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Biochemical Engineering
Design Project
2013
Portable Floating-Head Digester in the

Production of Biogas from Pig Dung
Almendral, Christine Mae C.

Baugan, Mary Joy A.
De Leon, Felma Grace C.
De Villa, Vernadete S.
Miranda, Dane Nathalie T.
Pineda, Roxanne D.
Pulhin, Alexis A.
Santos, Justine Rose F.
Engr. Norman Giovanni M. Guevarra
Chemical Engineering Department
Technological Institute of the Philippines
PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Biochemical Engineering Design Project
Abstract
The Philippines has been trying to make a shift to energy sources that will help alleviate the pollution
problems the country has been facing. Although this is a fact and the laws that has been passed by the
legislative branch are a proof of this, one possible source of energy is underappreciated, and this is
biogas production. The main objective of this paper is the discussion of the methods in which the
researchers were able to materialize a portable floating-head, methane-producing digester. After much
consideration, a metal digester made out of stainless steel was fabricated by an outer source, and
further improvements required the researchers to make a second digester that is connected to the
metal digester in series to have a faster reaction time. Modifications to the usual design of floating-head
digesters were applied, like adding a water tap and adding gravel in the reactor. Calculations based on
the capital gave an estimated 1.5 years to recover the money and then gain after that.
Introduction
Consequent to the increasing production of organic wastes as well as the increase of carbon dioxide in
the atmosphere, apparent rise in the Earths average temperature and extreme weather conditions are
being observed (Abrigo, 2008). There are a lot of responses from the scientific community to resolve this
phenomenon but the idea of biogas production is much overlooked when it comes to this aspect
(Knowles, 2010). Biogas is a combustible gas mainly composed of methane, carbon dioxide and other
trace elements (Adnan, 2010). Anaerobic digestion of animal manure and a wide range of organic
wastes produces biogas that can be utilized for electricity, heat and natural fertilizers for agriculture
(Alexopoulos, 2012). With the absence of oxygen, this microbiological decomposition of organic
substrates is being carried out in reactors called digesters (Culhane, 2012).
For this project, the focus is to design a bioreactor that would convert these organic wastes into
valuable source of renewable energy such as biogas. Anaerobic digestion is a potential solution to waste
management of pig manure disposal (Sharvelle, 2013). The methanogenic bacteria found in this type of
environment breaks down the organic matter found in the waste and produce methane in the process
of completing their life cycle (Adnan, 2010). The Department of the Environment and Natural Resources
(DENR) has been trying to encourage biogas production in large pig farms, especially those of which
waste lagoons are already available. The feces of the pigs are fed to the biodigester along with other
wastes which can be any organic material (Teune, 2010).

Overview of Biodigesters in the Philippines

Several biodigesters have been reviewed and considered as model for this project, an overview of which
is presented below:
Table 1 Average Costs of Biodigesters and their Materials of Construction (Teune, 2010)
Model
Cost (php)
Material
Average fixed dome model

Chinese-fixed dome
Box-shaped digester
DOST floating drum
DOST portable digester
Tubular digester
Chinese composite
25,000
70,000
80,000
100,000
15,000
85,000
70,000
Brick
Concrete
Concrete
Concrete and steel
Plastic Container
Polyethylene
Fiber glass
Because of economic reasons, it has been decided that the Industrial Technology Development Institute
of the Department of Science and Technology (DOST-ITDI) portable digester would be the best to cater
the objective of this project.
The figure below shows the different types of DOST-ITDI portable digesters. The researchers focused on
the third type, a metal digester with a floating gas holder.
Type I: Plastic Digester
with Plastic Gas Holder
Type II: Plastic Digester

with Metal Gas Holder
Type III: Metal Digester

with Floating Gas Holder
Figure 1 DOST-ITDI Portable Biogas Digesters

[Environmental Division Industrial Technology Development Institute (EnD ITDI, 2008)]

The ITDI Biogas Digester is a physical structure whose main function is to provide anaerobic condition
without the presence of air on it. This structure when loaded with biodegradable materials, especially
manure, will produce biogas (EnD ITDI, 2008). Biogas can be used for a number of ways like: cooking,
lighting, or running an internal combustion engine (Somashekar, 2009).
Floating Drum Digesters: Advantages and Disadvantages

