Innovative Biogas Plant – Flexible Biogas Production

Agriculture

Year of construction

2017

Project No.

2017-10001

Country

Hesse, Germany

Substrate

1,000 m³ of liquid manure and 500 tonnes of maize silage per year

Energy production

1.600 MWh per year

Technology

Biogas – hydrolysis, fixed-bed fermenter, solid fermentation (fully mixed reactor) and fermentation residue storage

Scope of delivery

Planning, approval planning,
manufacture/delivery, commissioning

ModulesHydrolysis: 60 m³
Fixed bed reactor: 60 m³
Fully mixed reactor 60 m³
Secondary fermenter 60 m³

At an experimental farm in Bad Hersfeld (Hesse), an innovative process was implemented as part of the ReBi research project – Flexible Biogas Production. The system begins with a hydrolysis stage followed by solid–liquid separation. The liquid phase is digested in a fixed-bed reactor, while the separated solids are further processed in a completely mixed reactor. This project is based on a technology co-developed by the founder of FlexBio (FNR funding codes 22400114 & 22401815).

The core concept is the multi-stage separation of the digestion process:

  • Hydrolysis with solid–liquid separation
  • Digestion of the liquid phase in a fixed-bed reactor
  • Further treatment of solids in a completely mixed reactor

This process allows biogas plants to operate with greater flexibility, balance fluctuations in energy demand, and significantly improve overall efficiency. The technology was developed and successfully tested by the founder of FlexBio, who implemented it at the experimental site in Bad Hersfeld.

Our Impact in Numbers

0

Delivered Projects

0

Ongoing Projects

0

Energy Generated (TWh)

0

CO₂ Reduction (tons)

Feedback

Urs Imlig

Appenzeller Milchspezialitäten AG

“The wastewater volumes kept increasing. FlexBio was able to provide us with a mobile pilot plant. After successful testing, the plant was quickly installed thanks to its modular design. And everything has been working very well and smoothly together.”

Alfred Oberlindober

CEO & Owner of the Private Brewery Schönram

“We are direct dischargers and, due to growth and the resulting increase in wastewater volumes, we reached the capacity limits of our existing treatment plant. In our search for a solution, we found FlexBio Technologie GmbH to be a competent partner. The cooperation has proven to be highly profitable. We particularly value the modular and flexible design, which can be expanded at any time.”

Josef Blüml

Halsbacher Qualitätsfleisch GmbH

“The compact container solution with drum screen, anaerobic stage, and MBR provides complete wastewater treatment. We are particularly pleased that we can reuse the treated water – this saves operating costs and is a real advantage for our environmental and sustainability goals.”

Ludger Seggering

Popp Feinkost GmbH

“Wastewater is full of energy. We were looking for a solution and found it with FlexBio – generating biogas from wastewater. We are satisfied with the installation of the plant. We are satisfied with the service. And we are satisfied with the results.”

Andreas Mehli

GRegio Energie AG

“FlexBio makes slurry valuable again! With the new farm biogas plant, FlexBio transforms slurry and organic waste into clean energy and high-quality natural fertilizer. In this way, sustainability becomes a real opportunity for agriculture – and the vision of paying for the tractor with slurry comes within reach.”

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