BDI
- Offer Profile
-
BDI-BioEnergy International GmbH is a technology and market leader in the planning and construction of customized biofuel production plants.
The company's patented multi-feedstock process enables the highly efficient production of biodiesel from a wide range of raw materials, including fresh vegetable oils and waste oils and fats from industry and commerce.With its BDI Advanced PreTreatment technology, the company also focuses on the purification and pre-treatment of all types of fresh and waste oils and fats for the production of renewable diesel, SAF, HVO and HEFA.
Visit us on:
Product Portfolio
Technology and Services
Biodiesel & Retrofit
- BDI's biodiesel technologies
are specially designed to convert even challenging raw materials such as animal fats, used cooking oils, trap greases, and vegetable oils into high-quality biodiesel. The technologies can process all kinds of feedstock containing between zero and 99 percent free fatty acids (FFA). The quality of the biodiesel produced exceeds the most stringent quality standards in accordance with EN 14214 and ASTM D6751. We design and build customized biodiesel plants offering maximum feedstock flexibility for our customers and modify existing plants to augment their efficiency and sustainability.
- Maximum feedstock flexibility: No limits on FFA content in raw material
- Reusable by-products: Process does not generate new waste streams
- Decades of experience: Global player in international industrial plant engineering
ANIMAL FAT
- In Europe, biodiesel production is closely linked to the use of animal fats. Animal fat typically contains five to 35 percent free fatty acids (FFA). This varies depending on its source and storage conditions. The longer it is stored, the more the fat degrades, which also dramatically increases the sulfur content. Another challenge in processing animal fats is the often high proportion of polymeric plastics such as polyethylene. When converting animal fats to biodiesel, suitable measures such as appropriate fat processing or separating out the polyethylene must be considered.
BY-PRODUCTS OF PALM OIL PRODUCTION
- Residues and by-products from the palm oil industry, such as palm oil mill effluent (POME) and palm fatty acid distillate (PFAD), are well-suited as feedstock for the production of biodiesel. PFAD is generally a clean raw material with a high FFA content and exhibits little variation in terms of quality parameters, but is more expensive compared to POME. Generally speaking, the water content, metal, sulfur, and other parameters in POME can vary greatly, depending on where it comes from and how it is delivered. A biodiesel process for the processing of by-products from palm oil production must therefore be designed in such a way that it is able to reliably compensate for significant fluctuations in quality.
INDUSTRIAL WASTE FATS
- Industrial waste grease, such as yellow grease, brown grease, black grease, or trap grease, is typically a mixture of organic waste oils and fats, as well as residues from wastewater systems. Due to their origin, these fats contain high levels of moisture, impurities and insoluble substances, and the triglycerides in the fats and oils may be chemically highly degenerated. When designing the biodiesel process, these challenges must be considered.
Technology
MULTI-FEEDSTOCK
- The BDI multi-feedstock process can convert a wide range of raw materials such as animal fats, used cooking oils, trap greases, and vegetable oils into high- quality biodiesel that exceeds the highest quality standards. Flexibility in terms of the raw materials used, maximum yield, low operating and maintenance costs, and the renowned reliability of our biodiesel plants guarantee the maximum possible cost-effectiveness.
REPCAT®
- With the fully continuous RepCAT® process, BDI has developed biodiesel technology for processing waste-based raw materials consisting of up to 99 percent free fatty acids (FFA). The use of a heterogeneous catalyst that is recycled and recirculated back into the process is the key to maximizing the efficiency of this technology. Another advantage of this process is the recovery of salt- free, distillate-quality glycerin as a by-product.
RETROFIT
- Producers of biodiesel face numerous challenges when attempting to give their plants an economic edge. However, off- the-shelf solutions designed to improve individual parameters such as yield, product quality, or feedstock flexibility prove ineffective. With the BDI Retrofit program, entire existing biodiesel plants are upgraded to the state of the art with the latest technology. To achieve optimum results, it is necessary to develop an individual master concept for each plant in order to implement the best possible
Advanced PreTreatment
- Renewable diesel and sustainable aviation fuel
in the form of hydrogenated oils and fats (HVO and HEFA) are becoming increasingly important, but strict requirements must be met regarding the impurities in the oils and fats used, in order to minimize negative effects on downstream process steps. Pretreatment is therefore a crucial step in the efficient and cost-effective production of renewable fuels, and the processing of waste materials in particular requires the best possible treatment technology.