A floating-drum digester consists of a gas-holder that floats directly on the fermenting slurry. As biogas
is being produced, the drum moves up and sinks back if it is being consumed (Kossman & Ponitz, 2007).
Floating biodigester yields several advantages over the other types of biodigester. These advantages
include higher gas production, less complicated in installation, simple and easy-to-understand operation
(Steyn, 2010). However, steel is relatively expensive and susceptible to corrosion. Compared to other
digesters, the steel drum has a shorter lifespan that is usually up to 15 years (Kossman & Ponitz, 2007).
Materials of Construction: Advantages and Disadvantages

Using high-density polyethylene and glass fibers reinforced plastic for floating drums was proven
successful but of higher construction costs compared to using steel.
Table 2 Materials of Construction for Biogas Storage Vessels (Walsh et al, 1988)
Material
Advantages
Disadvantages
Mild Steel
Usually the cheapest material of

construction; can last up to 15 years when
properly painted and maintained.
Rusts can be formed outside; surface

must be properly prepared.
Galvanized
Iron
Available at low cost. Years of good service

when properly maintained and painted.
Ferrocement
Less expensive than mild steel vessel of the

same size; suitable for precast products.
Plastic (PVC,
HDPE, <3
mm thick)
Readily available and easy to work with.
Must be treated before paint will

adhere; unpainted tanks have a useful
life of about five years.
Requires skilled labor to manufacture;
required a coating in the inside and
outside to improve impermeability to
gas; must be leak tested.
Plastics degrade in sunlight unless UV
treated; expensive.

Swine Industry in the Philippines

The swine industry in the Philippines is becoming intensified as a response to the increasing demand of
society for pork products (Catelo, Narrod, & Tiongco, 2008). As of July 2013, the countrys total swine
inventory stood at 11.88 million of pig heads in which 42.31 million is from commercial farming and the
76.53 million are from backyard farming. Approximately 36% were raised in commercial farms while
36% were in backyard farms [Bureau of Agricultural Statistics (BAS), 2013]. This trend results also to the
generation of large amount of animal wastes which brings environmental and health problems. These
problems include control of odor, emission of greenhouse gas, contamination of groundwater, surface
water run-off, discharge of animal pathogens and attraction of pests (Enturk & Yetilmezsoy, 2007).
IN MILLION HEAD
15000
10000
5000
0
2012
Backyard
7746
Commercial
4214
Total
11960
2013
7654
4231
11885
Figure 2 Philippine Swine Inventory by Farm Type, as of July 1, 2012-2013 (BAS, 2013)
The livestock and poultry sectors made significant contributions to Philippine agricultural economy in
the past decades (Devendra & Gardiner, 1995).
Among the livestock raised by the farmers are
carabaos, cattles, goats, hogs and ducks (BAS, 2013). The figure below shows how the swine industry
tops the livestock and poultry sector in the country.

9%
33%
8%
12%
Carabao
Cattle
Goat
Hog
38%
Duck
Figure 3 Livestock and Poultry Inventory by Animal Type, as of August 2013 (BAS, 2013)
Apparently, hog raising has the highest potential for biogas production among other sorts of livestock.
Hog manure produces a large volume of gas that makes hog raisers to build pens with manure collection
system to facilitate waste management (Teune, 2010).
The table below compares the biogas yield per volatile solids (VS) content for different feedstocks. With
a biogas production of 0.25 to 0.50 m3/ kg VS, pig slurry serves as an excellent choice for anaerobic
digestion.
Table 3 Characteristics of Agricultural Slurries (Monnet, 2003)
Feedstock
C:N Ratio
Biogas Yield (m3/kg VS)
Pig slurry
3:10
0.25 0.50
Cow slurry
6:20
0.20 0.30
Chicken slurry
3:10
0.35 0.60

Biogas as Fuel Used for Cooking

From the conventional type of energy source which is the firewood, the households with enough source
of income are now using LPG stoves. However, large numbers of households today are still using the
traditional source of fire because they cannot afford the increasing price of LPG (Teune, 2010).
Other
Coal
Wood
Charcoal
Kerosene
Gas
Electricity
0
10
20
30
40
50
60
Rural
Electricity
0.2
Gas
27
Kerosene
2.4
Charcoal
8.3
Wood
60.8
Coal
1.4
Other
0
Urban
1.3
43.4
4.7
6.8
41.8
Figure 4 Fuels Used for Cooking in Rural and Urban Areas in Terms of Population
(Teune, 2010)
Biogas Composition
Methane and carbon dioxide are the two major components of the biogas produced from any types of
substrates. Approximately, methane is about 45-85% in the biogas while carbon dioxide composition is
about 15-45%. Biogas is also composed of hydrogen sulfide, ammonia and nitrogen that are usually
present in small amounts (Alexopoulos, 2012).

