Navigation : EXPO21XX > BIOENERGY 21XX > H01: Biogas Plants > BDI - BioEnergy International AG
BDI - BioEnergy International AG
  • Offer Profile
  • BDI develops technologies for energy generation from by- and waste products while ensuring maximum protection of resources at the same time. As the leading specialised plant manufacturer, BDI provides customised turnkey BioDiesel and BioGas plants using technologies that were developed in-house.

    Our philosophy: “From Waste to Value

Product Portfolio
  • BDI BioDiesel

  • The multi-feedstock technology from the market leader
    Our customised BDI BioDiesel facilities work on the basis of the multi-feedstock process that we developed.
    This process enables us to turn a wide range of raw materials – for instance used cooking oil, animal fats, trap grease or vegetable oil – into precious BioDiesel.
    This environmentally friendly, ecologically sustainable process yields high-quality BioDiesel that exceeds the most stringent quality standards worldwide, such as EN14214 and ASTM D6751.
      • BioDiesel Applications

      • Types of raw material
        The first years of BioDiesel production were characterised by the utilisation of renewable raw materials. However, faced with the constant increase in the worldwide demand for food, it became necessary to open up alternative sources of raw materials. In the meantime, BioDiesel production based on residual and waste products such as used cooking oils, animal fats and trap grease has established itself as the way forward – last, but not least, due to the BDI multi-feedstock technology that we keep evolving further. However, there is still a huge potential of unused raw materials out there that needs to be made accessible. BioDiesel production from waste materials thus fulfils two essential functions: safe waste disposal and energy production.

        Animal fats
        The utilisation of animal by-products that constitute hazardous materials in a legal sense entails additional official procedures and monitoring and control mechanisms at the plant. Using BDI multi-feedstock technology also enables you to utilise hazardous materials (category 1 and 2 animal fats) in BioDiesel production. The EU has permitted this use in a regulation dating from 2005.

        Used cooking oil
        In addition to animal fats, used cooking oil is also available in large quantities, with every household producing several kilograms of used cooking oil every year. However, only 5-10 percent of this amount is collected for further processing in a structured way. By far the largest share is disposed of via the sewage system, causing problems for purification and waste water treatment plants. The potential for producing high-grade BioDiesel from used cooking oil thus remains enormous.

        Trap grease
        Wherever cooking fats or oils are used – for instance in large-scale kitchens, restaurants or supermarkets – oil may be filtered as a precious raw material from waste water. To do this, a grease trap must be installed at a point where it stops the fat from entering the sewage system. Where specialised technologies are used, the collected grease is excellently suited for producing high-grade BioDiesel while also solving what is a genuine waste problem for many municipalities.
      • BioDiesel Technology

      • BDI is the market and technology leader in the construction of customised BioDiesel plants based on the multi-feedstock procedure that we developed. This patented technology allows us to turn a wide range of raw materials such as animal fat, used cooking oil, trap grease and vegetable oils into high-grade BioDiesel that exceeds the most stringent quality standards such as EN14214 and ASTM D6751. This technology imposes no restrictions in terms of FFA content – the entire content of free fatty acids is turned into BioDiesel, allowing for yields of up to 100%. The unique flexibility in the use of raw materials, the highest possible yield, the quality of the product, the low operating and maintenance costs and the well-known reliability of BDI plants ensure the highest level of economic viability.

        No restrictions for FFA
        For the processing of raw materials with a particularly high content of free fatty acids, BDI has developed its RepCat technology. This highly innovative process allows for the processing of raw materials with an FFA content of up to 100%. A further benefit that distinguishes RepCat from other industrial processes is that it yields a completely saline-free glycerine grade with a minimum glycerine content of 95%, achieved through the complete recycling of the catalyser. The glycerine thus produced is a highly sought-after, easily marketable product used in a wide range of applications in other industries.

