main project

“INSTITUTE OF ENGINEERING AND RURAL TECHNOLOGY”
A Project Thesis on
BIOGAS GENERATION FROM STUBBLE IN NORTH INDIA
Submitted in partial fulfilment of the requirement for the degree of
B. TECH CIVIL ENGINEERING (8TH SEMESTER)
Under the Guidance of Mrs. SWETA MALVIYA
ASSISSTANT PROFESSOR OF DEPARTMENT OF CIVIL ENGINEERING
SUBMITTED BY
PRIYA YADAV (2001100000045)
EAKTA (2001100000030)
ATUL VAISHYA (2001100000026)
VIVEK KUMAR DHANGAR (2001100000065)
Department of CE, IERT Prayagraj i

DEPARTMENT OF CIVIL ENGINEERING INSTITUTE OF ENGINEERING
AND RURAL TECHNOLOGY,
PRAYAGRAJ
CERTIFICATE
This is to certified that VIVEK KUMAR DHANGAR is registered for the B. Tech program in
Department of Civil Engineering.
I hereby recommend that the dissertation entitled ‘BIOGAS GENERATION FROM STUBBLE IN
NORTH INDIA, be accepted as the partial fulfilment of the requirements for evaluation and award
of the B. Tech Degree.
Signature of HOD Signature of Supervisor Signature of External Examiner
MR. AMITESH BHATT MRS. SWETA MALVIYA
Department of CE, IERT Prayagraj ii

DECLARATION
We hereby declare that the work being presented in this report entitled “BIOGAS GENERATION
FROM STUBBLE IN NORTH INDIA” is an authentic record of our own work carried out under the
guidance of “MRS. SWETA MALVIYA” (Asst. Professor).
The matter embodied in this report has not been submitted by us for the award of any other degree.
Signature of students: -
Priya Yadav (2001100000045)
Eakta (2001100000030)
Atul Vaishya (2001100000026)
Vivek Kumar Dhangar (2001100000065)
DATE: -
Department of CE, IERT Prayagraj iii

ACKNOWLEDGEMENT
We express our great pleasure and gratitude to the honorable Guide Mrs. SWETA MALVIYA
(Assistant Professor) Civil Engineering for providing the opportunity and platform with facilities in
accomplishing the project-based laboratory.
We would also like to express special thanks to Dr. Vimal Mishra (Director IERT Prayagraj) for
providing such an innovative environment.
We express sincere gratitude to Mr. Amitesh Bhatt (Head of Department) Civil Engineering for
providing such needed facility and support.
We are sincerely thankful to Dr. Saket Kumar (Assistant Professor) Mr. Kuldeep Shukla (Assistant
Professor), and Mr. Chandresh Kumar Jha (Assistant Professor) for the guidance and constant
motivation provided in the successful completion of our academic semester. We record it as our
privilege to deeply thank you for providing the efficient faculty and facilities to make our ideas into
reality.
We are pleased to acknowledge, the indebtedness to our technicians who devoted themselves
directly and indirectly to make this project successful. Last but not the least we express our deep
gratitude and affection to our friends whose contribution in the completion of the project.
Priya Yadav (2001100000045)
Eakta (2001100000030)
Atul Vaishya (2001100000026)
Vivek Kumar Dhangar (2001100000065)
Department of CE, IERT Prayagraj iv

ABSTRACT
"In North India, the prevalent practice of stubble burning after crop harvesting poses a significant
environmental and public health challenge, leading to elevated levels of air pollution and
contributing to climate change. This unsustainable practice not only threatens the well-being of local
communities but also undermines the region's long-term agricultural sustainability. The problem lies
in the need to transition from stubble burning to a more eco-friendly and economically viable
alternative, such as biogas generation, while ensuring the well-being and livelihoods of rural
communities. This project seeks to address this critical issue by exploring the potential of biogas
technology as a sustainable and clean energy source, promoting a shift toward responsible
agriculture and environmental stewardship."
Biogas is the gaseous product of the biogenic fermentation of biomass. It has an approximate
composition of 50-70% Methane (a combustible gas), 30-50% Carbon dioxide and other trace
gasses depending on the nature of the biomass. It typically has a calorific value of 21–24 MJ/m3.
Anaerobic digestion of biomass can artificially be achieved under controlled conditions in
specifically designed plants known as anaerobic digesters or naturally at the bottom of marshes.
Biogas, a versatile energy source can be used for heating, cooking, lighting, electricity and if
purified further, it can be used as a vehicle fuel among other applications. The digestate is a widely
sought after organic agricultural fertilizer.
Under this project our main focus is to research and analyze the problem of impacts caused due to
stubble burning in north India. Biogas is currently used in many developing countries as an
alternative and renewable source of energy for wide spread range of applications. In contemporary
times, biogas has been used most extensively in India and China. Currently in Germany, biogas
technology is in advanced stages and being used to produce green electricity in the Mega Watt
range. Economic production of biogas can be economically achieved for both large- and small-scale
applications. Hence it can be designed to fit into rural, urban as well as regional and nationwide
energy needs.
Department of CE, IERT Prayagraj v

This chapter deals with the present scenario of stubble burning in north India and its impact on
environment, health and deteriorations of the AQI of NCR region.
The complete framework for designing Biogas generation plant at different levels include: -
1. Research and Analysis of Requirement of biogas energy.
2. Analysis of the present methods used to reduce the impact of stubble burning.
3. Sustainable methods to use crop residue to produce biogas and setting Community-Based
Biogas Plants.
4. Usage of Biogas for different purpose.
In this study, by addressing the technical, financial, and social aspects of biogas adoption, it's
possible to significantly reduce stubble burning and promote sustainable agriculture in the region.
Scaling biogas generation from stubble in North India involves addressing various challenges and
implementing strategies that can expand the adoption of this sustainable technology.
Department of CE, IERT Prayagraj vi

TABLE OF CONTENTS
Certificate…………………………………………………………….…..ii
Declaration……………………………………………………….………iii
Acknowledgement……………………………………………….………iv
Abstract………………………………………………………………..…v
Table of Content………………………………………………………...vii
List of tables…………………………………………………………..…ix
List of figures…………………………………………………………….x
CHAPTER 1:
1. INTRODUCTION………………………………………………….1-4
1.1 General………………………………………………………….1
1.2 Problem Statement……………………………………………...2
1.3 Scope and Objective…………………………….………………3
1.4 Organization of Dissertation……………………………………4
CHAPTER 2:
2. LITERATURE REVIEW………………………………………….5-7
CHAPTER 3:
3. METHODOLOGY………………………………………………..8-16
3.1 Description of the Study Area………………….........................8
3.2 Location………………………………………………………...8
3.3 Description of Agro-climatic Zone………………….……….…9
3.4 Soil Types…………………………………………….………...9
3.5 Land Utilization…………………………………….…………10
3.6 Area of Production and Productivity of major crops….………11
3.7 Plant and Machinery…………………………………………..12
CHAPTER 4:
4. OPERATIONS AND INVESTIGATIONS……………………17-38
Department of CE, IERT Prayagraj vii

4.1 Operating unit 1………………………………………………17
4.2 Operating unit 2………………………………………………18
Department of CE, IERT Prayagraj viii

4.3 Operating unit 3………………………………………………23
4.4 Operating unit 4………………………………..……………..25
4.5 Operating unit 5…………………………..…………………..26
4.6 Operating unit 6………………………………..……………..28
CHAPTER 5:
5. RESULTS & DISCUSSIONS……………………………………39-44
5.1 Key Findings…………………………………….……..…….39
5.2 Energy Potential……………………………….……...……..40
5.3 Realizing the potential……….………………………………41
5.4 Policy Recommendations……………………………………42
5.5 Energy Production…………………………………………...43
CHAPTER 6:
6. CONCLUSION…………………………………..………………...45
REFERENCES……………………………………………………..47-48
APPENDICES……………………………………………………...49-50
Department of CE, IERT Prayagraj ix

LIST OF TABLES
Table No. Title Page No.
1 Types of Soil 10
2 Land utilization of district 11
3 Area production & productivity of major crops 12
4 System Details 31
5 General Design Specification 33
6 Potential of different crop residues 38
7 Abbreviations 46
8 Energy Calculation 46
9 Assumptions used 47
Department of CE, IERT Prayagraj x

