TECHNOLOGY PACKAGE

FOR 1 MW CATTLE DUNG BASED POWER PLANT

TABLE OF CONTENTS
SECTION TITLE PAGE NO.

SUMMARY i

ACKNOWLEDGEMENT ii

TABLE OF CONTENTS iii

LIST OF FIGURES v

LIST OF TABLES vi
1 PLANT DESCRIPTION
1.1 Weighing of Cattle Dung (Weighing Machine) 1
1.2 Collection Tank (Collection Tank) 2
1.3 Homogenization of Raw Manure (Dissolution Tank) 2
1.4 Anaerobic Digestion (CSTR Type Digester) 2
1.5 Biofilter 3
1.6 Biogas Storage 4
1.7 Biogas Utilization 4
1.8 Biofertilizer Production 4
1.9 Effluent Treatment Plant (Activated Sludge Process) 5

2 MATERIAL BALANCE 7

3 ENERGY BALANCES 9

4 SPECIFICATIONS OF EQUIPMENTS 11
4.1 Specifications of Anaerobic Digester 11
4.2 Specifications of Double Pipe Heat Exchanger 13
4.3 Specifications of Biofilter 15
4.4 Specification of Effluent Treatment Plant 18

5 LAND AREA REQUIREMENT 19

6 INSTRUMENTATION & CONTROL PHILOSOPHY 21

6.1 Safety Design Criteria 21
6.2 Instrumentation 22
6.2.1 Selection 22
6.2.2 Instrument Power Supply 23
6.2.3 Instrument Signals 23
6.2.4 Control System 23
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6.3 Process Control and Plant Operation 24

6.3.1 Dissolution and Feed Preparation 24
6.3.2 Anaerobic Digester and Desulphurization Unit 25
6.3.3 Biogas Collection 26
6.3.4 Biogas Utilization 26

7 COST ESTIMATION 28

Annexure- 1 31
Annexure -2 37
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LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1.1 Process Plant Layout 6

2.1 Material Flow Diagram of 200 TPD Biogas Plant 9

3.1 Energy Flow Diagram of 200 TPD Biogas Plant 10

4.1 CSTR Type Anaerobic Digester 12

4.2 Double Pipe Heat Exchanger 14

4.3 Biofilter of H2S Removal 17

6.1 Process Instrumentation Diagram-1 34

6.2 Process Instrumentation Diagram-2 35

6.3 Process Instrumentation Diagram-3 36

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 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

2.1 Waste Characterizations for Material Balance 7

2.2 Material Balances Summary 7

3.1 Energy Balance Summary 9

3.2 Net Energy Balance for 200 TPD Plant 10

4.1 Specifications of Anaerobic Digester 11

4.2 Specifications of Double Pipe Heat Exchanger 13

4.3 Specifications of Biofilter 15

4.4 Specifications of Effluent Treatment Plant 18

5.1 Land Area Requirements for 200 TPD Plant 19

7.1 Price Break Up of Civil Works 28

7.2 Price Break Up of Mechanical Equipment 29

7.3 Summary of Electro Mech. Works 30

7.4 Summary 30

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PLANT DESCRIPTION SECTlON-1
Energy-deficient age in which we live today, demands that new and renewable sources
should be fully exploited. Biotechnologically produced energy has been identified as an
attractive alternative to increasingly scarce fossil-fuel supplies. Anaerobic fermentation of
organic wastes leading to biogas generation is one such process, which has considerable
potential to supplement energy supplies. Anaerobic digestion is the treatment of animal waste
slurry, food waste and other biomass in oxygen less environment to produce valuable by-
products, usable energy in the form of methane gas, organic fertilizer and protein. A biogas
plant is a decentralized energy system, which can lead to self-sufficiency in heat and power
needs, and at the same time reduces environmental pollution.

The plant includes the following unit operations:

(i) Weighing of Cattle Dung (Weighing Machine)

(ii) Collection of Cattle Dung (Collection Tank)
(iii) Homogenization of Raw Manure (Dissolution Tank)
(iv) Anaerobic Digestion (CSTR Type Digester)
(v) Biofiltration of Biogas (Biofilter)
(vi) Biogas Storage
(yii) Biogas Utilization (Gas Engine)
(viii) Biofertilizer Production
(ix) Press Water Treatment (Effluent Treatment Plant)

These unit operations are discussed in following subsections.

1.1 Weighing of Cattle Dung (Weighing Machine)

Cattle Dung collected from small dairy societies and dairy farms are brought in small
trolleys. Loaded trolleys are weighted by electronic weighing machine. After weighing, it is
unloaded in collection tank and the empty trolley is reweighed. The net weight of dung
collected is noted in the machine.

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1.2 Collection Tank (Collection Tank)

Collection lank is used for storing cattle dung. It is a rectangular tank of dimension
12m*12m*5.lm and working volume of collection tank is about 600m3. It can store 3 days
supply of cattle dung.

