BiogasPlantConstructionManual

FixeddomeDeenbandhumodeldigester:2to6cubicmeterbiogasgenerationperday

SKGSangha,EgyptJanuary2013

Forward

TheBiomassforSustainableRuralDevelopmentprojectisajointprogrammebetweenthe
EgyptianEnvironmentalAffairsAgency(EEAA),MinistryofStateforEnvironmentalAffairs,
GlobalEnvironmentalFacility(GEF)andtheUnitedNationsDevelopmentProgramme(UNDP)
Theprojectistofacilitateandacceleratethemarketdevelopmentfornewbioenergy
technologiesinEgypttoremovecertaintechnologicalandcapacitybarriersindevelopmentof
biogasprojectforEgypt.SKGSangha(SKGS)hasbeenselectedtoinstall100domesticbiogas
plantsintwogovernorates,FayoumandAssiyutinthehouseholdsselectedbytheBiomass
Project.SKGSwillinstall,monitorandmaintainunitsforaperiodoftenmonths.Duringthe
courseofplantsinstallationtrainlocalmasons,selectedbytheBiomassProjecton
construction,trainsupervisorystaff,againselectedbytheBiomassProjectondesign
parameters,monitoringandmaintenance.Thedesignoftheplantwillbeafixeddomeonthe
linesofDeenbandhumodelspecificallydesignedbySKGSsuitableforEgyptianconditions.As
themeantemperatureoftheEgyptisabout21degreesCelsiustheplanthasbeendesigned
with50dayshydraulicretentiontime(HRT).TheprojectwillbeimplementedbySKGSand
monitoredbytheBiomassProject.Aprimarylistofprobablebeneficiarieswillbemadebythe
localbodyofthegovernorateandwillbescrutinizedbythebiomassprojectandwillbesentto
SKGSforfinalselectionofbeneficiaries.Theselectedbeneficiarieswillbeprovidedwitha
suitablesizebiogasplantbasedonthecattlepopulationandnumberofmembersinthe
household.
KiranKumarK
Secretary
SKGSangha
skgsegypt@gmail.com
www.skgsangha.org

TableofContents

1.Introduction..................................................................................................................
2.SelectionofConstructionMaterials..............................................................................
2.1 Cement.
2.2 Sand
2.3 StoneAggregates

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.. 7

2.4 Apipetoconnectthedigesterandtheinlettank
2.5 Bracketsweldedgalvanizedironpipe

.. 8

2.6 Valvetocontrolthegasflow .. 8
2.7 Bricks
.. 8
2.8 HighDensityPolyEthylenePipe(HDPE)pipe.. 9
2.9 RubberHose
.
2.10 BrassNipple
..
2.11 BiogasBurner...
2.12 Water.
3.DeterminingPlantSize.
4.ConstructionSiteSelection..........................................................................................
5.Planlayoutforexcavationofpit.................................................................................
6.Excavationofpitforplantinstallation........................................................................
7.Castingthebedconcrete
8.Constructionofcentrepillar.
9.Guidepole.
10.Fixingfirstlayerofbricks.
11.Startingconstructionofthedigester..
12.Placingofinletpipe.
13.Plasteringtheoutsideofthepartlyconstructeddigester
14.Layingofbricklayerastopofthedigesterslurryflowdoor..
15.Pouringofcementwatertosealanypoursintheconstructeddigester..
16.Excavationofearthforconstructionofdisplacementchamber..
17.Layingoffoundationforthedisplacementchamber
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18.FixingofGInippleatthezenithofthedigester..
19.PouringofCementwaterontopofthedigesterandplastering.
20.RemovalofARAVANAfixedinsidethedigester.
21.Plasteringofdigesterinsideportion..
22.Applicationofcementpasteontheinsideportionofthedigester..
23.Applicationofcementcoat
24.Constructionofdisplacementtank.
25.Castingofconcreteslabs/platesmeantforcoveringthedisplacementtank.
26.Constructionofinlettank..
27.Curingofcivilworkswithwater
28.Compactingofthecivilworkswithsoil
29.Diggingofpittocollectspentslurry..
30.Initialfeedingofplant..
31.Requiredphysiochemicalconditionsforoptimumproductionofbiogas.
32.Constructionmeasurementsofthebiogasplant..
33.Designofthebiogasplant.
34.Materialrequirementforthebiogasplant
35.Deviationsfromthedesign..

Attachment:OperationandMaintenanceofBiogasPlant
Tables
Table:31.PhsioChemicalconditionsforoptimumproductionofbiogas..
Table:32.ConstructionMeasurementsofbiogasplant..
Table:34.Requiredmaterialforbiogasplantinstallation..

Figures
Figure:5.1PitLayouts.........
Figure:6.1Excavationofapitforplantinstallationusingmachine.
Figure:6.2Atrimmedpitreadyforbedconcrete
Figure:7.1Maintainlevelofbedconcretealltheroundusingplastictubefilled
withwater..
Figure:8.1Constructionofcentrepillar..
Figure:9.1Guidepoll.
Figure:9.2Guidepoll.
Figure:10.1Placingfirstlayerofbricks.............................................................
Figure:10.2Spacingfirstlayerofbricks
Figure:11.1Startingconstructionofthedigester.
Figure:12.1Placingofinletpipe.
Figure:12.2Placingofinletpipe.
Figure:12.4Fixingofinletpipe
Figure:12.4Fixingofinletpipelowerthantheslurryflowgateheight.
Figure:14.1Supportplankforboxtankceilinglayer..
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Figure:16.1Sandfillingtoraisetheareatorequiredheight....
Figure:17.1Firstlayerofbricks
Figure:17.2Brickshavetobefixedatrequiredmeasurements..
Figure:33.1:Planandsectionaldiagramofthebiogasplant.

