BIOGAS TECHNOLOGY

FOR
RURAL APPLICATIONS
AND
INDUSTRIAL WASTEWATER TREATMENT WITH A VIEW
TO ENERGY RECOVERY

Introduction: Properties of biogas Justification for rural & other applications.

Feedstock for biogas: Aqueous wastes containing biodegradable organic matter,
animal residues
Microbial and biochemical aspects
Operating parameters for biogas production.
Kinetics and mechanism
Dry and wet fermentation.
Digesters for rural application
High rate digesters for industrial waste water treatment.

TEXT BOOKS AND REFERENCES

1. Biotechnology Volume 8, H. J. Rehm and G. Reed, 1986, Chapter 5,

‘Biomethanation Processes.’ Pp 207-267

2. Khandelwal K. C. and Mahdi, “Bio-gas Technology”, Tata McGraw-Hill publ.

Co. Ltd., New Delhi, 1986.

3. K. M. Mital, Non-conventional Energy Systems, (1997), A P H Wheeler

Publishing, N. Delhi.

4. K. M. Mital, Biogas Systems: Principles and Applications, (1996) New Age

International Publishers (p) Ltd, N. Delhi.

5. Nijaguna, B.T., Biogas Technology, New Age International publishers (P) Ltd.,
2002

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References:
1. Effluent Treatment & Disposal: I Ch. E, U.K., Symposium Series No 96, 1986,
P 137-147, Application of anaerobic biotechnology to waste treatment and energy
production, Anderson & Saw.

2. ‘Anaerobic Rotating Biological Drum Contactor for the Treatment of Dairy Wastes’,
S. Satyanarayana, K. Thackar, S.N.Kaul, S.D.Badrinath and N.G. Swarnkar, Indian
Chemical Engineer, vol 29, No 3, July-Sept, 1987

3. Energy Environment Monitor,12(1),45-51,‘Biomethanation Technologies in Industrial

Water Pollution Control’ A.Gangagni Rao, Pune.

4. ‘Biogas production from sugar mill sludge by anaerobic digestion and evaluation of
bio-kinetic coefficients’, Tharamani. P, and Elangovan. R. Indian journal of
Environmental protection, 20, (10), 745-748, 2001.

5. ‘Biogas Production Technology: An Indian Perspective’, B.Nagamani and K.

Ramasamy (TNAU), Current Science, Vol7, No1, pp 44-55 10th July, 1999

INTRODUCTION:
Production of a combustible gas by anaerobic digestion of aqueous organic matter
by mixed bacterial culture involving methane producers is called ‘biomethanation’ and
the product is called ‘biogas’
PROPERTIES OF BIOGAS:
Composition: 60 to 70 per cent Methane, 30 to 40 per cent carbon dioxide, traces of
hydrogen sulfide, ammonia and water vapor.
It is about 20% lighter than air (density is about 1.2 gm/liter).
Ignition temperature is between 650 and 750 C.
Calorific value is 18.7 to 26 MJ/ m3 (500 to 700 Btu/ ft3.)
Calorific value without CO2: is between 33.5 to35.3 MJ/ m3
Explosion limit: 5 to 14 % in air.
Removal of CO2: Scrubbing with limewater or ethanol amine solution.
Removal of H2S: Adsorption on a bed of iron sponge and wood shavings.
Air to Methane ratio for complete combustion is 10 to 1 by volume.
One cubic meter of biogas is equivalent to 1.613 liter kerosene or 2.309 kg of LPG or
0.213 kHz electricity.
Pressure & Temperature needed to liquefy: Biogas needs 500 psi, at –83 oC & LPG
Needs 160 psi, at ambient temperature.

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Applications and Usage of biogas Additional appliance needed
Cooking fuel Design of Burner
Lighting Fuel Mantle lamp
As fuel for I. C. Engines Purification and dual fuel mode
To run a water pump or a generator
(Refer:Chapter11, ‘Biogas Systems’— K. M. Mital)

2.1.2 WHY Biomethanation in villages?

• COOKING
• LIGHTING
• FUEL FOR
DUNG BIOGAS KILN
PLANT BIOGAS • FURNACE
WATER ETC.

