Chapter III Design Trade Off

CHAPTER III
DESIGN METHODOLOGY
This section presents the methods that will be used in the design and
development of a small-scale bio-power system and the functions of each of the major
components developed system.
RESEARCH DESIGN
In this study, horse manure will be utilized to produce biogas which will serve as
fuel to generate electricity. For the maximum yield of biogas, the best ratio of horse
manure to water will be distinguished by conducting preliminary testing where 1:1 and
1:2 ratio will be considered. After obtaining the best ratio of manure to water, the biogas
to be produced will undergo laboratory testing to determine its biogas and digestate
components.
The prototype design will have three main components including the anaerobic
digester tank, gas holder and the generator. The feed will be introduced to the anaerobic
digester tank while the gas to be released will be collected by the balloon-type gas
holder and will then be used to produce electricity through generator. An additional
feature of this prototype is that it utilizes the digestate for production of liquid fertilizer.
For the development of the prototype, the significant factors to be considered are
the system components, the materials of construction to be used, the composition of the
methane gas and digestate to be determined by the parameters tested and the
characteristics of the existing biogas and the commercially available fertilizer.

Design and Development of a Small-scale Bio-Power System that Utilizes Chapter III
Horse Manure as a Feedstock by Gandola, M.L.V., Geron, A.L.M., Design Methodology
Lacdao, D.B.,Panopio, J.R.C. and Sarmiento, R.G.
DESIGN CONSIDERATIONS
Designing and developing a small-scale bio-power system involves the general
design of the digester, its materials of construction, the volume of liquid slurry to be
digested, the temperature of the area where the system is located, potential layering of
the slurry, the amount of power output, the retention time and the sustainability.
For the considerations with regards to the production of biogas, the materials to
be used must withstand high temperature condition since the bacteria present on the
process is mesophilic existing at 30 to 42 degree Celsius. In addition, the volume of the
biogas to be produced is considered in the designing the gas holder or collector.
For considerations with regards to the conversion of biogas to electricity, the
system must have a gas generator and a storage cell. The gas generator must not be
enclosed within the system due to the exhaust air and vibration during the process.
For structural consideration, high density polyethylene (HDPE) will be used for
the digester tank because the system will require a material which has a high durability
and high strength that can with stand high temperature. Also, the gas storage will used
HDPE as its base and rubber balloon for capacity extension. Primarily, the capacity of
the digester is considered, to determine how much biogas can be produced which will
then be converted to electricity. Moreover, the type of process whether batch or semi-
batch is also considered.
50
DESIGN TRADE-OFF
Design Efficiency
The system features a two-digester tank, a separate holder for the biogas
produced and a generator for the power output. The two-digester tank has its advantage
when it comes to continuity of the process. While the first tank is on the process of
digestion, the other tank can be filled up after 15 days, as stated on the equipment
operation.
The holder is a balloon-type gas holder which can expand when biogas starts to
produce. Comparing it to other existing holders, like floating drum, it is more efficient for
it can hold a greater amount of biogas.
The power-generating section features a commercially available generator which
is assembled with natural gas carburetor. Having this section is an edge of the system
comparing with the existing digester tanks. The primary purpose of the existing digester
tanks is for cooking purposes only. But with the developed design, the produced biogas
can be used to generate electricity and readily available for usage.
Economic Consideration
Most of the existing digester tanks are made of metals. However, polymer-based
digester tanks are becoming known in the industry because of its cheaper cost
comparing to metals.
The developed system is much expensive than those of the existing ones. It is
the power-generating section that contribute to the cost of the system. But considering
only the digester tank, there is not much difference with regards to its cost.
51
After the anaerobic digestion, the digestate can serve as alternative fertilizer
which its feature is comparable with the commercially available one. The money that the
community used up to avail the commercially available one can be used to other
necessities.
Environmental Consideration
The time consumed for the gathering of horse manure will be compensated by
the reduction of the emission of greenhouse gases coming from the decomposition of
the horse manure. More so, the environmental sanitation in the community will be
improved.
Safety Consideration
The developed system includes scrubbers for H2S and CO2. Addition of scrubber
increases the cost of the system but it reduces the risk of potential hazard due to the
presence of H2S. Moreover, it will increase the life span of the generator because
corrosion will less likely to occur.
DESIGN BASIS AND ASSUMPTIONS
The researchers conducted preliminary experiment where the ratio of manure to