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1.Introduction
Biogasplantisananaerobiccivilconstruction.Alltypesofsoftwastescanbefedintothisplant.
Differenttypesofbacteriawilldecomposethisfeedmaterialandgeneratebiogas.Biogasisa
combinationoffewgaseslikeMethane,carbondioxideandHydrogensulfide.Predominantlybiogas
containsabout65%methaneandabout35%carbondioxidewithtracesofothergases.Thetreated
wastewhichcomesoutofbiogasplantisrichwithusefulbacteriaandalsomajorandmicronutrients.
Biogasplantsarepreferredthroughouttheworldasanalternativesourceofenergysupplyandto
createwellfermentedslurrytobeusedasliquid/solidmanureintheagriculturalsoilsandalsoto
createsanitation.Sofarmillionsofbiogasplantshavebeeninstalledmainlytoprovidesustainable
energytoruralhouseholdsandoverallimprovementofhumanhealthandtheenvironment.Chinaand
Indiaareleadersintheline.Thebiogasplantsarepreferredasanalternativetoburningdriedanimal
dungcakes,fuelwoodandinsomecasesLPGfordailycookingneeds.Feedmaterialforthesebiogas
plantsarehumanwaste,meatandvegetablemarketwastes,foodprocessingfactorieswasteand
almostalltypesofanimaldung.

Manyfactorslikequantityoffeedstockavailableondailybasis,typeofwaste,wateravailability,space
availability,typeofsoilandgroundwatertableleveletc.,havetobestudiedbeforeinstallationofa
biogasplant.

Biogasplantespeciallythefixeddomemodelbiogasplantinstallationrequireswelltrainedand
experiencedmasonsapartfromqualitymaterial.Strictfollowingofdesignmeasurementsassuresa
longlastingbiogasplant.Successorfailureofbiogasplantsmainlydependsuponhowandbywhomit
hasbeeninstalledandwhattypeofqualitymaterialhasbeenusedapartfrommaintenancefactors.

Therearemanyadvantagesofafixedmodelbiogasplant.Itisunderground,savesspaceand
somewhatimmunetoclimaticconditions.Therearenomovingpartsandhencelesserwareandtare.
Almostnomaintenanceanditcostlessthanotherdesigns.

ThemanualhasbeenpreparedbySKGSangha(www.skgsangha.org)withitsvastexperiencein
constructionoffixedmodelbiogasplants(morethan105,000)fortheuseofmanagerialpersonnel
trainedonsiteandinprojectforfurtherpropagationofbiogasplantsinEgypt.

Thismanualhasbeendesignedinsuchwaythatitcanbeusedbyalayman,providedanexperienced
masonisavailabletoconstructafixedmodelbiogasplant.Stepbystepdescriptionalongwithfigures
andphotosprovidesaclearunderstandingandmethodsforinstallationoftheunit.

2.Selectionofconstructionmaterials:

MaterialAvailability:Almostallofthematerialsareavailablelocallybutfindingthemisaherculean
task.Thefollowingmaterialisrequiredforconstructionanduseoffixeddomemodelbiogasplant:
1. Cement
2. Sand
3. Stoneaggregates

4. Apipetoconnectthedigesterandtheinlettank
5. Bracketsweldedgalvanizedironpipe

6. Valvetocontrolthegasflow

7. Bricks

8. Highdensitypolyethylene(HDPE)pipe
9. Rubberhose

10. Brassnipple

11. Biogasburner

12. Water

2.1 Cement:Thisisavailablelocallyandcanbeboughtatanyquantitybutthemixofcement
whenitwasmadeisnotknown.Cementgraduallylosesitsbindingpowerduringthe
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prolongedstorage.Alwaysitisbettertousethefreshcementforbetterresults.A
wholesalerwhogetsfreshloadsfromfactoryeveryfewdaysmaybeidentifiedandcement
canbefromthisestablishment.LocallyavailableordinaryPortland42.5gradecementis
selectedforconstructionofplants.
2.2 Sand:SandisavailableinEgyptbutthesandparticlesizeistoosmalltouseitincivilworks.
Soasupplierwhocansupplybiggerparticlesizesandistobesoughtouttoprocuresand.
Thissandcontainslotsofpebblesandstonessizestartingfrom10mmto500mm.Thishas
tobesievedbeforeuse.Sandshouldbefreeofearthandclaytobeusedforbiogasplant
construction.
2.3 Stoneaggregates:
Riverbedpebblesarepredominantlyusedinconcreteinthese
governoratesofEgypt.Thepebblesurfaceissmoothandcannotholdthecementinthe
concretemix.Highersurfaceareasareneededforconcreting.Eventhoughifwebreakthe
pebblestogetmoresurfaceareaagainthesmoothnessofthesurfaceposesproblemof
cementbinding.Astrong,hard,roughsurfacedstoneaggregatesareneededforconcreting.
Thiskindofmaterialisnotavailableinthevicinityofthemanyareas.Searchforgranite
stoneaggregatesupplierhastobelaunched.Thismaterialhastobebroughtfroma
farawayplaceandtobeboughtinhigherquantities,37M3atatime.Eventhoughtheprice
ofthismaterialishigh,almosttriplethecostofpebblesthismaterialistobeused.The
granitestonepiecesof2025mmsizearepreferred.
2.4 Pipetoconnectdigesterandinlettank:
Manytypesofpipescanbeusedforthis
purposestartingfromplastictostoneware.15centimeterdiameterhigherthicknessPoly
VinylChloride(PVC)pipemaybeusedforthepurposeofconnectingtheinlettothe
digester.Thesepipesarelocallyavailablebuthavetobeorderedinadvancetogethigher
thicknesspipes.46mmthickPVCpipeispreferred.

