BioCrack II

Electrokinetic disintegration

  • Significantly higher gas yield from digester towers and digesters
  • Significantly lower electricity consumption by pumps and mixers
  • Lowest energy costs and low investment costs
  • Easy and flexible to retrofit
  • No regular maintenance, no inspections: always ready for use

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BioCrack - Electrokinetic disintegration for higher gas yields and reduced internal energy requirements of biogas plants

The easiest way to increase the economy of a biogas plant is to increase the specific biogas yield, i.e. the quantity of biogas generated from the biomass used. Cost reduction is another approach.
Electrokinetic disintegration with BioCrack helps you reach both of these goals. On one hand, the BioCrack electrokinetic disintegration process enables bacteria in digesters to access nutrients in the organic suspension more easily. The treatment boosts the enzyme activity and breaks down clumps such as aggregates or colloids of dead organic materials and bacteria. As a result, the digesting bacteria can access the nutrients better and easier. Combined, these two features make better use of the biomass, increasing the biogas yield. At the same time, the viscosity of the organic suspension decreases, reducing the power consumption of pumps and mixers, and allowing the digester to be mixed better. Mixer runtimes can be reduced, decreasing the overall costs for the biogas plant’s internal electricity consumption significantly. All in all, this improves the efficiency of the biogas plant significantly.
The system is easy to integrate and retrofit in existing workflows.

To Biogas World



BioCrack - Electrokinetic disintegration for higher gas yields and reduced disposal costs

The objective of every sewage treatment plant is eliminating as much of the contamination in the wastewater as possible with the lowest costs possible. And those are precisely the strengths of electrokinetic disintegration with BioCrack. Treating the sludge breaks down aggregates and colloids. As a result, the micro-organisms can access the nutrients easier, more of the contamination is degraded. If the sludge is stabilized anaerobically in digestion towers, this can increase the base or electricity yield by up to 15 percent. The costs for third party energy purchases are reduced, as are floating and sinking layer volumes. At the same time, the sludge viscosity is lower after treatment, decreasing the power consumption of pumps and mixers. Wastewater treatment in sewage treatment plants without sludge digestion can also be optimized with electrokinetic disintegration: The sludge treatment breaks down EPS structures, allowing better drainage of the sludge. This reduces the costs for sewage sludge disposal and flocculent requirements. In addition, the reduced viscosity decreases the energy requirements for ventilation. The system ensures stable process workflows and is generally easy to integrate and retrofit in the existing workflow, e.g. in the digester tower circulation line or the digester tower feeder. If no digester is installed, the return sludge can be treated before it is fed to the activation phase.

To Wastewater World

Disintegration in various markets

You want to know more about where to use the Vogelsang electrokinetic or mechanial disintegration systems? Then have a look at either our biogas world or our wastewater world.

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+61 2 46 47 8511



The BioCrack housing, which also serves as the outer electrode, is made of stainless steel. That makes the modules robust and resistant to corrosion – internal and external.
The electrode in the interior of the BioCrack module is protected by a casing consisting of a one-piece PE housing without joints and connections. That means that no medium can come in contact with the electrode and cause trouble.
The software of the digital power supply continuously monitors all important current values and automatically regulates them in the optimal range for most effective treatment. And if a malfunction ever does occur, the control unit registers it and takes protective measures.
The double-shielded supply line to the electrode head is equipped with an anti-kink device to prevent damage to the cable.
All important parameters of every individual BioCrack electrode are tested in the factory before use in the field.


If the BioCrack modules cannot be mounted on a wall etc., the BioCrack base is the solution: Up to six BioCrack modules can be arranged in a compact layout on it.

Design and operating principle

A BioCrack module consists of the BioCrack housing, which acts as the treatment chamber and external electrode, and the internal electrode in the middle of the housing. This is supported in connecting pieces at each end, which hold it in position. The electronics are installed in the head of the internal electrode; the energy is provided by the corresponding power supply. The medium flows through the treatment chamber where a high voltage field with tens of thousand of volts is generated between the internal electrode and the stainless steel external electrode. As the medium flows through the high voltage field, the electrical forces applied break down flocculant structures and clumps such as aggregates and colloids made up of dead organic matter and bacteria. It also boosts enzyme activity. Altogether, this ensures that the nutrients are far easier to access for the digesting bacteria, and the organic content can be transformed and broken down better. That ensures a higher gas yield, reduced viscosity of the medium and makes sludge easier to drain.

Images of models are similar.

Case Studies BioCrack

Case study - Kotthoff biogas plant - BioCrack

BioCrack: Retrofitting the biogas plant: smooth running and efficiency with BioCrack

Problem: Fibrous input materials, insufficient efficiency in the biogas plant
Solution: Electrokinetic disintegration with Vogelsang BioCrack

Read the Case Study

Case study - Hedeper biogas plant - BioCrack

BioCrack: Greater gas yield and lower energy requirements thanks to disintegration

Problem: Inadequate gas yield in the biogas plant
Solution: Vogelsang BioCrack® electro-kinetic disintegration unit

Read the Case Study

Case study - Biogas plant project of WHG Anlagenbau GmbH & Co. KG - BioCrack

BioCrack: Greater stability and energy efficiency in the biogas plant

Problem: Residual gas potential in the open final storage
Solution: Reducing residual gas potential and re-circulated quantities with BioCrack

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Case Study -Fava Marcello biogas plant - BioCrack

BioCrack: Upgrading the plant efficiency and stability

Problem: Inefficiency biogas production
Solution: Electrokinetic disintegration with Vogelsang BioCrack

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Case Study - sewage plant in south Germany - BioCrack

BioCrack: Greater gas yield and lower costs with BioCrack® disintegration unit

Problem: Excessive running costs at sewage treatment plant
Solution: VOGELSANG BioCrack electro-kinetic disintegration unit

Read the Case Study

Case Study - dairy Zott GmbH & Co. KG - BioCrack

BioCrack: Optimized process and degradation rate of sewage treatment plant

Problem: Strong fluctuation in utilization, low gas yield
Solution: Electrokinetic disintegration with Vogelsang BioCrack

Read the Case Study

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