Disciplinary Internship

UTILIZATION OF ORGANIC WASTE

INTO BIOGAS & MANURE
This project report briefly contains the
operation of centralized biogas production plant
GROUP-1
with slight process and working parameter
modification and reducing problems faced by
1. KEVAL HARIYANI (18BT01024)
farmers.
2. JENISH CHOVATIYA (18BT01026)
COMPLETED THE INTERNSHIP ON ➔ JUNE 29 3. DEEP MAHTO (18BT01036)
4. RAJ MEHTA (18BT01041)
UNDER THE GUIDANCE OF:-
FACULTY MENTOR:- MR. GAURAV SAXENA
INDUSTIAL MENTOR:- MR. SHEMAL PARMAR
 Acknowledgement

It is our pleasure to be a part of GSFC University that even under this COVID-
19 situation, they are offering us with a great discipline internship opportunity.
This internship has provided us with a valuable learning opportunity,
teaching us how to work with different people in different environments.
Which, after the Covid-19 outbreak and in today's modern rising society with
a new normal, is a requirement.
We would like to thank our mentor, Mr. Gaurav Saxena, for his assistance
during this internship. He is always eager to answer any questions we have
about our project, and their supportive advice and day-to-day monitoring
have made the internship a seamless and rewarding experience.
We'd like to express our gratitude to Mr. Shemal Parmar, who, despite his
hectic schedule, took time out for us, providing fantastic ideas for our
project, guiding and assisting us with all of our questions about the subject.
Thank you so much to both mentors for their kind attitudes and friendly
behavior, which lead us to an innovative and successful idea. We see this
chance as a significant step forward in our professional development, as it
has assisted us in honing our talents and expanding our knowledge, and we
will continue to work to better it.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Table of Contents
Acknowledgement ............................................................................................... 1
INTRODUCTION ....................................................................................................... 3
Why we have selected this topic as the part of our Disciplinary Internship? 7
PROCESSING OF ORGANIC WASTE INTO BIOGAS & MANURE ......................... 9
1. Collection of organic wastages .................................................................... 9
1.1 DIFFERENT WAYS VEGETABLE WASTE CAN FORM ................................... 9
1.2 MUNICIPAL SOLID WASTE IN VADODARA. ............................................... 9
1.3 COLLECTION OF WASTE:-......................................................................... 10
1.4 List of vegetable market in Vadodara .................................................. 13
2. BIOGAS PLANT COMPONENTS ..................................................................... 13
Operating unit 1: Biomass Reception / Storage & Substrate / Feed
Preparation........................................................................................................ 14
Operating unit 2: Fermentation and recirculation duct ............................. 17
ANAEROBIC DIGESTION ................................................................................ 21
SELECTION AND DESIGN CRITERIA:- ............................................................. 23
Operating unit 3:- Desulphurization unit ........................................................ 24
Operating unit 4:- Biogas storage tanks. ....................................................... 25
PROCESS UPGRADING OPTIONS:-...................................................................... 26
Enhancing biogas potential using Promoters : ............................................. 26
Operating unit 5:- Organic Manure Purification:- ........................................ 30
COST AND FINANCIALS OF THE IDEA IMPLEMENTATION.................................. 31
CONCLUSION:- ..................................................................................................... 37
REFERENCES .......................................................................................................... 38
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

INTRODUCTION
What is organic waste?
Organic waste, often known as biodegradable waste, is a sort of natural
refuse produced by plants or animals. Biodegradable plastics, food waste,
green wastes, paper waste, manure, human waste, sewage, and
slaughterhouse waste are just a few examples.
Why Landfills don’t work?
The majority of organic products appear to be harmless - after all, they are
natural. However, dumping it in landfills causes considerable environmental
damage. When organic waste is buried in a landfill, it undergoes anaerobic
decomposition due to a lack of oxygen. Methane is produced, which is then
released into the atmosphere. Biogas is an often underestimated and
neglected part of renewable energy in India. It nearly defies sense to believe
that the combination of organic waste and a flawed disposal solution could
yield a greenhouse gas 20 times more potent than carbon dioxide. While
solar, wind, and hydropower are the most popular energy sources in the
country, they are not the only ones. Biogas is a lesser known but highly
important option to foster sustainable development in agriculture-based
economies, such as India.
Biogas generation from locally available renewable organic resources can
be a viable alternative because it reduces GHG emissions. Biogas
technology offers an appealing pathway for utilizing various types of
biomasses to meet energy demands. This technology provides a unique set
of advantages, some of which includes improved waste management,
efficient rural ecology, reduced pathogenic diseases, enhanced rural
energy consumption, and strengthening agricultural structure.
What is Biogas?
Biogas is the fermentation of organic matter to produce a gaseous fuel,
commonly methane. It's an anaerobic process, meaning it happens without
the presence of oxygen. Biogas is technically the yeast that enables your
bread to rise or the alcohol in your beer to ferment. We don't use it in the
same manner we do other renewable energy sources, but the concept is
the same. Biogas can be utilized for a variety of purposes, including cooking,
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

