NORDTEC INTERNATIONAL

An Engineering, Procurement and Construction company

19th October, 2019

Subject: Cost Estimate for Biogas Generation and Purification System

Dear Sir/Madam,

We thank you for giving us an opportunity to provide a cost estimate for biogas generation and purification system.
We have prior experience and a proven track record of completing similar projects. Some of the major projects we
have recently installed:

 A biogas plant for production of 65,000 m3/day Biogas on turnkey basis

 A biogas plant for production of 55,000 m3/day Biogas on turnkey basis
 A Complete Ethanol Distillation unit for production of 100,000 Liters per day ENA Grade Ethanol on turnkey
basis
 A complete Power Plant for Production of 4.4 Megawatt Electricity using Biogas and Bagasse as fuel on
turnkey basis

With Regards,

Shakeel Ahmed
Director
 Treatment Strategy and Process Description

The process being offered is based on the concept of conversion of organic matter into biogas. The process of
conversion of organic matter into biogas occurs through a group of bacteria.

Screening and Grit Removal Chambers

The pretreatment unit shall consist of Screening and grit chamber. A Feed Preparation tank is also provided
wherein dilution water shall also be added to the dung to make the slurry. In these units the raw dung shall be
mixed with the dilution water and the inorganic solids and bigger floating matter will be removed

Mixing Tank
In the Mixing Tank the cattle manure is mixed with water to get the liquid slurry which can be fed to digester. Part of
the over flow from the reactor will also be mixed with the slurry in the feed tank. The mixing tank is fitted with
screens to further remove solid particles and unwanted fibrous material.

Buffer Tank
In the Buffer Tank the slurry is stored to equalize the flow to the biogas digesters

Biomethanation Process
In the biomethanation process, which is a high rate process, anaerobic digestion takes place in the mesophilic range
of temperature, i.e. 36o - 40oC. The pH inside the reactor is usually kept around 7.2 while proper ratio of volatile acid
and alkalinity is maintained.

The following three stages are involved in the process of anaerobic digestion.

a. Hydrolysis: In the process of hydrolysis the complex molecular compounds i.e. polymers are converted into the
simple molecular form i.e. monomers.

b. Acidogenesis: The monomers so formed at the end of hydrolysis process are converted into volatile fatty acids.
Acetic acid forms the major portion of volatile fatty acids. The process of conversion of monomers into acids is carried
out by a group of anaerobic bacteria known acid formers.

c. Methanogenesis: Acids produced at the end of Acidogenesis process are converted into carbon dioxide and
methane gases. The process of conversion of acid into gases is carried out by group of anaerobic bacteria known as
methane formers.

In the process offered, the bacteria responsible for digestion process are kept in suspension with the help of Lateral
as well as central mixers.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
CSTR Reactor

The CSTR Reactor is designed on the principle of anaerobic contact process. The raw effluent enters in each digester
at the top in a central shaft, recirculated sludge is also mixed with the raw feed. A central agitator is provided at the
top to facilitate mixing and downward movement of the mixed biomass. The effluent travels to the bottom of reactor
through central shaft. In reactor the effluent comes in the contact with active anaerobic culture maintained in
suspension. In the process, the organic matter in the effluent is converted to biogas and cellular mass. The liquid
travels upward in the reactor. Lateral agitators are provided for mixing and upward movement of the liquid. The
effluent is then taken out of the reactor through overflow pipe provided with a water seal.

CSTR reactor will be erected and fabricated at site using mild steel (ASTM A36) plates and structural members. The
reactor will be painted from inside with Epoxy paint in Gas Zone and synthetic enamel paint from outside.

Lamella Clarifier and Degasser Tower

The effluent will be received in a lamella clarifier where the active biomass will be separated and part of it is re-
circulated back to the reactor. Before entering into the lamella clarifier the effluent is passed through degassing
tower for removal of dissolved gases to achieve better settling in the lamella clarifier. Lamella clarifier is fabricated
fabricated in MS Plates and painted with Epoxy paint. Lamella Pack in FRP inclined at an angle of 60 Degree is
provided inside lamella Clarifier. The clarifier shall also be provided with sludge withdrawal arrangement. Sludge
Recirculation pumps is provided to recirculate the sludge back to the CSTR reactor.