- Robust and efficient: Centrifuge technology and process design optimized for waste oils with minimum oil losses
- Modular process units: Customized solution for each type of raw material and impurity
- Patented system: Polyethylene separation via a filterless process
USED COOKING OIL
- Used cooking oil (UCO) is the most important waste-based raw material for the production of renewable fuels such as sustainable aviation fuel (SAF), with the largest volumes being generated in industry and commerce. Relevant raw material parameters include its metal and phosphorus content, as even small amounts of these substances can negatively impact downstream processes. The quality of used cooking oil varies greatly, depending on both the origin of the oil and the method of collection. In general, a multi-stage purification process is required to prepare UCO for the production of renewable fuels, but high-quality oils require significantly less purification.
ANIMAL FAT
- Animal fats are an increasingly important feedstock for renewable diesel and sustainable aviation fuel (SAF) production. The quality varies, depending on their origin, processing method, storage time, and season. High temperatures and long storage times promote chemical and biological decomposition of the fat, increasing both its sulfur and nitrogen content. Another problem faced in the processing of animal fats is the proportion of polymeric plastics such as polyethylene, which can come from the ear tags of livestock or other waste plastics. A special filterless process has been developed to process animal fats with a high polyethylene content.
POME (PALM OIL MILL EFFLUENT)
- The oil content of wastewater from palm oil production also serves as a valuable feedstock for sustainable fuel production. The combination of impurities, water, solar radiation, and long retention times in separator basins allows for chemical and biological decomposition of the oil, resulting in the formation of degradation products. Processing this to yield renewable fuels requires a special design and multi-stage treatment process to not only overcome the challenging properties of the oil, but also to achieve the required product specifications.
Technology
Advanced PreTreatment
- BDI’s Advanced PreTreatment process is designed to be modular so that it can be optimally adapted and expanded to meet raw material requirements based on the core modules PrePurification, washing, and adsorption, as well as other optional modules. Possible extensions include a second adsorption stage, polyethylene reduction using a special process patented by BDI, or the separating out or conversion of free fatty acids from the raw material.
Smart Operations
-
Increased efficiency as well as optimized product quality and stabilized production. Our data-based process control system, BDI Smart Operations, is ideal for optimizing chemical process plants.
- Lower production costs: by reducing energy and operating resources and fewer operator interventions
- Improved plant efficiency: through predictive control based on mathematical models
- Increased production: thanks to stable utilization of the plant at maximum capacity
MANAGEMENT TOOLS FOR PROCESS MONITORING
- The BDI Dashboard is a management tool for the efficient and comprehensive monitoring of the plant. Graphical data presentation that links analysis results and process data with advanced trend analysis provides management with a quick and meaningful overview of the status of the production plant.
SIMULATION-BASED MODULES FOR PLANT OPTIMIZATION
- BDI Smart Operations uses its own mathematical models for the different process steps of various technologies, such as esterification, transesterification, distillation, and demethanolization for biodiesel plants, in order to check the correctness of dosing, residence times, or temperatures, for example, and to optimize them for operation.
AI-BASED MODULES FOR PLANT OPTIMIZATION
- BDI Smart Operations utilizes Al-based optimization modules to precisely control process parameters such as acid dosage in esterification or the operation of centrifuges, and to make efficient use of operating resources and energy.
Service
BDI Smart Operations
- Model predictive controllers (MPC) based on BDI’s mathematical models optimize chemical production processes. The result? Maximum efficiency, stable and robust production. Our customized controllers communicate all data to the control system, minimizing operator intervention and ensuring optimal, safe plant operation. With targeted adjustments of process parameters, you can achieve maximum efficiency gains.
Biogas
-
As a specialist plant manufacturer BDI is setting new standards in the refining of residual and waste materials with its biogas technology. Depending on the design, our biogas plants can utilize a variety of organic waste materials as substrate, from spent grains and yeast from breweries to organic waste from the food or biofuel industries.
