Biogas GICON EN

Innovative
technologies for
the production
and utilization
of biogas
Biogas Plants
From concept
to construction –
biogas plants
from one source

GICON Bioenergie GmbH
a capable technology partner
Enlargement of the test dimension and
spectrum at a large-scale research facility,
without risks to future investors.
Percolate fermentation plant Erfurt, Germany
Existing mechanical-biological
treatment
02
Residual waste and/or sourceseparated
organic waste
New plant combination:
GICON biogas plant
Existing disused
landfills or existing
wastewater
treatment plants
Residual wastes
Wastewater
The construction of biogas plants from concept through to commissioning,
including infrastructure, gas utilization or upgrading, and handling
of digestate.
GICON Bioenergie GmbH was founded in 2006 as an independent firm within the
GICON Group. The company develops, plans, and realizes biogas plants as a
general contractor or engineering contractor. Through the interdisciplinary structure
of the GICON Group, with more than 200 employees, and the experience
gained from the construction of more than 30 biogas plants, project management
of all phases – from concept development to permitting and on to commissioning
and operational optimization – can be guaranteed from one source.
Our philosophy is: the delivery of the optimal process and system solutions for
the unique requirements of the client. Therefore, several principle concepts for
biogas production are offered by GICON Bioenergie GmbH:
■ GICON Biogas Process (two-stage dry-wet fermentation with split hydrolysis)
■ multiple-stage wet fermentation process
GICON Bioenergie GmbH Spectrum of Services
■ Holistic concept and project development (for biogas plants)
■ Test fermentat. in an industrial-scale research facility for investment preparation
■ Overall planning (all planning phases, construction supervision, commissioning)
■ complete plant delivery and erection (turnkey) as general contractor
■ Operational optimization and engineering service for existing plants
■ Research toward the development and optimization of bioenergy processes
Residual waste and/or source-separated organic waste
Mechanical
pre-treatment
High-calorific
fractions
Organic fraction
(normally low-calorific,
damp)
Landfill
Landfill
leachate
Landfill gas
Thermal
utilization
Intensive
composting
(can be omitted)
Hydrolysis
Methane
production
Post-composting
Biogas (70% CH 4 )
Sewage gas
Landfill leachate treatment plant/
Wastewater treatment plant
Impurities
Compost
treatment
CHP or
upgrading to
biomethane
(optional)
Existing CHP or
gas utilization
Compost
Energy feed-in
(optional)
Electrical energy
Thermal energy
Biomethane
Energy feed-in
Purified
wastewater

Complete Services
for different applications
Pre-treatment of feedstocks
Biogas technologies
Utilization
Dry fermentation
Waste (biologically exploitable)
Structure- and impurity-rich Liquid and structure-poor
GICON Process
Biomethane production
Pretreatment (screening, crushing) Storage
Gas utilization
High-volume fermenter with
central agitator
Electricity and heat generation
Wet fermentation technology
classic/multiple-stage
Renewable raw materials
Organic material
Multi-stage reinforced-concrete
fermenter system
Fermentation residues
03