lighting, heating, and power generation. Biogas, in reality, is a wonderful and

practical way to assist rural and underprivileged populations' development
in all developing countries. However, this poses a dilemma. The organic
matter emits a gas, which we must convert into a liquid in order to use it. This
necessitates the use of labour, machinery, and manpower. Although
research is currently being conducted to determine the most efficient
means for making it operate, significant progress has been achieved, and
the technology is no longer novel.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Biogas in India
There are several differences between biogas and fossil fuels, but one of the
most significant for India is that biogas may be produced at home. Finding,
digging up, and converting crude oil to gas is difficult, but biogas does not
face the same challenges. Many farmers, those who have gardens or
greenhouses, could benefit from proper water management and
temperature control so that plants can be grown all year. It will take some
learning and investment, but it is doable for many people, particularly those
who live in rural areas. This would be the most beneficial to people in India
because it would help ease the strain of delivering reliable energy sources
based on fossil fuels, and would allow the country to become more energy
independent. Plus, the rural areas are places where the raw materials for
biogas will be more available, such animal manure, crop residues and
poultry litter. But this isn’t the first time most people there are hearing about
it.

Biogas in Agriculture Sector in India: Key Challenges

Although the conversion of agriculture waste – cattle dung and crop
residues – to biogas and digested slurry is a well-established and well-proven
technology in India, it has been underutilized, owing to the easy availability
of firewood and the relatively low cost of chemical fertilizer for most Indian
farmers.
Today's farmer communities must be taught that their agricultural revenue is
declining year after year as a result of increasing deforestation, degradation
of land quality, widespread use of chemical fertilizers and pesticides, a lack
of farm cattle, indiscriminate use of water for irrigation, and the use of heavy
vehicles for ploughing.
Farmers have become impoverished as a result of these ill-advised decisions,
which have also had an influence on their families' health and the rural
environment of communities. If this pattern continues, the coming years will
be significant.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Unending benefits of biogas technology

The majority of rural and semi-urban areas have a negative opinion of
anaerobic digestion (also known as biogas or bio methanation). This
technology serves people from all walks of life, but it is especially beneficial
to farmers in rural areas.
Farmers with dairy animals generally have free access to animal waste
(dung), which provide input feed for the biogas digesters. Normally, these
farmers stockpile their cattle's dung as a plant fertilizer, but it contains less
nitrogen than the digested biogas slurry produced by the biogas digestion
process, which is odourless and a better fertilizer to replace chemical
fertilizers. They can use the gas to cook and heat their homes, as well as to
power generators. Farmers can save money on LPG and toxic chemical
fertilizers and pesticides by using biogas technology.
In short, biogas technology is an integrated solution for sustainable
agriculture, improving health and lowering environment degradation.

The promise of biogas technology

Biogas technology can help in the following manner:
1. Enhance bio-security for dairy animals – being fully fermented, bio-
slurry is odourless and does not attract flies, repels termites and pests
that are attracted to raw dung.
2. Provides high quality and low-cost homegrown fertilizers for sustainable
agriculture.
3. Reduce energy poverty and ensure energy security.
4. Digested biogas slurry is an excellent soil conditioner with humic acid.
5. Increase forest cover as less firewood would be needed on a daily
basis.
6. Reduce weed growth
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Why we have selected this topic as the part of our

Disciplinary Internship?

This initiative aims to turn tons of organic waste from the market, such as
rotten or thrown-away vegetables and fruits, into biogas, which may then
be used as a source of energy in a variety of ways because it is abundant,
low-tech, and burns cleaner than any fossil fuel. This will cut methane
emissions from landfills while also providing a valuable and usable by-
product fertilizer for farmers to use on their crops.
But in India, there are certain problems regarding biogas production; which
are listed out here;
1. Biogas production is only up-to the level of households and at very small
case.
2. In India, there is no such biogas production units at very large scale which
connects farmers and biogas producers except one in Surat marketing
Yard. Even they are also producing biogas for their own canteen energy
requirements.
3. And this small case production requires farmers to spend so much time for
biogas production as it requires special time for feeding out organic
waste slurry and also the cleaning out the manure from biogas
dome/digester.
4. We have inspected in our native villages that, as the time required is very
much to operate this small capacity(at household levels) biogas domes;
farmers have completely discontinued their biogas production domes.
5. Due to improper/continues changing operating conditions in natural
biogas domes at their household levels; the biogas yield will be very low.
6. What the small-scale biogas production units do, as they directly put all
types of organic wastes into digester, which won’t give us best yield of
biogas as the manure also contains certain amount of unconverted
carbon amount.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

