Primary Modular Configurations
High-Efficiency Gas Separation & Purified Fluid Skid Solutions
Explore our precision-engineered, skid-mounted biomethane upgrading and auxiliary fluid filtration systems designed to meet European DIN EN 16723-1 and US pipeline injection standards.
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Industrial Macro Dynamics
Biomethane Upgrading: Global Megatrends & Decarbonization Mandates
The strategic shift from localized combined heat and power (CHP) generation to advanced biomethane purification, bio-LNG liquefaction, and pipeline injection.
Biomethane (renewable natural gas, or RNG) has transitioned from an agricultural sub-product into a tier-one renewable energy vector. While historical biogas utilisation heavily relied on internal combustion engines for combined heat and power (CHP) at modest thermal efficiencies (35%–42%), systemic decarbonisation policies—such as the European Union's REPowerEU initiative targeting 35 billion cubic metres (bcm) of annual biomethane production by 2030, and the US Inflation Reduction Act (IRA) Section 45Z clean fuel production credits—have catalyzed massive capital deployment toward biomethane upgrading infrastructure.
Raw biogas derived from anaerobic digestion of organic matter typically contains 50%–65% methane (CH₄), 35%–50% carbon dioxide (CO₂), alongside aggressive trace impurities including hydrogen sulphide (H₂S, 100–10,000 ppmv), volatile organic silicon compounds (siloxanes, 5–50 mg/Nm³), moisture, and trace oxygen/nitrogen. Biomethane upgrading is the rigorous process of bulk carbon dioxide removal, deep desulphurisation, and trace volatile contaminant polishing to produce a pipeline-compliant or transport-ready gas stream containing greater than 97%–99% CH₄.
Grid Injection Compliance
Strict regional calorific value specifications require deep CO₂ stripping down to <2.0% mol, oxygen <10 ppm, and dew points down to -40°C under 40–80 barg line pressures.
Bio-LNG & Heavy Mobility
Integration of upgrading trains with cryogenic liquefaction skid modules (-162°C) enables zero-fossil fuel logistics for maritime long-haul carriers and Class 8 heavy road haulage.
Biogenic CO₂ Valorization
Modern upgrading facilities capture the high-purity permeate CO₂ stream (>99.5%), transforming a byproduct into food-grade liquid CO₂ or synthetic e-fuel feedstock (Power-to-Gas).
Engineering Matrix
Comparative Evaluation: Core Upgrading Technologies
A rigorous quantitative benchmark comparing polyimide hollow-fiber membranes, 4-bed/6-bed vacuum swing adsorption (VSA/PSA), and high-pressure water scrubbing (HPWS).
| Performance Vector | 3-Stage Hollow-Fiber Membrane | Pressure Swing Adsorption (PSA) | High-Pressure Water Scrubbing (HPWS) | Amine Chemical Absorption |
|---|---|---|---|---|
| Methane Recovery Efficiency | > 99.2% (with recycle stage) | 96.0% – 98.0% | 97.0% – 98.5% | > 99.5% |
| Product Gas Purity (CH₄) | 97.5% – 99.5% | 96.5% – 98.5% | 96.0% – 98.0% | > 99.0% |
| Electricity Consumption | 0.20 – 0.28 kWh/Nm³ feed | 0.24 – 0.32 kWh/Nm³ feed | 0.25 – 0.35 kWh/Nm³ feed | 0.12 – 0.18 kWh/Nm³ (High Heat) |
| Thermal Energy Demand | Zero (100% Electrified) | Zero (100% Electrified) | Zero | 0.50 – 0.80 kWh_th/Nm³ |
| Chemical / Water Waste | None (Dry Separation) | None (Dry Adsorption) | Continuous Blowdown / Fouling | Solvent Degradation & Disposal |
| Skid Footprint & Modularity | Ultra-Compact (Containerized ISO) | Medium (Tall Vessel Columns) | Extensive (Pumping & Desorption Towers) | Extensive (Reboiler & Heat Exchange) |
Industry 4.0 Manufacturing
China Factory 4.0: Supply Chain Resilience & OEM Engineering Agility
How state-of-the-art Shanghai production centers leverage automated orbital welding, precision manifold CNC, and full-scale Factory Acceptance Testing (FAT) to deliver world-class capex advantages.
Global engineering procurement teams and renewable infrastructure developers face escalating capital equipment costs and protracted project delivery timelines from traditional Western suppliers. Shanghai Tongjie breaks this bottleneck by synthesizing European engineering design tolerances with the unparalleled velocity, vertical manufacturing integration, and cost competitiveness of China's advanced industrial ecosystem.
