Bio-Energy Pavilion 2022 | 28-30 September | India Expo Centre, Greater Noida
Title Sponsor: Atmos Power Pvt. Ltd.
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MAGAZINE | EDITION 19 | 2022
Liquid Biogas refueled to ships: Pg 12 Biogas Production from Pharmaceutical Waste: Pg 12 Sustainable Revenue Generation through Biogas to Power for Dairy Industry: Pg 26
www.biogas-india.com
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CONTENTS
Inside
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30
Swedish ship is refueled with liquid biogas for the first time
National Corner 12 Biogas production from pharmaceutical waste
26 Sustainable revenue generation through biogas to power for dairy industry
33 CSTR based semi dry fermentation of organic solid feedstocks
37 Implementation of biogas projects in India
43
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CSTR based semi dry fermentation of Organic Solid Feedstocks
From a sceptic to a pioneer
33
21
International Corner 16 Food waste depackaging and separation functions and recent industry advances
30 Swedish ship is refueled with liquid biogas for the first time
Published By
Financed By
Coordinated By
In-cooperation with
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From President’s Note Editors
Savita Boral Abhijeet Mukherjee
Designer Komal Raghav Administrator Vishal Kanchan Production Co-ordinator Kavita Tanwar
About The “Indian Biogas Association” (IBA) is the first nationwide and professional biogas association for operators, manufacturers and planners of biogas plants, and representatives from public policy, science and research in India. The association was established in 2011 and revamped in 2015 to promote a greener future through biogas. The motto of the association is “propagating biogas in a sustainable way”.
Dear Reader, I hope that you are safe and healthy! In COP26, India committed to achieve Net Zero by 2070. It is sending a positive signal for the investment in renewable energy sector. Even the recent budget provided support for the utilization of biomass in the industries, which is a much-needed impetus towards supporting the biogas industry in long term. To cover the potential from different biomass, we are featuring an article on biogas production from pharmaceutical waste in this edition. Another article, which is based on a different substrate for a biogas plant, will give you a perspective on how biogas can make dairy industries sustainable by providing additional revenue sources.
article on semi-dry fermentation promised a glimpse of contemporary technology. The article on innovative end-usage of the biogas plants to gives you a new perspective; more particularly it highlights alternative usage of the liquefied biogas in ships and how it can open up new avenues for the biogas sector. Also, it has to be borne in mind that the organic farming market is still unorganized and is in a nascent stage in India. Gradually, it’s bound to develop leading to the increasing demand for organic fertilizer, which can be provided by biogas plants. An article as a case study covers this perspective and explains how it changed the market in Germany. We wish you a safe, healthy, and greener future!
In continuation of usage of different biomass, an article from Twister will explain to you the de-packaging and separator functions to handle food waste to utilize it in the biogas plants. Food waste is also a promising substrate that can be utilized efficiently using proper pre-treatment processes. In addition, an article on how to implement the biogas projects in India will give you a basic idea of successfully implementing the biogas projects . Likewise, a technology-based
Dr. A. R. Shukla
President Indian Biogas Association
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AD
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Contributors Dr. A. R. Shukla
Abhijeet Mukherjee
He is the President, Indian Biogas Associaaon. AAer working for about 29 years in the pay scale of Joint Secretary, he superannuated as Adviser (Bio-energy) from the Ministry of New and Renewable Energy, (MNRE) in September; 2011. In total, he has about 48 years of experience.
He has more than 16 years of work experience with over 12 years specifically in renewable energy forms i.e. biogas generaaon from variety of feedstocks and its various forms of uulizaaon. Earlier in his tenure with GAIL, he was associated with its research and development wings and worked towards sustainable use of various clean fuels.
Mark Vanderbeken
Sameer Rege
He is Chairman and founder at Drycake. He is also the Inventor of the Twister De-packager. Being a visionary, dynamic and invennve leader, he is key to the Twister Technology. He is presently looking for opportuniies to make a posiive global impact upon creaang a more su sustainable; and clean energy system.
Lars Höglund
He is the CEO , Master Marine and owner of Furetank Rederi AB. Having a work experience of 40 years and sailing experience of about 25 years, he is into commercial operaaon of more than 20 vessels and 9 dual fuel vessels, which are being used for refuelling and is running LBG.
Srinivas Kasulla
He is an internaaonally renowned technocrat in the field of biogas. He accvely promotes Biogas at various levels in India. He has got over 20 years of experience in the Biogas industry and has lead several projects.His contribuuons towards innovaave developments of various addii addiives like enzymes, cultures, mixture of macro and micronutrients is exemplary.
Gajanan Patil As business leader with extensive experience in strategy formulaaon and implementaaon.He started the proprietorship firm ( Urja Bio System Pvt. Ltd. ) in 2006. In the last 15 years, he has done around 200 projects on waste to power from kitchen waste,caale dung, municipal waste dai waste. and dairy
Joseph Vimal. A
He is the Co-Founder and Managing Director of J & F Biogas Ltd. He has 3 years of experience in starrng Clean tech businesses in India. He is also CEO at FOV Biogas India, is a joint venture with FOV Fabrics AB, Sweden. He has done Bachelor’s degree in Engineering and Masters in Entrepreneu neurship from KTH Sweden.
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IBA’s commitment towards leapfrogging the prospects in the biogas/bio-CNG industry - Period: Jan, 22-Mar, 22 Indian Biogas Association sion/corpus of Rs 1.4 lakh urges Union Government to crore for the first five years set up ‘Biogas Fertiliser Fund period should be a welcome step. Prior to the February 2022 budget session, the Indi- IBA also proposed establishan Biogas Association (IBA) ing a blending quota for staturged the government to utory mixing of biomethane establish a ‘Biogas Fertiliser (CBG) in the city gas distribuFund’ with an initial invest- tion network and natural gas ment of Rs 1.4 lakh crore for pipeline. A tentative blending five years through various quota of 5% for the first five media outlets (such as The years, followed by a graduIndian Express, Econom- al increase up to 10% at the ic Times, TOI, and Business end of 10 years. It also stated Standard, among others). The that the GST council recently government has been ada- notified the escalation of the mant about doubling farm- GST slab from 5% to 12% for ers’ incomes by 2022. Nearly biogas plant-related equip50 million farmers will benefit ment and their parts. “This from the investment. Not only has put the biogas producwill the Biogas Fertilizer Fund ers in a challenging situation. ensure that India imports less With the end product, biogas, fossil fuel, but it will also as- and its other upgraded forms sist farmers with bio-fertilizer. being slated at a 5% GST slab, For materializing the envis- the GST rate escalation exacaged target of 5,000 plants erbates the existing inverted under the SATAT (Sustainable tax structure concerns ultiAlternative Towards Afford- mately leading to an increase able Transportation) scheme, in the overall project price,” it creating a ‘Biogas-Fertilizer pointed out. Instead, it sugFund’ with an initial provi- gested, a uniform concession-
al rate of 0% uniform GST rate across the value chain of the industry needs to be implemented to foster the growth of this industry, which is critical to India’s climate goals. The proposed outlay (to set up ‘Biogas Fertiliser Fund’) will benefit the industry by subsidising the additional cost incurred. IBA further explained that now for harnessing the total generation potential of 62.2 million tonnes per annum of Biogas/ Bio-CNG/ CBG/ RNG in India, a separate ‘Biogas-Fertilizer Fund’ is needed to be established, with an estimated financial corpus requirement of Rs 9.5 lakh crore. Out of this, Rs 1 lakh crore should be allocated to the ‘Credit Guarantee scheme’/ongoing subsidy, which would allow FIs (financial institutions) to suitably manage risk and take required credit exposure in the industry. It stated that the balance of Rs 8.5 lakh crore should be allocated towards
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‘Generation-based Incentive (GBI)’ at the rate of Rs 20 per kg of produced Bio-CNG (as per BIS Standards), for the duration of plant life, which is typically considered to be 15 years. The government expects to see a significant return on investment in the industry in the form of savings from reduced crude oil imports, reductions in chemical fertiliser subsidies, and meeting the GHG (Green House Gas) emission reduction target set out in the Nationally Determined Contributions (NDCs).The net value creation on the aforementioned accounts is expected to be Rs 1.5 lakh crores, resulting in a net surplus to the government’s coffers.