GICON Biogas Process
two-stage dry-wet fermentation with split hydrolysis
High-performance fermenter with effective
utilization of the reactor volume due to the
GICON Process.
Filling of a percolator
with agricultural machinery
04
Process flow diagram
of the GICON Biogas Process
Simple solution - enormous impact
The GICON Biogas process with most of its major process steps was developed at BTU
Cottbus (Prof. Busch et. al.) in cooperation with GICON and has been patent-protected
several times, including internationally (Patent DE 10 2204 053 615.5, additional patent
applications for design details and process variations). It has been designed to operate in
two steps, with a systematic separation of microbiological decomposition steps. During
the first step (hydrolysis), organic components are eluted from the substrate matrix and
converted into organic acids and other water-soluble decomposition products. This
watery solution (hydrolysate), containing organics, is fed into the second step, the methanization,
which is designed as a packed bed vessel. Due to the immobilization of methane-forming
microorganisms on the surface of the packing material, large methaneforming
potentials will be available at any given time. Thus, short residence times of
the hydrolysate can be achieved, a solution which poses a unique option for the controlla-bility
of the biogas production. The environmental conditions (temperature and pH,
among others) are controlled and optimized separately in both process steps. By applying
the innovative GICON biogas process, major disadvantages of conventional facilities
are omitted.
Since movement of the solid substrate does not occur during the operation, the system
is robust with respect to possible impurities content. This is especially important for feedstocks
such as biological wastes and landscaping-generated wastes. The use of the
organic fraction of household waste is also possible and has already been successfully
tested. Cleaning and maintenance of the percolation step can occur between substrate
charging cycles without interruption of the biogas generation process.
batch-wise addition and removal of feedstock
multiple percolators
in a garage setup
percolation
percolation
stabile by-product appropriate,
for example, for composting
percolate
= hydrolysate
percolate return
hydrolysate vessel
-buffer storage-
methane
production
control
hydrolysate
methane reactors
return
waste water, liquid fertilizer
biogas
70-80% CH 4
packed bed
aeration and
polishing pool
sludge
liquid
effluent

GICON Biogas Process
a future-proof energy technology
Efficient and stable
The primary goal during the development of the GICON Process was the attainment
of optimal process conditions for diverse groups of microorganisms in adherence
with high process stability. Accordingly, a two-stage process with integrated solid
separation and buffering of the liquids was implemented. The splitting off of CO 2 ,
which already occurs during the hydrolysis phase, can be separately discharged.
The result is a methane content in biogas within the methane reactors 15-20% higher
per volume than conventional plants.
Flexible and controllable on demand
Unprecedented in biogas technology is the controllability of biogas production. The
foundation of this feature is first, the buffering of energy-rich hydrolysate in an intermediate
storage tank, and second, the constant availability of the methane-forming
bacteria (immobilized on a solid carrier substrate in the methane reactor). Due to a
short residence time of the hydrolysate in the methane stage, a change in the rate of
hydrolysate feeding promptly effects a change in the biogas production.
Control of biogas production (depicted are results from investigations at BTU Cottbus,
Department of Waste Management)
Future-oriented energy generation should be safe, environmentally friendly, flexible,
and its application cost-effective. GICON biogas plants meet these requirements in
many ways. Almost all plant substrates can be utilized. Even small facilities can be
operated in a safe and efficient manner. GICON Bioenergie GmbH’s extensive technological
know-how in a wide spectrum is available to meet your biogas needs.
Sampling in the GICON – Cottbus large-scale
biogas research facility
Methane content in biogas,
excerpt from the process control system
05

The GICON Biogas Process
advantages at a glance
Biogas Plant in the Production
and Service Center Cottbus, Germany
Waste disposal
Renewable
energies
06
Organic wastes
Green waste, etc.
Energy crops
Wind
Sun
Reliable, flexible and economic
■ high process stability
- process collapse avoided by decoupling of acidification and methane formation
- separate control of both process steps
■ controllability of the biogas production
- adaption to load profiles possible
- no flare losses due to interruption of biogas demand during service and
maintenance events
■ flexible adaptation of different feedstocks
- both agricultural substrate (energy plants, solid dung) as well as loppings,
cut grass, and biological waste can be applied
■ compact installation size
- plants can be erected in the immediate vicinity of heat consumers
■ low energy consumption (due to a lack of a requirement for mixing
equipment, among other factors)
■ higher methane content
- methane content 15-20 % higher than conventional plants
- significant cost and energy savings for further upgrading to biomethane
■ high reliability and safe operating mode
- maintenance possible during uninterrupted production by parallel operation
of percolators
- small number of components subject to wear
■ low hydrogen sulphide content in the raw biogas
■ simple handling of the digestate
- agricultural utilization of non-degradable plant material without mechanical
dewatering is advantageous for humus formation and fertilization value due to
rich texture and output as a solid
Vision: 24h power plant/energy and disposal center
Controllable
GICON
biogas plant
Wind turbine
Solar power
station
Gas upgrading facility
RE based on need (compensation for the deficits
of solar power stations and wind turbines via a
controllable biogas plant)
RE acc. to
wind availability
RE acc. to
solar availability
CHP facility
Daytime
network load
distribution
Gas
(raw material, combustible
fuel, motor fuel)
Thermal energy
Electrical energy
around the clock
Energy supply

