FABRICATION OF DOMESTIC BIOGAS

UNIT
FOR SUSTAINABLE SOCIETY

Submitted by:
(12meu055)

MOHIT KHATRI
KETAN MALIK

(12meu045)
KARTIK CHAUHAN
(12meu044)
Supervisor: MR. GAGAN BARADIA
DR. ROHIT SINGH
LATHER

Department of Mechanical Engineering

HUDA Sector 23-A Gurgaon - 122017.

Tel : + 91 124 2365811 to 13 Fax : + 91 124 2367488
Email : ncu@ncuindia.edu

2015-2016

~2~

Declaration

CERTIFICATE
This is to certify that the project report entitled FABRICATION OF DOMESTIC
BIOGAS UNIT FOR SUSTAINABLE SOCIETY is submitted to THE
NORTHCAP UNIVERSITY in connection to the institute FINAL YEAR PROJECT

FABRICATION OF DOMESTIC BIOGAS UNIT FOR

program. This is a bonafide record of the work done by MOHIT KHATRI, KETAN

SUSTAINABLE SOCIETY

MALIK & KARTIK CHAUHAN under the supervision of Mr. GAGAN BARADIA
and Dr. ROHIT SINGH LATHER at THE NORTH CAP UNIVERSITY from 15 th
MAY 2015 to 30th APRIL 2016-04-26
The Project Dissertation is submitted in partial fulfilment of academic requirements for
THE NORTH CAP UNIVERSITY. This dissertation is a result of my own
investigation. All sections of the text and results, which have been obtained from other
sources, are fully referenced. I understand that cheating and plagiarism constitute a breach
of University regulations and will be dealt with accordingly.

Signature:

Countersigned by
Name of the Student:

MOHIT KHATRI (12MEU 055)

(Group Head/Divisional Head)

KETAN MALIK (12MEU 045)

KARTIK CHAUHAN ()

DATE:
Date:

PLACE:
~1~

Acknowledgement
A B.tech project is a golden opportunity for learning and self development. This project is
done as the final year project at THE NORTHCAP UNIVERSITY
This project was conducted under the supervision of Mr. GAGAN BARADIA and Dr.
ROHIT SINGH LATHER. I am grateful for their patience in giving useful constructive
comments for the enrichments for this project that cannot be forgotten forever, their time
and effort that has been contribute to me during the preparation of this project. I also would
to thanks to the entire teaching engineer in Faculty of Mechanical Engineering for their
guidance, comments, permission to use all the machine in the laboratory, sharing their
experiences and knowledge sharing during this project was carried out. Here also, I also
want to thanks for those whom that give me useful assistance in helping for this project
completion. Also, I would like to thank my parents for their moral support and my friends
for their help and their sharing in using computer software during designing the concept for
the project visualization and getting me the apparatus and materials for this project. . The
contributions of all the people are sincerely appreciated and gratefully acknowledged.

~2~

Abstract
For making a self sustained (sustainable society), we focused upon reducing the amount of
energy used by a household in the form of electricity and cooking fuel. In doing so a
survey is conducted and the behaviour of people is studied about whether they are
interested in using renewable sources of energy instead of conventional sources of energy,
if interested what type of renewable sources of energy they are using (considering solar,
biogas and geothermal as the main aspects) and as the result of that it is identified that
people of the urban society are more interested in using solar energy (for the generation of
electricity) and the energy from biogas(for cooking purpose).
In further extension to the project a small biogas unit is fabricated for use in the university
premises. The fuel which is used for the production of biogas is the waste (leftover food)
from the canteen. Around 6-8 kg of food is available as waste in the college canteen which
when fed in the biogas unit produced 1.5-2 kg of methane gas which can be used for
cooking in the university canteen itself.

