Process solutions

Biogas and biomethane from organic residues

Eight process solutions for biogas and biomethane from existing organic residues, including digestate, straw, distillers’ stillage, brewers’ spent grain and residues from starch, potato, palm-oil and sugarcane processing. Conventional energy crops such as maize silage are not the focus.

Process solutions

All process solutions at a glance

Eight specialised concepts unlock existing residues for biogas, biomethane, process energy and fertiliser products. Grouping them by material stream and industry provides a direct route to the most relevant solution.

Biogas and biomethane

Recover more value from existing digestate and fibrous biomass

These solutions recover additional energy potential from existing digestion residues and lignocellulosic materials—without the targeted use of conventional feed or energy crops.

Digestate valorisation for additional biogas

Targeted preparation, hydrolysis and renewed methane formation recover the remaining energy potential of fibrous digestion residues and support nutrient recovery.

Typical material streams: separated solids · digestate · biofiltrates

Explore digestate valorisation

Anaerobic digestion of straw and lignocellulosic residues

Existing biogas plants are upgraded for difficult-to-digest fibrous residues. Pretreatment and adapted fermentation increase feedstock flexibility and value creation.

Typical material streams: straw · crop residues · fibrous waste biomass

Explore straw anaerobic digestion

Food, beverage and fermentation industries

Convert operational side streams into energy and valuable products

Integrated circular concepts reduce external energy, disposal and wastewater costs while returning carbon and plant nutrients to usable products.

Biogas from distillers’ stillage

Stillage and other side streams are converted into biogas, process energy and organic NPKS fertilisers. The concept supports largely energy-autonomous production.

Typical material streams: stillage · press cake · yeast and process residues

Explore stillage-to-biogas

Biogas from brewers’ spent grain and brewery waste

Spent grain, press liquor and spent brewer’s yeast provide biogas, heat, power and—with suitable integration—cooling for energy-intensive production steps.

Typical material streams: spent grain · press liquor · brewer’s yeast

Explore brewery waste-to-biogas

Biogas from starch production residues

Pulps, waste starch, waste gluten, filter dust and suitable wastewater sludge are processed into biogas, process energy and organic fertiliser products.

Typical material streams: pulps · waste starch · gluten · sludge

Explore starch residue digestion

Biogas from potato processing waste

Peelings, starch-rich process waters and organically loaded process streams are recovered for energy and materials in an integrated process chain.

Typical material streams: peelings · process waters · cleaning media · sludge

Explore potato waste digestion

International agro-industries

Unlock large residue potentials from palm oil and sugarcane

The concepts combine residue treatment, biogas or biomethane production, on-site energy supply and nutrient recovery for international production locations.

POME biogas and palm oil mill waste

POME, decanter sludge and other liquid or fine residues are treated in an integrated process for biogas, biomethane, process energy and fertiliser products.

Typical material streams: POME · decanter sludge · EFB fractions

Explore POME biogas engineering

Sugarcane residues to biogas and biomethane

Sugarcane straw, bagasse, press mud and vinasse are converted into energy and organic fertilisers. Storage and material-flow concepts enable year-round operation.

Typical material streams: sugarcane straw · bagasse · press mud · vinasse

Explore sugarcane biomethane engineering

Typical client challenges

Which problems can the engineering consultancy solve?

Biogenic residues create costs

Digestate, stillage, straw, palm-oil residues and food-industry by-products must be stored, transported or disposed of.

Solution:

Development of suitable process and plant concepts for the energetic and material use of these residues.

Uncertainty regarding technology and process

Unclear material data, unverified supplier information and poorly coordinated interfaces increase investment and operating risks.

Solution:

Independent technical review, material-flow assessment, plausibility checks and clear definition of plant and supply boundaries.

Complex project delivery

Numerous stakeholders, international supply chains, schedule and cost pressure, and differing technical standards complicate delivery.

Solution:

Structured project coordination, schedule and quality control, construction supervision and support through commissioning.

Increasing regulatory requirements

EU and national rules on renewable energy, greenhouse-gas reduction, sustainability and biomethane affect investments and operations.

Solution:

Technical interpretation of requirements and transfer into plant concepts, documentation and project decisions, where required together with specialised legal and certification partners.

Unclear economics and revenue streams

Energy prices, biomethane revenues, feedstock costs, disposal costs and potential income from CO₂ certificates must be assessed together.

Solution:

Techno-economic assessment of alternatives and transparent foundations for investment, financing and operating decisions.

Operating problems and insufficient plant performance

Unstable processes, high internal energy demand, maintenance issues or missed performance targets burden operations.

Solution:

Analysis of process control and operation, development of optimisation measures, and operating, maintenance and training concepts.

Specialised process solution

Digestate valorisation for additional biogas and biomethane

The process solution unlocks the remaining energy potential of solid, fibre-rich fermentation residues and combines additional biomethane production with the upgrading of the contained plant nutrients into usable fertiliser products.

Explore digestate valorisation

Solid fermentation residues Aerobic hydrolytic pretreatment Multi-stage methane production Biogas/biomethane and organic fertilisers

Process solution for bioethanol plants

Biogas from distillers’ stillage and bioethanol residues

Distillers' stillage and other residues are converted into biogas, process energy and organic NPKS fertilisers. The integrated process reduces energy, logistics and disposal costs.

Explore stillage-to-biogas

Distillers' stillage and distillery residuesAerobic hydrolysisMulti-stage anaerobic digestionProcess energy and NPKS fertilisers

Client benefits

What tangible value do clients receive?

Lower project and investment risks

Errors and critical interfaces are identified as early as possible before causing major follow-on costs in construction or operation.

Better decision-making foundations

Technical, commercial and operational impacts are presented transparently and alternatives become comparable.

Additional value from residues

Residues can be developed as feedstock for biomethane, heat, power or other usable products.

Potential for additional revenues

Depending on the project, revenue from energy and biomethane can be supplemented by avoided disposal costs and income from CO₂ certificates.

Greater schedule, cost and planning certainty

Clear responsibilities, defined interfaces, structured documentation and continuous project control improve deliverability.

Independent representation of client interests

The consultancy is not tied to a plant manufacturer or supplier and is guided by the client’s technical and commercial objectives.

Your project

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