FCC

BIO-ROXX Boosts Efficiency at Mühlacker Biomethane Plant

2026-03-24

The Mühlacker biomethane plant in Baden-Württemberg, Germany, has recently enhanced its operational efficiency by integrating the BIO-ROXX substrate preparation module from Wangen Pumps. The system improves substrate consistency, handles long fibres, and effectively removes solid contaminants, addressing the growing complexity of biogas feedstocks.

The plant, established in 2007, processes around 30,000 tonnes of feedstock annually from over 120 suppliers, producing biomethane and fertilisers. With increasing use of long-fibre materials such as straw and manure, the existing dry infeed system proved inadequate, prompting a transition to a liquid-based infeed approach.

The BIO-ROXX module combines mixing and separation technologies to homogenise substrates and remove foreign matter before fermentation. Installed alongside progressing cavity pumps, the system ensures optimal substrate consistency and protects downstream equipment.

The upgrade has improved methane yields, enabled more uniform fermentation, and reduced operational disruptions such as floating or sinking layers. The modernised system also enhances flexibility, allowing operators to adjust substrate input based on demand and maintain stable plant performance.

The project was completed within six months without interrupting operations, demonstrating the effectiveness of advanced engineering solutions in supporting sustainable and efficient biogas production.

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