1.3 Homogenization of Raw Manure (Dissolution Tank)

The fresh cow manure is blended in two collection tank of dimensions 10m*l0m*4.lm. Both
dissolution tanks are equipped with homogenizer/mixer for completely mixing of the manure
and water. The homogenization of the waste provides a waste of uniform characteristics, and
a waste feed with a solid concentration not exceeding 10%. The slurry of this concentration is
fed into the CSTR digester.

The solid concentration in the raw waste is in the range of 14-16 %. Therefore, the waste is
diluted with water to reduce the solid concentration to about 10%. In the present report since
all the waste is to be collected and delivered to the plant in about 8 hours, while the feed to
the digester is feed over in 24 hours period. Two tanks (each of capacity 400m3) have been
provided to ensure that at any given time, one tank is available to feed the digester, while the
other tank is available to receive the waste. The combined capacity of the tanks is sufficient
to hold four days waste after dilution.

The homogenized waste is passed through a macerator to reduce the particle size to 5-10 mm
(a range of particle size effective for biodegradation). Screw pumps have been provided to
transfer the feed to the CSTR digester. A heating system (Double Pipe Heat Exchanger) is
provided to raise the temperature of the feed (during winter months only) which favors the
growth of microorganisms responsible for the decomposition of the waste. The flue gas from
the gas engine provides necessary heat energy for the heat exchanger.

1.4 Anaerobic Digestion (CSTR Type Digester)

The homogenized waste is pumped into two CSTR type digesters each of 5000 m3 working
volume where stabilization of organic waste takes place anaerobically with the production of
biogas. The CSTR digesters are cylindrical in shape; its dimensions are 18 m x 25 m.

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The main advantages of CSTR digesters are its perfect mixing system, ability to control
scum/sediments and handle high solid concentration.

Mixing in CSTR type digester can be achieved by two arrangements, first by agitator and
second by Jet Mixer. Agitator arrangement contains shafts on which impellers are mounted.
In large diameter digester, it is not easy to provide the agitator arrangement because a large
diameter shaft and impellers are needed and also the installation cost becomes high. Jet
Mixers are used to overcome this problem.

In Jet Mixing, a fast moving stream of liquid [Motive Liquid] is injected into a slow moving
or stationary liquid [Secondary Liquid]. The velocity gradient between the jet and secondary
liquid creates a mixing layer of jet boundary. This mixing layer grows in the direction of jet,
entraining / mixing bulk liquid into the jet.

Jet mixer / Mixing Eductor comprise of two critical components namely Motive Nozzle &
Diffuser. A predetermined amount of liquid [Motive / Operating fluid] is pumped through a
header in one or more jet mixers submerged inside the tank. Depending upon the application,
the operating fluid can be liquid drawn from the same tank or it can be second liquid drawn
from a different source that is to be mixed with the tank contents under consideration. The
Static Pressure at the entrance of nozzle is converted into Kinetic energy by allowing the
fluid to flow freely through a convergent type nozzle. As the operating fluid exits the nozzle,
it entrains [Entrainment Ratio=l:3] fluid from the tank through the suction chamber. The
operating fluid along with entrained fluid then undergoes thorough mixing in the partially
section of the diffuser. The divergent portion of the diffuser section then partially converts
the velocity head back to the static pressure at the discharge of the Eductor. The discharge
flow / Plume continue the mixing /agitating of the liquid and impart uniform mixing
throughout the tank. Jet diffusers may be obtained from M/s Mixrite Mixing Systems, 22
New Apollo Estate, Mogra Lane, Andheri (East), Mumbai 400 069,
E-mail: mixrite@gmail.com.

1.5 Biofilter

Biogas produced in digesters contains 400-1200 ppm H2S; 5 ppm exposure of H2S to human
being cause sever health problems and even death. H2S concentration above 200 ppm
damages the biogas engine. So, removal of H2S is necessary and it is done in a biofilter where
Thiobacillus group bacteria convert H2S into elemental sulphur. These bacteria arc
immobilized on packings of biofilter. The H2S concentration in treated biogas from biofilter
is around 100 ppm.

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1.6 Biogas Storage

Treated biogas from biofilter is automatically stored in gas holder. The produced biogas has a
composition of 55-60% methane and 35-40% carbon dioxide. A gas holder of 600 m3
capacity and dimensions has been provided which is sufficient to hold about three hours of
gas storage. In place of a conventional gas holder which is prone to corrosion, a dry type gas
holder will be used. This gas holder is made of a synthetic membrane (polyester) and is
suspended in a concrete silo or it may be of other type, which may be kept in open. The gas
holder is installed to buffer the differences between gas production and gas consumption. The
gas coming from the digester flows through a combination of gravel filter/security device and
enters the gas bag through the bottom flange. From the gas bag, the biogas is sucked off by a
blower and transferred to the engine / flare.