As the part of our project, we are working to resolve the above listed out
problems faced by farmers;
1. We found out a solution for biogas production at very large scale just like
how market yards sell the farm products of farmers to the consumers. So,
if we select a town, which is centralize by some numbers of villages, as a
center of waste collection and biogas production. Then this will be just like
what marketing yards do. So, we will collect the waste at very low cost,
which will benefit the farmers to have money for waste products also. This
waste then converts into biogas and manure, which will again be sold out
to the consumers and farmers respectively at certain price.
2. The above point would benefit the farmer to have biogas and manure
and also money for their organic waste, without spending special time for
it.
3. We will segregate the waste as per their carbon content, and operate
them in different temperature range digester condition, to have a best
yield of biogas out of it.

Like small carbon content can be treated into psychrophilic(15-30 degree

C) or mesophilic(25-40 degree C) range which will not require any energy
input but will give biogas. And large carbon content feed can be treated
into thermophilic range, which will result into very high and efficient
methane conversion and biogas yield though it requires certain energy to
raise temperature to 50-60 degree Celsius. This will solve the problem of
lower biogas yield in the case of natural household biogas production.

As a result, this project will assist in reducing food waste to landfills and
changing society's perspective to see food loss as an opportunity to turn
waste into a source of energy, reduce harmful gases, and generate capital
through wastage, thus contributing a small amount to the country's
economy.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

PROCESSING OF ORGANIC WASTE INTO BIOGAS &

MANURE
1. Collection of organic wastages

1.1 DIFFERENT WAYS VEGETABLE WASTE CAN FORM

Agricultural production: losses resulting from mechanical damage and/or
leakage during harvest operations (e.g., threshing or fruit picking), post-
harvest crop sorting, etc.
Post-harvest handling and storage: including losses due to spillage and
degradation during handling, storage and transportation between farm
and distribution.
1. Processing: includes spillage and degrading losses incurred during
industrial or home processing, such as juice manufacturing, canning, and
bread baking. Losses can occur when crops are sorted out if they are
unsuitable for processing, as well as during the washing, peeling, slicing,
and boiling processes, as well as during process interruptions and spillage.
2. Distribution: loss and waste throughout the market system, such as
wholesale marketplaces, supermarkets, retailers, and wet markets.
3. Consumption: including losses and waste during consumption at the
household level.

1.2 MUNICIPAL SOLID WASTE IN VADODARA.

The total amount of solid waste generated is approximately 750 MTP, while
the amount of solid waste collected by the Municipal Corporation is 400 MTP
per capacity per day. Municipal solid waste collected from various sources
such as commercial markets, vegetable markets, slaughterhouses,
residential areas, and miscellaneous is 20, 50, 10, 410, and 10
MT/day respectively, based on the total population.
The municipal solid waste contains 50% biodegradable organic matter,
10.25% recyclable solid waste, 8% inert solid waste, 12% unclassified foil
derbies and 20% moisture content. In recyclable solid waste, paper and
plastic are the main component.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

1.3 COLLECTION OF WASTE:-

To collect the organic waste first of all we will pick 10-20% of waste from the
vegetable market direct from the vendors and we will also collect the waste
which is collected by the municipal corporation which is approx. 40 MT/day.
In collecting samples, all types of structures must be considered, such as
large A.P.M.C. (Agriculture Produce Market Committee) bulk vegetable
markets where 100 to 120 MT of vegetables are handled every day and bulk
deals are made, and medium markets where 30 to 50 MT of vegetables are
handled every day and bulk deals are made (Central Markets in Cities
where Vegetable sold & purchased between big dealers & small vendors)
and Small Markets where 8 to 10 MT vegetables sold by small vendors to end
users (Multi location scattered small markets). Wet vegetable waste (green
leaves of vegetables and unwanted portions of vegetables like roots, etc.)
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

and dry vegetable garbage (partially decomposed or one- or two-day-old

veggies) are collected separately.
At our facilities, all of this waste will be stored in a shed.

Feed collection:- Market waste is collected and transported to the

production site through transportation vehicles. Cattle waste is collected
from cowsheds and transported to the location by their caretakers.
Segregation of daily municipal garbage collected by the municipality is
used to collect daily waste.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

1.4 List of vegetable market in Vadodara

2. BIOGAS PLANT COMPONENTS

The plant comprises 5 main operating units, viz;

Operating unit 1:- Biomass Reception / Storage & Substrate / feed
Preparation
Operating unit 2:- Fermentation and recirculation duct
Operating unit 3:- Desulphurization unit
Operating unit 4:- Biogas storage tanks.
Operating unit 5:- Organic Manure Purification.
The various operating units are described in the following sections;
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Operating unit 1: Biomass Reception / Storage & Substrate / Feed

