Study of Bio-Gas Plant

BIOGAS PLANT
INTRODUCTION :-
WHAT IS BIOGAS?
Biogas is a gas mixture which is generated when organic
compounds are fermented in the absence of air (anaerobic fermentation).
This gas mixture is mainly made of carbon dioxide (CO
2
) and methane
(CH

). !ethane is a combustible gas" which means it can be burned. #t

can be used as a fuel for coo$ing and lighting.
TH BIOLOGICAL GAS PLANT
% plant to collect biological gas has fi&e components' the inlet" the
fermentation chamber" the gas" the gas storage bag or tan$" and the outlet
and the exit pipe through which the gas is remo&ed. Organic matter such
as manure (human or animal)" duc$weed or rice straw is brought into the
fermentation chamber (through the inlet). The process of anaerobic
fermentation will ta$e place here to generate biological gas (biogas). #t
will also produce a substrate rich in nutrients which can be used as
organic fertili(er or fish feed.
The processing of manure" organic rubbish and wastewater in the
plant helps to $eep the en&ironment clean. There is no longer any bad
smell from sewage or li&estoc$ manure. Coo$ing by biogas is much
cleaner than coo$ing o&er a wood fire" and there is no smo$e to cause
lung problems and eye diseases.
Ty!"s Of Bio#as Plant
There are two $inds of biogas plant being widely used at the present
time'
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Study of Bio-Gas Plant
,lant with a thic$ plastic or rubber bag to store gas (-ig. +). This
plant has se&eral ad&antages. The in&estment cost is low" and the
plant is easy to ma$e. Howe&er" it needs a lot of space and does not
last for long.
$i#u%" &
Bric$.built installation with a fixed &aulted co&er(-igure 2). This
types of plant also has its ad&antages. #t is strong" cheap and made
of locally a&ailable materials" using simple building techni/ues
(Table +). #t is also &ery durable (-ig.0).
$i#u%" '
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Ta(l" &
$i#u%" )
T*" T"+*nolo#y
Begin by loading the fermentation chamber with the materials to be
fermented (manure or other wastes). 1ou should begin with an initial load
of 022 . 322 $g of materials for each cubic meter of the fermentation
chamber.
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This needs to be supplemented by an additional 4 . +2 $g each day
for each cubic meter of the fermentation chamber. The gas output will be
232 . 22 liters for each cubic meter of the chamber.
5xpressed another way" + $g of manure will ha&e a gas yield of 02
. 62 liters7day" for se&eral days. The gas yield from + $g of water hyacinth
will be 2 . 32 liters7day" for se&eral days.
One cubic meter of gas (8 +222 liters) is enough to coo$ the day9s food
for a 6 . : member family" or pro&ide lighting for . 3 hours. #t could
replace one liter of petrol to operate a 22; electric generator for two
hours.
T*" P%"+autions
The plant must be tested to ma$e sure it is water.tight and gas.
tight.
5nough fresh material must be added before it is used e&ery day.
There must be a water source to pro&ide enough water to clean the
li&estoc$ pens regularly" to pro&ide fresh material for the
fermentation chamber system. (5ach liter of manure needs + . 0
liters of water).
The plant must be e/uipped with a safety &al&e or <.shaped
barometer.
Chemicals such as detergents or pesticides must not be put into the
fermentation chamber.
%fter fresh manure and water is added to the fermentation chamber"
the &al&e should be opened so the gas can escape. %t this stage" the
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gas is mainly carbon dioxide. This should be done once or twice"
before the biogas plant comes into use for biogas production.
The gas from the fermentation chamber is not used directly" but is
stored in an auxiliary gas tan$ protected by a safety &al&e. #t is this
auxiliary gas tan$" not the main gas tan$" which is connected to any
domestic appliances.
,ITCHN WAST BASD BIOGAS PLANT
%n organism that can happily grow in an extreme en&ironment is an
extremophile. The extreme en&ironments include physical extremes li$e pressure"
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temperature and radiation and geochemical extremes li$e desiccation" salinity" pH and
low redox potentials.
Biogas ,lant at Trombay. The plant produces biogas from $itchen waste by
using thermophilic microorganisms that flourish in extreme en&ironment.
The biogas plant has following components' % mixer7pulper (3 H, motor)
for crushing the solid waste" ,remix tan$s" ,redigester tan$" *olar heater for
water heating" !ain digestion tan$ (03 m0)" !anure pits" =as lamps for
utilisation of the biogas generated in the plant.
The thermophiles are the extre.mophiles that can thri&e superbly at
high temperatures. They ha&e de&eloped such en(yme systems that can
help the organisms not only to sur&i&e at higher temperatures but also
grow and reproduce. They ha&e ability to use sulphurous waste and
con&ert it into non.toxic products. *ince the en&ironment for such
microorganisms sustains higher temperatures" many spoilage and
pathogenic organisms cannot sur&i&e in such extreme conditions.
Therefore it would be ideal if we can ma$e use of these organisms to
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degrade the $itchen waste to remo&e more toxic elements and then
sub>ect it to the traditional biogas plant for methane generation. ;hat we
need to do is to maintain the high temperature in the predigestor tan$.
P%"+autions -ay (" ta."n /*il" +oll"+tin# t*" .it+*"n /ast" :
% separate container for coconut shells" coir" egg shells" onion peels
and bones. These will not be processed in the biogas plant.
*eparate containers of small &olumes (3litre capacity) to collect the
wet waste (spoilt or stale coo$ed food" waste mil$ products etc.). The
&egetables refuse li$e peels of &arious &egetables" rotten potatoes" and
tomatoes" coriander lea&es etc. may be collected in garbage bags of 3.