1.7 Biogas Utilization

The digester gas (biogas) has a heating value of 22400 kJ/ m3. The produced biogas is
converted to thermal and electrical energy in a cogeneration power station. The entire station
consists of two biogas engine of 0.5 MW capacities or one biogas engine of 1 MW capacity.
The station is designed for 8000 hours operation each year. The electrical energy conversion
efficiency of the engine is 37%.

A portion of the electrical energy (~15% of the generated energy) would be required to meet
the in house power requirement and the balance would be fed to the grid. In order to meet the
in house power requirement during start-up (until the plant generates power) / breakdown of
the gas engines, a Low Tension supply should be availed for the purpose.
The electrical energy would be generated at 415 volts and would be stepped up to 11 KV
before supplying to the sub-station.

1.8 Biofertilizer Production

The digested substrate leaving the digester is stored in an effluent buffer tank of suitable
capacity (300 m3 working volume), from where it is taken up for dewatering in a screw press.
Three screw presses have been installed for the dewatering of the digested sludge.

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The digested substrate shows a much better availability of nutrients for the plants due to its
biochemical composition. It is almost free of odour and can be precisely applied due to its
homogeneity.

In order to improve the market value of the organic fertilizer, it would be necessary to
increase the solids concentration to around 70%. Sufficient area has been provided to dry the
dewatered residue for increasing the solids concentration upto 70% by solar drying.

1.9 Effluent Treatment Plant (Activated Sludge Process)

The BOD/COD concentration of the press water is quite high to be disposed off directly. So it
is required to treat the high concentration press water in the effluent treatment plant to meet
the regulatory discharge limits. The effluent treatment plant consists an aeration tank
followed by a secondary clarifier. The press water from the dewatering station is initially sent
to the press water collection tank for primary sedimentation and then to the aeration tank. The
effluent from the secondary clarifier, which is having concentration in the limit, is discharged
into sewage, and the settled solid are sent to the drying yard. Some of the activated biomass
(settled solid) is recycled to the aeration tank to maintain the food to micro-organism ratio.

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MATE RIAL BALANCE SECTION-2
This section covers the summary of the Material Balance Calculations. Table 2.1 shows the
characteristics of the waste, used in calculations.

Table 2.1: Waste Characterizations for Material Balance

S. No. Parameter Composition

1. Total solids 14-16%
2. Volatile solids* 80%
3. Sulphates (as SO4) * 0.80 %
4. Lignin* 35.45%.
Note: (*) Analysis on dry basis

Table 2.2 provides the material balances with reference to fig. 2:

Table 2.2: Material Balance Summary

Basis: 200 TPD

1 Homogenization Tank
Fraction of Dry Solid in Feed (X1) = 0.16
Fraction of Dry Solid in Diluted Feed (X2) = 0.1
Amount of Cow Dung (W1) = 200 TPD
Amount of Diluted Feed (W2) = 320 TPD
Amount of Water Added (W3) = 120 TPD
Dry Solid in Feed (Wds) = 32 TPD
Total Volatile Solid in Feed (Wvs) = 25.6 TPD

2 Anaerobic Digester (CSTR Type)

Volatile Solid Loading Rate (VSDR) = 2.56 kg/m3/day

Biogas Production Rate (Vg) = 10000 m3/day
Total Solid After Digestion (Wsad) = 19.32 TPD
Total Amount of Digested Slurry (W4) = 308 TPD
Solid Fraction in Digested Slurry (X4) = 0.063

3 Screw Filter Press

Solid Fraction in Dewatered Slurry (X5) = 0.35

Solid Fraction in Press Water (X6) = 0
Amount of Dewatered Slurry (W5) = 56 TPD
Amount of Press Water (W6) = 252 TPD

4 Drying Yard

Solid Fraction in Dewatered Slurry (X5) = 0.35

Solid Fraction in Biofertilizer (X7) = 0.7
Amount of Dewatered Slurry (W5) = 56 TPD

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Table 2.2 Continued

Amount of Biofertilizer (W7) = 28 TPD

Water Evaporated (Weva) = 28 TPD

5 Effluent Treatment Plant

Concentration of Biomass in Aeration Tank (X) = 3000 gm/m3

Concentration of Biomass in Recycle Stream (Xr) = 8000 gm/m3
Total Flow Rate to Aeration Tank (W8) = 403 TPD
Amount of Recycle Stream (Wr) = 151 TPD
Amount of Wast Water (Ww) = 22.6 TPD
Amount of Treated Water (W9) = 238 TPD

Figure 2.2: Material Flow Diagram of 200 TPD Biogas Plant

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 ENERGY BALANCES SECTION - 3
This section covers the total energy flow information of the Waste to Energy Conversion
Plant. Energy requirement by the various auxiliary equipments has been calculated on the
basis of material flow information as described in previous section. Net energy balance by the
plant depends on the total power generated by gas engine, and power consumed by various
auxiliary devices like pump, blower, agitator, heat exchanger etc.; auxiliary power
requirement data has been taken from the existing operating plant.
;
Table 3.1: Energy Balance Summary