LIST OF FIGURES
FIGURE TITLE PAGE

NO. NO.
1 Spatial distribution of MODIS active fire counts’ density in northern India 2
during 15th September 2021–December 15, 2021
2 Data From NASA Space center which depicts the evolution of the impact 3
of stubble burning in north India.
3 Map of district Prayagraj 8
4 Biogas Plant 13
5 Slurry storage tank 13
6 Slurry Pump 14
7 Sledge Pump 14
8 Organic waste crusher machine 15
9 Compressor 15
10 Three stage chamber purification 16
11 Storage Pressure vessels 16
12 Biogas Condensate Circuit 24
13 Gas flare System 27
14 Control Unit 32
15 Potential energy generation from different resources 39
16 Amount of feedstock used to generate 1 MW of energy. 41
Department of CE, IERT Prayagraj xi

CHAPTER-1
INTRODUCTION
1.1 General
When on one hand our country is progressing towards becoming world power we can not
forget our responsibility towards environmental sustainability as well as global health. The
entire globe is grappling with a respiratory disease; in this situation scientists are
predicting more respiratory impairment in north India due to annual stubble burning
mediated rise in air pollution. Over the years farmers of Punjab, Haryana and Western UP
have moved to specialized-high yielding rice-wheat cropping system, which is perceived
as “efficient”, but has come at huge environmental and health cost. Despite a ban by
Punjab Pollution Control Board, stubble burning is still practiced.
The main reason for stubble burning is the short time span available between rice
harvesting and sowing of wheat. As a result, farmers get less than 20-25 days between two
crops and they go for quickest and easiest way of burning crop residue. For this particular
reason, with the onset of winter farm fire becomes rampant in north India. Based on
NPMCR (2019), generation of crop residues is highest in the state of Uttar Pradesh (60
Mt) followed by Punjab (51 Mt) and Maharashtra (46 Mt) with a grand total of 500 Mt per
year out of which 92 Mt is burned. Among different crop residue burned, major
contribution was 43% of rice, followed by wheat (21%), sugarcane (19%) and oilseed
crops (5%) (Bhuvaneshwari et al., 2019). Burning of this precious raw material emits
harmful particulate matters (PM10 and PM2.5) and greenhouse gases (GHGs) like, 70%
Carbon dioxide (CO2), 7% Carbon monoxide (CO), 0.66% Methane (CH4), and 2.09%
Nitrogen dioxide (N2O) and have negative impact on air quality.
1.2 Problem Statement
Stubble burning is a substantial source of particulate matter and gaseous pollutants such
carbon dioxide (CO2), carbon monoxide (CO), nitrogen oxides (NOx), Sulphur oxides
(SOx), and methane (CH4) (PM10 and PM2.5). When levels of these air pollutants are
excessive, it is a risk for people's health. Particularly, PM2.5 and PM10 cause cancer.
Asthma, chronic obstructive pulmonary disease (COPD), bronchitis, lung capacity loss,
1
Department of CE, IERT Prayagraj
emphysema, cancer, and other serious neurological, cardiovascular, and respiratory
disorders are only a few of the additional health repercussions of air pollution. As a result
of the prolonged exposure to excessive pollution, mortality rates also rise. Apart from
contributing to air pollution, stubble burning deteriorates soils long term productivity also.
One-acre land produces 2.5-3.0 metric ton paddy straw and the burning of this one acre of
paddy straw can destroy 32 kg Urea, 5.5 kg Di-Ammonium Phosphate (DAP) and 51 kg
Potash manure which is already present in residues and soil. One third of nitrogen and
sulphur, 75% of potash and 25% phosphorus present in paddy straw when contacted with
heat and oxygen due to burning resulted in the emission of harmful oxides in the
environment. Although government is showing interest in addressing the issue of stubble
burning and air pollution but so far has fallen short in dealing with this crisis.
Figure 1 : Spatial distribution of MODIS active fire counts’ density in northern India
during 15th September 2021–December 15, 2021
2
Figure 2: Data From NASA Space centre which depicts the evolution of the impact of
stubble burning in north India.
1.3 Scope and Objective
Thus, a reasonable and efficient response to this major issue of north India is needed to
tackle this problem and move towards sustainable solution. When we look at the back
towards the usage of stubble to avoid burning then there were no such futuristic fruitful
methods. But at present we are having an alternative i.e. biogas production.
We agree that in India it's a working solution but the thing is there is still a need of
specific attention in this field.
Through this project our main objective will be to search and analyze the pre-treatment
methods which are physical, chemical and biological pre-treatments, that will be used in
the treatment of stubble before being processed further.
We also provide the detailed analysis of co- digestion process that will enhance the biogas
production. We will focus towards the minimal in cost and efficient plant setups. So
basically, our main objective will be to find the ways through which we can increase the
biogas yield and how it can be helpful for farmers.
3
1.4 Organization of Dissertation
The thesis has been documented in the following manner:

Chapter 1 gives the general view of the topic, and also deals with scope and objective of
the study.
Chapter 2 consists of the earlier studies made on similar works to set the guidelines of the
present work.
Chapter 3 gives the idea of the methodology adopted for the study.
Chapter 4 deals with key operating processes made for the of the biogas plant.
Chapter 5 consists of results obtained from the study and their discussions.
Chapter 6 deals with the conclusions drawn from the study.
4
CHAPTER-2
LITERATURE REVIEW
(i) Singh (2018) investigates the detrimental impact of paddy and wheat stubble burning
in Haryana and Punjab states of India, highlighting its adverse effects on
environmental health. The study underscores the urgent need to address this
environmental menace, given its significant implications for air quality, soil fertility,
and public health. Through a detailed analysis, Singh elucidates the various factors
contributing to stubble burning practices, including agricultural traditions, socio-
economic constraints, and policy gaps. Moreover, the paper discusses the potential
solutions and mitigation measures to curb stubble burning, such as promoting
alternative farming practices, implementing stricter regulations, and raising awareness
among farmers. By drawing attention to this pressing issue, Singh emphasizes the
importance of adopting sustainable agricultural practices and implementing effective
policies to safeguard environmental and public health in the region.
(ii) Asik Dutta (2022) et al. explore the multifaceted issue of crop residue burning in
India. The study provides a comprehensive analysis of the historical, current, and
prospective dimensions of this agricultural practice, shedding light on its
environmental, socio-economic, and health implications. Through a meticulous
examination of existing literature and empirical studies, the authors elucidate the
extent of crop residue burning across different regions of India, the types of crops
affected, and the associated challenges. Furthermore, the paper discusses various
strategies and interventions aimed at mitigating the adverse effects of crop residue
burning and promoting sustainable agricultural practices. By advocating for
collaborative efforts and comprehensive approaches, Dutta et al. underscore the
importance of addressing this pressing issue for the well-being of both the
environment and the agricultural sector in India.
(iii) Preseela Satpathy et al (2020) addressed the environmental and health concerns
associated with stubble burning in India's agricultural sector. They propose biogas
production from agricultural residues as a sustainable solution, mitigating air
5
pollution, improving waste management, and providing renewable energy. The authors
highlight the urgent need for government support and policy initiatives to promote the
widespread adoption of biogas technology among farmers. By advocating for further
research and innovation, they underscore the potential of biogas to contribute to
sustainable agriculture and climate change mitigation efforts in India. This research
serves as a significant step towards addressing the challenges posed by stubble
burning while offering a practical and environmentally friendly alternative.
(iv)Dey et al. (2022) explore India's potential for biomethane generation from waste
sources and its corresponding role in mitigating greenhouse gas emissions. The study
examines three end-use scenarios for biomethane: electricity generation, cooking, and
road transport applications. Through a comprehensive analysis, the authors evaluate
the environmental benefits of utilizing biomethane as an alternative energy source,
particularly in reducing greenhouse gas emissions. The research highlights the
significant potential of biomethane generation from waste streams in India and
underscores its role in promoting sustainable development and addressing climate
change concerns. By presenting empirical findings and assessing various end-use
options, Dey et al. provide valuable insights into the potential of biomethane as a
renewable energy resource and its implications for India's energy transition. Their
study contributes to the ongoing discourse on renewable energy development and
environmental sustainability in the country.
(v) Bhuvaneshwari et al. (2019) delve into the complex issue of crop residue burning in
India, examining the policy challenges and potential solutions associated with this
practice. Through a comprehensive analysis, the study highlights the environmental,
socio-economic, and health implications of crop residue burning, emphasizing the
need for effective policy interventions to address the challenges. The authors explore
various strategies and potential solutions aimed at mitigating crop residue burning,
including technological innovations, policy reforms, and community-based initiatives.
By advocating for holistic approaches and collaborative efforts, Bhuvaneshwari et al.
underscore the importance of addressing this pressing issue to promote sustainable
6
agricultural practices and safeguard environmental and public health. Their research
contributes valuable insights to the ongoing discourse on crop residue burning in India
and provides a basis for informed decision-making and policy formulation in the
agricultural sector.
7
CHAPTER-3
METHODOLOGY
In this study following steps has been adopted:
3.1 Description of the study area
Every research study is carried out for certain specific study area and it is essential to
describe the profile of that study area as various parameters described in the profile may act as
dependent factors. The study has been conducted in Prayagraj district of Uttar Pradesh.
3.2 Location
District Prayagraj is situated in Southern Eastern part of the State Uttar Pradesh. It lies
between the parallels of 24º 47’ north latitude and 81º 19’ east longitudes.
Figure 3: Map of district Prayagraj
8
3.3 Description of Agro-climatic Zone
Prayagraj district has such tropical climate that the average maximum temperature ranges
between 430C - 470C which may go as high as 480C during peak summers. The minimum
average temperature is 2-40C which may fall as low as 1.50C during peak winter months
(Dec.-Jan.) The average rainfall of the district is 960 mm and the monsoon season is spread
between July-September. Topographically, the district of Prayagraj belongs to the central
plane zone of Uttar Pradesh. The district Prayagraj may be divided in four different agro-
ecological situations AES i.e:
1. Black and Coarse-grey land.
2. Jamuna khaddar and Alluvial.
3. Ganga Low land and Sodic.
4. Ganga plain.
3.4 Soil types
AES Situation Soil Type Area in % / Block

