Request

Before the start of the project, the customer already had experience with biogas technologies and сформulated a request for biomethane production. This approach allows flexible use of biogas depending on market conditions — for electricity generation or biomethane.

The key challenge was integrating the solution into an operating biogas plant without stopping production. Therefore, Pro-Energy proposed a modular membrane technology that can be quickly installed without disrupting ongoing processes.

The system upgrades biogas to biomethane in line with European standards. Equipment by Bright (Netherlands) ensures compact, reliable operation with simple maintenance and no need for chemicals.

Characteristics of the biomethane plant

Raw biogas produced from mixed agricultural waste, mainly poultry waste.

A system for enriching biogas by passing it through a three-stage membrane system that separates CO2 into a separate stream, with CH4 being the final product. Before being fed to the membrane system, the biogas undergoes dehydration, desulfurization using activated carbon filters and siloxane purification.

Biogas enrichment capacity: 1 unit with a capacity of 2500 Nm³/h, which produces 1540 Nm³/h of biomethane.

Actual annual biogas production: 21.9 million Nm³, of which 12.8 million Nm³ of biomethane is produced after enrichment.

Implementation

The project began with a technical audit of the biogas complex. Based on it, we developed a solution that allowed us to integrate the new equipment into the system of the existing biogas plant without interrupting the customer's production processes. To ensure the appropriate quality of the biogas entering the enrichment stage, a solution was proposed at the design stage to reconstruct the biogas desulfurization system by replacing the air supply with oxygen (90-93% oxygen) to the fermenters. This made it possible to maintain a stable desulphurisation process and reduce the concentration of nitrogen (N2) in the biogas, which is critical for the enrichment process.

The installation of the plant took only two weeks due to the parallel preparation of the site during the production of the equipment in the Netherlands and coordinated work with the customer's team. Local contractors were also involved, which helped to avoid delays.

The launch was scheduled for the end of the year, despite the holiday season. The team ensured clear coordination between the equipment manufacturer, the customer's team and the GDM operator's specialists during the commissioning works, including the adjustment of gas parameters for connection to the GDM.

Provided full support to the customer in terms of development: conducted an audit of the biogas plant або biogas facility, prepared a technical solution, provided advice on the integration of the new plant and meeting the requirements of the GDM operator.

We developed design documentation for the construction of a biomethane complex with further integration with the existing biogas plant, taking into account the existing infrastructure and space constraints at the site.

We organised and coordinated the production of the equipment by our partners Bright Renewables (Netherlands) — the production time, including delivery to the construction site, was 34 weeks. At the same time, we prepared the site and the necessary utilities.

We completed all construction and installation works at the facility. The installation of the membrane enrichment plant lasted 2 weeks, which was made possible thanks to the coordinated work between all construction participants and the involvement of local contractors.

We carried out a full range of commissioning works in coordination with the equipment manufacturer.

We set up a biomethane quality control system and brought the plant to its design capacity.

We conducted an availability (continuity of operation) test with a plant load of at least 50% for 5 days, 24 hours a day, and a design capacity confirmation test for 8 hours. As a result, we achieved stable operation of the plant at the design parameters and continuous supply of biomethane to the gas grid.

Biomethane without delays - photo 1 — pro-energy.com.ua

Biomethane without delays - photo 2 — pro-energy.com.ua

Biomethane without delays - photo 3 — pro-energy.com.ua

Biomethane without delays - photo 4 — pro-energy.com.ua

Conclusion

The cooperation of the Pro-Energy team with the client's team resulted in stable production and supply of biomethane to the grid in compliance with the requirements of the GDM operator. The client received a reliable solution that operates continuously, does not require high operating costs, and demonstrates high energy efficiency throughout the year.

The implemented solution also improved operational stability and reduced dependence on external energy factors, ensuring predictable performance and long-term efficiency of the facility.

Pro-Energy has once again proved that it is capable of implementing complex projects in a short timeframe — with a deep understanding of the client's needs, integration into real-world production conditions, and a technically sound approach at all stages. This case study will become the basis for scaling up similar solutions at other agricultural facilities that are already looking towards energy independence and waste treatment through biomethane.

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Biomethane without delays

Request

Characteristics of the biomethane plant

Implementation

Conclusion

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