CHP plants (e.g. in biogas plants)2026-03-31T07:55:32+02:00

Combined heat and power plants – efficient energy generation and clean emissions

Aerial view of an industrial site with biogas plant and solar park

What is a combined heat and power plant?

A combined heat and power plant (CHP unit) is a compact energy installation that generates electricity and heat at the same time. This principle is known as combined heat and power (CHP) and allows energy to be used particularly efficiently.

Unlike conventional power plants, where a large share of the energy is lost as waste heat, a CHP unit puts this heat to direct use – for example for space heating or industrial processes. This makes overall efficiencies of up to 90 % achievable.

CHP units play a central role in biogas plants in particular: they convert the biogas produced into usable energy and make the plant economical and sustainable.

Challenge: emissions in CHP operation

Despite their efficiency, CHP units produce emissions during operation. These include:

  • Nitrogen oxides (NOₓ)

  • Carbon monoxide (CO)

  • volatile organic compounds (VOCs)

  • Formaldehyde and other unburnt hydrocarbons

With biogas in particular, fluctuating gas quality or incomplete combustion can lead to increased VOC formation. These substances are not only environmentally relevant but are also subject to strict statutory limits.

Exhaust plumes from industrial chimneys against a blue sky

Formaldehyde limit exceeded or measurement coming up?

Send us your plant data or your last measurement report. Initial response usually within 24 hours.

The role of catalysts in CHP units

Catalysts are installed in the exhaust gas stream of the CHP unit and ensure that pollutants are chemically converted:

VOCs → CO₂ + H₂O

CO → CO₂

(depending on the system, also NOₓ reduction)

Advantages of catalysts

Compliance with statutory limits

Modern emission regulations – especially for biogas plants – require reliable emission reduction.

Improved environmental performance

Reducing VOCs and other pollutants makes operation more sustainable.

Process stability

Catalysts help to achieve consistent emission values even when gas quality fluctuates.

Image and acceptance

Clean plants increase acceptance among authorities, investors and the public.

Background knowledge

Frequently asked questions

Answers on technology, legislation and processes.

What does the 44th BImSchV require for existing CHP plants?2026-10-15T13:08:53+02:00

The 44th BImSchV sets stricter emission limits for existing and new medium combustion plants, gas turbines and combustion engines (CHP). For existing plants, staggered transition periods apply depending on rated output and fuel type before the new limits for nitrogen oxides (NOx), carbon monoxide (CO) and formaldehyde must be met. Operators often have to retrofit their plants with SCR systems or oxidation catalysts in order to reliably achieve the required values and avoid losing their operating permit.

Which catalysts are suitable for biogas CHP units?2026-10-15T13:08:53+02:00

Two types of catalyst are mainly used in biogas CHP units: oxidation catalysts to reduce formaldehyde and carbon monoxide (CO), and SCR catalysts where a substantial reduction of nitrogen oxides (NOx) is required. As biogas often contains traces of hydrogen sulphide and siloxanes, the catalysts must either be designed to be particularly robust or be protected upstream by suitable gas cleaning systems such as activated carbon filters.

What is ammonia slip in SCR systems and how can it be avoided?2026-10-15T13:08:53+02:00

Ammonia slip refers to ammonia that passes through the SCR catalyst unused and is released into the environment with the exhaust gas. It occurs when more reducing agent is dosed than can react with nitrogen oxides on the catalyst. Causes include overdosing, uneven distribution of the reducing agent across the exhaust gas cross-section, exhaust gas temperatures that are too low, rapid load changes or a catalyst whose activity has declined. Ammonia slip is undesirable for several reasons: ammonia is itself an air pollutant, it can form deposits in combination with sulphur compounds, and it means unnecessary consumption of urea solution. It can be avoided with load-dependent dosing control, a sufficient mixing section upstream of the catalyst, an appropriate catalyst design and regular checks of the dosing equipment. In addition, a downstream oxidation catalyst can convert remaining ammonia. If your measurement reports show ammonia or your urea consumption is rising, send us the data so that we can assess the dosing and catalyst condition together with you.

How do catalytic converters help to comply with legal limits?2026-03-27T13:53:59+01:00

Catalysts specifically reduce critical pollutants such as VOCs, CO and formaldehyde. This ensures that emission limits are reliably complied with – even under varying operating conditions.

Do catalytic converters need to be serviced or replaced regularly?2026-03-27T13:52:52+01:00

Yes, the performance of a catalytic converter can be impaired by ageing or impurities (e.g. sulphur, siloxanes). Regular monitoring and maintenance are therefore crucial for a permanently high separation efficiency.

What advantages do catalytic systems offer over purely thermal processes?2026-03-27T13:52:39+01:00

Catalytic systems enable the oxidation of pollutants at significantly lower temperatures. This reduces energy consumption, lowers operating costs, and allows for a more compact system design.

Where are catalytic converters integrated in the CHP unit?2026-03-27T13:50:40+01:00

Catalytic converters are usually installed in the exhaust tract downstream of the engine. Depending on the system, oxidation catalytic converters or combined solutions are used, which are specially adapted to the composition of biogas.

Why are VOC emissions particularly relevant for biogas CHPs?2026-03-27T13:49:44+01:00

Biogas is not a fuel with a constant composition. Fluctuations in methane content or impurities can lead to incomplete combustion – and thus to increased VOC emissions. These must be treated in a targeted manner in order to comply with limit values.

What emissions are produced by CHP units with biogas?2026-03-27T13:49:18+01:00

In addition to CO₂ and water vapor, nitrogen oxides (NOₓ), carbon monoxide (CO) and unburned hydrocarbons – in particular VOCs and formaldehyde – are also produced during operation. The level of emissions depends heavily on the gas quality and combustion efficiency.

About Pure Air GmbH

Experience in exhaust gas treatment

Pure Air GmbH is built on many years of experience in catalytic exhaust gas treatment. Since 2025 we have brought this know-how together in Bamberg: we design catalysts for your plant, supply them and support them in operation, from CHP units to industrial installations.

Response
within 24 hours

Also for
third-party housings

Everything from
a single source

Engineer designing an exhaust gas treatment system on a CAD workstation

Contact us

Request a free quotation or get non-binding advice.

Pure Air GmbH
Am Börstig 12
96052 Bamberg

+49 (0) 951 96433250
+49 (0) 170 9630471

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