BIOGAS DIGESTERS IN INDIA: A REVIEW

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1 National Conference on Renewable and New Energy Systems (RNES-2011) December, 2011, SIET, Odisha BIOGAS DIGESTERS IN INDIA: A REVIEW Jyotiprakash Bhol, B.B.Sahoo and C. K. Mishra Department of Mechanical Engineering, Synergy Institute of Engineering & Technology, Dhenkanal, Odisha ABSTRACT In the present days, the environmental issues such as the greenhouse effect and correct waste disposal methods are gaining much attention throughout the community. In this context, the concept of controlled anaerobic digestion is perhaps a much overlooked example of a way to reduce greenhouse gas emissions and provide a better waste disposal method for organic waste. Biogas technology can not only provide fuel, but is also important for the comprehensive of biomass resources and enhancing the development of agriculture, forestry, animal husbandry, fishery, evoluting the agriculture economy, protecting the ecologic environment, realizing agricultural recycling, as well as improving the sanitary conditions, in rural areas. Rural India has a vast potential of biogas generation and application. During the past decades, biogas has been promoted mostly as a cooking fuel in the rural areas. Being a renewable source, biogas, when utilized properly, can replace the commercial and nonrenewable energy sources to a considerable extent in a variety of production activities. The aim of this paper is to discuss the various designs of a biogas plant to produce energy with special application to the India. The paper describes the general design considerations of biogas plants. Keywords: Biogas, Digester, RenewableEnergy 1. INTRODUCTION Energy in form of electricity has been an important element in achieving national development goals. Availability of electricity in terms of sufficient quantity and quality at affordable prices will stimulate economic growth. In relation with the depletion of energy fossil and environment degradation, developing new power plant based on renewable energy and technology improvement to increase efficiency use of energy are the best way to fulfill the electrification requirement. As the effect of rising oil price, provision of basic energy need for rural household especially for cooking and lighting become a critical energy issue. Biogas energy is one of some renewable energy sources, it could be found from sewage, liquid manure of hens, cattle, pigs, organic waste from market, food industry, and so on. Biogas production enables a sustainable agriculture with renewable and environmental friendly process system. Generally, biogas contains methane gas (CH 4 ) about 55 up to 80%. Biogas production systems have several benefits, such as (a) eliminating greenhouse gas, (b) reduction of odor, (c) betterment of fertilizer, (production of heat and power [1, 2, 3]. Biogas technology is one option which can meet the growing energy demand of rural areas in developing countries. The main factor in favour of this technology is its environment friendliness since it enables efficient waste utilization and nutrient recycling. Biogas technology can be put to use at both domestic and community level. Biogas is a versatile source of energy, which can be used to meet several end uses, including cooking, lighting and motive power generation. Biogas is produced by anaerobic digestion of biodegradable matter such as animal manure, agricultural residues, kitchen refuse etc. At present, designs of biogas plants utilizing bovine (cattle and buffalo) manure have been somewhat standardized, and are being widely disseminated in India. Among the designs being diffused, only three designs, namely KVIC (promoted by the Khadi and Village Industries Commission of India), Janata and Deenbandhu, have countrywide popularity. While the design promoted by KVIC is a floating gas-holder type of plant, both the Janata and Deenbandhu designs are of the fixed-dome type. In fact, Janata biogas plants are steadily losing their market share to the Deenbandhu plant, which is a comparatively new design and at present the most popular [4]. Biogas is produced by the breakdown of organic waste by bacteria without oxygen (anaerobic digestion). Like the gas in liquid petroleum gas canisters, methane can be burnt for cooking or lighting the house. It can also be used to power combustion engines to drive a motor or generate electricity. Controlled anaerobic digestion is by no means a radical or new concept. Large scale industrial digesters and small