Methane has a chemical formula of CH4 which denotes it has one molecule of carbon and four atoms of
hydrogen. It is used primarily for cooking and heating places since it is one of the main components of
natural gas. (Abril & Borges, 2004)
Table 4 Properties of Methane and Carbon Dioxide [Material Safety and Data Sheet (MSDS, 2010)]
Physical and Chemical Properties
Properties
Methane
Carbon Dioxide
Appearance
Colorless
Colorless
Odor
Odorless
Slightly pungent odor
State
Flammable gas
A slightly acid gas
Molecular weight
16.04
44.01
Boiling point (1 atm)
-258.7oF(-161.5oC)
-109.3oF(-78.5oC)
Specific gravity (air=1)
0.554
1.522
Freezing point/Melting point
-296.5oF (-182.5oC)
Vapor Pressure (at 21.2oC)
Permanent, non-condensable gas
838 psig
Gas density (at 21.2oC)
0.042 lb/ft3
0.1144 lb/ft3
Solubility in water (vol/vol)
3.3 ml gas/100 ml
0.90
Sludge Composition
Anaerobic digestion draws carbon, hydrogen and oxygen from the substrate. The essential plant
nutrients (N, P, K) remain largely in the slurry. The composition of fertilizing agents in digested slurry
depends on the fermented substrate and can, therefore, vary within certain limits (Kossman & Ponitz,
2007).
Viscosity
During the process of stable fermentation, reduction of the amount of volatile solids of about 50% is
observed which results to the decrease of the viscosity of the slurry. As well as the conversion of long
carbon chains into short carbon chains takes place (Kossman & Ponitz, 2007).
Odor

With the sufficient residence time inside the biodigester, all odorous substances will be completely
digested resulting to less odorous effluent sludge (Kossman & Ponitz, 2007).
Fertilizing Effect of Effluent Sludge

Spreading the digested slurry to the field before the start of vegetation is the best period of applying the
slurry. This is because it will help the soil to regain all the nutrients it gave during the harvest season
(Kossman & Ponitz, 2007).
Anaerobic Digestion Process

Anaerobic fermentation of the organic matter in the animal and human excreta and the agricultural
residues such as cassava and sugar cane will produce methane (Hislop, 1992). This will happen by mixing
the organic matter with water at the ratio of 1:2 and then allowing it to stay in the airtight container
called biogas digester (Lawbury, 2001). The process that will take place there will involve three stages;
hydrolysis, acidification and methanogenesis. In hydrolysis, conversion of insoluble organic matter into
soluble molecules takes place with the aid of fermentative bacteria. Then in the acidification, conversion
of the end products into acetic acid, hydrogen and carbon dioxide take place with the aid of acid
producing bacteria. Finally, the methanogenic bacteria will decompose the products of acidification into
methane and carbon dioxide (Alexopoulus, 2012).

Figure 5 The anaerobic digestion pathway from organic waste to methane (Eaton, 2009)

Synergistic community of microorganisms is found inside the biodigester which are responsible for
digesting organic matter to produce methane. These are the methanogens (archaea), bacteria, fungi,
and protozoa. The complex process of anaerobic digestion can be stated in four phases: hydrolysis,
acidogenesis, acetogenesis and methanogenesis. Exoenzymes are used by bacteria, protozoa and fungi
to convert complex organic molecules into monomers (hydrolysis). On the other hand, bacteria are
responsible for the conversion of monomers into organic acids (acidogenesis) and the conversion of
organic acids into acetic acid (acetogenesis). Finally, methanogens will do the last stage which is the
conversion of acetic acid into methane (methanogenesis) (Smith, 2002).
Methanogens is an anaerobic microorganism that does not require oxygen in living and growing. It is
important that the environment inside the biodigester remains completely free from oxygen. This
microorganism is from the archaea domain which can be classed either as hydrogenetrophic,
acetoclastic or methylotrophic based on the substrate used (Smith, 2002).
Of all the four stages in the anaerobic digestion, anyone of this has the possibility to become rate
limiting step. In case, that the hydrolysis stage is the rate limiting, the selection and process of feedstock
should be checked. Or if the acetogenesis is the rate limiting, heating of the digester is required for the
endothermic reaction to proceed. Above all, using the inoculum of right microorganism or introducing
organic materials that is versatile will help to accelerate the rate limiting step and will help to generate
more biogas (Smith, 2002).
Factors Affecting Biogas Production