Representatives from GIZ, PEDA, NDDB, and other industry stakeholders put forth their inputs for the industry. IBA, on behalf of the industry, participated in the event. It addressed some of the salient industry concerns related to: continuation of CFA, extension of Market Development Assistance (MDA) for organic manure, and harmonization of GST for the industry. The current ongoing MoU between NIBE and IBA was also emphasised. Apart from the interaction with the hon’ble Minister, it was a wonderful opportunity for IBA to network with various industry stakeholders who had come to the event.
Formulation of Indian StanAbove article has been cov- dards on Biogas ered in The Indian Express, On 19th Jan, a meeting was Jan 26th issue. called upon by Bureau of Indian Standards (BIS) regardrd IBA participated in 3 Inter- ing the current progress on national Conference in SSS- standardization of Biogas NIBE, Kapurthala Plants and the revision of exThe inauguration ceremony isting Biogas Plant standards. was organized on 9th March All the members of the pres2022, at NIBE, Kapurthala, ent ‘Biogas standards comPunjab by Shri Bhagwanth mittee’ formulated by MNRE Khuba, Minister of State for were present in the meeting the Ministry of New and Re- Following that, on February newable Energy and Minis- 17th, the ‘Biogas Standards try of Chemicals and Fertil- Committee’ convened a final izers, was the event’s chief meeting at the MNRE office guest. Other special guests to freeze the draught on stanfor the event were Mr. Dinesh dardisation. The discussion Jagadale, Joint Secretary, was chaired by Joint SecreMNRE and Dr. B. K. Kanaujia, tary, MNRE, and included all Director, NIT, Jalandhar. The members of the committee. highlight for the event was The draft report was thorHon’ble Minister’s interaction oughly discussed upon and with industry stakeholders. unanimously approved by all
the members of the committee. The document has been handed over to BIS team for incorporating the inputs and take it further for onward formulation as ‘Standards on biogas’. Bio-Energy Pavilion 2022 Indian Biogas Association is pleased to announce the “Bio-Energy Pavilion 2022” to be held at Renewable Energy India Expo at India Expo Mart, Greater Noida on 28, 29, and 30 September 2022. With the exception of the pandemic, IBA has been organizing the bio-pavilion for the past three years, with each successive event being larger in scale than the former. This time, the pavilion and conference are expected to spread the awareness about the Bio-Energy sector while also increasing visibility of the sector through the convergence of corporates, entrepreneurs, academicians, social organizations, lending institutions, and investors. This initiative aim to streamline scientific waste management practices, and is currently supported by various government schemes like Swachh Bharat, Sustainable Alternative Technology for Affordable Transportation (SATAT), Solid Waste Management, Ethanol Blending program, Compost promotional scheme, etc.
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Biogas production from pharmaceutical Waste
M
ailhem Environment Private Limited has designed and constructed an anaerobic treatment plant for one of the bulk drug manufacturers, capable of treating fermentation broth samples containing high levels of BOD, COD & TSS. In this case, the split between biomass retention time and hydraulic retention
time is critical to the success of anaerobic treatment: a M-UASB reactor (our indigenous reactor) followed by an external sludge separation system with biomass re-circulation. This solution offers the advantages of High organic loading capacity & highly settleable granular biomass with ease to operate & maintain. Other advantages are
the small footprint and the lower anaerobic effluent TSS values, facilitating the aerobic post-treatment Anthem Bio-sciences Pvt Ltd manufactures drugs using Soya Flour, Peptone, Tetrose and Cultures like - Yeast, Fungus as a primary raw material. Fermentation is the core process used to con-
Sr. No
Tests
Unit
Sample – 01 Without Solvent
Sample – 02 With Solvent
1
Total Solids
%
11 . 9580
10 . 3362
2
Total Volatile Solids @ 550°C
%
10 . 5715
8 . 8298
3
COD
%
17 . 6268
41 . 7078
4
BOD (@ 27°C, 3 days)
%
7 . 5803
20 . 2405
5
Total Kjeldahl Nitrogen as (N)
%
1 . 0996
0 . 8617
6
Total Organic Carbon
%
4 . 7471
9 . 8171
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vert these raw materials into drugs intermediate. However, this process generates massive amount of fermentation waste, which can cause damage to the environment due to the high organic load. In this regard, Anthem Bio-sciences had approached us to design a suitable upstream treatment process prior treating it in their effluent treatment plant.
treatment process for the generation of biogas. Conditioning of the feed slurry occurs in the slurry tank via a recirculation step that mixes it with recycled anaerobic effluent. . Furthermore, the pH-value and temperature are regulated and nutrients are dosed as needed to achieve optimal anaerobic biomass growth conditions in the M-UASB reactor.
We have the technology and expertise to offer turnkey solutions for treating in-situ process waste. Subsequently, the challenge was taken up by our R&D unit to study the process waste and design the biological treatment by setting up a pilot-scale plant. The objective of the study was to maximize the recovery of biogas while maintaining an optimal retention time.
2. The conditioned feed slurry is then pumped to the M-UASB reactor in constant, continuous flow A special Influent distribution system ensures that the Influent is equally distributed over the entire reactor surface area. Thus, the Influent passes through a dense anaerobic granular biomass bed, where the biological conversion process occurs, transforming the organic waste’s COD load (Chemical Oxygen Demand) 4. Our propriety moules, to biogas. which are internally installed at the top of the reactor, 3. Our experts modified the separates the treated slurry indigenous design of the from the produced biogas.
WORKING PRINCIPLE 1. The fermented waste broth requires pre-treatment to prepare it for the anaerobic
M-UASB reactor’s to allow for a longer contact time between bacteria and organic material. The M-UASB anaerobic digester is specially designed with internal baffles, partitions and launders (proprietary) for anaerobic treatment. The sludge blanket is comprised of microbial granules which are small agglomerations of microorganisms that resist being washed out in the up flow due to their weight. The microorganisms in the sludge layer degrade organic compounds. As a result, biogas is produced that is primarily composed of methane and carbon dioxide. Without the assistance of any mechanical components, the rising bubbles mix the sludge. Sloped walls deflect material that reaches the top of the M-UASB downwards as clarified effluent/overflow.
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The biomass settles to the bottom of the reactor, whiles portion of the treated effluent is recycled, and the rest is processed to separate solids and liquid digestate. The digestate solids will be transported to a sludge drying area for further processing into organic manure, while the liquid digestate will be treated in an Effluent Treatment Plant
is chemically scrubbed as a treatment procedure under controlled conditions, and is used as a source of energy for capital consumption, specifically boiler and cooking application.
vol%) which can be used for heating, upgrading to natural gas quality, or co-generation of electricity and heat. Digestion installations are technologically simple with low energy and space requirements.
The anaerobic process is an excellent method for the treatment of such high strength fermentation broths.
The focus was to generate biogas from the waste at the fermentation unit, which could replace or offset the
Treatment Capacity
Up to 25 cum/day
Type of Effluent
Fermentation Broth after process
Nature
Water base, thick slurry
Biogas Produced
Approx. 2250 -2500 cum per day at calorific value of 4800 - 5200 kcal /cum
Biogas Equivalent to LPG
Approx.1000 – 1125 Kg per day of LPG
Water Required
Approx. 20 CUM / day
Area Required
1500 sq. m.
(ETP). The generated biogas is a mix- processing industry’s demand 5. Biogas is collected and ture of methane (55-75 vol%) for grid electricity and LPG for piped to a biogas balloon. It and carbon dioxide (25-45 thermal energy.
Sameer Rege CEO
Mailhem Environment Pvt. Ltd.
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Food waste depackaging and separation functions and recent industry advances
T
his article discusses the requirements of a good food waste depackager and separator. We describe the equipment’s functions and introduce a novel technology for increasing the purity of the output stream It accomplishes this through the use of fewer moving parts, less energy, and a smaller system footprint.
