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Plants or in aerobic ponds Anaerobic digestion / degradation / treatment These terms are all used. Organic waste with the aim to produce biogas and a fertiliser.

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1 DESIGN OF BIOGAS PLANT 1.1 Introduction: Bio-gas Project, LGED Biogas can be obtained from any organic materials after anaerobic fermentation by three main phases. 1.2 Mechanism of biogas fermentation: A) Groups of Biogas microbes- Biogas microbes (Bacteria) Non methane producing Methane producing Fermentative Bacteria Hydrogen-producing acetogenic bacteria B) Groups of microbes involved in the 3 stages of biogas fermentation- 1 st stage: Fermentative bacteria- Hydrolyze & Ferments Organic substance Cellulose decomposing bacteria Saccharides Protein decomposing bacteria Amino acids Fat decomposing bacteria Fatty acids Volatile acids, H 2 & CO 2 Page-1

2 2nd Stage: Hydrogen producing acetogenic bacteria- Decompose the substances produced in 1 st stage Acetic acid, H 2, CO 2 3 rd Stage: Methane producing bacteria- Convert the substances produced in 1 st & 2 nd stage CH 4 & CO Design perameter: A) Selection of materials : B) Total solid (TS) contains calculations of organic materials Organic materials- Solid part : Total solid contained in a certain amount of materials is usually used as the material unit to indicate the biogas- producing rate of the materials. Most favourable TS value desired is 08% Liquid part : As per Annexure-I C) Favourable temperature, P H value & C/N ratio for good fermentation- Temperature: Mesophilic; 20 o c to 35 o c ( Annexure-II). P H value : Neutral P H and ranges 6.8 to 7.2 C/N ration : Ranges from 20:1 to 30:1 ( Annexure- VI ) Page-2

3 Kinds D) Table showing discharge per day, TS value of fresh discharge and water to be added to make favorable TS condition- Body weight Discharge per day TS value of fresh discharge (% by wt.) Water to be added with fresh discharge to make the TS value 8% Human Cow Chicken Pig E) Hydraulic retention time ( HRT)- For Mesophilic digestion where temp. varies from 20 o c to 35 o C and HRT is greater than 20 days. 1.4 Relationship between temperature, HRT & TS value of 8% : 30 O 25 O 15 O TS ±8% Temp. ( o c) HRT (days) Page-3

4 1.5 Cross-section of a digester: Vgs Vc V H V f V S a) Volume of gas collecting chamber = Vc b) Volume of gas storage chamber = Vgs c) Volume of fermentation chamber = V f d) Volume of hydraulic chamber = V H e) Volume of sludge layer = Vs Total volume of digester V =Vc+Vgs+V f +Vs 1.6 Geometrical dimensions of the cylindrical shaped biogas digester body: V 1 S 1 f 1 V 3 R 1 V 2 R 2 H S 2 R D f 2 Page-4

5 1.7 Assumptions: For volume Vc 5% V Vs 15% V Vgs + V f = 80% V Vgs = V H Vgs = 0.5 ( Vgs + V f + Vs ) K Where K = Gas production rate per m 3 digester volume per day. For Bangladesh K = 0.4 m 3 /m 3 d. For geometrical dimensions D= X V 1/3 V 1 = D 3 V 2 = D 3 V 3 = D 3 R 1 = D R 2 = D f 1 = D/5 f 2 = D/8 S 1 = D 2 S 2 = D Volume calculation of digester and hydraulic chamber: A)Volume calculation of digester chamber- Given : 6 cows of body weight 200 Kg each. Temp. = 30 O C (average) Sol n : Let HRT = 40 days ( for temp. 30 O C ) Total discharge = 10 kg X 6 = 60 Kg/day TS of fresh discharge = 60 kg X 0.16 = 9.6 Kg. In 8% concentration of TS ( To make favourable condition ) 8 Kg. Solid = 100 Kg. Influnt 1 Kg. Solid = 100 / 8 Kg influent 9.6 Kg Solid = 100 x 9.6/ 8 = 120 Kg. Influent. Total influent required = 120 Kg. Water to be added to make the discharge 8% concentration of TS =120 Kg - 60 Kg. = 60 Kg. Working volume of digester = Vgs + V f Page-5

6 Vgs + Vf = Q.HRT = 120 Kg/day X 40 days = 4800 Kg. ( 1000 Kg = 1 m 3 ) = 4.8 m 3. From geometrical assumptions: Vgs + V f = 0.80 V Or V= 4.8/0.8 = 6.0 m 3. (Putting value Vgs + Vf = 4.8 m 3 ) & D = V 1/3 = m 2.40 m. Again D H V3 = 4 (Putting V 3 =0.3142D 3 ) D Or, H = = 0. 96m D Say H = 1.00m Now we find from assumption as we know the value of 'D' & 'H' f 1 = D/5 = 2.40 /5 = m f 2 = D/8 = 0.30m R 1 = D = 1.74 m R 2 = D = 2.55 m V 1 = D 3 = m 3 Vc = 0.05V = 0.3 m 3 Now the dimension of digester chamber is kown & drawn below- V 1 =1.143m 3 V 2 V3 R 1 = 1740mm R 2 = 2550mm f 1 =480mm H =1000mm f 2 =300mm D = 2400mm B) Volume calculation of hydraulic chamber- Page-6

