DESIGN, CONSTRUCTION AND LEAKAGE DETECTION OF DOME-TYPE BIOGAS

DIGESTER AT KILANKWA II, KWALI, ABUJA.

*Ozigis, I. Ibrahim and Oloche, B.O.

Department of Mechanical Engineering

University of Abuja, Abuja.

*Idris.ozigi@gmail.com, 08062984934; profoloche@yahoo.com, 08023784402

*corresponding author

ABSTRACT

This work presents design, construction and leakage detection of dome-type biogas digester. The
designed biogas digester is rated at 10 m3 capacity with only the dome vault projecting above ground
surface as well as inlet, gas outlet pipe and slurry discharge openings. The construction began by
excavation of a pit of 3.3 m diameter and depth of 2.0 m. The biogas digester foundation, cylindrical wall
and dome vault were about 10 cm thick and made of high strength concrete at ratio of 1 kg cement: 0.009
kg sharp sand: 0.008 kg aggregate of 12 mm size. The finishing work included plastering the interior of
the biogas digester to cover over break and prevent hire cracks. The designed and constructed biogas
digester was pressure tested by using liquid manometer to detect leakage(s) prior to commissioning. The
pressure test set-up consists of the constructed concrete biogas digester, bicycle stand pump and plastic
piping system. The pressure gauge level difference of 48 cm was obtained, which later dropped to less
than 20 cm indicating presence of leakage in the biogas digester. Cracks in the biogas digester were
located after a painstaking and careful examination at the cylindrical wall and dome top, which were
scaled and sealed with sodium silicate and wet cement. The pressure test was conducted again and yielded
pressure gauge level difference of 60 cm, without dropping for over 20 minutes, which implies no leakage
in the biogas digester.

Key words: Biogas, Design, Digester, Leakage, Pressure.

1
 1. INTRODUCTION

Biogas digester power plant with biogas delivery capacity in the range of 5 m3/day to 50 m3/day

is on the increase with over 20 in operation across Nigeria. However, the utilization of biogas for cooking

and lighting has varying success due to challenges such as design and construction of the biogas digester

as well as leakages from the constructed digester among others (Usack, et al, 2012?). The design of

biogas digester entails detailed structure, plan and drawing of component parts that can be assembled to

function as a unit with little or no failure (Persson, et al, 1979). The house hold biogas digester has strong

appeal to rural environment (Rao and Parulekar, 2004).

The materials for construction of biogas digester utilize metal, wood, concrete, plastic and rubber

either to build completely or contribute to construction of laboratory, pilot or commercial biogas digester

(Ezekoye and Okoye, 2006; KENDBIP, 2009). Therefore, the design approach in this work by using

mainly fundamental geometric equations will enable craftsmen to undertake construction of biogas

digester with high degree of reliability.

Leakage detection in biogas digester requires careful probing, search, and examination to find

cracks including hire cracks and to provide remedies to arrest the source of leakage. Failure of anaerobic

digester has several consequences such as financial loss; undesirable flow of gas out of the digester can

cause environmental pollution and explosion (EA, 2013).

Load and stress analysis for the construction of the concrete digester beneath the ground surface

were not considered in this work but are necessary in high water table environment, commercial and large

sized biogas digester for heat and electricity generation (Sasse, 1988).

The dome-type biogas digester plant is located at Kilankwa II, Kwali Area Council, Federal

Capital Territory, Abuja. Kilankwa II is a rural settlement with active cassava farming and garri

processing as well as cattle rearing and has several functional water supply boreholes. The biogas digester

was built in an open level surface, hard clay soil, low water table and for the chief of Kilankwa II.

2
 The aim of this work is to design and construct dome-type biogas digester. Secondly, to perform

pressure test to detect presence of any crack prior to commissioning of biogas digester.

2. METHODOLOGY

The methodology consists of design of the component parts of dome-type biogas digester, construction

procedures and pressure leakage detection technique.

2.1 Design of Dome-Type Biogas Digester Plant

The biogas digester plant consists of the digester in which fermentation of organic matter with water

takes place and produces biogas and spent slurry.

2.1.1 Design of biogas digester

The design of dome-type biogas digester was based on fundamental geometric formulas adaptable to rural

environment with technicians and masons.

i. Gas requirement

The biogas digester was built for a household of ten people using one kitchen and a large parlour in a

building.

Quantity of biogas required for cooking per person (gc) = 0.227 m3 of biogas (Otim, et al, 2007?)

