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Improving the efficiency of biogas plants: innovative solutions to industrial challenges

Improving the efficiency of biogas plants: innovative solutions to industrial challenges Bay Zoltán Kutatóközpont

Biogas plants play a key role in the production of renewable energy, while efficiently recovering agricultural, industrial and municipal waste.

However, operations face many challenges: changing feedstocks, the regulatory environment, fluctuating energy prices and technological optimisation all affect the stability and profitability of operations.

Problems identified for biogas plants:

  • Feedstock management and variable fermentation yields – Complex substrates and anaerobic digestion processes require fine-tuning.
  • Nutrient balance and micronutrient deficiencies – Proper micronutrient intake is essential for the proper functioning of methanogenic bacteria.
  • Gas yield fluctuations and efficiency losses – Without optimisation of operating conditions, part of the potential energy production is lost.
  • Treatment and disposal of spread sludge – Due to the high ammonia content in some plants, sludge recovery and storage is a major logistical and environmental challenge, especially in winter.

Our institute offers expert and technological solutions that help to optimise fermentation processes, stabilise gas output and reduce operating costs in a real operating environment. Whether it is micro-element supply, ammonia treatment, fermentation analytics or technology development. Our services are designed to ensure that your biogas plant operates as efficiently as possible.

Services

Development and commissioning of ammonia removal technology

We offer proprietary technology to address the “ammonia problem” in biogas plants. Ammonia concentrations, which are harmful to methane production, can be reduced by a reverse-cycle desorption process. The technology will be optimised for the specific plant, taking into account its waste energy requirements, to achieve an efficiency-enhancing technology adapted to the site and its operating practices.

Analysis of fermented juice (with our industrial partner Biobyte Ltd.)

The efficiency of biogas production is strongly influenced by the composition of the fermentation liquid, which is a key parameter for the activity and stability of microbial communities. Our service includes detailed analytical analysis of the fermentation medium composition, including measurement of organic acids, ammonia, pH, VFA/TA ratio and other indicators. Based on the results obtained, we make recommendations to ensure an optimal fermentation environment, to maximise methane yield and to avoid unwanted fermentation side effects (e.g. acidification, accumulation of toxic metabolites).

Identification of microelement deficiencies (with our industrial partner Biobyte Ltd.)

The presence of certain microelements (Co, Ni, B, Se, etc.) in sufficient concentrations is essential for methanogenic bacteria and other fermentative microorganisms. Identification of microelement deficiencies involves laboratory analysis of biogas plant samples to determine the microelement content of the fermentation liquid and substrates. The analysis will also include bioavailability, which will determine the effective additive composition and the amount to be used. Based on this, a targeted micro-nutrient supplementation strategy adapted to the site will be developed to help maintain fermentation stability and maximise methane production.

Production of reactor-specific, individual microelement solutions

The efficiency, stability and growth of microbial communities in biogas plants utilising different organic wastes are strongly influenced by the availability and supply of microelements. Many methanogenic bacteria need iron, nickel, cobalt, molybdenum, selenium and tungsten, but the supplementation of microelements is often not sufficiently addressed during operation. If methane production is declining, one of the most important tests is to analyse the microelement composition. To support this, we undertake the analysis of biogas plant samples (microelements, organic acids) and the preparation of suitable microelement replacement mixtures.

As a research institute, we provide targeted innovative solutions to real challenges faced by industry.

We know not only the theoretical background of technological development, but also all aspects of practical implementation. We understand how companies operate, what they expect to deliver, and we know that an improvement is only of real value if it can be delivered on time, in operational conditions and with measurable results.

We always adapt our developments to the application environment, whether it’s technology optimisation, cost efficiency or even operational safety. We know that rapid response and predictable performance are key, so we work closely with our partners, realistic implementation timeframes we work within.

With our expertise, experience and practical focus, we deliver improvements that not only in laboratory conditions but also on an industrial scale.

Improving the efficiency of biogas plants: innovative solutions to industrial challenges Bay Zoltán Kutatóközpont

Contacts

Dr. Ádám István HEGYI

Division Director, Biotechnology Division

+36-70/6529429

adam.hegyi2@bayzoltan.hu