2 domestic digesters are in operation in many places around the world. The purpose of all these digesters is to produce combustible biogas which can be burned to provide energy for a whole range of uses. Biogas digester offers an all-in-one means to meet multienvironmental and economic requirements such as greenhouse gas reduction, renewable energy generation, organic wastes stabilization, odor elimination, pathogen removal and organic fertilizer production. In terms of application goal and scale, biogas digester can be categorized into two types, i.e. smallscale and medium/large-scale biogas digesters. The smallscale digester always has a limited working volume lower than 50 m 3 and serves primarily for household heating and cooking energy generation; in comparison, medium/large-scale biogas digesters are designed for industrial and municipal organic wastes treatment with COD/BOD reduction as a primary purpose and biogas production as a tipping fee. In contrast to the intensive research and development of medium/large scale biogas digester for decades, the importance of small scale one has been largely ignored. While, along with the fossil energy stringency in recent years, the benefit of applying small-scale digester to meet household energy requirement in the course of household wastes stabilization and organic fertilizer production has stepped into the vision of modern farmer families. The purpose of this report is to provide the method for the fabrication of the biogas digesters produced in India. This report will aim to identify key aspects of the design, concentrating on their function and the theory behind their function. Therefore, the aim of this report is to provide the reader with a basic explanation of the mechanics of anaerobic digesters of India. 2. THE BENEFITS OF BIOGAS Biogas systems make clean energy for household use. After an initial investment in the system, there is no need to spend money on fuel and no more smoke from wood or charcoal Cooking on biogas is quicker and easier than cooking with firewood Biogas systems kill the bacteria in livestock manure. A farm with a biogas system is a cleaner and safer place. Biogas systems produce excellent safe fertilizers for use on the farm. Biogas systems can help in the fight against global warming by allowing us to burn methane from organic waste, instead of letting it escape into the atmosphere where it adds to the greenhouse effect. It also helps by letting us leave more trees standing! 3. A BIOGAS DIGESTER Biogas is made by fermenting organic waste in a biogas digester. The size of a digester can vary from a small household system to a large commercial plant of several thousand cubic meters. Farmers use cow dung to feed their biogas digesters. Two simple biogas digester designs have been developed; the Chinese fixed dome digester and the Indian floating cover biogas digester (shown in Figures 1& 2). The digestion process is the same in both digesters but the gas 2 collection method is different in each. In the floating cover type, the water sealed cover of the digester rises as gas is produced and acts as a storage chamber, whereas the fixed dome type has a lower gas storage capacity and requires good sealing if gas leakage is to be prevented. Both have been designed for use with animal waste or dung. The waste is fed into the digester via the inlet pipe and undergoes digestion in the digestion chamber. The temperature of the process is quite important because methane-producing bacteria do their work best at temperatures between 30 40oC or 50 60oC. It takes from 2 to 8 weeks to digest a load of waste, depending on the temperature. The left-over slurry is removed at the outlet for use as a fertilizer. If you are looking into building a biogas system you will need to decide on the size of the digester. This will depend on how much biogas you need to meet your daily cooking (and lighting) requirements, the availability and amount of livestock manure and water (water, number of cows, goats or other livestock), and the materials available on site (bricks, etc) for construction of the digester. A regular supply of water is essential for operation of biogas plants. Rainwater harvesting could help with this The tubular plastic biogas digester promoted by SURUDE, Tanzania Takes 4 hours to build Runs on the excreta from either 1-2 cows, 5-8 pigs or 4 able-bodied people Needs 2 parts water for 1 part manure A 4m 3 digester produces 1m 3 of gas per day, enough for daily cooking and heating Biogas is not poisonous. The only danger is from explosion if it is mixed with air and lit by fire. However, it only explodes if mixed with air or oxygen with a lighted match or fire very close by. For example, you shouldn t ever lean into the tank with a lighted match! If you have a biogas leak in the house, and have good ventilation (windows, fresh air blowing through the house), it should not pose much danger of explosion. 4. DESIGNS OF BIO-GAS PLANT IN INDIA The purpose of this project was to design and build an anaerobic digester to meet the following criteria. The design should attempt to maximize the amount of biogas produced per unit time,