7 Vc h 3 h 3 V H h = h 3 +f 1 +H 1 f 1 Vgs h 2 = 800mm H 1 H 1 From assumptions: Vc = 0.05 V = 0.3 m 3 Vgs = 0.50 x (Vgs + V f + Vs) x K ( Where K = Gas production rate per m 3 digeste vol./day ) = 0.5 x 5.7x 0.4 =1.14 m (A) Again, Vgs = 50% of daily gas yield = 0.5 x TS x gas producing rate per Kg TS = 0.5 x ( 60 kg x 0.16 ) x 0.28 m 3 /kg TS ( See Annex- III ) = m (B) From A & B let Vgs = m 3. Vc + Vgs = 0.3 m m 3 = m 3 Again V 1 = [{(Vc + Vgs) - {π D 2 H 1 }/4 ] = [ {3.14 x (2.4) 2 x H 1 }/4] Or, H 1 = 0.110m We have fixed h = 800 mm water volume ( I mm = 10 N/ m 2 ) h = h 3 + f 1 + H 1 Or, h 3 = 0.210m. Again we know that Vgs = V H Or, m 3 = 3.14 x (D H ) 2 x h 3 /4 Or, D H = 2.85m Page-7

8 Now we know the dimension of hydraulic chamber. Moreover keeping h = 800 mm, we can choose or re-arrange the dimension considering availability of site and construction suitability. For most suitable dimensions we can select the drawing of Annexure- IX for 60 Kg cow dung per day as raw material. Note: For ready reference 4 family type Biogas plant's drawing is shown(standared dimension's) in Annexure-VIII, Annexure-IX, Annexure-X & Annexure-X1 where 40 Kg, 60Kg, 80Kg and 100Kg cow dung is considered as raw marterial per day respectively. If bigger size plant is required,it can be designed keeping all safety considerations in design and construction. Annexure- 1 TABLE-1: THE TOTAL SOLID CONTENT OF COMMON FERMENTATION MATERIALS IN RURALAREAS (APPROXIMATELY) Materials Dry matter content (%) Water content (%) Dry rice straw Dry wheat straw Corn stalks Green grass Human excrement Pig excrement Cattle excrement Human Urine Pig Urine Cattle Urine Annexure-II TABLE-2: BIOGAS-PRODUCING RATES OF SOME COMMON FERMENTATION MATERIALS ATDIFFERENT TEMPERATURES (m 3 /Kg TS ) Materials Medium temperature (35 o C) Pig manure Cattle dung Human wastes Rice straw Ordinary temperature (8 o 25 o C ) Page-8

9 Wheat straw Green grass Experimental conditions:- The fermentation period of the excrement materials lasts 60 days and that of the stalk type lasts 90 days. The fermentation material concentration ( total solid content ) is 6%. TABLE-3: BIOGAS PRODUCING RATES OF SOME FERMENTATION MATERIALS AND THEIR MAIN CHEMICAL COMPONENTS. Materials and their main components Yield of Biogas m 3 /kg TS Methane content ( % ) Animal barnyard manure Pig manure Horse droppings Green grass Flax straw Wheat straw Leaves Sludge Brewery liquid waste Carbohydrate Liquid Protein Annexure- III Annexure- IV TABLE-4 BIOGAS- PRODUCING RATES OF SEVERAL SUBSTANCES Material YpCMDV (m 3 /m 3 d) YpKgM (m 3 /KgTS ) Amount of biogas produced in a period of time ( as a % of the total yield) 0 ~15 (d) 15 ~ 45 (d) 45 ~ 75(d) 75 ~ 13 (d) Page-9

10 Water Hyacinth Alligator Weed Water Lettuces Cattle Dung Pig Manure Human Wastes Dry Grass Rice Straw Note: - The fermenting temperature is 30 o C. It is batch-fed fermentation. YpCMDV refers to the average yield of biogas per cubic meter of the digester volume during the period of normal fermentation ( m 3 / m 3 d) YpkgM refers to the yield of biogas per kilogram of the fermentation material (m 3 /kg TS) Annexure-V TABLE-5 : THE SPEED OF BIOGAS PRODUCTION WITH COMMON FERMENTATION MATERIALS. Speed Amount of biogas produced in a period of time (expressed as a percentage of the total yield of biogas) Time(d ) Materials Human wastes Pig manure Green grass Cattle dung Wheat straw * * ** * * ** ** * * ** * ** ** Biogas Producing rate (m 3 /kg TS ) * Biogas production is at the highest speed. ** Amount of Biogas produced to more than 90% of the total yield of a fermentation period. Experimental conditions: - Fermenting temperature 35 o C, the total length of fermentation period being Page-10

11 60 days for the excrement material and 90 days for the stalk type, the materials concentration; total solid content of the fermentative fluid being 6%. ANNEXURE- VI TABLE -6. CARBON-NITROGEN RATIOS OF SOME COMMON FERMENTATION MATERIALS (APPROX.) Material Carbon content of material (%) Nitrogen content of materials(%) Carbonnitrogen ration (C/N) Dry wheat straw :1 Dry rice straw :1 Corn stalks :1 Fallen leaves :1 Soybean stalks :1 Wild grass :1 Peanut stems and :1 leaves Fresh sheep :1 droppings Fresh cattle dung :1 Fresh horse :1 droppings Fresh pig manure :1 Fresh human wastes :1 ANNEXURE- VII TABLE-7 AMOUNT OF HUMAN AND ANIMAL WASTES DISCHARGED PER DAY ( APPROX.) Kinds Body weight Daily amount of excrement Daily amount of urine Annual amount of excrement discharged Annual amount of excrement collection Daily yield of biogas per capita (m3) Pig Ox Horse Sheep Chicke n Huma n Page-11

12 Note: The annual amount of excrements collected accounts for 80% of that discharge. Page-12

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