$ilo capacity. #t must be noted that such segregation is of utmost
importance for smooth running of the biogas plant.
*unlight is a&ailable almost throughout the year except for some days
in the months of ?uly.%ugust. This natural source of energy can be
effecti&ely used for pro&iding the thermophilic microorganisms their
natural en&ironment. This energy is used to heat water and by controlling
the proportion of hot water in the predigestor tan$" one can achie&e the
desired temperature that can be easily sustained for about a day. This
would pro&ide fa&orable surroundings for the potential use of
thermophiles to degrade the waste and sustain the culture. Thus the
system is self.sustainable and effecti&e.
%nother important aspect in smoother running of a biogas plant based
on solid waste is how effecti&ely one can a&oid the cho$ing of the plant.
This cho$ing may occur due to thic$ biomass that may be inaccessible to
the microorganisms to digest it. The logical solution to such a problem is
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to con&ert the solid waste into slurry that would be far more accessible
for the microbial action. % high power mixer to con&ert the solid waste
into slurry can achie&e this purpose. These two modifications certainly
impro&e design of the traditional biogas plant.
% $itchen waste based biogas plant has been installed at @ursery site
for en&ironmental friendly disposal of the waste generated in $itchens of
&arious canteens in B%)C premises. #t is expected that the plant can
process all the waste generated in these canteens. This plant wor$s on
similar principles of traditional gobar gas plants with the exception of
type of feed with the abo&e modifications.
The waste generated in $itchen in the form of &egetable refuge" stale
coo$ed and uncoo$ed food" extracted tea powder" waste mil$ and mil$
products can all be processed in this plant. Based on the understanding of
thermophilic microorganisms in particular and microbial processes in
general" there are two important modifications made in the con&entional
design of the biogas plant in B%)C '
#ntroduction of a 3 H, mixer to process the waste before putting it
into predigestor tan$. The waste is con&erted in slurry by mixing with
water (+'+) in this mixture.
<se of thermophilic microbes for faster degradation of the waste. The
growth of thermophiles in the predigestor tan$ is assured by mixing the
waste with hot water and maintaining the temperature in the range of 33.
62oC. The hot water supply is from a solar heater. 5&en one.hour sunlight
is sufficient per day to meet the needs of hot water.
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%fter the predigestor tan$ the slurry enters the main tan$ where it
undergoes mainly anaerobic degra.dation by a consortium of archae.
bacteria belonging to !ethanococcus group. These bacteria are naturally
present in the alimentary canal of ruminant animals (cattle). They
produce mainly methane from the cellulosic materials in the slurry.
The undigested lignocellulosic and hemicellulosic materials then are
passed on in the settling tan$. %fter about a month high /uality manure
can be dug out from the settling tan$s. There is no odour to the manure at
all. The organic contents are high and this can impro&e the /uality of
humus in soil" which in turn is responsible for the fertility.
%s the gas is generated in the main tan$" the dome is slowly lifted up.
#t reaches a maximum height of 4 feet holding 03 m0 of gas. This gas is a
mixture of methane (:2.:3A)" carbon dioxide (+2.+3A) and water
&apours (3.+2A). #t is ta$en through =# pipeline to the lamp posts. Brains
for condensed water &apour are pro&ided on line. This gas burns with a
blue flame and can be used for coo$ing as well.
The gas generated in this plant is used for gas lights fitted around the
plant. The potential use of this gas would be for a canteen. The manure
generated is high /uality and can be used in fields.
*uccess of this biogas plant depends a great deal on proper
segregation of the $itchen waste. The materials that can pose problems to
the efficient running of plant are coconut shells and coir" egg shells" onion
peels" bones and plastic pieces. *teel utensils li$e dishes" spoons etc. are
li$ely to appear in the waste bags from canteens. ;hile bones" shells and
utensils can spoil the mixer physically" onion peels" coir and plastic can
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ha&e detrimental effects on microbial consortium in the predigester and
main digestion tan$s which could be disastrous for the plant.
Thus the efficient disposal of $itchen waste can be eco.friendly as
well as cost effecti&e. ;hile calculating the cost effecti&eness of such
waste disposal one has to consider more than monetory aspects. The
dumping of uncoo$ed food in unmanned area may not be &ery ci&ili(ed.
#t can also lead to population growth of nuisance animals. #t is
undoubtedly unhygienic and can pose threat to the habitat. These factors
will add to the &alue of such plants. <sing the natural friends in the form
of thermophiles" methanogenic micro.organisms and their consortiums
we can certainly handle the $itchen waste and may be other
biodegradable waste li$e paper.
The biogas plant.some technical considerations
The biogas plant consists of two components' a digester (or
fermentation tan$) and a gas holder. The digester is a cube.shaped or
cylindrical waterproof container with an inlet into which the fermentable
mixture is introduced in the form of a li/uid slurry. The gas holder is
normally an airproof steel container that" by floating li$e a ball on the
fermentation mix" cuts off air to the digester (anaerobiosis) and collects
the gas generated. #n one of the most widely used designs (-igure 2)" the
gas holder is e/uipped with a gas outlet" while the digester is pro&ided
with an o&erflow pipe to lead the sludge out into a drainage pit.