2.5 Bracketsweldedgalvanizedironpipe:
Thispipe,diametertopsidemalethreaded
isneededtofixitonzenithofthesemisphericaldigester.Tomakeitunmovabletwoiron
wirepieceswereweldedonbothsidesofthepipeofabout30centimeterslongataheight
frombottom3centimeters.Theseweldedironpieceswillholdtheconstructionmaterial
andmakesthepipenotmovable.Pipeisavailableinthelocalmarketandgetitweldedata
localweldingshop.Bclass,pipemarkedwithbluecolourpaintispreferred.
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2.6 Valvetocontrolthegasflow: Thisdiametervalveisfittedtothebracketswelded

galvanizedpipefixedontopofthedigester.Thisvalvemaybemadewithanymaterial,iron,
gunmetal,plastic,PVC,brassetc.Manyofthemetalvalvesareleakingafterfewtimesof
operation.PVCvalvesarehavingnylonoringsandarelastingforlongtimewithoutgas
leakage.Thesevalvesarefragileandmaybreakbutleakproof.ThesePVCvalvesmaybe
usedintheproject.Thegasoutletpipeisthemostpronetodamagesasitisatthezenith
ofthedigester.Intheruralscenechildren,animalsandinsomecaseswindalsomovesthe
overheadpipelineandmaybreakthegatevalve.Ifametalvalveisusedthenthe
movementofthepipewillbetransferredtothebracketsweldedgalvanizedpipeandmay
causelooseningofthefixing.Ifithappensitisdifficulttofixthispipeasithastobefixed
frominsidethedigester.PVCvalvesarepreferredtoavoidthiseventuality.Avalvecanbe
replacedatanytimewithease.
2.7 Bricks:
Anytypeofbricksorareinforcedconcretecanbeusedforfloatinggas
holdermodelbiogasplants.Forfixedmodelbiogasplantasitisasphericalstructurealarge
surfacedcementmortarholdingbricksareneeded.Wellburntmudbrickswillholdthe
cementwell.ManypartsofEgypthallomudbricksareinuse.Thesebrickswillhaveholes
throughthebrickandgoodforverticalstructuresandlightweighttoo.Astheyhavelesser
surfaceareaandchanceofremainedhallospaces,thesphericalstructureofthebiogas
plantbecomesweakandmaybreakwithslighttensilepressure.Thatiswhysolidbricksare
preferredforfixedmodelbiogasplantsconstruction.Solidbricksarenotmadeinmany
places.Athoroughsearchhastobemadeintheprojectandadjoiningareastofindabrick
factorythatmakessolidmudbricks.Thebrickhastobewellburntandwellcompactedto
beusedforthebiogasplant.Thefactoryownersmaybeexplainedformakinghighquality
solidmudbricks.Thesizesofthesebricksare22centimeterlong,10centimeterwideand7
centimeterthick.
2.8 HighDensityPolyEthylene(HDPE)Pipe:Apipeisneededtoconnectthedigesterandthe
biogasburner.Thispipewillbelaidoverhead.Soitshouldhavecertaincharacterstickslike,
shouldnotbend,lastlong,nottocompresswithpressure,shouldnotbreakandetc.,.HDPE
pipeishavingallthesecharactersticks.EventhoughthereareHDPEproductsinthe
Egyptianmarkettheparticularpipeisnotavailable.Manyfactorieswerecontactedand
exceptonerefusedtomakethepipe.OneHDPEproductmanufacturerprincipallyagreedto
makethepipewithspecificthicknessbutaskedtogivehigherquantityorderastheyhave
tomakethenecessarymoldstomanufacturethepipe.Asthereisnootheralternativea
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5000meterorderwasplacedandtakenthedelivery.Thispipeishavingabout3millimeter
thicknessand20millimeterdiameter.
ThisisneededtoconnectthebiogasburnerandtheHDPEpipecoming
2.9 Rubberhose:
fromthedigester.Thisshouldhaveaspecificinnerdiameterassuitabletoconnectthe
biogasburnermetalpipe.Thisspecificsizeisnotavailableinthelocalmarketanditcanbe
broughtalongwiththebiogasburner.

2.10 Brassnipple:
Apipenippleisneededtoconnectthegalvanized
ironpipeconnectedtotheHDPEpipeandtherubberhose.Thiswillhaveafemalethread
ononesideandmalegrovesontheotherside.Thismalegrovessizeisequaltothesizeof
thebiogasburnermetalpipe.Asthisnippleishavingspecificsizeoftheburnerbettertoget
italongwiththebiogasburner.

2.11 Biogasburner:
LiquefiedPetroleumGas(LPG)burnersarenotsuitablefor
biogasburning.Biogasrequiresaspecificburnerasitishavingadifferentcompositionof
gases,differentpressureanddifferentcalorificvalues.Thesebiogasburnersarenot
availableinEgyptianmarket.Whenthereisaprojecttoinstallhighernumberofbiogas
unitsthenalocalLPGstovemanufacturercanbetrainedonmakingbiogasburners.The
stovebodyandthegasmixingtubesaresameastheLPGforbiogasburner.Burnertops,
controlvalvesandgasjetsarethethreepartsthathavetobemadeseparatelyforthe
biogas.Eitherthesepartscanbeimportedormadelocallytomakethebiogasstoves.For
thepresentprojectbiogasburnersareimportedfromIndia.
2.12 Water:Waterisavailableatmanyplacesforconstruction.Whereeveritisavailablethe
irrigationcanalwaterorthegroundwateraccumulatinginthedigesterbottomisusedfor
constructionandcuring.Itisthepipedwaterthatisusedinothercases.Beneficiariesused
thepipedwaterforinitialfeedingofdungandareusingthesamefordailyfeedingofplant.
Thepipedwaterisfilteredandchlorinated.Thechlorineinthewaterisantibacterial.
Becauseofthischlorinecontenttheplantsaretakingunusuallylongtimetogenerate
maturedbiogasinitially.Facultativebacteriawhichareaerobic/anaerobicmultiplyfaster
thananaerobicbacteriacansurvivethischlorinecontentinthewateranddowork.
Whereasanaerobicbacteriawhichareslowgrowingandsensitive,growslowanddonot
workinunfavorableconditions.Thisisthereasonforprolongeddaysofsmellygas
generation.Theplantswhicharefedwithmorewaterandlessdungwilltakeverylongtime
togeneratecompletefermentedgas.Manyofthetimesbeneficiariesweretoldtorecycle
thespentwaterfordailyfeedingand/useanimalurinefordailyfeedmaterial,dung
mixing.Itisbettertousecanalwaterwhereeveritisavailablefordailyfeeding.Otherwise
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tapwatercanbestoredinwidemouthedopencontainersatleastfortwodayswith
occasionalmixingfordailyfeeding.Aerationofwaterwilllessenthechlorineeffectbecause
ofevaporation.Allthebeneficiariesweretoldaboutthisproblemandhavebeenadvisedto
useonlythecanalwater.Beneficiarieshavetobeeducatedonthisissuefurtherduringthe
monitoringvisitsandtrainingprogrammes.

