Bionic World is the website of Bionic Laboratories BLG GmbH, a technology company in the field of microwave conversion technology (MWDP). We develop innovative solutions for the sustainable utilization of organic materials, biomass, plastic waste, end-of-life tires, and refinery residues. Our proprietary technologies convert these materials into valuable raw materials.

BIONIC LABORATORIES BLG GmbH was founded 15 years ago, while the BIONIC GROUP has been in existence for 20 years. During this time, we have become a technology leader in the commercial use of microwaves for depolymerization.

We offer 9 core technologies:

• µFuel: Sustainable fuel production from biomass
• µSoil: Organic/eco-fertilizer from biochar
• µWaste: Efficient waste/plastic conversion to oil and coal
• µSorb: Absorption and filter materials
• µCTL: Coal-to-liquid process, fuels from biochar
• µPower: Sustainable energy generation with bio-oils
• µTyre: End-of-life tire recycling to fuel and coal
• CO₂ Reduction: Significant, profitable emission reduction
• µAI: AI-supported process control

MWDP stands for Microwave Depolymerisation Process. This proprietary Bionic technology uses microwave energy to break down complex organic materials into their molecular components and convert them into high-quality products. The process is highly efficient, environmentally friendly, and energy-saving.

Bionic plants are local solutions for decentralized deployment:

• Waste management and recycling
• Agriculture and biomass utilization
• Chemical industry
• Energy sector
• Automotive industry (tire recycling)
• Municipal waste disposal

Bionic technologies are extremely environmentally friendly:

• 90% lower CO₂ emissions vs. conventional processes
• No combustion and low temperatures - therefore no dioxins or furans
• Energy efficient through proprietary microwave technology
• Circular economy: waste becomes raw material
• Sustainable products without fossil raw materials

The installation duration depends on the plant size:

• • A typical project takes approximately 1 year

This includes planning, permits, delivery, installation, and commissioning.

The current standard type is the mf200 with approximately 1-1.5 t/h input capacity:

• The space within a hall should be 600-800 m² with a height of approximately 12m
• An electrical connection value of ~1MW(max)/400V is required
• Tank and silo systems, usually for 5 days capacity, are installed outdoors
• Sufficient space for traffic and parking must be considered

Yes, we offer comprehensive training:

• Operator training: 5-day training for plant operators
• Maintenance training: 3-day technical training
• Online support: 24/7 remote assistance
• Refresher courses: Annual updates

All training is included in the plant price.

You can reach us in various ways:

• Phone: +49 (0) 1525 33 40 500
• Email: info@bionic-world.net
• Contact form: On our website
• Address: BIONIC LABORATORIES BLG GmbH, Eppertshausen, Germany

Our team typically responds within 24 hours.

µFuel is a microwave conversion technology for sustainable production of fuels and biochar from biomass. The process uses microwave energy at 300-400°C, is highly efficient (85% efficiency) and environmentally friendly.

µFuel processes various organic materials:

• Wood pellets and wood waste
• Agricultural waste (straw, corn stalks)
• Bio-waste, including uncontaminated sewage sludge
• Carbon-containing materials (min. 40% C content)

The process runs in four steps:

1. Preparation: Drying and shredding to ~15% moisture
2. Preparation: Pelletizing with a catalyst
3. Microwave pyrolysis: Heating to 300-450°C without oxygen
4. Condensation: Vapors are condensed and collected
5. Refining: Purification of products

From 1 ton of biomass:

• 250-400 liters of bio-oil/fuel (phenols/BTX/fuels)
• 300-400 kg of biochar
• 100-150 m³ of synthesis gas (e.g. H2, methane, ethane, pentane)

All products are commercially usable.

µFuel reduces CO₂ emissions by 90% compared to fossil fuels. A standard plant (24 t/day) saves approximately 12-15,000 tons of CO₂ per year and produces CO₂-negative products through biochar binding.

Project prices depending on plant size and feedstock:

• Please contact us for detailed information
• Plants range from laboratory reactors to facilities with 8,000 tpa capacity

Depending on type, amortization in 3-5 years through product sales and CO₂ certificates.

Maintenance intervals:

• Daily: Routine checks, cleaning
• Monthly: Filter changes, system inspection
• Yearly: Major inspection, magnetron check

Maintenance costs: approximately 8% of acquisition costs per year.

Yes! After refining, µFuel fuel meets EN 590 standard (diesel) or EN 228 (gasoline). It can be used in all conventional engines without modification. Typically, the oils are used as admixtures in refineries or as chemical raw materials.

µSoil is a high-quality organic/eco-fertilizer made from biochar, produced through a controlled composting and fermentation process. It is made from biochar as an end product of µFuel technology in combination with additional biomass and animal products, and sustainably improves soil quality.

Biochar has an extremely porous structure (500-1000 m²/g surface area) that:

• Stores water and nutrients
• Promotes soil organisms
• Stabilizes pH value
• Binds CO₂ long-term (1000+ years)

• 20-30% higher yields, depending on crop type
• 30% less irrigation requirement
• Long-term effect (over 2 years)
• Improved soil structure
• CO₂-negative agriculture

µSoil is suitable for:

• Agriculture (arable farming, vegetable cultivation)
• Forestry
• Horticulture and landscaping
• Reclamation of degraded soils
• Urban farming

Application amounts:

• Initial application: 10-20 m³/ha
• Maintenance: 5 m³/ha annually
• Horticulture: 10-20% admixture to soil

Incorporation into the upper 15-30 cm soil layer.

