Innovative technologies for the production and utilization of biogas

From concept to construction

biogas plants from one source

Bioenergie GmbH

2

THE IDEAL TECHNOLOGY FOR EACH TYPE OF FEEDSTOCK

STRUCTURE- AND IMPURITY-RICH

FEEDSTOCK

STRUCTURE-POOR STRUCTURE-POOR AND LIQUID

GICON® PROCESS

BIOGAS TECHNOLOGY

WET FERMENTATION OF WASTES

WET FERMENTATION OF AGRICULTURAL RESIDUES

GICON EXPERTLY HANDLES ALL ASPECTS OF BIOGAS TECHNOLOGYWhether you intend to process organic waste or rene-wable raw materials, high-solids or liquid feedstocks, municipal waste or food waste – GICON provides the

optimal biogas technology in conjunction with an appropriate feedstock pre-treatment.

Energy is created as a product from the fermentation process in the desired form as biomethane or electri-city and heat via a combined heat and power genera-tor. An additional product is conditioned solid dige-state.

BIOGAS PLANTS AND INFRASTRUCTURE FROM ONE SOURCEGICON Bioenergie GmbH was founded in 2006 as an independent firm within the GICON Group, which contains six divisions, 38 departments and more than 300 employees. The company develops, designs, and delivers biogas plants as a general contractor or engi-neering contractor and can fall back on experiences gained from the construction of over 30 plants.

GICON employs highly-qualified and experienced engineers. For complex tasks, we form inter-disciplinary teams with all the necessary competen-cies to guide projects through all phases – from concept and design through the permitting phase to commissioning and optimization of operation – all from one source. In this way, GICON delivers optimal process and system solutions for each client’s initial situation. Biogas plants from GICON process every form of decomposable feedstock and subsequently provide several different forms of energy. Small plants can also be efficiently and profitably operated.

The end result is a forward-looking generation of energy which in application is reliable, environ-mentally-friendly, adaptable and cost-effective.

GICON BIOENERGIE GMBH RANGE OF SERVICES

Holistic concept and project development Test fermentations in our large-scale research facility for simulation of actual operation and for preparation and protection of potential client investments Complete design, construction supervision and commissioning Complete plant delivery and erection (turn key) as general contractor Operational optimization and engineering services for existing plants Research and development towards optimization of biogas technologies

3

4

THE GICON® PROCESS T WO-STAGE, DRY-WET FERMENTATION WITH SPLIT HYDROLYSIS

Numerous advantages Numerous advantages Numerous advantages in comparison to conventional in comparison to conventional in comparison to conventional

biogas processesbiogas processesbiogas processes

Controllability of biogas productionControllability of biogas productionControllability of biogas production Methane content 15-20 % higher than by conventional plantsMethane content 15-20 % higher than by conventional plantsMethane content 15-20 % higher than by conventional plants

High process stability High process stability High process stability High availability and reliable means of operationHigh availability and reliable means of operationHigh availability and reliable means of operationHigh availability and reliable means of operationHigh availability and reliable means of operationHigh availability and reliable means of operation

Flexible use of feedstocks resulting from lack of sensitivity to impuritiesFlexible use of feedstocks resulting from lack of sensitivity to impuritiesFlexible use of feedstocks resulting from lack of sensitivity to impurities Simple and robust feedstock handlingSimple and robust feedstock handlingSimple and robust feedstock handling

No re-inoculation of feedstock, therefore low risk of siltingNo re-inoculation of feedstock, therefore low risk of siltingNo re-inoculation of feedstock, therefore low risk of silting Low energy requirement for operation Low energy requirement for operation Low energy requirement for operation Compact installation footprintCompact installation footprintCompact installation footprint Low risk of encrustation of piping, Low risk of encrustation of piping, Low risk of encrustation of piping,

pumps and aggregatespumps and aggregatespumps and aggregates

Structure-rich solid digestate, low treatment Structure-rich solid digestate, low treatment Structure-rich solid digestate, low treatment e� ort for post-compostinge� ort for post-compostinge� ort for post-composting

The GICON® Process was developed by a team led by Prof. Busch from the Department of Waste Manage-ment at the Brandenburg Technical University in Cottbus together with GICON, and has been inter-nationally patented. It is specially designed for impurity-rich waste feedstocks. A batch high solids anaerobic digestion process utilizing percolation, the unique characteristic of the GICON® Process is its two process stages highlighted by the deliberate separation of the hydrolysis and methanization decomposition processes.