3.DeterminingPlantSize

Thismanualismeantforhouseholdfixedmodel26cubicmeterbiogasgenerationcapacity50
daysHRTbiogasplantsinstallationinruralhouseholdsofEgypt.Othersizesofbiogasplantswith
differentparameterslike50%gasstorage,lesserHRTandetc.,arealsoavailable.Aqualifiedperson
whoishavingexperienceinthislinecandesignothertypesofplants.Asallthetraineesunderthis
projectareamateursitisbettertosticktotheconstructionmanualguidelines.Evenifafamilyof5
membersownsmorethan8animalsa2cubicmeterbiogasgenerationunitwillbeinstalled.Ifafamily
of10arehavingonly4animalsthenalsoa2cubicmeterbiogasgenerationunitwillbeinstalled.
Numberoffamilymembers,numberofanimalstheyownandbothinclusivewilldecidetheplantsize.
10kgofdungperanimalperdaymaybetakenasathumbruletoquantifythedungavailability.0.4M3
perpersonperdaymaybetakentoquantifythebiogasdemand.

4.Constructionsiteselection

Constructionsiteselectionisanimportantaspectofbiogasplantinstallation.Iftheplantis
awayfromsourceoffeedmaterialitisdifficulttofeedtheplantondailybasis.Ifitisfartherawayfrom
thegasutilizationpointthecostofpipelinewillincreaseandpipelinelyingwithoutsaggingbecomes
difficult.Andthewateravailabilityatthesiteisalsoanimportantfactortobeconsidered.Theplant
shouldnotbenearertoawatersourceandbigtrees.Consideringallthesefactorsacompromising
placehastobedecidedfortheinstallationofthebiogasplant.Fixedmodelbiogasplantsgenerate
highergaspressurehenceitisnotdifficulttocarrythegastotheutilizationpoint.Moreoverthecost
ofthepipelineisaonetimecost.Itisalwaysbettertoselectthesitenearertothesourceoffeed
material,sideoftheanimalconfinement.Insomecasesplantsinstalledinsidethehousesandunder
theroofarealsofunctioningwell.Thebeneficiaryconvenienceandeaseofdailyfeedingarethe
guidingrulesforsiteselection.

5.Planlayoutforexcavationofpit

Oncethesiteisselectedfortheplantinstallationalayouthastobemadefortheexcavationof
thepit.Wheretoconstructtheinlettankandwhereandhowtoplacethedisplacementchamberare
theimportantfactorstobetakencareatthisstage.Archtankandfeeding/inlettankshavetobe
constructeddiagonallyoppositetoeachother.Displacementchamber/outlettankhastobe
constructedwheretransportationofspentslurrybecomeseasy.Accordinglythepithastobe
excavated.

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Figure:5.1PitLayouts

Awoodenormetalpeghastobeinsertedintothesoilatthecentreandaropehavingequal
outsidelengthofthedigesterbasementconcretehastobetiedtothepegtodrawacirclefor
excavation.Arectangularportionfordisplacementchamberalsohastobemarkedonthegroundjust
touchingthedigestercircleusingrockdustoranyotherpowdertobevisibletothemachineoperator
orthemenwhowilldigthepit.

6.Excavationofpitforpantconstruction

Ifavailableanexcavationmachinewillbeengagedtodigoutthepit.Itsavesthelabourcost
andmoreovernumberofpitscanbemadeinaday.Fixeddomebiogasplantisasphericalstructure
sothepitshouldbeinacylindricalshape.Inmostofthecasesitisdifficultfortheexcavatingmachines
tomakeacylindricalpithencearectangularpitmaybemade.Manuallabourisrequiredtotrimthe
machinemadepitandtoexcavatethebottomportionofthepit.Ifthemanuallabourisengagedtodig
thepitthenacylindricalpitispreferredtolessentheburdenofunnecessarysoilexcavationand
shifting.Allthesoilexcavatedshouldbekeptaroundthepitforlaterbackfillingaroundandontopof
theinstalledunit.

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Figure:6.1Excavationofapitforplantinstallationusingmachine

Thebottomcurvedportionhastobeexcavatedbymanuallabourtotheexactsize.
Thedepthandradiusofbottomcurvedportionvariesaccordingtothesizeoftheplant.Moreoverthe
displacementchamberportionalsohavetobeexcavatedaccordingtothedesignparameters.After
completionthepitlookslikeasshowninthebelowphoto:

Figure:6.2Atrimmedpitreadyforbedconcrete

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7.Castingthebedconcrete

Bedconcreteislaidwith1:2:4or1:1:3mixofcement,sandandstoneaggregatesrespectively.The
mixofmaterialdependsupontheoilcondition.Ifthesoilishavingmoreorganicfractionthentherich
mixof1:1:3maybeusedandinothercasesmildmixof1:2:4maybeused.Inblackcottonsoilsthe
concretehastobereenforcedwithironwireof6mmdiameter.Theconcretehastobewell
compactedtoattainmorestrength.Concretehastobelaidaccordingtothedesignparameter.Care
hastobetakentomaintainthelevelonallroundusingthewaterfilledplastictube.

