Biogas Project (2024)
This write up is about the Bio- gas. The bio gas is produced from the organic matter like the cow dung, animal manure, off farm agricultural waste, and the municipal/ house hold green trash includes, rice husk, sorghum stalk, grain, corn, cotton stalk, sugarcane bagasse, tree roots, branches leaves, broken wood pieces, wood processing left over pieces, rotten foliage, urban furniture waste and dry / wet, poultry droppings, zoo animal excreta, all kinds of scrap of the cattle colonies, cattle auction centers or abattoirs, municipal / home kitchen’s vegetable peels, rotten cooked meals and many more, which otherwise, was good only for the landfill.
The discovery of the anaerobic digestion, (1870) took dramatic escalation after the Second World War (1939-1944). It altered the agricultural canvas opening new vista of harnessing energy, providing natural gas for cooking and heating the residential units and commercial structures and moving the industrial and transport sectors. The rural uplift planners, also gripped the idea instantly and started working on that low cast, natural, multi-dimensional sustained and easy power supply, rapidly uplifting the life quality of the farmers.
Currently (2024) China, has over 3 million bio gas plants and and Germany being number two, the world over, has 9, 496 (2023) producing 32, 500 GWH electricity. North America and African countries all prioritize it, over other alternate sources of energy, like coal, solar wind, hydro or -carbon. The Exxon, oil giant of the world, has estimated a triple-fold rise in the demand of the biogas by 2040.
Canada being no exception, has also set up, over 250 Biogas facilities (2023) mainly for the off-grid land-farmer communities, to facilitate their house-heating, cooking and the use of agricultural appliances and improve their farm’s health, whose soil has been impaired by the costly chemical fertilizer.
The easiest way for the land owners to start a small/ medium size (2.500 kg per day cow dung. biogas facility), is to combine the land cultivation with rearing the dairy heifers, or yearlings for dairy or beef and using their dung for anaerobic digestion yielding the Methane gas for energy purpose.
The rearing of the heifers for dairy or yearlings for slaughter is a paying business. Opting to develop the slaughter animal starts with buying the six months old calves at an rice of $ 4,00 per head. The birth weight of a baby calf in Canada, is about 15-20 Kg, which on average, rising on the mother’s milk or if weaned, on the dried milk powder The calves are then weaned & shifted gradually, from the mother’s milk to stall-feed. By the time they are one year old and called yearlings their gross weight touches 400- 550 kg in 6- 7 months, depending on the feed they eat. The current (2024) rearing cost of Canadian yearlings, is $ 5, per calf per day for 150 days x @ $, 5 + the purchase cost $t= 45,000 of 50 calves., The cost may further go up to cover the mortality, and illness. The live slaughter animals are auctioned at the current, (2024) sale rate of $ 5 per kg, Average 400 kg weight, x 5=2,000 x 50 animals= $ 1,00,000 per month which may be rounded up to 35, 000, per month.
The best feed to fatten the slaughter yearlings should have clean drinking water, proper periodical vaccinations and the balance diet with carbohydrates like gram/ wheat/ Rice/ Corn, stalk and crush. Boiled sweet & ordinary potatoes., oil seed cakes. protein, of soya bean oil, green leaves of corn, Australian Napier grass, Alpha (Bernice / Losen.) corn cobs, and minerals like salt etc. with weekly weight improving chart and veterinary consultation sheets.
A healthy dairy cow of average weight of 450 (K g) produces 7-10 kg. dung per day. { 6,00 calves reared for six months for slaughter sale and sold as yearlings, 50, per months, will produce (600 X 6=3,600,Kg manure per day, or X 30 days = 108 tons per month, which can be sufficient for the two digesters of 32 cubic meters each producing 80 cubic meter gas per head per day., equal to 240 kwh pr day This size digester is good only for the fresh dung which already has 85 % moisture. If dry dung is used then then it will be mixed with an equal volume of water and the size of the digester will be doubled i.e. 64 c. m.