TWO DISTINCT STAGES OF HYDROLYSIS AND METHANE FORMATIONIn the hydrolysis stage, organic macromolecules are biologically broken down into soluble organic sub-stances and discharged as an aqueous solution – the hydrolysate. The collection of the hydrolysate from all percolators takes place in a buffer tank from which the second stage, a fixed bed digester for methanization, is continuously fed. The fixed bed, with a high surface area-to-volume ratio, provides a colonization surface to methane bacteria which are immobilized within the methane digester. The resulting liquid, which is neutralized by the biogas process, is then fed to a second buffer tank, the process water tank, and re-circulated back to percolation in the hydrolysis stage.

LACK OF SENSITIVITY TO IMPURITIES AND ENCRUSTATION A fundamental advantage of the percolation process is its lack of sensitivity to impurities. This enables the application of organic and municipal wastes, impurity-laden solids and lawn/garden wastes as well as agricul-tural feedstocks such as energy crops or solid manure. Furthermore, the GICON® Process offers low wear and tear. High recirculation rates in conventional percolati-on processes lead to salt crystals in process water which can encrust on pipes and aggregates. In the GICON® Process, the crystals are deposited in the process water tank, where the pH is highest and the temperature is lowest. Pipes are therefore better protected against encrustations and crystal sludges can be discharged in a controlled manner from the process water tank.

LOW ENERGY REQUIREMENT AND HIGH AVAILABILITYBiogas plants based on a percolation process have low energy requirements, because among other things, no mixing technology is required. At the same time, batch operation leads to high availability. In comparison to conventional one-step batch processes, the characteris-tic GICON® Process immobilization of microorganisms in the methane reactor enables the residence time of the feedstock in the percolators to be significantly reduced and enables 100% fresh feedstock to be introduced into each batch. Seeding by mixing in solid digestate is not required, which also avoids silting of the digestate. Plants using the GICON® Process are therefore particularly compact in footprint.

5

Photos above left:Biogas plant in Richmond (Canada),First high solids anaerobic digestion plant for organic wastes utilizing the GICON® Process in North America

Photos below left:GICON-Biogas plant in Cottbus and loading of the percolators with feedstock

6

THE GICON® PROCESS T WO-STAGE, DRY-WET FERMENTATION WITH SPLIT HYDROLYSIS

PROCESS STABILITY AND HIGH BIOGAS QUALITYObjectives during the development of the GICON® Process were optimal process stability and increase of biogas quality while simultaneously providing for controllability of production.

The process stability is improved by the ability to create optimal conditions in isolated environments for hydrolytic and methanogenic bacteria. By mixing the process liquids from the two buffer tanks, the pH can be adjusted separately for both stages. The liquid is heated before it is fed into the digesters in separate external heat exchangers, so that hydrolysis and methane production can be operated at different tem-peratures levels. The decoupling of acidification and methane formation avoids a "tipping" of the process.

In the fixed-bed digester for methanization of the hydrolysis product, biogas is produced with very high methane content (above 70 %). The low calorific gases produced in the hydrolysis stage are collected separa-tely and fed to a separate use. Through this process, costs and energy can be saved in the upgrading to biomethane.