Figure:7.1maintainthelevelofbedconcretealltheroundusingplastictubefilledwithwater

8.Constructionofcentrepillar

Thecentrepillarhastobeconstructedwith1:10cementmortarasithastoberemovedlater.A6mm
ironwirehastobeplacedinthemiddleofthepillarprotruding5centimetersabovethepillarwhile
constructingit.Theheightofthepillarhastobemaintainedonparwiththeheightofthebed
concrete.Thispillarhastobeconstructedimmediatelyafterthecastingthebedconcrete.

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Figure:8.1Constructionofcentrepillar

9.Guidepole

Guidepolecanbeawoodenplankof5centimeterwideand2centimeterthick.Thisisthepolewhich
guidesthemasontomaintainthefixedradiustoconstructthehalfsphere.Anailisputthroughthe
plankattheprescribedlength(2centimeterlongerthanthedigesteractualradius)comingthroughthe
plankuptoalengthof5centimeters.Theguidepolewillhaveabout5centimeterlongerthanthe
requiredinnerradiusoftheplant.Theprojectionofnailandplankwillholdthefreshlylaidbrickfrom
fallinguntilthenextbrickisputinline.2centimeterhigherlengthofthenailontheplankthanthe
actualradiusofthedigesteristocompensatethe12mmthickplaster,cementpasteandcementcoats
appliedinsidethedigesterwallsafterbrickconstruction.

Figure:9.1Guidepoll

Figure:9.2Guidepoll

10.Layingofbricksasreinforcementlayer

Oncetheconcreteiscastedandcenterpillarisconstructedthefirstlayerofbrickshavetobelaidon
thewetconcreteforthedigesterandslurryexitpassageboxtank.Thefirstlayerofbrickshastobe
laidinsuchawaythatthedigesterconstructionbrickswillcomeinthecentreofthislayer.Thebricks
arelaidvertically22/23centimeterlongand11/10centimeterhigh.Thebricksarekeptinsuchaway
thatthegapbetweenthebrickshavetobenotmorethanabout1to1centimeters.Athinlayerof
cementmortarof1:4willbeappliedontheconcretefloorbeforeplacingthebricksandthegaps
betweenthebrickshavetobefilledwithcementmortar.Oncetheconcreteislaidandfirstlayerof
brickswerefixedtheworkhastobestoppedfortheconcretetoattainstrength.Thestructurehasto
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becuredafter12hourswithwateruntilthenextportionofworkhasbeenstarted.Theremainingbrick
afterthereinforcedlayerwhichweresourcedforplantconstructionhavetobewettedwithwater.
Cleanwatercanbepouredontopofthepileuntilallbricksgetwet.

Figure:10.1Layingof1stlayerofbricksFigure10.2:Spacingfirstlayerofbricks

11.Startingconstructionofthedigester

Constructionofmaindigesteralongwithslurryflowchamberboxcanbestartedafter24hoursof
fixingoffirstlayerofbricks.Ifthebottomconcreteislaidwithreenforcedconcretethenthiswork
hastobestartedafter72hoursofconcreting.Beforestartingofconstruction70%ofbricksrequired
fortheunithavetobeplacedinthewellofthedigester.Thiswillhelpthemasontoaccessthebricks
easily.Dependinguponthesizeoftheplantthethicknessofthedigesterwallvariesandaccordingto
thedesignthedigesterhasbeconstructed.Guidepolehastobeusedtomaintaintheradiuswhile
constructingthedigester.Cementmortarof1:4maybeusedforconstructionofthedigesteruntilthe
heightofthearch.Graduallythecementquantityinthemortarhastobeincreasedto1:2oncethe
digesterheightisincreasing.Carehastobetakentoavoidjointsoftwoormorelayersofbrickscome
inthestraightline.Brickshavetobecompacteddownwordsandsidewisealso.Trowelhandletipbe
usedtocompactthebricks.

Figure:11.1startingconstructionofthedigester

12. Placingofinletpipe

Inletpipewillbeplacedatthestipulatedheight.TheloweredgeofthePVCpipeshouldrestonthe
lowersideedgeofthebricksothatitwillnotslipdown.ThebindingofPVCandcementisnotstrong
sothepipehastobescratchedusingsawbladeteethhorizontallyi.e.thelinesshouldformaroundthe
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pipetotheextentofthepipecoveredinthedigesterwall.Arichmixofmortarshouldbeusedatthese
jointsandbrickpiecesshouldbeplacedintheloweranduppertriangularjoints.Theinletpipeshould
beplacedinsuchawaythattheinletpipetopedge,thecentrepillarandthecentreoftheoutletbox
tankshouldbeinastraightline.Theinletpipeinneredgeshouldbeat45centimetersawayfromthe
outsideofthefirstlayerofbricksataheightoftheguidepoleplacedverticallyonthecentrepillar.The
guidingrulefortheinletpipeplacingis:inletpipelowertopedgeshouldbebelowtheheightofthe
slurryflowrectangletopintheboxtank.

Figure:12.1Placingofinletpipe1

Figure:12.2.Placingofinletpipe

Figure:12.3Fixingofinletpipe Figure:12.4Fixingofinletpipelower
thantheslurryflowgateheight

13. Plasteringtheoutsideofthepartlyconstructeddigester

Oncethedigesterisconstructedtotheheightoftheboxtanktoptheconstructedportionofthe
digesteroutsidecanbeplasteredwith12mmthick1:4mixmortar.Digesterconstructionwillbe
continueduntiltheplasterofmortarisdried.Oncethemortarplasterisdriedandfixedthenthe
plasteredportionofthedigestercanbecompactedwithexcavatedearthuntiltheheightofthe
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plasteredarea.Backfillingofsoilaroundthedigester,apartfromcreatingmoreworkingspaceforthe
workerstomovebutalsocompactsthesoilaroundthedigester.

