers an engine upgrade service, which “brings legacy assets into the digital era at a fraction of the cost of a new CHP“. By combining a smart control panel with an engine overhaul by Gen-C’s expert engineers, operators can enjoy all the benefits of a more energy efficient, more reliable, and higher performing asset, says the group.

“Not only will engine owners experience far fewer process interruptions and increased electrical output, but our smart, data-driven upgrades also mean live monitoring, instant alerts, and the ability to track CHP performance over time, as well as supporting predictive maintenance – giving complete control to the operator, not the service provider,” adds James.

CHPs for every budget
The final focus area for Gen-C’s stand is its range of CHP engines “for every budget”.

“From brand-new large engines to smaller refurbished CHPs, and even options to rent, we can supply the right engine for your needs,” confirms James. “Working in conjunction with our partner LouwSon Energy, every CHP we supply comes with remote control and live monitoring as standard, meaning you can be sure your asset is primed for the digital era.”

To find out more about Gen-C’s range of engine control and optimisation solutions, visit stand G35 or go to www.gen-c.co.uk

SEaB Energy and others enter commercial discussions with Shimizu following UK-APAC Tech Growth Programme reverse pitch

SEaB Energy, the developer of a pioneering anaerobic digestion system that produces energy from organic waste, has won the opportunity to forge a partnership with Shimizu Corporation, one of Japan’s largest civil engineering, construction and architecture companies. Representatives of SEaB Energy are now invited to Shimizu’s NOVARE innovation facility in Singapore to explore collaboration arrangements with the corporation.

This was the outcome of a reverse pitch held in London, involving 10 UK scaleups vying to solve a ‘net zero building’ challenge posed by Shimizu. It was organised by the UK-APAC Tech Growth Programme, which helps high-growth technology companies to explore and secure commercial opportunities in the APAC region.

At the start of the event, representatives from Shimizu set out their plans to collaborate with UK tech companies to advance the corporation’s ‘Vision of 2030’ sustainable business strategy. Each of the 10 companies – carefully selected from among the UK’s leading sustainability tech startups – then presented how its technology could support Shimizu’s vision, before participating in a Q&A session.

Shimizu selected SEaB Energy as the winner because of its innovative, compact, easy-to-install anaerobic digestion systems housed in shipping containers. The systems are already being installed globally, both by SEaB Energy directly and through distribution and licensing agreements.

Sandra Sassow, SEaB Energy’s CEO, said: “We’re thrilled that Shimizu recognised the value creation opportunity of using sustainable energy and reducing CO2 emissions via our waste-to-energy technology. Our various sized platforms and the significant reduction in emissions they deliver will help Shimizu win new construction orders and further promote the use of electricity derived from renewable energy sources. This aligns with the corporation’s ‘Vision of 2030’ to realise a sustainable society.”

Shimizu has also invited three of the other participating companies to progress commercial discussions. They are:

• Faradai: a supplier of artificial intelligence (AI)-based systems for energy and emissions tracking
• Low Carbon Materials: a climate-tech company that develops product innovations for the decarbonisation of emission-intensive construction materials such as concrete and asphalt
• re:sustain: a supplier of an energy optimisation technology that works with any building management system and uses calibrated digital twins to deliver scalable carbon and energy cost savings for commercial buildings.

Daisuke Kato, Head of the Acceleration Group at Shimizu’s NOVARE facility, said: “Our focus on sustainability is strong, especially in Southeast Asia where we have a long history in construction. We were therefore delighted explore the solutions on offer in the UK-APAC Tech Growth Programme’s reverse pitch.

“The event was incredibly insightful and we were impressed by the advanced technologies and expertise showcased by the UK companies in the field of net-zero buildings. They highlighted that UK sustainability efforts are a few steps ahead of Japan, which is valuable knowledge as we strive to close the gap in APAC. It was inspiring to see so many UK tech companies aligned with our goals for a sustainable future in Asia Pacific.”