The bio gas plant operates in three stages:
The 10 tons dry or fresh dung, (per day) with equal volume of water if it is dry, will firstly be taken to the Agitator tank for a pre-digest treatment for six hours. A mechanical cutter / agitator, fitted in, will tenderize, crush and blend it, turning into a liquify form suitable for draining to the second phase chamber, The digester. The digester tank (of 62 cubic meter) with 40-45, degree centigrade temperature ad Ph level of 7 degree, will help start the acidification process of generating gas.
The semi liquified bio mass, reaching the digester tank, will need the same temperature of 40-45 degree, centigrade and Ph level 7, (maximum.) for the ambient production of gas. The four stages process will take three weeks to ferment the slurry (liquid bio-mass) wherein bacteria will be generated and produce 40 % Gas of the bio mass per day, which can be converted to 480 KWH electricity per day.
The Digesting chambers will be heated from inside, through the hot water pipe, wrapped inside of the chambers. The heated water recycled from a nearby boiler of 3000, liters capacity, will be set up at least four meters away from the digester & the agitator tanks. A mechanical stirrer or vibrator will also be provided in the tank, to constantly blend and create bubbles for the convenient split up the residue solids if any, for the easy digestible feed for the micro-organic worms taking birth in the digesting chamber for the natural anaerobic process. The first filling of the agitated dung/ biomass, in the digester chamber should not be more than 20 %. Of its capacity. The rest of the capacity, will be filled in the successive four weeks with 20 % filling every third day. After the first month, 20 % every second day in both the tanks.
The bio mass of the Digester tank starts anaerobic decomposition within .10-15 days, and continues to operate permanently, until the cycle is interrupted by jumble of the layers of the, sand, solids or excess ph level at the walls/ the floor of the digester tank. It is, therefore is necessary to keep scratching and removing such substance periodically and routinely monitoring the Ph level. In the second phase of the project the third digester of 350 (10 x 10 x 3.5) Cubic meter will also be developed to raise the gas production to 2.5 MWH er day.
The digester chamber, whether cubical or round silo shape, concrete, or metal with fixed or flexible dome, must be perfectly air tight and completely insulated to stop any gas leakage.). Its microbes-/ bacteria eats up the tiny well blended bio mass, dissipating its foul smell, laying eggs to multiply three times, to continue generating the gas, and completing their life cycle of sixty days and becoming of the part of the decomposed manure.
The process occurs under the following four stages to convert the matter into gas;
The raw manure /dung passes though the following four phases of decomposition.:
Hydrolysis.
Acidification,
Acetic acid production.
Release of the gases comprise of composition:
Methane gas(CH4) 55- 62 %
Carbon dioxide 25-35 %\\\\
Nitrogen 0- 7 %
Hydrogen 0- 1 %
Hydrogen Sulphate 0. 5 -1 %
Oxygen 0- .5 %
Facts of the production, conversion and versatile uses of the Methane gas.
- 2, 500. kg daily input of biomass / dung/waste, can produce 80 cubic meter(cm) methane gas.
(2) Or 80 cubic meter (cm) gas can be converted to 324 kwh electricity, ( this is ideal not actual)
(3) 2,500, daily input of the dung/biomass needs 32 cubic meter space.
(4) 1000 k g bio mass can produce 45 cubic meters gas, and 10 mton 450 cubic meter gas.
(5( To generate 2.5 MWH electricity per day, a digester of 350, M. 3, will be required wherein 24 tons dung/ biomass will be fed every day. The net power production, however should be adopted at 15 % less. discounting the power production fluctuation and the farm owner’s personal consumption and usual line losses.
(6) The Methane gas can also be condensed. as (C N G) condensed natural gas) for bottling / cylinders,) or further purified to 96 %, by passing through membrane to remove its moisture etc. qualifying for the liquified petrol for the vehicles
.( 7) The commercial exploitation of the biogas is versatile and empirical, both for domestic and industrial purposes
(8) The city grid, of Saskatchewan province buys electricity from alternate sources, including the iogas, @ 7-10 cents per KWH (2024) {2,500 kwh, sold for $.0-7 cents ( $ 175 per day or 5,250 per month.
(10) The gas can also be used on farm land, for kitchen cooking and heating houses and for all other power-based appliances.