Operating from our modern Jiading District industrial complex in Shanghai, we execute turnkey design, skid prefabrication, electrical assembly, and automated software integration under one roof. Holding Class II Contracting Qualifications in Environmental Protection Engineering and Mechanical & Electrical Installation alongside ISO 9001, ISO 14001, ISO 45001, and full EU CE Conformity, our specialized facility ensures that every skid is subjected to comprehensive pneumatic hydrostatic testing, helium leak-mass spectrometry, and full FAT functional testing before sea freight dispatch.
Vertical Component Sourcing
Direct tier-1 strategic partnerships with world-class membrane module manufacturers, certified pressure vessel foundries, and premium compressor brands guarantee shortened lead times and complete component traceability.
Rigorous Quality Traceability
Complete metallurgical mill test reports (MTR), non-destructive testing (NDT/X-ray) on all high-pressure gas headers, and serialized ISO 9001 quality compliance folders supplied with every delivery.
AI-Assisted SCADA & IoT Architecture
Every skid is outfitted with advanced Siemens or Allen-Bradley programmable automation controllers with secure edge-computing cellular telemetry for 24/7 predictive health monitoring and remote diagnostic dispatch.
38+
Invention & Utility Patents
17+
Years Engineering Heritage
100%
Factory Prefabricated & Tested
30-40%
Typical Capex Savings vs. EU/US
Field Engineering
Diverse Field Scenarios & Tailored Engineering Integrations
Engineered flexibility to handle raw gas variability across agricultural manure digesters, municipal wastewater treatment plants, and massive industrial landfill complexes.
Agricultural Digesters & Livestock Slurry
Equipped with primary biological scrubbers and dual-tower regenerative desulphurization beds to neutralize high H₂S concentrations (>5,000 ppm) typical of intensive dairy, swine, and poultry manure substrate operations.
Municipal Wastewater Sludge (WWTP)
Configured with heavy-duty thermal swing adsorption (TSA) chillers and activated carbon polishing arrays to systematically strip siloxanes (D4, D5) to below 0.1 mg/Nm³, safeguarding downstream catalysts.
Municipal Landfill Methane (LFG)
Engineered for atmospheric air ingress common to landfill vacuum wells. Features proprietary N₂/O₂ scavenger stages or selective multi-stage membranes to reject nitrogen down to pipeline standards (<1.5%).
Consultative Engineering Q&A
Frequently Asked Technical & Procurement Questions
Authoritative insights addressing methane slip mitigation, membrane degradation, compressor integration, and delivery parameters.
How does your 3-stage membrane upgrading system suppress methane slip to under 0.5%?
Our multi-stage process applies an intelligent recycle architecture. Raw biogas passes through the Stage 1 primary membrane separation loop; the permeate gas (consisting of high CO₂ with residual methane) is automatically routed to Stage 2 and Stage 3 membrane banks. The retentate from the secondary stages is recycled directly upstream of the primary compressor. This closed-loop recirculation ensures overall CH₄ recovery exceeds 99.2%, keeping methane slip in the final vent stream well below 0.5%, in total compliance with strict EU environmental directives.
What measures protect the gas separation membranes against fouling and early degradation?
Membrane integrity depends entirely on pre-conditioning. Tongjie integrates a multi-tier protection train: 1) Thermal condensation refrigeration condensing moisture to dew points below 3°C; 2) Regenerative active chemical-impregnated media beds removing volatile silicon compounds (siloxanes) and H₂S down to <0.1 ppmv; 3) Micro-coalescing aerosol filters with 0.01 µm absolute retention; 4) Feed gas preheating above the hydrocarbon dew point before entering the high-pressure polyimide hollow-fiber modules, completely eliminating liquid condensation and plasticization risks.
What are the project lead times and Factory Acceptance Testing (FAT) protocols?
Standard containerized skids (250 to 1,500 Nm³/h feed gas capacity) maintain an average delivery lead time of 12 to 16 weeks from approved P&ID sign-off. Prior to export boxing, each unit undergoes rigorous FAT protocols at our Shanghai plant, encompassing 100% radiographic weld audits, pneumatic pressure retention trials, dielectric insulation certifications, and simulated loop testing of all digital/analog I/O points within the PLC safety shutdown matrix.
Does Tongjie provide turnkey private-label (ODM/OEM) customization for EPC partners?
Yes. We regularly serve as the OEM engineering and manufacturing backbone for major international engineering contractors (EPCs) and proprietary clean-energy technology brands. We support customized structural container layouts, tailored paint specs (C5-M marine anti-corrosion), integration of regional preferred components (e.g., ABB, Endress+Hauser, Siemens, Schneider), branded HMI interfaces, and comprehensive technical documentation packages designed to client specifications.
Advanced Separation Systems
Precision Membrane & Specialized Fluid Decontamination Skids
Review our specialized portfolio of deoxygenation, degassing, pure water, and ultra-high salinity flowback recovery systems operating across global infrastructure installations.
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