Innovative concepts for the conversion of waste to energy

Biogas Plants

From concept to construction – biogas plants from one source

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GICON Engineering North America GmbH a dynamic engineering partner

Enlargement of the test dimension and spectrum at a large-scale research facility, without risks to future investors

Percolate fermentation plant Erfurt, Germany

Thermal utilization

Intensive composting Post-composting

(can be omitted)

Existing mechanical-biological treatment

Hydrolysis CHP orupgrading to biomethane(optional)

New plant combination:GICON biogas plant

Existing CHP or gas utilization

Wastewater

Landfill

Purified wastewater

Energy feed-in

Existing disused landfills or existing wastewater treatment plants

Residual waste and/or source-separated organic waste

Residual waste and/or source-separated organic waste

Organic fraction(normally low-calorific,

damp)

High-calorific fractions

Impurities

Compost

Energy feed-in(optional)Electrical energyThermal energyBiomethane

Biogas (70% CH4)

Residual wastes

Methane production

Landfill gas

Landfill leachate

Sewage gas

Compost treatment

Mechanical pre-treatment

Landfill leachate treatment plant/Wastewater treatment plant

GICON Engineering North America GmbH was founded in 2010 as an independent venture within the GICON Group. The company was formed to provide design and consulting services in the biogas sector for our growing client base in the USA and Canada, and to design high-solids anaerobic digestion (HSAD) biogas plants using the GICON Process for our North American partner, Harvest Power Inc. Our com-pany can rely on the expertise and assets of GICON Bioenergie GmbH and further-more on the wide-ranging expertise of the entire GICON Group to ensure timely and professional delivery of services, some of which are indicated below.Our objective is the delivery of the optimal process and system solutions for the unique requirements of each client. Therefore, several principle concepts for biogas production are offered by GICON Engineering North America GmbH, including: ■ GICON Biogas Process (two-stage dry-wet HSAD with split hydrolysis)■ continuously-stirred tank reactor (CSTR)■ multiple-stage wet fermentation process

Range of services offered by GICON Engineering North America GmbH:■ concept and project development■ overall planning (engineering contracting for all planning phases, construction supervision, commissioning supervision)■ insurance-backed guarantee of plant biogas yield for plants designed by GICON ■ consulting services for existing projects (owner’s engineer, optimization of operation, and other engineering services)■ proofs of concept■ implementation of fermentation tests at GICON's large-scale research facility in Cottbus for investment preparation■ research capacity for development and optimization of bioenergy processes

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Complete Services for different applications

Waste (biologically exploitable)

Dry fermentation

Biog

as te

chno

logi

es

Wet fermentation technology classic/multiple-stage

Pretreatment (screening, crushing) Storage

Pre-

treat

men

t of f

eeds

tock

s

Renewable raw materials

Structure- and impurity-rich Liquid and structure-poor

High-volume fermenter with central agitator

Multi-stage reinforced-concrete fermenter systemGICON Process

Organic material

Utili

zatio

n

Electricity and heat generation

Fermentation residues

Biomethane production

Gas utilization

GICON Biogas Process two-stage dry-wet fermentation with split hydrolysis

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 metha-nization, which is designed as a packed bed vessel. Due to the immobilization of metha-ne-forming microorganisms on the surface of the packing material, large methane-forming 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 control-la-bility of the biogas production. The environmental conditions (temperature and pH, among others) are controlled and optimized separately in both process steps. By app-lying 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 feed-stocks 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.

High-performance digester (circular green reactor) designed as a packed-bed vessel for efficient generation of biogas from hydrolysate

Process flow diagram of the GICON Biogas Process

Filling of a percolator with agricultural machinery

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hydrolysate vessel-buffer storage-

aeration andpolishing pool

sludgewaste water, liquid fertilizer

return

packed bed

biogas70-80% CH4methane

productioncontrol

liquideffluent

methane reactors

hydrolysate

percolate return

percolation

multiple percolatorsin a garage setup

percolate= hydrolysate

stabile by-product appropriate,for example, for composting

batch-wise addition and removal of feedstock

percolation

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Sampling in the GICON – Cottbus large-scale biogas research facility

Methane content in biogas,excerpt from the process control system

GICON Biogas Processa 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 CO2, 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 demandUnprecedented in biogas technology is the controllability of biogas production. The foundation of this feature is first, the buffering of energy-rich hydrolysate in an inter-mediate 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.

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 tech-nological know-how in a wide spectrum is available to meet your biogas needs.

