Biogas & Bioenergy Reactors (1L–50,000L)

Engineered for Circular Bioeconomy & Renewable EnergyDescription
KBiotech’s bioreactor systems are purpose-built for high-performance biogas generation, bioplastics fermentation, and CO₂-to-fuel conversion. Designed for R&D through full-scale industrial production, these reactors handle organic waste, syngas, glycerol, and CO₂ with precision. From 1L benchtop setups to 50,000L industrial systems, we provide reliable fermentation platforms that support energy recovery, carbon neutrality, and sustainable manufacturing.

Benefits
Modular scalability: 1L to 50,000L with unified control architecture
Real-time gas analytics (CH₄, CO₂, H₂, O₂)
BIOFLEX™ SCADA platform – 21 CFR Part 11, GMP-ready
Explosion-proof (ATEX/IECEx) for hazardous gas/dust zones
Specialized impellers for high-viscosity biopolymer fermentation
CIP/SIP capabilities with validated cleaning/sterilization
Integrates with upstream and downstream processes
Anti-corrosion and anti-biofilm vessel coatings available

Applications
Biogas Production: Anaerobic digestion of waste, manure, or syngas to CH₄
Bioplastics (PHA, PLA): Nutrient-limited fermentation with sticky substrates
CO₂ Fermentation: Acetogens/hydrogenotrophs for CH₄, acetate, or ethanol
Syngas-to-Biofuel: Conversion of CO/CH₄/H₂ into ethanol or butanol
Electromethanogenesis: Bioelectrochemical methane generation
Waste Valorization: Food/agricultural residues to biofertilizers or energy
ATEX Zone Operations: Safe bioprocessing in explosive environments

Technical Specifications
Parameter
Specification
Volume Range
1L – 50,000L (custom scalable)
Materials
316L SS, Hastelloy, Borosilicate glass
Temp Range
4°C – 150°C, dual-zone
Pressure Rating
Up to 15 barg
Mixing Options
Magnetic/top drive; Rushton, marine, helical
Sensors
pH, DO, ORP, foam, turbidity, biomass, gas-phase
Gas Handling
MFCs, inline gas sterilizers, condensate traps
Certifications
CE, ISO 9001, ATEX, cGMP optional
Zones
ATEX Gas 0–2, Dust 20–22

Type of Vessels
Lab-Scale: 1L–20L benchtop, ideal for early R&D
Pilot-Scale: 30L–500L modular units for process development
Production-Scale: 1,000L–50,000L fully integrated systems
Specialty Designs: Explosion-proof, anti-biofilm, high-viscosity setups

Software
BIOFLEX™ SCADA Platform
GMP-compliant control with 21 CFR Part 11 audit trail
Real-time analytics, recipe builder, remote access
Integration with upstream/downstream units
Full process logging and alarm history
Compatible with legacy tanks and sensors

Related Accessories: Analyzers and Modules
KG-FERM™: Real-time CH₄, CO₂, H₂, O₂ gas analyzer
KB-Incyte-VBC™: Inline biomass via permittivity
Feeding Pumps: Peristaltic or diaphragm feed dosing
Gas Skids: Mixing/sterilizing CH₄/CO₂/H₂ flows
Dosing Systems: pH-stat, antifoam, and nutrient feeds