For ten people

g10 0.227 10 2.27 m 3 bio gas

Quantity of biogas for one point of lighting a biogas lamp (gl) = 0.135 m3 of biogas (Otim, et al, 2007?)

Total biogas required for cooking and lighting

g T 2.27 0.135 2.405 m 3 bio gas

ii. Amount of cattle dung required

1 kg of fresh cattle dung manure produces (q1) = 0.04 m3 of biogas (Desal et al, 2013).

The required amount of cattle dung:

3
 gT
qd (1)
q1

Substituting values for qT and q1into eqn (1):

2.405
qd 60.125 kg of cattle dung
0.04

qd was taken as 65 kg to compensates for losses in the entire biogas digester plant.

iii. The volume capacity of biogas digester

The volume capacity of biogas digester was determined using the following relation (Desal et al, 2013):

mt
Vd (2)

Where

m is the sum quantity of cattle dung (qd) and water (qw) per day at ratio of 1:1 (Sambo, 2008?)

m qd q w 65 65 130 kg / day

t is retention days for the slurry= 30 days (Rao and Parulekar, 2004)

is bulk density = 400kg/m3 (Thirion, et al, 1998?)

Substituting values for m, t, and into eqn (2):

130 30
Vd 9.75 m 3 10 m 3
400

iv. Dimensions of the biogas digester

The cylindrical shape of the biogas digester was used to determine the dimensions as follows:

D 2 h
Vd (3)
4

Where D is diameter of the digester

h is height of the digester

D = 1.2 -2 hed (Desal et al, 2013)

hed is excavation depth for the biogas digester

D was selected be slightly above average of the range

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D = 1.65 hed (4)

Substituting values for Vd, and D into eqn (3):

(1.65h) 2 h
10
4

h 3 4.677

h 1 .6 m

To accommodate foundation that carriers the weight of digester and slurry, resulting in an increase of x =

0.3 m in height. This increase in height for depth of excavation also accommodate slope on foundation

required for slurry discharge.

The excavation depth for biogas digester:

hed h x (5)

Substituting values for h and x into eqn (5):

hed 1.6 0.3 1.9 2.0 m

Therefore, the biogas diameter:

D 1.65hed (6)

Substituting values for hed into eqn (6):

D 1.65 2.0 3.3 m

The thickness of the biogas digester concrete structure was taken as 10 cm, which means the effective

diameter of biogas digester is 3.3 - 0.2 = 3.1 m

2.1.2 Design of the slurry discharge chamber

The slurry discharge chamber has trapezoid shape with narrow width near the manhole and increased

outward. The capacity of the slurry discharge chamber is 18% capacity of biogas digester on conditions

such as a = b/2, l = 0.85b (Desal et al, 2013)

The capacity of trapezoid slurry discharge chamber:

5
 1
Vs 18%Vd (a b)(l h) (7)
2

Where a is narrow width

b is wider width

l is perpendicular distance between the two widths

h is height of the biogas digester

Substituting values for h, Vd, a, b and into eqn (7):

1
1.8 (0.5b b)(0.85b 1.6)
2

b 2 1.765

b 1.3 m, a 0.65 0.7 m, l 1.1 m

2.1.3 Design of gas storage dome vault

The dome vault is upper half of hemisphere with capacity expressed as follows (Sasse, 1988):

hgs
Vgs hgs (r
2
) (8)
3

Where hgs is height of dome from the crown of the digester

r is radius of the biogas digester

Vgs is 30% Vd (Sasse, 1988).

Substituting values for Vgs, Vd, and r to obtain hgs in eqn (8):

hgs
3 3.142hgs (1.55
2
)
3

1.047hgs 4.87hgs 3 0
3 2

Using equation solver, hgs = 0.87 m

2.1.4 Design of inlet feed pipe

Empirical relations were used to determine the dimensions of feed pipe into the biogas digester.

These relations are as follows (Otim, et al, 2007?):

6
 rp 0.14r

l p 2hgs

t p 0.01r (9)

Where rp is radius of feed pipe

lp is length of feed pipe

tp is thickness of feed pipe

Substituting values for hgs and r into eqn (9):

rp 0.14 1.55 0.217 m

l p 2 0.87 1.74 m

t p 0.01 1.55 15.5 mm

2.1.5 Design of gas outlet pipe

A stainless steel pipe of internal diameter of 10 mm, 3 mm thick and 25 cm long was selected

to connect the gas storage dome vault for transmission of biogas to the gas filter, biogas cooker and lamp.

