Bay Zoltán Research Institute
Smarter Biogas Plants: Chemical-Free Ammonia Removal for More Efficient Energy
The Challenge
Biogas plants are an important source of renewable energy, turning organic waste, such as agricultural residues, food waste, or sewage, into methane that can be used for electricity and heat.
However, many plants face serious operational challenges:
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Ammonia accumulation: When ammonia levels rise above safe thresholds, it inhibits the microorganisms that produce methane. Very high levels can drastically reduce energy output.
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Costly maintenance: Handling high-ammonia digestate requires extra storage and treatment, adding operational costs.
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Limitations of existing solutions: Conventional ammonia-removal methods rely on chemicals, membranes, or thermal/ vacuum stripping. These methods often consume a lot of energy, require regular maintenance, and may produce additional chemical waste.
The Innovation
Bay Zoltán Research Centre has developed a patent-pending, chemical-free ammonia removal technology that uses air and the plant’s own waste heat. This process removes ammonia safely and efficiently without chemicals, lowering both costs and environmental risks.
How it works:
Air stripping (desorption): Ammonia is removed from the fermentation broth using warm air at around 70 °C and near-atmospheric pressure.
Smart system design:
Dual-flow tray ensures optimal gas-liquid contact.
Indirect heating uses waste heat efficiently to warm the broth.
Optimised desorber column minimises entrainment and maximises ammonia removal.
© Bay Zoltan Institute
© Bay Zoltan Institute
Results & Benefits
Up to 60% reduction in ammonium-nitrogen levels in fermentation broth
More stable methane production → higher, more predictable energy output
Reduced digestate handling costs → lower storage and application expenses
Environmentally friendly operation → fewer chemical inputs, less energy, and reduced emissions
For plant operators, this means more reliable renewable energy generation with lower operating costs and less environmental impact.
Why is it important?
The technology is already deployed at industrial scale in Hungary, showing it is scalable and ready for international markets.
By improving efficiency and reducing costs, this innovation supports the global transition to renewable energy, making biogas plants more competitive and sustainable worldwide.
Impact for Society
Cleaner, more reliable renewable energy for homes, farms, and industry
Reduced environmental footprint of waste management
Lower costs for operators → potential for cheaper energy or expanded renewable energy access
Supports sustainable innovation in the circular economy
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