Auxiliary Power Requirement

SI.No. Equipment Capacity Units in Capacity Working Total Power

(kW) Operation (ton/hr) hrs/day Consumption
(kWh)
1 Raw Manure 25 1 40ton/hr 5 125
Pump
2 Agitator 15 2 12 360
3 Macerator 13 1 40 ton/hr 10 130
4 Feed Pump 6.5 1 40 ton/hr 10 65
5 Aerator 25 2 N/A 8 400
6 Secondary 2 1 N/A 8 16
Clarifier
7 Press Water Tank 3 1 40 ton/hr 8 24
Pump
8 Effluent Buffer 13 1 40 ton/hr 10 130
Tank Pump
9 Screw Press 6.5 3 20 ton/hr 8 156
10 H2S Blower 6.5 2 8 m3/hr 24 312
11 Substrate Pump 25 1 170 m3/hr 5 125
12 Raw Water Pump 6.5 2 40 ton/hr 5 65

13 Engine Blower 7.5 2 800 m3/hr 16 240

14 Flare Blower 7.5 1 500 m3/hr 13 98
15 36 2 N/A 9 640
Digester Agitator
16 Miscellaneous N/A N/A N/A N/A 550
Load
17 Fire Fighting 50 Used in Case of Emergency
Pump
Total Power Consumption 3436

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Table 3.2: Net Energy Balance for 200 TPD Plant

SI. No. Description Value Unit

1 Biogas Generation

i. Gas Yield 11000 m3/day

ii. Calorific Value 6.0-6.6 kWh/m3

2 Power Station

i. Electric Efficiency 37%

3 Energy Generation from Power Plant

i. Unit Energy Generated in Plant 1020-1120 kWh

ii. Energy Generated in the Plant 24480-26880 kWh/day
iii. Auxiliary Power Requirement 3436 kWh/day

4 Net Energy for Export to Grid

i. Daily Power Exported 21044-23444 kWh/day

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SPECIFICATIONS OF EQUIPMENTS SECTION-4
This section provides the specifications sheet of the various equipments.

Table 4.1: Specifications of Anaerobic Digester

1 Operating Parameters

Number of Digester (N) = 2

Working Volume of Each Digester (Vd) = 5000 m3
Substrate Flow Rate (W2) = 320 m3/day
0
Operating Temperature (T) = 25-30 C
Hydraulic Retention Time (HRT) = 31.25 days

2 Digester Tank Specification

Diameter of Digester Tank (Dt) = 18 m

Height of Liquid in Digester (HL) = 20 m
Height of Digester (Hd) = 25 m

3 Impeller Specification

Type of Impeller = 3 Blade Hydrofoil

Number of Impeller Set (Ni) = 3
Blade Angle at Hub (1) = 45
Blade Angle at Tip ( 2) = 22
Impeller Speed (Ni) = 6 rpm
Impeller Diameter (Di) = 5.4 m
Distance Between Impeller Set (Hi) = 8 m
Height Between Digester Bottom to
Impeller Bottom (Hdi) = 2 m

4 Shaft Specification

Material of Construction (MOC) = Stainless Steal

Diameter of Shaft (Ds) = 6.5 inch
Total Number of Turn Over in a Day (Nt) = 18
Working Hours in Day (Wh) = 9 Hrs
Total Power Requirement (P) = 640 kW/day

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A - 12
Table 4.2: Specifications of Double Pipe Heat Exchanger

1 Substrate Slurry (Cold)

Flow Rate (m) = 20 kg/s

Temperature at Inlet (t1) = 30 C
Temperature at Outlet (t2) = 36 C

2 Hot Fluid (Water)

Flow Rate (M) = 4.94 kg/s

Temperature at Inlet (Tl) = 75 C
Temperature at Outlet (T2) = 50 C

3 Inner Tube Specifications

Fluid = Substrate Slurry

Standard Size = 0.200 m
Inner Diameter of Tube (di) = 0.2027 m
Outer Diameter of Tube (do) = 0.219 m
Length of Tube (L) = 6 m

4 Outer Tube Specifications

Fluid = Hot Water

Standard Size = 0.260 m
Inner Diameter of Tube (Di) = 0.2545 m
Outer Diameter of Tube (Do) = 0.2731 m

5 LMTD and Heat Duty

Flow Mode = Countercurrent

LMTD = 28.46 C
Heat Duty = 516000 J/s

6 Heat Transfer Coefficients

Inner Tube H.T.C (hio) = 1626.97 W/m2K

Outer Tube H.T.C (ho) = 1521.06 W/m2K
Dirt Factor for Hot Water Fluid (Ud2) = 0.000176 (W/m2K)-l
Dirt Factor for Diluted Feed (Ud1) = 0.00053 (W/m2K)-l
Clean Overall H.T.C (Uc) = 786.12 W/m2K
Designed Overall H.T.C (Ud) = 505.54 W/m2K

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Table 4.2 Contd.