Preparation
This operation unit consisting of the process operations like feed collection,
feed storage, feed preparation, shredding of feed in fines, mixing and slurry
formation.
The organic waste collected per annum that are supplied to the operating
stage 1 are;
1. Market waste = 500 ton per year
2. Cattle manure = 200 ton per year
3. Daily feed = 2 ton approx.,

Feed Storage:- This segregated organic waste is then aggregated at biogas

production site under shed shown below where final feed material is
checked and sent for further processing.
 >
VEGETABLE
SHED
FROM MARKET

>
>
BIOGAS STORAGE TANK

CRUSHER

>
DIGESTER
DESULFURIZATION

>
Screw conveyor
>
UNIT

> >
OUTLET
TANK

>
> DEWATERING UNIT

>
MIXING TANK
WATER FOR
WATER TANK
SUPPLY
> IRRIGATION
COMPOSTING
UNIT
PUMP > MANURE
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Crushing in fines:- Here, the organic waste is crushed in fine and slurry eligible
material by using crusher. Then that crushed material is transported from
crusher to mixing tank via screw conveyor.

Water as a Source:- Water is used to make the organic fine material into
slurry which also reduces the ammonia content. Adding water would also
reduce the pumping cost of thick organic slurry and water also provides the
uniform organic content throughout the slurry fed in digester. The water is
fed from water supply tank to mixing tank via pumping it through.

Mixing Tank:- The use of mixing tank is to mix and homogenized the organic
waste and water in equal proportion and resulting into 50% concentrated
slurry. For this operation, we are using the 4-ton capacity mixer provided with
agitator and which costs around 42500rs. per unit.

We have selected 4-ton capacity only because as per our waste

assumption, it’s total 2 ton daily and equally 2 ton of water to be mixed.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Operating unit 2: Fermentation and recirculation duct

Digester:- We have selected 2 digesters with capacity of 75 m3 each,
because if we calculate total feed amount for 15 days of retention time and
of biogas volume then it will be around 60 ton of slurry and 10 m 3 for gas
volume.
The feed is digested in anaerobic condition and in mesophilic temperature
range that is 35 oC to 38 oC. The digester is working in batch operation mode
for around 15 days of time (roughly).
Here, we’ve attached and tried to explain the simple working of any
digester;

The mixed feed is then pumped into digester along with promoters we have
selected. In this digester, the anaerobic digestion reaction occurs with giving
out biogas.
The Digester is a constantly operating reactor that mixes the fermentation
substrate to produce a completely homogeneous media. Feeding is done
through a substrate pipe that runs above the fluid level in the Digester.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Feeding is a time-controlled process. The through holes in the wall for the
substrate pipe are above ground level and with this they are visible at any
time. Different types of digesters which we can use are:-

1. COMPLETE-MIX DIGESTERS
Manure is blended in complete-mix digesters, which are either
aboveground cylindrical tanks or belowground rectangular pits. The covers
are either hard or flexible. The temperature of the operational environment
can be either mesophilic or thermophilic. The complete-mix digester works
best with manure that contains 3 to 10% solids. HRT can last anywhere from
10 to 25 days.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

2. PLUG-FLOW DIGESTERS:-
A plug-flow digester is a cylindrical tank in which new manure is fed into one
end and gas and other by-products are forced out the other end. This
design can handle feedstock with 11 to 14 % solids and commonly uses hot-
water pipes to keep the temperature constant throughout the tank. More
than half of all digesters now in use in the United States use the plug-flow
system. A plug-flow digester is a long, thin, insulated, and heated tank with
a stiff or flexible lid that is built partially or completely below ground. It is often
used at temperatures in the mesophilic range. It's appropriate for livestock
operations that mechanically remove manure rather than washing it out.
Every day, manure is introduced to one end of the digester, where it
decomposes as it passes through the system as a "plug." The plug of manure
will reach the digester exit after a 15- to 30-day HRT.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

3. Fixed-film digester
A fixed-film digester is a column packed with media, such as wood chips or
small plastic rings, that supports a biofilm, which is a thin film of bacteria.
Microorganisms that produce methane grow on the media. This design can
handle feedstock with a solids content of 1 to 2% and has a retention time
of 2 to 6 days. In comparison to other digester alternatives for a given volume
of influent, the short HRT allows the use of comparatively compact digesters.
To maintain a steady upward flow, effluent having less than 1% solids is
usually recycled. Manure solids can fill the media in fixed-film digesters,
which is a disadvantage. The removal of manure solids from these digesters
lowers the amount of biogas that can be produced.