3 Be a continuous flow anaerobic digester. This has been specified because it seems that this will be the most practical design for continuous operation in a farm situation. Be simple and easy to understand so that the average person is able to grasp the function and theory behind each component of the design with only a small amount of guidance. The idea here is to encourage people looking at the design to think and understand the requirements for controlled anaerobic digestion and the continuous flow model. Be a durable, compact, versatile design which is capable of being shifted around if necessary to be displayed. Be operated with a minimum of monitoring, regulating, and adjusting (in other words, be easy to operate). Attempt to reduce time and money costs associated with maintenance Attempt to minimize the cost of setting up and running the digester without compromising the performance of operation or the other specifications of the brief Look aesthetically pleasing as another mechanism to effectively sell the concept! The fixed dome bio-gas plant buried underground. There are 3 main connecting parts: Mixing chamber: where animal excrement is mixed with water before it is poured into digester chamber Digester chamber: where excrement and water are fermented. Methane and other gases will be produced in the chamber and these gases will push manure and slurry at bottom of the floor into expansion chamber. Expansion chamber: collects excess manure and slurry. When gas is being used, manure and slurry will flow back into digester chamber to push gas up for usage. When the excess manure exceeds the volume of the chamber, the manure will be drained out. This system is called dynamic system, when gas is produced inside the pit, the gas pressure will push manure and slurry at the bottom of the pit to flow up into expansion chamber. When this gas is used the slurry in the expansion chamber will flow back into the digester chamber to push the gas up for usage. This happens consistently. Design of Biogas Digester According to the gas storage the digester is classified into three groups. Fixed -dome digester Floating type digester Bag type digester 3 Figure: Fixed-dome digester The costs of a fixed-dome biogas plant are relatively low. It is simple as no moving parts exist. There are also no rusting steel parts and hence a long life of the plant (20 years or more) can be expected. The plant is constructed underground, protecting it from physical damage and saving space. While the underground digester is protected from low temperatures at night and during cold seasons, sunshine and warm seasons take longer to heat up the digester. No day/night fluctuations of temperature in the digester positively influence the bacteriological processes. The construction of fixed dome plants is labor-intensive, thus creating local employment. Fixed-dome plants are not easy to build. They should only be built where construction can be supervised by experienced biogas technicians. Otherwise plants may not be gas-tight (porosity and cracks). A fixeddome plant comprises of a closed, dome-shaped digester with an immovable, rigid gas-holder and a displacement pit, also named 'compensation tank'. The gas is stored in the upper part of the digester. When gas production commences, the slurry is displaced into the compensating tank. Gas pressure increases with the volume of gas stored, i.e. with the height difference between the two slurry levels. If there is little gas in the gasholder, the gas pressure is low. Fixed-dome digester can be further classified into following types: Chinese fixed-dome plant is the archetype of all fixed dome plants. Several million have been constructed in China. The digester consists of a cylinder with round bottom and top. As the name implies, this type of digester has a gascollecting dome that is fixed. The digester is normally constructed using bricks and mortar and ends with a solid fixed dome in the shape of an igloo. Although this is the most well known digester design and the most widely used, it has a number of inherent disadvantages.the main disadvantage is the fact that it can only ever produce gas of variable pressure. As the biogas is generated it rises and accumulates in the brick dome from where it is piped to point of use. The volume and rate of gas production is dependent on the type and frequency of material fed into the digester as well as on the temperature. This means that the amount and pressure of gas available will continuously vary, making it less efficient to run any type of biogas equipment such as gas water heaters, lights and generators.the second disadvantage is related to the actual construction of the digester which requires a very high level of skilled labour.