NEED-BASED FLEXIBILITY AND CONTROLLABILITY POSSIBLE FOR THE FIRST TIMEUnprecedented in biogas technology is the controlla-bility of biogas production. The vision of a permanent-ly-available energy and disposal center is therefore almost within our grasp. The foundations of this fea-ture are both the buffering of energy-rich hydrolysate in an intermediate storage tank, and the constant avai-lability of the methane-forming bacteria (immobilized on a solid carrier substrate in the methane digester). This controllability makes adaptations to load transi-tions possible and eliminates flare losses during main-tenance works and interruptions in biogas utilization. Through parallel operation of the percolators, mainte-nance measures can be routinely performed without interruption of operation.

DIAGRAM OF THE GICON® PROCESS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Percolator with Drainage

Irrigation with Process Water

Percolate Gravity Flow

Utility Water Excess Water Biogas

Methane DigesterCombi-Bu� er

Percolate Process- water

HE

HE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .

Packing Materialfeedstock Mound

7

WET FERMENTATION BIOGAS PLANTS PROJECT DEVELOPMENT AND DESIGN

GICON can also fall back on decades of experience and comprehensive know-how for the construction and operation of wet fermentation biogas plants for wastes and energy crops. From design and permitting to turn key delivery of plants, GICON offers all services from one source. Through process adaptation, the require-ments of the plant and the feedstock to be treated can be best addressed.

WET FERMENTATION OF WASTESA significant portion of commercial and industrial waste is composed of organic substances. Use of these wastes to produce heat and electricity is the purpose of fermentation plants. The fundamental methodology involved in this biological process is the activity of anaerobic microorganisms in the absence of air or oxygen. In wet fermentation plants for waste, mainly poorly-structured feedstocks such as commercial kitchen and food waste, used cooking oil/greases or waste from the animal feed or food and beverage industry are fermented with agricultural waste such as crop residues, and solid/liquid manure.

Installation of the central mixer in a vertical fermenter

Biogas Plant in Les Herbiers (France) Central mixer in a vertical fermenter

8

WET FERMENTATION BIOGAS PLANTS PROJECT DEVELOPMENT AND DESIGN

WET FERMENTATION OF ENERGY CROPS AND AGRICULTURAL RESIDUESFor wet fermentation, silage of various plants is mostly used as a feedstock. When pure energy crops are used, a multi-stage system with combined dry and wet digestion is required to optimally exploit the feed-stock. A by-product of wet fermentation is a digestate similar to manure, which as a fertilizer is chemically far less aggressive than raw manure. In addition, nitrogen availability is better and the odor is less intense.

Site plan for a wet fermentation plant

Biogas Plant in Schlegel (Germany) Biogas Plant in Hertnik (Slovakia)

9

BIOGAS INJECTION ECONOMICALLY AND ECOLOGICALLY SENSIBLE

The injection of biogas into existing natural gas net-works has been gaining in economic importance. This development has been driven by new regulations aimed at reducing CO2 emissions through the use of renewable energies, also in the heating market. The positive CO2 balance of biogas results from production in the vicinity of the consumers and the possibility to couple with power and heat. Biomethane as a rene-wable energy source can be offered to practically every end user through pipeline injection.

GICON is a leading provider in the design of biogas conditioning and biogas injection facilities, recom-pression facilities in high-pressure transportation grids and gas pressure and measuring facilities.

GICON’S SERVICES FOR THESE FACILITIES

Facility concepts Permit planning incl. environmental reports Expert facility inspections and approvals Commissioning and start-up

Biogas injection facility designed for MITNETZ GAS in Leuben/Oschatz (Germany)

BIOGAS CONDITIONINGThe quality of biomethane to be injected must be adapted to the existing network quality. This process is called biogas conditioning. It is necessary so that the end consumer can easily continue to use their equip-ment safely and with the required gas quality. The cost of conditioning is dependent on the methane content of the biogas and the calorific value of natural gas in the network.

Currently, biogas conditioning is performed using liquefied petroleum gas (LPG), air or a combination of air and LPG. The biomethane is taken from a controlled air chamber and mixed with air and/or LPG. Then, compression is performed to the level of the network supply pressure.