Biogas Plant Construction
wet fermentation plants for wastes
Wet fermentation of wastes
An important portion of commercial and industrial wastes are composed of organic
substances. The utilization of these wastes for the generation of renewable energy
is the goal of fermentation plants. The biological processes underlying this process
occur through the activities of microorganisms, that is to say through the exclusion
of atmospheric oxygen. In waste fermentation plants, mainly commercial kitchen
and food wastes, used cooking fats, and wastes from animal feed, luxury food, and
grocery production are fermented with agricultural wastes (crop residues, manure
and liquid wastes) and utilized for heat and electricity generation. Via appropriate
adaptation of the process steps (pre-treatment or dewatering, for example) and the
fermenter concept, individual concerns of the to-be erected plant or the to-be-fermented
substrate can be addressed.
For well-founded experiences in the construction and operation of biogas plants for
wastes, GICON can fall back on the knowledge and experiences of GICON employees
who acquired it at former employers (like Linde AG, Schwarting Biosystem
GmbH and others). In agreement with Schwarting Biosystem the office in Konstanz
was taken over by GICON.
GICON Biogas plants - from design to turn key plant
■ efficient processing from one source
■ high quality
■ optimally adapted to need
Combined heat and power unit (CHP)
Integration of the CHP
Biogasyl biogas plant, France –
waste fermentation plant with complete mix
fermenter
Design of a wet fermentation plant for food
industry wastes
07

Biogas Plant Construction
wet fermentation plants for agricultural feedstocks
Biogas plant Dresden-Klotzsche, Germany
Klein Muckrow biogas plant, Germany
Site plan for a wet fermentation plant
08
Use of agriculturally-produced substrates/energy crops
In agricultural biogas plants, liquid manure and silage are most often utilized as feedstock.
From the digestate, fertilizer is produced as a by-product. These fertilizers are
chemically much less aggressive than raw liquid manure, nitrogen availability is better,
and the odor is less intensive. Digestate from wet fermentation („biogas manure") is a
liquid manure-like substance. For the pure use of energy crops, a multi-stage plant
would be required for optimal feedstock utilization – in some cases through the use
of dry fermentation for the optimal combination of logistical conditions.
Functional design for biogas production acc. to wet fermentation technology

