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Processes & productsReady-to-use processes and products

Our processes and products originate from our development and are ready to use. We would like to introduce you to our processes and products, which can be used directly in practice.

Digestate processing with the FaserPlus processGNS – Gesellschaft für nachhaltige Stoffnutzung mbH

GNS - Gesellschaft für nachhaltige Stoffnutzung mbH

With the FaserPlus process, we can produce mineral fertilisers and valuable substances from fermentation residues. The recovery of plant nutrients such as nitrogen and phosphorus from digestate from agricultural biogas plants and waste fermentation plants or sewage treatment plants is important for closing material cycles and reducing negative environmental impacts such as nitrate contamination in groundwater. Digestate processing with the FaserPlus process reduces emissions and generates valuable materials.

The process

Modified stripping process in which the ammonium nitrogen is removed from digestate with CHP waste heat without any use of alkalis, acids, other chemicals or external stripping media. Binding of nitrogen preferably with low-cost FGD gypsum producing ammonium sulphate solution and calcium carbonate as approved mineral fertilisers.

The advantages

  • Chemical-free
  • Resilient and low maintenance
  • Low operating costs
  • Low energy demand
  • Emission-free
  • Large-scale practice since 2008
  • Hygienist effect and digestion effect
  • Avoidance of ammonia inhibition in the fermenter
  • An optimal preliminary stage for total treatment to pure water

The products

  • Lime fertiliser
  • Ammonium fertiliser
  • Phosphorus-rich organic fertiliser
  • Purified organic fibres
Info sheet digestate treatment
Do you have any questions? Contact us:

Adding value by extracting bio fibres – magically green products

After generating energy in the biogas plant and producing fertiliser in the FaserPlus plant, the remaining lignocellulosic fibres are processed into sustainable Magaverde® bio fibre products from plant residues.

Our Magaverde® bio fibres are:

  • Pollutant-free and odourless thanks to an innovative and unique treatment process
  • Fully biodegradable with a contribution to humus formation
  • Made from selected residual materials from bioenergy production in environmentally friendly recycling and cascade processes

Our Magaverde® products are suitable for:

  • Agriculture and horticulture as mulch fleece for weed protection, as plant pot, as humus and nutrient supplier
  • Ecological packaging such as carrier bags, bags, cardboard boxes, shipping boxes, gift packaging, transport protection

Visit us also on our Magaverde website

Biofibers Biofibers
Biofibers Biofibers

Catalysts for thermal and thermochemical processes

The catalysts developed by GNS are used for the targeted reaction control of thermal and thermochemical processes. This increases the efficiency of the conversion and reduces environmental pollution caused by emissions and waste materials. In particular, we have specialised in the use of inexpensive and heavy metal-free consumable catalysts.

Biomass gasification with GNS catalysis

To make the potential of biomass gasification for decentralised heat and power generation more usable on the market, the advantages through higher efficiencies and lower emissions must be brought to bear. By catalytic reaction control, we can achieve a reduction in tar formation and lower the threshold temperature as well as an acceleration of the gasification reactions in biomass gasification. The result is the energetically optimal utilisation of the chemical energy of the biomass with reduced partial combustion and utilisation of internal heat sources (partial allothermal process control).

Efficiency through GNS catalysis

  • Maximum gasification efficiency
  • Minimisation of tar formation
  • Minimisation of losses

Universal application

  • Suitable for fixed and fluidised beds
  • Optimisation of existing plants
  • Gasification and post-combustion catalysts
Wood gasifier

Natural catalysts for fast and smoke-free grilling

The Grillspeed catalyst is a product of our many years of experience with catalysts in thermochemical processes. Its effect has been proven in numerous scientific studies and tested in practice in the B2B sector.

The mineral-based catalyst Grillspeed promotes a fast and even glowing of the charcoal with minimised smoke development. After lighting, the barbecue can be started much sooner. The food is cooked faster and more evenly. This leads to a particularly good grilling result. The catalyst Grillspeed is non-toxic and not harmful to the environment. We also offer complete use and application as a licence.

Technology provider for substrate digestion for biogas plants (2020)

Fermentation tests to demonstrate the digestion effect in treated and untreated fermentation residues.

State Office for the Environment, Agriculture and Geology in Saxony (2020)

Study to ensure the proper disposal of old medicines in the Free State of Saxony.

Biogas plant operator (2020)

Studies on the separation of a phosphorus-rich solid organic fertilizer from digestate.

German paper manufacturer operating throughout Europe (2020)

Analysis and studies on wastewater treatment from paper production.

