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Innovative<br />
technologies for<br />
the production<br />
and utilization<br />
of biogas<br />
<strong>Biogas</strong> Plants<br />
From concept<br />
to construction –<br />
biogas plants<br />
from one source
<strong>GICON</strong> Bioenergie GmbH<br />
a capable technology partner<br />
Enlargement of the test dimension and<br />
spectrum at a large-scale research facility,<br />
without risks to future investors.<br />
Percolate fermentation plant Erfurt, Germany<br />
Existing mechanical-biological<br />
treatment<br />
02<br />
Residual waste and/or sourceseparated<br />
organic waste<br />
New plant combination:<br />
<strong>GICON</strong> biogas plant<br />
Existing disused<br />
landfills or existing<br />
wastewater<br />
treatment plants<br />
Residual wastes<br />
Wastewater<br />
The construction of biogas plants from concept through to commissioning,<br />
including infrastructure, gas utilization or upgrading, and handling<br />
of digestate.<br />
<strong>GICON</strong> Bioenergie GmbH was founded in 2006 as an independent firm within the<br />
<strong>GICON</strong> Group. The company develops, plans, and realizes biogas plants as a<br />
general contractor or engineering contractor. Through the interdisciplinary structure<br />
of the <strong>GICON</strong> Group, with more than 200 employees, and the experience<br />
gained from the construction of more than 30 biogas plants, project management<br />
of all phases – from concept development to permitting and on to commissioning<br />
and operational optimization – can be guaranteed from one source.<br />
Our philosophy is: the delivery of the optimal process and system solutions for<br />
the unique requirements of the client. Therefore, several principle concepts for<br />
biogas production are offered by <strong>GICON</strong> Bioenergie GmbH:<br />
■ <strong>GICON</strong> <strong>Biogas</strong> Process (two-stage dry-wet fermentation with split hydrolysis)<br />
■ multiple-stage wet fermentation process<br />
<strong>GICON</strong> Bioenergie GmbH Spectrum of Services<br />
■ Holistic concept and project development (for biogas plants)<br />
■ Test fermentat. in an industrial-scale research facility for investment preparation<br />
■ Overall planning (all planning phases, construction supervision, commissioning)<br />
■ complete plant delivery and erection (turnkey) as general contractor<br />
■ Operational optimization and engineering service for existing plants<br />
■ Research toward the development and optimization of bioenergy processes<br />
Residual waste and/or source-separated organic waste<br />
Mechanical<br />
pre-treatment<br />
High-calorific<br />
fractions<br />
Organic fraction<br />
(normally low-calorific,<br />
damp)<br />
Landfill<br />
Landfill<br />
leachate<br />
Landfill gas<br />
Thermal<br />
utilization<br />
Intensive<br />
composting<br />
(can be omitted)<br />
Hydrolysis<br />
Methane<br />
production<br />
Post-composting<br />
<strong>Biogas</strong> (70% CH 4 )<br />
Sewage gas<br />
Landfill leachate treatment plant/<br />
Wastewater treatment plant<br />
Impurities<br />
Compost<br />
treatment<br />
CHP or<br />
upgrading to<br />
biomethane<br />
(optional)<br />
Existing CHP or<br />
gas utilization<br />
Compost<br />
Energy feed-in<br />
(optional)<br />
Electrical energy<br />
Thermal energy<br />
Biomethane<br />
Energy feed-in<br />
Purified<br />
wastewater
Complete Services<br />
for different applications<br />
Pre-treatment of feedstocks<br />
<strong>Biogas</strong> technologies<br />
Utilization<br />
Dry fermentation<br />
Waste (biologically exploitable)<br />
Structure- and impurity-rich Liquid and structure-poor<br />
<strong>GICON</strong> Process<br />
Biomethane production<br />
Pretreatment (screening, crushing) Storage<br />
Gas utilization<br />
High-volume fermenter with<br />
central agitator<br />
Electricity and heat generation<br />
Wet fermentation technology<br />
classic/multiple-stage<br />
Renewable raw materials<br />
Organic material<br />
Multi-stage reinforced-concrete<br />
fermenter system<br />
Fermentation residues<br />
03
<strong>GICON</strong> <strong>Biogas</strong> Process<br />
two-stage dry-wet fermentation with split hydrolysis<br />
High-performance fermenter with effective<br />
utilization of the reactor volume due to the<br />