water was the only parameter taken into consideration. From the ratios (1:1 and 1:2)
prepared, the 1:1 ratio produced the greatest yield. The chemical compositions of
manure including its proximate, complete and biogas analysis were used to determine
the total amount of biogas that can be produced. As an additional for future experimental
procedures, parameters including temperature which, through addition of water in the
52
slurry, is controlled, pressure of the collected gas, type of process (batch, continuous, or
semi-continuous), hydraulic retention time and organic loading rate will be adopted.
These stated physical/chemical qualities of manure can be used as basis for the
conversion of biogas to electricity system design.
PROPOSED DESIGN
A. General Functions of the Prototype
The general function of the prototype is the production of biogas from the manure
and its conversion to electricity while also being able to produce liquid fertilizer from
the remaining digestate. The anaerobic process including hydrolysis, acidogenesis,
acetogenesis and methanogenesis will be undergone by the liquid slurry to obtain
the biogas. The actual perspective view and the design of the prototype with its
process flow are shown in Figure 6 and Figure 15, respectively.
Figure 6. Perspective View of the Design of the System
53
Figure 7. Design and Specification of the Digester Tank
Figure 8. Design and Specification of the Gas Holder
54
Figure 9. Design and Specification of the Power-Generating Section
Figure 10. Back Side View
Figure 11. Front Side View
55
Figure 12. Right Side View
Figure 13. Left Side View
Figure 14. Isometric View
56
Figure 15. Process Flow Diagram of the Bio-Power System
57
B. Parts of the System
Anaerobic Digester Tank
Figure 16. Anaerobic Digester Tanks
An anaerobic digester tank permits naturally-occurring bacteria in the manure to
grow, multiply and be converted to biogas in the absence of oxygen and produce
low-odor digestate used as fertilizer. The small-scale bio power system will be
composed of two anaerobic digester tanks. Each digester tank has a capacity of
500L. It is connected to the feed inlet with a 3-in. diameter and 1.0 m long PVC
pipe. Since the set-up is semi-continuous process, the previous feed inside each
tank is being displaced by 500 L liquid slurry fed through the discharge pipe with a
diameter of 3 in. and length of 0.5 m that served as the digestate outlet.
58
Agitator
Figure 17. Agitator
Agitator is used for the stirring of liquid slurry inside the digester tank to not let
the solids be suspended at the bottom. It is made out of stainless steel to avoid
corrosion and is placed horizontally in the tank for better mixing.
Hydrogen Sulfide Scrubber
Figure 18. H2S Scrubber
59
Hydrogen sulfide scrubber is installed in each digester tank to lessen the H2S gas
produced in the system for small amount of it can be dangerous. It is 0.5 m long of
3-in diameter PVC pipe with compressed steel wool inside that serves as the
scrubbing agent.
Gas Holder
Figure 19. Gas Holder
The gas holder will be made of cylindrical HDPE at the bottom with a rubber
balloon at the upper part and has the maximum capacity of 1.5 m3. The holder will
be filled with water that will serve as carbon dioxide scrubber as well as hydrogen
sulfide. A pressure gauge is attached at the balloon for pressure monitoring.
60
Valves
Figure 20. Gas Valve Figure 21. Gate Valve
Valves are used to control the fluid flow. A 1/2-in diameter gas valves are
used in each gas outlets in the digesters and in the gas holder to control the flow of
the gas. In addition, a 3-in diameter gate valves are also attached for the feed inlet
and digestate outlet, and a 1-in diameter in the water inlet and outlet for the holder.
PVC Pipes and Fittings
Figure 22. PVC Pipes and Fittings
PVC Pipes and Fittings which do not easily corrode, light-weight, high-resistant
and low reactivity, are mostly used for the transportation of the liquid manure in the
anaerobic digester set-up. The PVC pipes used are in 3-in. Sch. 40 and are joined
together by sealants and solvent cements to avoid leakage.
61
Temperature and Pressure Gauge
Figure 23. Temperature Gauge Figure 24. Pressure Gauge
Temperature gauge is a device used that indicate or measure the
temperature where anaerobic digestion process must be maintained at mesophilic
temperature which is around 35°C. Pressure gauge, however, is a device that is
involved in measuring and monitoring the pressure necessary for the produced
methane gas to be fueled in the generator.
Biogas Generator
Figure 25. Biogas Generator
Biogas generator is a device which converts mechanical energy obtained from
the force driven by the biogas produced in the digester to electrical energy.
62
Lead Acid Battery
Figure 26. Lead Acid Battery
For the storage of electricity, lead-acid rechargeable battery is to be used. This is
linked to the generator to assure that no energy is leading to waste.
DESIGN COMPUTATIONS
This study involves the conversion of fresh horse manure into biogas and which
will be used for the generation of electricity. The digester is designed to process 0.5m3 of
liquid slurry for each batch.
Basis:
Capacity of one digester’s tank: 0.5m3 per batch (1:1 manure-water ratio)
Total slurry capacity: 1m3 (two-compartment digester)
Density of Horse Manure: 1008.9905 kg/m3
Density of Water: 1000 kg/m3
63
Ratio to be Used for the Liquid Slurry: 1 kilogram horse manure: 1 kilogram water
Hydraulic Retention Time: 30 days
a. Calculation of Feed Rate
𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