PURIFY • I. C. ENGINE +
PUMP OR
TO I. C. ENGINE +
COMPOST PIT GENERATOR
(MANURE)

• ENERGY RECOVERY, CLEAN BURNING

• SUBSTITUTES FUELWOOD & DUNG CAKE AS RURAL FUEL

• HYGIENIC DISPOSAL OF ANIMAL WASTE

• CONSERVATION OF MANURE VALUE

• MILD CONDITIONS: 30o C, pH 6.8-7.2, FEED ONCE A DAY

• BURNER, MANTLE LAMP AVAILABLE; EASY GAS PURIFICATION

FEASIBLE

• FOR RURAL FARM OR FAMILY SIZE PLANT, SUBSIDY AVAILABLE.

• DUAL FUEL ENGINE CAN PUMP WATER, GENERATE POWER

• BIOGAS TECHNOLOGY: SIMPLE & INDIGINOUS

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Commonly Used Feed for Biomethanation:

• WET ORGANIC WASTE AS FEED FOR BIOGAS PLANT

• ANIMAL WASTES: Excreta of cow, pig, chicken etc
• MANURE, SLUDGE: Canteen and food processing waste, sewage
• MUNICIPAL SOLID WASTE: After separation of non-degradable
• WASTE STARCH & SUGAR SOLUTIONS: Fruit processing, brewery, press
mud from sugar factory etc
• OTHER INDUSTRIAL EFFLUENTS (B O D): pulp factory waste liquor, leather
industry waste, coal washery wastewater etc.

2.2 MICROBIOLOGIAL ASPECTS OF BIOMETHANATION

The biomethanation of organic matter in water is carried out in absence of dissolved

oxygen and oxygenated compounds like nitrate and sulphate. The mixed groups of
bacteria are naturally occurring in the cow dung slurry and decomposition in three stages
finally produces a gas mixture of methane and carbon dioxide. Initially larger molecules
are hydrolysed to simpler molecules which in turn are decomposed to volatile fatty acids
like acetic acid, propionic acid etc. by a second set of bacteria. Methane forming bacteria
can convert acetic acid, hydrogen and carbon dioxde and produce methane.

HYDRLYSIS OF BIOPOLYMERS TO MONOMERS

CONVERSION OF SUGARS, AMINO ACIDS, FATTY ACIDS TO HYDROGEN,

CO2, AMMONIA AND ACETIC, PROPIONICAND BUTIRIC ACIDS

CONVERSION OF H2, CO2, ACETIC ACID TO CH4 AND CO2 MIXTURE

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2.3 Operating parameters affecting the biogas production:

1. Temperature is an important parameter. Mesophilic methane producing bacteria

grow at an optimum temperature of 35oC the gas production rate drops very much
when temperature is less than 10oC.
2. pH range of the waste water should be in the range of 6.8 to 7.8 as excess acid
state hampers the methane producing bacteria and the balance of nutrients is
disturbed.
3. Ratio of carbon to nitrogen in the waste water influent or C/N ratio is 30:1 and if
nitrogen content in ammoniacal form is less the bacterial growth is affected and
the process slows down.
4. Proportion of solids to water: This is found to be not more than 10 per cent for
optimum operation of digester to ensure sufficient decomposition of ‘ volatile
solids’ and rate of production of gas.
5. Retention time: The ratio of volume of slurry in the digester to the volume fed
into and removed from it per day is called retention time. Thus a 20 liter digester
is fed at 4 liters per day so that the volume of digester is constant the retention
time is 5 days. The required retention time is normally 30 days for mesophilic
(25-35oC) conditions.
6. Volumetric organic loading rate: This can be expressed as kg Vs per volume per
day based on the % weight of organic matter added each day to the digester
volume.
Digester loading rate %= (Per cent of organic matter in feed)/(Retention Time)
Loading rate range is 0.7 to25 kg VS/ m3 / Day

2.4. KINETICS OF ANAEROBIC FERMENTATION (Reference: Mital, pp 36-39):

Rate of substrate Utilization,

rs = Qmax * (Sx)/ (K+S) ---(1)
Where S is limiting substrate concentration
K is half life constant
X is concentration of bacterial cells
Qmax is maximum substrate utilization rate

For low substrate concentration, this equation is valid. For high substrate concentration, it
becomes as follows:
rs = Qmax*x ----(2)
The above model known as Monod model has limitations. For complex substrates, kinetic
parameters cannot be obtained for the entire concentration range.