We can also use this below listed digesters:-

1. Fixed Dome Biogas Plants
2. Floating Drum Plants
3. Low-Cost Polyethylene Tube Digester
4. Balloon Plants
5. Horizontal Plants
6. Earth-pit Plants
7. Ferro-cement Plants
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

ANAEROBIC DIGESTION
1. Anaerobic digestion is very sensitive to change in pH and it is important
to maintain pH of 6.7-7.4 for healthy system.
2. The reactor used in this type of system would almost certainly need to be
operated at mesophilic temperatures (between 25° C and 40° C) to
minimize heating costs. Even if the methane yield was better under
thermophilic conditions (between 55° C and 60° C), it would very likely
not be enough to offset the cost of maintaining the reactors 15° to 30°
hotter.
3. The percent of high moisture content in the organic waste facilitates the
anaerobic digestion.
4. Methanogenic bacteria that convert acetic acid and carbon dioxide to
methane.
5. Contact between the microorganisms and substrates.
6. Solids dissolved will form scum at digester bottom.
7. Reduction of Total solid/Volatile Solids(TS/VS) content, will increase biogas
production.
8. Biogas production process is microbial in nature is affected by
temperature, pH, volatile fatty acids, microbial population and ammonia.
9. Sewage also can be converted into digested bioenergy forms.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Temperature dependency:-

1. In general, a psychrophilic climate reduces the activity of methane-

producing bacteria, resulting in less methane generation and thus lower
biogas yields.
2. Thermophilic and Mesophilic environments are best for organic waste
decomposition.
3. Warmer circumstances increase sensitivity to rapid temperature
fluctuations for microbial functionality, especially for a Thermophilic
process.
4. As temperature levels are lower in psychrophilic and Mesophilic
conditions than in Thermophilic conditions, less energy is required in the
process; but biogas yield will be very low.
5. During Thermophilic operation modes, faster bacterial treatment of the
substrate allows for higher biogas production rates, which eventually
offsets higher energy demands to maintain the temperature level.
6. Dry Fermentation:- Also known as solid state Anaerobic digestion. During
Thermophilic operation modes, faster bacterial treatment of the
substrate allows for higher biogas production rates, which eventually
offsets higher energy demands to maintain the temperature level.
7. Wet Fermentation:- Also known as liquid state anaerobic digestion.
Biogas production rate is stable, and substrate transfer is seamless. In
commercial and large-scale manufacturing units, wet digestion has
slightly better energetic and economic features.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

SELECTION AND DESIGN CRITERIA:-

1. Cost: the installation and maintenance of the multi-stage system are
more expensive than that for the one-stage system.
2. Operational conditions: Because the operational parameters in the
multiple stages are diverse, the optimal operating conditions (e.g.,
temperature and pH) for microorganisms in multi-stage systems are more
demanding than in single-stage systems. On the other hand, because the
phases are separated, the process may be better controlled.
3. Using multi-stage systems improves the stability of the anaerobic digestion
process. Changes in the organic load rate, the variability of the
biodegradable feedstock, and changes in the ambient conditions are all
extremely sensitive to the methanogenesis step. As a result, the multi-
stage system is preferable to the single-stage system, since the
management of these conditions is more efficient, and the flow of
biodegradable feedstock from the first digester to the others is more
uniform in quantity and quality.
4. Multi-stage systems perform better than single-stage systems in terms of
volatile solids removal efficiency and biogas quality improvement
(methane content).

• Decreasing the temperature from 55 to 20 0C for 1, 5, 12, and 24 h in

different reactors almost stopped the biogas production.

• Temperatures above 60 0C have an adverse impact on hydrolysis and

acidogenesis stages due to the high ammonia concentrations generated in
the process.

• It was concluded that temperature fluctuations (i.e., more than ±3 0C d

(day)−1 under Mesophilic conditions and more than ±1 0C d−1 under
thermophilic conditions) should be avoided.

• Mixing also required for uniformity and good contact of bacteria and
slurry.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Operating unit 3:- Desulphurization unit

Desulphurization of Biogas produces:-
After the production of biogas in digester from organic slurry; this gas may
contain some minor amount of hydrogen sulphide present in it. This H2S may
cause corrosive effects in transportation of biogas pipelines or cylinders and
thus it emits SO2 which also very much harmful gas to the atmosphere.
There are many techniques being implemented to reduce the H2S content
in biogas;

1. Absorption of a substance into a liquid, such as water or a caustic solution.

2. Adsorption on a solid such as iron oxide-based materials, activated
carbon or impregnated activated carbon.
3. Biological conversion by which sulfur compounds are converted into
elemental sulfur by sulphide oxidizing microorganisms with addition of
air/oxygen.
Among these technologies, adsorption with high adsorption capacity is
recognized to be an energy efficient technology for hydrogen sulfide
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

removal. Because of nanotechnology providing high surface areas of

nanomaterial, developing a Nano scale adsorbent with high adsorption
capacity becomes promising for hydrogen sulfide removal.

Above figure is showing schematic of desulphurization process of biogas

produced. In this process, one needs to use the zero valent Iron filled tubes.
The impure biogas is then bubbled through Feo solution and in this solution,
H2S will get adsorbed and this is how biogas would be free from H2S.
The outlet biogas from desulphurization unit is then stored in Balloon storage
tanks.

