Project meeting of STEP at the site of the company ATS - Agro Trading & Solutions in Hardegsen (Photo: DBFZ)

Biogas System integration

Project ID 03KB072

PROKOSYS - Processes, components and systems for the flexible operation of biogas plants using organic waste material

Squeezing of maize silage (Photo: IKTS)


  • 01.10.2012 – 31.03.2015


Fraunhofer Institute for Ceramic Technologies and Systems IKTS
Biomass Technologies and Membrane Process Engineering
Winterbergstraße 28
01277 Dresden

Fraunhofer Institute for Ceramic Technologies and Systems (IKTS)
Winterbergstraße 28, 01277 Dresden, Germany

Dr.-Ing. Burkhardt Faßauer – project manager
Telephone: +49 (0)351 2553-7667

Björn Schwarz – further contact person
Telephone: +49 (0)351 2553-7745

Dr. Hannes Richter – further contact person
Fraunhofer Institute for Ceramic Technologies and Systems (IKTS)
Michael-Faraday-Straße 1, 07629 Hermsdorf
Telephone: +49 (0)36601 9301-1866

Dr. Marcus Weyd – further contact person
Fraunhofer Institute for Ceramic Technologies and Systems (IKTS)
Michael-Faraday-Straße 1, 07629 Hermsdorf
Telephone: +49 (0)36601 9301-3937


03KB072B - LMEngineering GmbH
03KB072C - DBI Gas- und Umwelttechnik GmbH
03KB072D - Weber Entec GmbH & Co KG

Associated partners

03KB072 - DREWAG – Stadtwerke Dresden GmbH

Cooperation partners



Results only available in German.


The joint research project PROKOSYS aims to develop strategies and technologies for more flexible supply with energy from biogas. The idea is to compensate under- or overproduction caused by more volatile renewable energy sources like wind or sun in order to stabilize grid performance. Furthermore combination of time controlled biogas production and effective treatment of biogas shall pave the way to new business cases for biogas plant owners due to gaining flexibility prices on the market directly or according bonuses from the RES, introduced in 2012.


Within the joint project components, processes and systems shall be developed for a biogas production and delivery “on demand”.  On the one hand an existing process for agricultural raw materials that was developed by the applicants will be technological basis for that approach. This process is able to be operated dynamically with agricultural substrates and will be adapted for PROKOSYS in order to use other organic waste material.

On the other hand, the energy density in certain mass flows shall be improved by gas treatment for small networks by means of ceramic membranes which are stable in terms of water vapor and H2S. By means of online analysis and control equipment that will be developed by other partners all single components shall be combined into systems, which enable highly flexible and optimal operation of biogas plants.



The IKTS Dresden is in charge of the experimental design and technical implementation of the flexible biogas production “on demand” in laboratory and pilot scale. First, the waste material flows are chosen and analyzed in terms of composition, energy content and decomposition behavior. The DECONDIS® process is adapted to these new substrates with a focus on flexible gas production with the help of systematic drainage and fermentation tests. In addition, any development of the project partners for a balanced production of biogas is to integrate and evaluate in both in the laboratory and pilot scale.


  • Feasibility studies with focus on adaptation of DECONDIS® process and practical implementation in test field
  • Adaptation of the existing pilot plant and verification of operational stability and effectiveness of the dynamic biogas production
  • Rating system for the transmission of results to the large scale

On the one hand, there is continuous production of biogas. On the other hand, in local gas networks there is a fluctuating gas demand, reaching a minimum in the summer months. One way of buffering the excess amounts of biogas is the purification and storage in gas filling stations. In the project purification membranes for biogas are further developed and tested in the laboratory of DBI.

In a pilot plant, the gas management and processing will be done under real conditions.

Weber Entec

Weber Entec is a specialist in the field of ultrasonic disintegration. During the project Weber Entec will develop an ultrasound unit for degassing of fermentation substrates in laboratory scale as well as for a pilot plant. In addition, Weber Entec is responsible for design and manufacturing of the ultrasound technology.



Adaptation DECONDIS® process on organic residuesStudies on degassing of fermentation substrates using ultrasound and / or special stirring regimesStudies on the effect of a separate hydrolysis step on the separable quickly available material flow

Flexible operation of biogas plant by dynamic gas storage and system operation


Test of membranes on ceramic support in the laboratoryStress testing of membranesPlanning and operation of flexible test facility for gas processingEnergy management, load-dependent operation mode of gas processingSystem evaluation

Weber Entec

Creating specifications for design and manufacturing of laboratory ultrasonic reactorPlanning and construction of the pilot ultrasound reactorStartup ultrasound technology



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