        Technological competitive advantages
        • Maximum flexibility in terms of raw materials – no restrictions regarding FFA content
        • Highest possible yield
        • No waste accumulated during the process – only reusable by-products
        • Exceeds all current and future quality standards
        • Many years’ global experience in large-scale industrial applications
      • BioDiesel References

      • During the last two decades, BDI has planned and constructed more than 30 large-scale industrial BioDiesel plants on four continents. By using our multi-feedstock technology, our customers are able to produce high-grade BioDiesel with a wide range of different raw materials that fulfil highly diverse industrial requirements. Our comprehensive after-sales service ensures long-lasting customer satisfaction.

        BioDiesel plant Argent (Stanlow, UK - Phase 1)
        Overall planning, delivery, construction of start up of High – FFA – Esterification for the production of methylesther phase
        • Technology: High – FFA – Esterification
        • Commissioned in: 2015
        • Capacity: 75.000 tons of BioDiesel per year
        • Feedstock: High – FFA - feedstock (e.g. trap grease, animal fat Cat 1)
        • Products: Methylester phase as intermedia product for BioDiesel production

        BioDiesel plant Amsterdam (Netherlands)
        „The largest multi-feedstock BioDiesel plant worldwide“

        • Customer: Biodiesel Amsterdam
        • Commissioned in: 2010
        • Capacity: 100,000 tons of BioDiesel per year
        • Raw materials: used cooking oil, animal fats, PFAD
        • By-products: glycerine (80%), solid fertilisers

        Other BioDiesel projects
        • 2014, Amsterdam (NL) - 150.000 t/a
        • 2013, Le Havre (FR) - 75.000 t/a
        • 2013, Hongkong (HK) - 100.000 t/a
        • 2008, Løsning (DK) - 50.000 t/a
        • 2008, Barnawartha (AUS) - 50.000 t/a
        • 2006, Vienna (AUT) - 140.000 t/a
        • 2005, Motherwell (SCO) - 50.000 t/a
        • 2002, Barcelona (ESP) - 31.000 t/a
        • 1998, Butler, KY (USA) - 5.000 t/a
    • BDI BioGas

    • The solution for industrial and communal waste
      The special BDI BioGas technology is intended for industrial and municipal users. A wide range of starting materials may be used in the process, such as organic waste or by-products from the food or biofuel industry.
      The reliable, stable bio-technological process and the compact size of the system allows for industrial BioGas production that is characterised by the highest possible level of profitability.
        • BioGas Applications

        • Industry
          Every industrial plant produces residual and waste products, for instance waste from slaughterhouses, stillage from the ethanol industry, brewers’ grains or residue from animal farming, such as nitrogen-rich waste from chicken farms.

          Raw materials / substrates:

          • Slaughterhouse waste
          • Distillation residue
          • Mucilage
          • Glycerine phase
          • Brewers’ grains
          • Sugar beet chips
          • Expired food
          • Residue from vegetable and fruit production
          Municipal waste is worth more than you think! By using BDI BioGas technology, you can process your municipal waste products and produce precious energy at the same time. This way, you will be able to prove to the citizens of your municipality that you are actively striving for solutions to municipal waste disposal issues while adding value to your region at the same time.

          Raw materials / substrates:

          • Organic waste
          • Kitchen waste
          • Expired food products
          • Organic waste from the catering and commercial
          • sector
          • Industrial waste and residual products
          • Green waste
          • Agricultural waste

          With a BDI BioGas plant, you will be able to utilise regulatory framework conditions that have been defined for the long term, guaranteed feed-in tariffs for electricity and the manifold possibilities of newly liberalised energy markets. Furthermore, your investment will make a precious contribution to environmental protection and sustainability.
        • BDI BioGas Technology

        • Substrate Management
          BDI BioGas technology enables us to produce high-grade BioGas from any kind of organic waste and residual material. In addition to any desired mixture of different raw materials, our technology is also capable of processing a single type of raw material, without adding further substrates.

          Anaerobic fermentation & BioGas treatment
          Our highly developed BDI BioGas technology is especially intended for BioGas production from a wide range of different, sophisticated industrial and municipal waste products that are available all year round. We guarantee the highest possible level of efficiency for any starting material, thus also ensuring extremely high profitability.

