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Processes for biomass gasification and fermentation treatment – the GNS processes

Our processes for biomass gasification and fermentation residue treatment are developed in-house and are "ready to use". We would like to present you our processes, which can be used directly in plant practice, in more detail.

Treatment of fermentation residues with the GNS system – the FaserPlus process

With the FaserPlus process, we can produce mineral fertilisers and recyclables from fermentation residues. The recovery of nutrients from farm manure and biowaste is important to maintain our future food production while reducing the negative environmental impact. The processing of fermentation residues with the GNS system reduces emissions and produces valuable materials.

The FaserPlus process:

  • Nitrogen recovery
  • Chemical-free
  • Low energy consumption

The products:

  • Lime fertiliser
  • Ammonium fertiliser
  • Fibres

The advantages of processing fermentation residues with the FaserPlus process

  • Chemical-free without acids and alkalis: only REA gypsum certified as operating material according to REACH
  • Solid without prior separation: fibre- and dirt-resistant, self-cleaning containers and apparatus
  • Low operating costs: 1/10 of the cost of gypsum instead of sulphuric acid, low power and heat consumption and low cleaning effort
  • Industrial practice since 2008 and as a FaserPlus process since 2016 - also suitable for sewage treatment plants
  • Integrated hygienisation: 1 hour at 70 °C according to hygiene regulation EG No. 1774/2002
  • Without emissions or waste gases into the environment
  • Optimum pre-press for total treatment: downstream stages such as drying or water treatment are relieved and thus more cost-effective

Efficient fertiliser management with new fertiliser products from fermentation residues

Transporting fermentation residues over long distances can be expensive. The production of mineral fertilisers worthy of transport opens up new ways for cost-effective and low-emission N-fertiliser management.

The process:

Modified stripping process in which ammonium nitrogen is removed from fermentation residues using CHP waste heat without the use of alkalis, acids or external stripping media. Binding of the ammonia, preferably with FGD gypsum, producing ammonium sulphate solution and lime as approved mineral fertilisers.

Application:

  • Energy-saving and environmentally friendly process for reducing emissions and losses of fertiliser nitrogen from fermentation residues
  • The important partial step towards total recycling and closing nutrient cycles in agriculture
  • Prevention of ammonia inhibition and removal of excess nutrients during fermentation of nitrogen-rich substrates such as chicken manure

Biomass gasification with GNS catalysis – gasification of wood, straw and sewage sludge

GNS catalysis is a thermochemical process for the production of synthesis gas for electricity generation. In order to make better use of the potential of biomass gasification for decentralised heat and power generation on the market, the benefits must be realised through higher efficiencies and lower emissions. This can be achieved through catalytic reaction control and adapted process conditions.

An overview of the biomass gasification process:

Efficiency through GNS catalysis:

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

Universal application:

  • Suitable for fixed and fluid bed
  • Optimisation of existing plants
  • Gasification and post-combustion catalysts

Catalytic reaction control in biomass gasification can reduce tar formation and lower the threshold temperature and accelerate the gasification reactions. In addition, the process convinces by energetically optimal utilisation of the chemical energy of the biomass with reduced partial oxidation and utilisation of internal heat sources (partial all thermal process control).

Status:

  • Implementation and testing of the overall concept in a research and pilot plant (50 kWel) on the campus of HS Merseburg (2002 to 2005)
  • Application at eight different plants for wood gasification from 30 to 500 kWel
  • Optimisation of existing plants (fixed and fluidised bed)

GNS-afterburning-catalysts – catalysts for processes and efficient exhaust gas treatment

Among other things, we develop and test special bulk catalysts for engine exhaust gas purification from biomass gasification. By using a catalyst-combination consisting of a particularly powerful oxidation catalyst and a robust protective catalyst, the catalyst poisons can be trapped in the inexpensive protective catalyst before entering the highly active oxidation catalyst.

The advantages of the procedure:

  • Reliable compliance with the emission limit values for CO, benzene and other pollutants throughout the operating period
  • Lower costs and improved catalyst service life
  • Suitable for CHP exhaust gases, CHP systems, CO, benzene and NOX
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