<strong>GICON</strong> Process.<br />
Filling of a percolator<br />
with agricultural machinery<br />
04<br />
Process flow diagram<br />
of the <strong>GICON</strong> <strong>Biogas</strong> Process<br />
Simple solution - enormous impact<br />
The <strong>GICON</strong> <strong>Biogas</strong> process with most of its major process steps was developed at BTU<br />
Cottbus (Prof. Busch et. al.) in cooperation with <strong>GICON</strong> and has been patent-protected<br />
several times, including internationally (Patent DE 10 2204 053 615.5, additional patent<br />
applications for design details and process variations). It has been designed to operate in<br />
two steps, with a systematic separation of microbiological decomposition steps. During<br />
the first step (hydrolysis), organic components are eluted from the substrate matrix and<br />
converted into organic acids and other water-soluble decomposition products. This<br />
watery solution (hydrolysate), containing organics, is fed into the second step, the methanization,<br />
which is designed as a packed bed vessel. Due to the immobilization of methane-forming<br />
microorganisms on the surface of the packing material, large methaneforming<br />
potentials will be available at any given time. Thus, short residence times of<br />
the hydrolysate can be achieved, a solution which poses a unique option for the controlla-bility<br />
of the biogas production. The environmental conditions (temperature and pH,<br />
among others) are controlled and optimized separately in both process steps. By applying<br />
the innovative <strong>GICON</strong> biogas process, major disadvantages of conventional facilities<br />
are omitted.<br />
Since movement of the solid substrate does not occur during the operation, the system<br />
is robust with respect to possible impurities content. This is especially important for feedstocks<br />
such as biological wastes and landscaping-generated wastes. The use of the<br />
organic fraction of household waste is also possible and has already been successfully<br />
tested. Cleaning and maintenance of the percolation step can occur between substrate<br />
charging cycles without interruption of the biogas generation process.<br />
batch-wise addition and removal of feedstock<br />
multiple percolators<br />
in a garage setup<br />
percolation<br />
percolation<br />
stabile by-product appropriate,<br />
for example, for composting<br />
percolate<br />
= hydrolysate<br />
percolate return<br />
hydrolysate vessel<br />
-buffer storage-<br />
methane<br />
production<br />
control<br />
hydrolysate<br />
methane reactors<br />
return<br />
waste water, liquid fertilizer<br />
biogas<br />
70-80% CH 4<br />
packed bed<br />
aeration and<br />
polishing pool<br />
sludge<br />
liquid<br />
effluent
<strong>GICON</strong> <strong>Biogas</strong> Process<br />
a future-proof energy technology<br />
Efficient and stable<br />
The primary goal during the development of the <strong>GICON</strong> Process was the attainment<br />
of optimal process conditions for diverse groups of microorganisms in adherence<br />
with high process stability. Accordingly, a two-stage process with integrated solid<br />
separation and buffering of the liquids was implemented. The splitting off of CO 2 ,<br />
which already occurs during the hydrolysis phase, can be separately discharged.<br />
The result is a methane content in biogas within the methane reactors 15-20% higher<br />
per volume than conventional plants.<br />
Flexible and controllable on demand<br />
Unprecedented in biogas technology is the controllability of biogas production. The<br />
foundation of this feature is first, the buffering of energy-rich hydrolysate in an intermediate<br />
storage tank, and second, the constant availability of the methane-forming<br />
bacteria (immobilized on a solid carrier substrate in the methane reactor). Due to a<br />
short residence time of the hydrolysate in the methane stage, a change in the rate of<br />
hydrolysate feeding promptly effects a change in the biogas production.<br />
Control of biogas production (depicted are results from investigations at BTU Cottbus,<br />
Department of Waste Management)<br />
Future-oriented energy generation should be safe, environmentally friendly, flexible,<br />
and its application cost-effective. <strong>GICON</strong> biogas plants meet these requirements in<br />
