Securing the future
MT-ENERGIE – A leading supplier of Biogas production systems In the ever-changing field of renewable energy, MT-Energie GmbH & Co. KG is one of the leading producers of complete biogas production systems, including biogas conditioning and injection systems. With the know-how that comes from many years of experience, we are able to offer our clients systems which are both economic to run and highly efficient. As at December 2008, we have completed 160 projects, which corresponds to around 90 Megawatts of installed generating capacity. Our services include the design, planning and building of biogas systems and specialty components such as purification and injection systems. Furthermore, we are able to offer our clients intensive technical and biological process support. With a regular staff of 260 employees, MT-Energie mostly provides turn-key biogas plants. Our components are in use in more than 700 projects worldwide. MT-Energie has developed an excellent reputation in the biogas industry and has exhibited strong growth in Germany and Europe. As a private company, we value our corporate freedom which allows us the flexibility to put our customers first.
Dr. Holger Schmitz
Christoph Martens
Torben Brunckhorst
Bodo Drescher
International Project
Founder and owner,
Commercial Management
Marketing and
Management and
Research and
Implementation
Development
Sales
How is biogas made? Biogas is a mixture of carbon dioxide and methane. Biogas forms in any place where organic material decomposes in an oxygen-free (i.e. anaerobic) atmosphere, for example, in the intestinal tracts of cows. When properly harnessed, biogas can be used for many purposes, including as a fuel, for heat and for power generation. Biogas plants (also known as anaerobic digesters) use the natural process of fermentation on a large scale. To this end, a constant feedstock of organic material such as maize silage, grass, sunflowers, sugar beet or manure (liquid or solid) is fed into the digester (or fermenter). Because these input materials all primarily consist of water, they liquefy during the biogas production process. After the input material has been completely broken down, an odourless liquid remains – the digestate: this is not only a high quality fertiliser, but also constitutes the final step in the food chain.
Our Services If you want to produce biogas successfully and profitably, you need a partner you can rely on. Our customers appreciate the efficiency and cost-effectiveness when the planning, construction and on-going support for their biogas plant is provided from a single source. This is why MT-Energie can offer you a complete services package to safeguard your investment.
Project development
Project implementation
MT-Aftersales-Service
Profitability analysis
Construction phase
Biological process support
• Biological input analysis
• Construction and installation
• Digestion sample analysis
• Plant rating (tank size, input system, plant output) • Financial aspects • Profitability analysis (liquidity/profitability)
• Feedstock recommendations Initial commissioning
• Monitoring process stability
• Technical and biological
• Advice on the introduction
commissioning of the plant
of new feedstocks
• Operator training Planning and Regulatory Support
Technical & Maintenance Services
• Site planning with a view to possible expansion
• Provision of maintenance work
• Support with planning permission
• Remote monitoring
• Support with planning aspects of gas and
• 24hour hotline
electricity feed-in
• Process Evaluation Operations Management (optional)
Farm based biogas plants In order to enable small farms to reduce greenhouse gas emissions for a reasonable cost, MT-Energie has developed a single-stage biogas plant (up to 500kW) that is specially designed to use solid and liquid manure (slurry) as the input feedstock. Since liquid manure breaks down far more rapidly than materials such as maize silage, our one-stage biogas plant makes for a far more attractive concept from an economic standpoint. Owing to the use of a high proportion of liquid manure, the substrate from the fermenter contains only minute residual gas potential – and thus there is no reason to invest in a post-fermentation system. Existing outdoor slurry storage tanks can be integrated into biogas plants as post-fermentation systems. The fermenter empties itself out periodically via an overflow element. A helical rotor pump is installed to reduce the fluid level in the event the system needs to be serviced.
Crude biogas plants Biogas plants whose input mainly consists of silage derived from maize, whole plants or grass generally use a continuously operating two-stage decomposition process that is far slower than the process used in a one-stage slurry based plant. The biomass can remain in the two-stage system for a longer time, thanks to an integrated post-fermenting unit whose environmental conditions for the bacteria are the same as those in the fermenter. This, in turn, enables us to ensure that a maximum amount of gas is produced from input materials that take longer to break down, since up to 20 percent of the possible gas yield is generated during this second stage. For maximum efficiency, two-stage plants are generally the better choice for plants greater than 500 kW. In addition, this type of post-fermenting system optimises the overall biological stability of the biogas plant. Thus, for example, in the event that suboptimal feeding of the plant results in an elevated acid load in the fermenter, the requisite balance can be readily restored by re-circulating material from the post-fermenting unit. As a result of growing concerns about climate change and the finite supply of fossil fuels, alternative energy sources are taking on ever- increasing importance. Crude gas plants in the megawatt range combined with biogas conditioning systems could make a major contribution to a clean and self-sufficient energy supply in the coming years. Energy companies are becoming increasingly interested in producing biogas whose quality is on a par with that of natural gas. As we have already built a number of crude biogas plants, MT-Energie is the perfect partner for such projects as well, since we offer complete input and processing solutions.
