Troubleshooting Biogas: A Simple Fix with Big Impact

During a recent visit to a wastewater treatment plant, one of our team members discovered an opportunity to put Energenecs’ biogas expertise to work. We spoke with 

How did this project come about?

I was actually at the plant for a demo on some pumps. While we were touring the facility, I noticed they had a biogas system. The first thing I asked was, “How’s it working?” They showed me around and pointed out the flare system. When I asked about it, they said it hadn’t worked properly in years. Instead, they had to go out and manually light it with a torch every so often.

Manually lighting it? That sounds risky.

Exactly. They told me they sometimes had to step back because it could be unpredictable. They were lighting the flare every few hours or every couple of days depending on the gas buildup. I said, “That doesn’t sound right—why don’t we have one of our technicians come take a look?” We offered to stop by for a courtesy visit.

What did the Energenecs team find?

Our technician, Larry Claude inspected the system and discovered the problem was fairly simple: an electrical wiring issue. A wire had been cut at some point, which meant the igniter wasn’t receiving the signal to automatically light the flare.

What role does the flare play in a biogas system?

When a plant produces more biogas than it can use, that excess gas needs to be safely burned off. That controlled burn prevents raw gas from being released into the atmosphere.

Was fixing the wire all it took?

That was the main issue, but while Larry was there he also performed a full system check. He inspected components, reviewed when parts like diaphragms were last replaced, and made adjustments to the pressure and valve settings that control when gas is released and burned. Those calibrations helped the system run more efficiently.

What was the result after the repair?

About a month and a half later, I followed up with the plant. They told me the system was running great and that they no longer needed to go out and manually light the flare. In fact, they said the adjustments had significantly improved the overall efficiency of the system.

What does this say about Energenecs’ role in biogas systems?

A lot of facilities don’t realize Energenecs has the expertise to work on biogas systems—even ones that weren’t originally installed by us. Our team can inspect systems, diagnose problems, and often improve performance by repairing or upgrading key components.

What’s the takeaway for facilities with biogas systems?

If something isn’t working quite right—or hasn’t worked for years—it’s worth having someone take a look. Our technicians are experienced in troubleshooting and optimizing biogas systems across the Midwest. Often, a relatively small fix or adjustment can make a big difference in safety and efficiency.