The good news is that a new generation of this vital plastic recycling technology has emerged wherein clogging and component wear issues have also been addressed.
doing so in the most environmentally friendly manner possible while producing distinct plastic, organic, and inert outputs.
Food waste depackagers and Continue reading to learn separators serve a variety of about the capabilities of this functions and are designed to equipment , how it could be automatically separate organimproved, and how one com- ic material from the following: pany is addressing the issue through a case study in India. ● source-separated food and Improved recycling technologreen waste from household gy for plastic is long overdue. Depackaging and separator kerbside collections, The public is becoming more functions aware of the environmental ● the organic fraction of mudamage that plastic packag- Fig. 1 - The compact Twister nicipal solid waste (known ing causes. Despite its un- accomplishes depackaging as “residual waste” or “black matched ability to keep food and separation activities in bag” waste) which is, generfresh and safe to eat, plastic one unit. ated by trommel screening, is losing popularity with the public. Boris Johnson, the UK The purpose of this equip- ● pre-consumer organic Prime Miinister, stated “Plas- ment is to open all bags and food waste such as catering tic recycling does not work” containers and separate the waste from the hospitality (BBC October 2021). organic material. The chal- industry’s kitchens, company lenge has evolved to include canteens, educational, insti-
Fig. 1
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pumped or transported into a treatment process to maximize value and energy of the material. Additionally, it must do it in accordance with the local “waste hierarchy”. Not to mention the necessity for environmental stewardship. Secondary functions of a food waste separator The secondary role of a food waste separator organic output stream are to:
tutions, cruise ships, prisons etc. ● the food processing industry, and ● inedible food from supermarkets, and the food distribution logistics industry. Why depackage and seprate? The market drivers Depackaging and separation are driven by national waste management treatment hierarchies, which impose on the waste sector the following obligations:
cess food waste organic content for feeding an anaerobic digesters, or for composting in windrow or in-vessel Opening every bag pack and packet A decent depackager/ separator must handle packaged food waste and be capable of opening each bag, package and packet. That is a tough challenge for the equipment. Consider for a moment the huge variety of materials, shapes and sizes available for food packaging today. That is an extremely difficult task for any machine. Not only must , each container be opened, but it must also be completely emptied. Above all, it must remain free from clogs and blockages after hundreds of hours of operations.
● minimising waste, ● reduce what’s unavoidable, ● in that sequence, reuse and recycle, and ● beyond that, energy extraction is the fall-back choice, with landfill being the least desirable of all. The industry is motivated to create separators that In practice, as the water con- generate a clean, contamtent is already high in food, ination-free organic paste, the preferred option is to pro- “pulp” or “soup” that may be
● the greatest extent feasible, avoid the inclusion of insoluble non-organic pollutants in the organic fraction, including inert materials such as stones, grit, sand, silt, and clay, metal pieces, and plastics. Maintain the water content to provide a fluid viscosity in the organic fraction output suitable for onward conveyance and, if digested, to meet the water content requirements of the anaerobic digestion process which it feeds, ● prevent being damaged by the presence of occasional “unexpected items” such as the cutlery, and crockery accidentally dropped into food waste bins. Perhaps too little attention has been devoted in the past to the removal of inert materials ranging in size from stones to clay particles. Even in small quantities these contaminants can accumulate in anaerobic digestion tanks. Once digester efficiency detoriates as a result of excessive inert
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material accumulation, emptying and cleaning the digester can be dangerous, costly, and time consuming. This has a detrimental effect on the energy output. The imperative of avoiding microplastics in the environment A new requirement has been introduced in response to scientific and public concerns over plastic pollution and its possibly disastrous effects on the health of the world’s oceans, and eventually on humans. This function is necessary to avoid generation of microplastics (small chips and granules of plastic).
To avoid blockages, first generation separation technologies reduced particle size. However, a significant amount of microplastic particles were produced. As a result the latest depackagers/separators avoid hammering paddle-smashing, and shredding. This results in energy saving. Aditionally, the larger surface area of tiny plastic particles retained more water. Thus, a higher-grade plastic output results from less destructive processing, more acceptable for recycling or as an RDF. So, the days of discarding this material should now be gone.
continue to remove plastic after the digester. They must, as a significant amount of food tends to adher to the plastic generated by early separation machinery. However , separating plastic and grit after the digester is not a smart idea. It results in inefficient digester operation, due to elevated substrate viscosity, a greater tendency for hard crust to form on the digester surface, inefficient mixing and grit, sand, and silt buildup in the digester.
Separation of plastics before the digester is the future
digestion tank must be shut down and dug out. That entails heavy cleaning costs and the loss of biogas output. Additionally, when digester availability declines, power companies may see a decrease in the price they pay for each unit of electricity.
Eventually, when build-up reaches a certain point the
Tiny plastic particles have the potential to be re-concentrated in oceans in ways that pose a threat to species . Microplastics (little bits of plastic) wash ashore in the intertidal zone, gradually breaking into smaller pieces. As a result, plastic accumulates on vulnerable beaches. It’s difficult to say that after food waste separation, any microplastic can be tolerated. As a result, users of this equipment now have an added responsibility to minimise microplastics. When used as a digestate fertilizer, it is spread on the land and eventually washes into the sea over geological time. Low microplastics in current food waste separator technology
While reducing microplastic content is crucial, it is also critical to maintain organic content. AD operators require the entire calorific content of food waste to genetate biogas. For this reason, many
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The Drycake Twister™ Food Depackaging and Separator System
fect while the organic fraction is transferred to an optional separate unit, called a Seditank which removes inert Recent generation of depack- materials and any small plasager/separators that aims tics/ microplastics to meet all of these requirements is the Drycake Twister- Case study: Bangalore AirTM high-speed vortex depack- port, Genia Global and Adaging and separator system, verio Waste Systems work which can be supplemented together on innovative move by SeditankTM and Clean- toward sustainable managepressTM units as needed. This ment of air transport infrais a technology that will soon structure be operational in an Indian trash facility. Bangalore Airport is the third-largest airport in India As the third generation of and is known for its innoDrycake’s unique vertical cy- vation and high standard of clonic separation technique, sustainability. It has launched it is primarily designed to pro- a new project to repurpose vide a depackaged food waste food waste and reduce enersubstrate suited for AD plants. gy consumption. The Twister operates on the principle of a separation vortex. The system consists of a feed hopper with an upper screw auger to prevent material from bridging and a lower screw auger to feed the machine.
500kW generator motor and also to make vehicular biomethane (CNG) for airport vehicles. To do this a new anaerobic digestion plant and biogas upgrading facility will be built on site to process the waste generated at the airport and in flight.
Twister technology was selected for the duty of depackaging garbage prior to entering the digester by the engineering firm Adverio Waste Systems in collaboration with the biogas system provider. The rationale cited was its capacity to produce an organic outlet of excellent quality. The model employed for this project has the capacThe facility will process the ity to process 5 T/hr of bioairport’s 15,000t of biowaste waste The project is schedper year, producing 2.25 mil- uled to be completed in late lion Nm3/year of biomethane 2022 Genia Global intends and 14,625MWh of total en- to apply this model to multiergy. ple other airports across the globe. This energy will be used to generate electricity with its
The unit debags in the hopper, requiring no preliminary size reduction. A vortex is formed in the screening drum by the action of an integral turbine. This simultaneously forces the organics through a screen while the packaging is ejected for discharge. Flexing and vibration in the air of the high-speed vortexcontribute to the cleaning ef-
Mark Vanderbeken Chairman and Founder
The TWISTER De-packager
Online Biogas Training
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From a sceptic to a pioneer Hans Grötzinger is a passionate crop, biogas and organic farmer. He discovered renewable agriculture while searching for better soil fertility and stability in view of the climate change. He applies some of the measures mentioned under this term, but not all of them. He focuses on humification, a well-balanced supply of nutrients and organic fertilization. - By Christian Dany
H
illing in the Lower Bavarian district of Landshut: Hans Grötzinger sticks a spade into the soil of his field. “The chunks in the soil are good,” he explained. “They maintain the soil structure so that the soil won’t become too muddy when it rains. Below the chunks is the fine soil.” He then digs more than 30 centimeters below the surface. There is no visible cultivated layer, which is no wonder, as the organic farmer Grötzinger stopped using a plough three years ago. Another interesting factor is the test with a one meter long soil probe: it can easily be pushed into the soil as far as it will go. 37-year old Grötzinger then inspects a field of fiveweek-old oat plants dispersed with buckwheat and gooseg-
rass. “The buckwheat is from the previous catch crop and the goosegrass shows there is good nutrient availability,” he explains. We then see a demonstration of renewable agriculture live when his brother, Josef, works the remnants of a catch crop blend into the soil with a seedbed cultivator.
industrial companies nearby. Employment opportunities have accelerated structural change.
