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Home SolutionsBiogas & Biomethane Biogas stations on silage

Biogas stations on silage

Do you grow corn? Turn it into electricity and heat. We design and build biogas plants on silage for agribusiness.

Without a biogas plant:

  • Problems with the grain market and product sales.
  • Dependence on energy sources.
  • Excessive expenditure on mineral fertilisers.
  • Dependence on logistics.
  • Unstable income from harvests.

With it, you get:

  • Converting silage into biogas and electricity.
  • Complete energy independence of the farm.
  • Our own organic fertiliser — digestate.
  • Biogas — energy that is easy to transport.
  • Stable energy profits.

When should you contact us?

01

You grow corn or other silage crops.

02

Energy autonomy is needed for agricultural enterprises.

03

You have land that is not used for food production,

04

You want to sell electricity.

About raw materials

Biogas plants on silage are one of the most efficient ways to produce biogas in Ukraine. The main raw material is corn silage, specially grown for energy needs. Biogas from corn silage has high calorific value and stable composition.

Among the most popular processing technologies are:

  • CSTR (continuous stirred tank reactor) — suitable for medium-sized plants;
  • HLR — high-load reactors with a dry matter content of 14–18%, used for working with concentrated raw materials.

 

A 1 MW biogas plant requires approximately 20,000 tonnes of silage per year. With a yield of 40–80 tonnes per hectare, this equates to 250–500 hectares of crops.
Such biogas plants in Ukraine enable farmers to diversify their sources of income, reduce their dependence on fluctuations in grain markets, and stabilise the energy supply of their farms.

Biogas stations on silage - photo — pro-energy.com.ua

Are you interested in the possibility of producing biogas from silage?

Request a free consultation, and our managers will provide comprehensive information on your questions.

Cooperation options:

  1. Turnkey development — from concept to launch.
  2. Raising funds for an agro-energy project.
  3. Partnership with investors and banks.
  4. Consulting on electricity markets.

Ways to recoup costs:

  • Sale of electricity.
  • Possibility of excess heat recovery.
  • Own consumption.
  • Replacing chemical fertilisers with organic digestate.

Biogas technologies for silage processing

For silo-based biogas plants, we recommend classic CSTR agricultural reactors with flexible covers and membrane gas holder roofs. For this raw material, the typical biogas yield is approximately 200 m³ per tonne of silage, which ensures stable and predictable generation.

Before feeding into the fermenter, the solid raw material undergoes preliminary preparation: grinding and homogenisation. Most often, a feeding-type feeding system or a moving floor is used, which we consider to be the optimal solution in terms of reliability and uniformity of loading.

Biogas from silage has a low H₂S content (up to ~50 ppm), so a simple gas treatment scheme is used: purification with activated carbon filters. Siloxane removal and special desulphurisation technologies are not required — the gas composition is stable and technologically “clean”.

The priority use of gas is electricity generation (CHP). Biomethane from silage is not accepted on the EU market, so upgrading is not feasible. At the same time, silage can be used as a co-substrate in projects involving the production of biomethane from other types of raw materials — in this case, biogas from silage is directed only to CHP for the energy supply of the complex.

All station components are integrated into SCADA and commercial accounting systems with full control of raw materials, fermentation process, biogas parameters, and electricity and heat production and consumption.

Click on the image to enlarge
Your single partner for effective solutions

A systematic approach
from Pro-Energy

We offer a range of engineering and consulting services to support 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
Commissioning and start-up operations
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 stations on silage - 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 stations on silage - 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 stations on silage - 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

    Is it possible to grow silage specifically for biogas production?

    Yes, this is common practice in the EU and Ukraine. Biogas from corn allows you to stabilise profits per hectare.

    What is the possible capacity of a biogas plant for 500 hectares of silage?

    With average yields of up to 2 MW. This is sufficient for the complete autonomy of a farm or commercial sale of energy.

    Which is better — CSTR or HLR?

    HLR (high-load reactors) are twice as efficient: they reduce the volume of the reactor, reduce costs, and provide stable results in the production of biogas from corn.

    Is special preparation of silage required?

    No, corn silage is a ready-to-use raw material. It has stable moisture content and high carbon content, making it ideal for biogas plants.

    Is certification possible for biomethane exports?

    Yes, we help prepare projects in accordance with European biomethane certification standards for export.

    What is the economics of a silage project?

    The payback period for a biogas plant on silage is 5–7 years. It depends on the technology chosen, the energy market, and the yield.

    Can silage be combined with other types of raw materials?

    Yes. Corn biogas is often combined with cattle waste or poultry manure to optimise the composition of the biomass.

    How much biomethane can be obtained from a tonne of silage?

    On average, up to 200–220 m³ of biogas from corn, of which 55–60% is methane. After purification, it becomes biomethane, suitable for export or refuelling vehicles.