Biogas-fired steam boiler

Biogas-fired steam boilers convert locally produced biogas into process steam for industrial applications. This not only allows you to capitalize on your organic waste streams, wastewater treatment or digestion installations, but also reduces your dependence on fossil fuels.

Every biogas stream has different requirements. That is why the Callens Group doesn’t start from a standard boiler, but from the available fuel, the desired steam consumption and the characteristics of the production process. The result is an installation that gets maximum efficiency out of the available energy.

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When is a biogas-fired steam boiler worthwhile?

A biogas-fired steam boiler is especially worthwhile when you have your own biogas production or access to a stable external biogas stream.

With biogas, you reduce your natural gas consumption and the associated CO₂ emissions, making it an important building block in the energy and sustainability strategy of many companies.

5 reasons to consider biogas as a fuel for steam production

  • You want to reduce your dependence on natural gas.
  • You have your own digestion installation.
  • You produce biogas through wastewater treatment.
  • You have access to an external source of biogas.
  • You want to lower the CO₂ emissions of your steam production.
Brouwerij De Brabandere Bavikhove ST biogas 25 T PRJ12427 1
Outputup to 100 MW
Capacity25 kg/h to 150 t/h steam
Design pressure

Fire-tube boilers: 0.5 to 40 barg  

Water-tube boilers: 0.5 to 100+ barg

Efficiencyup to 95 %

Technical specifications of biogas-fired steam boilers

The performance of a biogas-fired steam installation is not only determined by the desired steam flow, but also by the properties of the available biogas.

Factors such as methane content, humidity, pressure, flow rate and any contaminants have an important influence on the design of the installation.

That’s why our specialists always analyze your specific context before developing a solution.

By tailoring the steam installation to the specific properties of the available biogas, we create a reliable heat supply with maximum energy efficiency.

benefits

Advantages of a biogas-fired steam boiler

Biogas gives companies the opportunity to produce steam using a renewable energy source. As a result, this technology combines the reliability of a conventional steam boiler with the benefits of a more sustainable energy supply.

Fewer fossil fuels

Biogas fully or partly replaces natural gas within steam production.

Lower CO₂ emissions

Because biogas comes from biomass or organic waste streams, its climate impact is considerably lower than that of fossil fuels.

Valorization of waste streams

Organic residual products are no longer seen as waste, but as a valuable energy source.

More energy independence

Companies become less dependent on external energy suppliers and fluctuating natural gas prices.

Proven technology

Biogas can be used in industrial steam boilers with a reliability that is comparable to natural gas.

Broadly applicable

Biogas-fired steam boilers are suitable for a wide range of sectors and applications, such as the paper and cardboard industry and waste processing.

How do you integrate a biogas-fired steam boiler into your existing infrastructure?

A biogas-fired steam boiler is easy to fit into an existing steam system.

We can equip the boiler to process 100 % biogas, or to run partly on biogas and partly on another fuel. In the latter case, the boiler automatically uses the best available fuel.

Brouwerij De Brabandere Bavikhove ST biogas 25 T PRJ12427 2
Callens Service Onderhoud 3

Maintenance of your biogas-fired steam boiler and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best, even after commissioning. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance in line with the legal and technical requirements of your installation.

You can also count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 on-call service, an extensive range of spare parts and the expertise of our service technicians, we carry out interventions quickly and effectively.

Even the best maintained installation can malfunction or shut down unexpectedly. That is why the Callens Group offers various service packages, tailored to the response time and support you need. So even in unforeseen situations, you can count on our expertise.

More about our service contracts
partnership

Why partner with Callens Group?

60 years of experience in EPCS projects

An independent integrator focused on your specific needs

Flexible project execution

Short decision-making lines and a personal approach

Unique service & maintenance support

With 13 locations, always close by

Schermafbeelding 2026 08 28 100631
“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”

Projects with biogas-fired steam installations

20200827 101137
Thermal technology Steam boilers Biogas-fired

Steam glues together the production phases of cardboard producer

Capacity6 t/h
Operating pressure18 barg
Working pressure15 barg
Brouwerij De Brabandere Bavikhove ST biogas 25 T PRJ12427 1
Thermal technology Valorizing waste flows Biogas-fired +2

Steam boiler utilizes brewery’s biogas maximally

Capacity2.5 tons/h
Operating pressure13 barg
Working pressure8 barg

Discuss your challenge or project with our experts

Would you like to explore which solution is suitable for your specific project?