~3~

Table of Contents
Acknowledgement .....................................................................................
...iii
Abstract ....................................................................................................
.....iv
Chapter-1:
Introduction.............. ......................8
1.1 Introduction to sustainable society
8
1.2 Brief introduction about biogas
unit.8
Chapter-2:

Literature

Review.......................................................................10
2.1

Why

biogas

as

fuel.............................................................10
2.2

Research

Paper

Study ........................................................11
2.3 Important Parameters Considered in Literature
Review...15
2.4

Key

Findings..........................................................................15
Chapter-3:

Problem

Definition.....................................................................16
Chapter-4:

Model

Construction

and

Solution...........................................17
4.1 Design of Biogas Unit for the
University.............................17
4.2
Required.................................................................18

~4~

Materials

4.3

Cost

of

Materials....................................................................19
4.4

Fabrication

of

Biogas

Unit ...................................................22
4.5
Preparation ...........................................................................27
4.6
Process ..................................................................................27
Chapter-5: Discussion of Results and Validation.....................................28
5.1

Observation

and

Calculations..............................................28
5.2

Efficiency

of

Biogas

unit .......................................................29
5.3

Breakeven

Analysis ..............................................................29
Chapter-6: Conclusions and Recommendations for future work.........30

Chapter-7:
References.................................................................................31

~5~

List of Figures

Page no.

Figure 1: Model ...........9

Figure 2: Design ..........17
Figure 3: Fabrication (Fermenter) .......22
Figure 4: Fabrication (Digester tank) ......22
Figure 5: Fabrication (fig 3)............. .......22
Figure 6: Fabrication (Fermenter 2) ....23
Figure 7: Result (Feed pipe) ................24
Figure 8: Result (Outlet valve) ................24
Figure 9: Result (Overflow pipe) .............25
Figure 10: Result (Gas outlet valve) ....................25
Figure 11: Result (Final setup) ................26
Figure 11: Burning of methane ...............28

1 Introduction
1.1 Introduction to Sustainable Society
By sustainable society we mean to produce the model of a society that will be self
sustained that means whatever it will take from the nature (in the form of resources,
energy etc.) it will return it to the environment in one form or the another.

~6~

Global warming and climate change become the extensively focused issues at present. It
is urgently required to build a low-carbon sustainable homeland. In recent years, with the
rapid development of economy, the global greenhouse gas emission has increased
continuously, meaning that environmental protection has crossed national boundaries, and
sustainable development has become the most important topic for human.Also it is
important to find the ways by which the waste products that are produced within the
society are minimized or how can we use them again.

1.2 Brief introduction about biogas unit

The home based biogas unit is fabricated to reduce the demand for cooking fuel (LPG) by
making the use of leftover waste food which is of no use. According to a study done by
ARTI (Indian Appropriate Rural Technology Institute) we can get 250g of methane for 1kg
of waste food. The fabrication of such type of biogas unit is done in the college premises
for helping the canteen manager by cutting down the use of LPG for cooking by using the
leftover food from the canteen only.

The biogas unit consist of mainly 6 parts:1.

2.
3.
4.
5.
6.

Fermenter or digester tank (1000 litres)

Collector tank (750 litres)
Feed pipe
Gas removal valve
Slurry outlet
Gas stove

~7~

~8~

FIG 1(Model)

2 Literature Review
The purpose of literature review is to capture current state of use of renewable sources of
energy in the urban sector as well as to document the current methods and techniques that
are used.

Approach: Solar energy and energy from biogas are preferred over geothermal energy
because of cost efficiency and easy installation. Further for comparing the estimated cost
and the actual cost fabrication of biogas unit is done for the university and the results are
studied.

2.1 Why Biogas as a Fuel

Out of a total of 19.20 million households in India, 5.37(28%) [4] reside in urban areas.
According to the study the demand for cooking fuel in the urban areas is increasing from
69.57 MTCR (million tonnes of coal replacement) in 1994-1995 to 86.72 MTCR in 19992000. Only a part of urban households has access to clean sources of cooking fuel such as
LPG and electricity. Also the traditional methods of cooking in the rural areas leads to
many health problems. So there is a need for clean fuel for cooking in India

~9~

2.2 Research paper study

S.No YEAR TITLE
.
1.

1990

AUTHOR

Study

in

sirsi P.R. Bhat, Study of 8 villages from

block (Karnataka) H.N.