(11) The residue waste of the digester, about (30 % of two, digesters of 5 tons =) 1,600 kg per day. Is also a bye product of the slurry, which is collected from the lower layers of the decomposed biomass that oozes out constantly. It is. S natural and nutrient dens, cheap, popular and alternate farm manure, bulk sold currently (2024) @ 40 cents per kg against the costly and soil health impairing chemical fertilizer. The biogas plant can earn an additional income of (40 cents x 1600 = $ 6,400. per day.
(12) The Ph levels of (acidity) should be checked every day to be kept at Ph level 7. If it increases, the bacterial activity to produce gas will be adversely slowed. Lime stone cooled in water for 8 hours be added to the DC to reduce the Ph level to 7.
(13) The Digester chamber temperatre should be mantaine 40 to 45 degee centigrade/100 fareinheig.
(14) Water requirement for 4,000 lite rper day for ( 4,000 lit oer day for 600 cattls cattles and 6,000 lit per day for the biogasplant.The waste water will be used for land farming.l
(15) The waste water( mixed with the slurry will also be used for liquid sluury fertilizer
COST OFF THE CAPITAL ASSETS. (2024)
- LAND. 50 acres. $ 1,00,000
Preferably, 50 fertile acres with a well or nearby water body and access to the city grid, for selling power. The land will facilitate easy feed for animals and dung for the bi-gas plant.
CATTLE SHEDS for 6.00 animals) $ 2,00,000.
Covered and heated, for 6,00 yearlings, 3 Sq. meter per head, 1800 Sq, meter rounded to 2,000 sq. m. Plus the cattle’s open roaming area (10 acres). 2,000 sq. meters. @ $ 100 per Sq meter=2,00,000
MANURE DUMP YARD (50 Tons (total, 500, cubic meters)
Partitioned, half for fresh / half open for dry bio mass. Cost @ $ 50 x 250 m3 $ 12,500
- AGITATOR TANK. Cost $ 1,000
For 2 tons mass + water, every second day. size, 2.6 cubic meter Cost @ $ 50 per cubic meter x 2.5= $ 150
. ( 4) ANAEROBIC Digester TANK cost @ 50 p.. = 17, 500
(one) for 10 tons Biomass + water+ gas) 216 cubic meters (6 x 6 X 6 m =216 c m construction cost 100 x 216= 21, 600 producibg 480 kwh per day
- GAS STORAGE TANKS cost 10,000
(2 ) The excess gas for the farmer’s own use will be transferred to the cylinders .
( 6) The slurry tanks (10 x 10 x 1.5 (150 cubic meters) Cost 10,000
Biogas & the boiler components, security valves memberane etc 30,000.
Total cost of the capital assets.
Land 1,00,000
Cattle shed 2,00.000
Agitator tank 1,000
.Digester Tank (216 M3) 21, 600
Gas storage 10,000
The Slurry tank 10,000
Componants equioment and installation 30,000
Total cost of the capital assests. ——————————- 3, 52,000
The lowest layer of The bio mass slurry forms the decomposed dung at a ratio of 30 % of the total mass. The residue (slurry) is then channeled to a separate tanks sky open, and slanting floors with 30, degree decline to allow the gravitational flow to the farmland or for packing as the crystalized dry granules. Three ton (30%) of bio mass may be collected every third week) Currently, (2024) the dry manure bulk lowest sale rates are 40 cents per kg. (@ $.300 per ton.
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Any bio gas plant set up in Saskatoon needs to have the approval from the provincial Govt where the farmers needs to submit the whole feasibility.
DRAFT FEASIBILITY.
- The scheme description, with the past experiences of the planners submitted with the, feasibility, sources of the finances for the capital assets and the running expenses, expected net income and the maps of the required buildings, if needed.
- Probable quantity of the water required with waste water, retreatment/ filter/recycle plan,
- Description of the environmental risks involved and their protection.
- The plan for the waste management.
- The private sale of biogas and power is
- allowed. The Govt also buys 7-10 cents per KWH. from the farmer, with the connection cost realized from the consumer or the grid authorities.