+ = capacity of the digester
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

+ = 0.50 𝑚3
1008.9905 𝑘𝑔/𝑚3 1000𝑘𝑔/𝑚3
𝑚𝑎𝑠𝑠 𝑜𝑓 ℎ𝑜𝑟𝑠𝑒 𝑚𝑎𝑛𝑢𝑟𝑒 = 251.1188 𝑘𝑔 𝑝𝑒𝑟 𝑏𝑎𝑡𝑐ℎ
= 𝟖. 𝟑𝟕𝟎𝟔 𝒌𝒈 𝒑𝒆𝒓 𝒅𝒂𝒚
b. Calculation of Organic Loading Rate
Fresh Horse Manure: 5.5 lbs VS/36 lbs Fresh Material (15.2777% VS/FM)
%𝑉𝑆
𝑓𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑋 𝐹𝑟𝑒𝑠ℎ 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝑂𝐿𝑅 =
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑑𝑖𝑔𝑒𝑠𝑡𝑒𝑟 ′ 𝑠 𝑐𝑜𝑚𝑝𝑎𝑟𝑡𝑚𝑒𝑛𝑡
𝑘𝑔 15.2777% 𝑉𝑆
8.3706 ∗
𝑑𝑎𝑦 𝐹𝑀
=
0.5 𝑚3
𝒌𝒈 𝑽𝑺
= 𝟐. 𝟓𝟓𝟕𝟕
𝒅𝒂𝒚
64
c. Justification of Calculated Feed Rate
Number of Horses: 20
Average Amount of Manure produced by a horse: 16.3265 kg/day
Horse Manure Available per day: 326.53 kg
Recommended OLR (standard – rate anaerobic digesters):
1.25 – 2.5 kg VS/m3 per day
Since the amount of available manure is greater than the required for the
digester and the organic loading rate is within the recommended for the said
operating parameter, the calculated feed rate is justified and a digester’s
compartment capacity of 0.5m3 is a realistic assumption.
d. Calculation of Biogas Holder Capacity
Maximum Methane Producing Capacity: 0.260 Nm3 CH4/kg VS

𝐵𝑖𝑜𝑔𝑎𝑠 𝑌𝑖𝑒𝑙𝑑
%𝑉𝑆 Biogas
= 𝑚𝑎𝑠𝑠 𝑜𝑓 ℎ𝑜𝑟𝑠𝑒 𝑚𝑎𝑛𝑢𝑟𝑒 𝑥 x Reported methane value x
𝐹𝑟𝑒𝑠ℎ 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 %methane
15.2777% 𝑉𝑆 0.260 𝑚3 𝐶𝐻4 𝐵𝑖𝑜𝑔𝑎𝑠