Several parameters are needed to be controlled to improve the activity of microorganisms and to
increase the efficiency of the anaerobic digestion (Monnet, 2003).
Total Solid Content

Solid contents are classified into three categories: low, medium and high system. For the low solid (LS)
system, it has less than 10% content of the total solid (TS). Then, for the medium solid (MS), the range is
from 15-20% of TS. Lastly, the high solid (HS) account for 22-40% of the TS. As the total solid content
increases, the digester volume decreases because the demand for water requirements will become
lower (Themelis, 2002).

Temperature
Mesophilic and thermophilic conditions are the range of the temperature that the anaerobic digestion
will occur. Mesophilic conditions fall under the temperature of 20-450C while thermophilic conditions
lies between 50-650C (Baertsche & Wicks, 2010).
Feedstock composition and the type of digester will dictate the optimum temperature but it should be
noted that it is needed to maintain relatively constant to ensure the continuous gas production (Jenangi,
2001).
Retention Time
Retention time states the time required to obtain the complete degradation of organic matter. It
depends upon with the process temperature and waste composition. For the digester under mesophilic
condition, it will take 15-30 days while in the thermophilic digester; it will take 12-14 days (Monnet,
2003).
pH
The pH inside the biodigester must favor all the four phases present in the production of biogas. In the
preliminary acid phase digestion, the pH falls from six to lower because carbon dioxide is given off. This
can last for about two weeks. As digestion continues, less amount of carbon dioxide is produce while the
methane produced continues to increase which result also in increasing the pH. When the mixture
becomes less acidic, methane fermentation occurs. The pH now will range from 7-8.5. The mixture
becomes well buffered that any addition of acid or alkali will result only to the adjustment of mixture
back to the stabilize pH (Fry, 1973).
Mixing
Mixing offers several advantages. These include the larger contact between the microorganism and
substrates, improvement of the ability of population of the bacteria in obtaining nutrients, hinder the
formation of the scum and achievement of uniform temperature gradient. Different feedstocks must be
mixed well before entering to the digester to obtain higher yield of biogas production (Monnet, 2003).

Table 5 Factors Affecting Biogas Production (Pohland & Harper, 1997)

Most popular is within the mesophilic range of 180oF to 104oF. Optimum occurs
Temperature
around 86oF to 95oF; thermophilic digestion is also possible (113 to 141oF); small
fluctuations from established effective temperature range can upset process
Retention Time
Depends on influent concentration, type of influent, and temperature. Typically 1 to

30 days in full-scale treatment systems and 10 to 20 years in landfills
Air
Bacteria
Must be excluded; toxic to anaerobic processes

Dependent upon waste and temperature; Methanosarcina might be preferred for
high rate methane production processes
C/N Ratio*
Less than 43:1
C/P Ratio*
Less than 187:1
pH
Successful range of 6.0-8.0; optimum is near 7.0
Volatile Acids
Bicarbonate alkalinity should exceed volatile acids alkalinity
Solid Contents
Optimum influent solids content is 7-9% by weight; but high rates have been
observed at higher concentrations
The presence of certain cations and heavy metals in sufficient concentrations are
Toxic Substances
toxic to the anaerobic process; too numerous to generalize, but, in general, high
concentrations of halogenate organics can be harmful
Project Guidelines
The government of the Philippines, in response to the need for laws and policies, have passed on several
legislations to support the usage of biogas as a form of energy. The following are some examples of
these: (Teune, 2012)
1. Philippine Energy Plan (PEP) PEP is a vision for the future of the source of energy in the
Philippines, its goal is to attain at least 60% utilization of self-sufficient energy via alternative
fuels beyond 2010.
2. Republic Act (RA) 8749 RA 8749 is more popularly known as the Philippine Clean Air Act of
1999, this RA aims to reduce greenhouse gas emissions in the Philippines by controlling the