Karnataka is done and the

[1]

data

Chanakya
and

2004

of

3.

2009

and

maximum

floating drum (KVIC model)

Sarbjit

and fixed dome (Janta and

models Singh

family

collected

of Singh,

economics of
different

successfully

ath
potential is studied.
K. Jatinder Comparison
between

Comparative
study

for

N.H. operating biogas units is

Ravindran
2.

KEY POINT

size Sooch

Deenbandhu
done

on

model)

is

basis

of

the

biogas plants for

installation cost, operating

state

cost and breakeven point.

of

Punjab,

India [2]
Global
warming H.

The GMP (Global Warming

mitigation

Mitigation

PathakN.

potential

of JainA.

carbon

Potential)

credit

from

and
the

biogas plants in Bhatia S. biogas plants in India was

India [3]

Mohanty

calculated.

Navindu
4.

2005

Dissemination
cooking

Gupta
of S.D.

energy pohekar,

alternatives

in Dinesh

A review of all cooking

energy

sources

is

done

and their use by different

~ 10 ~

Indiaa

review kumar, M economic

[4]
5.

2010

Ramacha

ndran
Biogas generation P.
potential
anaerobic
digestion

specified.
The potential of generation

by Venkatesh of biogas from anaerobic

wara Rao, respiration
for Saraj

S. municipal

of

solid

waste,

crop

Baral,

residue, agricultural waste

energy

Ranjan

etc. in India is studied

India [5]
1991

is

sustainable
development

6.

groups

Economics
family

in Dey,
Srikanth
Mutnuri
of TARA
sized CHANDRA

Cost calculations of KVIC

and

Janta

type

biogas

biogas plants in KANDPAL,

plant is done followed by

India [6]

cost benefit analysis and

BHARATI

JOSHI and sensitivity analysis.

CHANDRA
SHEKHAR
7.

2005

SINHAt
Biogas scrubbing, S.S. kapdi, The

paper

deals

with

compression and V.K. Vijay, increasing the quality of

storage:
perspective
prospectus
8.

2007

S.K.
and Rajesh,
in Rajendra

biogas by removing Co2

and

making

it

transportable like fuel such

Indian context [7] Prasad

Techno-economics Pallav

as CNG.
The potential of reduction

of

of amount of Co2 released

biogas-based Purohit,

water pumping in Tara

in the atmosphere using

India: An attempt Chandra

the biogas based water

to internalize CO2 Kandpal

pumping

~ 11 ~

system

is

emissions
mitigation

9.

10.

2011

1986

and

in India is studied and how

India [9]

Carlos

renewable

Monroy

make

Biogas
as

an Dahiya
to and

energy

can

difference

is

estimated.
The effectiveness of biogas

plant A.K.

slurry

as

P. studied

fertilizer

is

yields

of

and

chemical

Vasudeva

different

fertilizers [10]
Anaerobic

n
Prema

measured.
Effects of feeding different

vegetable ,

for

biogas Devi

production [11]

Krishna

Nand*
rural Huang

Financing
renewable

Liming

energy:

between

are

fruit and vegetable wastes

S. such as mango, pineapple,

tomato, jackfruit, banana

& and orange, is studied and

the most suitable fuel is
known.
The paper analyses the
current

status

of

Rural

China and India.

China

and India [12]

Fermentation and H.
methanogenic

N. Decomposition rates and

Chanakya, pattern of different dry and

characteristics of a*
leafy

crops

Renewable Energy (RRE) in

comparison

1997

and

energy poverty in Bhide,

processing wastes Sumithra

13.

benefits

The availability of energy

and

2009

economic

Benefits [8]
A special focus on Anjali

digestion of fruit Viswanath

12.

with

payback period.

alternative

1992

along

other economic

slurry

11.

estimated

R. green

solid

biomass Venkatsub studied.

~ 12 ~

wastes

are

feedstocks
solid

in

a ramaniya

phase m

&

biogas fermentor Jayant

14.