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-igure. 2. Biagram of =obar.=as ,lant <sed to Obtain !ethane from
Bung by %naerobic -ermentation
The construction" design" and economics of biogas plants ha&e
been dealt with in the literature (+0 . 2+). -or biogas plant construction"
important criteria are' (a) the amount of gas re/uired for a specific use or
uses" and lb) the amount of waste material a&ailable for processing. -ry
(+:)
*ingh (2+)" and others (+" 0) ha&e documented se&eral guidelines
for consideration in the designing of batch (periodic feeding) and
continuous (daily feeding) compartmentali(ed and non.
compartmentali(ed biogas plants that are of either the &ertical or
hori(ontal type. #n addition" Doll (+4) has recently dealt with the scientific
principles" process engineering" and shapes of digestion reactors" and with
the economics of the technology.
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Bigester reactors are constucted from bric$" cement" concrete" and
steel. #n #ndonesia" where rural s$ills in bric$ ma$ing" bric$ laying"
plastering" and bamboo craft are well established" clay bric$s ha&e
successfully replaced cement bloc$s and concrete. #n areas where the cost
is high" the EsausageE or bag digester (+) appears to be ideal (-igure 0).
The digester is constructed of 2.33 mm thic$ Hypalon laminated with
@eoprene and reinforced with nylon. The bag is fitted with an inlet and an
outlet made from ,FC. 5&en if imported from the <nited *tates" the cost
of the digester and the gas holder (both combined in one bag) is only +2
per cent of that for a concrete.steel digester. %nother ad&antage is that it
can be mass produced and is easily mailed. #n rural areas" the whole
installation is completed in a matter of minutes. % hole in the ground
accommodates the bag" which is filled two.thirds full with waste water.
=as production fully inflates the bag" which is weighted down and fitted
with a compressor to increase gas pressure.
-igure. 0. Biagrammatic *$etch of the E*ausageE Bag Bigester !ade of
Hypalon Daminated with @eoprene
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5n&ironmental and operational considerations
Ra/ 0at"%ials 1&23
)aw materials may be obtained from a &ariety of sources .
li&estoc$ and poultry wastes" night soil" crop residues" food.processing
and paper wastes" and materials such as a/uatic weeds" water hyacinth"
filamentous algae" and seaweed. Bifferent problems are encountered with
each of these wastes with regard to collection" transportation" processing"
storage" residue utili(ation" and ultimate use. )esidues from the
agricultural sector such as spent straw" hay" cane trash" corn and plant
stubble" and bagasse need to be shredded in order to facilitate their flow
into the digester reactor as well as to increase the efficiency of bacterial
action. *ucculent plant material yields more gas than dried matter does"
and hence materials li$e brush and weeds need semi.drying. The storage
of raw materials in a damp" confined space for o&er ten days initiates
anaerobic bacterial action that" though causing some gas loss" reduces the
time for the digester to become operational.
Influ"nt Solids Cont"nt 1&45 &25 '&3
,roduction of biogas is inefficient if fermentation materials are too
dilute or too concentrated" resulting in" low biogas production and
insufficient fermentation acti&ity" respecti&ely. 5xperience has shown that
the raw.material (domestic and poultry wastes and manure) ratio to water
should be +'+" i.e." +22 $g of excrete to +22 $g of water. #n the slurry" this
corresponds to a total solids concentration of 4 . ++ per cent by weight.
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Loadin# 1&65 &23
The si(e of the digester depends upon the loading" which is
determined by the influent solids content" retention time" and the digester
temperature. Optimum loading rates &ary with different digesters and
their sites of location. Higher loading rates ha&e been used when the
ambient temperature is high. #n general" the literature is filled with a
&ariety of conflicting loading rates. #n practice" the loading rate should be
an expression of either (a) the weight of total &olatile solids (TF*) added
per day per unit &olume of the digester" or (b) the weight of TF* added
per day per unit weight of TF* in the digester. The latter principle is
normally used for smooth operation of the digester.
S""din# 1&65 &23
Common practice in&ol&es seeding with an ade/uate population of
both the acid.forming and methanogenic bacteria. %cti&ely digesting
sludge from a sewage plant constitutes ideal EseedE material. %s a general
guideline" the seed material should be twice the &olume of the fresh
manure slurry during the start.up phase" with a gradual decrease in
amount added o&er a three.wee$ period. #f the digester accumulates
&olatile acids as a result of o&erloading" the situation can be remedied by
reseeding" or by the addition of lime or other al$ali.
!H 1&65 &23
Dow pH inhibits the growth of the methanogenic bacteria and gas
generation and is often the result of o&erloading. % successful pH range
for anaerobic digestion is 6.2 . 4.2G efficient digestion occurs at a pH near
neutrality. % slightly al$aline state is an indication that pH fluctuations are
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not too drastic. Dow pH may be remedied by dilution or by the addition
of lime.
T"-!"%atu%" 1&)5&65&25 '&3
;ith a mesophilic flora" digestion proceeds best at 02 . 2 CG with
thermophiles" the optimum range is 32 . 62 C. The choice of the
temperature to be used is influenced by climatic considerations #n
general" there is no rule of thumb" but for optimum process stability" the
temperature should be carefully regulated within a narrow range of the
operating temperature. #n warm climates" with no free(ing temperatures"
digesters may be operated without added heat. %s a safety measure" it is
common practice either to bury the digesters in the ground on account of
the ad&antageous insulating properties of the soil" or to use a greenhouse
co&ering. Heating re/uirements and" conse/uently" costs" can be
minimi(ed through the use of natural materials such as lea&es" sawdust"
straw" etc." which are composted in batches in a separate compartment
around the digester"
Nut%i"nts 1&)5&75&25 '&3
The maintenance of optimum microbiological acti&ity in the
digester is crucial to gas generation and conse/uently is related to nutrient
a&ailability. Two of the most important nutrients are carbon and nitrogen
and a critical factor for raw material choice is the o&erall C7@ ratio.