standards by which industries, private sectors and citizens release their gases into the
atmosphere.
3. RA 9275 Republic Act 9275 is known as the Clean Water Act of 2004, its mission is to preserve
the countrys water sources by tightening the standards by which pollutants are released in the
bodies of water in the Philippines area of responsibility.
4. The Renewable Energy Act of 2008 By giving incentives to those who will be using energy
sources that are renewable and sustainable, the government aims to increase the usage of the
aforementioned technology,
5. Presidential Decree (PD) 984 This PD is known as the Pollution Control Decree of 1976, its aim
is to prevent, abate and control the pollution in all aspects in the country.
6. PD 1586 is entitled as the Establishing Environmental Impact Statement System including
other Environmental Management Related Measures and for Other Purposes. Its goal is to
achieve and maintain a balance between socio-economic growth and environmental protection.
7. PD 1151 This PD is known as the Philippine Environmental Policy. By requiring environmental
impact assessments, the government aims to form an intensive program to protect the
environment.
8. PD 1152 is known as the Philippines Environment Code. This Presidential Decrees goal is to
formulate policies and standards to prescribe to the citizens for the protection of the
environment.
9. The RA 7160 Local Government Code of 1991 is a legislation that transferred certain functions of
the DENR to local government units (LGUs), the LGUs extend their help to the government by
implementing proper waste management in the society.
10. RA 9003 is known as the Ecological Solid Waste Management Act of 2000, and its main goal is to
protect the health of the public and the environment by adopting an ecological waste
management program.
Moreover, the following are Presidential Decrees which, again tries to promote the usage of a certain
technology with the hope of promoting it, in this case, biogas projects:
11. PD 1068 this gives fiscal support to those of whom will produce non-conventional sources of
energy, this includes biogas.
12. PD 1159, known as the Agricultural Investments Incentives Law, which supports the integration
of biogas works in pig farms and other livestock farms.

Equipment Design
The gas collector of the digester is basically an inverted drum placed inside another drum that is filled
with water. When biogas is produced, the inner tank is filled with gas causing it to rise out from the
inner tank. As biogas is removed for use, the inner gas storage tank sinks back into the larger, outer
tank.
Figure 6 Schematic Diagram of a Portable Floating-Head Biodigester
The cycle is a repeated one. When the inner drum is empty and sinks back again to the outer drum, the
production of gas will take hours before it floats back again and be used for cooking. The amount of gas
produced by the digester, in a short period of time, is capable to cook a meal consisting of easy-to-cook
foods like egg, hotdog and meatloaf.
The feed manure can last up to one month with only water to assist in the production of biogas. When
the manure dries out, water must be added so that the cycle will go on. Stirring is important to ensure
that water is thoroughly mixed with the manure.

Building Material of the Digester

Stainless steel vessels are easy to fabricate and can resist corrosion. These type of vessels can sustain
gas without having too much to give off. Unlike plastic, steel vessels are heavy and hard, it can resist
force and high pressure without structural deformation.
Originally, HDPE was chosen to be the material for the digester. But, plastics are hard to fabricate and
must be customized upon orders. Fabrication is costly, only few manufacturers fabricate plastic because
mold sizing takes long before the plastic is injected or blown in it.
Equipment Sizing
The digester has a capacity of 100L for the stainless steel tank and 200L for the plastic drum; has a
height of 3.5 ft and 3.2 ft respectively. With a diameter of 1.9 ft, the high-density polyethylene (HDPE)
drum has a wider area compared to the steel tank, with a diameter of 1.13 ft.
For the stainless steel tank, a 1 hole was drilled at the top part of the tank and a pipe was fitted in it to
serve as the outlet for the slurry. Along with that, a 2 pipe, starting from the bottom, is extended to the
middle of the tank to serve as the feed inlet. The overhead tank of slightly smaller volume serves as the
gas collector. It has a volume 75 L with a height of 3.05 ft and a diameter of 1.05 ft.
For the plastic drum, a feed inlet tube with a diameter of 4 was connected at the upper part of the
tank. A 1 hole was connected to it to for the slurry outlet. At the bottom part, a 1 hole was drilled to
function as the water outlet. All holes are sealed with epoxy and threaded tape to prevent gas leaks.
The water trap is made of a PVC pipe that is cut into a length of 10. Two lids (clean out) were attached
to both ends to cover the open area. Epoxy was used to seal the connections, to ensure that there are
no leaks. Two holes were punched at the top of the lid, one for the inlet gas from the digester and the
other for the outlet gas to the stove.
Agitation and Use of Impellers