ha
AES 1 Black & Clay loam to 48% / 230.1 Shankargarh,

coarse gray sandy loam Koraon, Manda,
land Meja
(Jamunapar)
AES 2 Jamuna Loam & 10% / 51.1 Jasra, Karchhana,

Khaddar & Sandy Loam Chaka, Kaundhiara
alluvial
((Jamunapar)
AES 3 Ganag low Sandy loam to 15% / 92 Pratappur,
9
land & sodic sodic Handia,
(Gangapar) Phulpur
AES 4 Ganga plane Sandy loam & 27% / 138.1 Phulpur,

(Gangapar) clay Saidabad,
Soraon
Table 1: Types of Soil
3.5 Land utilization
Sr. No Particulars Area (Hectare)
1 Total Reported Area 557.012
2 Gross Irrigated Area 392.142
3 Forest 21.454
4 Cultivable Waste 13.335
5 Current Fallow 76.546
6 Other Fallow 25.347
7 Usar and uncultivable land 16.585
8 Under non-agriculture use 78.094
9 Pasture land 1.638
10
10 Orchards, tree & bushes 9.656
11 Net sown area 314.356
12 Area sown more than once 184.682
13 Gross sown area 499.018
14 Area sown in Kharif 229.439
15 Area Shown in Rabi 256.296
16 Area shown in Jayad 10.283
17 Cropping Density (%) 158.3%
Table 2: Land utilization of district
3.6 Area of production & productivity of major crops
S.N Crop Area(ha) Production(MT) Productivity(q/

. ha)
1 Paddy 171824 370562 21.57
2 Wheat 211378 469115 22.19
3 Barley 5074 5074 1025
4 Jowar 5854 8246 14.09
5 Bajra 27752 30868 11.12
6 Urd 3587 1713 4.78
11
7 Moong 3409 3409 4.51
8 Masoor 7348 6209 8.45
9 Gram 15308 14543 9.50
10 Pea 4364 4290 9.83
11 Arhar 16646 18075 10.86
12 Lahi/mustard 1040 810 7.79
13 Alsi 859 288 3.35
14 Til 550 124 2.26
15 Sugarcane 736 33202 451.12

Table 3: Area production & productivity of major crops
3.7 Plant and Machinery
3.7.1 Biogas Plant
There are several types of biogas plants some are constructed by excavating
land and constructing the required infrastructure within excavation, while some utilize large
tanks to carry out same operation above ground; but irrespective of type they are designed for
anaerobic decomposition of organic waste to generate biogas. The main components of biogas
plant include slurry tank, digester, dome or floating cover, sludge tank, sledge pump and
slurry pumps.
12
Figure 4: Biogas Plant
3.7.2 Slurry Storage Tank
A slurry tank is usually a specially designed steel tank capable of

storing a wide range of farm waste and slurry.
Figure 5: Slurry storage tank
3.7.3 Slurry Pump
It an operational term defining pumps that are used to pump slurries, in most
cases centrifugal pumps are used for this purpose.
13
Figure 6: Slurry Pump
3.7.4 Sledge Pump
It an operational term defining pumps that are used to pump sledges, the
appropriate positive displacement pumps are used for this purpose.
Figure 7: Sledge Pump
3.7.5 Organic waste crusher machine
It a crusher class machine which utilizes appropriate crushing arrangement to

crush the organic waste like waste food products into required size.
14
Figure 8: Organic waste crusher machine
3.7.6 Compressor
It’s a device used to increase pressure of a gaseous fluid by converting

mechanical energy supplied to it to pressure energy of fluid.
Figure 9: Compressor
3.7.7 Three stage purification system
It’s a multistage-selective membrane based purification system which is

specifically designed to purify biogas into Bio-CNG.
15
Figure 10: Three stage chamber purification
3.7.8 Storage pressure vessels
They are vessels or tanks designed to store a fluid under pressure, the range of
operating temperature & pressure and nature of fluid to be stored determines constructional
requirement of pressure vessel.
Figure 11: Storage Pressure vessels
16
CHAPTER-4
OPERATIONS AND INVESTIGATIONS
4.1 Operating unit 1- Biomass Reception / Storage & Substrate / feed Preparation
The materials required for the fermentation process are received in operating stage 1.
The materials that are supplied to the operating stage 1 are
i. Cow Dung / Poultry litter