2.1.6 Design of manhole, manhole and feed pipe covers

A manhole of dimensions of 60 cm by 60 cm by 10 cm thick was selected for the opening

between biogas digester and slurry discharge chamber. A force fit wooden block of 60 cm by 60 cm by

10 cm with flanges and wooden block of 4 cm thick and of diameter 43 cm with flanges were

constructed for closure of manhole and feed pipe openings inside the digester during pressure testing.

2.2 Construction

The 3.3 m circle was marked out using measuring tape and stake on surface of ground at the

location. The pit of 3.3 m diameter was dug to the depth of 2.0 m (Fig.1). Similarly, the slurry discharge

chamber with dimensions of wider and narrow widths of 1.3 m and 0.7 m were marked out with

perpendicular distance of 1.1 m between two widths and dug to a depth of 2.0 m. High strength concrete

(HSC) mixture of 1 bag of cement, 1 wheel barrow of sand, 1.5 wheel barrows of gravel and water

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 0.1 m

1.1 m
1.55 m

0.7 m 1.3 m

(a)

Feed inlet pipe Gas outlet pipe

Dome vault

0.8 m

Concrete wall

Biogas digester Slurry discharge

2.0 m chamber

Manhole

Foundation
3.3 m

(b)
Fig.1: (a) Plan (b) Section of dome-type biogas digester at Kilankwa II, Kwali, Abuja

(at ratio of 1 kg cement: 0.009 kg sharp sand: 0.008 kg aggregate of 12 mm size) were produced and

spread at bottom of dug pit as foundation to support the load of filled-up biogas digester. The foundation

floor was slightly sloped from 30 cm at feed inlet side to 25 cm at the far end of slurry discharge

chamber. A rod of 5 mm thick was formed into rectangular shape rings of 6 cm by 10 cm. The

rectangular rings had its 5 cm inserted into wet concrete foundation floor at a spacing of 20 cm round the

circle of the digester. The remaining 5 cm of the rectangular rings project out to be covered by concrete

wall for binding the concrete wall and foundation of biogas digester. The formwork for the concrete wall

was constructed by use of 8 ft by 4 ft by 2 mm thick mild steel plate and 12 mm steel rod as well as

binding wire. The rods were cut to form a circle slightly less than diameter of the biogas digester (Fig.

2). The sheet metal formwork was set to create a gap of 10 cm from the wall of biogas digester pit and

8
held firmly together and to the projected rectangular rings on the foundation floor (Fig.3). The high

strength concrete mixture was produced and poured into the cavity created by the formwork to the dug

digester pit to form the concrete wall of the biogas digester except at the manhole. The slurry discharge

chamber of three walls was built and connected through the manhole of the biogas digester.

Foundation Formwork Cavity for concrete wall

Fig.2: Cylindrical with slurry chamber dug pit Fig.3: Digester wall formwork

The dome vault was constructed by installation of a wood guide post located at bottom centre of biogas

digester. Strong timbers and planks to withstand weight of concrete for dome construction were used.

Wood pillars were also installed round the circle of the biogas digester. Wood structure made of 2 in by

3 in plank in the form of mesh network was constructed to form the dome vault over the digester (Fig.4).

The inlet feed and gas outlet pipes were placed and held by binding wire on the wood mesh network

structure. The rubber feed pipe was made to slope with its bottom end held at 60 cm away from the

bottom of the digester. Ceiling board was nailed over the mesh network structure except at the feed inlet

and gas outlet pipe openings that are not covered (Fig.5). Parting sand and clay of 4 cm thick was spread

9
Guide post Mesh network Feed pipe Ceiling board Slurry chamber Block work

Fig.5: Dome vault covered with ceiling board

Fig.4: Wood mesh network for dome vault

The inlet feed and gas outlet pipes were placed and held by binding wire on the wood mesh network

structure. The rubber feed pipe was made to slope with its bottom end held at 60 cm away from the

bottom of the digester. Ceiling board was nailed over the mesh network structure except at the feed inlet

and gas outlet pipe openings that are not covered (Fig.5). Parting sand and clay of 4 cm thick was spread

on top of the ceiling board (Fig.6). The high strength concrete (HSC) mixture was produced and spread

up to 10 cm to form the dome vault concrete thickness. Concrete casting started from the digester crown

to cover the base of the dome vault and spread to the top of the dome (Fig.7). About 200 litres of water

was sprayed gently on top of the dome at morning and evening each day for five days. Blue leather was

spread on top of the dome vault after pouring water each day. About 200 liters of water was poured

inside the digester each day for five days, to prevent crack and ensure proper setting of the concrete

structure. On the sixth day, the wood mesh network structure, guide post and pillars were removed from

inside the digester. The adhered parting sand was scaled off. The first plastering of the interior walls and

roof of the digester was with 1 bag of cement: 1 wheel barrow of sand to refill over break and cracks.