The design does not include the use of impellers or any agitator. Mixing of the digester contents was
done immediately after the addition of water into the manure to destroy and avoid sinking and
swimming layers inside the tank. Even without mixing device, the activity of the methanogenic bacteria
can be improved through the release of biogas because there is already a certain agitation happening
through the raising gas. This is achieved by the movement of substrates with the different thermocline
and by the inflow of fresh feed. (Teune, 2012)
Maximum height of the

floating-head steel tank
HDPE plastic drum digester
PVC sludge outlet with

epoxy for leak prevention
Improvised water trap
1/2" ball gate valve of the

steel tank
Connection of the plastic

drum digester to the tank
Conventional household
stove
Gas hose from the digester

to the stove
Pail for sludge overflow

collection
Figure 7 Equipment parts and connections

Figure 8 Overall project setup

Design Constraints
With its small surface area, the biodigester is not capable of producing a gas that will last for a whole
day of cooking. Instead, gas will be produced by batch for not less than 6 hours for one meal.
Installation Cost
The cost to set up the biodigester, including parts and labor was approximately 16,460 php and would
replace the need for at least one 11-kg Liquefied Petroleum Gas (LPG) gas cylinder per month. The
simple payback for the installation cost, based on the average cost of 800 php per 11-kg gas, is

estimated to be in one year and a half. After one and a half years, all of the biogas can be considered as
free. Computations of which are presented below.
Table 6 Detailed expenses for the fabrication (Agustin, 2013)
Items of Work
Materials
SS Sheet 1.2 mm
PVC pipe 2" dia
PVC fittings
Ball valve 1/2" dia
Consumables
Sub-total
Labor Cost
Sub-total
Qty
Unit
Unit Cost (php)
Total Cost (php)
1.000
2.00
1.00
1.00
1.00
sheet
length
lot
p
lot
6858.00
635.00
1270.00
381.00
1270.00
1.00
lot
3810.00
6,858.00
1,270.00
1,270.00
381.00
1,270.00
11,049.00
3,810.00
3,810.00
FABRICATION COST
14,859.00
Table 7 Breakdown of Overall Expenses

Item
Unit Cost (php)
Stainless steel floating head digester
14,859.00
HDPE Drum
500.00
Water trap
150.00
Water hose
100.00
Gas hose
60.00
Gas stove
500.00
Miscellaneous
291.00
Total
16460.00
Installation Cost Payback Calculation

Assuming a monthly average increase of 3% in the cost of LPG,
(

where:
F - future value; A - uniform amount per period; I - interest rate; n - number of periods
(Assakkaf, 2000)
Assuming a year of money back,
(
(
Based on the installation cost of 16,460 php,

Methodology
The pig dung was collected in the backyard of Leangs residence. The manure was just dumped in the
unoccupied area near their piggery. With the use of shovel and pail, 30 kilograms of this manure was
gathered and fed into the steel digester and HDPE drum. Water was then added in a mixture of 1:1
through the inlet pipe. As the sludge overflowed through the outlet pipe, the floating head immediately
telescoped out of the tank. The air inside the digester was then released through the ball valve in the
upper side of the gas holder. This made the floating head sink back to the outer tank that indicated the
discharge of the unwanted gas initially formed. Water was then added again and the tank rose up once
more. This time, the floating head gradually descended and the sludge came out without any pressure
applied even with the closed valve. This suggested that the digestion can be started. With the HDPE
Residential pigery in
Sapang Palay, Bulacan
Gathering of pig manure
Loading to the floatinghead steel tank
Transferring of pig dung

to the plastic drum
Mixing of 1:1 ratio of

manure and water
Assembly of parts and

checking of connections
Preventing any gas leak

(bubble test)
Allowing anaerobic
digestion inside the tank
Lighting of the biogas