Biogas handling
complete service through to feed-in
Gas upgrading/conditioning and feed-in of biogas
The feeding in of biogas in an upgraded form as biomethane into existing natural
gas networks and the associated utilization possibilities are increasingly gaining in
economic importance. New legal requirements for CO 2 reduction through the use of
renewable energies are promoting this development, including in the heating market,
as biomethane as a renewable energy source can thereby be offered to virtually
every end-user.
The gas grid access regulation of 2008 formed the legal framework for the preferred
feed-in of biomethane. The advantage of this process lies in a better energetic
utilization of the renewable raw materials (use in the vicinity of consumers/combined
heat and power) and therefore also in the CO 2 balance. The grade of the biomethane
to be fed in is to be adapted to the given grade of the network (= conditioning). The
conditioning costs depend primarily on the methane content of the biomethane and
the calorific value of the natural gas present in the network. Current state-of-the-art
are biogas conditioning units with liquefied gas (propane/ butane-mix), conditioning
units using air and systems in which air and liquefied gas are conditioned. The conditioning
is necessary so that the existing equipment of the gas end user can be used
safely, problem-free, and according to the contractually-guaranteed gas quality.
Technical concept for biogas conditioning
and feed-in with air and liquefied gas
Technologically, the apparatus consists of four basic units: liquefied gas supply, air
supply, mechanical equipment, and the gas-measured mixing chamber. The biomethane
(grade acc. to DVGW Worksheet G260) is extracted from an air receiver
(interface). Using calibrated measurements, the entry flow is captured. The acquired
biomethane is then mixed according to air and liquefied gas rules. Next, the
compression to network pressure occurs. Several locking mechanisms and the
dimensioning of tubes and mixing chambers ensure the intended operation of the
system engineering.
Such a manner, despite supply of air into a combustible gas, does not lead to critical
system conditions or hazards. The set up of the systems engineering takes place
professionally and safely in different spaces which are separated from each other.
Additional protection against the occurrence of a hazardous explosive atmosphere in
terms of operational safety requirements is offered by the ventilation concept and
area monitoring.
Kerpen biogas conditioning and feed-in facility,
designed in its entirety by GICON
View of the machine room of biogas
conditioning and feed-in facility
Supervision by GICON on behalf
of the client
09

Production and Service Center Cottbus
design and research platform
The large-scale research facility ensures
GICON the ability to test unique possibilities
and client-specific requests in an industrial
scale and without risk to future investors.
Tests with original material in the barrel array
at the large-scale research facility
Innovative design variant of the hydrolysis stage:
combined transport and process container
10
High-tech skills in science and praxis
Since the most recent amendment of the EEG (Renewable Energy Act), the operation
of bioenergy plants has become even more economically advantageous. Furthermore,
with the GICON Biogas process, an innovative solution for the more efficient generation
of energy is available. Despite the success of other new technology concepts, the
bioenergy sector still holds an enormous developmental potential ready for application.
The GICON – Großmann Ingenieur Consult GmbH as parent company of the GICON
group has matured into a recognized, independent, complete service provider in this
sector. Alongside research and development activities related to the GICON Process,
project development and planning for conventional biogas plants for various application
needs are also part of the our range of services.
For extensive research purposes, a large-scale research facility was erected in
Cottbus in 2007. In this research and development center, further optimization of the
GICON biogas process is being carried out. In addition, through the execution of
project-specific prepatory test trials with original material, a high degree of security for
the design and planning of each client's plants can be achieved. With the current test
facility, systematic design of batch tests in several barrel arrays up to large-scale
container tests can be implemented. This enables the generation of a reliable basis
for planning. Through use of this systematic procedure, a guarantee for gas yield can
be ensured.
The company supports a tight cooperation network consisting of renowned research
institutions.
Aerial view of the large-scale research facility in Cottbus

