Schmack Biogas Technology

Plant Engineering Know-how and Biological Expertise

Biogas is a major source of renewable energy. Unlike wind and solar power, biogas can be produced on a predictable basis from replenishable, locally available waste and residues. This enables the reliable production of electricity, heat, gas or vehicle fuels – renewable resources that are crucial to the global energy transition.

Partner to Farmers, Municipal Utilities and Energy Providers

HZI Schmack has more than 25 years of experience in constructing, maintaining, operating and optimising biogas plants. In addition to turn-key construction, including project development, permit planning and commissioning finished plants, HZI Schmack’s offering extends to technical and biological services for economical long-term operation.

HZI Schmack also offers power-to-gas solutions for producing additional green gases such as hydrogen and synthetic methane with BiON® biological methanation technology.

Your Plant in the Best Possible Hands

Besides new builds, HZI Schmack can provide comprehensive solutions around your biogas plant:

Entire plant (1)

  • Overall technical and biological optimisation and support
  • Conversions and extensions
  • Operational management
  • Regular maintenance
  • Design/approval
  • Recurring inspections and documentation support

Raw materials/silo (2)

  • Raw material management
  • Evaluation of feedstocks
  • Silo extension
  • Determination of DM/DMorg
  • Fermentation tests/NIRS
  • Silage quality

Charging (3)

  • Modernisation and optimisation:
    – Technical process
    – Biological processes
    – Energy usage
  • Help with process disruptions
  • Operating resources

Digester (4)

  • Review and optimisation of agitator technology
  • Gas tank replacement/ management
  • Concrete dome renovation
  • Wastewater analytics
  • Process analytics

CHP unit/technology centre (5)

  • Regular maintenance
  • Greater flexibility
  • Biogas cleaning
  • Heat utilisation/concept
  • Gas conditioning

Fermentation residue store (6)

  • Modernisation and new build
  • Fermentation residue analytics
  • Fertiliser value (DüMV)
  • Determination of heavy metals (BioAbfV)
  • Fermentation residue treatment
  • Fermentation residue management
  • Overall technical and biological optimisation and support
  • Conversions and extensions
  • Operational management
  • Regular maintenance
  • Design/approval
  • Recurring inspections and documentation support
  • Raw material management
  • Evaluation of feedstocks
  • Silo extension
  • Determination of DM/DMorg
  • Fermentation tests/NIRS
  • Silage quality
  • Modernisation and optimisation:
    • Technical process
    • Biological processes
    • Energy usage
  • Help with process disruptions
  • Operating resources
  • Review and optimisation of agitator technology
  • Gas tank replacement/ management
  • Concrete dome renovation
  • Wastewater analytics
  • Process analytics
  • Regular maintenance
  • Greater flexibility
  • Biogas cleaning
  • Heat utilisation/concept
  • Gas conditioning
  • Modernisation and new build
  • Fermentation residue analytics
  • Fertiliser value (DüMV)
  • Determination of heavy metals (BioAbfV)
  • Fermentation residue treatment
  • Fermentation residue management

Technology and Services

Whether you’re seeking to utilise residues sustainably, diversify your agricultural business, generate energy in combination with heat, upgrade gas for feed-in to the grid or generate fuel, HZI Schmack can supply a turnkey concept for your plant – also independently of the Germany Renewable Energy Sources Act (EEG).

  • Expertise in matters related to the EEG
  • Accurate economic assessment of your plant
  • Suitable concept for individual operation
  • Biological expertise, also spanning complex substrate mixtures
  • Technical and biological services

To be able to continue operating older plants economically, it’s essential to take a proactive approach to planning modernisation and optimisation work. You also have to keep pace with a constantly changing legal framework that opens up new options for ongoing operation. Often even minor conversion work or modifications to the biological, technical and organisational processes are sufficient to increase overall efficiency. We can

  • Advise you on the new economic options arising from changes in the legal framework
  • Create a modernisation concept individually tailored to your plant to optimise performance and yields
  • Make sure that all the relevant technical requirements relating to operational reliability are met
  • Extend the life cycle of your plant
  • Boost your profits by improving the efficiency of your plant

Biogas substrates require special handling at the storage, preparation, feeding and mixing phases. For many years HZI Schmack has been developing and manufacturing its own high-quality components. We also supply and build in components from other manufacturers. We’d be glad to advise you.

The main factor in the success of a biogas plant is smooth, economically efficient operation. To assure this, HZI Schmack provides expert advice, preventive maintenance and intelligent planning. The operating costs, as opposed to the investment costs, make up around 85 per cent of the total costs over the life cycle of a plant. You can find out more about our technical services here.

Whether you need an initial biological consultation, support in the event of process malfunctions or an all-in service, HZI Schmack can help you with over 25 years of experience, the sound know-how of its scientific staff and various levels of support with process biology. Our lab is:

  • DIN EN ISO/IEC 17025:2018-accredited (in accordance with the test method specified on the accreditation certificate)
  • Notified and approved for analytics and sampling
  • Approved in accordance with the requirements of the German Federal Compost Association

Our all-inclusive service for your biogas plant minimises the work and expense involved for you in running the plant. The service spans the complete range of plant management duties, including operational management, procuring raw materials and assuming administrative tasks.

You’ll find additional information on wet fermentation and biogas plants on the website of our subsidiary Hitachi Zosen Inova Schmack GmbH www.schmack-biogas.com.