Biogas Recovery

Biogas will be collected at the top of the reactor and will be stored in a gasholder separately constructed. Biogas
holder is fabricated in MS plated and shall be of floating type. Biogas from biogas holder will be compressed and sent
to boiler for burning. Flare stack is provided to flare the excess biogas.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Detailed Technical Specifications for CSTR Reactors

Type CSTR digester, operating in

Mesophilic Range of temperature
Design Standard API 650
Tank Geometry Cylindrical Tank with Dome shaped
roof
Diameter 28.5 meters
Height 18 meters
Free Board 0.75 meters
Operating Pressure 200 mmwcg
Maximum Pressure 400 mmwcg
Thickness of Shell 20mm – 6mm
Annular Plate 12mm
Base Plate 8mm
Roof Plate 6mm
Support System Central Column Supporting
Sludge Recycle System Overflow from Digester with
Degasser and Lamella Clarifier

Mechanical Components for Biogas Digester

Central Agitator: Propeller Type mixer with very High Transport capacity.
Fabricated in SS 304. Provided 1440 RPM Flame proof motor. The Agitator RPM 1
shall be 70 – 96 RPM

Lateral Agitator: Propeller type mixer provided with SS 304 Impeller. RPM of the
Agitator shall be 340 RPM. The Agitator shall be provided with 3 Phase 3
1440 RPM motor. The agitator shall be fabricated in SS 304.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Details of Biogas System Components

Mechanical
SN Treatment Unit MOC
Equipment

Buffer Tank (Feed MS Steel Digester Feed

1
Sump) Pumps
Mild Steel, Epoxy
2 CSTR Digester Painted inside in As above
Gas Zone Only
MS Epoxy Level Indicator,
3 Flare Stack
Painted inside PG

Mild Steel, Epoxy

4 Degasser -
Painted inside
Mild Steel, Epoxy
Sludge
Painted inside
5 Lamella Clarifier Recirculation
Provided with
Pumps
FRP Packs
Mild Steel, Epoxy
6 Gas Holder Biogas Blower
inside & Outside.

7 Pressure Breaker MS Epoxy Water Seal Type

8 Vacuum Breaker MS Epoxy Water Seal Type

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Details of Installed Equipment

Raw Feed Pumps : Horizontal Centrifugal Pump With Semi-open impeller, SS

A 304 Construction, Coupled with 2900 RPM, 3 Phase squirrel cage induction type
Motor.
Sludge Recirculation Pumps: Horizontal Centrifugal Pump having semi open
B impeller, SS 304 material, Coupled with 2900 RPM, 3 Phase squirrel cage induction
type Motor.
Liquid Flow Meter: Electro-magnetic flow meter SS 316 material, complete with On
C
site Indication and Integrator
Gas Flow Meter : Vortex type gas Flow meter to measure instantaneous and
D
Total Gas Flow, SS 316 construction.
Pressure gauges for liquid pressure measurement : Bourdon type pressure gauges
E
with ½” NPT connection, pressure ratings 0-5.0 kg/cm2, 4” Dial Size.

Pressure gauges for Gas pressure measurement : Diaphragm type pressure

F
gauges with ½” NPT connection, pressure ratings 0-1000 mmwcg, 4” Dial Size.

G Temperature Gauges: Dial Type temperature Indicator with 0-100 deg C range.
Manometer for measurement of Gas pressure in Digester : U Tube manometer
H
encased in wooden casing, with range of 0-750 mm
Biogas Blower: Rotary Twin Lobe type compressor pressure rating of 3500
I mmwcg. Provided with safety Valve, Non Return Valve, Coupled with flame proof
motor.