The smaller farms closed down about 30 or 40 years ago. Grötzinger himself also did not follow a predestined course of life. After his apprenticeship in agriculture, he no longer enjoyed working Grötzinger’s father Josef in that profession. “For five switched to organic farming years, I worked as a paramedin the Naturland Association ic. I wasn’t really interested in as early as 1989. “We were a dairy cattle,” he said. mixed farm, with dairy cattle and bullock fattening,” said But when the special permit Grötzinger. The quadran- for livestock breeding expired, gle-shaped farmhouse lies on he experienced a turnaround: the main street of the village, “We would have needed just like some of the other more pasture, but were a litfarms. But most of the ap- tle too penned between the proximately 500 inhabitants road and the Bina River,” said live in the adjacent residential Grötzinger. He enrolled in the area. There are some large organic agricultural college
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in Landshut-Schönbrunn and graduated as a master of agriculture. He later gave up livestock breeding and revolutionized the business: “We have a lot of clover grass in the crop rotation. That can be optimally utilized in the biogas plant. I have good technical skills, which is just what we needed,” said Grötzinger, who has two sons.
ter to ensure a guaranteed supply of heat for the seven households connected to the heating grid. In return, power is reduced in mid-summer. Grötzinger wants his plant to run as much as possible on residues which it does: The main component of the feedstock is grass silage made of grass clover and catch crops, 32 to 35 percent of it consists of sloped floor deep litter maThe biogas plant, which has nure, which he buys in addian electric capacity of 210 tion. Only 15 percent of it is kilowatts (kWel) was set maize silage. up along the lines of the build-owner model in 2010 Biogas plant as a nutrient with connected load. A 100 supplier kWel CHP unit for flexible operation was added in 2016. On the organic farm, the Grötzinger: “We operate a lit- biogas plant fulfills the imtle according to the tempera- portant function of a “nutriture.” That means full power, ent plant”. In return for the particularly in October and manure he buys, Grötzinger November, when grain maize partly returns digestate as is being dried, and in win- fertilizer and partly receives a nutrient input. He also cooperates with other biogas plants, from which he gets grass clover in exchange for the digestate. The Lower Bavarian considers cooperation an important aspect at many levels: In a community of five farmers, he tests and develops the cultivation
of linseed: “If it works, we’ll expand it.” He ventures into unusual farming methods in other ways, too: He cultivates spelt, oats, grain maize and even sweet maize, of which the cobs are picked and sold as barbecue maize. Grötzinger sells around two thirds of the field crops as cash crop, one third goes into the biogas plant. “Reallocation and consolidation of the farm holdings resulted in a great infrastructure,” he says. Most of the farm boundaries have been readjusted and 80 percent of the fields are less than 2.5 kilometers away. They have an average size of about 4 hectares. And besides that, crop production benefits from the loess soils in this area. Crop and energy farmers also have about 20 hectares of grassland, many of which are wildflower meadows along the Bina River. Grötzinger farms a total of 150 hectares, a large part of which is leased land. The basis of Grötzinger’s crop rotation is clover grass. He says that well-planned crop rotation will ensure a clean, healthy plant stock; for example, as a prevention against stone blight in wheat. Catch crops are planted after each primary crop to ensure that
“We have a lot of clover grass in the crop rotation. That can be optimally utilized in the biogas plant” - Hans Grötzinger
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the soil is always covered. For example, he grows vetch rye or Landsberger mixture, which generally consists of vetches, scarlet clover and Italian ryegrass.
catch crops for a long time now. We also used to have solid manure. We had 2.8 to 3.5 percent of humus, but did not manage to get more than that,” he said, looking back. He found solutions in princiThis mixture regularly brings ples that today are summed the organic farmer a har- up as “renewable agriculture”. vest of more than 30 tons He changed the inversion and of fresh matter per hectare soil sampling methods and with about 28 percent of dry also organic fertilization. substance. “That’s about half a maize harvest and there He has been tilling the soil is also a cash crop on top of without a plough for about 4 that.” The additional revenue years now, as it did more to and the humification more destroy the life and structure than make up for all the work of the soil than enhance it: and the hours spent on the “Ploughing interferes with the tractor. Grötzinger has his development of bacteria. Furown seed blending unit with ther down, there are anaerowhich he can also make indi- bic bacteria that are brought vidual mixtures. Besides that, to the surface, which you he also puts in more under- can smell.” Instead of doing sown crops when he plants that, Grötzinger removes the grain and maize: for exam- crop residue and puts it into ple, white clover, rye-grass or the surface retting. Later, he grain legumes. stirs the soil with a cultivator at a depth of about 15 centiRetting instead of ploughing meters and then compacts it with a Cambridge-type roller. So far, not so good. “Even with good yields and good agricul- Anything that has a thick tural practice, the problems sward, like clover grass and did not decrease, they rath- Landsberger mixture, is cut er tended to increase,” said right down to the roots,” he Grötzinger. The yields were explained. The rotary tiller, not stable enough, especially that he leases, cuts to a depth during dry periods. So he took of 3 to 5 centimeters. “If there a closer look at new forms are straw and maize stubbles, of agriculture and how to green rye and whole crop sibrace himself for the climate lage, we use a blade cultivachange. He considers the tor because it consumes less enrichment of humus as the diesel.” The special hydraumost important task for the lic cultivator with adjustable future because of its capabil- depth can also cut plants to ity to retain water and nutri- that depth. ents. “We have been planting
“That’s how I put organic material into the soil with maximum soil conservation,” said Grötzinger. He refrains from using retting control, like enzymes or the like: “It needs time. The material stays in there for three to ten days. The more there is, the longer it takes for the organic matter to be converted.” The chisel ploughing is followed by rolling. He says that is important to ensure that the CO2 is retained in the soil rather than being outgassed. And besides that, the soil retains its resistance to heavy loads much faster. “If left for a few weeks, the soil becomes porous and compaction is reduced. We hardly ever need a rotary harrow, even though our soil is heavy.” Although this kind of tillage requires several cycles, it uses up less diesel: “We only use between 2 and 4 liters of diesel per hectare for each flat cultivating and rolling cycle.” The annual consumption is 28,000 liters, which is about 2,000 liters less than when he was still using a plough. Fertilization according to Albrecht/Kinsey The changing tillage methods go hand in hand with soil analyses according to the Albrecht/Kinsey method, which is applied to create a balanced proportion of nutrients in the soil and adequate levels of trace elements. Grötzinger explained the theory of “scar-
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city despite abundance”: “Today, you have to eat ten times more salad than after World War II to absorb the same amount of trace elements. This method will provide us with food items that are simply more nutritious.” The farmer, who comes from Hilling, works with the agricultural retailer Josef Hägler and with Geobüro Christophel, and supervises the soil samples of other operating farms in the region. The Albrecht/Kinsey method primarily focuses on the cation exchange capacity, which is a measure of the quantity of nutrient cations that occurs in interchangeable form and that is thus accessible to plants (for example Ca2+, Mg2+, K+). It also used to examine the interaction of nutrient contents, for which there are special ratios, such as the carbon:nitrogen ratio: “Within two years, we adjusted the C:N ratio to 9:1 (10:1 would be ideal). We started off at 5:1,” said Grötzinger, “That’s too tight for most of the farms, no matter whether they have dairy cattle or biogas.” According to Grötzinger, another indication is the calcium:magnesium ratio: “Ideally, it would be 68:12. We had 75:11. Too much calcium prevents other nutrients from being absorbed.” Grötzinger also found that the pH level is not a decisive criteria: “There’s no point fertilizing according to a pH
level.” In the past, too much calcium was often used in fertilization if the pH level was low. But he believes that if the nutrients are well-balanced, there will automatically be a good pH level of around 6.5. His farm was discovered to have a shortage of boron and sulphur. Sulphur deficiency is a widespread phenomenon, he said, but you need enough sulfur for nitrogen availability and to build up humus. Grötzinger recommends having soil analyses made during the soil dormancy period before the soil is fertilized – ideally in November. Repeated analyses should then be made on the same date after two or three years. He recommends taking samples from a very good and a very bad area and from two or three average areas. A standard analysis costs around 100 Euros.
