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INTRODUCTION
With the advent of technology all nations in the world are struggling to come up
with money power. All of them are improving their manufacturing capabilities and
incorporating automation so as to reduce the lead time. But it is also truth that the
coming generations may not see the fossil fuels if they are consumed at the high rate.
Also the energy crisis forced us to think for new and new fuels. In this context
renewable energy generation has become hot topic in the world community. The bio
gas plants come under this discipline and lot of initiatives have been taken by
different countries to harness energy from animal wastes.
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I. Hydrolysis
II. Acidogenesis
III. Acetogenesis
IV. Methanogenesis.
1.2.1 Hydrolysis
In general, hydrolysis is a chemical reaction in which the breakdown of water
occurs to form H+ cations and OH- anions. Hydrolysis is often used to break down
larger polymers, often in the presence of an acidic catalyst. In anaerobic digestion,
hydrolysis is the essential first step, as Biomass is normally comprised of very large
organic polymers, which are otherwise unusable. Through hydrolysis, these large
polymers, namely proteins, fats and carbohydrates, are broken down into smaller
molecules such as amino acids, fatty acids, and simple sugars. While some of the
products of hydrolysis, including hydrogen and acetate, may be used by methanogens
later in the anaerobic digestion process, the majority of the molecules, which are still
relatively large, must be further broken down in the process of acidogenesis so that
they may be used to create methane.
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1.2.2 Acidogenesis
Acidogenesis is the next step of anaerobic digestion in which acidogenic
microorganisms further break down the Biomass products after hydrolysis. These
fermentative bacteria produce an acidic environment in the digestive tank while
creating ammonia, H2, CO2, H2S, shorter volatile fatty acids, carbonic acids, alcohols,
as well as trace amounts of other byproducts. While acidogenic bacteria further breaks
down the organic matter, it is still too large and unusable for the ultimate goal of
methane production, so the biomass must next undergo the process of acetogenesis.
1.2.3 Acetogenesis
In general, acetogenesis is the creation of acetate, a derivative of acetic acid, from
carbon and energy sources by acetogens. These microorganisms catabolize many of
the products created in acidogenesis into acetic acid, CO2 and H2. Acetogens break
down the Biomass to a point to which Methanogens can utilize much of the remaining
material to create Methane as a Biofuel.
1.2.4 Methanogenesis
Methanogenesis constitutes the final stage of anaerobic digestion in which
methanogens create methane from the final products of acetogenesis as well as from
some of the intermediate products from hydrolysis and acidogenesis. There are two
general pathways involving the use of acetic acid and carbon dioxide, the two main
products of the first three steps of anaerobic digestion, to create methane in
methanogenesis:
While CO2 can be converted into methane and water through the reaction, the main
mechanism to create methane in methanogenesis is the path involving acetic acid.
This path creates methane and CO2, the two main products of anaerobic digestion.
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Table 1.1: Typical composition of biogas
Compound Formula %
Nitrogen N2 0-10
Hydrogen H2 0-1
Oxygen O2 0-0
Sugar 1.17
Liquer 10.12
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Tapioca flour 0.95
Cow 0.307
Buffalo 0.286
Pig 0.217
Chicken 0.242
Duck 0.310
Elephant 0.241
Waste 0.100
Depending upon the design of plant and mode of working, biogas plants are of
following types:
Batch type biogas plants as shown in figure 1.2 are appropriate where daily
supplies of raw waste materials are difficult to be obtained. A batch loaded digester is
filled to capacity sealed and given sufficient retention time in the digester. After
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completion of the digestion, the residue is emptied and filled again. Gas production is
uneven because bacterial digestion starts slowly, peaks and then tapers off with
growing consumption of volatile solids. This difficulty can overcome by having
minimum to digester so that at least one is always in operation. This problem can also
minimize by connecting batch loaded digester in series and fed at different times so
that adequate biogas is available for daily use.
ii. Batch type plants may have several digesters for continuous supply of gas.
iv. This type of plants require large volume of digester, therefore, initial cost
becomes high.
v. This plant needs addition of fermented slurry to start the digestion process.
