Existing biogas plants often work well but they by far not exhaust the entire potential they actually have.  BTS Biogas has developed various repowering solutions, all aiming at remarkably increasing the general efficiency of the gas plant.

Each solution implies the replacement of the entire feeding line as well as setting up an upgrading technology according to the existing substrate.

Example of biogas plant repowering

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Repowering Deutsch


Steps for optimisation

1. Check-up of the entire plant


Before carrying out a planned optimisation measure, an existing biogas plant must undergo an overall check-up so that sustainable economic decisions can be made.

This check-up includes the following main areas:

  • substrates used
  • biological efficiency of the plant
  • technical condition of the technology used 
  • energy efficiency of existing technology 
  • existing safety technology 
  • condition of the structural facilities, buildings and containers 
  • compliance with the ordinance concerning manure
  • general authorisation of conformity in accordance with current legislation.

2. Biological system evaluation using the dinaMetan database


Repowering basically starts with the evaluation of substrate input materials.

The software dinaMetan developed by BTS Biogas allows accurate evaluation. The web-based database, which was developed from approximately 100,000 laboratory analyses carried out in the company's laboratory, enables accurate determination and classification of the current biological efficiency of biogas plants.

Thanks to dinaMetan, accurate feed controls are carried out through analyses using near-infrared spectroscopy (NIRS), thus enabling to predict and plan an optimised and profitable substrate mix. dinaMetan also determines optimal biological efficiency, allowing maximum production of energy, the rate of degradation of the substrates, the consumption of bacteria during the fermentation process, ideal volumetric loading, optimal sojourn time in the fermenter, as well as convenient substrate costs for the generated kWh. For all biogas plants, whether for renewable raw materials, by-products of the food industry, slaughterhouses or mono-fermentation of chicken manure and other organic residues, the highest possible system efficiency can be specifically planned in advance and thus implemented sustainably.

3. Substrate processing with the BIOaccelerator


The fermentation of cheap or free substrates, such as landscape maintenance material, grass silage and other organic by-products, requires substrate processing. Thanks to the substrate processing technology BIOaccelerator, all organic solids are crushed and cell walls are broken. Thanks to the significantly enlarged surface area of the substrate, the biogas bacteria can considerably increase their degradation activity. The contents of plant cells, such as enzymes and nutrient salts, can be optimally used for gas production. The degradation time of the organic matter is significantly reduced. The biological efficiency of the organic matter can be increased to almost 100 per cent depending on the basic substance. In addition, up to 60 per cent of stirring energy can be saved, and pump performance throughout the entire biogas power plant is significantly improved.

4. Energy-efficient feeding technology

feeding technology

In existing biogas power plants, in 80% of all cases the solids feeder is too small in design. For practical and economic reasons, it needs to be filled once a day. Solids feeders made of corrosion-free materials in sizes ranging from 15 to 130 m³ in volume are now cutting-edge. For a cubic metre of loose silage, approximately 300 kg of weight can be applied. This means that, in the case of a 500 kW system, with 30 tonnes of silage daily, a feeder with a volume of approximately 90 m³ is necessary.

5. Energy-efficient stirring technology

stirring technology

The stirring technology represents the highest share of the internal power consumption of a biogas power plant (60 per cent). A biogas fermenter with volumes of 1,500 - 3,000 m³ has an annual power consumption of more than 100,000 kWh. Energy-efficient stirrers are perfectly and automatically adapted to the current performance requirements using frequency inverters, and have an annual energy consumption of 30,000 kWh. In this way, 70,000 kWh or up to €15,000 can be saved per container.

6. Energy-efficient pump technology

Progressive cavity pumps

Progressive cavity pumps are cutting-edge. By using frequency inverters, the necessary power requirements can be exactly adjusted, thus making them highly energy-efficient. By processing the substrate with the Bioaccelerator, no interfering substances and fibrous components are present in the substrate, which considerably prolongs the service life of the pump.

7. Examination of leaky membrane roofs and gas leaks in system components

membrane roofs

Due to unskilled assembly of container roofs and pipe installations carried out by non-professionals, leaks very often arise already during commissioning. It is more and more common that membrane roofs and, in this case, single-shell roofs, leak after 5 -10 years, which allows biogas to escape into the atmosphere. Leaks are also present in pipe joints. In addition to the emission impact on the environment and the safety aspect of biogas loss, there is significant financial and economic loss.

8. Measurement and control technology


Measurement and control technology plays an essential role in repowering.

In addition to the control of all system components, sensors for fermenter heating, gas storage volumes, liquid levels in the containers and timers, the storage of all relevant data is a fundamental requirement for an economical biogas power plant operation. Cutting-edge measurement and control technology is the basic requirement for the optimisation of technology and of the overall functioning of a system.

9. State-of-the-art safety technology


Many older biogas power plants no longer meet the current required safety measure regulations. Integrated PVC pipes are to be replaced by stainless steel and PE pipes. A lack of overfill prevention systems and level controls represents a major environmental risk. In many plants, functioning gas detection devices and fire detectors are missing. Gas flares or adequate gas appliances are legally mandatory.

In the future, this will apply to all clamp silos and substrate storage spaces, in addition to biogas power plants.

Check Up

  • 1) Survey performed by our technicians and biologists

    • Detection of all the significant system data
    • Evaluation of the efficiency of the main operating elements
    • Analysis of substrates with portable NIRS device
    • Samples taken from all the tanks

  • 2) Visit to present the reports

    • Biological results
    • Proposals to ensure the maximum biological and economic performance of the supply
    • Technical proposal to optimize the efficiency and profitability of the system

  • 3) Technical and biological analysis of the system

    • Performance of lab tests
    • Evaluation of opportunities to optimize the supply with dinaMETAN
    • Evaluation of any technical modifications required

Ersatzteile und Service – auch für Biogasanlagen fremder Hersteller

METANlab - in-house laboratory for specific analyses

Generating biogas without using corn

AFTER SALES SERVICE - 24/7 technical and biological customer service

Small and large biogas plants with patented weighing  system

BTS AUTOMATION - 360° plant control

Showing the way forward in biology, service, process controls & substrate preparation

Showing the way forward in biology, service, process controls & substrate preparation

Performance guarantee and efficiency well above the market average

Performance guarantee and efficiency well above the market average

New American Sharholders in BTS Biogas

US Investor Group Acquires Large Minority Stake

  • GTS Syngas
  • TS energyGROUP