Operating unit 4:- Biogas storage tanks.

Balloon Storage Tank:-
Here we have used 3 balloon storage tanks which are 700 m3 capacity of
each. Each storage unit is costing us around 95000 Rs. This storage tanks can
capable enough to handle the gas at any temperature ranges from -30 to
70 oC. This storage tanks are easy to install and requires very less
maintenance. This storage tank provides us the advantages like no leakage,
highly durable, with sturdy construction, utility and efficient also.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

There are several advantages to utilizing this as a storage facility, including

the fact that it is constructed of durable rubberized fabric, which makes it
foldable and light weight, and that it is easy to adjust anyplace on the
ceiling, top or bottom. Because it is composed of cloth, it does not rust.

PROCESS UPGRADING OPTIONS:-

There are a number of different upgrading technologies on the market. The
main solutions are;
1. Water wash technique, which ‘scrubs' contaminants like CO2 and H2S
from raw biogas with high-pressure water;
2. Chemical wash, which removes pollutants using absorber liquids such as
glycol ethers or amines;
3. Pressure swing adsorption (PSA), which removes contaminants using
adsorbent beds;
4. Cryogenic upgrading, which entails compressing, cooling, and then
expanding biogas until CO2 is condensed and extracted as a liquid.
5. And membrane technology, which uses gas permeation to separate
CO2, O2 and H2 from CH4 and N2.

A batch process has minimal investment and operational costs, while

continuous systems provide greater process stability and output
predictability, as well as higher biogas yields when used appropriately.

Enhancing biogas potential using Promoters :

Supplementing anaerobic digesters with tiny quantities of trace inorganic

elements, such as iron, nickel, and cobalt, which increases bacterial activity,
is one technique of increasing biogas potential.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

The methane concentration and volume of digested biogas might be

increased with targeted nutrition addition.

Many nanoparticles (NPs) can help anaerobic digestion (AD) of organic

wastes produce more biogas. The large surface area to volume ratios of NPs
increases the number of active sites accessible, which is an important
feature for a variety of reactions. For example, NPs can aid hydrolysis by
providing a large surface area to volume ratio for microbes to bind to
organic molecules' active sites. Alternatively, NPs might function as electron
donors/acceptors and cofactors for key enzymes engaged in a variety of
bioprocesses, therefore increasing their yields.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Effect of nanoparticles (NPs) on biogas production :

NPs have been identified as a suitable low-release electron donor (Fe2+)
throughout the methanogenesis process, resulting in increased biogas
yields. These might also play a role in the production of critical microbial
enzymes required for the AD process. It benefits bacteria that are involved
in hydrolysis-acidification processes by increasing organic load, i.e.,
disturbing the cell membrane of other microbes that are more sensitive. This
process causes a significant number of proteins and celluloses to be
released, which promotes the formation of hydrolysing-acidifying
populations. The effect of NPs on the physical and chemical characteristics
of the environment around methanogenic bacteria, such as pH, ammonia
nitrogen concentration and volatile fatty acid content, might also be linked
to enhanced methane generation in the presence of NPs.
By functioning as an oxidation-reduction agent, co-enzyme, and terminal
electron acceptor, Fe is necessary for the normal development and activity
of AD bacteria. Furthermore, the inclusion of these NPs lowers the lag phase
time necessary to achieve the biogas and methane production peak. The
crucial influence of metal ions on the development of anaerobic microbial
populations, as well as a reduction in the lag time in the AD process, might
explain these gains in biogas generation.

Fe NPs are the most promising nanomaterials for increasing biogas

generation by stabilizing the AD process and promoting the growth of
helpful microbes to the AD process and the enzymes involved, among the
other NPs. It is more advantageous to use Fe nanoparticle as a promoter.
VFA (Volatile Fatty Acids) concentrations are high in the digestor before
adding the promoter, but after Fe supplementation, VFA levels are reduced
to extremely low levels, and methane generation increases, which is
desirable.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

The addition of 15 mg/L Fe NPs maintain the pH at 6.9 and enhances the
removal efficiencies of total and volatile solids by 25.6 and 10.9 %,
respectively. Iron oxide nanoparticles are used as an additive/promoter in
the system, which "feeds" the microorganisms that break down organic
waste. This addition boosts biogas generation and also converts iron
nanoparticles into harmless salt. Furthermore, as compared to conventional
methods, it provides a substantial improvement in the breakdown of organic
waste.

Fig. Effects of Fe NPs on biogas production during AD process.

Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Operating unit 5:- Organic Manure Purification:-

After the completion of the residence period for biogas generation, the
leftover slurry can be utilized as an organic fertilizer similar to manure in
agriculture. As a result, we must first eliminate the presence of water in the
digester's output slurry. Dewatering is the process of removing water, and it
is carried out in a Dewatering Unit.

