µFuel – micro-fuel

Bionic µFuel is the core technology of the Bionic platform. In a specially developed microwave reactor, organic materials – for example, wood, agricultural residues, or biogenic waste – are thermally converted in a low-oxygen environment. Volumetric heating with microwaves creates very uniform temperature control, largely avoiding the classic disadvantages of conventional pyrolysis plants (hotspots, incomplete conversion, long heating times).

The result of the μFuel process is a defined product mixture of gas, oil, and solid biochar. The process control can be adjusted to optimize the proportion of liquid energy carriers, process gases, or biochar, depending on the requirement. The technology is modular, scalable, and suitable for both decentralized facilities and industrial cluster installations.

µSoil – micro-soil

Bionic µSoil begins exactly where μFuel ends: with the use of the biochar generated in the process. Biochar possesses a large inner surface, high porosity, and special chemical stability. In combination with nutrients and organic matter, it creates a high-performance soil conditioner that follows the principle of South American Terra Preta.

In the μSoil concept, the biochar is specifically loaded with nutrients and combined in tailored recipes with organic components and mineral fertilizer. This creates fertilizers and soil additives that significantly improve water retention capacity, cation exchange capacity, and nutrient efficiency. Simultaneously, the carbon bound in the biochar is stabilized in the soil for decades to centuries, acting as a permanent CO2​ sink. μSoil thus combines agricultural benefit with measurable climate protection.

µWaste – micro-waste

µWaste describes the application of the μFuel technology to plastic and municipal waste streams. Instead of landfilling mixed waste or incinerating it in classic waste-to-energy plants, it is converted into oil, gas, and solid carbon in a controlled microwave conversion process. The process conditions are designed to generate as few pollutants as possible and to selectively retain or separate problematic components.

This creates an additional option for municipalities and waste management companies between landfilling and incineration: waste streams are reduced, energy is recovered, and dependence on fossil primary energy sources decreases. μWaste can be used both as a standalone facility and as a module in larger Bionic systems.

µTyre – micro-tyre

µTyre is the Bionic technology tailored specifically for scrap tires and rubber-containing residues. Tires are considered a particularly difficult waste stream worldwide: they are robust, difficult to shred, and contain a complex mixture of rubber, steel, and additives. In the μTyre process, the tires are pre-processed so that they can be efficiently converted in the microwave reactor.

The resulting products include oil fractions that can be used as energy carriers or as feedstock for the chemical industry, process gases for internal energy supply, and biochar fractions that are further utilized in μSoil or μSorb products. μTyre thus unlocks a previously problematic waste stream as a raw material source and simultaneously reduces the risk of landfilling and open burning.

µPower – micro-power

Under µPower, Bionic summarizes the coupling of microwave conversion with classic power plant and CHP (Combined Heat and Power) technology. The gases and oils arising from the μFuel, μWaste, or μTyre process are used to generate electricity and heat – either in the form of decentralized combined heat and power plants, turbine solutions, or other units.

This results in compact, highly integrated plant concepts where residues are converted into energy and products, while simultaneously providing process heat and electricity for internal consumption or feeding into the grid. μPower is therefore an important component for economic, nearly energy-autonomous facility locations.

µSorb – micro-sorb

µSorb denotes the Bionic product line for filter and adsorbent materials based on biochar. Through targeted process control, post-treatment, and activation of the carbons, the pore structure and surface chemistry can be adjusted so that certain pollutants are bound particularly well.

Application areas range from water and wastewater treatment to air and exhaust air treatment, as well as industrial liquids and gas streams. μSorb products can be used as loose bulk material, in filters, or in composite materials, and offer a sustainable alternative to classic fossil-based activated carbons.

CO2​ / NOx​ / NH4​ Reduction

A central goal of Bionic technologies is the measurable reduction of emissions. By using biogenic residues and incorporating the resulting biochar into μSoil and μSorb products, permanent CO2​ sinks are created. At the same time, process control and exhaust gas purification can be designed so that NOx​ and NH4​ emissions are significantly lower than in classic reference facilities.

This facilitates compliance with national and European environmental regulations and creates additional options for CO2​-oriented business models, for example via certificates or climate protection programs. In many projects, not only the balance sheet of individual facilities is considered, but the entire life cycle of the utilized raw materials and products.

AI-supported Process Control

With the increasing complexity of the facilities, the digital level gains importance. Bionic therefore relies on AI-supported process control: operational data from sensor technology, actuators, and analytics are continuously collected, evaluated in real time, and used for the optimization of process management.

Machine Learning models recognize patterns, deviations, and trends that would be difficult to spot using classic methods. On this basis, temperature profiles, residence times, gas flow, or mixing ratios can be automatically adjusted. This increases efficiency and availability, reduces manual control effort, and enables standardized remote operating models – extending to the management of entire facility fleets.

µCTL – micro-char-to-liquid

µCTL forms the conclusion of the technological chain: the refinement of biochar into synthetic liquid fuels. Here, Bionic utilizes the coal liquefaction process developed by Friedrich Bergius, but transfers it to modern, biogenic carbons from the μFuel process.

Under high pressure and defined temperature, carbon and hydrogen react to liquid hydrocarbons. A solid, difficult-to-transport energy carrier is thus transformed into a liquid energy carrier that can be integrated into existing logistics and infrastructure systems. μCTL thus opens up additional value creation paths – especially where high-quality specialty fuels or chemical intermediates are in demand and fossil raw materials are to be replaced.

Taken together, μFuel, μSoil, μWaste, μTyre, μPower, μSorb, Emissions Reduction, AI Process Control, and μCTL form a continuous technology ecosystem: from the capture and conversion of raw materials, through energy and product utilization, to CO2​ sinks and synthetic fuels. Bionic thus provides a complete platform for the industrial use of microwave conversion technology.