Digestate treatment with Leonardite and In-wa Quartz Organic fertilization with organic manure from the biogas plant is of prime important on Grötzinger’s farm. He separates the thick part of the digestate and in that way, extracts around 500 tons of solid phase per year. Grötzinger processes the liquid phase with Leonardite and In-Wa Quartz, which are both approved in organic farming. “The high proportion of grass clover produces 7 kilograms of nitrogen per cubic meter in the manure. Despite the high protein content, the digestate no longer smells after it has been processed. That works one hundred percent,” he says. The In-Wa Quartz makes the manure black, although only 0.5 liter of it is needed for every 100 cubic meters. The digestate goes into a rotting phase and that brings
“There’s no point fertilizing according to a pH level” - Hans Grötzinger
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about a stimulating effect for ger have any fertilizer burn. self-protection. Spreading manure over open soil would cause rotting,” he “In an experimental field, said. “You would ‚encourage‘ we treated organic rapeseed weeds to grow.” Grötzinger with In-Wa Quartz and lime,” has also produced “MC comsaid Grötzinger when talking post” from the solid phase. about a particular incident. “To do that, the material is spread on a storage clamp “The rapeseed had been and compacted. completely infested with the rapeseed gloss beetle. The The nitrate and moisture connext day, there wasn’t a single tent must be well-balanced. beetle to be seen.” He says It takes eight weeks for comthat Leonardite is a lignite post that is rich in humic acid precursor that results from to form and that way there is the humification of plant mat- less carbon loss than in usuter. That makes it rich in hu- al compost,” he explains. Acmic acids (up to 90 percent). cording to the current fertil“The Leonardite binds the ni- izer ordinance, MC compost trogen and the plant gets it lit- may no longer be produced tle by little, whenever it needs on open fields, although as it, which means that there is it turns out, it is completeno free nitrogen present in ly dry beneath the storage the soil.” This conditioning clamp and Nmin sampling prevents nitrate from being has not shown considerable leached out. “I have two di- amounts of nitrogen. That is gestate storages,” he said why Grötzinger stores the solwhen explaining his nutrient id phase in a covered horizonmanagement methods. “The tal clamp and then distributes digestate from the farms that it like that. supply me with clover grass is not treated, unless this is ex- “The system needs time to pressly requested. The treat- warm up,” Grötzinger summent costs 1 Euro per cubic marizes. He maintains that meter.” you cannot expect any miracles overnight. But the trend Composting digested, sepa- in the right direction became rated solids clear quite quickly. “We managed to produce between 0.2 Grötzinger spreads liquid di- and 0.5 percent of humus gestate with the trailing shoe within three years – dependmethod and makes sure it is ing on the location,” he said. distributed over cultivated But he spends a lot of time fields. That can be achieved on the plant production sysby cultivating catch crops tem, criticizing that the bigand by splitting the individu- gest problem of some of the al applications. “We no lon- farms nowadays is the lack of
time. “Everyone is in a hurry, nobody wants to wait.” He criticizes the lack of patience and the fact that liquid manure or digestate is then spread on the fields in as early as March. “If you see how wet the soil is, you shouldn’t be driving over it with a total weight of 25 tons.” He said that last year, he sowed maize as late as June 2nd and then managed to shred 60 tons of fresh matter; and that is all grown organically with a supply of 15 cubic meters of digestate. “I’ve never known anyone not to succeed because they did something too late, but rather because they did it too early. Just wait and keep cool,” he says. “If you take pleasure in the method and the soil, the rest will practically work by itself.”
Reprinted from
- Biogas Journal
Images owned by German Biogas Association
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Sustainable revenue generation through biogas to power for dairy industry
E
nergy is the driving force of every living being. As humans, we are completely reliant on the food ,we consume on a daily basis. The dairy industry is a significant supplier of our daily necessities such as packaged milk, cheese, paneer etc, As these products are rich protein source to vegetarian people, there is an increasing demand for quality products. Pune district in Maharashtra state is one of the pioneers in milk production, it is home to some of India’s largest dairy companies, including Bhagyalakshmi dairy, Schreiber Dynamics, and Parag foods, all of which are market leaders in dairy and allied products. Their success also inspires a large number of new entrepreneurs to establish small units in milk and allied prod-
ucts.
waste and net reduction of environmental pollution, to Environmental concerns the generation of significant rather than energy recovery amount of energy. is the prime motivator for waste-to-energy facilities, In the current scenario, opwhich help in treating and erating dairy solely for the disposing / reusing of wastes. purpose of selling milk and Energy in the form of biogas, milking products is not comheat or eletricity is viewed as mercially viable; similarly, the an added benefit, enhancing costs of fodder, concentrate the viability of such projects. feed, electricity, and labour In majority of the devel- are included. To sustain this oped countries, entire waste dairy industry, we must think management system is being about generating extra revemanaged profitably by pri- nue from the waste. As per vate industry or non-govern- 2019 Census, India is havment organizations with tip- ing 192.49 million cow and ping fee for waste treatment 109.85 million buffalo. Due of serving as a major revenue to the low cost of milk and stream. high cost of fodder, animal husbandry has become proThe primary benefits of hibitively expensive for dairadopting technologies for ies. Goushala derives all of its energy recovery from ur- revenue from dry cows and ban wastes are reduction of this is entirely reliant on do-
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nations .We are trying to support them by converting dung into energy and value added fertilizers via waste to wealth projects. This model has been successfully implemented in a number of modern dairy farms and Goushalas. Agricultural Development Trust, Baramati, Krishi Vigyan Kendra (Farmers Science center), Baramati was established on 1st August 1992 under the affiliation of ICAR. From 1992 to 2008, the operational area of KVK served the entire Pune district; however, with the establishment of a new KVK in district, the operational area has been reduced to the district’s seven tehsils. Krishi Vigyan Kendra, Baramati is model, hi-tech & national award winning KVK of India that has been working for the development of sustainable agriculture for 24 years The aim of Krishi Vigyan Kendra is to shorten the time lag between the technology transfer from research institutions to the farmer’s field in order to sustainably increase agriculture and allied sector productivity and income. At the Agricultural Development Trust KVK, Baramati, having 500 cattle, we are properly taking care of them. The challenge is to manage a large amount of cattle dung. They were concerned about it in a way that is reliable and does not harm the environment and community. Thus we arrive at the solution of
biogas that generates revenue and sustainable solution for our problem with minimum capital expenditure. We have contacted Urja Bio System Pvt. Ltd., Pune for the same. After a fruitful discussion, it was agreed to set up biomethanation plant at KVK, baramati, Based on 500 cattle, It was proposed for setting 10 TPD biogas to Power generation project. Keeping future perspective in mind. The plant is set up for 10 TPD cattle’s dung and is capable to generate @ 400m3 / raw biogas per day. A proper well functional plant is set up at the site. The farm now receives 600 kWH/day electricity (60 kW x 16 hrs per day), significantly reducing major dependency on MSEB (State Electricity Board Power), which previously provided interrupted, power supply leading to usage of diesel gensets. The digested slurry is sent to solid liquid separator, where the solid particles are separated. After micro-organic value addition, we convert it into “PROM (Phosphate Rich Organic Manure)”. Approx 2.5 ton of PROM (Phosphate Rich Organic Manure) is generated at site. Phosphate Rich Organic Manure (PROM) is a value added organic fertilizer used as an alternative to Di Ammonium Phosphate and single supper phosphate. While all plants require phosphorus, its availability in the soil is limited,
posing problems in agriculture. In many areas phosphorous must be added to soil for extensive plant growth that is necessary for crop production. The solubility depends upon pH of the soil, ambient condition and bacteria present in the soil. Phosphate Rich Organic Manure (PROM) is a value added product produced made by co-compositing high-grade rock phosphate in fine size (say 80% finer than 54 microns) with organic matter collected from various sources such as dung waste, poultry litter etc. To increase the efficiency, Phosphate Solubilizing Bacteria (PSB) and nitrogen fixing bacteria are added. The production of phosphorus rich organic manure (PROM) is standardized to contain 18% P2O5 with 22% moisture is a highly promising, which natural, better and cheaper substitute of di-ammonium phosphate (DAP). The use of PROM will reduce the cost of fertilization to the farmers, and will also result in the conservation of phosphate mineral, a non-renewable resource due to the high residual effect. The agronomic efficacy of this new P-fertilizer is higher than that of the complex phosphatic fertilizers available in the market today. ‘PROM’ is suitable to Neutral and alkaline soils, which will prove to be a boon to the Indian farmers. In the long run, this product will
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succeed as it has significant price advantage compared to the other chemicals. In 2017, was Global Organic Fertilizers market registered volume consumption of nearly 18.23 million tons, amounting to approximately USD 5.87 billion. The global organic fertilizers market is projected to witness healthy growth at a CAGR of 7%, reaching more than USD 8.25 billion through 2023. The changing perception of farmers and end users towards environment friendly farming methods is driving the demand for organic fertilizers worldwide. The separated digested Liquid slurry which is enriched with bio culture upon micro filteration is next step, which is dripable to crops through the tanker, same is available in packaging of 5 liters and 40 liters, in the form Cans, which is being sold to local farmers.