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second chamber where biomethanation takes place. In single stage, acidogenic and
methanogenic stage are carried out in the same chamber without barrier. These plants
are economic, simple and easy to operate. these plants are generally for small and
medium size biogas plants. However ,the two stage biogas plants are costlier, difficult
in operation and maintenance but they produce more gas. These plants are preferred
for larger biogas plant system.
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plant helps in consistent pressure which can be adjusted by regulating weight. The
main drawback of this is that metal cost is large and maintenance cost is also high. To
tackle this problem the scientist have created high density polyethylene.
Advantages:
iii. They saves women and children from drudgery of collection and carrying of
firewood, exposure to smoke in the kitchen, and time consumed for cooking and
cleaning of utensils.
iv. They also produces enriched organic manure, which can supplement or even
replace chemical fertilizers
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v. They leads to improvement in the environment, and sanitation and hygiene.
viii. Household wastes and bio-wastes can be disposed of usefully and in a healthy
manner.
ix. The technology is cheaper and much simpler than those for other bio-fuels, and it
is ideal for small scale application.
xii. Anaerobic digestion inactivates pathogens and parasites, and is quite effective in
reducing the incidence of water borne diseases.
xiii. Environmental benefits on a global scale: Biogas plants significantly lower the
greenhouse effects on the earths atmosphere. The plants lower methane
emissions by entrapping the harmful gas and using it as fuel.
i. The process is not very attractive economically (as compared to other biofuels)
on a large industrial scale.
iii. Biogas contains some gases as impurities, which are corrosive to the metal parts
of internal combustion engines. Thus the use of biogas may damage cylinder
parts.
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Chapter 2
DESIGN STRATEGY
The following dimensions have been used to work out the volume of digester and
gas holder.
Diameter = 0.915 m
Height = 0.75 m
2
Volume of digester = d h
4
= * 0.9152 * 0.75
4
= 0.493 m3
Diameter = 0.75 m
Height = 0.75 m
2
h
Volume of Gas holder = 4 d
= * 0.752 * 0.75
4
= 0.331 m3
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Table 2.1: % of type of solid present in feed stock
Type of feed stock Total Solid TS(%) Volatile Solid VS(% of TS)
Calculation
Now,
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Thus, the predicted biogas yield is 0.264 m3/kg VS from Cow dung slurry.
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Chapter 3
A brainstorming was done to decide what has to be done and how? For this a list
of the required parts was prepared. Out of which some parts were decided to be
purchased directly from the market and some were decided to be fabricated. They are
as follows:
The following are the parts required for the setup of biogas plant:
3.1.1 Digester
A biogas digester as shown in figure 3.1, is a large tank where inside Biogas is
produced through the decomposition/breakdown of organic matter through a process
called anaerobic digestion. Its called a digester because organic material is eaten and
digested by bacteria to produce biogas.
The main function of biogas holders is to control the gas, both upstream and
downstream, by applying an adequate driving force (pressure) to carry the biogas
around the system at the required pressure and flow rate. The figure 3.2 shows gas
holder.
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Figure 3.2: Gas holder
A fitting is used in pipe systems to connect straight pipe or tubing sections, adapt
to different sizes or shapes and for other purposes, such as regulating (or
measuring) fluid flow. Various pipe fittings are shown in figure 3.3.
A pipe as shown in figure 3.4, is a tubular section or hollow cylinder, usually but
not necessarily of circular cross-section, used mainly to convey substances which can
flow liquids and gases (fluids), slurries, powders and masses of small solids.
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Figure 3.4: PVC pipes
3.1.5 Consumables
Consumable as shown in figure 3.5, are the materials that are necessary for
makings the joints leak prof. For example: adhesive,sealant, teflon tape etc.