produced
drum,
Figure 9 Photo journal of the methodology for the digester setup

water was added until the sludge overflowed in the outlet PVC pipe. The gas hose was then assembled
and connected from the steel tank and plastic drum to the back of the stove. Gas leaks were checked
though the use of bubbles.
Anaerobic digestion was allowed to take place and it took approximately three hours to attain the
maximum height of the floating tank. The biogas produced was consumed for almost 30 minutes to cook
rice and boil
water.
Figure 10 Setup of the biodigester installed in Leangs residence in Sapang Palay, Bulacan
Community Selection
The swine industry, which accounted for 80% of the total livestock production in the country, registered
an average of 1.02% growth for the last five years. The top producing region is the Central Luzon with an
average production of 301, 897.6 metric tons of hog production, followed by the CALABARZON region
and Western Visayas (BAS, 2013).
Metric Tons

350,000
300,000
250,000
200,000
150,000
100,000
50,000
0
2008
2009
2010
2011
2012
Figure 11 Hogs: Volume of Production in Different Regions of the Country, as of January 1, 2008-2012
(BAS, 2013)
Notably, Central Luzon is known for hog raisers, which is the main source of waste for the biodigester.
Bulacan is one of several first class provinces in the Republic of the Philippines (Provincial Information
Technology, 2013). One can find this place in Region III, which is part of the central Luzon region
(Department of Foreign Affairs, 2013). Fifty kilometers off North of Manila, with three component cities,
21 municipalities and 569 barangays, the researchers have found Brgy. Sapang Palay in San Juan del
Monte (one of the main cities of Bulacan), as an excellent candidate for the recipient of the biodigester.
Initially, the designated recipient was Brgy. Ping-As in Alitagtag, but due to unforeseen problems, an
alternate was chosen. Experiencing the place, the researchers have made a smart choice, the place was
not well developed; not exactly poor but it was a place where people were grateful for a way to save
their earnings. The place was ideal as mentioned earlier, owing to the fact that the main industry in
Sapang Palay was farming and livestock, which means feces of animals and wastes from households
were readily available.
Maintenance and Operation

The biodigester must be fed with a 1:1 mixture of water and pig dung initially. Daily maintenance
includes checking inlet and outlet PVC pipes to ensure that the water level inside the tank is adequate

and that no air is entering. Aside from pig dung or other animal manure, kitchen waste like fruit peeling,
food scraps or other sources of carbohydrates may also be added. Periodic cleaning in two to four years
must be done. Properly maintained biodigesters can last up to 15 years.
Results
Since another digester of twice the volume of the steel tank was used, the time required for the floatinghead tank to achieve its maximum height was just approximately three hours. Upon consumption, it
sank back to the tank and biogas was being produced again. Utilization of this time interval would be
enough to cook a days meal.
The biogas produced an intense blue flame and can be compared to the flame that emerges in a heavyduty stove. This blue flame can be observed up to 15-20 minutes until the floating-head tank goes back
to its original position. With the usual cooking time of 5-7 minutes, kg of hotdogs cut into pieces can
be achieved in only 2-3 minutes using the biogas.
The initial feed loading of 30 kg in each of the steel tank and plastic drum can last up to a month
provided that sufficient water will be added daily to avoid deposits at the bottom. Cleaning, which
involves emptying of the digesters can be done every 5 or 6 months. This will ensure longer lifespan for
the bioreactor.
Discussion
Stainless steel was a right choice for the material of construction of the floating head tank. The thickness
of the material can withstand the pressure released during the production of biogas unlike the HDPE
drum that had its lid already deformed. Aside from the fact that the fabrication of a plastic floating head
will be more expensive than that of stainless steel, plastic drums of larger wall thickness are relatively of
high cost when purchased in the market. This is because customized premolded plastics are processed
through blow molding that usually produce plastics of smaller wall thickness.
The idea of connecting another digester in series with the floating head tank effectively reduces the
retention time needed for the digestion process and increases the rate of biogas production. The gas
escaping through the space between the steel tank and its inverted head can be considered negligible in
comparison with the large volume of methane being produced.