The removed water can be reusable in mixing it with organic waste. And
water free manure now will be ready to package and sell.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

COST AND FINANCIALS OF THE IDEA IMPLEMENTATION

So, for the start up we required a land and some of the instruments as a start-
up cost.

INSTRUMENTS* IMAGE PRICES

PER PIECE
CRUSHER RS.43,000
(SHREDDER)

Conveyor RS.
1,00,000

Pumps RS. 10,000

Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Mixing tank RS. 42,500

Promoter (90% RS. 3000

regeneration)

Digester RS.
20,00,000
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

Storage of RS. 95,000

biogas

Compressor RS. 35,000

(rotary
compressor for
low pressure
steam )

Boiler on site RS.

1,00,000

Desulphurization RS.
7,60,000
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

INSTRUMENTS* = All the prices are taken from an online site named India mart
(https://www.indiamart.com/ )
Start Up Costs & Sources of Funds
INR
Start Up Costs unit 1,06,63,000
Land and construction 50,00,000.00
Crusher 2 86,000.00
Conveyor 2 2,00,000.00
Pumps 3 30,000.00
Mixing tank 1 43,000.00
Promoter (90% regeneration) 1 3,000.00
Digester 2 40,00,000.00
Storage of biogas 3 2,85,000.00
Compressor 3 1,05,000.00
Boiler on site 1 1,00,000.00
Desulphurization 1 7,60,000.00
Piping network 1 24,000.00
Hardware 1 24,000.00
Permits 1 3,000.00
Sources of Funds 1,06,63,000
Partners' Capital Contribution 1,06,63,000
promoter (90%
regeneration) Chart Title
compressor
0%
1%
storage of biogas
3%
pumps digester
0% 38% boiler on site
1%

mixing tank
0% Other desulphurization
8% 7%
land and
covyeor crusher
constuction
2% 1%
47%
piping network
0%

hardware
0%

permits
land and constuction crusher covyeor 0%
pumps mixing tank promoter (90% regeneration)
digester storage of biogas compressor
boiler on site desulphurization piping network
hardware permits
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

As for the source of funds, we required a loan from bank.

Financial projections

(INR) Year 1 Year 2 Year 3

REVENUE PER ANNUM [A] 1,07,08,020 1,12,43,421 1,18,05,592

Biogas price = 15 Rs per
kg, (monthly 2289 kg) 34,335 4,12,020 4,32,621 4,54,252
Organic fertilizer = 1.5rs
per kg ( monthly 572000
kg) 8,58,000 1,02,96,000 1,08,10,800 1,13,51,340
day month

VARIABLE COST [B] 7,640 2,29,200 27,50,400 35,17,920 36,93,816

Promoter cost
300 9,000 1,08,000 1,13,400 1,19,070

Maintenance 500 15,000 1,80,000 1,89,000 1,98,450

Insurance 40 1,200 14,400 15,120 15,876

Utility 1,800 54,000 6,48,000 6,80,400 7,14,420

Transport cost
5,000 1,50,000 18,00,000 18,90,000 19,84,500
Furniture cost
50,000 6,00,000 6,30,000 6,61,500
CONTRIBUTION PER
ANNUM [C] = [A-B] 79,57,620 77,25,501 81,11,776
contribution margin 74% 69% 69%

FIXED COSTS 13,86,000 14,55,300 15,28,065

Salary (7 person) 2,450 73,500 8,82,000 9,26,100 9,72,405

Skilled labour (2 person) 1,400 42,000 5,04,000 5,29,200 5,55,660

Cash Flow Before Tax 65,71,620 62,70,201 65,83,711

Cash Flow After Tax (Tax
Rate is assumed at 26%) 48,62,999 46,39,949 48,71,946
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

BREAK EVEN ANALYSIS:-

Break even analaysis

Fixed cost 13,86,000 14,55,300 15,28,065

Contribution margin 74% 69% 69%
Sales to achieve
Breakeven 18,65,045 21,17,992 22,23,892

PAYBACK CALCULATIONS:-

Payback Calculation Year

- 1 2 3

Cash Flows (1,06,63,000) 48,62,999 46,39,949 48,71,946

Cumulative Cash Flows (1,06,63,000) (58,00,001) (11,60,052) 37,11,894

Intermediate Step - - 3

Payback in years - - 2.8

So, we get our payback in 2.8 years.