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Parting sand Iron rod Feed inlet pipe Concrete Dome vault Outlet pipe Leather Feed pipe

Fig.6: Dome vault Construction with concrete Fig.7: Completed dome vault on top of digester

2.3 Leakage Detection

The wooden blocks of 60 cm by 60 cm by 10 cm thick and wooden diameter of 43 cm by 4 cm thick

were force fitted into the manhole and bottom of feed pipe inside the digester by two technicians. Wet

clay and cement were used separately to seal the openings and any over break and likely source of air

leakage inside the digester. Two bicycle pumps were connected together using plastic pipe and valves.

The pipe system has second T-junction valve in which one line runs to form the liquid manometer

(Fig.8). Liquid column in a u-tube manometer with one open to atmosphere while the other pipe was

connected to the gas out let pipe on top of the dome vault. On completion of the piping connections,

simultaneous pumping of the two pumps was started to pressurize the digester for a period of about 20

minutes. To measure the pressure, the pumping process was stopped and valves 1 and 2 were closed,

while valve 3 remained open to read the pressurized biogas digester. A fast decrease of pressure on the

column indicates presence of leakage in the digester (Clemens, et al, 2012).

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 Liquid manometer
Valve 3
Stake
Open to atmosphere
Water Plastic pipe line

Manifold Valve 1

Bicycle
stand
Gas outlet pipe pump 1

Bicycle
Presurized
stand
biogas Valve 2 pump 2
digester

Wood to cover manhole

Wood to support and cover feed pipe
Fig.8: Pressure test rig for leakage detection in dome-type biogas digester

3. RESULTS AND DISCUSSION

The results and discussion presented which includes tables and figures were on design, construction

procedures and leakage detection of a dome-type biogas digester plant.

3.1 Design of Dome-Type Biogas Digester

The design began from site investigations which include location as well as the design of component

parts of the biogas digester plant. The technical data for the biogas digester plant are as shown in Table 1.

Table 1: Technical Data for the Dome-Type Biogas Digester Plant

S/N Item
1 Type of feed
2 Source of feed
3 Source of water
4 Soil type
5 Location
6 Materials of construction
7 Gas consumption/day
8 Cattle dung required/day
9 Water required/day
10 Dung slurry bulk density
Description
Mainly cattle dung
Cattle rearing community
Functional boreholes
Hard clay, no rock, level land, low water table
Chief of Kilankwa IIs house, Kilankwa II.
HSC mixture of cement, sand, gravel and water
2.405 m3
65 kg
65 kg
400 kg/m3

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 The component parts of the biogas digester are the digester, slurry discharge chamber, gas storage

dome vault, feed inlet pipe and gas outlet pipe with specifications as shown in Table 2. The plan and

section drawing of the biogas digester are as presented in Fig.1 The above mentioned component parts

described in this work are slightly different to component parts of biogas unit such as reception tank,

digester, gas holder and over flow tank described by Samer (2012) and RCSD (2008). However, the

sizing of biogas unit depended on similar factors such as gas requirement, amount of waste among other

factors. In sizing of biogas digester, loading rate and detention are most important factors (John Fry,

1974). The availability of adequate feed and water for initial loading which is multiplication of daily

loading for period of retention of 30 days was used in this work. This biogas digester will also require

thereafter, weekly loading of feed of about 65 kg and slurry withdrawal twice monthly. Although, design

approach to determine dimensions of the shape of digester may differ, all uses volume of gas required,

loading and plant capacity (Otim, et al, 2007?). The differences arose due to use of proportion by the later

author while this work uses mainly fundamental geometrical formulas.