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Chen and Hashimoto, Biotechnology Bio-engineering Symposium 8, (1978) p 269-
282 and Biotechnology Bioengineering (1982) 24: 9-23

Volumetric methane rate in cubic meter gas per cubic meter of digester volume
V = (Bo So / HRT)[1- K / (HRT*µm-1+K)]
Bo = Ultimate methane yield in cubic meters methane (Varies from 0.2 to 0.5)
So = Influent volatile solids concentration in kgVS/m3
(Loading rate range = 0.7 to 25 kg VS/m3 d)
HRT = Hydraulic retention time in days
0.06 So
K = Dimensionless kinetic parameter, for cattle dung, K= 0.8+ 0.0016e
µm = Maximum specific growth rate of the microorganism in day-1

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 RURAL DIGESTERS ACCEPTED BY MNES:

(Digesters for rural application)

1. KVIC (FLOATING DOME)

• MASONRY CYLINDRICAL TANK

• ON ONE SIDE INLET FOR SLURRY
• OTHER SIDE OUTLET FOR SPENT SLURRY
• GAS COLLECTS IN INVERTED ‘DRUM’ GAS HOLDER OVER
SLURRY
• GAS HOLDER MOVES UP & DOWN DEPENDING ON
ACCUMULATION OF GAS /DISCHARGE OF GAS, GUIDED BY
CENTRAL GUIDE PIPE
• GAS HOLDER (MILD STEEL): PAINTED ONCE A YEAR.
• K V I C Mumbai
• MEDIUM FAMILY SIZE BIOGAS PLANT HAVING GAS DELIVERY OF
3 M3 /DAY REQUIRES 12 HEAD OF CATTLE AND CAN SERVE A
FAMILY OF 12 PERSONS

TECHNICAL DETAILS OF A 3 M3 /DAY BIOGAS PLANT OF

FLOATING DRUM DESIGN
Name of the model KVIC Model
Size for 3m / day gas delivery 4.15m high, 1.6m dia, Volume 8.34m3
3

Inlet pipe 0.1m dia, 4m long

Inlet tank 0.75m dia, 1m high
Outlet pipe 0.1m dia, 1.1 m long

Retention period 30 to 50 days

Gas Holder 1.5 m dia, 1m high
Construction of gas holder MS sheet & angles, fabricated.
Constr. & layout, digester Brick, cement, digester below G. level

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2. JANATHA (FIXED DOME)
inlet
BIOGAS

outlet

• DIGESTER WELL BELOW GROUND LEVEL

• FIXED DOME GAS HOLDER BUILT WITH BRICK & CEMENT
• BIOGAS FORMED RISES PUSHES SLURRY DOWN
• DISPLACED SLURRY LEVEL PROVIDES PRESSURE-UPTO THE POINT
OF ITS DISCHARGE/ US

3. DEENABANDU (FIXED DOME, MINIMISES SURFACE AREA)

• FIXED DOME PLANT, MINIMISES SURFACE AREA BY JOINING THE

SEGMENTS OF TWO SPHERES OF DIFFERENT DIAMETERS AT THEIR
BASES
• FIXED MASONRY DOME REQUIRES SKILLED WORKMANSHIP AND
QUALITYMATERIALS TO ELIMINATE CHANCE OF LEAKAGE OF GAS
• AFPRO, 25/1A,Institutional Area, D block, Panka Rd, Janakpury, N.Delhi.