7 Heat Transfer Area, Tube & Hair Pins

Actual Heat Transfer Area (Ap) = 49.54 m2

Number of Tube Lengths (L) = 12
Number of Hair Pins = 6

8 Pressure Drop

Pressure Drop at Inner Tube Side -

Cold (Pi) = 1481 Pa
Pres. Drop at Annulus Side - Hot
(Po) = 5207 Pa

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Table 4.3: Specifications of Biofilter

1 Operating Conditions

Operating Temperature (T) = 25 C

Operating Pressure (Patm) = 1 atm
Volumetric Flow Rate of Biogas (Vg) = 10000 m3/day
Volumetric Flow Rate of Air (Va) = 8 m3/day
Inlet Concentration of HI2S in Gas (Cgo) = 1200 ppm
Outlet Concentration of H2S in Gas (Cge) = 100 ppm

2 Filter Bed Specifications

Area of Filter Bed (Af) = 5.56 m2

Working Volume of Filter Bed (Vf) = 5.56 m3
Empty Bed Residence Time (EBRT) = 48 sec.
Actual Residence Time (RT) = 44.2 sec.

3 Packing Specifications

Type of Packing = Pall Ring

Material of Packing = Polypropylene
Size of Packing (Dp) = 7.62 cm
Void fraction of Packing () = 0.92
Specific Surface Area of Packing (a) = 73.2 m2/m3
Heap Weight of Packing (Whp) = 60 kg/m3

4 Packed Column Specification

Diameter of Column (Dc) = 1.52 m

Total Length of Column (Ltc) = 5.2 m
Length of Packing (Lp) = 3.05 m
Gas Superficial Velocity (Ug) = 0.0635 m/sec
Total Pressure Drop (Pt) = 730 Pa

5 Column Internals Specification

Diameter of Gas Distribution Pipe (Dpg) = 7.62 cm

Velocity of Gas in Gas Distribution Pipe (Vpg) = 25.4 m/sec
Diameter of Liquid Feed Pipe (Dpl) = 6.35 cm
Minimum Liquid Rate (Lmin) = 5 lt/sec
Packing Gas Injection Support Plate Types = TS - 854
Liquid Distributor Type = TP - 976
Bed Limiter Type = TP - 825
Liquid Feed Pipe Type = TP-719

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Table 4.3 Contd.

6 Structural Specifications

Material of Construction = Stainless Steel

Design Pressure (P) = 107.15 kPa
Thickness of Column Shell (ts) = 4 mm
Thickness of Nozzle (tn) = 3 mm
Maximum Vertical Distance for
Compensation (Hvd) = 152.4 cm
Maximum Horizontal Distance Compensation
(Hhd) = 21.5 cm
Area of Compensation Provided (Aacr) = 304.8 mm2
Area of Compensation Required (Acr) = 93.8 mm2
Distance Between Upper Packing Layer to
bottom surface of Liquid Feed pipe line (HA) = 79.4 cm
Distance Between Upper Packing Layer to
Bottom Surface of Liquid Distributor (HB) = 20.3 cm
Distance Between Centre of Gas Feed Pipe to
Bottom of Support Plate (HC) = 38.1 cm
Thickness of Holder of Column Internals (HD) = 0.661 m

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A - 17
Table 4.4: Specification of Effluent Treatment Plant

1 Operating Data

Intel BOD Concentration in Press Water (So) = 1250 mg/l

Outlet BOD Concentration in Press Water (S) = 10 mg/l
Volumetric Flow Rale of Press Water (Qpw) = 252.01 m3/day

2 Aeration Tank Specifications

Average BOD Load = 1.4 kg BOD/m3/day

Aerobic SRT = 6 days
Number of Aeration Tank = 1
Working Volume of Aeration Tank = 361 m3
Diameter of Aeration Tank (Dat) = 10.5 m
Height of Aeration Tank = 5 m
Hydraulic Retention Time = 34.4 hrs
Quantity of Biomass Produced (Px,bio) = 181 kg/day
Air Requirement (Ro) = 10020 m3/day
Type of Aerator = Bubble Ceramic Diffuser
Height of Aerator From Tank Bottom = 0.5 m

