How Drone-based Laser Methane Detectors Enable Safe Operations in the Biogas and Biomethane Industry

With the rapid development of the biogas and biomethane industries across Europe, Southeast Asia, and China, biogas power plants are playing an increasingly important role in regional and global energy structures. As a key component of renewable energy systems, biogas power generation contributes significantly to energy decarbonization, energy security, and greenhouse gas emission reduction.

However, during long-term operation, methane leakage risks are unavoidable in biogas plants. Potential leakage points may exist at digesters, pipelines, valve connections, gas storage units, and auxiliary equipment. Traditional manual inspection methods are labor-intensive, inefficient, and highly dependent on personnel experience. As plant sizes continue to expand, these methods struggle to achieve comprehensive coverage, often leaving blind spots that compromise safety management and operational efficiency.

Against this backdrop, drone-based laser methane detection technology (Drone-based TDLAS Methane Detection) is increasingly being adopted by biogas facilities. By integrating Tunable Diode Laser Absorption Spectroscopy (TDLAS) sensors with unmanned aerial platforms, this solution enables non-contact, long-range, and rapid scanning of large facilities. It allows operators to efficiently identify and localize methane leaks, significantly improving inspection efficiency, reducing personnel exposure to hazardous environments, and providing reliable data to support digital operations, emissions management, and regulatory compliance.

From an industry scale perspective, China represents one of the world’s largest biogas markets. According to research data, as of 2017, approximately 109,976 biogas projects/facilities (excluding small household digesters) were in operation across the country. A more recent review similarly indicates that China operates more than 100,000 biogas or biomethane facilities, spanning agricultural, industrial, and municipal organic waste treatment applications.

Among these installations, a significant portion are classified as industrial-scale or large-capacity biogas projects. Statistics suggest that over 8,000 large-scale biogas plants in China have daily processing capacities exceeding 1,000 m³. These facilities typically feature large footprints, dense equipment layouts, and continuous operation requirements, placing higher demands on methane detection coverage, response speed, and measurement reliability.

Under these conditions, the adoption of drone-based laser methane detection solutions is becoming a key pathway for large biogas power plants to enhance intrinsic safety, improve operational efficiency, meet increasingly stringent environmental regulations, and advance toward intelligent and low-carbon energy operations.

Why do biogas plants need methane remote sensing?

The core product of biogas plants is methane (CH₄), which typically accounts for 50–65% of biogas composition. Due to its high flammability and strong global warming potential, uncontrolled methane leakage may lead to the following consequences:

● Increased risk of fire and explosion

● Elevated safety hazards for on-site personnel

● Excessive greenhouse gas emissions, affecting regulatory compliance (e.g., EU MRV requirements and GHG monitoring frameworks)

● Long-term energy losses caused by chronic leaks, reducing overall power generation efficiency and revenue

Key methane leakage risk points within biogas facilities include:

● Anaerobic digesters and digester roofs

● Gas storage bags and gas holders

● Biogas upgrading and purification systems

● Compressors, valves, flanges, and connection points

● Aboveground pipelines and underground gas conduits

● Areas surrounding flare stacks

● Sludge tanks and digestate storage zones

These areas often feature complex spatial layouts and limited accessibility, making it difficult for manual inspection methods to achieve full coverage. As a result, airborne methane detection using drone-mounted laser sensors is increasingly recognized as an industry-standard approach for improving inspection coverage, detection efficiency, and overall safety performance.

The advantages of drone based laser methane remote sensing technology

A drone-based methane detection system powered by TDLAS (Tunable Diode Laser Absorption Spectroscopy) enables the following capabilities:

- Non-contact, Long-range Detection

The laser beam can target methane gas plumes from tens to hundreds of meters away, eliminating the need for personnel to enter hazardous or hard-to-access areas.

- High Sensitivity (PPM-level)

The system is capable of rapidly identifying small-scale methane leaks, making it well suited for detailed inspection of roof seals, valve assemblies, pipelines, and connection points.

- High Inspection Efficiency

A single drone flight of 10–20 minutes can cover an area that would typically require 2–3 hours of manual inspection, significantly improving operational efficiency.

- Three-dimensional Leak Mapping and Data Recording

The system supports the generation of leak trajectories, concentration point data, and flight path records, which can be used for:

● Environmental compliance audits

● Operation and maintenance (O&M) documentation

● Leak source tracing and root-cause analysis

● Before-and-after comparison testing following leak repairs

- Ideal for Large-scale and Distributed Facilities

Large biogas and biomethane plants, livestock-based biogas facilities, and centralized anaerobic digestion projects often feature wide coverage areas and dense equipment layouts, making drone-based inspection particularly effective compared with traditional ground-based methods.

3.Typical Application Scenarios in Biogas and Biomethane Plants

- Digester Roof Leak Detection

The drone can hover and scan the top of anaerobic digesters to rapidly identify:

● Inadequate roof sealing

● Abnormal operation of pressure relief valves

● Gas leakage from nozzles, flanges, and inspection windows

● Traditional manual inspection often requires personnel to approach elevated tank roofs, posing significant safety risks.

- Ground-level and Pipeline Inspection

By flying along predefined pipeline routes, the drone-based system can detect:

● Leakage from buried pipelines, indicated by rising methane plumes

● Damage to pipeline insulation layers

● Concentrated emissions around valve stations

This approach is particularly suitable for long-distance pipelines and facilities with complex branching networks.

- Upgrading and Compression Area Monitoring

Gas upgrading and compression zones typically feature dense mechanical equipment, high operating temperatures, and complex layouts, making them high-risk areas for methane leakage.
Drone-based inspection enables rapid, comprehensive coverage without interrupting plant operations.

- Flare Stack Compliance Monitoring

Incomplete combustion at flare stacks can result in direct methane emissions.
The drone system allows methane monitoring from a safe standoff distance, verifying whether unburned methane is escaping from the flare tip.

- Post-maintenance Verification and Annual Audit Inspections

The drone can generate complete inspection reports, including flight records and concentration data, supporting:

● MRV (Monitoring, Reporting, and Verification) requirements

● ESG disclosures

● Third-party environmental and safety audits

Practical Value in Real-world Operations

Overall, drone-based laser methane detection systems provide significant operational and safety benefits for biogas power plants:

● Reduce inspection time by 70–90% compared with traditional manual patrols

● Increase leak detection probability, achieving coverage rates exceeding 95%

● Minimize worker exposure to hazardous areas, improving overall site safety

● Support compliance with EU and local government GHG regulations, including MRV and emissions reporting requirements

● Reduce methane losses, thereby improving overall energy efficiency and power generation revenue

For large-scale biogas plants, RNG/biomethane upgrading facilities, and centralized agricultural biogas stations, drone-based methane inspection is increasingly becoming a standardized and best-practice monitoring approach.

As the biogas and renewable energy sectors continue to expand rapidly, biogas plants face increasing demands for safety, emissions reduction, and operational efficiency.
Powered by high accuracy, high efficiency, and enhanced operational safety, BLV’s drone-based laser methane detection solutions have already been deployed at numerous large-scale biogas power plants across Europe, and are becoming a core inspection tool for the biomethane industry.

Whether for commissioning and acceptance testing of new projects or routine inspections during operation, BLV’s drone methane detection systems help biogas operators build a safer, lower-carbon, and more intelligent future.
If you are interested in learning more, we welcome you to contact us for further discussion.