J Pressure switches for High & Low Pressure Indication and Blower operation.
Flame Arrestor: Suitable Dia. SS Flame arrestor suitable for biogas
K

Breather Valve: 150 / 100 mm Dia Dead weight type breather valve, pressure
L
setting 500 mm WCG and vacuum setting 70 mmwcg.
Plate Type Heat Exchanger : Plate type heat exchanger to reduce the temperature
M
of feed
N Moisture Trap : Baffle Wall Type Moisture Trap fabricated in SS 304
O PLC: For process variable control and Monitoring
P Variable Frequency Drive: For blower and feed Pump frequency control
Q Control Valves: For process control

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
 H2S Scrubbing System
The H2S Scrubbing System consists of Mild Steel Tanks installed with support structure for housing biological
culture. As the biological reaction is aerobic in nature, air is injected in to the incoming biogas stream and it is fed
into the scrubbers. The biological culture oxidizes the hydrogen sulfide within the biogas, producing elemental
Sulfur and other sulfates

The H2S Scrubbing System comprises the following main systems

 Circulating pumps.
 Water flow meter for circulation pumps
 Meter for supply of treated effluent
 Meter for supply of raw water
 Frequency controlled air blowers for adding of atmospheric air to the process
 Air flow meter
 PLC Controller
 Gas Detector system

Biogas flow (m3/h) 14200 m3/hr

Biogas flow variations Max 1% per minute

Biogas temperature at inlet of H2S Scrubber 30-35

Biogas pressure at inlet to H2S Scrubber (mbar) +20 / +30

Ambient temperature Min. 150C, average 32 0 C and max.

450 C
Supply of treated digester effluent 25-50% of total liquid supply
(screened to 0.1 mm particles)
H2S raw biogas (max ppmv) 30,000 (3%)
H2S clean biogas (max ppmv) 200
Relative humidity in clean gas (% RH) 100

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Bio-methane Concentration System

The bio-methane concentration system operates on the principal of chemical absorption. Chemical absorption
guarantees an easily tunable production (large turndown ratio, up to 1:4) and a constant performance in purification.
All the apparatus works in low pressure (no certification or special permissions required to the users), simple
equipment with low maintenance (no multistage pumps installed, all the sulfur compounds are removed before
compression and standard compressors can be used), low energy consumption (only the pure gas is compressed),
negligible methane losses, no accumulation of sulfur into equipment, negligible water consumption, no need for
frequent cleaning of equipment (reduced shutdown time).

The system is completely automated and monitored by a dedicated PLC control panel. Plant is prefabricated in TPI
shop on skid units to minimize erection time. Piping is extensively prefabricated and the units are pre-wired to
junction boxes to allow a fast execution of site cabling.

The system is further equipped with a standard CO2 recovery unit, designed and configured for the production of
food grade quality CO2.The biogas stream from H2S Scrubber will be diverted to the Upgrading Biogas Equipment for
processing. The purified biogas is obtained at the top of the absorber and piped to a valved connection.

The resultant inert vent stream vapor exiting the Extraction System’s Stripper will be sent to the CO2 recovery plant.
Inlet stream will include a temperature and a pressure measurement and a flow meter to allow for various flow rate
selections. When the raw gas is directed to the Inlet Purifier, the H2S content will be reduced to acceptable levels
before further processing in the extraction system. The Solid Mass Purifier includes an O2 injection system to improve
the efficiency of purifier.

After processing in the H 2S purifier, the raw gas is sent to the absorber tower for CO 2 extraction. In the Absorber
Tower, the gas passes through a series of packed beds designed to allow sufficient contact time for efficient
absorption of the CO2 into the Absorbing Solution. The purified biogas exits from the top of the Absorber Tower
through a specialized demister section designed to minimize the physical loss of your recirculation solvent.

The rich solution (solution rich in carbon dioxide) is then pumped from the Absorber Sump to the Lean/Rich Heat
Exchanger, where it is heated before entering the Stripper Tower. Enhanced pre- heating by a high surface double
passage plate heat exchanger (with a temperature approach lower than 10 °C) will allow to minimize heat
requirements of the plant (lower methane consumption).

Moreover high inlet temperatures of the rich solution will ensure maximum stripping in the top portion of the
Stripper Tower. The lean solution (solution stripped of carbon dioxide) accumulates in the Stripper Sump and flows to
the Steam Heated Reboiler. The solution steam generated in the Reboiler is piped to the Stripper Sump where it flows
upward, countercurrent to the rich solution. The absorbed CO2 is released from the rich solution, flows to the top of
the Stripper Tower. The CO2 then exits the Stripper Tower and enters the Product Cooler and Knock-Out Drum,
where the solvent steam is condensed and the CO2 cooled. The resultant condensate from the Product Cooler is
returned to the system, providing the condensate for a wash packed section.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Solid Bed Purifier

The Solid Bed Purifier is filled with first charge of purifying material (Iron Idroxide / Oxide based). Estimated life
minimum 6 months.