= 251.1188 𝑘𝑔 𝑀𝑎𝑛𝑢𝑟𝑒 𝑥 𝑥 𝑥
𝐹𝑀 𝑘𝑔 𝑉𝑆 60% 𝐶𝐻4
= 𝟏𝟔. 𝟔𝟐𝟓𝟎 𝑚3 𝒑𝒆𝒓 𝒃𝒂𝒕𝒄𝒉
= 0.5542 𝑚3 𝑝𝑒𝑟 𝑑𝑎𝑦
Biogas Holder Capacity = Number of Compartment x Biogas Yield
= 2 𝑥 0.3153 𝑁𝑚3
65
= 𝟏. 𝟏𝟎𝟖𝟑 𝑚3
e. Calculation of Power Output
Biogas Equivalent (1m3): generate 1.25kWh of electricity
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 = 𝐵𝑖𝑜𝑔𝑎𝑠 𝑌𝑖𝑒𝑙𝑑 ∗ 𝐵𝑖𝑜𝑔𝑎𝑠 𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡
1.25 𝑘𝑊ℎ
= 16.6250 𝑚3 𝑥
1𝑚3 𝐵𝑖𝑜𝑔𝑎𝑠
= 𝟐𝟎. 𝟕𝟖𝟏𝟑 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒃𝒂𝒕𝒄𝒉
= 𝟎. 𝟔𝟗𝟐𝟕 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
= 28.8628 𝑊 𝑓𝑜𝑟 24 ℎ𝑜𝑢𝑟𝑠
Electric Generation per Day 0.6927 kWh
692.7081 Wh
Power rating of LED lamp 5W
Usage Time per Day 12 hours
Number of Bulbs that can be lit up 11
FABRICATION AND ASSEMBLY
The necessary materials are gathered and are processed based on the design
specifications before considering the fabrication and assembly of the bio-power system.
HDPE or High Density Polyethylene is used for the digester tank and gas holder to
prevent the corrosion that may take place due to different reactions in biogas extraction.
66
Adjustments are made on the specifications due to the different set of standards of some
materials.
A fabricator is acquired to ensure that the system made is closed and that no gas
will escape to the atmosphere during the operation.
DETERMINATION OF HORSE MANURE
The analysis of horse manure will be based from volatile solids, moisture content,
and N-P-K. The testing will be held at Lipa Quality Control Center. Each component will
be determined using different methods. Kjeldhal method will be applied for the
determination of nitrogen while Colorimetric method for the phosphorus. Moreover, the
potassium will be determined using Atomic Absorption Spectroscopy. In AAS, manure is
aspirated and atomized in a flame. This produces free, unexcited ground state atoms in
the flame. A light beam from a hallow cathode lamp or an electrodeless discharge lamp
is directed through the flame into a monochromator, and onto a detector that measures
the amount of absorbed light. A wavelength is chosen to match the characteristics of the
element in the sample.
DETERMINATION OF BIOGAS
The analysis of biogas comprising methane, carbon dioxide, and hydrogen
sulfide is to be analyzed by the Philippine Institute of Pure and Applied Chemistry
(PIPAC) using Gas Chromatographs (GC) with Flame Ionisation Detector (FID) and
Thermal Conductivity Detector (TCD).
67
Solutes interact in gas detectors as they elute from the column. This interaction
into an electric signal sent to the data system is then converted by the detector. A
chromatogram is generated as the magnitude of the signal is plotted versus time (from
the time of injection). Compounds found in the biogas are burned in a hydrogen-air flame
through flame ionization detector and the carbon containing compounds produce ions
that are attracted to the collector. The number of ions striking the collector is measured
and the signal is produced. Thermal Conductivity Detector (TCD), on the other hand,
allows the use of detector cell wherein a heated filament with an applied current is
contained. A change in the filament occurs as carrier gas having solutes passes through
the cell. The change in current is compared against the reference cell current.
Measurement of the difference is done and generation of the signal is obtained.
DETERMINATION OF THE COMPONENTS OF DIGESTATE
The analysis of the digestate will be in terms of the following content: % Nitrogen,
% Phosphorus, % Potassium and % Carbon. The testing will be done at Lipa Quality
Control Center. On the other hand, each component, the N-P-K-C, will be determined
using the same method in the determination of the components of horse manure.
EQUIPMENT OPERATION
In order to achieve the desired property of the products, appropriate operation of
the equipment is highly important. With both theoretical and hands-on experience
recommended, the learning process is an immense necessity in the operating
equipment. The following procedures serve as the basis of operation of the bio-power
system:
68
1. From the ratio 1:1 of manure to water, about 71.5 kg both of manure and
water is mixed.
2. Approximately 143 kg of liquid slurry is made and is then poured to the
digester tank.
3. The slurry is mixed thoroughly by the use of an agitator which is operated
manually.
4. To maintain the mesophilic temperature required for anaerobic digestion,
temperature gauge is placed on the digester tank.
5. A small amount of slurry will be obtained from the anaerobic digester tank
through the draining outlet to monitor its pH.
6. To remove traces of hydrogen sulfide in the biogas produced, it will be
passed through a hydrogen sulfide scrubber.
7. On the gas holder base, a 0.10 meter-high water is placed which serves
as the carbon dioxide scrubber.
8. The cleaned gas is collected to the balloon-type gas holder which has a
gas valve to control the amount of biogas that can be released.
9. To control the pressure, a pressure gauge is placed on the upper part of
the balloon gas holder.
10. The gas collected will be directed to the generator and to avoid waste of
energy, the generated electricity can be transferred to a lead-acid
rechargeable battery.
69
11. Considering semi-continuous process, the previous load is displaced by a
new feedstock mixture per every 15 days. The digestate or the displaced
liquid slurry, which serves as the fertilizer, is discharged through the
discharge pipe and is then collected in small chamber.
STATISTICAL TREATMENT OF DATA
T – test will be used to statistically determine if there are significant differences
between the properties of the biogas produced from the horse manure and the digestate
or the residual slurry from the existing biogas.The mean properties that will be attained
from the horse manure-extract biogas will be taken as true value for the computations of
p-value.
70