- Energy as a Service: Energy for customers, no equity allocation, good for the environment
- Customized process design: Optimized according to available organic waste materials
- Energy independence and carbon credits: Local production of biogas from on-site by-products or waste
BREWER'S SPENT GRAIN
- Approximately two billion hectoliters of beer are produced worldwide each year. For every hectoliter produced, the main by-products of the brewing process are 20 kg of spent grains and yeast. Anaerobic fermentation of these waste products can cover up to 100% of a brewery's heat, energy, or electricity needs. This efficiently and sustainably replaces energy that would otherwise be generated using fossil fuels, helping breweries move toward energy independence and zero carbon emissions.
FOOD PRODUCTION
- In the EU, about 100 million metric tons of food are wasted each year, which equates to around 200 kilograms per person. This significant amount of waste could be put to good use if its carbon and hydrogen content were to be used for biogas production. This could provide a significant portion of the energy needed to power food processing plants or the truck fleets of waste collection companies.
POULTRY INDUSTRY
- A chicken produces approximately 200 grams of manure each day. A typical chicken farm produces thousands of metric tons of manure each year. Slaughterhouses also produce large amounts of waste, wash water, and rinse grease. All of these resources are optimal energy sources and are ideal for use in a BDI Biogas plant. The biogas produced can be used on site or, after purification, be fed into the gas grid at a profit.
Technology
BIOGAS
- BDI’s Biogas technology is characterized by a biogas process that has been optimally designed for each specific waste material. In a single- or multi-stage fermentation process, the ideal conditions for anaerobic fermentation are ensured in order to achieve maximum yield and the highest quality of biogas. The plant concept features a compact design and is able to use a variety of organic residues as the substrate. In addition, the remaining digestate can be utilized as a certified agricultural fertilizer.
GreenTech Solutions
-
As a knowledge center for the development of chemical processes
BDI GreenTech Solutions guides its customers through all phases of technology development, from the concept to market maturity. We offer decades of experience in chemical recycling and the upcycling of waste streams, as well as the scaling up of chemical processes.
- Efficient use of resources: Knowledge center for the development of innovative recycling processes
- Proven process integrity: Scale-up in state-of-the-art laboratories and an explosion-proof technical center conforming to ATEX II standards
- Comprehensive process engineering expertise: Seamless integration of main and secondary processes for complete production plants
TECHNICAL AND ECONOMIC EVALUATION
- Rapid results, efficient use of resources, and direct access to experts are key in the development of innovative processes. We offer our expertise to assess the technical feasibility and economic viability of your idea or process concept usually starting at Technology Readiness Level (TRL) 4.
PROTOTYPING, RESEARCH AND DEVELOPMENT
- As a key element of BDI GreenTech Solutions, we offer fast and flexible capacities in our state-of-the- art laboratories and in our technical center outfitted with ATEX Category II equipment. As part of the process development and prototyping process, we produce initial product samples for our customers, in order to verify the integrity of the process and to test market acceptance.
SCALE-UP AND ENGINEERING
- Extensive expertise in chemical process engineering: We implement complete production plants for recycling processes, green chemistry, and biorefineries based on customer specifications and test processes in our own facilities. The knowledge gleaned from this facilitates the scale-up and ensures seamless integration of the main process steps and all the necessary secondary processes.
PLANT CONSTRUCTION AND COMMISSIONING
- As a full-service contractor for the construction of industrial facilities, we provide coordination, management, and supervision of the construction process. After completion, commissioning tests, and a performance run, we hand over the turnkey plant. In addition to ongoing service, maintenance, and spare parts management, we offer training courses for the operating personnel. We are also your trusted partner for retrofits and upgrades.
Technology
SYNCYCLE®
-
The technological approach of a decentralized and modular concept enables the customer to convert plastic waste into valuable resources on the spot. SynCycle® makes chemical recycling a viable and adaptable technology that is accessible to all those involved in the plastics value chain. The one-stop-shop concept of SynCycle® technology transforms non-recyclable plastics into new products.