 MOC: SS 316
 Filled with Metal Filling
 Equipped with discharging Device
 Maximum Height: 10.5 meters

Absorber Tower

The Absorber Tower is designed and manufactured for efficient removal of CO2 from the raw gas being processed. It
includes stainless steel packing complete with solution distributor and re-distributors to protect against possible
channeling of the liquid solution.

 Absorbs CO2 into the solvent solution

 Wash section recover amine/solvent traces from the vent stream
 Low pressure drop design, DP monitoring
 Stainless Steel Tower – Nuts & bolts in hot dip galvanized Carbon Steel
 Stainless Steel Internals
 Stainless Steel Structured Packing - High performance corrosion resistant structured packing
 Solvent distribution & redistribution trays
 High Efficiency Wire-Mesh Demister

Stripper Tower

The Stripper Tower is designed and manufactured for efficient removal of CO2 from the absorbing solvent. It includes
stainless steel packing complete with solution distributor and re-distributors to protect against possible channeling of
the liquid solution.

 Desorbs CO2 from the rich solution

 Low system factor design to compensate foaming tendency, DP monitoring
 Stainless Steel Tower – Nuts & bolts in hot dip galvanized Carbon Steel
 Stainless Steel Internals
 Stainless Steel Structured Packing - High performance corrosion resistant structured packing
 Solvent distribution & redistribution trays

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Biogas Booster

 Provides sufficient positive pressure to overcome pressure drops across piping, treatment components and the
absorber tower
 Centrifugal design
 Carbon steel body with internal corrosion resistant lining – stainless steel impeller
 Flow control with feed gas flowmeter and suction pressure control system

Solution Generator

 Solution Generator is designed to produce the necessary volume of solution steam as required to effectively strip the
CO2 from the rich solution
 Produces solution steam necessary for stripping CO2 from the rich solution entering the stripper tower
 Heat source: saturated steam 6 bar
 Stainless Steel construction
 Installation linked with stripper tower


Stripper Tower Condenser

The reflux condenser is specially dimensioned for low pressure drop and to avoid mist formation.

 Water Cooled
 SS Plate & Frame
 Design pressure 6 barg

Stripper Condensate Tank

The reflux drum is designed and manufactured for efficient removal of the entrained condensate after the reflux
condenser.

Solution System
The solution system employs a step type filtration system to effective remove down to 25.0 micron from the
circulating solution without excessive filter loading and change out being required. This is required to lower the
potential for foaming in the system that will result in lower production and operational difficulties.

Inherent in the design of this system is a solution / solution heat exchanger that utilize the heat from the stripper
tower’s lean solution to pre-heat the systems rich solution from the absorber sump. This design allows for a higher
inlet temperature to the stripper tower where the majority of the CO2 vapor will be stripped in the top section. This
design lowers the potential for liquid hang-up in the tower as is effected when a large amount of CO2 vapor is
released in the stripper towers lower section. Also, with the higher inlet temperature, during this heat transfer
operation, CO2 vapor is released from the rich solution, which again contributes to the lower overall heat input to the
system required.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Solution System Components

 Lean / rich heat exchanger – plate & frame – Stainless Steel plates – 10 barg design
 Water cooled trim cooler – Stainless Steel plates – 10 barg design
 Rich solution – Stainless Steel solution pump and filter
 Lean Solution – Stainless Steel solution pump
 Flow meters, temperature indicators, pressure indicators, etc. to allow for monitoring and controlling flows for rich
and lean solutions with data acquisition

Bio-methane Compression System

The purified Biogas Methane generated through the system will be compressed through Multiple Compressors
working in a parallel configuration. The gas will be compressed upto a pressure of 24 bar.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
 Tentative Cost Estimate
Mechanical Fabrication and Installation of Biogas Generation System