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4. PRAGATI
• COMBINES FEATURES OF KVIC & DEENABANDU, MAHARASHSTRA
• LOWER PART: SEMI-SPHERICAL IN SHAPE WITH A CONICAL BOTTOM
• UPPER PART: FLOATING GAS HOLDER
• POPULARISED IN MAHARASHTRA, UNDARP, PUNE

5. FERROCEMENT DIGESTER:
• CAST SECTIONS, MADE FROM A REINFORCED (MORTAR+WIRE
MESH)- COATED WITH WATER PROOFING TAR
• S E R I, ROORKEE

6. FRP DIGESTER:
• FIBER REINFORCED PLASTIC MADE BY CONTACT MOULDING
PROCESS

7 UTKAL / KONARK DIGESTER

Reference: ‘Konark biogas plant-A user friendly model’ Mohanty, P.K., and Choudury,
A. K, (Orissa Energy Dev. Agency), Journal of Environmental Policy and Studies 2(1);
15-21

Konark Biogas plant:

• SPHERICAL IN SHAPE WITH GAS STORAGE CAPACITY OF 50%

• CONSTRUCTION COST IS REDUCED AS IT MINIMIZES SURFACE AREA
• BRICK MASONRY OR FERROCEMENT TECHNOLOGY
• A PERFORATED BAFFLE WALL AT THE INLET PREVENTS SHORT
CIRCUITING PATH OF SLURRY (OPTIONAL)

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8 FLEXIBLE PORTABLE NEOPRENE RUBBER MODEL:
• FOR HILLY AREAS, MINIMIZES TRANSPORT COST OF MATERIALS

• BALLOON TYPE, INSTALLED ABOVE GL, MADE OF NEOPRENE

RUBBER

• FOR FLOOD PRONE AREAS, UNDERGROUND MODELS NOT SUITABLE

SWASTHIK COMPANY OF PUNE DESIGN

HIGH RATE DIGESTERS FOR WASTE WATER TREATMENT:

1. ANAEROBIC FILTER (UPFLOW and DOWNFLOW)

2. UPFLOW ANAEROBIC SLUDGE BLANKET DIGESTER( UASB)
3. ANAEROBIC LIQUID FLUIDISED/ EXPANDED BED DIGESTER
4. ANAEROBIC ROTATING DISC CONTACTING DIGESTER
5. ANAEROBIC MEMBRANE DIGESTER
6. ANAEROBIC CONTACT DIGESTER

Effluent Treatment & Disposal: I Ch. E, U.K., Symposium Series No96, 1986., P 137-
147, Application of anaerobic biotechnology to waste treatment and energy production
Anderson & Saw.
Energy & Environment Monitor, 12(1) 45- 51, ‘Biomethanation Technologies in
industrial water pollution Control’ A.Gangagni Rao, Pune.

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HIGH RATE DIGESTERS FOR WASTE WATER TREATMENT:

1. ANAEROBIC FILTER (UPFLOW and DOWNFLOW)

• ANAEROBIC FILTER CONTAINS A SOLID SUPPORT OR PACKING

MATERIAL IT WAS DEVELOPED BY YOUNG & MC CARTHY IN 1967

• WASTEWATER FLOWS FROM BOTTOM UPWARDS THROUGH THE

PACKING, GAS SEPARATES, BACTERIA ARE RETAINED MOSTLY
IN SUSPENDED FORM,HRT RANGE OF 0.5 TO12 DAYS IS OBTAINED

• SINCE SUSPENDED GROWTH TENDS TO COLLECT NEAR THE

BOTTOM OF THE REACTOR, ACTIVITY IS HIGHER THERE.

• TYPICAL ORGANIC LOADING RATE OF 1 TO 40 KG COD/

M3/DAYAND A SRT OF 20 DAYS IS ACHIEVED.

• AVOIDANCE OF PLUGGING DUE TO ACCUMULATION OF SOLIDS

IN THE PACKING MATERIAL AND ENSURING AN ADEQUATE
FLOW DISTRIBUTION IN THE BOTTOM OF THE REACTOR ARE
THE LIMITATIONS OF THIS.