year cal fertilizer replacement. Following are some of the 5. 850 - 900 Ton CO2 footprint major achievements through reduction. this project: 6. Scientific waste manag1. Better revenue generation ment achieved at source through sale of micro filter ensuring no land-filling. digested slurry as organic manure and PROM Generation. 7. Reduction in substantial GHG effect. 2. Reducing major dependency on State Electricity Board Power(MSEB) 3. Enrichment of soil. 4. 875 Ton per annum chemi-
“ The use of PROM will reduce the cost of fertilization to the farmers.”
Revenue generation though the project 1. Saving from Power generation: 600 units x Rs. 05/unit x 350 days = 8.75 lakh/year 2. Revenue generation from sale of PROM: 2.5MT/ day x Rs. 6000MT x 350 days=Rs.52,50,000/year 3. Revenue from liquid manure = 15,000 liter x Rs. 0.25 x 200 days = Rs.7,50,000/year Total revenue generated from this project Rs. 68, 75,000.00/
Gajanan Patil
Managing Director
Urja bio system Pvt. Ltd.
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Furetank contributes in LBG effort to produce fossil-free shipping
I
t takes two to Tango! For environmentally conscious Swedish ship operator Furetank, having built methane powered cargo ships is not enough. The key to turning them fossil free is a supply of liquid bio- methane. As a result, ground breaking Furetank shipping has signed a letter of intent with Eskilstuna Biogas, paving the way for the construction of a new biogas facility. The plant is envisaged to be built with the goal of producing 5,000 tonnes of LBG per year. The Swedish Environmental Protection Agency’s subsidy for climate initiatives provides around $15.1 million to the biogas plant project.
big investment and achieve the large-scale biogas production that we are planning. It is also very gratifying to find a partner who sees business opportunities in leading the way towards climate neutrality,” – Eskilstuna Biogas on the partnership with Furetank.
cubic meters of liquefied gas can be accommodated in two tanks on the vessel. Fure Vinga, oil/chemical tanker that was built in 2021 and is sailing under the flag of Sweden, was used for refuelling of the ship. Refuelling takes place at minus 162 degrees. The storage takes place at seven-bar Refuelling of a ship with Liq- pressure and is sufficient uid Biogas for five weeks of operation. Fure Vinga is equipped with Furetank became the first so-called dual-fuel engines, shipping company in Swe- which means they can run den and second in the world on both gas and conventional to bunker LBG in 2018. Now bunker oil. they confirmed to have a clear plan for the transition. Good biogas has its price There have been a lot of different opinions about ship- When compared to running ping, implying as if the ship- on oil, running on liquefied ping industry doesn’t care biogas, both fossil natural gas “In addition to these grants about the environment. This (LNG) and biogas (LBG), reand public production sup- can pave the way to show to duces all emissions of sulphur port for biogas, a long-term the world that the shipping dioxide, nitrogen oxides, and agreement with a strong part- industry can also go in a fos- particulates. However, carbon ner is required to make this sil-free way. Six hundred (600) dioxide emissions from fossil
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fuels are lowered as well. In terms of operation, there are no distinctions between natural gas and upgraded biogas. Furetank purchases its gas from Skangas in Lidköping, believing that it is of substantially higher quality than natural gas, with a methane content of 94%.
bio.”
“For natural gas, methane percent varies between 80% and 92-93%. So, it is good biogas we buy, but the price is another story. The biogas costs twice as much. I wish biogas production soon will be boosted. Our target is clear. We are going for 100%
Furetank LBG stand
Biggest challenge for refuelling gas Whether it is about LNG or LBG, the challenge is the infrastructure. This is just being built now for LNG, and LNG is fully compatible with LBG.
Furetank developed a new series of vessels that are on the top of the class according to the IMO’s climate standards for shipping. These vessels operate mainly on LNG, but their ambition is to switch
over to LBG. With LBG produced in the right way, they can run the vessels completely without emitting extra CO2 or harmful particles. “Furetank committed to buying at least 75 percent of the produced fuel for ten years. Production is to start in the last quarter of 2023.” - Eskilstuna Biogas When all shipping companies need to start paying for their CO2 emissions, this will be positioning Furetank one step ahead!
“ For natural gas, methane percent
varies between 80% and 92-93%. So, it is good biogas we buy, but the price is another story. The biogas costs twice as much. I wish biogas production soon will be boosted. Our target is clear. We are going for 100% bio.”
Lars Höglund
CEO, Furetank
Crossword Puzzle
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8.0 5
R 1
6
s 3
R
A
4
D
E
E
2
P
s R
TOP DOWN 1. The energy content of biogas (in kWh) per cubic meter. 3. It is a device found in CSTR type biogas plants, required for mixing and uniform heat dispersion in the biogas plant.
Answers of Crossword 7.0
5. Thermodynamic process utilized by many biogas-based power plants, coal fired power plants and nuclear reactors. It converts the heat energy to mechanical energy by cyclical process of heating and condensation of a fluid, typically water.
Please send your answer to info@biogas-india.com to win attractive prizes. Answers to be published in the next edition of magazine.
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CSTR based semi dry fermentation of Organic Solid Feedstocks
J
&F biogas offers a semi dry fermentation process based on the CSTR (Continuous stirred tank reactor) for the conversion of feedstocks with high dry matter content to biogas. The technology has been in use for over 15 years, with close to 100 biogas plants operating primarily in Europe. Organic solid feedstocks such as paddy straw, press mud, poultry litter, bagasse, napier grass have dry matter between 20 % to 85%. CSTR semi dry fermentation process can be used for feedstock with up to 35% dry matter without addition of water.