Biowaste biogas plants Anaerobic digestion of biowastes is capable of conferring multiple environmental and socio-economic benefits. As society faces bio-waste as a resource, biowastes are diverted from landfills. Throughout digestion, not only is biogas generated, but biowaste is also transformed to digestate which contains significant fertiliser value. Therefore, anaerobic digestion offers the unique possibility of reduced emissions, renewable energy generation and biowaste recovery by closing the natural biological circle and converting waste into high quality fertiliser. Biowastes can come from innumerable sources such as households or the food processing, slaughterhouse or catering industries. Therefore, biowaste biogas plants are individually planned according to legal requirements. Waste reception, storage, milling and hygenisation are designed on the base of the expected volume and characteristics of the input. Pre-treated waste is then digested in a two-stage biogas plant.
Electric current Renewable raw materials
Feeding into the public power supply and private consumption
Combined heat and power generation (CHP)
Biowaste Biogas
Heat
houses, stabling, industry
Air-supported double membrane roof Gas collector
Manure
Gas collector
Mixer
Digester Direct feeding and conditioning
High-quality agricultural fertilizer
Post-Digester Pump room
Feed overflow
Gas collector
Residue storage tank
Perfectly planned and calculated Feasibility analysis and profitability analysis During the planning phase, we provide expert advice to ensure that your biogas plant will be tailor-made exactly to your needs and situation. We draw up a detailed feasibility study in order to analyse the profitability and financial liquidity of a biogas project. Although we use tried-and-tested components in order to construct complete systems, every single project always demands an individual approach. Our experts inspect the site and analyse the operational process options. While planning the project, we also give consideration to possible future expansion. It goes without saying that you may also wish to be responsible for certain aspects of the project. Our team will take this into account in the design and planning process. We are happy to provide you with advice and support at any point in the project development and implementation as well as the management and operation. Additionally, help can be provided finding the right financial solution for your particular requirements. For any kind of financing, you will benefit from our long term proven track record with numerous successful projects and our long-standing cooperation with financing bodies and banks.
Planning and Regulatory Permissions It takes a lot of time, effort and experience to put together the planning permissions. We are able to compile the planning application regardless of whether an order is finally placed. This reduces the time it takes from the initial idea through to the actual operation of your plant. Thanks to the combination of our know-how and sound planning preparation, we are able to maximise the smooth running of your project in terms of subsidies, financing and planning. Our workforce includes a range of experts who are familiar with all the official procedures and who all work closely together. Our architects, technical draughtsmen and civil engineers put the necessary paperwork together swiftly and react flexibly to possible changes. The uniform structure of our biogas systems also helps to accelerate the procedure.
Project implementation Constructing the Biogas Plant You receive a complete plant consisting of a two-stage biogas system using MT components throughout, from the solids feeder through to the residue storage tank. Oversized components and buildings produce no yield, but only cost money. By contrast, our "slim" approach keeps the investment costs as low as possible. And, in spite of that, the systems can be expanded later on with a manageable outlay. Our components are designed to coordinate seamlessly in terms of structure and function: that means there are no problems with the interfaces. You can decide for yourself what scope our work should have: from pure construction of a digestion line through to the provision of a turn-key system including all ancillary work; everything is possible and tailored to your needs and wishes.
CHP and transformer The combined heat and power (CHP) plant is not one of our own components. But, thanks to our many years of practical experience, we are well able to judge which CHP goes best with your biogas system. Framework agreements with the suppliers safeguard our access to the best units on the market. Many customers have problems in dimensioning the transformer correctly. We supply the matching product including transmission station.
Gas conditioning MT-Energie offers the full range of biogas technology. This also includes conditioning the biogas in a special plant, as an alternative to turning it into electricity on the spot. Here we work together with a strong partner. The BCM® process on licence from DGE GmbH Wittenberg separates the biogas into CO2 and methane by means of non-pressurized amine washing. Initial commissioning It takes a lot of experience to handle a biogas system. Without a doubt, it is a challenge for the operator to commission his new biogas system. This is why our staff offers you intensive support during this phase. We pay particular attention to making you familiar with the safety instructions. During on-going operation, it is easy to forget that a biogas system produces explosive gas For customers whose biogas systems are approaching completion, we offer operator training courses. All important aspects are explained in manageably sized groups. The courses consist of both theory and practice. The major subjects covered include: • Computer-aided system control • Safety on a gas-producing system • Biological principles of the digestion process for various different substrates • Start-up procedure
MT-Laboratory – We look after your bacteria! There are reasons that we put so much emphasis on the realistic calculations of economic profitability before we truly take on a project. One thing should always be kept in mind: a biogas plant is not the same as a wind turbine or a solar collector. The deciding factor as to whether a biogas system is a success is the biology. The profitability is tightly coupled with the stability and effectiveness of fermentation process, independent of what substrate (feedstock) is used. Our specialist biological process team, MT-Genius, advises the operators of over 300 systems Europe-wide. Not only do operators of MT biogas systems use our advice, operators using our competitors’ systems also rely on our competence, since MT-Energie is market leader in this field.