Dr Lian Hutchings, Head of Growth at Low Carbon Materials, said: “It was an honour to be selected to present our net zero construction solutions to Shimizu. As a climate tech startup with ambitions to expand into new geographical markets, including the APAC region, we very much look forward to continuing our discussions with the corporation.”

The UK-APAC Tech Growth Programme provides free and subsidised support to technology companies aspiring to enter one or more of 11 markets: South Korea, Japan, Taiwan, Singapore, Vietnam, Malaysia, the Philippines, Thailand, Indonesia, Australia and New Zealand. It is delivered on behalf of the government by international business development consultancy Intralink.

Companies can apply to participate here.

Jeremy Shaw, who leads UK-APAC Tech Growth Programme, said: “Initiatives such as this are just some of the ways the Programme highlights the latest UK technologies to potential customers and partners in Asia Pacific. The fact that Shimizu has decided to continue discussions not just with the winner but with three of the other participating companies is confirmation of the huge interest in UK technology.

“We congratulate SEaB and the other participants and look forward to supporting them on the next stage of their journey into the APAC region.”

In the UK, the sector is forecast to overtake nuclear by 2029

“Biogas… It’s Happening”, will be the overarching theme of this year’s World Biogas Expo taking place in Birmingham, UK, on 10-11 July 2024. Organized by the Anaerobic Digestion and Bioresources Association (ADBA) and the World Biogas Association (WBA), the event is the only trade show solely dedicated to the anaerobic digestion (AD) and biogas sector.  This year, it will bear testimony to the rapid growth of the industry as forecast by the International Energy Agency (IEA) in its World Energy Outlook 2023 report*.

Key players in the AD and biogas sector will gather at the NEC Birmingham to hear about market trends and policy in the conference area and explore the busy exhibition where over 150 AD and biogas companies will showcase their products, services and innovations.

Headlining the speakers’ line-up of industry leaders in the Engine Room theatre will be Former Secretary of State for Environment, Food and Rural Affairs, UK Government and Chair of the International Fugitive Emissions Abatement Association (IFEAA) George Eustice.

He will be joined by senior representatives of major stakeholders within the sector, including the Climate and Clean Air Coalition, the HSE Science and Research Centre, the Environment Agency, Food Chains, CCm Technologies, IBBK Fachgruppe Biogas GmbH, Borea, Alps Ecoscience, Organic Roots, Bioelectric, ANGI Energy Systems and many others. Debates will focus on how decarbonisation through AD can be rolled out through finance, transport, agriculture and other key sectors of the economy.

The Expo will also feature side events dedicated to on-farm AD and the integration of AD and biogas into decarbonisation strategies for municipalities in the UK.

“The World Biogas Expo represents a fabulous opportunity for people to come together and collectively identify the opportunities and challenges that we’ve got in delivering for the industry and the world”, explains Charlotte Morton OBE, WBA Chief Executive. “There is a huge amount to learn about the latest trends and technologies, what other companies are doing, what is happening in other countries, and this is a platform for a great exchange of ideas as well.”

Co-located to the World Biogas Expo will the the World Biogas Summit – a global thought-leadership forum hosted by the World Biogas Association which this year will welcome Jo Tyndall, Director, Environment Directorate, OECD as the keynote speaker alongside other very high profile participants.

The evening of 10^th July will also be a time for celebration with the winners of this year’s AD and Biogas Industry Awards competition being revealed at a gala ceremony hosted by sustainability champion Chris Hines, former Sustainability Director of the Eden Project and Special Adviser to the UK Minister for the Environment Michael Meacher.

Three unmissable events in one place over two days at a very exciting time for the AD and biogas sector!

Registration to the World Biogas Expo is free and can be completed at: www.biogastradeshow.com; www.world-biogas-summit.com

*between 8% and 22% / year by 2030. Source: IEA, World Energy Outlook 2023

Biomethane-to-hydrogen (and graphene) climate technology comes to Worthy Farm

Clean hydrogen developer, Hexla, and British climate tech firm Levidian have joined forces to bring Levidian’s LOOP technology to Worthy Farm in Somerset in what’s described as a world first example of carbon-negative hydrogen production from biomethane.