Control of biogas production (depicted are results from investigations at BTU Cottbus, Department of Waste Management)

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The GICON Biogas Processadvantages at a glance

GICON biogas plant in Schöllnitz, Germany

Organic wastes

Rene

wab

le

ener

gies

Vision: 24h power plant/energy and disposal center

Sun

Controllable GICON

biogas plant

Wind turbine

Solar power station

Thermal energy

Gas (raw material, combus-tible fuel, motor fuel)

Electrical energy around the clock

Ener

gy su

pply

RE acc. to

wind availability

RE acc. to

solar availability

Daytime network load distribution

RE based on need (compensation for the deficits

of solar power stations and wind turbines via a controllable biogas plant)

Gas upgrading facility

CHP facility

Energy crops

Green waste, etc.

Was

te d

ispos

al

Wind

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

GICON biogas plant in Cottbus, Germany

Biogasyl biogas plant, France –waste fermentation plant with complete mix fermenter

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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-fer-mented 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 em-ployees 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

Design of a wet fermentation plant for food industry wastes

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Biogas Plant Construction wet fermentation plants for agricultural feedstocks

Use of agriculturally-produced substrates/energy crops

In agricultural biogas plants, liquid manure and silage are most often utilized as feed-stock. 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.

Biogas plant Dresden-Klotzsche, Germany

Functional design for biogas production acc. to wet fermentation technology

Klein Muckrow biogas plant, Germany

Site plan for a wet fermentation plant

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Biogas handling complete service through to feed-in

Kerpen biogas conditioning and feed-in facility, designed in its entirety by GICON

View of the machine room of biogasconditioning and feed-in facility

Supervision by GICON on behalf of the client

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 CO2 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 CO2 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 condi-tioning 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 bio-methane (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.

Production and Service Center Cottbus design and research platform

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 genera-tion 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 applica-tion 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.

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

Innovative design variant of the hydrolysis stage: combined transport and process container

Tests with original material in the barrel array at the large-scale research facility

Aerial view of the large-scale research facility in Cottbus

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Innovation through ResearchR & D projects in the bioenergy sector

R & D projects

Large-scale testing of the GICON Processin 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.)

dCO2-Sensor

Planning tool

Expansion of the feedstock spectrum for bio-gas 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 HermosSystems 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

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 dCO2-sensor with expanded measurement range and biocidal membrane (dCO2Sensor); 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 frame-work 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 net-works 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 exchangesGICON 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.

Topics completed since 2005 or currently in progress, as of March 2010. Complete overview at: www.gicon.de

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ECOSYSTEM SAXONIAGesellschaft für Umweltsysteme mbH www.ecosax.de Primary Disciplines: water resources mangement, civil/hydraulic engineering

GICON International Headquarters Tiergartenstraße 48 | 01219 Dresden/Germany I Telephone: +49 351 47878-0

GICON Engineering North America GmbH Tiergartenstraße 48 I 01219 Dresden/Germany I Telephone: +49 351 47878-0

GICON Bioenergie GmbH Tiergartenstraße 48 I 01219 Dresden/Germany I Telephone: +49 351 47878-0

GICON Industrial-Scale Biogas Research Facility Gerhart-Hauptmann-Straße 13 | 03044 Cottbus/Germany | Telephone: +49 355 494967-0

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GIC

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, S

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GICON Engineering North America GmbH, Chief Executive Officer: Prof. Dr.-Ing. habil. Jochen GroßmannRegistry Court: Dresden District Court, HRB 10 679 | Tax Number: 201/109/06162 | VAT Number: DE272779071

as of 09/2011

GICON Solar GmbH & Co. KG Jatznick www.gicon.com Primary Disciplines: photovoltaic system planning

GICON Engineering North America GmbHwww.gicon.comPrimary Disciplines: biogas plant design and construction, feedstock evaluation, technical consulting (North America)

Dr. Kühner GmbH www.dr-kuehner.de Primary Disciplines: enviromental protection and plant safety engineering

Geologische Landesuntersuchung GmbH www.glu-freiberg.de Primary Disciplines: mining technology, geothermal engineering, geology

Institut für Angewandte Ökosystemforschung GmbH www.ifaoe.de Primary Disciplines: ecological research and monitoring, EIS preparation

I.M.E.S. GmbH – I.M.E.S. Gesellschaft für innovative Mess-, Erkundungs- und Sanierungstechnologien mbHwww.imes-gmbh.dePrimary Disciplines: soil and groundwater conservation and modeling

BGD Boden- und Grundwasser GmbH Dresden I Dresden Headquarterswww.bgd-gmbh.de Primary Disciplines: soil water, groundwater, and surface water research and management

GICON Bioenergie GmbHwww.gicon.comPrimary Disciplines: biogas plant design and construction, feedstock evaluation, technical consulting (worldwide)

GICON - Großmann Ingenieur Consult GmbHwww.gicon.comPrimary Disciplines: facility and permit planning, renewable energyengineering, environmental management/remediation, IT solutions