Bomestic sewage and animal and poultry wastes are examples of
@.rich materials that pro&ide nutrients for the growth and multiplication
of the anaerobic organisms. On the other hand" @.poor materials li$e
green grass" corn stubble" etc." are rich in carbohydrate substances that are
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essential for gas production. 5xcess a&ailability of nitrogen leads to the
formation of @H0" the concentration of which inhibits further growth.
%mmonia toxicity can be remedied by low loading or by dilution. #n
practice" it is important to maintain" by weight" a C7@ ratio close to 02'+
for achie&ing an optimum rate of digestion. The C7@ ratio can be
>udiciously manipulated by combining materials low in carbon with those
that are high in nitrogen" and &ice &ersa.
To8i+ 0at"%ials 1&)5&65&23
;astes and biodegradable residue are often accompanied by a
&ariety of pollutants that could inhibit anaerobic digestion. ,otential
toxicity due to ammonia can be corrected by remedying the C7@ ratio of
manure through the addition of shredded bagasse or straw" or by dilution.
Common toxic substances are the soluble salts of copper" (inc" nic$el"
mercury" and chromium. On the other hand" salts of sodium" potassium"
calcium" and magnesium may be stimulatory or toxic in action" both
manifestations being associated with the cation rather than the anionic
portion of the salt. ,esticides and synthetic detergents may also be
troublesome to the process.
Sti%%in# 1&)5&65&7 - &25 '&3
;hen solid materials not well shredded are present in the digester"
gas generation may be impeded by the formation of a scum that is
comprised of these low.density solids that are enmeshed in a filamentous
matrix. #n time the scum hardens" disrupting the digestion process and
causing stratification. %gitation can be done either mechanically with a
plunger or by means of rotational spraying of fresh influent. %gitation"
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normally re/uired for bath digesters" ensures exposure of new surfaces to
bacterial action" pre&ents &iscid stratification and slow.down of bacterial
acti&ity" and promotes uniform dispersion of the influent materials
throughout the fermentation li/uor" thereby accelerating digestion.
R"t"ntion Ti-" 1&25 '&3
Other factors such as temperature" dilution" loading rate" etc."
influence retention time. %t high temperature bio.digestion occurs faster"
reducing the time re/uirement. % normal period for the digestion of dung
would be two to four wee$s.
Be&elopments and processes for rural areas
Two years ago" the 5conomic and *ocial Council of the <nited
@ations adopted a sur&ey" presented in +C:4 to the Committee on *cience
and Technology for Be&elopment" listing the on.going research and
de&elopment in uncon&entional sources of energy. -rom the point of &iew
of the de&eloping countries" it is heartening to note that the Euse of farm
wastes to produce methaneE has also been identified in the <nited
@ations ;orld ,lan of %ction for the %pplication of *cience and
Technology to Be&elopment.
The 5conomic and *ocial Council for %sia and the ,acific"
moreo&er" adopted the Colombo Beclaration at its thirtieth session" which
determined that the most urgent priorities for action are in the fields of
food" energy" raw materials" and fertili(ers" and that these priorities would
be best met by the integrated biogas system (#B*).
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%n integrated system aims at the facile generation of fertili(er and
ac/uisition of energy" production of protein &ia the growth of algae and
fish in oxidation ponds" hygienic disposal of sewage and other refuse" and
is a tangible effort to counteract en&ironmental pollution. The heart of the
system is the biogas processG it has the potential to EseedE self.reliance in
relati&ely primiti&e economies (+" 22" 20). %llied benefits include the
de&elopment of rural industry" the pro&ision of local >ob opportunities"
and the progressi&e eradication of hunger and po&erty (-igures.6).
-igure. . Biogas Cycle in China (*ource' -%O *oils Bulletin 2" )ome"
+C::)
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-igure.3. #nteracti&e Doop of )ural or Fillage -arming *ystem Based on
Biogas or !ethane 5conomy
The coupling of a photosynthetic step (2 . 26) with digestion
pro&ides for the transformation of the minerals left by digestion directly
into algae that can then be used as fodder" as feed for fish" as fertili(er" or
for increased energy production by returning them to the digester process
(-igure 6).
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-igure. 6. *implified *cheme #ndicating Farious Combinations of
Bigestion and ,hotosynthesis for -odder" -ertili(er" and -uel ,roduction
(%fter ?.;.!. Da)i&iHre" ?. *ci. *oc." Thailand" +C::)
The #B* aims at putting bac$ into soil and water what has been
ta$en from them" and increasing the amounts of nutrients by fixing CO
2
and @
2
from the atmosphere into the soil and water through
photosynthesis by algae. #n&ol&ing low cash in&estments on a
decentrali(ed basis" the implementation of #B* pro&ides employment to
the whole wor$ force without disruption of the rural structure.
-urthermore" it is an apt example of soft technology that does not pollute
or destroy the physical en&ironment. %t the College of %griculture of the
<ni&ersity of the ,hilippines" preliminary wor$ on a small scale has
begun. #n 5ngland" an 5co.house (-igure C) has been built by =raham
Caine on the Thames ,olytechnical ,laying -ields at 5ltham" southeast of
Dondon. )esults on the pro>ect" howe&er" are not yet a&ailable.
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-igure. :. *implified *cheme #ndicating Farious Combinations of Bigestion and
,hotosynthesis for -odder" -ertili(er" and -uel ,roduction (%fter ?.;.!. Da)i&iHre" ?.