Our engineers are happy to think along with you, from initial exploration to concrete engineering.

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Questions? We have the answers.

Voor een brouwerij die niet alleen Belgische bieren produceert, maar ook biogas als nevenproduct, installeerde de Callens Group een nieuwe stoomketel van 2,5 ton/u die het biogas optimaal benut als duurzame brandstof voor de stoomproductie. De bestaande, verouderde ketels blijven behouden als back-up en ondersteunen indien nodig de werking. Wanneer er onvoldoende biogas beschikbaar is, kan de installatie automatisch overschakelen naar een combinatie met aardgas. Daarnaast voerde Callens de nodige elektrische aanpassingen uit en werd een centrale PLC-stuurkast voorzien voor een vlotte bediening en opvolging van de installatie. Dankzij deze oplossing verlaagt de brouwerij haar ecologische voetafdruk en verhoogt ze de valorisatie van haar eigen energiebronnen.
Ontdek hier alle details van het project.

Biogas is produced when organic material such as sludge, manure, food residues or other biological waste streams is broken down by micro-organisms. The gas consists mainly of methane (CH₄) and carbon dioxide (CO₂) and can be used as a renewable fuel to produce process steam.

In any sector where biogas is produced. These are typically sectors where large amounts of organic waste streams are released — think food companies, breweries, dairy processors, slaughterhouses, wastewater treatment plants, farms and waste processors. Companies with a digester or wastewater treatment plant can often use the biogas produced directly for their heat or steam supply.

That will depend on the composition of the biogas. In many cases, unwanted components such as water vapor, sulfur compounds or other contaminants are removed in advance to guarantee stable combustion and a long service life for the installation. The required treatment is determined based on an analysis of the available biogas stream.

Many biogas-fired steam installations are designed as dual-fuel installations. In that case, the system can switch automatically to natural gas when biogas production is temporarily lower than the heat demand. This keeps the steam supply guaranteed without any risk of production loss. Want to know which backup strategy is most suitable for your site? The Callens Group specialists will be happy to advise you.

Cost-effectiveness will depend on factors such as the amount of biogas available, the natural gas price, steam consumption and the number of operating hours. For companies that already have a stable biogas production, steam production is often one of the most efficient ways to make the most of the biogas’s energy value.

Biogas is the raw gas a digestion process releases. Biomethane is produced after the biogas is further purified to a quality comparable to natural gas. Both fuels can be used for steam production, but biomethane generally offers more flexibility in terms of injection into the gas grid.

As an EPCS integrator, the Callens Group takes charge of the entire process: from on-site analysis and engineering to installation and service. You can find out more about the various steps in our workflow here.

In certain cases, yes. Depending on the burner, the controls and the properties of the biogas, existing installations can be adapted to run fully or partly on biogas. A technical analysis is necessary to determine the feasibility and modifications that may be required. Considering making an existing installation more sustainable? The Callens Group specialists will be glad to explore the possibilities.

The methane content and composition of the biogas have a direct influence on the available output, combustion and the efficiency of the installation. That is why the burner control is tailored to the properties of the available biogas, to guarantee you a stable and efficient operation.

For a brewery that not only produces Belgian beers but also biogas as a by-product, the Callens Group installed a new steam boiler of 2.5 t/h that makes optimal use of the biogas as a sustainable fuel for steam production. The existing, aging boilers are retained as backup and support operation when needed. When insufficient biogas is available, the installation can automatically switch to a combination with natural gas. Callens also carried out the necessary electrical modifications and provided a central PLC control cabinet for smooth operation and monitoring of the installation. Thanks to this solution, the brewery is reducing its ecological footprint and valorizing its own energy sources. More details:

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