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Home SolutionsBiogas & Biomethane Biogas plants at breweries

Biogas plants at breweries

We convert brewer’s grains, yeast and waste water into biogas, energy and cost savings. An alternative to drying: lower costs — better results.

Without a biogas plant:

  • The cost of disposing of beer grain.
  • The operating costs of drying are an expensive and energy-intensive solution.
  • Search for a market for dry feed.
  • Dependence on the energy market.
  • High production costs.

With this, you get:

  • Savings on disposal
  • The possibility of replacing natural gas with biogas
  • Generation of electricity and heat for internal use
  • Consistent waste processing and reduced pressure on storage facilities
  • Predictable energy independence and protection against market fluctuations

When should you contact us?

01

You are left with large quantities of beer grain

02

The drying of beer grain is unprofitable or results in losses

03

You are looking for energy independence and an alternative to natural gas

04

You want to turn waste into energy and reduce costs

About raw materials

The main feedstock for biogas plants at breweries is beer grain, as well as excess yeast and process effluents. These streams contain a significant amount of organic matter and are well-suited for biogas production. At the same time, beer as a product contains alcohol, which can inhibit the anaerobic digestion process; therefore, its feed into the biogas plant requires control or restriction.

Beer grain have a relatively high dry matter content and a fibrous structure; therefore, they are typically used in stirred CSTR reactors, which ensure stable operation when processing heterogeneous feedstock. Liquid effluents with high COD can be further treated in high-load reactors (UASB/EGSB), but as a separate process unit.

Biogas plants are tailored to the company’s logistics: feedstock can be supplied either as a mixture (beer grain + wastewater + yeast) or via buffer tanks, with the feed rate, temperature, and pH being regulated.

The main applications for biogas are replacing natural gas in boiler rooms or using combined heat and power (CHP) to supply electricity and heat for the enterprise’s own needs.

Biogas plants at breweries - photo — pro-energy.com.ua

Would you like to compare the costs of a drying plant and a biogas plant?

Book a free consultation, and our managers will provide comprehensive information regarding your questions.

Options for collaboration:

  1. Comprehensive turnkey development for the food industry.
  2. Co-funding or attracting investment from partners.
  3. Grants for biogas production from international organisations.
  4. Equipment-backed loans through Ukrainian banks.
  5. EPC+O&M contracts — we build, operate and share the profits.

Ways to recoup the investment:

  • Replacement of natural gas.
  • Reducing the cost of drying beer grain.
  • The use of heat in industrial processes.
  • Energy self-sufficiency of the enterprise.
  • Reducing disposal costs.

Biogas technologies for breweries

For breweries, we recommend CSTR reactors with pre-treatment involving homogenisation and, where necessary, the grinding of solid fractions, such as co-substrates. For liquid effluents with high COD and low suspended solids content, high-load anaerobic UASB/EGSB reactors are sometimes used; however, in most industrial projects, CSTR ensures more stable operation with variable feedstock composition and the presence of solid impurities. A buffer tank is usually employed prior to feed into the reactor to average the flow, adjust temperature and pH, as well as homogenisation systems for stable substrate dosing.

The gas is purified to remove H₂S and moisture. As hydrogen sulphide levels in brewery effluent are usually moderate, a basic purification process is employed: activated carbon filters or other sorption solutions, followed by gas drying to protect gas pipelines and power equipment.

The gas is then used for combined heat and power (CHP) generation, simultaneously producing heat for the brewery’s operational processes, such as water heating, and meeting the facility’s own energy requirements. The biogas can also be fed directly into boilers in place of natural gas, thereby partially or completely replacing the use of fossil fuels.

All components are integrated into the SCADA and commercial metering systems, enabling monitoring of raw material feed, reactor temperature and load, as well as the composition and flow rate of biogas (CH₄, CO₂, H₂S), and the metering of generated electricity, heat and internal consumption.

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Your single partner for effective solutions

A systematic approach
from Pro-Energy

We provide a range of engineering and consulting services for project implementation. From concept to efficient operation of the plant using your raw materials and location.

