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Power-to-gas plants convert electricity into synthetic gases such as hydrogen and methane. This technology has a key role to play in the transformation of our energy system: renewably produced synthetic gases replacing fossil fuels for industrial, transport and heating applications, where they make a decisive contribution to decarbonisation and defossilisation. This reduces greenhouse gas emissions and actively counteracts global climate change. Synthetic gases such as hydrogen and methane also allow the existing gas infrastructure to be utilised – a decisive advantage when it comes to implementing and integrating renewable energy.

The power-to-gas process involves the use of electrolysis and methanation systems. The first step in electrolysis is to separate water (H2O) into hydrogen (H2) and oxygen (O2) with the help of electricity. The hydrogen produced can be utilised directly or for other processes. Methanation involves a reaction used to convert hydrogen and carbon dioxide (CO2) into synthetic methane (CH4) and water. The hydrogen can come directly from electrolysis plants or from synthesis gas (syngas), which is produced thermochemically from biomass or waste.

The CH4-rich product gas or substitute natural gas (SNG) resulting from methanation can be used immediately, stored in existing gas infrastructures or liquefied by additional systems.

With our complete range of services, we can support you in all phases of delivery of the system:

  • Concept development
  • Planning & engineering
  • Execution & commissioning
  • Monitoring
  • Operation & maintenance

We have a wide range of services to assist you from the outset. You choose what’s right for you from our service packages:

  • Feasibility studies
  • Front-end engineering and design
  • Basic and detail engineering

Launch an enquiry here: Schmack Biogas Online Check (

Technology and Services

Our core competencies are concept development, engineering, construction and the assembly of turnkey plants. With a successful 100-year-plus track record of delivering EPC projects in the waste-to-X and renewable gas sectors, we at HZI are very well positioned to implement hydrogen projects in our target markets.

Customers can rely on our expertise in the construction of integrated hydrogen plants. We have the specialist know-how to develop and construct hydrogen plants of different sizes based on different technologies.

As an experienced system integrator, we’re ideally placed to deliver safe, reliable and efficient hydrogen installations. Our integrated solutions span the actual production of the hydrogen as well as compression, storage and filling.

What makes our solutions stand out:

  • We’re a global solution provider for integrated hydrogen production plants.
  • We plan and deliver safe, reliable and efficient hydrogen projects.
  • Our designs are holistically optimised for low specific energy consumption, high operational availability and low operating and maintenance costs.
  • We offer a Europe-wide service network in cooperation with local partners.

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Our catalytic methanation systems convert hydrogen and carbon dioxide into synthetic methane and water. A wide range of sources of CO2 gas (biogas, syngas or pure CO2) can be used.

We’re an experienced system integrator with the know-how to provide catalytic methanation solutions in modular configurations and fully integrate them into your infrastructure. Our end-to-end methanation solution can also include upstream or downstream process equipment.

Our single-stage reactors work on the basis of the gravitational flow principle, rely on a minimum of moving parts and are economical in terms of power consumption. The oil-free system also enables the temperature to be reliably maintained at around 280°C and allows the stable production of high volumes of methane.

Our catalytic methanation system produces a dry, methane-rich product gas at moderate pressures, ideal for direct use, feeding into the gas grid or liquefaction. The system can also be designed to provide fully demineralised water and high-temperature process heat, which allows good overall efficiency.

What makes our solution stand out:

  • It produces high-quality methane at high efficiency.
  • Oil-free water and steam circulation control enables straightforward reactor operation and reliable hot-spot temperature control.
  • The main media flow by gravity, minimising moving parts and allowing pump-free operation.
  • The modular, prefabricated design allows scalability and saves time during installation.
  • We offer a Europe-wide service network in cooperation with local partners.

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Our BiON® biological methanation technology uses special microorganisms to metabolise hydrogen and carbon dioxide into methane. This anaerobic process can be operated very dynamically and is highly robust when it comes to handling impurities in the raw gas. The system retains its dynamics in on-off mode: a rapid restart is easy after a shutdown. With our biological expertise we’re able to use anaerobic substrates to create process conditions under which the microorganisms can achieve optimum performance without the need for high levels of additives or complex dosing technology. Modelled on nature, the process works best at moderate temperatures of 65°C and can withstand pressures of 5 to 10 bar without any problems.

The cubic geometry of the continuous stirred-tank reactor (CSTR) makes it easier to maintain the temperature in standby mode. This means less expenditure on insulation and heating. The system is designed to allow easy access for inspection, maintenance and service.

What makes our solution stand out:

  • It produces high-quality methane at high efficiency.
  • It features an advanced, efficient and robustly designed reactor geometry.
  • The system allows flexible start-stop operation
  • There is little additive consumption or dosing required thanks to utilisation of existing substrates.
  • We offer a Europe-wide service network in cooperation with local partners.

More information:

INPEX plant, Japan