Project Demonstration
The protable floating-head biodigester was presented to the Chemical Engineering Students of
Technological Institute of the Philippines, Manila (TIPM). Six first-year students, one third-year student
and five fourth-year students, with a total of 12 participants attended the said demonstration. It was
held at C-112 from 3:00 pm 5:00 pm last October 10, 2013. The activity started with the introduction
of the group members and followed by the discussion of how the digester works. A powerpoint
presentation was provided for the audience to have a clearer insight of the topic being discussed. A
trace of slight aversive reaction was evident when they knew that the biogas being produced from the
reactor actually evolved from pig dung. Questions like, how did the group came up with the idea of
methane capture, how was the manure collected and how was the whole set-up has been transported
from Bulacan to the campus considering the weight of the tank and drum, were raised by the freshmen
Discussion of how the

biodigester works
Open forum: "How did you

collect the manure?"
Audio-visual presentation
of the steps undertaken
Lighting of the stove and

emergence of blue flame
Utilization of the biogas

produced though cooking
"It seems to taste normal":

Free tasting
Explanation of the parts of

the digester set-up
Opening of the drum by

one of the freshmen
Group picture with the

attendees
group during the open forum.

Figure 12 Photo journal of the project demonstration

On the other hand, the juniors asked about the reactions taking place during the anaerobic digestion. To
reveal the preparatory steps undertaken, a documentation in the form of an audio-visual presentation
was also shown. The apex of event was the lighting of the stove. Students were able to observe how the
floating head gradually sinks back upon the consumption of the biogas. The freshmen group actually
tried it themselves and a hint of amusement was evident on their faces when the blue flame emerged
from the stove. Surprisingly, they were not hesistant to eat the pieces of hotdogs cooked using the
biogas though they know where it came from. Filled with curiosity, one of them even asked the
permission to see how the manure looks like inside the digester. He said that the slurry just looks like
soil or mud and that the odor was still tolearable. The activity ended with the distribution of evaluation
forms and expression of gratitude to the attendeed for their valuable time and active participation.
Figure 13 Freshmen participants together with the organizers: (from the left: Miranda, De Leon, Ungria,
Araojo, Aragon, Palquiran, Punzal, Vidal, Valentin, De Villa and Santos)
Positive responses and comments were given by the participants. Being eco-friendly, innovative,
creative, and harworking were the values they attained from the activity. Generally, sense of social
responsibility in protecting the environment was reflected from their comments and suggestions.
Moreover, they were able to learn that chemical engineering principles can really be applied into
practice to solve todays problems like that of waste disposal management.

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Biochemical Engineering

Portable Floating-Head Digester in the

Almendral, Christine Mae C.

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Overview of Biodigesters in the Philippines

Average fixed dome model

Type II: Plastic Digester

Type III: Metal Digester

Figure 1 DOST-ITDI Portable Biogas Digesters

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Floating Drum Digesters: Advantages and Disadvantages

Materials of Construction: Advantages and Disadvantages

Usually the cheapest material of

Rusts can be formed outside; surface

Available at low cost. Years of good service

Less expensive than mild steel vessel of the

Readily available and easy to work with.

Must be treated before paint will

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Swine Industry in the Philippines

Among the livestock raised by the farmers are

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Biogas Yield (m3/kg VS)

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Biogas as Fuel Used for Cooking

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Slightly pungent odor

A slightly acid gas

Boiling point (1 atm)

Specific gravity (air=1)

Freezing point/Melting point

Vapor Pressure (at 21.2oC)

Permanent, non-condensable gas

Gas density (at 21.2oC)

Solubility in water (vol/vol)

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Fertilizing Effect of Effluent Sludge

Anaerobic Digestion Process

methane and carbon dioxide (Alexopoulus, 2012).

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Factors Affecting Biogas Production

Total Solid Content

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Table 5 Factors Affecting Biogas Production (Pohland & Harper, 1997)

Depends on influent concentration, type of influent, and temperature. Typically 1 to

Must be excluded; toxic to anaerobic processes

Less than 43:1

Less than 187:1

Successful range of 6.0-8.0; optimum is near 7.0

Bicarbonate alkalinity should exceed volatile acids alkalinity

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Figure 6 Schematic Diagram of a Portable Floating-Head Biodigester

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Building Material of the Digester

Agitation and Use of Impellers

PORTABLE FLOATING-HEAD DIGESTER IN THE PRODUCTION OF BIOGAS FROM PIG DUNG

Maximum height of the

HDPE plastic drum digester

PVC sludge outlet with