Process Optimisation in Biogas

Specialising in process optimisation for anaerobic digestion and biogas facilities across the UK. With extensive hands-on experience in plant performance improvement, we apply data-driven strategies and technical expertise to increase gas production, reduce operational risks, and boost overall efficiency.

A computer monitor displaying a schematic diagram of a biocontrol system, with an industrial setting including pipes, machinery, and equipment in the background.

Maximise Biogas yields, enhance efficiency and improve reliability.

Feedstock Optimisation

Optimising feedstock is the foundation of efficient biogas production. Our service includes:

  • Comprehensive feedstock analysis to assess biogas potential and consistency

  • Nutrient balancing to maintain ideal ratios of macro and micronutrients

  • Pre-treatment strategies to improve digestibility and gas yields

  • Feedstock blending advice to optimise stability, throughput, and energy output

Biogas feedstock being ejected from feeder

Biological Stability

Maintain a healthy and resilient digestion process. We monitor and maintain the biological health of your AD plant to avoid costly process upsets:

  • Continuous monitoring of key indicators: VFAs, alkalinity, pH, and ammonia

  • Microbial population assessments to ensure biological resilience

  • Early warning systems for identifying instability before it impacts performance

  • Rapid intervention protocols to restore balance and minimise downtime

Gas Production Maximisation

A reliable plant is a profitable plant. Our proactive support includes:

  • Predictive maintenance planning using tools like vibration analysis and thermal imaging

  • Critical spares analysis to reduce response time and risk of extended downtime

  • Equipment standardisation to simplify maintenance and streamline spare parts management

  • Redundancy assessments to eliminate single points of failure and enhance plant resilience

What this involves:

  • Detailed Yield Analysis: Reviewing current gas production data to identify inefficiencies and limiting factors in the digestion process.

  • Process Adjustment & Optimisation: Modifying loading rates, retention times, and mixing strategies to enhance substrate breakdown.

  • KPI Monitoring & Performance Tracking: Ongoing assessment of volatile fatty acids, gas composition, and digestion efficiency.

  • Trace Element & Nutrient Supplementation: Applying targeted additives to support microbial health and maximise methane output.

  • Advanced Process Control Recommendations: Implementing automated or real-time monitoring systems to improve responsiveness and control.

What it’s important:

  • Improves Profitability: Higher gas yields increase energy output and revenue, especially in plants feeding into the grid or supplying CHP systems.

  • Reduces Waste: Maximising digestion efficiency means more value is extracted from each tonne of feedstock, reducing residual waste.

  • Enhances Process Efficiency: Identifying and removing bottlenecks helps streamline operations, improving consistency and throughput.

  • Supports ROI: Better biogas performance accelerates return on capital investments and lowers operational costs.

  • Meets Regulatory & Sustainability Goals: Efficient production supports compliance with environmental targets and decarbonisation strategies.

Reliability Enhancement Programs

A reliable plant is a profitable plant. Our proactive support includes:

  • Predictive maintenance planning using tools like vibration analysis and thermal imaging

  • Critical spares analysis to reduce response time and risk of extended downtime

  • Equipment standardisation to simplify maintenance and streamline spare parts management

  • Redundancy assessments to eliminate single points of failure and enhance plant resilience

Electrical piping, hand turning dial in biogas plant

Talk to our specialists:

If you need help with your business reach out today to speak to one of our expert teams.

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Pressure gauge mounted on stainless steel equipment, indicating pressure in PSI and bar.

FAQ’s

  • Process optimisation involves improving the biological, mechanical, and operational aspects of an AD plant to increase efficiency, boost biogas yields, and minimise downtime. It includes feedstock analysis, process monitoring, and adjustments to maximise plant performance.

  • We recommend a performance review at least annually, or whenever significant changes occur (e.g., new feedstock types, scaling up, or recurring issues). Regular optimisation helps maintain stable, compliant, and profitable operations.

  • Biogas yield directly impacts your plant’s energy output and financial return. By optimising gas production, you can increase renewable energy generation, improve return on investment, and reduce the volume of undigested waste.

  • We monitor key indicators such as volatile fatty acids (VFAs), alkalinity, pH, ammonia, and microbial activity. This helps us detect early signs of imbalance and implement corrective measures before performance is affected.

  • We’ll provide full remediation and foundation advice tailored to your site and budget.

  • No, in most cases our assessments and recommendations can be implemented alongside daily operations. We work flexibly with your team to minimise disruption and ensure safe delivery of any interventions.

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Get in touch

Need support optimising your AD plant?

To find out more about our services and would like a quote. Contact us today.

consult@biocongroup.co.uk

+44 (0) 1642 679000

1 Navigator Court, Stockton-On-Tees, England, TS18 3TQ