This article discusses the possibility of converting sugarcane industry based feedstock’s such as press mud and bagasse to biogas using CSTRbased semi dry fermentation process. It is estimated that India alone could generate close to 441,000 tonnes of CBG per year by using press mud as a feedstock for biogas generation.
high Dry matter (DM). The process can handle organic waste up to 30-35% DM without additional water for dilution. A unique mixing system was developed for handling high viscosity inside the digester, typically associated with feedstock containing high dry matter.
In the context of sugarcane industry, press mud has 30% DM (Dry matter) and bagasse 1. CSTR semi-dry fermentahas 50% DM respectively tion process which can be digested using There are various types of CSTR Semi dry fermentation anaerobic digestion technol- process. ogies available for digestion of various organic feedstock. 2. Press mud Selecting the right technolIn comparison to other tech- ogy for a specific substrate is Filter cake, commonly known nologies, the CSTR semi-dry critical to the successful op- as press mud, is the suspendfermentation process re- eration of a biogas plants. J & ed impurities separated, quires half the size of digest- F Biogas has developed CSTR during the process of cane ers, has lower operating costs, based semi dry fermentation juice clarification by the suland generates very little or no process, which is specifically phitation process. Press mud liquid slurry in biogas plants. suited for organic waste with traditionally is used as ma-
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nure through the bio-compost process by spraying spent wash on press mud. Sugar mills that are not attached to distilleries, sell the press mud to the sugarcane growers at concessional rates. For every 100 tons of sugarcane crushed, about 3.5 to 4 tons of press mud cake are generated as a by-product. It is a soft, spongy, amorphous and dark brown material, containing sugar, fiber and coagulated colloids, including cane wax, albuminoids, inorganic salts and soil particles. It consists of 70-73% water and 0.9 -1.5% sugars, organic matter, nitrogen, phosphorus, potassium, calcium, sulphur, coagulated colloids and other materials in varying amounts.
potential is not completely realized. Press mud is rich in organic matter, and the macro and micro nutrients, thus being a good substrate for production of biogas through anaerobic fermentation. 3. CSTR semi dry fermentation technology for converting press mud to biogas
Press mud has close to 7075% moisture, 25-30% dry matter and 75-80% organic dry matter. With semi dry Fermentation process, press mud with 30% DM can be digested without adding any water. Press mud with 30% DM when fed in to the digesters decomposes to close to 20% DM inside the digester. The 20% DM inside the digestIn the context of the sugar er is mixed with high viscosity industry, press mud is one of mixing system for reaching the by-products where the a uniform mass. Proprietary
mixers are used for mixing of high viscosity substrates in the digesters. The digestate, which is generated post-digestion has close to 20% DM (Dry matter) and 80% moisture. The digestate generated is in form a thick sludge which can be further dried and can sold as high value organic manure. There is no liquid slurry generated using CSTR based semi Dry fermentation process. The liquid slurry handling process is very minimal. 4. Bio-CNG potential from press mud in india The table here summarizes the total CBG generation potential from Press mud in India. Domestic production of CBG
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from press mud generated at sugar mills will save close to USD 270 Million worth of Forex savings per year on natural gas imports.
yield tests were conducted based on batch type fermentation process. Bagasse has dry matter of 50%, and Volatile solids are 90% of dry matter. The biogas yield of bag5. Comparison of CSTR semi gase using batch type process dry fermentation and other was 207 m3 of biogas per ton technologies of fresh matter. On Per ton VS(volatile solids) basis, the The table below compares yield is about 460 m3 of Biosome of the key parameters gas. In a continuous fermen-
CSTR Semi Dry fermentation will be suitable for digestion of bagasse, which has dry matter of about 50%. It is observed that viscosity in the digesters increases significantly during digestion of bagasse, thus a very strong and high viscosity mixing system is required for bagasse digestion.
for a 100 tons/day capacity press mud to biogas plant using CSTR semi dry fermentation process and other technologies such as wet fermentation based process
7. Biogas purification & bottling Biogas generated through the fermentation process can be subsequently upgraded to bio-CNG/CBG (compressed biogas). Upgraded biogas (CH4 > 95%) of natural gas quality can be used as a replacement for CNG (Compressed natural gas) and liquefied petroleum gas (LPG) in
tation process the gas yield will increase by 10 to 15%. The estimated yield in a commercial plant will be about 227 m3 per tonne of bagasse. The biogas yield from bagasse is two times the yield of press 6. Biogas from baggase mud however the cost of bagasse and its alternate appliBagasse is another substrate, cations need to be factored which can be potentially used for arriving at suitable applifor biogas generation. Biogas cation of bagasse.
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various domestic and industrial applications. Press mud and bagasse based biogas plants would thus eventually generate additional revenues for sugar mills. Government of India is actively encouraging sugar mills to use press mud for bio-methane generation to meet the rising demand for petroleum fuels and natural gas in India.
has been the main product with commercial value for quite a long time. Over a period of time, among other products, several by-products have evolved such as alcohol, power generation from bagasse, ethanol, CO2 production , organic manure via composting, etc. Press mud along with bagasse have huge potential for CBG generation from the sugar industry. CBG Conclusion produced from press mud Sugarcane as a crop is very along with bio-manure genunique which is used for pro- erated has an enormous poducing various primary and tential to add additional revesecondary products. Sugar nues stream to sugar industry
as a whole. CSTR Semi Dry fermentation process will be one of the best suited technology for handling press mud and bagasse with lower operating costs, minimal water requirement and higher overall efficiency in the digestion process. In addition to sugarcane industry-based feedstock, other organic feedstock such as paddy straw, poultry litter and Napier grass are also suitable for CSTR based semi dry fermentation process.
Joseph Vimal. A
Managing Director, J & F Biogas Pte. Ltd.
+91 7838447489 , + 91 7727077257
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Implementation of biogas projects in India
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he implementation or the realisation of a biogas project includes all stages of development, from idea formulation to feasibility studies and plant engineering to plant start-up. Project initiators (for example, entrepreneurs who are willing to install Bio-CNG plants under SATAT) can choose to carry out specific phases of a biogas project themselves, depending on their personal commitment and available financial and people resources. Concept development, feasibility studies, capital expenditure planning, permitting procedures, plant construction, and commissioning are all covered.
tial areas of work in depth. Formulation of a concept and a project outline Once a biogas project idea has been established, the project initiator/entrepreneur should create a project outline to serve as a guide for the project implementation.
This outline can also be used as a starting point for project evaluation. The project outline is used to determine not only the project’s site-specific technical feasibility, but also how it will be financed and whether it will be eligible for any government funding or subsidy (If any available). The project overview can also be The next parts are primarily used to make preliminary conpresented in the form of tab- tact with suitable engineering ular checklists to provide a full firms or experienced compaoverview of the procedures nies with good track record. required for project realisa- It is desirable to gather some tion and to discuss the essen- preparatory knowledge about
the planning approach and operation of a biogas plant from industry experts such as the Indian Biogas Association. Further preliminary information should be amassed on current biogas technology suppliers and plant operators, especially if identical substrates are to be used. When evaluating a biogas project, it’s vital to look at the big picture, which includes substrate availability, the biogas plant itself, and Bio-CNG and organic manure/digestate supply to offtakers. The three essential components depicted in Figure 1. must be evaluated in the same depth from the start, with the goal of conducting a well-founded initial appraisal of the project concept. The project outline should be written out in the following steps and reviewed using
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the mathematical methods provided in this Guide to avoid any needless additional complications in subsequent phases of planning:
accessible. 4. Cost estimates, government subsidy eligibility, any additional revenues like carbon credits and economic profitability. 1. Determination of the feed- 5. A review of the Bio-CNG stock/raw material supply and organic manure offtake chain; calculation and analy- strategy. sis of available feedstock vol- 6. Whether the plant’s official ume. permissions will be issued, 2. The plant’s rough techno- and it will be approved by the logical design including the local community and all the detailed BOQ . relevant departments/per3. A review of the land that is missions.
The above-mentioned factors do not require definitive conclusions during the initial evaluation of the project (this will happen during the later planning phase). Instead, the goal is to make sure that there is at least one, if not several, viable solutions for completing the project successfully.
