Plant construction & technology
ENGINEERED FOR PERFORMANCE

With more than 400 planned and built biogas plants in 27 countries on five continents, WELTEC is a biogas pioneer with proven expertise. Our strength lies in our ability to provide individual, technically sophisticated solutions. Our high proportion of self-developed components and consistent use of stainless steel technology guarantee flexible substrate use, quick assembly, and consistently high quality standards, regardless of location.

Biogas process
Overall concepts from substrate input to gas utilization

WELTEC BIOPOWER takes a holistic approach to biogas plant construction, handling the technical integration of all process steps throughout the entire production process. This includes integrating the substrate feed, digestion in the anaerobic digester, and connecting the various applications for the biogas and resulting digestion residue. This ensures a fully optimized, efficient turnkey plant.

Substrates

Biogas plants recycle a wide range of organic waste materials and convert them into valuable renewable energy.

Preparation

Before solid substrates are used for the fermentation process, they must be prepared.

Contribution

Processed substrates are controlled and continuously introduced into the stainless steel tank.

Pre-storage

Sufficient upstream storage capacity is crucial for flexible plant operation.

Fermentation

The actual biogas process takes place in the fermenter.

Gas utilization
Electricity, heat or biomethane
& CO2

There are a variety of ways to upgrade the biogas produced: generating electricity in a combined heat and power plant (CHP), processing it into biomethane for feeding into the grid, or using it as fuel. WELTEC will plan for optimal gas utilization according to your energy and economic goals. While turning biogas into biomethane of natural gas quality, CO₂ is created as a by-product. This CO₂ can be extracted, processed, and used in various ways, such as in the food industry for soda water, as a refrigerant in cooling systems, or to fertilize greenhouses.

WELTEC BLUE WATER
Nutrient management & digestate treatment

WELTEC BLUE WATER separates manure and digestion residues into valuable products: high-quality solid and liquid fertilizers as well as purified water for irrigation or process use. The volume reduction through water separation significantly reduces transport and storage costs. Economical starting at 50,000 tons per year.

WELTEC CONTROL
Take full control of your biogas plant.

The web-based WELTEC CONTROL software gives operators quick access to all relevant system parameters. The individually configurable dashboard allows you to monitor important process data at all times, even on the go, with simultaneous access for multiple users. From energy planning to exportable reports for authorities, intuitive control ensures maximum transparency and efficient work processes.

Any more questions?
our answers

The most important questions and answers at a glance. We are always there for you personally for individual concerns.

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WELTEC plants are designed for a wide range of organic waste materials: from municipal organic waste, food waste and food waste to industrial waste such as spent grain, slurry or glycerin to agricultural substrates such as manure, manure and energy crops. Each system is individually tailored to the available substrates and their properties.

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Economic efficiency depends on several factors: substrate availability, plant size, gas utilization (electricity, heat, biomethane) and regional conditions. WELTEC prepares a detailed profitability calculation for each project and supports you with funding applications. Many investments pay for themselves within a few years.

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It usually takes 12 to 24 months from planning to commissioning — depending on project size, approval process and individual requirements. WELTEC takes care of the entire project management: from approval to construction to training of your operating personnel.

What happens to the fermentation residues after fermentation?

The fermentation residues are hygienised, rich in nutrients and are ideal as organic fertiliser in agriculture. They contain valuable nutrients such as nitrogen, phosphorus and potassium and can replace chemical fertilizers. This is how the cycle is closed sustainably.

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Yes, WELTEC will also support you over the long term: We offer comprehensive service contracts, technical support, spare parts supply and remote monitoring of your system. Our goal is trouble-free, economical continuous operation — worldwide.

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Absolutely. WELTEC analyses existing plants and develops concepts for increasing performance, expanding substrates or optimising gas utilization. Modernization of outdated technology is also part of our range of services.

Feel free to contact us directly!

+49 (0) 4441 99978-0
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