3 Sedimentation Tank Specifications

Recycle Ratio = 0.6

Area of Sedimentation Tank (Ast) = 12.6 m2
Number of Clarifiers = 1
Diameter of Sedimentation Tank (dst) = 4.01 m
Liquid Height in Sedimentation Tank = 3.5 m
Liquid Height in Sedimentation Tank = 4 m
Cone Height of Clarifier = 0.4 m
Liquid Height in Sedimentation Tank = 3.5 m
Cone Angle = 10
Solid Detention Time (td) = 4.2 hrs
Width of Launder (Wlo) = 0.5 m
Length of Effluent Weir Plate (L) = 9.5 m
Type of Notch = V - Notch
Angle of Notch () = 90
Total Number of V-Notches (N) = 24
Flow Per Notches (Q'ac) = 10.5 m3/day/notches
Head Over V-Notch (H) = 0.024 m
Average Designed Flow Rate From Clarifier(Qac) = 252 m3/day
Actual Weir Loading = 1.1 m3/m.day
Dimension of Effluent Box = 2x2 mxm
Difference Between Height of Water in
effluent Box to Height of Effluent Launder = 0.31 m
Flow in Each Launder (Ql) = 1.46 lt/day
Depth of Launder (Y1) = 0.31 m
Total Depth of Launder (D1) = 0.71 m

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 LAND AREA REQUIREMENT SECTION -5

Table 5.1 provides the list of equipments/units and the ground area requirements.

Table 5.1: Land Area Requirements for 200 TPD Plant

S.No Equipmcnt Number Dimension Total Usable Land Area

Volume Volume (m3) Requirement
(m3)
1. Collection Tank 1 12m x 12m x 5.1m 735 600 160
2. Homogenization 2 10m x 10m x 4.1m 820 640 220
Tank
3. Dry Well with pumps, 1 6m*5mx7.5m 225 200 33
macerator etc.
4. Digester 1 18 m x 25m 12750 10000 560

5. Biodesulphurizer 1 1.52m x 5.2m 9.44 5.5 2

Packed Column
6. Effluent Buffer 1 10.5 x 4.6m 400 310 96
Tank
7. Dewatering Station 1 14.2m x 6m x 10.2m 870 800 95
8. Double Pipe Heat 1 10m x 6.5m x 4.0m 260 - 71
Exchanger Shed
9. Gas Holder 1 10m x13m 1020 1000 90

10. Gas Flare 1 - 450 - 16

11. Hooper Bottom Settling 1 4m x 2m 25 - 14
Tank
12. Press Water 1 4m x 3.0m 37.7 30 14
Collection Tank
13. Aeration Tank 1 10.1m x 5m 1230 950 175
14. Secondary Clarifier 1 4.1m x 4.2 m 56 44 15
15. Manure Drying Yard 1 100m x 45m x 7m 31500 28500 5000
16. Fire Fighting Station 1 6mx 6m x 3m 108 - 40

17. Laboratory 1 8m x 6m x 4m 192 - 53

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 Table 5.1 Contd.

S.No Equipmcnt Number Dimension Total Usable Land Area

3 3
Volume (m ) Volume (m ) Requirement
18. Control Room 1 8m x 8m x 4m 256 - 71
19. Electricity Station 1 10m x 8m x 4m 320 - 88
20. Gas Engine (0.5 MW) 2 20m x 3 m x 3m 180 - 66
21. Weigh Bridge 1 5m x 2m x 1m 10 - 12
22. Administrative Office 1 8m x 6m x 4m 192 - 55
23. Security Office 1 6m x 6m x 3m 108 - 40

Total land area requirement = 6986 m2

Land area requirement for spacing between different units, lawns, parking and open space
etc. accounts for about 30 % of the total land area, i.e. 2100 m2 Gross land area requirement
for 200 TPD biogas plant = 9086 m2 9100 m2
2.25acre 2.5 acre.

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INSTRUMENTATION & CONTROL SECTION-6
PHILOSOPHY
The basic features of biomethanation of cattle dung plant to produce biogas and then power
generation are:

1) Handling of large quantities of slurry having silt and suspended solids.

2) Acidic and corrosive nature of slurries which necessitate selection of suitable material of
construction for instrument sensors/transducers
3) Large quantities of slurry holds up in some of the equipments with considerable time lag in
measurement of process parameters & corrective action based there on.
4) Control of temperature & pressure in digesters as well as biological desulphurization
unit within a narrow and critical range.
5) Handling of biogas with CH4 as inflammable gas and it being the major constituent.
6) Critical control of various parameters in biogas engine.
7) Economics of the plant cost as one of the major consideration but with out sacrificing the
safety aspects of the plant

6.1 Safety Design Criteria

The basic approach in selection of instruments & control philosophy is to ensure safety of the
plant, machinery and that of the plant personnel during operation and maintenance. Some of
the major considerations are:

1) All the field instruments shall have minimum Class-IP-55 protection.

2) All the motors in the plant from dung collector to slurry feed lines to the digester will be
with IP-55 protection. The motors from digester onwards in any process stream line will be
flame proof as they are likely to be exposed to biogas containing methane environment.
3) All motors shall be provided with over load protection and protection against single
phasing.
4) All the instruments will have field indicators. Remote indicator will be provided wherever
required.
5) All the control panels shall have IP-20 class protection.
6) Instruments to be used for control purpose shall be independent of the instruments used for
process parameter measurement as far as possible..
7) All field instruments will be provided with grounding.

