Use case · Wastewater

Sewage Sludge to Power

Turn dried sewage sludge into clean gas for power and heat, on site, in one container.

The problem

Sludge is costly to get rid of

Every wastewater treatment plant produces tonnes of sewage sludge every day. Most of it is trucked away, spread on fields, or sent to a large incinerator far from town. That costs money, diesel and time.

A truck tipping dewatered sewage sludge at a wastewater plant
Trucked away
Sewage sludge being spread across an open field
Spread on fields
A large sludge incinerator plant with its stack, far from town
Burned far from town
The X-150 container gasifier installed beside a wastewater treatment plant
The solution

Treat it where it is made

The X-150 is a containerised gasifier that sits beside your plant. Dried sludge goes in; a high-temperature reactor bed turns it into clean gas. The gas runs an engine for power, and the recovered heat can dry the next load of sludge.

The process

How it works

01
Dry

Dewatered sludge is dried to 15% moisture or less, using the X-150's own recovered heat where possible.

02
Gasify

A top-blown, single-stage reactor bed at about 1,000–1,100 °C converts the sludge into gas, without burning it.

03
Clean

The gas is filtered and cooled, clean enough for engines.

04
Power and heat

A gas engine turns it into electricity; heat is recovered for drying, heating or cooling.

The breakthrough

Built for high-ash waste

Sludge is full of ash. At high temperature the ash melts, hardens into clinker and chokes most gasifiers. Our team in Germany spent twenty years on this one problem. In the X-150, a poker from above and water-cooled rollers below remove the slag while the reactor keeps running.

Hardened clinker slag removed from the reactor bedTwo engineers examining clinker taken from the X-150 reactor

Technical specifications

Input capacity
150 kg/h of dry waste (up to about 1 t/h of wet, dewatered sludge)
Feed preparation
Dried or pelletised, 15% moisture or less
Reactor
Top-blown, single-stage fixed bed, operating above the ash melting point (about 1,000–1,100 °C)
Slag handling
Poker plus water-cooled roller grate, continuous removal while running
Electrical output
150–180 kW (rated on wood; output on sludge depends on its energy content)
Heat output
430–470 kW thermal (rated on wood)
Operating modes
Air mode for power and heat (gas-engine CHP); absorption chiller for cooling; oxygen-steam mode for hydrogen-rich gas
Footprint
20-ft containers: process container plus gas-engine container
Control
Laser bed control and remote monitoring; EXOS fleet system launching December 2026
Scaling
Modular: ten X-150s give 1.5–1.8 MW electric, and units can move to a new site
Other feedstocks
Household waste, straw and wood waste
Validation
Externally validated by leading research institutions; government-funded development

Figures are rated values. Site performance depends on the sludge and the project design.

Benefits

What it means for your plant

Less trucking and disposal cost
Power and heat on site
Heat that dries your sludge
Modular and movable: add units as you grow
A row of X-150 container units installed on a site

Need more capacity? Add units.

Sunrise over a wastewater plant that generates its own power

Sludge to energy, on site.

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