Chapter III Design Trade Off

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Chapter III Design Trade Off

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CHAPTER III

components developed system.

characteristics of the existing biogas and the commercially available fertilizer.

Designing and developing a small-scale bio-power system involves the general

process is mesophilic existing at 30 to 42 degree Celsius. In addition, the volume of the

biogas to be produced is considered in the designing the gas holder or collector.

For considerations with regards to the conversion of biogas to electricity, the

batch is also considered.

it can hold a greater amount of biogas.

The power-generating section features a commercially available generator which

can be used to generate electricity and readily available for usage.

corrosion will less likely to occur.

DESIGN BASIS AND ASSUMPTIONS

The researchers conducted preliminary experiment where the ratio of manure to

procedures, parameters including temperature which, through addition of water in the

conversion of biogas to electricity system design.

A. General Functions of the Prototype

the remaining digestate. The anaerobic process including hydrolysis, acidogenesis,

acetogenesis and methanogenesis will be undergone by the liquid slurry to obtain

process flow are shown in Figure 6 and Figure 15, respectively.

Figure 6. Perspective View of the Design of the System

Figure 7. Design and Specification of the Digester Tank

Figure 8. Design and Specification of the Gas Holder

Figure 9. Design and Specification of the Power-Generating Section

Figure 10. Back Side View

Figure 11. Front Side View

Figure 12. Right Side View

Figure 13. Left Side View

Figure 14. Isometric View

Figure 15. Process Flow Diagram of the Bio-Power System

Anaerobic Digester Tank

Figure 16. Anaerobic Digester Tanks

An anaerobic digester tank permits naturally-occurring bacteria in the manure to

Figure 17. Agitator

corrosion and is placed horizontally in the tank for better mixing.

Hydrogen Sulfide Scrubber

Figure 18. H2S Scrubber

Figure 19. Gas Holder

sulfide. A pressure gauge is attached at the balloon for pressure monitoring.

Figure 20. Gas Valve Figure 21. Gate Valve

PVC Pipes and Fittings

Figure 22. PVC Pipes and Fittings

together by sealants and solvent cements to avoid leakage.

Figure 23. Temperature Gauge Figure 24. Pressure Gauge

Temperature gauge is a device used that indicate or measure the

temperature where anaerobic digestion process must be maintained at mesophilic

temperature which is around 35°C. Pressure gauge, however, is a device that is

methane gas to be fueled in the generator.

Figure 25. Biogas Generator

Biogas generator is a device which converts mechanical energy obtained from

Figure 26. Lead Acid Battery

For the storage of electricity, lead-acid rechargeable battery is to be used. This is

linked to the generator to assure that no energy is leading to waste.

liquid slurry for each batch.

Total slurry capacity: 1m3 (two-compartment digester)

Density of Horse Manure: 1008.9905 kg/m3

Density of Water: 1000 kg/m3

Hydraulic Retention Time: 30 days

a. Calculation of Feed Rate

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑢𝑟𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

𝑚𝑎𝑠𝑠 𝑜𝑓 ℎ𝑜𝑟𝑠𝑒 𝑚𝑎𝑛𝑢𝑟𝑒 = 251.1188 𝑘𝑔 𝑝𝑒𝑟 𝑏𝑎𝑡𝑐ℎ

= 𝟖. 𝟑𝟕𝟎𝟔 𝒌𝒈 𝒑𝒆𝒓 𝒅𝒂𝒚