Innovation through Research
R & D projects in the bioenergy sector
R & D projects
Large-scale testing of the GICON Process
in Cottbus.
Developm. of the hydrolysis stage for process
adapt. to wastewater treatment plant operation
Fermentation of hemp with subsequent
preparation of the residual fibers for use in
street construction
Monofermentation of glycerin wastewater
Microbiol. analysis methods for optimization of
biogas proc. (in coop. BGD – a GICON Co.)
dCO 2 -Sensor
Planning tool
Expansion of the feedstock spectrum for biogas
production (in cooperation BTU Cottbus,
ATB Barnim and Frankfurt/M. University)
Generation of various enzyme mixtures for
acceleration of solid fermentation processes
(in cooperation TU Dresden and HS Anhalt)
Intelligent control of biogas plants
(in cooperation with TU Dresden and Hermos
Systems GmbH)
Real Flex
IGNIS – client is the AT-Association
(Association for Support of Adapted, Social
and Environmentally-friendly Technologies)
Expansion of the feedstock spectrum,
Biomethane plant as a universal energy
generation and waste disposal plant
Production and Service Center – Cottbus
(GA)
Goal
Topics completed since 2005 or currently in progress, as of March 2010. Complete overview at: www.gicon.de
Transformation of a new process for energy generation from renewable raw materials into
market maturity
Development and testing of a ballast stage for less-than-capacity wastewater treatment plants
for improvement of economic viability
Mixing-in of hemp fibers into AMA for the improvement of the separation properties during
production and compaction of asphalt; affordable and effective substitution of the current
aggregates; coupling of hemp fiber digestion with energy production in biogas plants
Monofermentation of raw glycerin; evaluation of the results of the test facility and creation of
design tools
Process optimization of two stage biogas plants;
Rapid system for measurement of microorganisms during the process
Collaborative project for optimization of biotechnological manufacturing processes through the
application of a novel dCO 2 -sensor with expanded measurement range and biocidal membrane
(dCO 2 Sensor); Subproject: model-supported process for microalgae development
Development of a computer-aided planning tool for autarkic, renewable energy supply concepts
at any site with the most diverse boundary conditions
Collaborative project for two-stage biogas technology: investigation of circuit variants and
optimization of thermal management as well as the optimization of feedstock post-treatment
during two-stage operation of biogas plants
Development of a process for increase in efficiency of the hydrolysis process within the framework
of biogas generation from renewable energy sources; Development and implementation of
a reactor for the cultivation of enzymes and for the manufacture of enzyme mixtures
Development of process data capture methods and objectives for control of renewable raw
material plants; development and application of supervision and control solutions; development
of control, process, and data classification models
Integration of reliable wireless communication systems in sensor/actuator networks for
automation applications – sub-project: prototype application of radio-based sensor/actuator networks
for the monitoring and control of modern biogas plants
Income generation and climate protection through sustainable utilization of municipal solid
waste in megacities – a holistic approach. As example: Addis Ababa in Ethiopia
(Sub-project 1: biogas module pilot project)
Further development of the GICON Biogas Process for an absolutely flexible, deployable
energy generation and waste disposal plant; further research activities toward the expansion
of the developed process for new feedstocks such as biogenic wastes
Production of inoculated packed-bed packing materials, large-scale, long-term verification of
process parameters, use of landscaping-generated wastes
Academic exchanges
GICON participates in permanent exchange with several colleges and universities. Especially tight contact exists between the GICON Division
of Energy and the Environment and the Technical University – Dresden, the Brandenburg Technical University – Cottbus (BTU), and Anhalt College
in Köthen.
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GICON Bioenergie GmbH
Tiergartenstraße 48 I 01219 Dresden I Telephone: +49 351 47878-0 I Fax: +49 351 47878-78
GICON Biogas-Großtechnikum Cottbus
Am Großen Spreewehr 6 I 03044 Cottbus
GICON Large-Scale Research Facility – Cottbus
Gerhart-Hauptmann-Straße 13 I 03044 Cottbus
E-Mail: info@gicon.de I http://biogas.gicon.de
Managing Partner: Prof. Jochen Großmann; Chief Executive Officer: Dr. Hagen Hilse
Registry Court: Dresden District Court, Registry Number: HRB 25314
GICON Bioenergie GmbH
GICON Production and Service Center – Cottbus
GICON Large-Scale Research Facility – Cottbus
GICON Großmann Ingenieur Consult GmbH
Offices GICON:
Berlin
Bitterfeld-Wolfen
Cottbus
Erfurt
Freiberg
Hamburg
Kiel
Konstanz
Leipzig
Nürnberg
Rostock
Schwedt
Companies of the GICON Group
BGD Boden- und Grundwasser GmbH Dresden
Institut für Angewandte Ökosystemforschung GmbH
I.M.E.S. GmbH
Dr. Kühner GmbH
Geologische Landesuntersuchung GmbH Freiberg
Ecosystem Saxonia
Gesellschaft für Umweltsysteme m.b.H.
as of 03/2011
Photos: GICON, Simone Kühn