Home to the Glastonbury Festival, Worthy Farm currently produces power using an anaerobic digestion plant that turns tens of thousands of tonnes of cow slurry and waste silage into energy. The LOOP technology will allow the farm to capture the carbon from some of the biomethane produced as part of this process and turn it into super-material graphene and clean hydrogen, which will be used to generate electricity through the existing combined heat and power plant.

The installation is expected to deliver a saving of up to 25 tonnes of carbon dioxide equivalent each year, while the graphene will be sold as an additive to boost the performance of products as wide-ranging as batteries, concrete and plastics.

Hexla is providing funding to support the development of an industrial-scale LOOP1000 that will deliver the lowest cost clean hydrogen in the world over the lifetime of the plant as a result of the production of high-quality graphene. Hexla and Levidian have also agreed a Collaboration Agreement under which Hexla will become a global deployment partner of the LOOP technology with plans to deliver up to 300 LOOP1000 units that will drive down the emission of hundreds of thousands of tonnes of CO2e per year.

Hexla Founder Andy Yeow said: “Since early 2019, our team has been researching clean hydrogen production technologies around the world, so it is a great pleasure to be announcing what we expect to be the first of many successful deployments in conjunction with Levidian today. The Levidian LOOP, with its unique solid carbon by-product of high-quality graphene, is the standout technology – from both a thermal efficiency and marginal cost basis – in an extremely competitive field.”

“We are proud to be playing a key role in the scale-up of this truly game-changing technology and are focused on deploying it on an industrial scale to some of the most attractive hydrogen production markets in the world.”

Levidian CEO John Hartley said: “The Worthy Farm project is a great example of innovation within the agricultural sector and an important showcase of the vast flexibility and potential of our technology in decarbonising hard-to-abate industries, while unlocking new revenue streams.

“We’re delighted to be working with Hexla to help further our aims for this pioneering technology, including the development of our LOOP1000 unit, which will deliver industrial-scale levels of decarbonisation and place us amongst the best available carbon capture technology on the market.”

In March, a German agricultural firm commissioned one of Weltec Biopower’s Kumac digestate processing systems. The equipment separates solid matter from water, providing a number of reported benefits, including improved concentration of nutrients (for easier transportation and reduced fertilizer application cost), as the firm explains here.

This is the first Kumac plant to go live in Germany, in addition to the 16 that have been built worldwide to date. The firm, Agrar GmbH Reichenbach, based in the Vogtland region of Saxony, specialises in dairy farming and the cultivation of feed crops. In addition to the dairy farm with 1,400 cows and breeding cattle, the farmers have been operating a biogas plant with an electrical output of 845 kW since 2006. The facilities generate up to 72,000 tonnes of liquid manure and digestate per year.

Every day, the biogas plant feeds 12,000 kWh of electricity into the public grid. In addition, the plant supplies up to 500 kW of heat to small consumers and to the site of the former Paracelsus Clinic in Reichenbach via a heating network. The plant’s main business consists of the delivery of biogas via a 3.2-km raw biogas pipeline to the heating plant of Stadtwerke Reichenbach for the base load supply of flats and social facilities. The amount of electricity generated each year corresponds to the annual consumption of around 6,000 private households.

The introduction of modern technologies and systems such as the Kumac system greatly contributes to the recycling of nutrients and the conversion of liquid manure into compost, fertiliser, animal bedding or biogas substrate, says Weltec Biopower. For the conversion, Kumac makes use of tried-and-tested processes that are fine-tuned to each other.

Fertilizer boost
“In Reichenbach, the output of the Kumac process consists of around 25 percent solid and 20 percent liquid farm manure and 55 percent dischargeable water,” explained Lars Bittermann, Managing Director of Agrar Reichenbach GmbH. “The resulting solid matter and the nutrient concentrate are applied as organic, high-quality fertiliser to our own crops. In this way, long transport routes are avoided.”
“This closes an efficient material flow cycle, and the individual areas of our portfolio interlock perfectly. From the cultivation of feed crops to dairy farming to the utilisation of the liquid manure in the biogas plant and the processing of digestate into fertiliser and water, all components have their place.”

