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Processes & products Ready-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.

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Digestate processing with the Faser-Plus process

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

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

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

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.

Our references

Beverage group in Germany (2023)

Preliminary process engineering for the fermentation of spent grains with recovery of nutrients and biofibers.

Magaverde® production and product development (2019-2022)

Accompanying and supporting the BENAS Group in setting up production and product development/testing for Magaverde® biofibre products at the BENAS biogas plant site (Ottersberg). The installed production capacity for pulp products is 2,500 t/a and for paper 6,500 t/a.

Private operator of a biowaste fermentation plant (2019)

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

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.

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

Food waste digestion plant, UK (2016)

Process evaluation and preliminary planning for the removal of nitrogen and phosphorus from the digestate of a food waste fermentation (3.2 MWel, 80,000 t/a input) up to the production of a nutrient-poor process water.

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)

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