3.2 Construction Procedures for the Biogas Digester Plant

The assessment include layout for the facility which implies location of the biogas digester,

proximity to the kitchen, open to atmosphere and direct sunlight, hard clay with low water table and

clearance of more than 10 m from large trees (Samer, 2012). This site is assumed to have adequate

bearing stress capable to prevent collapse of concrete structures beneath the ground surface where earth

and water pressure increases with depth (Sasse, 1988). However, commercial biogas digester will

incorporate load and stress analysis for concrete structure sited in clay (Sasse, 1988). This site

investigation and location of biogas digester is similar to site selection procedure for biogas digester in

Rajput (2011) and Bajgain (1994). The construction materials are mainly HSC mixture of cement, sharp-

sand, gravel, 6 inches blocks and water in this work and do not include bricks among others (Bajgain,

1994). After 1st plastering, a day later, the 2nd plastering of walls and roof in interior of the digester was

done with mixture of 1bag of cement: 1 cement bag of sand. The last process was followed a day later, by

13
brush finishing using wet cement, twice round the walls and roof to seal any crack including hire cracks.

These sequences of plastering and finishing are slightly different due to materials of construction to the

sequence described by KENBIP (2009). BEE (2004) reported a biogas digester at size of 400 m3 for

electricity generation, which is more complex than a digester of 10 m3 for house hold use in this work.

Table 2: Specifications of component parts of the Dome-Type Biogas Digester

S/N Component parts Description Value

1 Biogas digester
Shape Cylindrical
Volume capacity 10 m3
Excavation diameter 3.30 m
Excavation height 2.0 m
Effective diameter 3.1 m
Effective height 1.6 m
2 Slurry discharge chamber
Shape Trapezoid
Volume 1.8 m3
Perpendicular width 1.1 m
Short width 0.7 m
Long width 1.3 m
3 Gas storage dome vault
Shape Domed
Volume 3.0 m3
Radius 1.55
Height 0.87 m
4 Feed inlet pipe
Shape Cylindrical
Material Rubber
Volume 0.26 m3
Radius 0.217 m
Length 1.74 m
Thickness 0.014 m
5 Gas outlet pipe
Shape Cylindrical
Material Metal
Internal diameter 10 mm
Wall thickness 3 mm
Length 25 cm
6 Manhole
Shape Rectangular (approx)
Length 60 cm
Breadth 60 cm
Thickness 10 cm

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 3.3 Leakage Detection Prior to Commissioning of Dome-Type Biogas Digester

The pressure guage level difference of 48 cm was obtained, which later dropped to less than 20 cm

indicating presence of leakage in the biogas digester. Cracks in the biogas digester were located after a

painstaking and careful examination at the cylindrical wall and dome top, which were scaled and sealed

with sodium silicate and wet cement (EA, 2013). The pressure test was conducted again and yielded

pressure guage level difference of 60 cm, without dropping for over 20 minutes, which implies no

leakage. Pressure testing rig for detection of gas leakages at the upstream of biogas digester as described

by KENBIP (2009) is different to pressure testing rig at downstream of biogas digester in this work.

Leakage detection technique may be regular on monthly basis as described by Persson, et al, (2012).

Leakage detection is necessary to avoid collapse of structure and emission of pollution on the environment

(EA, 2013). In this work, leakage detection was carried prior to commissioning the biogas digester.

Leakage detection is also to avoid cost of removing initial loading of feed and water from the digester

(Usack, et al, 2012?). Interior pressure monitoring of pressurized biogas digester in this work is different

from smoke test and hydraulic testing to detect gas and water leakages, respectively (RCSD, 2008). A

reduction of water level after a period indicates presence of leakage while leakage detection using smoke

test is mainly suitable for big leakages shown as visible smoke outside of digester (Clemens, et al, 2012).

4.0 CONCLUSIONS

The design, construction and leakage detection of dome-type biogas digester were investigated.

From the work carried out, the following main conclusions were drawn:

1. A cylindrical biogas digester was designed and constructed with rated capacity of 10 m3 to utilize 65

kg of cattle dung and water each day and to provide 2.405 m3 of biogas for firing in biogas cooker

and lighting of biogas lamp.

2. The component parts of the dome-type biogas digester such as the digester, gas storage dome vault,

slurry discharge chamber, feed inlet and gas outlet pipes were designed and constructed.

15
3. Pressure gauge level difference of 60 cm was obtained from the liquid manometer pressure test rig

for over 20 minutes without any fast pressure decrease.

ACKNOWLEDGEMENT

We appreciate the training in construction and assemblage of biogas facility conducted by Chinese

South-South Corporation Technicians and sponsored by West Africa Agric. Productivity Programme.

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