*ci. *oc." Thailand" +C::)
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Cost.benefit analyses
There is no general answer to the economic feasibility of biogas
production. @ational economic considerations play an important role. #n
Iorea" wood is in short supply (2:) and domestic fuel substitutes li$e rice
and barley straw" and coal and oil could be conser&edG wood could be a
foreign.exchange earner in the field of handicrafts. #n #ndia"
transportation costs of coal and oil to the rural areas is high and an extra
burden on an already poor farmer.
The consumption of commercial and non.commercial energy for
the whole of #ndia" as determined for the period +C62 . +C:+ by the -uel
,olicy Committee )eport" is pro&ided in Table 0.
T%BD5 0. Consumption of Commercial and @on.Commercial 5nergy in
#ndia
1ear Coal
(!illion
Tons)
Oil
(!illion
Tons)
5lectricity
(Billion $wh)
-irewood
(!illion
Tons)
Cow
dung
(!illion
Tons)
Fegetable
waste
(!illion
Tons)
+C62 . 6+ :.+ 6.:3 +6.C +2+.2 33.04 0+.24
+C63 . 66 6.2 C C 02.6 +++.42 6+.24 0.+
+C:2 . :+ :+ + + C3 4.: +22.:3 6:.24 0:.::
Sou%+"s:
)eport of the -uel ,olicy Committee"+C:G *.@. =hosh" #n&ention
#ntelligence +2'60 (+C::).
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The rural share in the energy consumption of electricity and coal is
not considerable because" as the )eport of the ,anel of the @ational
Committee of *cience and Technology on -uel and ,ower indicates" the
large towns and cities with populations of 322"222 and more
accommodate only 6 per cent of #ndia9s total population but consume
about 32 per cent of the total commercial energy produced in the country.
#n the &illages" howe&er" $erosene is used for lighting" but it is
clear that with increasing population" biogas generation seems to offer
solutions in the areas of fuel a&ailability" electricity" fertili(er for cash
crops" and would pro&ide other socio.economic benefits.
On the other hand" cost.benefit analyses of methane generation
&ary widely" depending upon the uses and actual benefits of biogas
production" public and pri&ate costs associated with the de&elopment and
utili(ation of methane" and on the technology used to generate methane.
*e&eral factors ha&e been listed in the economics of biogas generation
(+" +: . +C" 24). %n appropriate example is the fact that a &illage.model
gas plant" which cost )s 322 some years ago" cost )s +"322 in +C: and
)s 2"222 in +C::. Hence" a significant problem is whether rural people
who cannot spend )s 2"222 can cope with increasing inflationary and
digester construction material costs.
The Ihadi and Fillage #ndustries Commission has helped to tac$le
the problem through rural community co.operation and a scheme of
subsidies and loans to encourage indi&idual families" groups of families"
institutions" and communities to construct biogas plants. %n analysis of
cost and income for a plant producing 0mJ7day is gi&en in Table . The
net annual income of approximately <*K62 shows that the capital
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in&estment of <*K02 can be recouped in about six years. There are also
incidental ad&antages of hygienic impro&ement" the absence of smo$e
and soot in gas burning" con&enience in burning" and the increased
richness of manure.
TABL 69 Cost.Benefit %nalysis of Ihadi and Fillage #ndustries
Commission ,lant (in <* dollars)
a. Capital cost
=as holder and frame K C0.3
,iping and sto&e K 0 :
Ci&il engineering construction (tan$" inlet and outlet" etc.) K2+2.+
Total K004.0
b. %nnual expenditure
The interest on in&estment at CA K 02.
Bepreciation on gas holder and frame at +2A K C.0
Bepreciation on piping and sto&e at 3A K 2.2
Bepreciation on structure at 0A K 6.0
Cost of painting" once a 1ear K 6.:
Total K 3":
c. %nnual income
=as 0mJ per day at K+.3 per 2CmJ (+"222 cu.ft.) K 32.0
!anure (: tons" composted) with refuse +6 tons at K per ton K 6.2
Total K++.0
d. @et annual income (b . c) K 3C.6
*ource' 5*C%, Bocument @)75=@BB7" 22 . 26 ?une +C:4
).#.T. *a$harale
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Study of Bio-Gas Plant
Health ha(ards
Health ha(ards are associated with the handling of night soil and
with the use of sludge from untreated human excrete as fertili(er.
#n general" published data indicate that a digestion time of + days
at 03 C is effecti&e in $illing (CC.C per cent die.off rate) the enteric
bacterial pathogens and the enteric group of &iruses. Howe&er" the die.off
rate for roundworm (%scaris lumbricoides) and hoo$worm
(%ncylostoma) is only C2 per cent" which is still high. #n this context"
biogas production would pro&ide a public health benefit beyond that of
any other treatment in managing the rural health en&ironment of
de&eloping countries.
CAS STUD:
Pla+" : Ra;a%a-(a!u Sa.*a% ,a%.*ana5 Ra;a%a-na#a%9
).#.T. *a$harale
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Study of Bio-Gas Plant
Ai- : Study of Bio #as !lant
INTRODUCTION
There are about 222 Bistilleries in #ndia producing )ectified *pirit"
,otable %lcohol and 5xtra @eutral %lcohol (5@%) mainly from *ugar
Cane !olasses as raw material. Buring the manufacturing process a
highly polluting waste product called E*pent ;ashE is generated.
This eff#fuent has following characteristics'.
C*a%a+t"%isti+s of S!"nt Was*
+) Bistillery Capacity ' 02"222 Diter7Bay
2) 5ffluent Luantity ' 32 !
0
7 day
0) BOB ' 32"222 mg7ltr (approx)
) COB ' C2"222 mg7ltr (approx)
3) pH ' to 3.2
6) Temperature ' C3 to +22 C
:) *alts ' *ulphates" chlorides " phosphates
etc in &arying /uantities.
