Reporoa Organics Processing Facility, Taupo
Warner Construction is proudlyly comissioned by Ecogas, a leading innovator in sustainable energy, to help divert food waste from landfills and convert it into biogas, renewable energy, and nutrient-rich biofertiliser.
Over an initial three-year period, Warner Construction was commissioned to deliver major tank construction and supporting infrastructure upgrades to support Ecogas' mission. The project required a tailored approach to engineering and construction, ensuring durability, compliance, and long-term performance.
Warner continues to support Ecogas with ongoing maintenance, design input, and engineering solutions that fine-tune and improve operational efficiency. Their role has evolved into a trusted long-term relationship, helping optimise this vital facility for future growth and sustainable impact.
Ecogas Reporoa
Date: 2023 - Current
Client: Pioneer Energy Ltd
Job Scope:
Tank Farm Construction: 5 x Stainless Steel Tanks
Tank Size: Capacity
23m diameter, 9.8m high, filled within 600mm from the top with food waste
20,000 bolts used per tank farm construction
Tank insulation:
40mm chill panels allowing 200mm air space
Inlet and outlet tank, along with Anaerobic Digestion (AD) tanks
Complementary Infrastructure:
Inlet tank for processing distribution
Suction pumps for fluid movement around the inside of tanks
Tank nozzles for fluid and gas flow regulation
Gas line installation for biogas collection and transfer
Specialised Tank Assembly:
Installed 3 Anerobic Digestion tanks with bladder domes
Top first assembly approach followed by mechanical lifting from the ground up for installation
Testing and Commissioning
Hydro testing conducted before operational commissioning
Pipe Work & System Modifications:
Designed and assembled pipework for gas and fluid transfer
Installed moisture removal system in gas line (drop pots)
Developed and modified components to enhance operational efficiency
Professional Skill Set & Expertise
Warner Construction demonstrated the following expertise throughout the project:
Tank Design & Fabrication
Mechanical & Structural Assembly
High-Precision Bolt Installations
Biogas System Integration
Pump & Pipeline Engineering
Quality Testing & Hydro Testing
Innovative Component Development & System Enhancements
Ongoing Working Relationship & Maintenance Responsibilities:
Today, Warner continues to support Ecogas with ongoing maintenance, design input, and engineering solutions that fine-tune and improve operational efficiency. Their role has evolved into a trusted long-term partner, helping optimise this vital facility for future growth and sustainable impact.
Maintenance & System Improvements fall under the following responsibilities:
Screw conveyor maintenance for material transport efficiency
Pump & filter maintenance to ensure optimal performance
Pipework modifications to enhance gas moisture removal
Development of new componentry to improve system operations