Sr. No Description of Works Total Amount

(USD)
01 Fabrication and Erection of Biogas Digesters with Accessories (Pressure and Vacuum
7,935,500
Breakers, Gantry, Overflow Weir etc.(16 Nos.)
02 Fabrication and Erection of Degasser Towers (16 Nos.)
03 Fabrication and Erection of Lamella Clarifiers (8 Nos.)
885,000
04 Fabrication and Erection of Gas Holders (8 Nos.)
05 Fabrication and Erection of Moisture traps
Total 8,820,500

Integral Piping within Plant Premises

Sr. No Description of Works Total Amount

(USD)
01 Integral Piping and Pipe Supports within Plant Boundary Limits 80,000
Total 80,000

Civil Work for Biogas Generation System

Sr. No Description of Works Total Amount

(USD)
01 Complete Civil Works for Equipment Foundations, Control Room and other units 902,000
Total 902,000

Supply and Installation of Mechanical Components for Biogas Plant

Sr. No Description of Works Total Amount

(USD)
01 Central Agitators for Biogas Digesters (16 Nos)
02 Lateral Agitator for Biogas Digesters (48 Nos)
03 Biogas Blowers (6 Nos.) 163,000
04 Biogas Feed Pumps (4 Nos.)
05 Sludge Recirculation Pumps (16 Nos.)
Total 163,000

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
Complete Electrical & Instrumentation Supply and Works for Biogas Plant

Sr. No Description of Works Total Amount

(USD)
01 Complete Instrumentation Supply and Works for Biogas Digester 175,000
Total 175,000

Mechanical and Civil Construction of Feed Pre-Treatment System

Sr. No Description of Works Total Amount

(USD)
01 Collection Tank
02 Screw Conveyor
03 Mixing Tanks
250,000
04 Screening and Grit Removal Tanks
05 Buffer Tank
06 Static and Dynamic Mixers
Total 250,500

Mechanical and Civil work for Hydrogen Sulfide Scrubbing System

Sr. No Description of Works Total Amount

(USD)
01 Hydrogen Sulfide Scrubbing System along with Accessories 3,750,000
Total 3,750,000

Mechanical and Civil Work for Methane Concentration System

Sr. No Description of Works Total Amount

(USD)
01 Methane Concentration System along with Accessories 5,850,000
Total 5,850,000

Supply and Installation of Methane Compression System

Sr. No Description of Works Total Amount

(USD)
01 Methane Compressors with Accessories (5 Nos.) 550,000
Total 550,000

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
 Grand Total
Sr. No. Description of Works Total Amount
01 Mechanical Fabrication and Installation of Biogas Generation System 8,820,500
02 Integral Piping within Plant Premises 80,000
03 Civil Work for Biogas Generation System 902,000
04 Supply and Installation of Mechanical Components for Biogas Plant 163,000
05 Complete Electrical & Instrumentation Supply and Works for Biogas Plant 175,000
06 Mechanical and Civil Construction of Feed Pre-Treatment System 250,000
07 Mechanical and Civil work for Hydrogen Sulfide Scrubbing System 3,750,000
08 Mechanical and Civil Work for Methane Concentration System 5,850,000
09 Supply and Installation of Methane Compression System 550,000
Total 20,540,500 USD*

Total in Words: Twenty Million five hundred and forty Thousand and Five hundred US Dollars *

*The prices quoted are exclusive of all taxes and duties, any taxes applicable will be charged as per actual

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk
 Terms and Conditions

1. This offer is tentative in nature, based upon current conditions and is subject to change. Nordtec
International should not be held liable in case of change in final offer based on a complete and
comprehensive design activity

2. Nordtec International’s scope of work comprises only of the works defined in the description of works. Any
additional work will be charged as per actual.

3. Our prices are inclusive of all labor charges, consumables and material.

4. All tools and implements will be arranged by Nordtec

5. The prices quoted are exclusive of all taxes and duties

6. The client will be responsible for the supply of Utilities (Electricity, Power, Water etc.) at the site.

7. The client will be responsible for providing secure and clean workspace for Nordtec workforce.

8. In case of any rises in the cost of material, consumables or labor due to any change in laws, regulation or by-
laws made by government authorities, local or otherwise, the increase in cost will be added to the total price.

Suite # C-15, The Plaza, PECHS Block 6, 92 21 34520 321 info@nordtec.pk

Shahrah-e-Faisal, Karachi 75100, Pakistan. 92 21 34860 320 www.nordtec.pk