Dry matter reduction
In the first step of the liquid manure and digestate treatment, flocculants are added to the source material. These additives ensure flocculation of even the finest components, facilitating their separation from water. At the same time, they contribute to the reduction of odour emissions. After the material has been squeezed through a belt press via various rollers against a second, water-permeable belt, the solid material can be used directly as fertiliser, compost, animal bedding or biogas substrate with a dry matter content of up to 30 percent.

Subsequently, the liquid phase is passed through a tank in which small particles and suspended solids are separated. Any remaining solid particles are removed by means of a fine filter. In the next step, the filtrate traverses a three-stage reverse osmosis process to remove salts and nutrients. The resulting liquid fertiliser is rich in nitrogen and merely accounts for one quarter of the original volume. Clear water accounts for the greatest share of the treatment products and is currently discharged into the receiving water.

European funding
The scalable modular system can be used for quantities from 70,000 tonnes of liquid manure or digestate a year. Should the processing needs increase, several Kumac lines can easily be combined. “The processing here is almost fully automated, which also minimises the amount of personnel required”, said Bittermann. Operators who decide to set up a system can receive funding from the European Agricultural Fund for Rural Development.

This article contains paid for content produced in collaboration with PowerUP.

Politicians, scientists, and industry stakeholders alike are continuously seeking sustainable energy sources as a contribution to the international efforts in reducing greenhouse gas emissions. However, challenges in establishing alternatives to fossil fuels include costs, technology gaps, as well as accessibility and reliability.

Biogas is widely considered as one puzzle piece in the bigger picture of tomorrow’s energy sources: Being produced out of organic waste, it tackles both the problems of waste management and finding renewable energy sources.

However – ”The use of biogas in energy production is hindered by several factors, including a lack of efficiency of many gas engines themselves, which are a centerpiece in the transformation of biogas into heat and energy”, states Thomas Achrainer, one of the founders of PowerUP GmbH. As an established expert for gas engine services regarding biogas power plants, PowerUP has specialized in innovative solutions to get the biogas sector ready for the next decade.

The biogas market today – an overview

Especially in electricity production, biogas has been found as a promising alternative to fossil fuels, which still made up the majority of global energy sources in 2022: Coal alone had a share of more than 35% that year, followed by natural gas with 22%.^[1]

Yet, renewable energy sources like biogas are on the rise: In 2022, the capacity of biogas energy installed globally equaled 21.5 gigawatts. In total, the worldwide biogas market – including applications like cooking, heating, and, with the largest share, energy production – was estimated to size USD 65.53 billion in 2023. Between 2024 and 2030, a compound annual growth rate (CAGR) of 4.2% is expected.^{[2] [3]}

Obviously, the direction is clear: Biogas is expected to become an increasingly important factor in global energy supply. Advantages include renewability and waste utilization, but also increased stability in the energy supply of developing countries and rural regions. Still, there is considerable room for improvement.^[4]

Major challenges for biogas engine operators: What are the struggles?

“Biogas often needs to undergo a special processing step in order to make it accessible to energy production”, says Thomas Achrainer. After all, this natural product can come with sometimes considerable variation in its composition. But despite advanced processing, biogas engines need to be adaptable enough to cope with inconsistencies during combustion.

However, these are not the only intricacies that biogas engines (or rather, their operators) are confronted with.

Inefficient facilities

Costs are a determining factor when it comes to the adoption of renewable energy sources. Biogas makes no exception, which is why the energy sector needs to have state-of-the-art technologies at its disposal. Speaking of gas engines taking center stage in energy production with biogas, Thomas Achrainer illustrates: “Modern gas engines are real power horses, as they can achieve high efficiency levels when used in energy production. However, even when using gas engines by established market leaders, there is often room for improvement.”