many ways. Almost all plant substrates can be utilized. Even small facilities can be<br />
operated in a safe and efficient manner. <strong>GICON</strong> Bioenergie GmbH’s extensive technological<br />
know-how in a wide spectrum is available to meet your biogas needs.<br />
Sampling in the <strong>GICON</strong> – Cottbus large-scale<br />
biogas research facility<br />
Methane content in biogas,<br />
excerpt from the process control system<br />
05
The <strong>GICON</strong> <strong>Biogas</strong> Process<br />
advantages at a glance<br />
<strong>Biogas</strong> Plant in the Production<br />
and Service Center Cottbus, Germany<br />
Waste disposal<br />
Renewable<br />
energies<br />
06<br />
Organic wastes<br />
Green waste, etc.<br />
Energy crops<br />
Wind<br />
Sun<br />
Reliable, flexible and economic<br />
■ high process stability<br />
- process collapse avoided by decoupling of acidification and methane formation<br />
- separate control of both process steps<br />
■ controllability of the biogas production<br />
- adaption to load profiles possible<br />
- no flare losses due to interruption of biogas demand during service and<br />
maintenance events<br />
■ flexible adaptation of different feedstocks<br />
- both agricultural substrate (energy plants, solid dung) as well as loppings,<br />
cut grass, and biological waste can be applied<br />
■ compact installation size<br />
- plants can be erected in the immediate vicinity of heat consumers<br />
■ low energy consumption (due to a lack of a requirement for mixing<br />
equipment, among other factors)<br />
■ higher methane content<br />
- methane content 15-20 % higher than conventional plants<br />
- significant cost and energy savings for further upgrading to biomethane<br />
■ high reliability and safe operating mode<br />
- maintenance possible during uninterrupted production by parallel operation<br />
of percolators<br />
- small number of components subject to wear<br />
■ low hydrogen sulphide content in the raw biogas<br />
■ simple handling of the digestate<br />
- agricultural utilization of non-degradable plant material without mechanical<br />
dewatering is advantageous for humus formation and fertilization value due to<br />
rich texture and output as a solid<br />
Vision: 24h power plant/energy and disposal center<br />
Controllable<br />
<strong>GICON</strong><br />
biogas plant<br />
Wind turbine<br />
Solar power<br />
station<br />
Gas upgrading facility<br />
RE based on need (compensation for the deficits<br />
of solar power stations and wind turbines via a<br />
controllable biogas plant)<br />
RE acc. to<br />
wind availability<br />
RE acc. to<br />
solar availability<br />
CHP facility<br />
Daytime<br />
network load<br />
distribution<br />
Gas<br />
(raw material, combustible<br />
fuel, motor fuel)<br />
Thermal energy<br />
Electrical energy<br />
around the clock<br />
Energy supply
<strong>Biogas</strong> Plant Construction<br />
wet fermentation plants for wastes<br />
Wet fermentation of wastes<br />
An important portion of commercial and industrial wastes are composed of organic<br />
substances. The utilization of these wastes for the generation of renewable energy<br />
is the goal of fermentation plants. The biological processes underlying this process<br />
occur through the activities of microorganisms, that is to say through the exclusion<br />
of atmospheric oxygen. In waste fermentation plants, mainly commercial kitchen<br />
and food wastes, used cooking fats, and wastes from animal feed, luxury food, and<br />
grocery production are fermented with agricultural wastes (crop residues, manure<br />
and liquid wastes) and utilized for heat and electricity generation. Via appropriate<br />
adaptation of the process steps (pre-treatment or dewatering, for example) and the<br />
fermenter concept, individual concerns of the to-be erected plant or the to-be-fermented<br />
substrate can be addressed.<br />
For well-founded experiences in the construction and operation of biogas plants for<br />
wastes, <strong>GICON</strong> can fall back on the knowledge and experiences of <strong>GICON</strong> employees<br />
who acquired it at former employers (like Linde AG, Schwarting Biosystem<br />
GmbH and others). In agreement with Schwarting Biosystem the office in Konstanz<br />