A biogas injection facility consists of four basic units – the LPG supply, the air supply, the mechanical equipment and the gas metering and mixing trains. By multiple controls in the facility, hazardous situations are not encountered in spite of contact of air with a combustible gas. A sophisticated ventilation concept offers additional protection against explosive gas states.

GICON designs the following elements of biogas conditioning and injection facilities:

EI&C and safety engineering Static gas mixers and gas detection technology Liquefied gas storage tank and LPG-evaporator Compressor Odorization

10

RESEARCH AND DEVELOPMENTINNOVATION AS A FOUNDATION OF ROBUST COMPETITIVENESS

Cottbus Research Cottbus Research Cottbus Research and Development Centerand Development Centerand Development Center Test facility for percolation Test facility for percolation Test facility for percolation

and gas production at di� erent scalesand gas production at di� erent scalesand gas production at di� erent scales

Several hundred small and pilot plant tests Several hundred small and pilot plant tests Several hundred small and pilot plant tests for feedstock analysisfor feedstock analysisfor feedstock analysisfor feedstock analysisfor feedstock analysisfor feedstock analysis

Scalability of laboratory results to industrial scaleScalability of laboratory results to industrial scaleScalability of laboratory results to industrial scale

Continuing process optimizationContinuing process optimizationContinuing process optimization

Development of new processes and productsDevelopment of new processes and productsDevelopment of new processes and products

Feedstock investigations for clientsFeedstock investigations for clientsFeedstock investigations for clients

11

Continuous market-oriented research and develop-ment is a cornerstone of GICON company philosophy. On this basis, GICON has become a hotbed of inno-vation in the biogas sector.

For extensive research services, GICON opened a large-scale research facility in Cottbus in 2007, the largest privately-owned biogas research facility in Germany. In this research and development center, the GICON® Process above all is being continuously optimized. In addition, new biogas processes can be designed and planned in test series. This approach minimizes risks to actual operation and helps to ensure the predicted gas yield.

ACADEMIC EXCHANGEGICON maintains a close network with numerous prestigious national and international research institutions. Specific cooperation agreements forbiogas technology development have been comple-ted with the Technical University of Dresden, the Brandenburg Technical University in Cottbus and the German Biomass Research Center.

POWER-TO-GASTo mitigate the volatile availability of energy from renewable sources such as wind or photovoltaic, GICON has developed a special patent-pending power-to-gas process for biological catalytic methanization. In times of excess supply, the energy is converted via electrolysis to H2 and is methanized with the addition of CO2. Methane (CH4) is storable and can be conver-ted on demand into electrical energy or heat, or be fed into the natural gas grid.

CONTAMINANT REMOVAL WITH ASSISTANCE OF THE GICON® PROCESSThe GICON® Process enables utilization of contamina-ted feedstock such as HCH and thus reduces an envi-ronmental hazard. GICON combined its existing skills for remediation of contaminated sites with those of bioenergy and developed this ground-breaking method. This GICON innovation was made possible in part by longstanding research cooperation with Anhalt University of Applied Sciences.

wast

e han

dlin

g

organic waste

lawn/garden waste

Org. fraction of MSW

wind

sunrene

wabl

e ene

rgy wind farm

solar power installation

percolators

GICON biogas plant

� xed-bed methane digester +4H2 + CO2 >CH4 + 2H2O bi

olog

ical

desu

lfuriz

atio

n

upgr

adin

g (b

iom

etha

ne)

Biogas

RE based on solar availability

excess energy during grid overload

RE based on wind availability

direct injection based on demand electrical grid

natural gas CHP

gas network as storage

peak loads

biomethane injection

O2electrolysis

H2

hydrolysis gas(CO2-rich)

Hydrolysate

Vision: Power-to-Gas by biological catalytic methanization of H2

Großmann Ingenieur Consult GmbH

GICON GroupTiergartenstr. 48 I 01219 Dresden, Germany I Phone +49 351 47878-0 I Fax +49 351 47878-78 I info@gicon.de

www.gicon.com, www.gicon-engineering.com