More about the systematic approach

Our services:

Concept development and feasibility study
Project development and permits
Development of project documentation
Supply of technological equipment
Construction and installation
Start-up and commissioning works
Service maintenance

Biogas projects implemented

Generation of feed-in energy at an agricultural enterprise

Chernihiv region
The plant was put into operation: February 2022
More details
Biogas plants at breweries - photo 1 — pro-energy.com.ua
Project completed

Biomethane plant with a capacity of 750 Nm3/h of raw biogas

Khmelnytskyi region
Year of implementation: December 2023
More details
Biogas plants at breweries - photo 2 — pro-energy.com.ua
Project completed

Biomethane plant with a capacity of 600 Nm3/h of raw biogas

Ukraine, Chernihiv region
Commissioned: 2023
More details
Biogas plants at breweries - photo 3 — pro-energy.com.ua
Project completed

Why choose Pro-Energy?

We are committed to long-term partnerships!

More About us
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Many years of experience

We have been successfully operating in the bioenergy sector since 2014. We have the knowledge, experience and understanding of the specifics of working in the Ukrainian market.

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Unique partnerships

We have reliable partners. Therefore, we can offer solutions that will allow each project to reach its full potential.

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Reliable technologies

We use technologies with 90% availability for stable operation of installations, which guarantees efficiency and return on investment.

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Stable work

We do not leave our customers alone after commissioning the facility. We provide 24/7 technical support and remain available under any circumstances.

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Ready to discuss the implementation of your project?

Leave a request for a free consultation.





    Frequently asked questions

    What types of brewery waste can be converted into biogas? 


    The main raw material is beer grain, which is produced in large quantities. Brewer’s yeast residues, wash water from equipment cleaning, and expired beer are also used in biogas production. All of these waste streams are suitable for conversion into biogas, and the process itself helps to reduce the load on wastewater treatment plants.

    Is it worth comparing beer grain drying with a biogas plant?

    Yes, and a biogas plant is often the more economical and sustainable option. Beer grain drying requires large volumes of gas, and biogas plants produce it. Furthermore, the capital costs for a biogas plant may be on a par with those for drying, but the project offers additional benefits: energy independence and reduced CO₂ emissions.

    What type of reactor is best for beer grain? 


    The optimal solution is stirred CSTR reactors, which ensure stable operation with heterogeneous feedstock: beer grain, yeast, and sludge. For liquid effluents with high COD, high-load reactors (UASB/EGSB) may additionally be used as a separate treatment stage.

    What is the biogas yield from beer grain?


    Between 80 and 110 m³ of biogas can be produced from 1 tonne of beer grain, depending on moisture content, yeast type, and fermentation conditions. This makes biogas from beer grain a promising fuel that can fully or partially replace natural gas in industrial processes.

    Is a generator required for a biogas plant?


    Not necessarily. If the aim is to replace natural gas in the brewery’s boilers, it is sufficient to burn the biogas directly. This option significantly reduces the project cost, as the generator is the most expensive part of the system. At the same time, the payback period for the biogas production plant is shortened.

    What is the payback period for a biogas plant at a brewery?


    Typically 3–5 years, depending on the scale of production, the cost of energy sources, and the chosen model for using biogas. Against a backdrop of rising gas prices and carbon pressure on businesses, biogas plants in Ukraine are demonstrating an even faster payback period.

    Are there any examples of similar projects in Ukraine?


    Yes, Pro Energy has implemented several biogas plants at breweries, which operate successfully using beer grain and wastewater. We can provide case studies, their efficiency figures, and economic indicators — please contact us for a consultation to receive a presentation.

    Can beer grain be processed together with other types of waste?


    Yes, biogas plants can operate on mixed feedstock. For example, beer grain can be combined with food industry or agricultural waste to increase biogas yield. This approach optimises biogas production, increases plant flexibility, and allows for better adaptation to seasonal changes.