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6.2 Instrumentation

6.2.1 Selection

The instruments are selected to meet specific features of the application point. Some of
the criteria are as follows.

1) Flow meter in slurry lines shall be of Ultrasonic / Electro magnetic type without having
any moving part where the calibration of the instrument may be affected because of solids
/silt / fibrous material suspension in the liquid, The flow meters in the large size biogas line
will be orifice type sensor with differential pressure transmitter calibrated for volumetric flow
rate. Normal flow rate shall be between 50-70% with 90% as the maximum.

2) Pressure gauges for low pressure measuring range will be diaphragm type for better
accuracy, while those for high pressure application will be bourdon type. The normal
operating range shall be 30-70% of full scale.

3) Temperature measuring sensors are of RTD type (PT-100) wherever remote indications are
required while bimetallic/vapor filled gauges will be used where only field indications are
needed.
4) Remotely operated valves will be selected, such as to come in fail safe condition in case of
power failure.

5) Electric contacts will open in emergency/abnormal conditions to bring the equipment in

fail-safe condition. The instruments and gauges will be suitable for rating to with stand up
130% of the maximum range without affecting the calibration.

6) The instrument range, in general, will be selected such that the normal operating range will
be between 40% and 70% of the full scale.

7) Pressure switches shall be adjustable type and used for alarm annunciation or trip functions
as needed.

8) Transparent tubular type level gauges shall be used for clear liquid while capacitance/ ultra
sonic, type with multiple probes along the length, shall be used for slurry application.

9) The sensor assembly for CH4 & H2S analyzer shall be field mounted while the electronics
shall be installed in a control panel with suitable power supply. The instrument shall have
display at local control panel with contacts available for signal transmission for PLC.

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10) The critical process parameters shall have display at local control panel as well as
contacts in the instruments for onward transmission to PLC for remote
indication/control purposes.

11) All remotely operated valves (MOV) will have limit switches to display on/off indication
on LCD and also for status on PLC. These valves will also have manual over ride facility.

6.2.2 Instrument Power Supply

For normal instrument and control applications, the power supply will be class-iv, 230 V,
single phase, 50HZ.
Supply for critical control system will be from UPS (Uninterrupted. Power Supply) system at
230 V, single phase, 50 HZ (Class-II)/24 V DC (Class-I). In case of normal power supply
failure, the UPS shall be able to supply power for 30 minutes.

6.2.3 Instrument Signals

The field instruments, wherever required either for remote indication or control function, will
be connected to PLC based controlled system. The signal from the instruments will be (i)
current - 4-20 mA (ii) voltage - 230V AC or 24 V DC (iii) RTD-Pt-100 ohm (iv)
pulse/frequency (v) digital signals will have potential free contact or powered.

6.2.4 Control System

The basic purpose of process control system in the plant is to operate various equipment in
the plant within the specified limits of process parameters. However, more importantly, the
safety of plant, plant personnel and environment has to be ensured, apart from to bring the
plant to safe condition in case of abnormal/emergency eventualities requiring minimum
human intervention.

The plant for biogas production by methanation of cattle dung and subsequent power
generation shall be operated based on PLC (Programmable Logic Controller) and SCADA
(Supervisory Control and Data Acquisition) system. Barring a few initial operations like
cattle feed tank, homogenization tank and feed tank, and later on the effluent treatment
section of the plant, all other operations requiring critical control, will be operated through
PLC/SCADA.

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The gas engine normally has its own control panel inclusive of PLC. However, this will have
interface with the plant main PLC. The main PLC will also have interface with MCCS
(Motor Control Centers), UPS etc.

SCADA will work on HMI (Human Machine Interface) and will be interconnected with PLC
through appropriate communication system. It will be operated through a PC in the control
room. The SCADA will basically monitor & control the process parameters, display alarms,
computation and interfacing with data acquisition, storage, retrieval etc. Apart from
indications and status of various equipment/ components like valves, selection of pumps,
Macerators, PLC programming will also be done through SCADA. Data acquisition storage
& retrieval shall also be done through SCADA.

The PLC system will carry out various control functions, status monitoring etc. All PLC
related components are housed in a panel mounted in the control room. PLC is connected to
SCADA through appropriate communication links.

6.3 Process Control and Plant Operation

Non-critical operations will be carried out from LCP only with/without status display on PLC
depending upon the requirement. However, all critical operations shall be carried out either
from PLC or in some cases LCP but must have display at PLC. Control logics for process
control shall be only through PLC and LCP operation can not intervene. The plant can be
operated in auto/manual mode. Auto/manual switches for operation of valves will be
provided on the control panel. Auto/manual feed back is taken to the PLC system for display
on the SCADA system.

6.3.1 Dissolution and Feed Preparation

The agitator motors mounted in cattle dung collector, homogenization and feed tank will be
operated from locally from LCP. Similarly the submersible pumps in the first two tanks will
be operated from LCP.