14. Layingofbricklayerastopofthedigesterslurryflowdoor

Oncebackfillingofsoilaroundthepartlyconstructeddigesterisoverthenthecircularlayerwhich
coversthetankdoorcanbetakenup.Brickspiledinverticalcolumninbothsidesoftheboxtankwill
supportawoodenplankof60centimeterlong,10centimeterwideand23centimeterthick(seefigure
14.1).Woodenplankhastobeplaced1centimeterlesshighthanthedesignmeasurement.
Adjustmentofheightcanbedoneusingcementmortarontopoftheplank.Afteradjustingthecorrect
heightanewspaperorcementbagpaperhavetobeplacedonthewoodenplank.Arichmixmortar
layerhastobespreadand2fullbrickshavetobeplacedfromboththesidesofthedigesterwall.Care
hastobetakentoplacethesebricksabout2centimetersonthewallandtheremainingportiononthe
mortarontopofthepapercoveringthewoodenplank.Theremainingdistancemaybecoveredwitha
fullbrickoraportionofacutbrick.Compactthebricksusingrichmixmortar.Continueconstructionof
thedigester.Secondlayerofbricksontopofthefirstlayerontopofthewoodenplankalsoshouldbe
placedwithrichmixmortar.Oncethedigesterworkiscompletedandwhentheworkontheboxtank
isstartedthenthesupportingbricksandthewoodenplankcanberemovedcarefullynotdisturbing
thedigester.Oncethewoodenplankisremovedthencementpastecanbeusedonthebottomsideto
adjustheightaccuratelyaccordingtothedesign.

Figure:14.1Supportplankforboxtankceilinglayer

15. Pouringofcementwatertosealanypoursintheconstructeddigester

Plaincementwillbemixedwithdoublethequantityofwaterforthispurpose.Presentlythislayerof
cementwaterhastobeappliedontheoutsideportionoftheconstructeddigester.Bythetimethe5/6
17

layersofdigesterisconstructedontopoftheslurryflowdoortopthispouringofcementwateractivity
canbetakenup.Thiscementwatershouldcovertheentirenewlyconstructedoutsideportionofthe
digestercoveringallthejoints.Ifanyholesappearafterthiswaterapplicationtheholeshavetobe
coveredwithcementwaterormortariftheholesarebig.Plasteringofthisnewlyconstructedportion
canbetakenupimmediatelywhenthecementwaterisstillwet.Oncethisplasteringiscompletedand
theplasterissetthebackfillingofsoilaroundthedigestercanbetakenup.

16. Excavationofearthforconstructionofdisplacementchamber

Oncethedigesterconstructionabovetheboxtankdoorcoverlayeriscontinuingtheworkerscanstart
diggingtheareaneededfordisplacementtank.Theexcavatedsoilcanbeusedforbackfillingthepit
aroundthedigestertothebottomheightofthedisplacementtank.Accordingtothemeasurement
providedinthemanualthepithastobeexcavated.Carehastobetakenwhilecompactingsoilaround
theboxtankbynotdisturbingthestructureasitisconstructedwithathinlayerofbricksandstillitis
notattainedstrength.Waiteuntilthefilledupsoilattainscompaction.Thefilledupsoilwillgodown
bycompactionbythetimetheareareadyforconcrete.Sandmaybeusedontopofthesoiltoraise
theareatotherequiredheight.

Figure:16.1sandfillingtoraisetheareatorequiredheight

17. Layingoffoundationforthedisplacementchamber

Oncethesoilaroundthedigesterespeciallyaroundtheboxtankandspacerequiredforthe
displacementchamberiswellcompactedandsettledthenbaseconcretecanbelaid.Basingonthesoil
weightbearingcapacityironwiremaybeusedinthebedconcreteintheloosesoils(especiallyblack
cottonsoils).1:2:4mixofcement,sandandstoneaggregatesmaybeusedforthisbaseconcrete.10
centimeterswiderconcretebedisrequiredonallsidesthantheconstructingtankoutsidedimensions.
Oncetheconcreteislaidthefirstlayerofbricksforthedisplacementtankhastobefixedtothe
concreteusingcementmortar.Constructionoftankwillwaituntiltheconcreteattainsstrength.
Thicknessofthisconcretedependsuponthesizeoftheplantanddesignmeasurementhastobe
followed.Careshouldbetakentomaintaintheexactrectangleshapeofthedigester.

18


Figure:17.1FirstlayerofbricksFigure:17.2Brickshavetobefixedatrequiredmeasurements

18. FixingofGInippleatthezenithofthedigester

Whenthedigesterconstructionanglereachesmorethan45degreesthelayersofbricksmayfall.To
avoidthiscounterweightsmaybehangedasshowninthebelowdrawing.Oncethedigester
constructionreachesthefinalstage,whenonlyafewcentimeterdiameterofbrickconstructionisleft
outpreparationforfixingthebracketsweldedGInipplemaybetakenup.Removeonetoplayerof
bricksfromthecentrepillaratthewellofthebedconcrete.TakemortarcarryingironARAVANAand
covertheoutsidebottomportionofitwith2layersofanyoldnewspaperorcementpaperbag.Invert
theARAVANAandbalanceitontheguidepoleverticallyplacedonthecenterpillarandfixtightlythe
entiresetupcoveringtheleftoutdigesterholeatthezenith.Placingonelegonthedigester,pour
somedrycementontopofthepapercoveringtheARAVANAvisiblefromoutside.Keepthebrackets
weldedGInippleverticallyinthecentreoftheholeandporesomerichmixcementmortar.Fillthe
gapswithbrickpiecesandfixthemwithmorecementmortar.Poursomedrycementonthemortar.
Waiteforatleast10minutesuntilthearrangementisdriedandsettledbeforecontinuinganyworkon
thedigester.