The following are the parts purchased from market for the assembly of biogas
plant:
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Figure 3.6: 500 litre PVC tank
The 300 litres tank as shown in figure 3.7, is used as gas holder.
The 4 inch PVC pipe as shown in figure 3.8, is used for the inlet of the biomass
into the digester tank.
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Figure 3.8: 4 inch PVC pipe
The 3 inch PVC pipe as shown in figure 3.9, is used for the outlet of the slurry
from the digester tank.
The 4 inch male and female adapter as shown in figure 3.10, is used for
connecting the inlet pipe to the digester tank and the 3 inch male and female adapter is
used to connect the outlet pipe to the digester tank.
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Figure 3.10: 3 and 4 inch male and female adapter
The 4 inch end cap as shown in figure 3.11, is used to cover the open end of the
pipe.
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3.2.7 4 inch tee
A tee as shown in figure 3.12, the most common pipe fitting, is used to combine
(or divide) fluid flow. Tees can connect pipes of different diameters or change the
direction of a pipe run, or both.
An elbow as shown in figure 3.13, is installed between two lengths of pipe (or
tubing) to allow a change of direction, usually a 90 or 45.
A valve as shown in figure 3.14, is a device that regulates, directs or controls the
flow of a gas by opening, closing, or partially obstructing various passageways.
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Figure 3.14: 1/2 inch gas valve
An elbow as shown in figure 3.15, is installed between two lengths of pipe (or
tubing) to allow a change of direction, usually a 90 or 45.
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Figure 3.16: m-seal epoxy compound
The M-Seal Gasket Sealant as shown in figure 3.17, is used as a replacement for
gaskets, seals, gasket dressing, cork, rubber gasket. It is also used for sealing timing
cover, gear box casing and carburetor packing. M-Seal Gasket Sealant forms a
flexible rubbery bead in paste form with excellent ability for filling gaps and
withstands temperature up to 140 Centigrade.
Thread seal tape as shown in figure 3.18, lubricates allowing for a deeper seating
of the threads, and it helps prevent the threads from seizing when being
unscrewed..The tape also works as a deformable filler and thread lubricant, helping to
seal the joint without hardening or making it more difficult to tighten,and instead
making it easier to tighten.
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Figure 3.18: teflon tape
The 2 inch wide steel strip as shown in figure 3.19, is used to provide support to
the digester tank to prevent the bursting of tank due to biomass pressure.
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Chapter 4
FABRICATION
The figure 4.1 shows the flow chart of procedural steps followed for the
fabrication of set up.
A mild steel frame was fabricated in the college workshop. The manual metal arc
welding (MMAW) was used. The flat mild steel plates of suitable lengths were
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welded together to form the stand. After fabrication, finishing was done to remove
spatter. The figure 4.2 shows the welding of frame.
The top of both the tank was cut with the help of a hand cutter. After cutting the
the sharp edges were filed properly to remove burr. The figure 4.3 shows the cutting
of tank tops.
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4.4 Pipe routing
The 500 litres tank was marked at suitable points for the inlet passage of the
biomass into the tank and for the outlet of the slurry from the tank.
Similarly, the 300 litres tank was marked at the top for the tank for fixing the gas
valve.
4.5 Assembly
The following steps was performed during the assembly of biogas plant:
i. Plumbing
4.5.1 Plumbing
The 4 inch PVC pipe was fitted into the bottom of the 500 litre tank which is the
passage of inlet of biomass into the tank with the help of 4 inch male and female
adapter. A tee was provided after the female adapter to insert a pipe at right angle. An
end cap was fitted at the open end of the pipe.
The 3 inch PVC pipe was fitted at the top of the 500 litre tank with the help of 3
inch male and female adapter for the outlet of the slurry. An elbow was fitted to
change the direction of slurry flow. The figure 4.4 shows the plumbing work.