ii. Silage (Agriculture / Horticulture waste, Forage crops. Etc.)
iii. Grain waste / De -oiled Cake.
iv. Water (largely recycled)
The portion of each individual component is entered into the feeding program in the panel
display. By using the weighing feet of the mixing container, the quantity of each substance
which is added to mix can be weighed, controlled and recorded.
4.1.1 Silage:
The Agriculture / Horticulture residue and forage crops are fine shredded to produce
silage, which is stored in the Silage Vats (Client Scope) which has to be built on site. JCB /
Tractor-trolley may be employed to transfer silage from Silage vats to the Biogas Plant in feed
section. Silage is filled into the solid material reception (sliding floor / substrate or silo) at the
service building and transported by the closed trough screw conveyors.
4.1.2 Cow dung / Poultry litter:
The liquid manure from farm is fed from the stables into a lagoon and pumped from
the lagoon to the receiving tank with the pump. The storage tank is a round tank that is made
of prefabricated elements of reinforced concrete. The agitator system is mounted inside this
receiving tank. The agitator ensures that the liquid manure in the receiving tank is of a
consistent and homogeneous quality. The tank is covered by a permanent roof made of a
fabric-reinforced synthetic material and its walls are 6.00m high. A reception and discharge
17
station for liquid manure is mounted to the receiving tank to be able to feed liquid manure
into the mixing tanks.
The liquid manure in the receiving tank is fed into both mixing tanks via the respective Rota
Cuts which are installed in the technical building and consists of the flow mill cutters and the
biomass inlet pumps. The pumping process stops as soon as the calculated or preset quantity
has been transferred.
4.1.3 De-oiled Cake / Grain Waste:
The De-oiled cake / grain waste is stored in a silo at the site (Client Scope) and then
fed in to the screw conveyors. From there it is transferred to the mixing tank. The filling
process stops as soon as the calculated or preset quantity has been transferred. Recirculated
material feed: An appropriate content of dry matter (DM) of max. 15 -18 % of the substrate
mix is set in the mixing container. For adjusting the DM-content, slurry suspension can be
added to the mixing container from the recirculation duct using the pump. The pumping
process stops as soon as the calculated or preset quantity has been transferred.
4.1.4 Water:
Water from the available source is added by using the pump for prewashing. Adding
water can improve mixture pumping performance on the one hand and on the other hand it
can be used to regulate the ammonium content and other constituents of the slurry suspension.
4.1.5 Mixer
Mixer Tanks has got capacity of 8 m³ and are designed as closed stainless steel tanks.
The Substrates are homogenized using the Agitators if desired. The Agitators can be activated
optionally via the panel display when the individual ingredients are added. After all the
ingredients have been added, the substrate will be homogenized. The agitation time is entered
via the panel display and is adjustable. Pumping process is controlled by the weighing system.
4.2 Operating unit 2: Fermentation
4.2.1 Digestor
18
The Digester has a capacity of 6423 m 3 each and liquid volume of 5697 m 3.
Fermentation substrate is fermented within the mesophilic temperature range between 35°C to
38°C. The Digester is a continuously working reactor in which the fermentation substrate is
mixed to create a fully homogenous medium. Feeding takes place via a substrate pipe that
ends in the Digester above the fluid level. Feeding is a time-controlled process. The through
holes in the wall for the substrate pipe are above ground level and with this they are visible at
any time.
Based on the amount of substrates (volumes) that have been added, a corresponding volume
of fermentation residue is transported to the water recovery unit and solid separation unit. An
air hose in the overflow pipe is submerged just below the fluid level in the Digester. This air
hose is used to blow air, which is supplied by the compressor, into the overflow pipe at
regular intervals in order to help the fermentation residue flow freely through the overflow
channel. The Digester is a round reinforced concrete container that is clad with the insulation
material and a trapezoidal metal sheet. The finished components of a height of 8.5 m are
placed on a binding layer and at the base joint they are fixed by a cast-in-place concrete bed
plate or the general procedures followed in that particular regions.
There is a gas chamber above the fluid, which is sealed with a gas barrier film. The gas barrier
film which is used, shall meet the requirements in accordance with the Local Regulatory. The
gas density of the film used for the Digester has been tested according to the standard
temperature of 23°C and a pressure difference of vacuum to 1 bar.
The Digesters are covered by a gas barrier film, a fabric-reinforced PVC- material coated with
Polyester and a weight of about 850 g/m², supported by a central column of hardwood. The
Inner side of the film is reinforced by polyester tapes that are mounted on the VA-ridge plate
in the centre of the roof using fixing plates and bolts. The covering is statically dimensioned
considering its own weight, wind and snow load.
There are four agitators in the digester. During fermentation, the agitators are used to mix the
substrate around to ensure a consistently homogeneous mixture. The agitators can be
repositioned by using the lifting and swiveling devices in order to improve the homogeneous
nature of the mixture and prevent the formation of a thick floating layer. The agitators are
19
used only in submerged mode. The Digester includes a heating in order to compensate for
heat loss and warm up the substrates after they have been added. The organic substances in
the substrates are decomposed as far as possible in the Digester’s anaerobic environment. This
leads to the formation of biogas, which consists of methane CH4 and carbon dioxide CO2.
4.2.1 Desulphurization:
The biogas also contains a minor amount of hydrogen sulphide (H2S), which needs to
be removed before the gas is used. For this reason, the gas chamber in the Digester is
equipped with a biological desulphurization system. The compressor continuously blows a
controlled, small quantity of air into the Digester gas chamber.
The amount of air is regulated in accordance with the hydrogen sulphide content.
When the hydrogen sulphide content increases, the air feed increases accordingly; when the
hydrogen sulphide content decreases, the air feed also decreases. The oxygen content of the
biogas is measured and displayed. The oxygen content should be between a minimum of 0.1%
by volume and a maximum of 0.8 % by volume. Under no circumstances the oxygen content
may exceed 6 % by volume. Then there will be the risk of explosion. To avoid a back-flow of
biogas into the air feed, an inhibitor is fitted to the digesters.
In the biological desulphurization process, bacteria firstly oxidise the hydrogen

sulphide into sulphate and then reduce the sulphate to form elementary sulphur. Low oxygen
content is generally sufficient for the bacteria (< 1 % by volume). The bacteria settle on the
surfaces of the gas chamber in the digesters. A thin floating layer serves as surface on top of
the slurry suspension. The floating layer provides moisture and nourishment for the bacteria.
The elementary sulphur deposits on the surfaces in the digesters, particularly on the floating
layer, and is recognisable as a yellowish white coating. These deposits of elementary sulphur
are successively discharged from the suspension chamber along with the fermentation residue
and do not accumulate in the digesters. High and low pressure safety system: An additional
high and low pressure safety system is connected to the gas chamber in the digester. This
system ensures that excessively low or high pressures cannot arise in the digester. The high
and low pressure safety system consists of a fluid barrier.
20
When the pressure in the digester changes, the filling levels in the torus and in the blow-off
pipe also change. When the pressure in the digester is zero, both filling levels are the same.
The cross-sectional area ratio of the blow-off pipe and the torus is approx. 1:2.5. This means
that the filling level in the torus will alter relatively to the filling level in the blow-off pipe by
a ratio of 1:2.5. If the pressure in the digester increases (e.g. 0 to 3 mbar), the fluid levels in
the torus and in the blow-off pipe will also change. The fluid in the torus is subjected to
greater pressure and drops. The fluid level in the blow-off pipe rises. The height difference in
cm between the filling levels in the torus and the blow-off pipe corresponds approximately to
the pressure in the digester in mbar (a measurement of 1.5 cm corresponds to 1.5 mbar
pressure in the digester, this can be checked against the pressure indication on the pressure
monitoring device).
Superfluous fluid in the high and low pressure safety system will be released via the overflow
pipe as the pressure increases. The high pressure safety triggers at about 2.5 – 3 mbar
(depending on the density of the fluid in the fluid lock) If under pressure occurs in the
digester (e.g. 0 to -1.5 mbar), the fluid levels in the torus and in the blow-off pipe will also
change:
Fluid is drawn into the torus and the level rises. The fluid level in the blow-off pipe drops.
The height difference in cm between the filling levels in the torus and the blow-off pipe
corresponds approximately to the pressure in the digester in mbar (a measurement of 1.5 cm
corresponds to 1.5 mbar under pressure in the digester, this can be checked against the
pressure indication on the pressure monitoring device). Superfluous fluid in the high and low
pressure safety system will flow back into the digester via the connection pipe as the under
pressure increases. The low pressure safety device triggers at about -1.5 mbar (depending on
the density of the fluid in the fluid barrier).
4.2.2 Excess pressure:
The CHP performance is controlled by the pressure of the gas bubble in the digester.
When the pressure increases, the CHP runs up to 100 % output. The feed (substrate feed) to
the digester can be adjusted to produce no more than the maximum quantity of biogas that the
CHP can process at 100 % output.
21
The control system (software) ignites the gas flare when the CHP is out of operation or the
biogas production exceeds the quantity that the CHP is capable of consuming.
If the pressure in the digester increases further, because the gas flare failed to ignite or the gas
production exceeds the consumption of all active consumers, a hardware contact in the control
system (set at the gas flare manometer) will attempt to ignite the gas flare a second time and
trigger an alarm. The operator is alerted by the alarm telephone and must ensure that the fault
is rectified immediately.
If, in spite of these measures, the pressure in the digester continues to rise, the high and low
pressure safety system will be activated. The high and low pressure safety system consists of
a fluid barrier.
When the high and low pressure safety system triggers due to excessive pressure, the fluid
level in the fluid barrier is 2.5 cm. That corresponds to an actuation pressure of about 3 mbar.
When the high pressure safety unit triggers, biogas is released from the digester through the
fluid lock and allowed to escape into the atmosphere via the blow-off pipe. Dependent on the
quantity of gas that is to be released, the pressure in the digester can increase to between 3 and
a maximum of 4 mbar.
4.2.3 Low pressure:
When the biogas consumption (by the CHP or the gas flare) reduces the pressure of
the gas bubble in the digester to the lower limit set in the panel display, the control
software will switch off all consumers. If the pressure drops further, a hardware contact in the
control system (setting at the digester manometer) will activate the system's emergency
switch-off and trigger an alarm. The operator is alerted by the alarm telephone and must
ensure that the fault is rectified immediately.
If, in spite of these measures, the pressure in the digester continues to drop, the high and low
pressure safety system will be activated. When the high and low pressure safety system
responds due to excessively low pressure, the fluid level in the fluid barrier is 1.5 cm. That
corresponds to an actuation pressure of about -1.5 mbar. When the low pressure safety unit
22
triggers, outside air from the atmosphere is drawn through the fluid lock into the digester via
the blow-off pipe.
4.3 Operating unit 3- Condensate circuit
4.3.1 Condensate circuit
The biogas from the Digester is warm and damp. In order to use the biogas in the Gas
Engine, it must first be cooled and dried as the moisture would damage the combustion
engine. The biogas passes to the Gas Engine through underground pipes. Passing the gas
through underground pipes reduces the gas temperature and condenses the moisture out of the
gas. In order to discharge the generated condensate to the condensate duct, the gas pipes are
routed to the duct at a gradient of at least 1 %. The condensate is separated out by the water
trap inside the condensate duct. The water trap prevents uncontrolled gas leakage.
The submersible pump is installed in the condensate duct. This pump, which is controlled by
the fluid level, transfers the condensate to the water recovery unit. The condensate pump may
only operate when it is submerged (covered with fluid). The fill level is monitored by the float
switch, which triggers an alarm and activates the emergency switch-off when the high and
low limits arenot kept. There are three float switches in the condensate duct. These devices
are switch at different switch actuation points.
4.3.2 Overfill safety unit, float switch:
The filling level may not exceed a defined maximum as this would lead to water ingress into
the gas pipe. When the float switch is activated, it triggers an alarm and initiates a complete
system emergency-switch off. It also generates an alarm signal via the alarm telephone.
4.3.3 Upper and lower switching-off point, float switch:
When the upper switch actuation point is reached, the condensate pump will start up
and continue to operate until the lower switch actuation point is reached. It is located above
the hydraulic seal.
4.3.4 Minimum filling level safety unit, float switch:

