The blueFLUX process –
From waste to energy

Efficient conversion of organic waste into sustainable energy sources

The blueFLUX process enables the direct conversion of municipal sewage sludge, biowaste, agricultural residues, wood residues and other organic residues into high-quality energy sources such as hydrochar, biochar, synthesis gas, or green hydrogen – efficiently, economically and sustainably.

The process is based on a patented thermochemical reaction and has a modular structure.

Material and thermal cycles ensure particularly high resource efficiency with minimal emissions. Conversion is decentralized, flexible and independent of fossil fuels.

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Process steps

Material feeding and storage

Storage and preparation of input materials – optimum preparation for all further processing steps.

1

Pre-carburization

In the HTC (hydrothermal carbonization) process, the organic input is converted into a liquid HTC sludge under pressure and temperature. This breaks down the organic structure and creates an energy-rich intermediate product that is optimally prepared for further use.

2

Drainage

The HTC sludge is dewatered mechanically. The resulting process water is reused in the HTC process to minimize the amount of fresh water required. The process water is used directly or treated via distillation. Excess distillate is treated in a waste water treatment plant and made available for further processing. The concentrate can be reused to recover valuable materials.

3

Carbonization / drying

The central reaction step involves the thermal carbonization and drying of the dewatered HTC sludge to produce HTC coal. The condensate produced in the KDC process is either mixed with the input material or returned for dewatering.

4

Gasification

The hydrochar produced is converted into hydrogen-rich synthesis gas in a downstream gasification step under controlled conditions. The process produces only minimal residues.

5

Gas treatment

The resulting synthesis gas is purified, analyzed and technically processed. Depending on the application, it can be further processed to produce hydrogen, used as a process gas or fed directly into the grid. The gas quality is continuously monitored and regulated.

6

Efficiency through process coupling

The process stages of our FLUXone systems are designed to work together efficiently – the waste heat generated from hydrolysis and gasification is used directly for the subsequent process steps. This increases overall efficiency and reduces operating costs.
However, the system can also be operated on a modular basis – individual process stages (e.g. charring only) can be used independently of each other and flexibly integrated into existing infrastructures.

  • High efficiency through coupled processes

  • Reduction of operating costs through residual heat recovery

  • Modular expandability for future application requirements

The future of energy starts here

From system selection to project planning – we’re here to advise you every step of the way.

Phone
+49 (0)8803-90071-0

E-MAIL
info@bluefluxenergy.de

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