Any one of the two numbers of macerators and also any one of the two screw pumps can be
brought on line to feed slurry to the digester, thus providing enough redundancy for

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these venerable equipments. The operations are carried out from LCP/PLC. The MOVs in the
system can he operated either from i ,CP or from PLC,

Interlock

1) Neither m the macerator motor can be started until at least one of the two screw pumps is
in operation.
2) In case (he screw pump slops, the operating macerator motor will trip automatically.
3) Neither of Ore screw pumps can be started unless all the MOV upto at least one of the
digesters is open.
4) In case, any of the MOV in the digester line is closed, the operating macerator motor and
screw pump motor will trip.

6.3.2 Anaerobic Digester and Desulphurization Unit

Each of the digester is provided with (1) agitator (2) level switches high and low (3)
temperature indicator controller (TIC) (4) temperature indicator TI (5) Pressure transmitter
(PT). The temperature of the slurry in digester tank is controlled by slurry circulation
arrangement through heat exchangers HX-2 and HX-3 in an external loop. The hot water
supply from the biogas engine section, heated by flue gas discharge from the engine to HX-I
is used as the heat source. The heat supply to the slurry in HX-2 and HX-3 will be controlled
by auto on/off of the hot water circulation pumps, which can be operated either from
LCP/PLC also. Electro pneumatically operated valves, GV-25 and GV-26 installed in the hot
water supply lines to the slurry heat exchangers, HX-2 and HX-3 will also close
automatically, once the desired slurry temperature is reached. When the temperature in the
digester drops below the set point, the slurry circulation pump and one of the hot water
circulation pumps will start and the valve in the hot water supply line of the HX-2/3 will open
automatically. A control valve (normally open for fail safe condition) has been provided in
the engine flue exhaust line to the atmosphere to regulate the flue gas flow to the hot water
HX-1.
The operation of agitators in the digester is from LCP/PLC.
Temperature sensors with multi channel temperature indicator on LCP/PLC are
provided to map temperature at various locations in the digester.

The biogas from the digesters goes to biological desulphurization unit for removal of H2 S.
The pressure in the desulphurization unit and hence up stream in the digesters are

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required to be maintained as critical process parameters. A control valve, CV-1, has been
provided in the gas discharge line from thc digester and suction to the blower system operates
based on pressure signal from the PIC, mounted on desulphurization unit, to maintain
predetermined pressure.

Interlocks

I) The MOV in the slurry feed line to the digester will close in case LS(Level switch) is high
and will open automatically based on 'low' signal from LSHL
2) M-10/M-11 will start when temperature in TIC is low.
3) The valves, GV-25/GV-26 will open only when M-10/M-11 are in operation. A) M-10/M-
11 will stop in case temperature in TIC is high.
5) GV-25/26 will close automatically when M-10/M11 not in operation.
6) Valve in hot water supply line to HX-2/HX-3 will close when temperature in the digester
is high.
7) Valve in hot water supply line to HX-2/HX-3 will open when temperature in digester is
low.

6.3.3 Biogas Collection

The biogas from the desulphurization unit goes to the gas holder via a manually operated
valve. However, this line is also connected to flare stack through a flame arrestor and a
motorized valve (MOV). This valve is normally open and power supply to close to bring the
plant to a fail safe condition in case of power failure where operations in down stream can not
be carried out.

The biogas produced and piped to the gas holder is metered and logged through a totalizer
with display in both LCP and PLC.

The CH4 and H2S content in the gas are also monitored in the line through a gas analyzer.
The pressure and level of gas in the gas holder are continuously maintained.

6.3.4 Biogas Utilization

This section consists of 2 nos. of gas feed blower and gas engines to generate power. The gas
holder provides a surge collection tank when plant is not in operation, gas supply source
when gas is in short supply. One of the two blowers will be in operation with

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another stand by. The selection of blower and their START/STOP operations are controlled
from LCP/SCADA. The speed of the blower is controlled by Variable Frequency Drive
(VFD) to meet the varying capacity requirement and also to maintain pressure in the surge
tank. Pressure Relief valves have been provided at discharge of each blower which are
generally of positive displacement type. The VFD is controlled by pressure signal from
pressure transmitter at engine suction to provide gas to the engine at constant pressure. The
motor drive speed can also be adjusted manually from blower LCP.

The blower speed, blower in operation and trip indications will be available on the blower
panel. Blowers can be manually started/stopped from PLC/LCP. When pressure in pressure
switch in the blower feed line goes down below a set valve the blower shall trip.
Gas from the blower via a surge tank goes to engine. The flow rate will be recorded and also
totalized through at orifice-differential pressure transmitter flow meter in field as well as PLC
display.

The engine will have its own control system/PLC & control logic which is interfaced with
main PLC. The process instrumentation diagrams of biogas plant, depicted in figures 6.1, 6.2
& 6.3 arc given in Annexure 1.

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