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2. UPFLOW ANAEROBIC SLUDGE BLANKET DIGESTER (UASB)

• UASB REACTOR IS BASED ON SUPERIOR SETTLING PROPERTIES

OF THE SLUDE
• INFLUENT FED INTO THE REACTOR FROM BELOW LEAVES AT
THE TOP VIA AN INTERNAL BAFFLE SYSTEM FOR SEPARATION
OF THE GAS, SLUDGE AND THE LIQUID
• GAS SEPARATED FROM SLUDGE, COLLECTED BENEATH PLATES
• IN QUIET SETTLING ZONE, SLUDGE SEPARATES, SETTLES BACK
TOWRDS DIGESTION ZONE.
• ORGANIC LOADING RATES OF 10 TO 30 KG COD /M3 DAY
• REACTOR MIXING SHOULD BE ONLY BY THE GAS PRODUCTION
• HRTRANGE OF 0.5 TO 7 DAYSS IS FEASIBLE WITH EXCEL.
SETTLING SLUDGE AND A SRT OF 20 DAYS(AT 35 0 C)
• REF: TIDE,VOL9,NO4, DEC.1999,PAGE 232

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3. ANAEROBIC LIQUID FLUIDIZED/ EXPANDED BED DIGESTER

• ACTIVE BIOMASS IS ATTACHED TO SURFACE OF SAND

PARTICLES THAT ARE KEPT IN SUSPENSION BY UPWARD
VELOCITY OF LIQUID FLOW
• DEGREE OF BED EXPANSION IN EXPANDED BED IS 10-20% AND IN
FLUIDIZED BED IT IS 30-100%
• BIOMASS RETENTION IN THE REACTOR IS EFFICIENT ,SRT OF 30
DAYS
• PARTICLES PROVIDE LARGE SURFACE AREA FOR MICROBIAL
GROWTH AND BETTER MIXING COMPARED TO PACKED BED, HRT
RANGE OF 0.2 TO 5.0 DAY ACIEIVED.
• TYPICAL RANGE OF LOADING RATE OF 1 TO 100 KG COD/M3 /DAY
• REF: COMPREHENSIVE BIOTECHNOLOGY-MURRAY MOO YOUNG,
VOL4, PAGES1017-1027.

4 ANAEROBIC ROTATING BIOLOGICAL DISC CONTACTOR

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THE DISCS PROVIDE SURFACE FOR GROWTH OF METHANE BACTERIA
AND MIXING OF SLURRY AS IT FLOWS THROUGH CYLINDRICAL
BIOREACTOR.
Reference Article: ‘Anaerobic Rotating Biological Drum Contactor for the Treatment of
Dairy Wastes’, S. Satyanarayana, K. Thackar, S.N.Kaul, S.D.Badrinath and N.G.
Swarnkar, (NEERI) Indian Chemical Engineer, Vol 29, No 3, July-Sept, 1987.

5. ANAEROBIC MEMBRANE DIGESTER:

• SUSPENDED GROWTH REACTOR, COMBINED WITH A SEPARATOR

• EXTERNAL ULTRA / MICROFILTRATION MEMBRANE UNIT FOR
SOLID-LIQUID SEPARATION
• PERMEATE BECOMES THE EFFLUENT AND THE BIOMASS IS
RETURNED TO THE REACTOR
• MEMBRANE UNIT ROVIDES POSITIVE BIOMASS RETENTION AND
PARTICULATE FREE EFFLUENT

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6 ANAEROBIC CONTACT DIGESTER

• BIOMASS SETTLED IN A SECOND TANK, RECYCLED TO THE

DIGESTER.
• RECYCLE GIVES HIGHER SRT AND EFFICIENCY
• MIXING IN THE FIRST TANK AND EFFICIENCY OF SETTLING IN
THE SECOND TANK IMPROVES PERFORMANCE.
• REQUIRE HRT OF 10 DAYS OR MORE.

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