23
The filling level may not fall below a defined minimum as the back pressure of the
flu-id in the fluid barrier will drop and it might allow the biogas to escape under the influence
of the gas pressure in the Digesters (alarm signal). When the float switch is activated, it
initiates a complete system emergency-switch off and triggers an alarm. It also generates an
alarm signal via the alarm telephone.
There are three float switches in the respective condensate shafts. These devices all switch at different
switch actuation points.
i. Overfill safety unit, float switch: The filling level may not exceed a defined
maximum as this would lead to water ingress into the gas pipe. When the float
switch is activated, it triggers an alarm and initiates a complete system
emergency-switch off. It also generates an alarm signal via the alarm
telephone.
ii. Upper and lower switching-off point, float switch: When the upper switch
actuation point is reached, the condensate pump will start up and continue to
operate until the lower switch actuation point is reached. It is located above the
hydraulic seal.
iii. Minimum filling level safety unit, float switch: The filling level may not fall
below a defined minimum as the back pressure of the fluid in the fluid barrier
will drop and might allow biogas to escape under the influence of the gas
pressure in the digesters (alarm signal). When the float switch is activated, it
initiates a complete system emergency-switch off and triggers an alarm. It also
generates an alarm signal via the alarm telephone.
24
Figure 12: Biogas Condensate Circuit
4.4 Operating Unit 4 - Fermentation
To store the residue produced by the fermentation process, the residue storage tank,
with a filling capacity of 300 m³, is planned in a gas-tight design. The storage unit is a round
tank made of PEHD. The finished components are placed on a surface and at the base joint
they are fixed by a cast-in-place concrete bed plate. Unlike the digesters, the residue storage
tank is not insulated and not heated. Therefore, the fermentation residue is pumped to the
Organic fertilizer unit. There it cools down before it is discharged and applied. Furthermore,
the residue storage tank is a completely gas-tight PEHD tank. In order to balance pressure, the
residue storage tank is connected to the gas chamber in a digester via a gas shuttle tube and a
shut-off valve located above the fluid.
25
4.5 Operating unit 5 – Gas Utilization
The machinery for gas utilization is installed in operating Stage5. For utilizing the gas,
a Gas Engine is planned along with a generator – with an electrical power of 1000 kW
(combustion power: -0.5 M 3 / kW)
In order to burn the biogas in the Gas Engine, the gas pressure has to be increased with the aid
of gas compressor. The output of the gas compressor is regulated. In order to limit noise
emissions, the Gas Engine is mounted in a noise-insulated cabin. The biogas is burnt in the
gas engine and the resulting energy is converted to electricity by the generator.
The combustion air is drawn in from the outside via the feed air fan. The inlet air generates an
overpressure in the noise-insulated cabin of the Gas Engine. The exhaust air flows out via the
silencer. In order to limit noise emissions, the Gas Engine is mounted in a noise insulated
cabin.
The air inlet and outlet channels are equipped with sliding block absorbers for noise
reduction. The inlet channel is additionally equipped with a dust filter. The exhaust gases
produced by the combustion process in the Gas Engine are routed through the outer wall into
the vertical exhaust gas silencer via an exhaust pipe system. The exhaust gas silencer is
designed to be 10.00 m above from the surface ground level or according to the calculation of
the chimney height. The generated thermal energy is used to heat the Digester. Additionally,
the available heat from the Gas Engine can be used for other heating purposes. The excess
heat is dissipated in the emergency cooler.
In accordance with the safety regulations for agricultural biogas systems, the gas amount that
has to be released in case of an emergency must be limited to max. 20m³/h. For this reason,
the gas flare is pressure controlled and automatically operated. Flame traps installed in front
of both the Gas Engine and the gas flare which prevent flames backfiring in the pipe system.
4.5.1 Gas Flare system
Emergency flare: The biogas plant is equipped with a permanently installed

emergency flare. The gas flare must be placed in a secure distance which is at least 5m
from other buildings, 10m from the Digester’s and 8 m from the residue containers.
26
The emergency flare is only used in the event of malfunctions of the intended operation,
because for planned stops of the Gas Engine, the generation of gas can be reduced by
operational measures (Feeding of the Digester is switched off) and due to the storage function
of the gas storage membrane of the Digester’s, the gas storage has enough capacity for regular
maintenance works. To avoid longer downtimes of the gas engine, the operators of the plant
have spare parts in store. The gas flare is designed for safe and odour-free combustion of
excess or unusable biogas from 53 % (CH4) by volume (e.g. during commissioning).
Essentially, the gas flare system is a forced-air fan burner. The burner system includes a type-
approved flame trap and gas regulator system complying with required standards.
The gas flare is controlled by the pressure in the gas bubble in the Digester. The gas flare
automatically ignites when a given maximum pressure (set in the control system) is reached.
The pressure control arrangement and flame monitoring system guarantee safe operation. The
flare can be checked automatically and regularly using the control unit.
27
Figure 13: Gas flare System
4.5.2 Lubricating oil station:
The CHP needs engine oil as lubricant to work without problems. The lubrication
station is placed in the technical room, separated from the CHP. The fresh and the used oil are
stored in tanks approved by the building supervisory authorities.
4.6 Operating Unit 6 – Mechanical BOP/ Electrical BOP/ Civil
4.6.1 Mechanical Balance of Plant

28
4.6.1.1 Raw water supply system:
Raw water is required per day for 1 x 1063 KWe Bio-methanation plant.
Suitable raw water pumping station and storage provisions for 500 KL is made.
4.6.1.2 Fire Protection system:
For the Plant building, Engine room, Sub station and Control rooms suitable
portable fire extinguishers will be provided as per norms. For the outdoor areas like
Feed stock silage, Digesters etc., Fire hydrants as per norms will be provided.
4.6.1.3 Design Basis:
The following sections describe briefly the design basis adopted for the
various Mechanical equipment of the Project. The design, manufacture, inspection,
testing and installation of all equipment and systems covered herein shall conform to
the latest editions of Indian and International codes and standards. Best engineering
practices shall be followed wherever the relevant standards are not available.
4.6.1.4 Water System