Our services include: • Service contracts involving VOA/TAC analysis, pH measurements and definitions of the acid spectrum. • Further analysis such as definition of dry matter (DM) and organic dry matter (oDM), measurement of the ammonium concentration and the electrical conductivity. • Fermentation tests with your substrates. • Determining of the residual gas potential. • Definition of the concentration of trace elements.
Apart from the analysis results, you will receive world-class assistance with regards to standard measuring results, gas yields, additives to the process (trace elements, enzymes) or other specific questions. We have extensive experience, both with plants of different types run with renewable raw materials and with co-fermentation plants Further advantages: • Favourably priced service contracts without a minimum contract period. • We analyze the samples directly after receiving them through the mail. You will get the results on the same day. • We will show you possible ways to optimise your system; for example, through feed management and system controls • You will be informed of system problems before they become serious – this protects you from financial losses. • Owing to our integrated research and development activities, you will always profit from the state-of-the-art technology, enabling you to approach the challenges of tomorrow.
MT-Service – Your success is important to us You can rely on us even after the start-up phase of your biogas system. With the help of remote monitoring, we can track (constantly, if necessary) the changes in your biogas system. This allows for constructive cooperation between system operators and our team here at MT. In the event that your biogas system is no longer running optimally, we will help to set it right, both quickly and competently. Our team was put together specially for this type of work, and we are happy to advise and help you. No matter what the future brings, you will always benefit from our years of experience with: • 24 hour repair service • Customer support by telephone • Identification of optimisation possibilities • Maintenance and repairs • System expansions A reliable partner does what he promises - and we exemplify that.
MT-BiomethanŽ – The answer to future demands Many biogas plants work without an optimum thermal concept for crucial improvements in the overall efficiency of the plant. This is usually a result of the location. It is extremely rare for a biogas system to be located directly in an industrial or commercial estate with many potential consumers for heat generated in the plant. Frequently, there is no possibility of making profitable use of the heat in the near vicinity. Turning biogas into electricity directly at the biogas plant is therefore less efficient. In many cases it would be better to turn it into electricity directly at the point of consumption, so that optimum use can be made of the heat as well as the electricity generated. The natural gas network is a suitable transport medium. But biogas has to be conditioned first before it reaches the quality of natural gas. This is exactly where our affiliated company MT-Biomethan GmbH comes in, with its biogas conditioning technology. The company holds the licence rights for the production and operation of plants using the BCMŽ process of non-pressurized amine washing by DGE GmbH, Wittenberg, and functions as licensee. This cooperation enables the MT Group to offer its customers completely self-contained biogas projects.
The power of unlimited opportunities There are virtually no limits to the opportunities for using high-purity refined gas. There are already options available for using this high-value energy carrier by feeding it into the public natural gas supply for firing CHP plants at the ideal location.
• Centralised utilisation from decentralised generation will represent a fundamental requirement on future energy carriers that biomethane already fulfils. Possible options for biomethane use are manifold. • Enormous amounts of energy are used as heat. Biomethane is an ideal fuel for this purpose. • Biomethane used as a fuel in converted vehicles represents the replacement fuel of the future. • Energy storage capabilities accomplished by liquefaction provide new economic and ecological possibilities. • CO2-neutral manufacturing and highly efficient utilisation of biomethane will make a substantial contribution to climate protection.
MT-Energie GmbH & Co. KG Ludwig-Elsbett-Straße 1 27404 Zeven (Germany) Tel.: +49 (0) 42 81 - 98 45 - 0 Fax: +49 (0) 42 81 - 98 45 - 100 E-Mail: info@mt-energie.com Internet: www.mt-energie.com
www.mt-energie.co.uk
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MT-Energie UK LTD 200 Brook Drive, Green Park Reading RG2 6UB (Great Britain) Tel.: +44 (0) 11 89 - 25 32 48 Fax: +44 (0 ) 11 89 - 25 32 49 E-Mail: info-uk@mt-energie.co.uk www.mt-energie.co.uk