Innovative technology
vapocircle technology
A holistic agricultural cycle for biogas production & refinement with own mineral fertilizer production
Our new patented VapoCircle technology makes it possible to generate your own electricity and heat as required and to produce your own mineral fertilizer.
The problem & the solution
Electricity or fuel from renewable energies is not always available exactly when it is needed. These fluctuations often occur when using renewable energies – wind turbines produce electricity as soon as the wind blows and solar panels as soon as the sun shines.
These fluctuations mean that at certain times there is either too much or too little electricity in the grid. This is where the great advantage of the regenerative storage power plant comes into play.
A regenerative storage power plant offers a combination of power plant and energy storage. It produces electricity and heat on demand – exactly when it is needed.
The electricity generated can be fed into the public grid at times of high prices, thus generating higher revenues and improving the economic efficiency of the system.
Gas refinement
The producer receives income from various areas, including the basic remuneration under the EEG or the flex premium.
With the EEG 2021, support for flexibilization is still possible. The flexibility requirements stipulate that flexibilized biogas plants must call up at least 85% of their installed capacity for at least 1,000 hours per year (4,000 quarter hours).
The producer has several individual or a combination of several of the following options for gas upgrading:
The producer decides whether the gas is fed into the gas grid or sold through direct marketing by trading the electricity directly on the exchange.
Another benefit for the producer is the use of heat through a large buffer storage tank for their own farm buildings and other consumers such as entire heating networks for several households.
It is also possible to feed the electricity generated into the public grid as required and thus take advantage of the high prices.
Producers have the opportunity to use biomethane as a fuel and thus save a large amount of CO2 compared to conventional fuels. By using these low-carbon energy sources, a reduction in greenhouse gas emissions into the atmosphere is achieved.
Mineral oil companies can credit the CO2 that producers save on fuel to their own carbon footprint by purchasing CO2 certificates.
The producer chooses whether to produce either electricity or fuel or a combination of both (hybrid power plant).
The fermentation section
VapoCircle technology combines the advantages of the Returgant Direct and the Vapogant.
The combination of the Returgant Direct with the Vapogant digestate evaporation system makes it possible to achieve above-average gas production with small tanks. The Returgant Direkt biomass recirculation filter ensures complete fermentation of the input materials, resulting in a higher gas yield.
The additional gas yield is further increased if ultrasonic treatment is carried out by the WaveBox downstream of the Returgant Direct. Evaporation achieves a volume reduction of up to 70 % of the annual volume. The liquid phase can be thickened to up to 20 % dry matter.
The heat recovery and multiple use of the heat for the Vapogant fermentation residue evaporation also provides an energy-efficient advantage.
What is Farm AS?
Farm AS is colloquially known as ASL (ammonium sulphate solution) which can be produced by farmers themselves. Farm AS is a clear, colorless mixture and, depending on the concentration, has a nitrogen content of up to 8.5% (=100% ammonium nitrogen). depending on the concentration.
Farm AS as a fertilizer improves humus formation by stimulating the activity of soil organisms. In the soil, Farm AS is bound to clay minerals and humus, which prevents leaching.
The targeted use of Farm AS as a depot fertilizer is achieved using the Cultan process. By applying it directly into the soil, a reduction in nitrogen loss is achieved, which would otherwise be caused by leaching and outgassing.
A maximum plant-effective fertilizer is produced, with which a maximum yield can be achieved.
Mineral fertilizer production
Farmers can produce their own Farm AS mineral fertilizer in combination with a biogas plant using VapoCircle technology. This makes it possible to use nitrogen fertilizer in excess of the 170 kg N limit. Farm AS is a valuable commercial fertilizer and can also be sold if there is a surplus. The Vapogant fermentation residue evaporation system enables the fermentation of substrates with an increased ammonia/nitrogen content (including gas) that were previously classified as difficult. Through intelligent crop rotation and the use of legumes, the mineral fertilizer requirement can be covered from the farm’s own fodder cultivation and, in addition, approx. 40% farm AS can be sold to farmers who grow market crops, for example.
But how should the fertilizer be applied and how do the minerals ultimately reach the plant?
With the CULTAN process(Controlled Uptake Long Term Ammonium Nutrition), the plant is supplied with concentrated nitrogen through a fertilizer depot in the soil to guarantee long-term nutrition.
The roots grow towards the depot. This results in better and denser root development and the plant can store larger water reserves.
Advantages of VapoCircle technology
Advantages for the farmer/producer
- no competition between milk producers and biogas producers,
- Organic slurry upgrading
- Own mineral fertilizer production Farm AS
- Improving the fertilizer balance by releasing or converting nutrients
- Better flowability through fermentation and separation
- Saving storage space
- Utilization of surplus feed, e.g. grass silage
Benefits for the environment
- Nutrient hub
- Humus build-up
- Less ammonia pollution for the environment
- Improvement of the CO² balance through energetic use of liquid manure
- Sensible use of methane from liquid manure
- Closed transport
Benefits for the population
- CO2 storage
- Low odor pollution during transport and application
- Sustainable concept
- Secure energy supply on site
- Avoiding the “plate-tank conflict”
- Satisfying the hunger of mankind
In order to provide mankind with sufficient food, not only can crops be harvested, but they must also be fertilized intensively. Until now, mineral fertilizer has mostly been produced using a process dating back to the First World War (Haber-Bosch). In order to produce mineral fertilizer industrially, a lot of expensive natural gas is required.
At best, Farm AS is produced in agriculture with a lot of grassland, the surplus of Farm AS can then be used in agriculture for market crops (e.g. wheat) for targeted fertilization with Farm AS.
Short & sweet
With the help of the regenerative storage & fuel power plant, farmers can sustainably utilize their waste materials such as grass silage, liquid manure and liquid manure press cake.
Producers feed electricity into the grid and thus contribute to security of supply.
Fuel is produced from biomethane. This can be used by customers and CO2 certificates can also be sold to oil companies.
Thanks to VapoCircle technology, it is possible to produce your own FarmAS mineral fertilizer, which can even be sold if there is a surplus.
The regenerative storage power plant and the regenerative fuel power plant make it possible to generate electricity and heat on demand and produce your own mineral fertilizer!