was taken over by <strong>GICON</strong>.<br />
<strong>GICON</strong> <strong>Biogas</strong> plants - from design to turn key plant<br />
■ efficient processing from one source<br />
■ high quality<br />
■ optimally adapted to need<br />
Combined heat and power unit (CHP)<br />
Integration of the CHP<br />
<strong>Biogas</strong>yl biogas plant, France –<br />
waste fermentation plant with complete mix<br />
fermenter<br />
Design of a wet fermentation plant for food<br />
industry wastes<br />
07
<strong>Biogas</strong> Plant Construction<br />
wet fermentation plants for agricultural feedstocks<br />
<strong>Biogas</strong> plant Dresden-Klotzsche, Germany<br />
Klein Muckrow biogas plant, Germany<br />
Site plan for a wet fermentation plant<br />
08<br />
Use of agriculturally-produced substrates/energy crops<br />
In agricultural biogas plants, liquid manure and silage are most often utilized as feedstock.<br />
From the digestate, fertilizer is produced as a by-product. These fertilizers are<br />
chemically much less aggressive than raw liquid manure, nitrogen availability is better,<br />
and the odor is less intensive. Digestate from wet fermentation („biogas manure") is a<br />
liquid manure-like substance. For the pure use of energy crops, a multi-stage plant<br />
would be required for optimal feedstock utilization – in some cases through the use<br />
of dry fermentation for the optimal combination of logistical conditions.<br />
Functional design for biogas production acc. to wet fermentation technology
<strong>Biogas</strong> handling<br />
complete service through to feed-in<br />
Gas upgrading/conditioning and feed-in of biogas<br />
The feeding in of biogas in an upgraded form as biomethane into existing natural<br />
gas networks and the associated utilization possibilities are increasingly gaining in<br />
economic importance. New legal requirements for CO 2 reduction through the use of<br />
renewable energies are promoting this development, including in the heating market,<br />
as biomethane as a renewable energy source can thereby be offered to virtually<br />
every end-user.<br />
The gas grid access regulation of 2008 formed the legal framework for the preferred<br />
feed-in of biomethane. The advantage of this process lies in a better energetic<br />
utilization of the renewable raw materials (use in the vicinity of consumers/combined<br />
heat and power) and therefore also in the CO 2 balance. The grade of the biomethane<br />
to be fed in is to be adapted to the given grade of the network (= conditioning). The<br />
conditioning costs depend primarily on the methane content of the biomethane and<br />
the calorific value of the natural gas present in the network. Current state-of-the-art<br />
are biogas conditioning units with liquefied gas (propane/ butane-mix), conditioning<br />
units using air and systems in which air and liquefied gas are conditioned. The conditioning<br />
is necessary so that the existing equipment of the gas end user can be used<br />
safely, problem-free, and according to the contractually-guaranteed gas quality.<br />
Technical concept for biogas conditioning<br />
and feed-in with air and liquefied gas<br />
Technologically, the apparatus consists of four basic units: liquefied gas supply, air<br />
supply, mechanical equipment, and the gas-measured mixing chamber. The biomethane<br />
(grade acc. to DVGW Worksheet G260) is extracted from an air receiver<br />
(interface). Using calibrated measurements, the entry flow is captured. The acquired<br />
biomethane is then mixed according to air and liquefied gas rules. Next, the<br />
compression to network pressure occurs. Several locking mechanisms and the<br />
dimensioning of tubes and mixing chambers ensure the intended operation of the<br />
system engineering.<br />
Such a manner, despite supply of air into a combustible gas, does not lead to critical<br />
system conditions or hazards. The set up of the systems engineering takes place<br />
professionally and safely in different spaces which are separated from each other.<br />
Additional protection against the occurrence of a hazardous explosive atmosphere in<br />
terms of operational safety requirements is offered by the ventilation concept and<br />
area monitoring.<br />
Kerpen biogas conditioning and feed-in facility,<br />
designed in its entirety by <strong>GICON</strong><br />