Water system consists of raw water supply system.
 Raw water / fire water storage reservoir is planned to be provided
considering two (2) weeks' make up water requirement. The raw water
reservoir shall be above ground structure of RCC construction with central
partition.2 x 100% raw water supply pumps of horizontal centrifugal
construction will meet the Plant make up water requirement.
 The fire water system will be designed as per statutory requirements. It is
proposed to install one (1) no. diesel drive hydrant pump, with one motor
driven pump of identical capacity as standby. 1 x 100% Jockey pump will
be considered for pressurization of the hydrant network.
 The raw water and fire water pumps will be housed in common pump
house. Suitable handling arrangement will be provided for handling of
equipment for erection / maintenance.
4.6.1.5 Fire Protection System
29
 Fire protection system generally shall be designed based on Loss
Prevention Association (LPA) guidelines and NFPA standards.
 The fire protection system shall be designed on the following basis:
 Control and extinguishing of only one fire at a time occurring
through the whole Power plant area.
 Fire spreading is assumed not to exceed the fire area limits it arises
from.
 Design water demand shall generally not exceed the greatest
amount of water required for each fire scenario
 For the purpose of system design, the entire Power Plant is
considered as ORDINARY HAZARD risk as per the classification
of TAC.
 The various types of fire prevention/protection systems considered
for fighting the fires in different plant areas/buildings are :
 Fire Hydrant System
 Fire detection
 Portable Fire Extinguishers
 Fire detection and alarm system.
4.6.1.6 Ventilation and or Air Conditioning System
Ventilation and or air conditioning facilities shall be provided for the various
plant premises to ensure proper working environment both for men and
machines and to maintain necessary environmental conditions for proper
storage of plant & machinery, equipment and materials in the following areas.
 Power house and Plant buildings.
 Switch gear and cable cellar room.
 Raw water, Fire water pump house MCC room.
 All toilets / store room etc.
4.6.1.7 Wet Ventilation System
 Wet ventilation system consisting of air washer unit in masonry
construction with adequate capacity centrifugal fan including dry metallic
filters, auto viscous air filters, water spray bank, circulating spray water
30
pump, spray water basin, supply air ducting etc. shall serve the following
areas in Power–house building.
 Cable spreader room
 Switchgear room
 Engine - Alternator Hall
 General Exhaust Ventilation
 General Exhaust Ventilation with wall mounted axial flow fans is
considered for toilets and other miscellaneous areas.
4.6.1.8 Air conditioning system
 Air conditioning system facilities shall be provided for the various areas to
ensure proper functioning of equipment and for human comfort. For
critical areas like all control rooms,
 Chemical test lab, Instrument lab etc. air conditioning system shall be
designed for continuous duty and office room/ conference room shall be
designed for intermittent duty.
 Air conditioning is proposed to be provided for the following areas in
Power House building and other areas in the plant.
 Control room area
 UPS room
 Office area
4.6.2 Electrical Balance of Plant
 For Start up power and other Power requirements a suitable substation will be
provided. A suitable transmission line will be provided for the incoming power
into the substation from the grid. A suitable distribution system with step down
Transformers for supply of power to the various auxiliaries at 415 V and 220 V
will be installed.
 Power is generated at 415 V. This is transmitted through a Switch gear and
power cables to a step up Transformer (415V / 22 KV). The substation
described above will be suitably equipped to receive power. The 22 KV
transmission line will be used for evacuation of Power to the nearest receiving
station of the State grid.
31
4.6.2.1 General Principles of Equipment Design
 The design of the electrical system will be based on the requirements for
the safe & reliable performance of the captive power plant and the
interconnected electrical system and to ensure safety and convenience in
operation. 100% redundancy will be provided in auxiliary power supply
feeders to 415V PCC of the Power Plant to ensure the reliable power
supply even during cable failure and transformer outages.
 All items of electrical equipment will be suitable for operation plant
environment. The Design ambient temperature for all electrical equipment
shall be 50° C.
 All items of electrical equipment will be suitable for continuous and short
time duty in the environmental conditions prevailing at site without
exceeding temperature rise values stipulated in relevant IS standards.
 The design, manufacture, inspection, testing and installation of all
equipment and systems covered herein shall conform to the latest editions
of Indian and International codes and standards. Best engineering practices
shall be followed wherever the relevant standards are not available.
4.6.2.2 System Details
The system details at various utilization equipment voltages will be as

given below:-
32
Table 4: System Details
4.6.2.3 Electrical System /Control Unit
In the switch room, there are the switching cabinet and the PC with
display for the biogas plant. The display is used to select the operating modes (manually or
automatically) and to display the operating states, to display data and to generate reports. The
switching cabinet is fitted with an isolator switch and a system emergency switch-off. Key
switches for the drives of the main components are provided so that each drive can be
switched off or enabled.
The alarm selection unit has a buffer battery and in the event of emergency alarms, it sends
independent alarms by telephone to at least two responsible people with different telephone
numbers. Additionally, the malfunction is annunciated by acoustic signal. Malfunctions of the
four gas sensors are additionally signaled by an acoustic signal, as well as an optical signal in
the relevant areas and outside the technical building. The switching cabinet is equipped with
the fan as well as a fire warning device.
33
Figure 14: Control Unit
4.6.3 Civil Balance of work
The major design standards that are required for the construction of biogas plant is
discussed below.
4.6.3.1 Codes and Standards

The Indian Codes and Standards as applicable will be generally used for
design of civil and structural works.
Grade Specification
M15 Grade slab, paving, drain etc.
M20 Lightly loaded structures.
M25 Precast units.
34
M25 For all structural elements unless noted otherwise.
M25 For STG foundation, tank foundations and water retaining

structures.
1:3:6 Plain Concrete below tank foundations and water retaining

structures.
1:4:8 Plain Concrete below Footings, grade slab and base slab of
drains.
1:5:10 Fill concrete.

Table 5: General Design Specifications
 All structural concrete will be made dense and nonporous with water cement
ratio not exceeding 0.45. Plasticizers will be used, if required, to maintain the
required slump.
 For structural concrete items, Ordinary portland cement (33/43/53 Grade)
conforming to IS:8112 will be used. High yield strength deformed bars
conforming to IS 1786 will be used for reinforcement.
 Design of structural concrete for liquid retaining structures and dry basements
for which external water proofing is not provided, will be designed in
accordance with the recommendations of BS:8007. Crack width will be
restricted to 0.1 mm. Minimum thickness of structural elements for water
retaining structures with two layers of reinforcement will be 200 mm.
 Design of RCC structures will be by limit state method as per IS: 456.
Foundation will be sized for working loads and designed by limit state method
considering appropriate partial safety factors as per IS: 456.
4.6.3.2 Steel Structures
Design of steel structures will be carried out by working stress method as
per IS:800.
35
Generally all shop and field connections will be welded, except for field
connections of bracings and other minor members, which can be bolted
type. Structures will be generally designed as rigid frames in the transverse
direction and as braced frame in the longitudinal direction.
All moment connections, if bolted will be of High strength friction grip
bolts. Shear and other minor connections, if bolted may be made with mild
Steel / High strength bearing bolts.
4.6.3.3 Foundation for Underground Structures
The foundation type and depth will be decided based on the soil investigation
Parameters. Settlement criteria for shallow foundations will be generally as follows

(subject to specific requirement & differential settlement):
 25 mm for plant buildings and structures.

