6th Framework Programme
Case Study 4: Karstädt

Case Study 4: Karstädt

The location of this biogas plant was chosen because of the availability of a large quantity of manure. Next to the plant is a big agriculture cattle farm with some 3,000 animals and the manure (round about. 50 000 t/a) get directly pumped in the plant. This saves money for transport and reception capacities are kept for co-substrates. Other farmer can also bring the manure of their cows and can receive the residues of the plant as fertilizer for their agricultural land. There are also food producing companies nearby, which can dispose their organic waste in the plant cost-effectively. A benefit for this kind of input choice is that the plant is thus not dependent on crops, harvest times and crop prices. The rural area where the plant has been installed is underprivileged and the option of developing agriculture into energy producing businesses is a possible solution for strengthening the region. The heat is used on site, mainly for the pasteurization processes. A special feature is the further use of the excess heat from the pasteurization process to cool the substrates from 70 to 40 °C before they are fed into the fermenter.

Key data

Type of plant: Co-fermentation (cow manure, organic wastes)
Location: Karstädt, Germany
Operator: BioKraft Karstädt, Brandenburg
Constructor: Farmatic Biotech Energy AG, Nortorf
Operation start: 2001

Operation facts

Mode: 2 stage
  Wet fermentation
Temperature range: Mesophilic
Main fermenter: 1 x 4,000 m3
Secondary fermenter: 1 x 1,500 m3
Final storage tanks: 2 x 5,000 m3 on site
  2 x 6,000 m3 on farm
Feedstock: Cow manure (75 %)
  Organic wastes (25 %)
Annual amount: 67,000 tons
Use of gas: 2 CHPs with 601 kW el ecah
  GE Jenbacher

Energy production

Electrical output: 8,900,000 kWh el
  supply for 2,124 households
Thermal output: 6,000,000 kWh
  equals 600,000 l heating oil
Use of thermal energy Pasteurization

Additional information

Special feature: Special monitoring system
  ith automation and visualisation (touch panels)
  Manure is directly feed in through pipeline
Investment: 4,000,000 €
Annual running costs: 300,000 € depreciation
  215,000 € staff
  430,000 € maintenance

Diagramm of plant