Disciplinary Internship Group-1 Roll no. (24,26,36,41)

CONCLUSION:-
The production and use of biogas for domestic purposes can drastically
reduce the depletion of natural resources like forests, which are otherwise
the prominent and traditional source of energy for cooking and lighting. It
removes dependence on forest and enhances greeneries leading to
improved environment.
The use of biogas digesters as replacements for single resident septic systems
is not eco-nomically viable due to high costs and low benefits. Regardless,
biogas digester technology has successfully been used on a municipal,
agricultural, and domestic scale through- out the world. Large scale biogas
generation through anaerobic digestion is viable eco- nomically, producing
enough biogas to lower energy costs and providing a valuable source of
fertilizer for agriculture. Small scale use is only viable in developing third world
countries, where fuel sources are scarce and waste management systems
are needed to prevent harm to human and environmental health. Besides
cheap alternative sources of energy, a need for more advanced and
proven commercial biogas systems, and regulation barriers, the amount of
waste generated by a single household does not have a large enough
nutrient potential to produce enough biogas in a digester to be eco-
nomically viable.
Conventional septic systems, if installed and maintained correctly, can
successfully replace failing systems. Improved education, regulation,
management, and funding for septic system programs are needed to
guarantee working systems and thus preserve environmental and human
health.
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

REFERENCES
1. Important Source:- https://www.e-ducation.psu.edu/egee439/node/727
2. file:///D:/Study%20Materials/Collage/6th%20Semester/Internship-
6th%20Semester/Materials/Operating%20conditions%20and%20design%20
criteria.pdf For Operating parameters, The Conditions Inside the Reactor
and certain feed composition to follow.
3. www.irjet.net, VERMICOMPOSTING OF VEGETABLE MARKET WASTE USING
EUDRILUS EUGENIAE EARTHWORMS AT VADODARA CITY
4. SOLID WASTE MANAGEMENT OF VADODARA CITY- FEASIBILITY STUDY”
5. https://www.researchgate.net/publication/292606637_Catalytic_Effect_of
_Tungsten_on_Anaerobic_Digestion_Process_for_Biogas_Production_from_
Fruit_and_Vegetable_Wastes
6. https://www.ijemr.net/DOC/AStudyOnTheInfluencingParametersOnBiogas
ProductionFromJackFruitWasteFeedstock(10-13).pdf
7. https://www.extension.uidaho.edu/publishing/pdf/CIS/CIS1215.pdf
8. https://www.mdpi.com/2227-9717/8/10/1224
9. https://www.birmingham.ac.uk/Documents/college-
eps/civil/research/biogas-quantity-quality-anaerobic-digestion.pdf
10. https://www.e-education.psu.edu/egee439/node/727
11. https://www.researchgate.net/publication/292606637_Catalytic_Effect_of
_Tungsten_on_Anaerobic_Digestion_Process_for_Biogas_Production_from_
Fruit_and_Vegetable_Wastes
12. https://www.ijemr.net/DOC/AStudyOnTheInfluencingParametersOnBiogas
ProductionFromJackFruitWasteFeedstock(10-13).pdf
13. https://www.biogasworld.com/news/reduce-the-costs-of-biogas-plant/
14. https://www.renergon-biogas.com/en/biogas-calculator
15. https://www.epa.gov/agstar/how-does-anaerobic-digestion-work
16. file:///C:/Users/RAJ%20MEHTA/Downloads/ChemEngineering-03-00076-
v2.pdf
17. https://www.semanticscholar.org/paper/Impact-of-iron-nanoparticles-on-
biogas-production-Abdelwahab-
Mohanty/3e41376ca2f2047d8ede10d750fdd95f50de8aeb
18. https://doi.org/10.1016/j.biortech.2018.05.050
19. https://www.iaeng.org/publication/WCE2016/WCE2016_pp784-789.pdf
20. https://link.springer.com/article/10.1007/s13399-020-00985-7
Disciplinary Internship Group-1 Roll no. (24,26,36,41)

21. https://doi.org/10.1016/j.renene.2015.10.053
22. https://www.sciencedaily.com/releases/2014/10/141022103350.htm
23. https://patentimages.storage.googleapis.com/cf/dc/4d/fe4cd4666d0bc
5/US20140017753A1.pdf
24. https://dir.indiamart.com/search.mp?ss=iron+nanoparticles&src=as-
context%3Akwd%3Dironnan%3Apos%3D1%3Acat%3D132%3Amcat%3D161
744&prdsrc=1&mcatid=161744&catid=132
25. https://dir.indiamart.com/impcat/agricultural-shredder.html?biz=10
26. https://www.indiamart.com/proddetail/700-m3-biogas-balloon-
2202870862.html
27. https://www.indiamart.com/proddetail/commercial-biogas-plant-
17312517148.html
28. https://m.indiamart.com/proddetail/tank-mounted-mixer-7877701173.html
29. https://dir.indiamart.com/impcat/inclined-screw-conveyor.html
30. https://manurefertilizermachine.com/cow-dung-dewatering-machine/
Disciplinary Internship Group-1 Roll no. (24,26,36,41)
Disciplinary Internship Group-1 Roll no. (24,26,36,41)