THE GOVT. OF CANADA AND NUMEROUS OTHER AGENCIES ARE ALSO AVAILABLE TO HELP THE ENERGY FARMERS
The Canadian Bio-gas Association. (CBA)
Ph No. 1 (613) 822-1004/ email. jgreen@biogasassociation.ca
The CBA guides the bio gas farmers to establish and solve their problems, including providing loans to set up the biogas plants.
The federal govt. had announced a program of agriculture partnership (2021), for which $ 15 million, were allocated. The Saskatchewan farmers had set up only 8 bio-gas facilities uptom 2023.
To get the membership, send the following information; to the CBA.
Full name the last name.
Name of the Organization with address.
Email/ phone No.
The saskatoon city government has schemes for the returns and rewards for the reduction of the Carbon gases, and performance credit standards .
The city govt, also has three programs for the bi-gas/alternative energy producers to buy back their excess energy for the grid
Contact Saskatoon City Hall, 223, Third Avenue, North, (8-5 PM
Light & Power section, (306)-975-2414—(306) 975-2621 )
The city Govt. also has three options for the bio-gas and alternative energy producers to sell their excess power to the city grids.
Net meting program. (2) Future credit in the energy bills and (3) Small power (up to, 100 Kwt H. per day) purchase @ 7 cents per kwh. Up to 2026. (The power purchase rates were revised jn 2023)
List of the manufacturers of biogas- equipment’s of plant.
- GRUNER RENEWABLE ENERGY CO. India (collaboration with Germany). Also works in collaboration
By 2023 installed 310 gas units of upto 300 tons waste capacity.
Address: 22nd floor Winsdsior Ground Plot, Sector 1-c, 125 Noi*\da (UP)India
Email: info@grunerrenewable.com/ Ph. 1800 890-5180.
They manufacture: Agitator, Mixers, Pumps, Temperature controllers, Gas purifying membrane, to purify up to 96 %, Safety valves, controlling gas emission, Cylinders for bottlings the high density condensed gas. Digester tanks inside piping, Blenders, Stirrers, bubble blowers, and grinders etc
- AGRI KUMP GMBH (Germany). (Est. 2002-23). Also upgrade methane gas purification.
PH. + 49. 9826-65959-0 /email: . Infoagriukump.com
Add. 91732 Merken Dorf. Germany.
(700 employees/ installed over 1,000. bio gas plants wit 400 MWH
- B D I BOI ENERGY INTERNATIONAL GROUP (Austria)
Ph. + 43 (316) 409-100. E -mail. bdi@bdi-bioenergy.com
- MANURE MANAGER. (Canada)
Biogas equipment supplier.
- PLAN ET BIOGAS. GMBH. (Germany) Office USA / Canada.
Canada: Add, 157 \kCushman Red. St Catherine, Ont. I2M 6T4.
+1 (905) 935-1969) Email; info@planetbiogas.ca
- Alibaba.com (Made in China)
(6A)Gas purification system. (14,000 Guz ZYdUs $ April 24)
(6B) Biogas power plant ($ 37000-57,000)
- FUTURE BIOGAS LTD. U.K.
10-12 Frederic Sanger Road, Guildford G U Z Z Y D (U.K)
- WELL TEC BIO POWER. (Germany)
Euro pages. (UK).http:/ weltechbiopower.com
- SCANDINAVIAN BIO GAS FUEL INTERNATIONAL AB Sweden)
- The BIOMASS GASIFICATION PLANT ( China)
E mmail ; info@powermaxgasifiers.com
(pH.,+ 86 (510) 68229610/ And 86( (138) 208- 3566
l The co. uses heat to transform carbon inn to natural gas.
- QUANTUM GREEN. Add. 526-1, Shree Kumaran Garden Tamil Nadu 641031(India).
Ph.+ 91 (824) 8100-799)& 91-(880) 787-2115
Email; quantumgreentechnology@gmail.com (Rcd. Repl11/5/24. Prices not quoted)
- Storm Fisher (Canada)
- RENER GON INTERNATIONAL A G SWITZERLAND.
- AB HOLDING SPA (Italy)
- AMERESN( BIO GAS Wing) (New Jersey,U S.A).
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