Mixed plastic waste serves as the raw material, which is shredded, dried, and melted. In the pyrolysis reactor, the polymers are broken down into shorter hydrocarbons, producing pyrolysis gas. The downstream unit uses a condensation process to convert the pyrolysis gas into two oil fractions, which are refined to the highest quality standards and can be returned to the value chain of the plastics industry as a raw material.
Research & Development
- Research and technology development
are elementary components of BDI’s efforts to continue setting standards in special plant engineering with its own technologies.
- Reliable research results: In our own large-scale laboratory and technical center outfitted with ATEX equipment
- Scale-up of process concepts: From laboratory test series to industrial plants
- Decades of experience: In the processing of by-products and waste from industry and commerce
BIODIESEL
- BDI's biodiesel processes convert a variety of raw materials such as animal fats, used cooking oils, and vegetable oils into high-quality biodiesel. They can process feedstocks containing up to 99 percent free fatty acids (FFA), thereby guaranteeing maximum feedstock flexibility.
BIOGAS
- BDI's biogas technology is geared towards industrial and municipal users. The anaerobic fermentation process is able to utilize a wide range of feedstocks such as food industry by-products, organic waste, or by-products from the biofuel industry for conversion into biogas.
ADVANCED RECYCLING
- BDI supports customers with developing chemical recycling processes with GreenTech Solutions. Via chemical recycling, waste streams from industry and commerce can be converted back into valuable resources and used sustainably in the circular economy.
Service
Research and development
- Research results are validated in our own large-scale laboratory to ensure risk-free implementation in the industry. As a recognized specialist for the scaling up of process concepts, we guide you through the entire development process, from the first laboratory test to the finished industrial plant. BDI’s research focuses on the development of green technologies for processing industrial and commercial by-products and waste. We also research opportunities in the areas of sustainable energy production and green chemistry.
Customer Service
- State-of-the-art process plants
require not only regular maintenance and servicing, but also constant further development. A dedicated team of customer service professionals provides world-class support to ensure your ongoing processes are running optimally, both today and tomorrow.
CUSTOMIZED PERFECTION
- Plant operators face a variety of unique challenges. Our customer service solutions are designed to optimize plant profitability in both the short and long term. For example, feedstock flexibility and production volumes are improved, and profitability is assured.
PEAK PERFORMANCE
- Failure to diagnose and resolve potential production disruptions and risks in a timely manner can result in high costs. With our maintenance services, plant operators can ensure that their equipment is always operating at peak performance.
MAXIMIZED COMFORT
- An intensive exchange of information with comprehensive advice between plant personnel and the technology provider is also crucial for efficient operation. Our team of highly skilled professionals delivers the expertise you need, when you need it.
COMPREHENSIVE CARE
- Operating a plant safely also means protecting people, the environment, and the plant from external influences. We analyze and address both physical and digital threats to ensure the safety of your people and your plant environment, as well as the protection of your assets.
Service
ABOVE COMPETITION
-
- BDI plant fitness check/plant assessment
- Analysis to eliminate bottlenecks in the process
- Continuous process improvement
- Updating and optimization of process control system
- 24/7 hotline
- Troubleshooting and comprehensive root cause analysis
- Preventive maintenance
- Spare parts services
ONE-STOP SHOP
-
- On-site support from BDI experts
- Online process coaching/on-site training
- Sharing of technical information
- Training in laboratory and analysis management
FREE YOUR MIND
-
- Overall plant safety inspection
- SIL inspection
- HAZOP analyses
- Electrical inspection (ATEX report
Selected International Reference Projects
- More than 70 industrial plants and RetroFit projects attest to our expertise and know-how in international plant construction.
ENVIEN Group
-
Improvement of by-product quality through new by-product line
Location: Komárom (Hungary)
Z-Energy
-
Improvement of biodiesel quality through implementation of new transesterification
Location: Auckland (New Zealand)
Glycerin distillation
-
Glyerine distillation
Location: Europe
PreTreatment Europe
-
Advanced PreTreatment
Waste oils and fats
Feedstock PreTreatment
-
Advanced PreTreatment
Waste oils and fats
RETROFIT Spain 2024
- Increase of feedstock flexibility