4 Constructing a dome using bricks and mortar is a task suitable only to a very experienced brick layer and is also time consuming. A critical aspect of a digester is that it has to be constructed and sealed in such a way that it is airtight - any crack in the structure will allow the biogas to escape. History has shown that this aspect has been the biggest cause of failure of fixed dome digesters due to the development of cracks as the cement cures and/or as a result of differential settlement of the structure. More than 50% of this type of digester has a functional life span of more than 3 years. (labelled on diagram as Mixing Tank ), through which manure is fed into the plant. The manure then ferments separating the slurry from the methane gas which rises and collects at the top of the digester tank, and is released through the gas outlet pipe. The slurry passes into the outlet tank where it is ejected from the plant and can be used as fertilizer on the field. Figure: Deenbandhu Model Janata model was the first fixed-dome design in India, as a response to the Chinese fixed dome plant. It is not constructed anymore. The mode of construction leads to cracks in the gasholder - very few of these plants had been gas-tight. Camartec model has a simplified structure of a hemispherical dome shell based on a rigid foundation ring only and a calculated joint of fraction, the socalled weak / strong ring. It was developed in the late 80s in Tanzania Deenbandhu, the successor of the Janata plant in India, with improved design, was more crack-proof and consumed less building material than the Janata plant. with a hemisphere digester. A domestic bio-gas unit is a digesting chamber where manure, from both cows and humans, ferments to provide biogas, through the release of methane. Biogas is seen as a clean fuel, and provides a feasible alternative to cooking gas. In colder climates like the lower regions of the Himalaya the Deenbandhu fixed model is ideal because the digestion chamber is underground providing good insulation against the cold. We have found that the critical factors for success with Bio-gas are ensuring quality during construction, and training user groups in the correct use and maintenance of their plants. Ignoring these critical issues often leads to the failure of biogas plants perpetuating the myth that bio-gas technology is inappropriate in the Himalaya and elsewhere in the country.we use a design optimised for a longer 55 day cycle so that the mixture gets more time for digestion. Care is also taken to choose sites that get 2-3 hours of sunlight in winter. We have found that while the production of gas does reduce by about 25% during three months in winter, the plants function very well and one cubic metre plant provides 2-3 hours of clean cooking fuel every day. For rural communities this not only provides efficient low-cost fuel but reduces the strains of overgrazing of animals on the land. The main feature of a Deenbandhu biogas plant is the fixed underground digester chamber, constructed with a layer of bricks and an additional layer of cement mortar forming the roof above. Connected to the underground chamber is an inlet tank 4 Figure: Floating type digester Figure: Floating type digester In the past, floating-drum plants were mainly built in India. A floating-drum plant consists of a cylindrical or dome-shaped digester and a moving, floating gas-holder, or drum. The gasholder floats either directly in the fermenting slurry or in a separate water jacket. The drum in which the biogas collects has an internal and/or external guide frame that provides stability and keeps the drum upright. If biogas is produced, the

5 drum moves up, if gas is consumed, the gas-holder sinks back. Floating-drum plants are easy to understand and operate. They provide gas at a constant pressure, and the stored gas-volume is immediately recognizable by the position of the drum. Gastightness is no problem, provided the gasholder is de-rusted and painted regularly. The steel drum is relatively expensive and maintenance-intensive. Removing rust and painting has to be carried out regularly. The life-time of the drum is short (up to 15 years; in tropical coastal regions about five years). If fibrous substrates are used, the gas-holder shows a tendency to get "stuck" in the resultant floating scum. The arrangement of inlet and outlet and the components are suitably oriented for design flexibility and suitable condition of the area. According to the buried position of the dome the digester can be divided into the following ways. There are different types of floating-drum plants: KVIC model with a cylindrical digester, the oldest and most widespread floating drum biogas plant from India Pragati model with a hemisphere digester Ganesh model made of angular steel and plastic foil BORDA model: The BORDA-plant combines the static advantages of hemispherical digester with the process-stability of the floating-drum and the longer life span of a water jacket plant. Figure: Underground Digester Figure: Bag type digester Figure: Semi buried Digester According to the geometrical construction; The digester can be classified in following pattern according to the geometrical construction of the dome. Figure: Ground Digester 5. CONCLUSIONS Figure: Design according to the geometrical shape According the orientation of inlet and outlet 5 In this report, the design, theory and operation of different anaerobic digester types used in particular to India are explained. With farmers continually facing rising production costs and environmental issues such as the green house effect

6 and waste disposal methods, it is believed that controlled anaerobic digestion certainly has the potential to provide some solutions to these issues. Thus we have seen that biogas is a promising tool for employment generation, energy self sufficiency and reduction of greenhouse gases. Also it helps in reducing deforestation thus saving lots of species from extinction If applied on large scale it can prove to be a boon for a developing county like India. We have seen that India has immense potential in biogas generation that is still untapped. It has overall health benefits as well as those who initially used to cook food with woods have to live in smoke caused by burning of wood during cooking now biogas gives them a best alternative. REFERENCES 1. King, G Livestock in the future. Animal science, University of Guelph Powers, W. and Van Horn, H.H dietary manipulation to alter manure composition and odor. In: animal production systems and the environment: An International conference on odor, water quality, nutrient management and socioeconomic issues. July 19-22, 1998, Des Moines, IOWA. 3. United nations updated guidebook on biogas development energy resources development series 1984, no. 27, united nations, New York, USA. 4. NCAER, Evaluation Survey of Household Biogas Plants Set up During Seventh Five Year Plan. Report submitted to Ministry of Nonconventional Energy Sources by National Council of Applied Economic Research (NCAER), New Delhi, India (1993). 6

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