          Fermentation residue processing & waste water purification
          Fermentation residue is a precious by-product of the fermentation process that may be further processed into clean water and fertiliser. The separation is performed by the BDI fermentation residue processing technology where the liquid content is treated in the membrane-bio reactor (MBR) system to yield clean water.

          Energy conversion
          BioGas from reused material is a flexible source of energy and may be used for the following applications:
          • Production of electricity, steam and hot water by means of a combined heat and power unit
          • Production of heat for local supply
          • Purified bio-methanol that may be fed into the gas grid or used as a bio-fuel for vehicles

          • Customised, complete industrial solutions Implemented by a reliable, professional plant construction expert
          • Continuous, permanent operation
            No deposit of settling sediments (e.g. sand, glass etc.) in the system
          • Low operating cost, high flexibility in terms of raw materials
            No chemical additives, even the highest nitrate values in the substrate are admissible
            High degradation rate and fast gas production Patented fermenter design to support optimum contact between the substrate and micro-organisms. Prevention of foam formation and floating layers.
        • BioGas References

        • As a specialist in the processing of industrial and municipal waste and residue products, BDI has demonstrated its overall competence, from engineering all the way to plant construction, in numerous international BioGas projects.
          All BioGas plants realised by BDI display a high level of process reliability and thus also year-round availability.

          BioGas plant Göss
          • Start of construction: Spring 2015
          • Handover: Beginning 2016
          • Capacity: Steam boiler: 0,71 MWth
          • CHP: 0,45 MWel; 0,47 MWth
          • Substrates: spent grain: 18.300 t/a
          • surplus yeast: 1.450 t/a
          • filtration sludge: 900 t/a
          • Substrate volume: 20.650 t/a
          • Products: BioGas, electricity & heat, high-value digestate
          • BDI´s Scope: engineering, project management, plant construction, commissioning, after-sales service, plant operation
          • CO2 reduction: 1.257 t/a resulting from substitution of natural gas in the brewery

          Other BioGas projects

          • Pamukova, Turkey – planning and construction of the overall plant
          • Podlasie, Poland – planning and construction of the overall plant
          • Etampes, France – planning and construction of the overall plant
          • Marl, Germany – planning and construction of the overall plant
          • Este, Italy – planning and construction of the overall plant
          • Portland, Oregon, USA – statutory engineering approval procedures
          • Benet, France – Planning and delivery of the waste separation facility

      • BDI RetroFit

      • Plant optimisation from the technology leader
        BDI can improve and optimise your existing BioDiesel plant: the BDI RetroFit programme was developed especially for existing large-scale facilities and increases flexibility in terms of raw materials as well as improving the quality of the BioDiesel.
        After implementing the programme, low-grade raw materials such as cooking oils, animal fats and trap grease can also be used.
        BDI BioDiesel distillation ensures that the quality of the produced BioDiesel remains constantly high even when using low-grade raw materials.
          • RetroFit applications

          • Quality requirements for BioDiesel are becoming more stringent all the time – due to more demanding legal specifications on the one hand and increasingly sophisticated customers on the market on the other. This constitutes a great challenge for BioDiesel plant operators. Rising prices for highly refined plant oils and the deteriorating quality of cost-efficient residual and waste products mean that highly flexible technologies are now required to process a broad, wide-ranging mix of raw materials. Of course, we are also seeing a stronger political willingness to make the energy supply sector more independent, to process waste and residual products into clean energy and to become more “green” in a sustainable manner.

            BioDiesel quality
            At the moment, the entire BioDiesel production sector must conform to international quality standards such as EN14214 and ASTM D6751. In addition, plant operators should also start preparing for even more stringent parameters in future. For plants using obsolete technology, having to live up to high quality criteria may have a negative effect on yield, plant capacity or raw material flexibility.