Prices vary depending on quantity:

• Bulk (>100 t): €200-300/t
• Bags (25 kg): €15-20 per bag

ROI through higher yields in 2-3 years.

µWaste is a technology for efficient recovery of plastic and municipal waste. It is one of the strengths of the Bionicfuel system and converts problem waste into valuable raw materials.

• Mixed plastics (PE, PP, PS, PET)
• Municipal waste (residual waste)
• Packaging waste
• Electronic waste (after pre-sorting)
• Medical waste

From 1 ton of plastic waste:

• 600-800 liters of pyrolysis oil
• 150-200 kg of carbon black
• 50-100 kg of metals (recyclable)
• Minimal residue (<5%)

Yes, significantly:

• No dioxins or furans
• 85% lower CO₂ emissions
• Higher recycling value
• No ash or slag

Prices are project-based.

Minimal pre-sorting recommended:

• Removal of metals (automatically with magnets)
• Removal of glass and stones
• Maximum moisture content: 20%

The process is relatively insensitive to impurities.

µSorb refers to high-quality absorption and filter materials that emerge from the Bionicfuel process. The biochar has exceptional absorption and filtering properties.

• Water filtration: Removal of heavy metals and pollutants
• Air purification: Absorption of VOCs and odors
• Industrial filtration: Process water purification
• Oil absorbent: Absorption of oil and chemicals

µSorb materials have:

• 500-1000 m²/g surface area
• 95-99% filtration efficiency for heavy metals
• High capacity
• Regenerable through thermal treatment

Advantages over conventional activated carbon:

• Higher absorption capacity
• Sustainable production
• CO₂-negative
• Broader application spectrum

Yes! µSorb can be regenerated through:

• Thermal regeneration (400-600°C)
• Chemical regeneration
• 3-5 cycles possible

After end of life, it can be used as soil amendment (µSoil).

µCTL (micro-char-to-liquid) is the adaptation of the coal hydrogenation process developed by Nobel Prize winner Friedrich Bergius (1931). Bionic has modernized this process and applied it to biochar.

The process:

1. Biochar is ground and mixed with catalyst
2. Hydrogen is added under high pressure (200-300 bar)
3. Hydrogenation occurs at 400-500°C
4. Liquid hydrocarbons are produced

From 1 ton of biochar:

• 600-750 liters of synthetic fuel
• High quality (similar to GTL/BTL)
• Low sulfur and aromatics
• High cetane number (>40)

• Utilization of existing biochar
• Higher-value fuels than direct pyrolysis
• CO₂-neutral (with green hydrogen)
• Compatible with existing infrastructure

Hydrogen sources:

• Green hydrogen (electrolysis with renewable energy)
• From own synthesis gas (reforming)
• External hydrogen purchase

For maximum sustainability, we recommend green hydrogen.

µPower combines the Bionicfuel process with conventional power plant technology for sustainable energy generation. It uses synthesis gas and pyrolysis oil for electricity and heat production.

Three energy sources are utilized:

• Synthesis gas: Combustion in gas engines/turbines
• Pyrolysis oil: Combustion in diesel engines
• Process heat: Combined heat and power

Overall efficiency: 70-90%

Performance by plant size (at 24 t/day input):

• Electrical power: 400-600 kW
• Thermal power: 800-1,200 kW
• Electricity production: 9,600-14,400 kWh/day

Yes! Advantages:

• 24/7 operation possible
• Independent of wind and sun
• Storable fuels
• Adjustable according to demand

Ideal as a complement to renewable energies.

Electricity generation costs, depending on production method:

• With fuel costs: 12-18 ct/kWh
• With own biomass: 8-12 ct/kWh
• With subsidies: 6-10 ct/kWh

Competitive, especially with own biomass source.

Yes, various subsidy programs:

• EEG feed-in tariff (Germany)
• CHP surcharge
• Investment subsidies for biomass plants
• EU programs for renewable energy

We support with the application process.

µTyre is a specialized plant for processing end-of-life tires. It uses microwave technology for efficient recovery of a problematic waste product.

Annually, over 1 billion end-of-life tires are generated worldwide:

• Difficult to dispose of (not biodegradable)
• Health and environmental risk
• Valuable materials are lost
• Landfilling is prohibited in many countries

From 1 ton of end-of-life tires:

• 400-500 liters of pyrolysis oil (like diesel)
• 300-400 kg of carbon black (industrial carbon)
• 100-150 kg of steel cord (recyclable)
• 50-100 m³ of synthesis gas

Recovery rate: >95%

Carbon black from µTyre has high quality:

• Usable in new tires (up to 30%)
• Industrial applications (paints, plastics)
• Market value: €500-800/t

Important revenue factor alongside the oil.

Minimal pre-treatment:

• Coarse shredding (shredder) to 10mm size
• Rims must be removed
• Car, truck, aircraft, old tires processable

Steel cord is automatically separated during shredding.