teCH4+ is a technology-based company specialised in optimising anaerobic digestion through its continuous thermal hydrolysis.
The Polanco Process, its patented technology for municipal wastewater sludge management, increases biogas production by up to 35% and reduces biosolids volume by 50%. The solution, applicable to WWTP sludge and biogas plants, builds on the scientific legacy started in 1979 by Fernando Fernández-Polanco and stands out for its technical rigour, reliability, and cost reduction.
Continuous thermal hydrolysis is a “pressure cooker” that subjects sludge to high pressures and temperatures to accelerate the limiting stage of anaerobic digestion: hydrolysis or solubilisation of organic matter.
The advantages of thermal hydrolysis in a WWTP are increased biogas production (+35%), reduced biosolids volume (-50%), hygienisation that guarantees agricultural application, and reduced digester volume and CAPEX (-50%).
Increases sludge biodegradability and biogas yield.
Improves dewaterability, reducing biosolids volume and management costs.
High pressures and temperatures eliminate pathogens, producing biosolids suitable for agricultural use.
Doubles the organic loading to digestion and allows to increase capacity without new infrastructure.
As a continuous process, the Polanco Process requires a single hydrolysis reactor. This sets it apart from technologies that need 2, 3 or 4 reactors to operate in batches and makes it inherently more economical and more compact.
By operating in steady state, with all parameters constant over time around the setpoint, it is a more stable and easier-to-control process.
The application of a double flash, or steam explosion, maximises solubilisation and the recovery of process vapours, which preheat the sludge in in-line steam injectors and reduce energy consumption.
Another distinctive feature of the process is the evacuation of pressurised non-condensable gases, so they can be conveyed to their final destination without the need for additional mechanical equipment.
The first step in implementing the Polanco Process is a technical feasibility, economic profitability, and return on investment (ROI) study. Based on the specific data of the case under study, rigorous mass and energy balances are developed as the basis for evaluating the integration of thermal hydrolysis into the existing or planned treatment line. After evaluating the different scenarios and configurations, the technical parameters are translated into the key financial indicators of the potential project.
The first of these is operational savings (OPEX), taking into account benefits in both biogas and biosolids. By comparing these savings with the estimated capital expenditure required (CAPEX), profitability is calculated and expressed as ROI, Net Present Value (NPV), or Internal Rate of Return (IRR).
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Our references in thermal hydrolysis technology have continued to grow since the first commercial Polanco Process plant, installed at Copero WWTP (Seville, Spain) and in operation since 2020.
This installation was a decisive milestone in the history of teCH4+, continuing a scientific legacy that began in 1979 and more recently started its international expansion with the installation at the FBS WWTP (Fquih Ben Salah, Morocco) in 2025.
A journey that, in addition to commercial plants, has included pilot projects such as those in Guijuelo in Salamanca and Valdemingómez in Madrid. Because continuous learning is essential for a business project with a Quality Management System certified according to the ISO 9001:2015 standard by Bureau Veritas.
Biogas production is increased by up to 35% and the biosolids volume to be managed is reduced by up to 50%.
During the development of the technology, thermal hydrolysis pilot plants were built for clients in France and Chile, followed by a demonstration plant in Turkey. After developing the technology in Spain, it was internationalized in 2025 with a commercial plant in Morocco.
Yes, by subjecting the waste to high pressures and temperatures, the process guarantees the total elimination of pathogens and its safe agricultural use.
Because the sludge is hydrolysed, the digesters can operate with shorter hydraulic retention times (HRT) and double their organic loading rate (OLR), reducing the digestion volume to half that required by a conventional process.
We continue a scientific legacy that, after beginning its journey in 1979 from basic science, went through all scale-up stages and culminated in our successful commercial references and ISO 9001 quality certification.
As part of IWA AD-19, we had the pleasure of hosting the technical visit to the Pinedo WWTP. This plant serves 1.8 million equivalent inhabitants of the metropolitan area of Valencia, returning reclaimed.
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