19

19. PouringofCementwaterontopofthedigesterandplastering

Followthestepsdescribedinpointno.15tocovertheremainingportionofthedigesterandplaster
theoutsideofthedigesterwith12mmthickcementmortarof1:4.Careshouldbetakennottotouch
andexertanypressureontheareawherethebracketsweldedGInippleisplacedwhileplasteringthe
digestertop.

20. RemovalofARAVANAfixedinsidethedigester

SlidetheguidepoleonthecentrepillarholdingtheARAVANAtoslackenthetightlyfixed
arrangement.OnceitisslackenedremovetheguidepoleandtheARAVANA.Paperontopofthe
ARAVANAmaysticktothemortarandhavetoberemovedcarefullynotleavinganypaperportion
onthedigester.Alongwiththisarrangementthecentrepillaralsowillberemovedentirely.

21. Plasteringofdigesterinsideportion

Preparethecementwatermixdescribedinpointno.15andapplythesameonallthesurfaceareaof
insidedigesterandplastertheentireareawith12mmthickand1:4mixofmortar.Smoothenthe
surfaceareabyrubbingtheplasteringwithwoodentrowel.Anyfallenmortaronthebedconcretecan
bepressedtothebedconcreteasaplasteringlayer.

22. Applicationofcementpasteontheinsideportionofthedigester

Thisisthemostcrucialpartofthebiogasplantconstructionwhichmakesthedigestergasleakproof.
Cementshouldbemadeintopastemixingwaterforthispurpose.Usually1:1ratioofwaterand
cementismixedtogettherequiredconsistency.Throughmixingofmaterialswillassurethelumpless
paste.Applyabout1to1mmthicklayerofthiscementpasteonalltheinsidesurfaceareaofthe
digesterusingthetrowel.Careshouldbetakennottoleaveanyportionwithoutthecementpaste.
Lightinginthedigesterisnotmuchwhiledoingthisactivitysoputawhitecolourplasticbagatthe
bottomoftheboxtanktoreflectthelightandtellpeoplewhoareonoutsidenottoblocklighting.1
5bagsofcementmaybeneededforthispurposedependinguponthesizeoftheplant.

23. Applicationofcementcoat

Thiscementcoatoninsidesurfaceareaofthedigesterwillbedonetwice.Oncewhenthecement
pasteappliedacquiredsomedrynessandsecondtimewhentheplantisreadyforinitialfeeding.
Cementmixedwithdoublequantityofwatermaybeusedforthispurpose.Anordinarypaintbrush
willbeusedforthispurpose.Justlikeanypaintingworkthiscementcoatalsoappliedontheentire
insidesurfaceareaofthedigesternotleavinganyportionuncovered.

24. Constructionofdisplacementtank

20

Oncethebaseconcreteattainsstrengththedisplacementtankconstructioncanbetakenup.Ahole
forslurryexithastobeleftoutwhileconstructingthedisplacementtank.Thisexitholecanbekepton
anysideofthedisplacementtankdependingupontheneedofthehousehold.Untiltheheightofthe
slurryexitholearoughplasteringonoutsideportionandallremainingportionfineplasteringhastobe
done.

25. Castingofconcreteslabs/platesmeantforcoveringthedisplacementtank

Thisworkcanbetakenuponthedayofbedconcretelayingoranyotherconvenientdayofplant
installation.Eachplatewillhavetobecastedwith6070centimeterwidth,120140centimeter
lengthandwith68thickness.6mmironwirecuttotherequiredmeasureswillbeusedinthese
plates.Dependinguponthesizeoftheplant36platesarerequired.1:1:3mixofcement,sand
andstoneaggregatesmaybeusedfortheseslabs.4verticaland56horizontalironwiresare
requiredforeachplate.Clearanareatotheextentoftheplatesrequirementandleveltheground
usingshawl.Covertheareawith12centimeterthicksandlayer.Putemptypapercementbagsor2
layersofoldnewspapersonleveledandsandcoveredarea.Placebricksonoutsideofexactplate
dimensionsformingarectangle.Onelayerofbrickscanbeuseasonesidefor2plates.Coverthebricks
withpaperinsuchawaythattheconcretedonotsticktothem.Pourconcretemixtotheextentof2
centimeterthicknessandplacetheironwiresverticallyandhorizontallyandbindallthejointswith
thinironwire.Pourmoreconcretemixontopofthewiresandcompacttheconcretewithtrowel
initiallyandlaterwithawoodenplank.Alltherequiredplatescanbemadeatthesametime.

26. Constructionofinlettank

Whilethedisplacementtankisunderconstructionthearearequiredforinlettankhastoberaisedfor
layingofbedconcrete.Oncethissoiliscompactedandwellsettledthenbedconcretewith1:2:4mix
maybelaid.Atleast10centimetermorelengthyareathantheinlettankouterareaonallsideshasto
becoveredwithconcrete.Oncethisconcretehasattainedsufficientstrengththentheinlettank
constructioncanbetakenupaccordingtothemeasurementsmentionedinthemanual.

27. Curingofcivilworkswithwater

Thisisanotherimportantfactorforthelongevityoftheplants.Allcementstructuresattainstrength
whentheyarecuredwithwater.Allthecivilworksincludingtheconcreteplateshavetobecuredwith
waterfornotlessthan15days.Curinghastobetakenupinsuchawaythatthecivilworksdonotget
driedcompletely.Whenallthecivilworksoutsidesarecoveredwithsoilitbecomeseasytomaintain
moistureinthestructuresandlessentheburdenofapplicationofwaternumberoftimesinaday.

28. Compactingofthecivilworkswithsoil

Theinlettank,displacementtankandthedigestershouldbecompactedwithsoilonalloutside
portions.Thedigestertopshouldbeatleast10centimeterunderthesoilandsoilhastobecovered
21

aroundtheinlettankatleast15centimetershighonallsides.Exceptonthesidewheretheslurryexit
holeinthedisplacementchamberallothersidesshouldbecoveredwithsoiltotheheightofthetank.

