The rise of biogas production in modern, sustainable farms

Farmers around the world are turning to biogas production as a sustainable solution to manage agricultural waste and generate renewable energy. However, common issues such as high operational costs, inefficient digestion processes and handling large volumes of digestate often affect optimal performance. HRS offers advanced systems, built to address these challenges, enhancing efficiency, reducing costs and maximizing energy recovery in anaerobic digestion systems.  

 

 

How to choose the right systems for your farm? 

 

Choosing the right biogas systems for your farm is a really important decision that directly impacts operational efficiency, environmental compliance and profitability. With multiple options available, understanding your specific requirements and the capabilities of various technologies is essential. Here’s a guide to help you make an informed decision: 

 

1. Assess your feedstock

 

Start by evaluating the type and quantity of organic waste generated on your farm. Different feedstocks have unique biogas yields and require specific handling systems: 

 

• Livestock farms: Focus on manure-based systems, as animal waste is a rich source of biogas. 

• Crop farms: Systems optimized for silage, crop residues and other plant-based materials are ideal. 

• Mixed feedstocks: For farms producing a variety of organic waste, a flexible system like the HRS Digestate Concentration System (DCS) ensures optimal performance across multiple inputs. 

 

2. Determine your energy and waste management goals

 

Clearly define your list of priorities: 

 

• Energy production: If your primary goal is to generate electricity or thermal energy, focus on systems like the HRS Biogas Dehumidification System (BDS), which maximizes biogas quality for use in Combined Heat and Power (CHP) engines. 

• Nutrient recovery: Farms aiming to create high-quality bio-fertilizers should prioritize digestate concentration systems like the HRS DCS. 

• Waste volume reduction: If reducing waste handling costs is a priority, opt for systems that minimize digestate volume while retaining nutrient value. 

 

3. Understand system scalability

 

The size and scale of your farm will influence your choice: 

 

• Small to medium farms: Look for compact, skid-mounted systems that are easy to install, operate and maintain. 

• Large farms: High-capacity systems with multi-effect evaporation, such as the DCS, ensure efficiency while handling significant waste volumes.

 

4. Ensure compliance with regulations

 

Adherence to environmental and health standards is non-negotiable: 

 

• Pasteurization requirements: For farms using animal by-products, the HRS Digestate Pasteurisation System (DPS) ensures compliance with global standards, including PAS110 and ABPR. 

• Odor and emission control: Systems with integrated dehumidification and heat recovery minimize environmental impact and improve community relations. 

 

5. Budget and ROI considerations

 

Finally, consider the total cost of ownership and return on investment (ROI): 

 

• Systems like the HRS DCS and DPS deliver significant savings by reducing waste handling and energy costs, often achieving ROI within a few years. 

• Look for government incentives or subsidies to offset upfront investment costs. 

 

By carefully considering these factors, you can select a biogas system that aligns with your farm’s unique needs, ensuring maximum efficiency, regulatory compliance, and long-term profitability. If you’re unsure where to start, consult with our experts to design a system tailored to your farm’s requirements. 

 

 

HRS Solutions to boost biogas efficiency 

 

The HRS systems are designed to optimize every stage of the anaerobic digestion process:  

 

• Energy recovery: Systems like the BDS and DCS incorporate heat recovery to reduce energy consumption.   

• Efficient waste management: By concentrating and pasteurizing digestate, farmers reduce waste volumes and create valuable by-products.  

• Long-term durability: HRS solutions are built to withstand harsh conditions, ensuring reliable performance with minimal maintenance. 

 

1. Biogas Dehumidification Systems (BDS)

 

Biogas often contains water vapor, which, if left untreated, can lead to corrosion and inefficiency in combined heat and power (CHP) engines. The HRS Biogas Dehumidification System (BDS) removes more than 90% of the water content by cooling biogas from 40°C to 5-7°C. 

 

Key benefits: 

 

• Extends the lifespan of CHP engines by preventing corrosion and cavitation. 

• Reduces energy costs with up to 20% heat recovery. 

• Skid-mounted for easy installation and designed for flows from 150-1,700 kg/h. 

 

This system protects expensive equipment, ensuring long-term savings and operational efficiency for farmers. 

 

2. Digestate Concentration Systems (DCS)

 

Digestate, the by-product of biogas production, poses storage, transportation and disposal challenges due to its high water content. The HRS Digestate Concentration System (DCS) reduces digestate volume by up to 80% using multi-effect evaporation. 

 

Key benefits: 

 

• Reduces costs for storage, transport and disposal. 

• Increases nutrient concentration, creating a high-value fertilizer. 

• Creates a closed-loop system by reusing water and heat from the process. 

 

Farmers benefit from lower operational costs and an additional revenue stream through concentrated digestate products. 

 

3. Digestate Pasteurization Systems (DPS)

 

To meet regulatory standards and enhance the value of digestate, pasteurization is essential. The HRS Digestate Pasteurization System (DPS) ensures the removal of pathogens and compliance with global standards such as PAS110. 

 

Key benefits: 

 

• Up to 60% heat regeneration for energy efficiency. 

• Batch reporting for complete traceability. 

• Flexible configurations tailored to individual operations. 

 

By pasteurizing digestate, farmers can meet strict environmental standards while creating safe and marketable products. 

 

 

A sustainable future for farmers 

 

Biogas production reduces waste and aligns with global sustainability goals. By implementing advanced HRS technologies, farmers can enhance the efficiency of their AD plants, cut costs and unlock new revenue streams, making biogas a profitable and eco-friendly solution. 

 

For a tailored solution that meets your farm’s specific needs, contact us and schedule an audit.