View of the machine room of biogas<br />
conditioning and feed-in facility<br />
Supervision by <strong>GICON</strong> on behalf<br />
of the client<br />
09
Production and Service Center Cottbus<br />
design and research platform<br />
The large-scale research facility ensures<br />
<strong>GICON</strong> the ability to test unique possibilities<br />
and client-specific requests in an industrial<br />
scale and without risk to future investors.<br />
Tests with original material in the barrel array<br />
at the large-scale research facility<br />
Innovative design variant of the hydrolysis stage:<br />
combined transport and process container<br />
10<br />
High-tech skills in science and praxis<br />
Since the most recent amendment of the EEG (Renewable Energy Act), the operation<br />
of bioenergy plants has become even more economically advantageous. Furthermore,<br />
with the <strong>GICON</strong> <strong>Biogas</strong> process, an innovative solution for the more efficient generation<br />
of energy is available. Despite the success of other new technology concepts, the<br />
bioenergy sector still holds an enormous developmental potential ready for application.<br />
The <strong>GICON</strong> – Großmann Ingenieur Consult GmbH as parent company of the <strong>GICON</strong><br />
group has matured into a recognized, independent, complete service provider in this<br />
sector. Alongside research and development activities related to the <strong>GICON</strong> Process,<br />
project development and planning for conventional biogas plants for various application<br />
needs are also part of the our range of services.<br />
For extensive research purposes, a large-scale research facility was erected in<br />
Cottbus in 2007. In this research and development center, further optimization of the<br />
<strong>GICON</strong> biogas process is being carried out. In addition, through the execution of<br />
project-specific prepatory test trials with original material, a high degree of security for<br />
the design and planning of each client's plants can be achieved. With the current test<br />
facility, systematic design of batch tests in several barrel arrays up to large-scale<br />
container tests can be implemented. This enables the generation of a reliable basis<br />
for planning. Through use of this systematic procedure, a guarantee for gas yield can<br />
be ensured.<br />
The company supports a tight cooperation network consisting of renowned research<br />
institutions.<br />
Aerial view of the large-scale research facility in Cottbus
Innovation through Research<br />
R & D projects in the bioenergy sector<br />
R & D projects<br />
Large-scale testing of the <strong>GICON</strong> Process<br />
in Cottbus.<br />
Developm. of the hydrolysis stage for process<br />
adapt. to wastewater treatment plant operation<br />
Fermentation of hemp with subsequent<br />
preparation of the residual fibers for use in<br />
street construction<br />
Monofermentation of glycerin wastewater<br />
Microbiol. analysis methods for optimization of<br />
biogas proc. (in coop. BGD – a <strong>GICON</strong> Co.)<br />
dCO 2 -Sensor<br />
Planning tool<br />
Expansion of the feedstock spectrum for biogas<br />
production (in cooperation BTU Cottbus,<br />
ATB Barnim and Frankfurt/M. University)<br />
Generation of various enzyme mixtures for<br />
acceleration of solid fermentation processes<br />
(in cooperation TU Dresden and HS Anhalt)<br />
Intelligent control of biogas plants<br />
(in cooperation with TU Dresden and Hermos<br />
Systems GmbH)<br />
Real Flex<br />
IGNIS – client is the AT-Association<br />
(Association for Support of Adapted, Social<br />
and Environmentally-friendly Technologies)<br />
Expansion of the feedstock spectrum,<br />
Biomethane plant as a universal energy<br />
generation and waste disposal plant<br />
Production and Service Center – Cottbus<br />
(GA)<br />
Goal<br />
Topics completed since 2005 or currently in progress, as of March 2010. Complete overview at: www.gicon.de<br />
Transformation of a new process for energy generation from renewable raw materials into<br />
market maturity<br />
Development and testing of a ballast stage for less-than-capacity wastewater treatment plants<br />
for improvement of economic viability<br />
Mixing-in of hemp fibers into AMA for the improvement of the separation properties during<br />
