Syspro Automation has successfully designed, manufactured, and validated two pilot-scale systems aimed at the valorization of biogas: a Forced-circulation loop bioreactor for Single Cell Protein (SCP) production and a Taylor flow-based reactor optimized for microbial ectoine synthesis. Both systems form an integrated pilot platform developed for research and industrial demonstration.

Engineering and Process Development

The engineering phase began with the complete process design and simulation of both reactor systems.

For the forced-circulation loop bioreactor, development focused on optimizing gas–liquid mass transfer, controlling bubble residence time, and ensuring homogeneous mixing. These parameters are critical to enhance the biological conversion of methane (CH₄) and carbon dioxide (CO₂) into microbial biomass under stable operating conditions.

In parallel, the Taylor flow-based reactor required precise hydrodynamic modeling to maintain a stable slug-flow regime. This configuration enables accurate control of nutrient supply and oxygen transfer, both essential for maximizing ectoine accumulation.

During the basic and detailed engineering stages, comprehensive process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and detailed equipment specifications were developed to ensure system integration, safety compliance, and operational reliability.

Equipment Integration and Automation

Equipment and instrumentation were selected in accordance with process requirements and regulations applicable to biogas handling. The main equipment scope included stainless-steel reactor vessels, mass flow controllers for biogas and air, gas scrubbing units, peristaltic and centrifuge pumps, heat exchangers, and multi-parameter sensors for pH, dissolved oxygen, and methane (CH₄) composition. All components were specified in compliance with ATEX and Pressure Equipment Directive standards.

Following receipt inspection, mechanical assembly, electrical wiring, and instrumentation integration were carried out at Syspro’s pilot facility, strictly adhering to the approved engineering documentation.

Automation and process control were implemented through a programmable logic controller (PLC) integrated with a SCADA interface, enabling both local and remote operation. The system provides:

  • Continuous monitoring of process conditions

  • Automatic regulation of key parameters

  • Comprehensive data logging

  • Safety interlocks for pressure deviations and gas leak detection

Remote connectivity allows real-time supervision and parameter adjustment when required.

Validation, Installation and Commissioning

After assembly and internal validation, both reactors successfully passed mechanical integrity tests, connection verification, and full automation control checks, confirming reliable performance of all instrumentation and auxiliary systems. The units were then prepared for transport, disassembled, and shipped to the wastewater treatment plant in Lleida, Spain (AQUALIA).

Installation and reconnection were carried out according to the approved engineering documentation and safety protocols, with functional testing confirming operational readiness under standard conditions. Both the forced-circulation loop bioreactor and the Taylor flow reactor are now fully installed and commissioned in Lleida, where they are currently operated by consortium partners UVA and AINIA as part of the ongoing research and demonstration activities.