The biogas industry is booming – but while large plants have long been trimmed for efficiency, small plants often fall short of their potential. Yet process measurement technology in particular can make a big difference in small biogas plants: economically, ecologically and technically.
Small biogas plants – big challenges
Operators of small biogas plants face their own unique hurdles. Firstly, low margins: yields are limited, while operating costs are relatively high. In addition, there is irregular substrate quality: different biomasses lead to fluctuating gas production. And hardly any monitoring: without technology, problems often go unnoticed for a long time.
Process measurement technology is often seen as an expensive additional option – wrongly, as it turns out.
What exactly is process measurement technology?
Process measurement technology includes Measuring and monitoring systemsthat precisely monitor the biological and technical processes in a biogas plant. Typical components include sensors for gas analysis (methane, CO₂, H₂S), level meters in the fermenter, pH and temperature sensors, online measurement of organic acids and flow meters for substrates and gas.
This technology provides real-time data on the basis of which well-founded decisions can be made.
Why process measurement technology is particularly worthwhile for small systems
Greater efficiency – more yield with less input
With precise data on the gas composition, the feeding of the fermenter can be optimized. This means less substrate use, more gas production and lower costs.
With small systems in particular, every improvement has an immediate impact on profitability.
Early warning of faults
Whether acid formation, temperature drop or sulphur problems – sensors detect anomalies at an early stage. This prevents production downtime and expensive repairs.
More transparency – less bureaucracy
Funding programs and legal requirements increasingly demand documented operating data. Process measurement technology automatically provides the necessary evidence – reliably and quickly.
More flexibility in substrate use
Those who measure precisely can react quickly and specifically to changes – be it due to seasonal biomass or fluctuating substrate quantities.
This makes small systems adaptable and future-proof.
Modern technology – specially developed for small systems
Today, there are customized solutions that are also suitable for smaller budgets, for example a low-cost entry-level solution with just a few sensors, a modular design for later retrofitting and cloud systems with access via smartphone or laptop.
Ideal for operators who have little time or do not have in-depth technical knowledge.
Practical example: A farmer relies on measurement technology
An operator of a 150 kW biogas plant installed simple sensors for gas and temperature monitoring.
The result:
- +10 % methane yield
- -8 % Substrate costs
- Amortization after less than one year
Clear proof that even small measures can have a big impact.
Challenges and how to overcome them
Of course, there are also hurdles – but they can be overcome. On the one hand, there are the acquisition costs: subsidies or leasing models create financial leeway. But also an understanding of the technology: training and support from providers make it easy to get started.
Nobody has to master the technology alone – support is there.
Small technology, big benefits
Process measurement technology is not a luxury, but a necessary investment in the future of small biogas plants. It improves efficiency, lowers costs, reduces environmental pollution – and brings transparency to operations.
Those who measure wisely today can operate sustainably tomorrow – and show that even small systems can make a major contribution to the energy transition.