            Maximum yield
            Your plant should be able to process 100% of your raw materials into high-grade BioDiesel, without using precious triglycerides and free fatty acids during the process.

            Nominal capacity
            If you wish to fully utilise the potential of your investment, your plant should definitely achieve the nominal capacity that you paid for.

            Flexibility in terms of raw materials
            Technologically obsolete plants require highly refined, expensive plant oils for their operation.
            State-of-the-art plants, on the other hand, are able to operate at least partially or even exclusively with lower-cost raw materials such as used cooking oils, trap grease or low-grade animal fats

            Reusable by-products
            With a state-of-the-art plant, you will be able to generate additional yields – for instance with high-grade glycerine – while obsolete plants produce waste products such as filter material, soap stock and free fatty acids

            Plant availability
            Your plant should run using a stable, robust process all year round.
            Unwanted downtime will cause unforeseeable losses.

            Operating material
            Obsolete plants require pricy sodium methanolate as a catalyst – new plants run on much cheaper operating materials.

            Plant safety
            Health and safety standards for plants are becoming more and more stringent all the time.
            Only state-of-the-art facilities live up to existing and future safety standards and guidelines.
          • RetroFit Technology

          • Every BioDiesel plant is unique. For this reason, one-fits-all solutions to improve individual parameters such as yield, product quality or flexibility in terms of raw materials are not productive.
            For optimum results, a customised overall concept needs to be developed for each plant and only those technological solutions be implemented that best fit the individual facility.
            No one does this better than BDI: building on our experience gained in more than 30 realised BioDiesel plants using our own technology, we are able to identify and optimise the correct individual elements to make a successful whole.
            The result – sustainable improvement of your plant performance.

            Process optimisation
            In many cases where quality requirements and capacity volumes are not complied with, this failure is due to the fact that the basic layout of the technology does not reflect all framework conditions in the best possible manner.
            As we have a wide range of BioDiesel technologies available, there are countless possibilities for process optimisation – from adjustments in the use of operating materials all the way to the complex integration of new process steps – a great many things may be done.

            Preparation of raw materials
            To be able to use raw materials of different qualities for BioDiesel production, it is necessary to remove components that hinder and inhibit the process. The wide range of different raw materials such as vegetable oils, used cooking oil, animal fats and trap grease means that there is a broad spectrum of products available for preparing these materials.

            To comply with increasingly stringent, essential parameters in the current BioDiesel standards – for instance monoglycerine content, overall contamination or sulphur content – it is often necessary to install a downstream distillation column.
            Based on the know-how that we have accumulated over the years, BDI has developed several different distillation options.

            High FFA esterification
            Raw materials with a high content of free fatty acids (more than 20%) cannot be processed into standard-compliant BioDiesel without the appropriate pre-treatment. BDI has developed a process for this that allows for the utilisation of raw materials with a free fatty acid content of up to 99%, for instance distilled palm fatty acids (PFAD), animal fats and trap grease. This entails several benefits for plant operators, for instance the opening up of new sources of raw materials, lower overall raw material costs and the use of fewer chemicals.

            Glycerine distillation
            Glycerine is a by-product of BioDiesel production with a standard purity of 80%. By means of additional processing steps, it can be turned into a higher-grade product that is a great deal more profitable on the chemicals market as it is used in a number of technical and pharmaceutical applications. Depending on customer specifications and the raw material used, BDI is able to upgrade glycerine into technical glycerine (purity content from 98.5%) according to the pharmacopoeia.
          • RetroFit References

          • Based on our many years’ experience in BioDiesel plant construction, BDI is able to identify improvement possibilities in any existing plant and to draw up and implement appropriate solutions. Ever since the introduction of the RetroFit programme, BDI has proved this competence in numerous fully implemented projects, making plants with highly different underlying technologies all over the world fit for the future.

