KOMPOTEC Nieheim

Our concept, applied for the first time in Nieheim, aims to maximise the use of biowaste as a resource while minimising emissions and optimising energy efficiency. We use a dry fermentation process to produce high-quality biomethane that replaces 100% of fossil natural gas. In addition, 9,000 tonnes of CO₂ are extracted from the biogas for the production of biogenic dry ice, thus avoiding fossil CO₂. The fermentation residues are then fully returned to the ecological cycle as compost and liquid fertiliser. By integrating large-scale photovoltaics as well as a wind turbine, the plant is not only self-sufficient, but also contributes to the region's electricity supply. Specifically, the plant produces

• up to 680 m³ of biomethane per hour
• 7.0 million kWh of renewable electricity per year after deducting its own requirements
• 23.000 tonnes of compost per year
• 9.000 tonnes of liquid fertiliser per year

In total, the plant avoids 18,000 tonnes of CO₂ emissions per year. 
 

The plant in Nieheim has been producing biogas since 2006. However, BEKON's new continuous fermentation process will significantly increase the yield once again, while the plant's own electricity will be generated directly on site using large-scale PV systems and a wind turbine. An AI-supported energy management system will maximise the in-house use of the electrical energy generated on site, thus minimising the amount of electricity purchased. The CO₂ produced when refining the biogas into biomethane is both sold as biogenic dry ice for industry and permanently bound in precast concrete elements. Non-fermentable woody parts of the biowaste are utilised in a biomass power plant to heat the plant. The fermentation residue is processed into high-quality compost and liquid fertiliser for organic fertilisation and soil improvement in agriculture.

With appropriate purity, organic waste can be completely converted into high-quality compost. This means that biowaste can already be recycled in a closed cycle. However, energy can also be recovered from this closed cycle by means of fermentation, without any loss of quality in the compost. Despite this enormous economic and ecological potential, the public hardly recognises biowaste as a valuable resource or even as an energy source. Despite the energy transition and although biogas processes have been on the market for a long time, only around 33% of separately collected biowaste was used for sustainable energy production in Germany in 2020, according to the BMUV. This is particularly remarkable, as composting has been established throughout the country for decades. We therefore hope that our Nieheim flagship project will also raise awareness of biogas production from waste as an important component of the energy transition.

The composting plant in Nieheim was already one of the most modern plants in the world before the current remodelling work. This is because the Eggersmann Recycling Technology companies have been using this site for research purposes since Eggersmann Anlagenbau was founded in 2008. Newly developed processes and technologies are trialled here in the company's own facilities and important experience is gathered. For example, the innovative compost fine processing concept as well as the new ARCTOS BM 36 pre-shredder haven been implemented in Nieheim for the first time.

Right: Fine compost treatment with CO₂MPOSTCLEANER as used in Nieheim (more).