Investor in new technologies (2019)

Assessment of a pyrolysis of plastic waste and a waste oil processing to fuels

International planner and project developer for biogas plants (2019)

Emission evaluation of a biorefinery plant for waste fermentation with total treatment of the fermentation residues

Municipal operator of a biowaste fermentation plant (2019)

Utilization test of by-products of a waste fermentation plant

Private operator of a biowaste fermentation plant (2019)

Preliminary planning for the energetic use of solid digestate from a waste fermentation plant

Biowaste fermentation plant (2018)

Laboratory testing and suitability testing of solid digestate as fuel

Waste engineering investigations during the refurbishment of a high-rise building (2018)

Recording, analysis and classification of waste according to waste code numbers and waste quantities for disposal during the refurbishment of a high-rise building

Consulting and expert opinion on digestate processing (2018)

Consulting in the selection, technical and economic evaluation as well as planning of plants for the treatment of fermentation residues on behalf of private clients

Glass producer in Germany (2018)

Investigation of by-products with regard to their usability

Waste Assessment Information Portal IPA (2017 / 2018 and 2020)

Revision of waste profiles for the information portal for waste assessment IPA on behalf of the federal government and the federal states, respectively

Gravel and stone producer in Germany (2017 / 2018)

Feasibility study for sludge water treatment and development of a technical solution concept

Austrian energy village with 1,100 inhabitants (2016 - 2018)

Engineering and support for the conversion, commissioning and optimization of a wood gasification plant with efficiency increase through GNS catalysis.

Saxony-Anhalt State Office for Environmental Protection and Agriculture (2017)
Wastewater treatment plant 600,000 EGW (2017)

Fermentation tests to investigate the effects of co-fermentation of a residue from a landfill leachate treatment with digested sludge, flocculation and post-digestion sludge treatment

Biogas plant > 1 MW (2016)

Fermentation tests to investigate the effect of a lignin digestion preparation Studies on the separation of phosphorus from fermentation residues

Biowaste fermentation plant, GB (2016)

Laboratory tests for the removal of nutrients from fermentation residues

Operators of biowaste anaerobic digestion plants from England (2016)

Process engineering consulting for the removal of nutrients from fermentation residues

Realization of a digestate treatment system GNS at the 5 MWel biogas plant (construction 2008, extension 2011, FaserPlus process 2016)

The individual planning concept was drawn up in 2007, taking into account the special features on site and using existing tanks and aggregates. The technical implementation was carried out by the plant operator himself. The large-scale functionality of the process was demonstrated in practical operation at the fermentation residue treatment plant, which operates in fully automatic mode. Since 2011, long-term experience with the use of a lot of poultry manure with recycling of the N-reduced fermentation residues. 2016 Testing of the FaserPlus process for co-treatment of biogas fibers (separation after stripping). Location: Ottersberg near Bremen, Client/Partner: BENAS-Biogasanlage GmbH

Biowaste fermentation plants (2014 - 2016)

Laboratory studies on the reduction of the formation of salt crusts and the reduction of salt loads in the percolate of a biological waste treatment plant

Global general contractor and operator of plants for biological and mechanical waste recycling (2014 - 2016)

Process engineering advice to reduce the formation of salt crusts and the reduction of salt loads in the percolate of a biological waste treatment plant

Two well-known manufacturers of wood gasification plants (2014 - 2016)

Efficiency increase through GNS catalysis, for the use of other biomasses and for catalytic engine exhaust gas purification

Project developer for renewable energy technologies from England (2015)

Erstellung eines Technologieüberblicks "General Assessment of Advanced Conversion Technologies by Gasification / Pyrolysis"

Project developer for renewable energy technologies from England (2015)

Chemical-technical assessment of thermochemical waste treatment plants with balancing and evaluation of emissions

Developer and operator of recycling technologies (2013 - 2015)

Chemical-technical assessment and scientific-technical support of a process for fuel production from waste plastics

Saxony-Anhalt State Office for Environmental Protection (2014)

Collection of hazardous waste analysis data with additions to the ABANDA waste analysis database and classification verification

Municipal utilities of a municipality with approx. 61,000 inhabitants (2011 - 2013)

Efficiency increase of gas generation from wood by GNS catalysis and tests for catalytic engine exhaust gas purification

Realization of a digestate treatment system GNS at a biogas plant (3 MW electricity equivalent) with biomethane production (2011-2012)

After removal of the ammonium nitrogen, 70% of the liquid fermentation residues are returned to the biogas plant. The high proportion of nitrogen that enters the biogas plant with the poultry manure can thus be almost completely removed from the process and converted to mineral fertilizers. By recovering heat from the digestate treatment, the neighboring chicken fattening farm can also be supplied with heat. Location: Saxony-Anhalt, Röblingen am See, Plant manufacturer: AIM Technical Solutions GmbH, Timelkam (A)

Project developer for renewable energy technologies from Munich (2011)

Determination and evaluation of potentials of straw-based biomass for a plant location in Germany

German market leader for pressing and briquetting machines (2009)

Testing and characterization of alternative biofuels for the production and use of straw briquettes in biomass boilers

Digestate treatment plant of a biogas plant (3 MW electricity equivalent)

Engineering for the construction of the GNS digestate treatment plant 2011 for 5.5 to 12.6 t/h throughput, general contractor AIM Technical Solutions GmbH, Austria

FiberPlus plant of the BENAS biogas plant (11.3 MW electricity equivalent)

Engineering for construction of GNS digestate treatment plant in 2008 for 10 to 25 t/h throughput, expansion in 2011, conversion to FiberPlus process in 2016

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