This waste product namely spent wash" though highly polluting"
may be a &ery useful source of non.con &ent ional energy if. it is treated
properly with the help of correct process technology.
).#.T. *a$harale
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Study of Bio-Gas Plant
POTNTIAL TO PRODUC NRG:
$RO0 SPNT WASH:
*pent wash from Bistillery #ndustry can be anaerobically digested to
generate biogas which is a potential resource of non.con&entional energy.
%ccording to the technology pro&ided by *ul(er" up to 2.3 @! 7$g of
biogas can be produced per $g of COB degraded. -rom the spent wash of
f) 02"222 D,B Bistillery approximately 322 ! 7hr biogas can be
generated. This biogas can be used as fuel in boiler to general e steam or
can also bo used in biogas gensents *o generate electrical power.
APPROPRIATNSS O$ TCHNOLOG: IN
PRSNT NATIONAL CONTST
,resently #ndia is facing se&ere crisis regarding a&ailability
far fossil fuel" li$e Biesel" ,etrol or Coal. @ational )esource
of fossil fuels are limited and demand for con&entional fuels is
increasing with increased industrial acti&ity its. Be&elopmet of any
alternate non .con&entional source of energy under these circumstances is
therefore" &ery much useful. The generation of biogas while treating the
effluent for en&ironmental protection is thus a welcome approach which
ser&es dual purpose of pollution control and energy resources. Biogas
generated from a 02"222 D,B Bistillery effluent treatment is e/ui&alent
to about 3"222 Tons of coal per year" or can be used to generate
approximately + !; of electric power.
TCHNO CONO0IC <IABILIT: O$ WAST
RC:CLING $OR NRG: PRODUCTION:
).#.T. *a$harale
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Study of Bio-Gas Plant
%s indicated abo&e the biogas produced from distillery waste
effluent can be used for sa&ing coal7oil7bagasse in the distillery boiler
resulting in substia sa&ing in con&entional fuel.
%nnexure.# attached along with this note indicates the techno.
econom'' &iability for Bistillery waste treatment for generation of energy.
#t may be interesting to note biogas e/ui&alent to about )s :3"22"222
lacs worth of cost is produced from a 02"222 D,B Bistillery effluent
treatment plant. The biogas plants are therefore &ery much techno.
economically feasible and ha&e &ery low pay bac$ period of 2.0 years
only.
INDIGNOUS AND $ORIGN
TCHNOLOGIS A<AILABL:
-or treatment of distillery of fluent E#agooningE is the con&entional
#ndigenous technology" where distillery effluent is stored in large open
lagoons. The efffulent is allowed to degrade aerobically in these lagoons
resulting in foul smell" les(9ir of coloured effluent into subsoil water
strata and long time re/uired for deqradation before their final
disposal.
,resently the following -oreign Technologies for anaerobic
ally treating the distillery spent wash is a&ailable'
1) *ul(er Brothers Dtd" *wit(erland
2) Ba$ardi
3) *=@" -rance
4) ,a/ues
).#.T. *a$harale
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Study of Bio-Gas Plant
Out of the different. technologies a&ailable presently only *ul(ers
ha&e modified their original process to suit #ndian conditions
and other technologies are mostly based on 5uropean Bistillery
,lant effluent where Mbeet.roof is used as raw material
compared to sugar cane molasses in #ndia. The effluent generated
from Cane *ugar molasses processing is much more difficult to treat and
digest compared to clear effluents from beet.root based sugar7distillery
industry.
Therefore *ul(ers technology has been found to be most
suitable and successful in #ndian conditions. There are
maximum number of biogas plants (23 @os) installed in #ndia
based on *ul(ers process for productions of methane from
distillery effluent.
POTNTIAL USR INDUSTRIS:
The anaerobic waste water treatment process de&eloped by *ul(ers
can also be used by the following #ndustries'
1. ,ulp and ,aper !ill
2. Bairy
3. -ood ,rocessing
4. -ruit and Fegetable processing plants.
5. Deather and textile #ndustry
6. *ugar #ndustry
7. !eat and ,oultry #ndustry.
).#.T. *a$harale
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Study of Bio-Gas Plant
!7s. ,adam>ee ,ulp and ,aper #ndustry" has installed a double
digester system for treating their paper mill effluent based on *ul(ers
Bio.methanisation process for ,aper ,lant effluent.
0OST $ASIBL UTILISATION 0OD AND
TH TCHNOLOG: A<AILABL:
The most feasible utilisation of the biogas produced from the
distillery waste effluent" is for the use of the biogas in distillery boiler
for generation of steam. Biogas burners ha&e been de&eloped by reputed
manufactures li$e;esman Thermal 5ngineering ,rocesses ,&t Dtd"
Thermax Dtd" !7s. ? @ !arshall etc." who pro&ide burners and the
complete combustion e/uipment for utilisation of the biogas produced
for its utilisation in the boiler.
Fery recently =ensets based on biogas as fuel has also been
cte&eiopea by #ndian Companies li$e Iirlos$ar Cummins Dtd" Iirlos$ar
Oil 5ngines etc where biogas can directly be used for generating
electrical power.
;e ha&e installed a 322 IF% =enset at one of the biggest
*ugar -actory in !aharashtra" where trials are presently being
done. #t is thus seen that indigenous technology is a&ailable
for utilisation of the non.con&entional energy generated from the
use of distillery waste.