 40 mm for non-plant buildings and structures.
 80 mm for steel storage tank foundations.
For design of walls of basement, trenches, channels etc. below ground, lateral pressure
due to a vertical surcharge of 10 KN/m² will be considered in addition to earth and
ground water pressure etc. In case of heavy wheel loads, lateral surcharge due to
actual wheel loads will be substituted. When a portion or whole of the adjacent soil is
below free water surface, computations will be based on submerged weight of soil
plus full hydrostatic pressure.
75 mm thick lean concrete 1:4:8 will be provided below footings, base slab and water
retaining structures as mudmat. The following factors of safety will be considered for
stability of foundation and underground structures (Ref. IS: 456 & IS: 3370)
 Stability against overturning and sliding - 1.5

 Stability against uplift - 1.2
4.6.3.4 Building Foundation
36
Type of foundation system, i.e. piled foundation, isolated footing or raft
foundation will be decided based on the loads, soil conditions and as per
recommendation of detailed geo-technical reports.
4.6.3.5 Foundations for Vibratory Equipment
All machine foundations will be designed in accordance with the

provisions of the latest edition of national standards, international standards
and manufacturer’s standards.
4.6.4 Organic Fertilizer Unit
For each Digester the effluent would be of the order of 135 kL /day with 5.5 - 7% TS.
The Digester Effluent has wide ranging use as organic manure including for grains/ sugar
cane farming, but have preferential applications for, short cycle, forage/energy crops &
horticulture products farming.
The effluent from the Biogas Digester is sent to the organic fertilizer unit where the solids &
the liquid are separated. The separated solids can be used as organic fertilizer by further
processing such as composting adding up other available materials. Advantages of using
digester effluent as fertilizer are:
 General Positive impacts on environment:

 Decrease of odor of manure
 Less CH4 emissions
 Reduce ground water contamination
 Close nutrient cycle with using biogas plant effluent as fertilizer:
 Nutrients in feedstock of biogas plants can be reused after anaerobic
digestion.
 Only few losses of nutrients during storage, transport and biogas
process.
 Improvements on manure quality with anaerobic digestion:
 Degradation of cells, organic acids and long chain organic matter
37
 Increase of availability of nutrients (especially nitrogen)
 Increase of humus on the fields (compared to combustion)
38
CHAPTER-5
RESULTS & DISCUSSION
5.1 Key Findings
 Crop residues are a waste stream with a high untapped potential for energy
generation and greenhouse gas mitigation.
 Using all sustainably recoverable residues from the current global production
of crops suitable for anaerobic digestion: rice, wheat, maize, rye, barley, oats,
rapeseed, sugar beets, sugarcane, and sorghum, there is a potential to generate
3,080 to 3,920 TWh or 300 to 380 bcm biomethane per year.
 It takes into account ploughing in and diversion of a part of the residues to
feeding animals.
 The biomethane could meet the combined natural gas consumption of China
and Japan.
 If the energy is converted into electricity instead, it can meet the needs of 393
to 500 million people or 5.2 to 6.5% of the world populatio.
 Anaerobic digestion of select crop residues can mitigate greenhouse gas
emissions equivalent to 865 to 1,100 Mt CO2 per year, equivalent to the
emissions of Germany in the form of avoided emissions from the production of
fossil fuel-based electricity and heat and those from burning of crop residues in
the field.
Crop Rice Wheat Maize Rye Barley Sugarcane

Residue(Million
39
tonnes)
Global Crop 770 772 1135 14 147 1842

yield estimate
Harvesting 1.33 1.33 1.5 1.86 1.55 0.28

residue
coefficient
Processing 0.23 0.21 0.18 0.22 0.27 0.2

Residue
Recovery factor 90 90 90 90 90 0
Total solids 96 90.15 89.6 86 85 86
Volatile Solids 79.4 93.55 93.2 93.7 94.4 86.3
Methane Yield 335.6 213.43 360 179 195 252

Table 6: Potential of different crop residues
5.2 Energy Potential
If all of the sustainably available residues (25-35%) from select crops were to be
collected and anaerobically digested, they have the potential to 3,080 to 3,920 TWh that can
be used on-farm or exported in the form of electricity and heat or as 300 to 380 bcm
biomethane. The biomethane could meet the combined natural gas consumption of China and
Japan. If converted into electricity, it can meet the needs of 393 to 500 million people or 5.2-
6.5% of the world population.
5.3 Realizing the Potential
Both ploughing in of residues and feeding them to animals are a desirable way of
using crop residues. Those retrieved sustainably, in excess of these needs should be prioritized
to be recycled via anaerobic digestion for energy and nutrient recovery. Currently, only a
40
small proportion of crop residues is being utilized to its full potential. Some residues such as
sugarcane are utilized for ethanol production in the US and Brazil. A part of rice and wheat
straw is burnt domestically for fuel or in biomass boilers. Burning residues domestically
causes significant air pollution and has an adverse effect on the health of women. We assume
that currently 5% of the currently sustainably recoverable residues of rice, wheat, maize, rye,
barley, oats, rapeseed, sugar beets, sugarcane, and sorghum, that are not fed to animals (25-
35%) are utilised for anaerobic digestion. We assume that this will increase to 25% by 2030
and 50% by 2050, keeping in mind the challenges in recovering residues from small farm
holdings.
With increasing population, increased availability of calories per person and shift in diets, it is
estimated that crop production will need to increase annually by 1.3% till 2030 and 0.8% till
2050 to meet the increased demand for food.
Assuming that crop production targets for 2030 and 2050 are met, in order to fully realise the
potential of crop residues by 2050, the crop residue collection and digestion will need to be
increased to 40% by 2030 and 80% by 2050. If this is achieved, the energy generation
potential is 2,316 TWh/year and 5,432 TWh/year and GHG abatement potential is 531 Mt
CO2 eq./year and 1,063 Mt CO2.
41
Figure 15: Potential energy generation from different resources
5.4 Policy Recommendations
To achieve this potential, policy and regulatory support is required because the ability to
decarbonize energy production is dependent upon being able to operate at least on a level
playing field as entrenched and existing operators. The multiple contributions from biogas
(treating waste as well as producing energy and fertilizers) are often not accounted for as a
value so operators do not receive payment for these. Therefore biogas is considered often to
be more expensive than fossil fuels and policymakers have difficulty in understanding the full
intrinsic value- especially where fossil fuels receive substantial incentives and tax breaks.
The types of support required will vary depending on the particular geography in question,
but at the high level the global industry needs:
 The removal of all fossil fuel subsidies to create a level playing field. This includes the
gradual removal of subsidies to lower the retail price of fuels to consumers as well as
eliminating tax breaks for exploration and exploitation of fossil fuel reserves.
According to the IMF current fossil fuel subsidies represent 6.5% of global GDP, the
highest externality ever recorded.
 Making a national commitment to reduce greenhouse gas emissions to nett zero by
2050. The United Kingdom has announced this commitment and put binding
legislation before Parliament to ensure it is enforced long term.
 The drafting of national energy plans to raise the level of renewable energy production
and consumption over a future period (a decade is normal) and incorporating into this
target for the production of biogas by anaerobic digestion.
 Anaerobic digestion to be urgently included in all government strategies for meeting
greenhouse gas abatement targets recognizing the GHG abatement benefits of
anaerobic digestion and incentivized via carbon markets.
 Anaerobic digestion to be included in all renewable energy generation incentives.
 To develop knowledge, raise awareness and implement regulations, standards and
certifications for safe trading and use of digestate.
42
 The implementation of circular economy strategies with AD at their core; and,
anaerobic digestion to be nominated as the preferred method of treatment of all
biodegradable wastes (human – sewage and food; agricultural; commercial; industrial)
accompanied by policies to increase capture.
5.5 Energy Production
It was found that for the production of 1MW of energy, the most feedstock was used in
biogas plant, an average of 22.56 m3 of sludge; to improve biogas yield from one m3, it would
be necessary to reduce the sludge hydration. Given that biogas produced at the sewage
treatment plant is during sludge disposal, there is no reason to increase the sludge thickening
before fermentation and increase production efficiency. As an excellent alternative choice,
biogas production by evaluating organic wastes in an industrial biogas plant, methane gas is
produced and converted into heat and electricity energy in co-generation systems. Biogas
plant needs an average of 4.7 tons of charge to produce 1 MW of power. Considering the
amount of feedstock to produce 1 MW of energy in a biogas plants, the input used has more
methane and is more caloric than the input used in biogas plant. The efficiency and reliability
of the devices used significantly impact the final effect of obtaining the biogas for production.
The higher the reliability, the higher the efficiency.
43
Figure 16: Amount of feedstock used to generate 1 MW of energy.
CHAPTER-6
CONCLUSION
 Generating biogas provides a sustainable solution for waste management by

