Methanica Modular Biological Methanation Plant and Stainless Steel Reactor Facility
TECHNOLOGY

Biological Methanation Technology

Methanica converts biogenic carbon dioxide (CO₂) and green hydrogen (H₂) into renewable methane (CH₄) through a controlled biological process. Using naturally occurring methanogenic microorganisms, the system operates under mild conditions inside standardized modular reactor units for industrial deployment.

TECHNOLOGY

Converting CO₂ into Renewable Methane

Inside the biological reactor, methanogenic microorganisms continuously convert biogenic carbon dioxide and renewable hydrogen into methane. The process operates under controlled thermophilic conditions and produces renewable methane suitable for existing gas infrastructure.

Biological Reaction

CO₂ + 4H₂ → CH₄ + 2H₂O

Methanogenic microorganisms catalyze the biological conversion under controlled reactor conditions.

Reactor Biology

  • Methanogenic microorganisms
  • Immobilized carrier media
  • Continuous gas conversion
  • Stable biological process

Process Output

  • Renewable Methane (CH₄)
  • Water (H₂O)
  • Pipeline-quality gas
Detailed process flow diagram showing inputs, purification, compression, bioreactor, recycle, upgrading, and grid injection
ENGINEERING DATA

Engineering Specifications

Current design parameters of Methanica's biological methanation technology.

1
55°C

Process Temperature

Thermophilic biological operation

2
<200 mbar

Operating Pressure

Near-atmospheric process

3
58%

Power-to-Gas Efficiency

Including reaction heat

4
10–110%

Operating Load

Flexible renewable operation

5
20 ft ISO

Container Module

Standardized MSU design

PROCESS ADVANTAGES

Why Biological Methanation?

Biological methanation provides an alternative approach to conventional catalytic systems by operating under mild conditions while maintaining compatibility with renewable hydrogen production and existing gas infrastructure.

Methanica stainless steel biological methanation reactor vessel closeup with R-101 identifier
Low-temperature operation
Near-atmospheric pressure
Biological conversion process
Modular containerized deployment
Flexible renewable integration
Existing gas grid compatibility
MODULAR DESIGN

Standardized Modular System Units

Methanica's Modular System Units (MSUs) are standardized reactor systems designed for scalable deployment. Capacity is increased by adding identical modules, enabling installations from pilot facilities to large industrial plants.

Modular scalability diagram from 1 MSU (single module) to 4 MSUs, 12 MSUs, and Full Scale Industrial Plant
PERFORMANCE ESTIMATOR

Engineering Performance Estimator

Estimate system size, hydrogen demand, methane production, electrolysis capacity, and operating requirements based on the available CO₂ stream from your facility.

Input 01· Available CO₂ stream from your plant50 Nm³/h

Nm³/h raw-gas CO₂ after processing · biogas, sewage gas, industry. Rule of thumb: a 500 kW biogas plant delivers around 120–150 Nm³/h CO₂.

Input 02· Current CO₂ utilization

Forgone CO₂ revenue is deducted (80 €/t).

Input 03· Electrolysis power price60 €/MWh

30 €/MWh · PPA — 140 €/MWh · grid supply. This alone determines whether the project pays off.

Method: conversion rate 0.96 · CH₄ heating value (LHV) 9.97 kWh/Nm³ · 4,000 operating hours/year · number of MSUs = ⌈VCO₂/50⌉ · H₂ demand = VCO₂ · 4 · electrolysis capacity = VCO₂ · 4 · 4.7/1000. Regulatory conditions: hydrogen must be RFNBO-compliant (additionality plus geographic and temporal correlation per Delegated Regulation (EU) 2023/1184; monthly temporal correlation until 2029, hourly from 2030); certification via an EU-recognized system required (ISCC EU, REDcert, CertifHy); the product must reach the transport sector to count toward the BImSchG sub-quota. Model calculation based on TRL 5 development status. No operating data. Not an offer.

MSUs required1
e-methane yield (LHV)1.91 GWh/a
Electrolysis capacity0.94 MWel
H₂ demand200 Nm³/h
Power demand3.8 GWhel/a
Electrolysis power cost-225,600 €
O&M (4.5 % CAPEX)-60,084 €
Gross return before debt service p. a.+365,158 €RFNBO revenue at 340 €/MWh (LHV), in addition to existing biomethane revenue
DEVELOPMENT STATUS

Technology Validation

Methanica is progressing from laboratory validation toward industrial demonstration through modular pilot deployment.

TRL 5
Validated in relevant environment
6 Patents
Protected biological methanation technology
€590,000
Public innovation funding
2.5 ha
Pilot site secured
2026–2027
Construction & validation
Methanica technical plant schematic background

Ready to Evaluate Your CO₂ Source?

Discuss your project, available CO₂ stream, and technical requirements with the Methanica engineering team.