=PCTATION $RO0 GO<RN0NT
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Study of Bio-Gas Plant
DPART0NTS AND USR INDUSTR::
#t has been found that loo$ing to the high cost of biomethanisation
plant for the use of the waste product" many distilleries are unable to
arrange finance for installing these plants. it is expected that =o&ernment
should pro&ide assistance in the form of
a. *ubsidy for ,reparation of techno.economic feasible report
for such pro>ects.
b. The subsidy for installation of such pro>ects.
c. To pro&ides soft loan7finance.
d. To exempt such pro>ects7 e/uipments used in this pro>ects"
from different taxes and duties li$e excise" sales tax" wor$s
contract Dax etc.
e. To allow +22A depreciation in the &ery first year of the
operation of the plant.
f. To pro&ide the pro>ect construction material li$e steel"
cement etc or priority and concessional rates.
g. To allow paralleling of biogas based power stations with grid power.
h. To re/uest *tate Be&elopment %gencies for pro&iding
technical and financial support" to the user industry for such
pro>ects
i. To reduce rates of import" duty and customs duty on import
of large capacity biogas gensets 7gas turbines (up to + . 2 !;).
;e appreciate the =o&ernment efforts being made through #)5B%
for pro&iding soft loans to the user #ndustry for installation of Biogas
).#.T. *a$harale
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Study of Bio-Gas Plant
plants for use of non con&entional energy. ;e also appreciate the central
=o&ernment decision to exempt biogas plants and other non con&entional
energy generation plant from excise duty.
!aharashtra =o&ernment has done a commandable >ob by
exempting such plants from sales tax. ;e hope that the Central and *tate
=o&ernment will come forward to pro&ide other technical7financial
support and exemption in taxes and duties for promoting of technologies
for waste recycling and resources reco&ery systems.
TCHNO > CONO0IC <IABILIT: ANAL:SIS
I9 TCHNICAL $ASIBILIT: :-
+. Bistillery Capacity ' 02 ID,B
2. Luantity of 5ffluent ' 32 !
0
7 day
0. C O B ' 42" 222 N +"22"222 mg7 ltr
. B O B ' 2" 222 N 32" 222 mg 7 ltr
3. pH ' .2 . .3
II9 OUT$LOW CHARACTRISTICS :
+. 5ffluent Luantity ' 32 !
0
7 day
2. C O B )eduction ' 63 N :2 A
0. B O B )eduction ' 42 N 43 A
. pH ' :.2 N :.3
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Study of Bio-Gas Plant
III BIOGAS PRODUCTION :-
+. Biogas =eneral O
2.3 @!
0
7 $g of COB
Bestroyed ' +3":32 @!
0

2. Calorific &alue of Coal ' 222 Ical 7 $g
0. 5/ui&alent Coal sa&ing ' 20.623 T7 d
. ,rice of Coal considered ' )s +" 622 7. per Ton
3. *a&ings per annum ' )s ++0.2 lacs
<9 0AN POWR R?UIRD :-
+. Chemist #n charge ' +
2. Operators '
<I CONO0ICS :
+. ,lant P !achinery including
)oyalty" Technology fee"
5rection P commissioning. ' )s +C2.22 lacs
2. Ci&il wor$ sub>ect to soil
Conditions ' )s +C.22 lacs
0. Trasnport" #nsurance"
Octroi" *ales Tax etc ' )s 23.22 lacs
QQQQQQQQQQQQQQQQQQQ
Total ' )s 20.22 lacs
<II9OPRATIONAL =PNDITUR 1$OR )@@ WOR,ING DA:S3
A $I=D COST '
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Study of Bio-Gas Plant
+) #nterest O +3.3 on :3 A
of the cost of Biogas plant ' )s 2:.22 lacs7 yr
2) !aintenance O + A on plant
%nd machinery ' )s +.C2 lacs7 yr
0) O&erhead ' )s +.22 lacs7 yr
) *alaries P wages of Chemist
#ncharge P Operators.
3 persons O )s 2"222 7.
,er annum. ' )s +.22 lacs7 yr
QQQQQQQQQQQQQQQQQQQQQQ
)s 0+.02 lacs7 yr
B <ARIABL COSTS :
+) Chemicals ' )s +.23 lacs7 yr
2) 5lectricity 2 I; O
)s 2 7. per unit ' )s 3.:6 lacs7 yr
QQQQQQQQQQQQQQQQQQQQQQ
Total ' )s :.2+ lacs7 yr
=rand Total (%R B) )s 04.0+ lacs7 yr
%fter stabili(ation of the process normally no chemicals are
re/uired to be added regularly.
<III SA<INGS :
)s ++0. lacs (.) )s 04.0+ lacs 8 )s :3.2C lacs 7 yr
,%1 B%CI ,5)#OB 8 )s 20.22 lacs
QQQQQQQQQQQQQQQQQQQQQ
)s :3.2C lacs7 yr
8 0 to years
I= 0ANS O$ $INANC :
+) Own Contribution ' 23 A
).#.T. *a$harale
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Study of Bio-Gas Plant
2) Doan from -. #s ' :3 A
Contribution of *<DS5)9* B#O=%* ,D%@T* for 5n&ironmental
,rotectionP=eneration of non.con&entional energy in #@B#%
S9N9 BAN, A
*<DS5) Brothers Dtd" *wit(erland is a multinational" multi.
di&ision large industrial group based in *wit(erland. The Company has
namely +2 di&isions and has a annual business turno&er of <* K+2"222
million. The Company has now a subsidiary in #ndia $nown as *<DS5)
(#ndia) Dtd which deals mainly in textile machinery and chemical plant
P e/uipments.