29. Diggingofpittocollectspentslurry

Aholeinthegroundhastobeexcavatedjustundertheslurryexitholeinthedisplacementchamberto
collecttheslurryflowingoutoftheplant.Thepitdimensionsvarydependinguponthesizeofthe
plant.Thepitshouldbeexcavatedinsuchawaythatitshouldholdatleast10daysfeedstock.A2
cubicbiogasgenerationperdaycapacityplantwillbefedwith50kgofdungandabout50litersof
watereverydayandhencetheslurrycollectingpitshouldhaveacapacitytohold1000litersofslurry.

30. Initialfeedingofplant

Theplantrequiresbigquantityoffreshanimaldungandwatertofeeditinitially.Theplantswere
installedwith50dayshydraulicretentiontimeandrequire50daysfeedstockasinitialfeed.A2cubic
metergasgenerationperdaycapacityplantrequires50kgdungperdayandhence50kgx50daysi.e.
2500kgofdungisrequiredforinitialfeedingoftheplant.Beneficiarieswereadvisedtopileupthe
dunggeneratedintheiranimalconfinementondailybasisstartingfromthedayofdecisiontoinstall
theplantinshadedarea.Therequireddungforinitialfeedingwillbeaccumulatedonsitebythetime
theplantisinstalledandcompletedcuring.Initialfeedingwillbedoneusingtheirrigationwaterbut
notthetapwaterasitcontainschorine,anantibacterialmaterial.

31. Requiredphysiochemicalconditionsforoptimumproductionofbiogas

Sl.
Character
Range
comments
No.
1
pH
6.87.2

2
C/Nratio
1:2530

3
Temperature
3235
Canbecompensated
withHRT
4
Solidsconcentration 810

5
Toxicsubstances
0 25ppm
Table:31.PhsioChemicalconditionsforoptimumproductionofbiogas

22

32. Constructionmeasurementsofthebiogasplant

Sl.
No.
1
2
3
4

Description

2M3

3M3

AHeightoftheMixingTank
60
60
BThicknessofDigesteratGINipplelevel
10
10
CWidthoftheDisplacementTank
100
100
DDisplacementtankheightabovethe
45
45
holebottom
5
EWidthofthemixingtankconcretebase 100
100
6
FWidthofmixingtank
60
60
7
GThicknessofdigestermasonrywork
7
7
8
HThicknessofbaseconcreteatdigester
7
8
base
9
JHeightofthetapperportionorheightof 55
60
thecentrepillar
10 KHeightoftheinletpipeinneredgefrom 30
45
thebaseconcrete
11 LHeightofthearchfromthebottominner 25
25
tipoftheinletpipe
12 MInitialslurrylevelheightfromthearch
72
90
13 NRadiusoftheDigester
132
150
14 PArchheightfromarchtankconcrete
48
63
base
15 QLengthofthearchtank
70
70
16 RThicknessofarchtankwallunderthe
22
22
displacementtankwall
17 SArchtankheightuntilthebottomofthe 56
76
concretebaseofthedisplacementtank
18 TDiameterofthedigester
264
600
19 UHeightoftheslurryexitholefromthe
40
40
bottomofthedisplacementtank
20 VWidthoftheconcreteunderthedigester 25
25
base
21 WLengthoftheDisplacementtank
175
250
Table:32.Constructionmeasurementsofbiogasplantincentimeters

23

4M3

6M3

60
13
120
48

60
13
120
53

110
70
10
10

120
80
10
15

65

80

50

60

25

25

100
165
68

110
190
75

90
22

90
22

84

90

660
45

380
55

25

25

280

300

33. Sectionandplanofthebiogasplant

Figure:33.1:Planandsectionaldiagramofthebiogasplant

24

34. Materialrequirementforthebiogasplant

Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

2M3

Description

3M3

Wellburntsolidmudbricksof22x10x7mm 1050
1250
Cementbagsof50kgeach,42.5gradeOPC
16
19
Sandcourseincubicmeters
1.5
2
Sandfineincubicmeters
1.5
2
Stoneaggregatesmadefromgranitestonein 1
1.5
Cubicmeters
6mmironwireinkilograms
8
10
Bindingironwireinkilograms
0.1
0.1
150mmdiameter6mmthickPVCpipein
1.5
1.75
meters
Bracketswelded1.2diameterGInippleof30 1
1
centimeterlong
PVCgatevalveof20mmdiameternos.
1
1
Stainlesssteelbodydoubleburnerbiogasstove 1
1
100mmlongGalvanizediron20mmdiameter 2
2
nipples
Femalethreadedbrassmetalpipenipple
1
1
Rubberhoseinmeters
1
1
HighDensityPolyEthylene(HDPE)pipeof20
50
50
mmdiameterinmeters
Plumberinmandays

Freshanimaldungforinitialfeedingintons
2.5
3.75
Table:34.Requiredmaterialforbiogasplantinstallation

4M3

6M3

1850
24
2.5
2.5
2.5

2650
34
4
4
3.5

20
0.2
1.9

25
0.25
2.2

1
1
2

1
1
2

1
1
50

1
1
50

7.5

35. Deviationsfromthedesign

Thismanualincludesdesignandconstructionmaterialquantitiesforthebiogasplantsof2,3,4and6
cubicmeterbiogasgenerationperdaywith50daysHRT.Designandsizeofaplantotherthan
mentionedaboveisfeasibleandaskilledengineershouldbeconsultedfordeviationsfromthe
provideddesigns.Thebiogasplantsizeisdependentontheaveragedailyfeedstockandexpected
hydraulicretentiontimeofthematerialinthebiogassystem.Generally,25kilogramsoffeedstock
complimentedwith25litersofwaterperdaywithahydraulicretentiontimeof50dayswillrequire
about2.5cubicmetersemisphericaldigester.

25