production and compaction of asphalt; affordable and effective substitution of the current<br />
aggregates; coupling of hemp fiber digestion with energy production in biogas plants<br />
Monofermentation of raw glycerin; evaluation of the results of the test facility and creation of<br />
design tools<br />
Process optimization of two stage biogas plants;<br />
Rapid system for measurement of microorganisms during the process<br />
Collaborative project for optimization of biotechnological manufacturing processes through the<br />
application of a novel dCO 2 -sensor with expanded measurement range and biocidal membrane<br />
(dCO 2 Sensor); Subproject: model-supported process for microalgae development<br />
Development of a computer-aided planning tool for autarkic, renewable energy supply concepts<br />
at any site with the most diverse boundary conditions<br />
Collaborative project for two-stage biogas technology: investigation of circuit variants and<br />
optimization of thermal management as well as the optimization of feedstock post-treatment<br />
during two-stage operation of biogas plants<br />
Development of a process for increase in efficiency of the hydrolysis process within the framework<br />
of biogas generation from renewable energy sources; Development and implementation of<br />
a reactor for the cultivation of enzymes and for the manufacture of enzyme mixtures<br />
Development of process data capture methods and objectives for control of renewable raw<br />
material plants; development and application of supervision and control solutions; development<br />
of control, process, and data classification models<br />
Integration of reliable wireless communication systems in sensor/actuator networks for<br />
automation applications – sub-project: prototype application of radio-based sensor/actuator networks<br />
for the monitoring and control of modern biogas plants<br />
Income generation and climate protection through sustainable utilization of municipal solid<br />
waste in megacities – a holistic approach. As example: Addis Ababa in Ethiopia<br />
(Sub-project 1: biogas module pilot project)<br />
Further development of the <strong>GICON</strong> <strong>Biogas</strong> Process for an absolutely flexible, deployable<br />
energy generation and waste disposal plant; further research activities toward the expansion<br />
of the developed process for new feedstocks such as biogenic wastes<br />
Production of inoculated packed-bed packing materials, large-scale, long-term verification of<br />
process parameters, use of landscaping-generated wastes<br />
Academic exchanges<br />
<strong>GICON</strong> participates in permanent exchange with several colleges and universities. Especially tight contact exists between the <strong>GICON</strong> Division<br />
of Energy and the Environment and the Technical University – Dresden, the Brandenburg Technical University – Cottbus (BTU), and Anhalt College<br />
in Köthen.<br />
11
<strong>GICON</strong> Bioenergie GmbH<br />
Tiergartenstraße 48 I 01219 Dresden I Telephone: +49 351 47878-0 I Fax: +49 351 47878-78<br />
<strong>GICON</strong> <strong>Biogas</strong>-Großtechnikum Cottbus<br />
Am Großen Spreewehr 6 I 03044 Cottbus<br />
<strong>GICON</strong> Large-Scale Research Facility – Cottbus<br />
Gerhart-Hauptmann-Straße 13 I 03044 Cottbus<br />
E-Mail: info@gicon.de I http://biogas.gicon.de<br />
Managing Partner: Prof. Jochen Großmann; Chief Executive Officer: Dr. Hagen Hilse<br />
Registry Court: Dresden District Court, Registry Number: HRB 25314<br />
<strong>GICON</strong> Bioenergie GmbH<br />
<strong>GICON</strong> Production and Service Center – Cottbus<br />
<strong>GICON</strong> Large-Scale Research Facility – Cottbus<br />
<strong>GICON</strong> Großmann Ingenieur Consult GmbH<br />
Offices <strong>GICON</strong>:<br />
Berlin<br />
Bitterfeld-Wolfen<br />
Cottbus<br />
Erfurt<br />
Freiberg<br />
Hamburg<br />
Kiel<br />
Konstanz<br />
Leipzig<br />
Nürnberg<br />
Rostock<br />
Schwedt<br />
Companies of the <strong>GICON</strong> Group<br />
BGD Boden- und Grundwasser GmbH Dresden<br />
Institut für Angewandte Ökosystemforschung GmbH<br />
I.M.E.S. GmbH<br />
Dr. Kühner GmbH<br />
Geologische Landesuntersuchung GmbH Freiberg<br />
Ecosystem Saxonia<br />
Gesellschaft für Umweltsysteme m.b.H.<br />
as of 03/2011<br />
Photos: <strong>GICON</strong>, Simone Kühn