The Ewastewater treatment di&isionE of *<DS5) under technical
collaboration agreement in +C46 agreed to pro&ide ,rocess $now.how"
design and detail engineering ser&ices to !7s. Chemical Consultants P
5ngineers. !7s CC5 started offering biogas plants based on *<DS5)9*
Technology for primary treatment of effluents from Bistilleries" and
ha&e by now supplied 23 plants on turn.$ey basis.
T%"at-"nt of Distill"%y fflu"nts :
Bistillery effluent is $nown for its &ery high pollution loads in
the form of high BOB P COB le&els" creating bad odour if allowed to
degrade in open lagoons. Till the arri&al of 9*<DS5)9 Technology in
#ndia" lagooning was the only $nown method of distillery effluent
treatment process" where in distillery effluent was allowed to be stored
).#.T. *a$harale
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Study of Bio-Gas Plant
in large open lagoons spread in an area of +2.+3 acres and for &ery long
periods of 2 to 0 months for aerobic degradation of high BOB7COB
&alues. Open lagooning results in release of large amount of methane
gas into atmosphere" bad odour around the entire distillery7lagooning
area" seepage of effluent in the subsoil and polluting underground
water.stream and causing soil degradation.
SULAR T"+*nolo#y fo% ana"%o(i+ Bio-"t*anisation P%o+"ss:
9*<DS5)
+
Technology for the first time pro&ided a longtime
meaningful solution to these problems" in addition to the most simple
and useful method of collecting the biogas (methane) generated during
the anaerobic treatment process and its use as a fuel for generation
of steam or electric power for running the distillery.
!7s. Chemical Consultants P 5ngineers in a period of last 6
years ha&e supplied and commissioned +3 Biogas plants for different
distilleries in the country ()ef. %nnexure.# Table of Biogas
,ro>ects completed). Bue to increased business acti&ities" the
partnership (!7* CC# ) firm hns now de&eloped into a ,ublic Dimited
Company named ;estern Bio *ystems Dtd" ,une. !7s. ;estern Bio
*ystems Dtd are presently executing another +2 Biogas ,ro>ects and by
the end of +CC0" there would be at least 23 running Biogas ,ro>ects
operating on 9*<DS5)9 technology in #ndia.
POLLUTION CONTROL
).#.T. *a$harale
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Study of Bio-Gas Plant
5&aluating the performance of the 9*<S5)T Technology based
,lants" it is estimated that these 23 Biogas ,lants shall be
treating approximately ++.23 !illion litres of effluents per day
from the 23 distilleries" where they are installed
$UL SA<ING
9*<DS5)
+
Technology guarantees upto :2A degradation of
COB" and biogas /uantity of upto 2.3 @! of Biogas generated
from each Ig of COB degraded from the distillery effluent.
Considering an a&erage COB le&el of C2"222 mg7litre in spent
was" the Biogas /uantity being generated amount to 0"33"222 @!
7day. This /uantify of Biogas is e/ui&alent to approx. 302 tons of coal
sa&ing per day. Thus the non.con&entional energy generated in the form
of Biogas"while reducing pollution" is a ma>or contribution of these
biogas plants operating in +2 different states in #ndia ()ef %nnexure.2 list
of state wise distribution of biogas plants in #ndia) for the purpose of
understanding we can say that this is e/ui&alent to mo&ement of one
train load of coal (in 22 wagons of 23 tons capacity each) e&ery day.
WSTRN BIO S:ST0S LTD
#t is interesting to note thus !7s. ;estern Bio *ystem Dtd" ,une
are the biggest" supplier of Biogas ,lants" based on *<DS5) Technology
in #ndia. %lso they ha&e supplied largest capacity Biogas ,lant (+222
! 7hr of biogas)in the country =eographically spea$ing !7s. ;estern Bio
*ystems Dtd has Biogas plants installed in largest number of status in the
country. These Biogas ,lants are handling effluents from different type of
distilleries namely con&entional" batch type" semi continuous" impro&ed
).#.T. *a$harale
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Study of Bio-Gas Plant
batch or continuous type of distilleries" supplied by &arious %lcohol plant
manufacturers.
9*<DS5)
+
Technology for treatment of effluents from cane sugar
molasses based distilleries" has thus pro&ed to be most suitable and
successful system" and has made &aluable contribution to reduce
pollution in #ndia" and has pro&ided a perinial source of non.
con&entional energy" whereby these 23 Biogas ,lants shall
continue to sa&e approx. +"32"222 tons of coal e&ery year for years to
come.
).#.T. *a$harale
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Study of Bio-Gas Plant
).#.T. *a$harale
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Study of Bio-Gas Plant
CONCLUSION O$ CAS STUD:
#n )a>arambapu *a$har Iar$hana" *ugar cane !olasses is used as
raw material for producing rectified sprit material for producing )ectified
portanble %lcohol P 5xtra @eutral %lcohol.
The waste produce li$e spent wash from Bistillery #ndustry can be
anaerobically digested to generate biogas to generate biogas which can be
used as fuel in boiler to generate steam or can also be used in biogas plant
gensents to generate electrical power with +22 A pollution free.
).#.T. *a$harale
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Study of Bio-Gas Plant
CONCLUSION
#n biogas plant Iitchen waste product cattle waste product etc are
well used to produce biogas while treating the effluent for en&ironmental
protection is thus a welcome approach which ser&es dual purpose of
pollution control and energy resources .
).#.T. *a$harale
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Study of Bio-Gas Plant
R$RNCS
nBi%on-"ntal S+i"n+" : -
By N
*<DS5)T* B#O. =%* ,D%@T
By . *ul(ars Brother Dtd.
www.agnet .org7lib
www.unu.edu7unupress7 unu pboo$s
).#.T. *a$harale
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