converting organic waste into a valuable energy source. This process reduces landfill
use, decreases greenhouse gas emissions, and contributes to a cleaner environment by
mitigating the release of harmful pollutants.
 Enforcing the ban on burning of crop residues in the field.
 Giving rural households access to digesters, biogas and biogas stoves.
 For small farms: setting up cooperatives to collect and digest crop residues at
scale.
 For large farms: Requiring farms above a certain size to have nutrient
management plans that include crop residues.
 Making information on crop-based digestate available to farmers, both to
support use on farm and also to get fair value for their export.
44
 Biogas production offers a renewable energy source that can be harnessed for
electricity, heating, and as a transportation fuel. This reduces dependence on fossil
fuels and enhances energy security. Biogas can also stabilize energy costs and provide
a reliable energy supply, especially in rural and off-grid areas.
 The biogas industry can stimulate economic growth by creating jobs in biogas plants'
construction, operation, and maintenance. Additionally, the sale of biogas and its by-
products, such as bio-fertilizers, can generate additional revenue streams, making it an
economically viable alternative to conventional waste treatment and energy production
methods.
 Ongoing research and development in biogas technology aim to improve the
efficiency and cost-effectiveness of biogas production. Innovations such as
thermophilic digestion, high-solid digestion, and integrating advanced materials can
enhance reactor productivity and reduce operational costs, making biogas generation
more accessible and scalable.
 Biogas generation is a key component of the circular economy model, where waste is
converted into valuable resources, promoting sustainability and resource efficiency.
 By recycling nutrients and producing renewable energy, biogas plants contribute to a
closed-loop system that benefits both the environment and the economy. The
integration of biogas technology into energy markets and waste management systems
is crucial for building a sustainable future.
 Governments should incentivize widespread investment in refueling network for
biomethane as a transport fuel and infrastructure for injection of biomethane into the
gas grid. Developing the infrastructure network will encourage growth in anaerobic
digestion and biomethane upgrading.
 Sustainability and greenhouse gas emissions criteria for all agricultural production to
ensure land is managed with due diligence to the environmental impact and energy
crops can be integrated into production in the most sustainable way.
45
REFERENCES
1. Preseela Satpathy ( Hochschule Emden/Leer) & Chinmay Pradhan , Nov 2020 –

Biomass Conversion & Biorefinery
https://www.researchgate.net/publication/346007898_Biogas_as_an_alternative_to_stub
ble_burning_in_India
2. Ritvik Rai & Kanishk, BITS Pilani, Department of Mechanical Engineering and
Biological Sciences, Rajasthan – 333 031, India https://www.e-ijep.co.in/42-10-1167
3. M. Keerthana Devi, College of Natural Resources and Environment, Northwest A&F
University, Taicheng Road 3# Shaanxi, Yangling 712100, China & M. Oviyapriya
Department of Biotechnology, Kamaraj College of Engineering and Technology, Near
Virudhunagar, Madurai 625 701, Tamil Nadu, India
https://www.sciencedirect.com/science/article/abs/pii/S0960852422012019
4. https://www.mdpi.com/1996-1073/14/11/3157
46
5. Department of Agriculture of Prayagraj. www.prayagraj.nic.in
6. Directorate of Economics and Statistics. Department of Agriculture. www.up.gov.in
7. https://www.researchgate.net/publication/305444675_Paddy_straw-
based_power_generation_from_biogas_Fazilka_District_in_Punjab_Leading_the_Way
8. I. S.Horváth, M. Tabatabaei, k. Karimi, and R. Kumar. Recent updates on biogas

production - a review, Biofuel Research Journal, 2006;10:394-402.
9. Jabrinder Singh, DIT University, December 2018 – Environmental Quality Management
https://www.researchgate.net/publication/329974964_Paddy_and_wheat_stubble_blazin
g_in_Haryana_and_Punjab_states_of_India_A_menace_for_environmental_health
10. Akashdeep Dey & Rachel Camilla Thomson, The University of Edinburgh, January
2023
https://www.researchgate.net/publication/365255818_India's_biomethane_generation_po
tential_from_wastes_and_the_corresponding_greenhouse_gas_emissions_abatement_po
ssibilities
11. S. Bhuvaneshwari, Dept of Civil Engineering, SRM Institute of Science and Technology,
7 March 2019 https://www.mdpi.com/1660-4601/16/5/832
12. Report published by UN and world biogas association here: worldbiogasassociation.org
13. World fertilizer trends and outlook to 2020 www.fao.org/3/a-i6895e.pdf
14. The energy production and potential as per area of cultivable land available
www.nationmaster.com/country-info/stats/Agriculture/Arable-land/Hectares
15. The case study of innovative biogas plant in Italy
www.researchgate.net/publication/305371248_Biogasdoneright_An_innovative_new_sy
stem_is_commercialized_in_Italy
47
APPENDICES
Table 7 : Abbreviations
CO2 Carbon Di-oxide
AD Anaerobic Digestor
bcm Billion Cubic Meter
Mt Million Tonnes
Gt Gigatonnes
TwH Terra watt Hour
BOP Balance of Plant
ECU Electrical Control Unit
48
Table 8 : Energy Calculation
1 Watt 1 Joule per second
1 Watt Hour 3,600 Joules
1 kilowatt hour 3,600,000 Joules = 3.6 MJ
1 m3 of biogas 22 MJ
6.11 kilowatt hour total energy
1 m3 of methane 10.19 kilowatt hour total energy
Table 9 : Assumption used
Methane content of biogas 60%
Digestate to feedstock ratio 0.85
Electrical energy conversion efficiency 40%
Thermal Energy conversion efficiency 50%
Parasitic Load 10%
Fugitive emission 2.5%
Emission in production of N-Fertiliser 5,881 g CO2,eq/kg N
Emission in production of P2O5-Fertiliser 1,011 g CO2, eq/kg P2O5
Emission in production of K2O-Fertiliser 576 g CO2, eq/kg K2O
49
Emission in production of CaO-Fertiliser 130 g CO2,eq/kg CaO
World population forecast- 2022 8 Billion
World population forecast- 2030 8.6 Billion
50

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“INSTITUTE OF ENGINEERING AND RURAL TECHNOLOGY”

BIOGAS GENERATION FROM STUBBLE IN NORTH INDIA

Submitted in partial fulfilment of the requirement for the degree of

B. TECH CIVIL ENGINEERING (8TH SEMESTER)

Under the Guidance of Mrs. SWETA MALVIYA

ASSISSTANT PROFESSOR OF DEPARTMENT OF CIVIL ENGINEERING

PRIYA YADAV (2001100000045)

ATUL VAISHYA (2001100000026)

VIVEK KUMAR DHANGAR (2001100000065)

Department of CE, IERT Prayagraj i

Signature of HOD Signature of Supervisor Signature of External Examiner

MR. AMITESH BHATT MRS. SWETA MALVIYA

Department of CE, IERT Prayagraj ii

Priya Yadav (2001100000045)

Atul Vaishya (2001100000026)

Vivek Kumar Dhangar (2001100000065)

Department of CE, IERT Prayagraj iii

Priya Yadav (2001100000045)

Atul Vaishya (2001100000026)

Vivek Kumar Dhangar (2001100000065)

Department of CE, IERT Prayagraj iv

Department of CE, IERT Prayagraj v

1. Research and Analysis of Requirement of biogas energy.

4. Usage of Biogas for different purpose.

Department of CE, IERT Prayagraj vi

Department of CE, IERT Prayagraj vii

Department of CE, IERT Prayagraj viii

Department of CE, IERT Prayagraj ix

Table No. Title Page No.

2 Land utilization of district 11

3 Area production & productivity of major crops 12

5 General Design Specification 33

6 Potential of different crop residues 38

Department of CE, IERT Prayagraj x

FIGURE TITLE PAGE

5 Slurry storage tank 13

8 Organic waste crusher machine 15

10 Three stage chamber purification 16

11 Storage Pressure vessels 16

12 Biogas Condensate Circuit 24

13 Gas flare System 27

15 Potential energy generation from different resources 39

16 Amount of feedstock used to generate 1 MW of energy. 41

Department of CE, IERT Prayagraj xi

1.2 Problem Statement

1.3 Scope and Objective

The thesis has been documented in the following manner:

3.1 Description of the study area

Figure 3: Map of district Prayagraj

1. Black and Coarse-grey land.

2. Jamuna khaddar and Alluvial.

3. Ganga Low land and Sodic.

3.4 Soil types

AES Situation Soil Type Area in % / Block

AES 1 Black & Clay loam to 48% / 230.1 Shankargarh,

AES 2 Jamuna Loam & 10% / 51.1 Jasra, Karchhana,

AES 3 Ganag low Sandy loam to 15% / 92 Pratappur,

AES 4 Ganga plane Sandy loam & 27% / 138.1 Phulpur,

Table 1: Types of Soil

3.5 Land utilization

Sr. No Particulars Area (Hectare)

1 Total Reported Area 557.012

2 Gross Irrigated Area 392.142

4 Cultivable Waste 13.335