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A 1/2 inch gas valve was fitted at the top of the 300 litre tank for the outlet of the
biogas produced.
The 300 litre tank(gas holder) was inverted and then inserted into the 500 litre
tank(digester). The figure 4.6 shows the insertion of gas holder in digester.
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4.5.3 Guiding of gas holder with the help of frame
The gas holder was balanced and guided with the help of the frame placed
outsided the digester tank. The figure 4.7 shows the guiding of gas holder with frame.
After the fabrication, the joints were checked for leakage as shown in figure 4.8.
For this, the gas holder was kept half drawn into the digester tank for 10-12 hours. If
there was any leakage the gas holder would completely drawn into the digester tank.
But if there was no leakage, it would kept floating in the digester tank.
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The figure 4.9 (a) and (b) shows complete setup of biogas plant.
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Figure 4.9 (b): Setup of biogas plant.
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Chapter 5
TESTING
A set up of biogas plant was fabricated and completed. The various PVC pipe
connections and PVC tanks were tested with water for leakage. The digester was
filled with cow dung-water mixture and the gas holder was lowered in the digester
tank. Then the plant was left un disturbed for twenty days. After a span of twenty days,
the gas holder rised above and touched the frame as shown in the figure 5.1. Then the
yield of biogas plant that is the gas was examined. It was observed that the gas so
produced and collected in the gas holder extinguished the flame when brought near to
it. This confirmed that when the plant is started then first of all we always get carbon
dioxide gas. Then the valve was opened to release the CO2 gas. When the gas holder
became empty then the valve was closed. Again the disgester was fed with cow
dung-water mixture from the inlet pipe.
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Chapter 6
BILL OF MATERIAL
The following table 6.1 shows the bill of material which have been utilized in the
completion of project.
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Chapter 7
RESULT
The objective of project entitled A Setup of Biogas Plant has been successfully
achieved. The biogas plant has digester volume of 0.493 m3and gas holder volume
0.331 m3. In its initial phase of anaerobic digestion, biogas plant gave carbon
dioxide gas which was purged out. The biogas plant was again fed with cow
dung-water mixture. The biogas plant is currently running in the third phase that is
methanogenesis phase. Due to current low ambient temperature conditions, it is
expected that biogas plant will start giving methane gas in few days.
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Chapter 8
The Indian government is taking lot of initiative in making people aware with
renewable resources for energy production. In this arena, biogas production is one of
the technique which is being used from long time. Presently there is a greater thrust in
the biogas production from waste. An increasing awareness among the public
regarding sustainable use of resources will only enhance the production and use of
biogas. It can hence be expected that biogas will have a significant growth in India at
all levels of usage (household, municipality and industry) for both heat generation and
electricity production. Both the central and the state governments in India have
recognized the significance of biomass-based energy in the context of development of
the rural population. It is also heartening to note that steps are already being taken in
this regard. For instance, in Feb 2010, the Haryana Government has formulated a Rs.
85 crore project for setting up 50,000 family size biogas plants to harness the potential
of generating biogas for cooking and organic manure in the fields. More such
investments and efforts are on the horizon. In sum, India has significant potential for
generating heat and electricity from waste in the form of biogas. While only a portion
of the potential has been tapped, it is likely that more investments in this direction
could accelerate exploitation of this source in future.
1) Once biogas plant starts producing methane gas, there is need to calculate the
yield of biogas.
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4) The biogas plant can be studied for the effect of methanogenesis inoculants which
enhances the methanogenesis phase of anaerobic digestion.
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REFERENCES
2. www.en.wikipedia.org/wiki/Biogas.
3. www.energypedia.info/wiki/Types_of_Biogas_Digesters_and_Plants.
4. www.covillage.org.in/ecopedia/alternate-energy/advantage-and-disadvantages-of-
biogas.
5. www.buisnessmantraa.in/bio-gas-india-current-status-future-possibilities.
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