Despite good efficiency levels between 40 and 50%, biogas engines for energy production can be further improved and adapted to specific customer needs. For instance, the tolerance for larger variations in gas quality can be improved, circumventing the need for laborious gas preparation steps.^[5]

Additionally, specially developed gas engine parts can be incorporated to further increase the efficiency of engines. These elements may include spark plugs, blowby filters, as well as many other components to increase not only efficiency, but also durability.

Complex maintenance

Maintenance can easily become a major issue when operating complex facilities with large and delicate systems. And despite regular servicing being essential to ensure longevity of costly gas engines and to avoid unplanned interruptions, it often comes with significant downtimes. This is even more true when the facility in question is located in considerable distance to either the gas engine manufacturer or a qualified service partner.

Gas engine operators are therefore seeking for possibilities to either decrease the costs and efforts related to maintenance or to combine servicing with customized upgrading of existing systems.

Dated systems – costly replacements

The average lifetime of biogas engines can extend over more than 25–30 years. However, as technology moves on, many power plants have only dated gas engines at their disposal, increasing both maintenance costs and susceptibility to errors. Even so: Replacements are costly, and an untimely phase-out of a gas engine undermines the aspiration of a sustainable energy production.

Keeping track with technological progress, though, does not necessarily imply regularly replacing multiple components of power plants. Instead, possibilities to upgrade existing systems are extremely requested with the aim to make older gas engine generations future-proof.

Powering up biogas engines – being prepared for tomorrow’s challenges

“Challenges drive innovation. Without them, we’d have stagnation instead of progress”, says Thomas Achrainer. And in fact, the hurdles in the operation of biogas engines have prompted the industry to develop approaches to increase efficiency, reliability, and independence.

To that end, PowerUP not only offers maintenance services for MWM® and INNIO Jenbacher® engines in 52 countries – the condition-based overhaul allows cost and resource efficiency by only exchanging those parts that have actually reached the end of their lifetime. Component replacements, on the other hand, also include PowerUP-designed gas engine spare parts that are able to further increase the efficiency and longevity of biogas engines – such as blowby systems and cylinder heads.

In addition to dedicated spare parts and upgrade options for existing engines, PowerUP has also developed PUPGEN: The combination of an overhauled INNIO Jenbacher® Type 3 engine and targeted adaptations by PowerUP makes it an extremely versatile while cost-effective addition to the company’s line-up.

^[1] https://www.statista.com/statistics/269811/world-electricity-production-by-energy-source/

^[2] https://www.statista.com/statistics/1032922/biogas-capacity-globally/

^[3] https://www.grandviewresearch.com/industry-analysis/biogas-market

^[4] https://energypedia.info/wiki/Advantages_and_Disadvantages_of_Biogas

^[5] https://www.energie-lexikon.info/gasmotor.html

The Anaerobic Digestion and Bioresources Association (ADBA) welcomed the government’s full outcome published on 25 January on the Green Gas Support Scheme (GGSS) Mid-Scheme Review. As announced in October 2023, the scheme will be extended by 3 years to 31 March 2028, providing continuity for the sector.

“This is good news for the UK’s growing green gas industry,” said ADBA Chair Chris Huhne, welcoming the announcement. “The extension until 2028 gives investors and developers more long-term certainty to build new biogas plants. It also confirms other positive proposals we recommended in our consultation response last year.”

Aligning with ADBA recommendations during the Review, the outcome further endorses critical proposals including maintaining current tariff guarantees and commissioning deadlines, retaining the 50% waste feedstock threshold, and continuing requirements for responsible digestate management.

“Biogas can play a key role in decarbonising the hardest-to-decarbonise sectors in the country” added Huhne. “With the right policy support, biogas can provide more energy than nuclear in 2031. We can build hundreds of biogas plants on time and on budget in the time it takes to announce another delay to a nuclear power plant. Moreover, green gas is easy to store and so it is a better back-up to cheap solar and wind.”

Today’s announcement brings positive steps on multiple fronts, yet the work is far from done. ADBA looks forward to continuing engagement with the government on optimising policies and regulations to sustainably grow the UK’s biomethane sector.