            Key facts reference plants

            Location: Bakersfield
            Customer: Crimson Renewable Energy L.P. / Bakersfield
            Location: Bakersfield
            Implemented in: 2014
            Underlying technology: BDI multi-feedstock
            Scope: BioDiesel purification step, Installation of by-product treatment
            Result: Improve of BioDiesel and glycerine quality, Implementation of new by-product (fertilizer)
            Delivery of process vessels and tricanter
            Increase of profitability with high quality materials

            Location: Scotland
            Customer: Argent Energy
            Implemented in: 2011
            Underlying technology: BDI multi-feedstock
            Scope: implementation of raw material preparation and “High FFA” esterification
            Result: use of cheaper raw materials, capacity expansion, improvement of profitability

            Other RetroFit projects

            2011, Renewable Energy Group (REG) – implementation of new transesterification and BioDiesel washing process
            2011, Barcelona, Spain – new phase separation unit for glycerine processing
            2011, Lünen, Germany – sulphur reduction unit
            2011, Altorricon, Spain – BioDiesel distillation
            2010, Malchin, Germany – modification of process control system
            2009, Arnoldstein, Austria – waste water treatment plant
            2005, Malchin, Germany – sulphur reduction unit
        • BDI bioCRACK

        • BDI bioCRACK process – a globally unique refinery integrated biomass-to-liquid concept for 2nd generation biofuels

          This innovative bioCRACK technology was significantly boosted between 2010 and the present due to the cooperative collaboration between OMV (Location Schwechat) and BDI. OMV supported the project with resources and post processing as well as the valuation of the liquid raw products. The scientific monitoring happened by the Institute of Chemical Engineering and Environmental Technology (CEET) of the Technical University Graz (processing of byproducts). An experimental approach was realized with the construction of a pilot plant for diesel production in the refinery Schwechat and its operation of several years.
            • bioCRACK - Technology

            • In the patented bioCRACK process, with the help of liquid phase pyrolysis in a hot carrier oil with temperatures of up to 400°C and atmospheric pressure due to pyrolysis reaction the solid biomass (e.g. Wood or straw) is transformed in short-chain hydrocarbons. Due to the interaction between biomass and carrier oil, hydrocarbons with high hydrogen saturation arise which originate from the carrier oil as well as from the biomass. This innovative approach only gains on economic importance due to a decisive technical detail. The carrier oil is replaced by a cost effective intermediate product from the oil refinery (vacuum gas oil – VGO) at the bioCRACK process. This intermediate product is not directly usable as fuel because at room temperature it shows a similar consistency as margarine. In a refinery, the VGO has to be devided and processed under high temperature and pressure with help of a fluidised bed cracker (FCC). With this treatment the VGO is transformed in Diesel only in low parts but more in short-chained petrol, which in Europe can’t be settled in this amount and has to be exported. BDI provides this unique service for mineral oil companies to produce 2nd generation biofuels.

              Advantages of bioCRACK
              • feasible with little technical effort and cost effective to operate
              • high feedstock flexibility and quick to apply
              • synergy effects between BtL-technology and conventional mineral oil industry
              • the end product can be fed into refinery directly
              • the product can, with an existing refinery unit, be implemented into a diesel-like fuel phase with biogenic share, which meets the existing diesel fuel standard EN590
              • through existing distribution channels the produced fuel can directly reach the users/consumers – without adaption of the distribution network
              • verifiable GHG savings of significantly more than 83% according of to a study of the Joanneum Research, 2015
              • the by-products like lean gas and pyrolysis products (pyrolysis oil, coal) can be utilized energetically or be enhanced into valuable products
            • bioCRACK - References

            • Cooperation with Austrian mineral oil company OMV

              • Cooperation with Austrian Mineral oil company OMV
              • Pilot plant fully integrated in OMV refinery
              • Project duration: April 2012 – End 2014
              • Service cost: € 7 Mio (state-subsidized by Austrian Climate & Energy Fund)
              • Raw materials: lignocellulosic biomass, VGO
              • Input capacity: 2,4 t biomass/d
              • Output capacity: 500 t raw diesel/a
              • Products: raw diesel, bio-char, bio-oil