Fig 1: Approach to the Biogas Project in General STEP-1 Examine the feedstock long-term availability
-Which self-produced feedstocks are likely to be available in the long run? If you are planning or have large agricultural land to produce your own feedstock. -Do I have any plans to change my agricultural land in the medium or long term? What impact will this have on my biogas plant? Can I rely on feedstocks, apart from the produces in my agricultural land in the long run (in terms of biology/materials, method, and biogas production etc)? Is it worthwhile to use other feedstocks in light of the legal requirements? -If other feedstocks are available then reliability of the agreements is to be looked into for the long term supply
Biogas Magazine | Edition 19 | 39 Visit some of the existing Biogas plants – -As a means of gaining experience and informaSuccess Stories which are operating at least at tion, go visit some existing plants. the 75% or above the designed capacity What are the structural options in the market? Where are the issues with the structure or process? -What were the solutions to such issues? -What have current plant operators’ experiences been with various component and feedstock combinations? -Try to visit and study the plant in detail – may be for 5 – 6 days visit to the same plant might give more information rather than single day visit Calculate how much time you have available
-Calculate, how much time you’ll need each day for basic inspections and maintenance. Is this feasible given the circumstances on my own produced feedstock or procured from outside. -What kind of working schedule is feasible for my project/company? Will I need outside help? (For example, who will take over the agricultural feedstocks from your own land/others land, what after the entrepreneur? Who will maintain and operate the plant?) -Will I need outside workers or in-house workers?
Examine how the Bio-CBG and Organic Manure can be put to good use/Sale.
-Are there any possible Bio-CBG offtakers near to the project? -Whether Bio-CBG will be supplied only to the OMC’s or any other offtakers as well? -How much Bio-CBG and Organic Manure the plant need to produce versus how much is sold consistently every month?
Calculate how much fund is available
-Examine your financial situation. -What do you think your income position will be like in the future? -Are you expecting any substantial changes in your financial condition in the near future?
Step 1 Objectives: An initial Study of the existing -Acquiring knowledge about what plants/compoBiogas Project/Business nents are available in the market -Gathering experience from real-world biogas plants -Understanding the actual equipment’s, civil works, electricals, automation etc. and their realistic costs.
Feasibility Study/Report Preparation:
entrepreneur has decided to advance to the next step of the potential biogas project It will be necessary to pre- based on the project outline. pare a feasibility study/report This would typically rely sigonce the project company/ nificantly on the project plan,
with the primary goal being to identify all technical, economic, and other early facts and parameters and thoroughly examine them. In contrast to the project outline,
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which gives a preliminary qualitative assessment of the proposed project, the feasibility study’s goal is to provide a quantitative assessment of the proposed project as well as potential implementation options. The major criteria for conducting a feasibility study on a biogas plant project, which are mentioned in further depth below:
addresses the following objectives: • A study of all characteristics and site-specific criteria is conducted to determine the project’s actual achievable technical and economic feasibility and not just the dressed hypothetical figures in excel sheets. • Assessment of technical and economic risks. • Examining possible organA feasibility study is a deci- isational and operational sion-making document that frameworks.
• Identifying exclusion criteria. • Establishing a foundation for preparing an application for a government subsidy/or any other available funding/ carbon credits. • Establishing a foundation for determining the realistic financial viability
STEP-2 Engage the services of a recognised and experi- -These persons are critical to the project’s future enced engineering firm/engineering department development and planning, and they will be inof a renowned biogas company/consultant. volved in all subsequent processes. Involve them for minimum 3 - 5 years after biological commissioning of the project. -They have access to contacts at permitting authorities as well as regional authorities and any relevant permissions required to set up the biogas project and operate it in long run One of the missing link is getting in touch with an experienced biogas operator/ advisor
An experienced biogas adviser is knowledgeable in the construction and management of biogas plants and can provide expert guidance on a variety of topics, including site selection and plant design, as well as construction and commissioning.
Decide and Finalize the type of the technologies to be involved, construction procedures as well as the sizing of the entire plant with appropriate justification.
-Site contour, soil report, is an example of defining site characteristics -Choosing a location (with reference to a general plan of the plant, buildings, etc). -The nearest offtake or gas feed-in point is located – both for Bio-CNG and organic manure -With reference to the company’s future vision and operational restructuring actions necessary by the biogas plant, a decision on appropriate plant configuration/design and technology should be made. -The plant components are sized based on a potential analysis. Get a third-party validation or the expert advice after finalizing. -Procedure question: How would I like the project to be carried out? -Do I want a turn-key plant? If yes, then the BOQ should be decided by the owner of the plant and not by the supplier.
Biogas Magazine | Edition 19 | 41 -Do I want to divide the plant construction process into many contracts that will be awarded separately? -How much of the work do I intend to complete on my own? -Is it possible for me to share the project with other companies? -Which contracts from the projects do I intend to put up to tender? (Civil works, electricals, mechanicals etc.) -Allow for a variety of possibilities. Step 2 Objectives:
Feedstock availability and logistics The success of a biogas plant hinges on the availability of sufficient and consistent raw material/feedstock for round the year for loading into the facility. Consider the cost of procuring the feedstock needed for the particular project. Livestock farms have an advantage because they already have low-cost access to substrate (dung), which is ready to be used in a nearby plant without the need for complicated logistics. Farms that keep livestock have this advantage. Furthermore, the digestion process can improve the quality of organic manure as a farm fertiliser. A crop-producing farm’s availability of substrate will depend solely on the available agricultural land and associated supply costs. Depending on the type and availability of feedstocks, a biogas plant will require a specific technology.
-Involvement of an expert engineering firm or advisor in the preparation of a feasibility study. -Determination of the preferred plant size and type, as well as potential offtakes for Bio-CNG and organic manure
Because feedstock’s availability is distributed and offtaker distribution is variable, feedstock logistics is critical in the overall supply chain. This includes all business and market-related activities aimed at supplying a particular feedstock. Material and information flow between supplier and offtaker is optimised. Securing long-term feedstock supply contracts is critical for a biogas plant that requires consistent feedstock input throughout the year. Sign contracts with suitable feedstock suppliers well before the plant installation starts or the civil work is being carried out. This will allow the plant itself, as well as the storage areas and storage tanks, to be planned around the anticipated feedstock and delivery intervals, balancing out any fluctuations in feedstock deliveries to the site. Prior to signing the contract, determine how feedstock de-
liveries will be billed. Billing is generally based on delivered volume. To avoid low-quality substrates, detailed quality standards and inspections are required. Feedstock pre-treatment (crushing and/ or mixing) and loading into the digester are accomplished by appropriate metering. The choice of pumps and conveying equipment depends on the substrates and treatment level. Decision Making The choice of technology for a planned biogas project will depend on the available feedstocks. The existing infrastructure, the involved parties, and the available financing. Once this is done make a detailed budget
Biogas Magazine | Edition 19 | 42 Depending on the procedure, a cost budget can be created.
The cost budget should always allow budget control with +-10% variation Organize the cost items into the following blocks: Each and every individual item costs to be included with detailed specifications and minimum of 3 quotations need to be looked into comparing with similar specifications. Feedstock costs (daily/monthlu/annually with 5-10% as losses) Maintenance and repair Depreciation Interest on the capital (equity/debt) Insurance Labour/Manpower/Overheads Costs Planning/Engineering/Design/Technology costs Utilities Cost to be covered in with the variations. Transport Cost of Bio-CNG and Organic Manure Chemicals/Arkalture/Brenzyme/gas booster/Odour control etc., cost to be included One should break down the costs of each component and estimate the cost of any work you plan to do yourself or contract.
Financing of the Project
The amount of money needed for external financing must be determined. You should take advantage of the bank’s financial advice; the Company’s financial situation should be thoroughly examined before deciding on a financing strategy. There should be a comparison of financing options. Whether with or without collateral and the project financials should be vetted by the third party before starting the actual project.
Srinivas Kasulla
Biogas Expert
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