1998

[13]
Plug

Moda~
flow K.S.

digestors

for JAGADISH

Study of different biomass

for biogas generation is

biogas generation *,H.N.

done as only cow dung as

from leaf biomass CHANAKY,

the

[14]

spread

P.

feed

restricts
of

the

biogas

RAJABAPAI technology.
AH and V.
15.

1995

ANAND
Cost of anaerobic SEEMIN

An attempt has been made

digestion

RUBAB

for

technology:

AND TARA analysis and evaluation of

the

development,

Household biogas CHANDRA

the

plants

affecting the cost of the

in

India KANDPAL

[15]

three

various
types

factors
of

biogas

plants in India has been

made

and

to

develop

functional relationship for

the
16.

2007

Production

operation

and

maintenance cost.
of D. Elango, Experiments

are

biogas

from M.

conducted

municipal

solid Pulikesi,

different

waste

with P.Bhaskar

biogas

to
methods

production

study
of
using

domestic sewage alingam,

solid waste with a fixed

[16]

hydraulic retention time of

V.

Ramamurt 25 days.

~ 13 ~

hi,
17.

2002

S.

Sivanesan
Household Biogas P. Purohit, This review is a summary
DigestersA

A. Kumar, of different aspects of the

Review [17]

S.

Rana, design and operation of

T.C.

small-scale,

Kandpal *

biogas

household,

digesters

covers

and

designs,

construction and other imp

18.

1986

solar-assisted G.

parameters.
N. In order to increase the

biogas system: A TIWARI

new

approach and

[18]

production

of

biogas

in

A. winters a new design is

CHANDRA

proposed and studied.

2.3 Important Parameters Considered in Literature Review

1. Type of feed
2. Cost of construction
3. Efficiency
4. Amount of methane gas produced
5. Hydraulic retention time
6. Effect of temperature on gas production
7. Capacity of the unit
8. Calorific value of the gas
9. Effect on global warming

2.4 Key Finding

1. Apart from cow dung a lot of materials such as dry leaves, leftover
food, remains of fruits and vegetables can also be used as fuel for
production of biogas.

~ 14 ~

2. Total cost of construction and maintenance of fixed dome biogas

plants is less than floating drum type biogas plants..
3. Efficiency of cow dung based biogas plants is much less than the
biogas plants operating on other fuels.
4. Hydraulic retention time for cow dung based biogas plants is 30-35
days and for leftover food and vegetables type of biogas plants is 5-7
days.
5. The optimum temperature for production f biogas is around 35
degree Celsius (from the study done by comparing the yields at
20,35 and 45 degree Celsius.)

2 Problem Definition

There is a lot of food that is wasted in houses, buildings and other places. That waste food
if used properly can produce a lot of energy and can also be used to produce methane gas
which can be used for cooking purposes and has many advantages over LPG and other
sources.
A step is taken to produce renewable energy from the waste leftover food from college
canteen and fabricating a biogas unit of 1.75 cubic metres to produce and store the biogas
which further can be used for cooking purposes in the college canteen itself.
This is the second step towards making our college a fully sustainable organization after
the installation of solar panels in the university for generating electricity. The biogas unit is
made using PVC equipment generally used for storing water and other plumbing tools are
used.

~ 15 ~

4 Model Construction and Solution

4.1 DESIGN OF BIOGAS UNIT FOR THE UNIVERSITY

FIG 2 (CAD MODEL)

~ 16 ~

4.2 MATERIAL REQUIRED

Tank 1000 litre

Tank 750 litre

90 mm t 1pc

90mm female adapter 1pc

90 mm male adapter 2 pieces

90 mm ailed cap 1 pc

Pvc pipe 90 mm dia 2 meter long 1 pc

Elbow 63 mm 1 pc

63 mm checknut 1pc

63 mm male adapter 2 pieces

Pvc pipe 63 mm dia 1 meter long 1 pc

12.5 mm pvc male adapter 1pc

12.5 mm galvanized iron elbow 1pc

Brass gas cock

Ball valve 15 mm dia 1pc

90mm barell piece

63 mm barell piece

50mm barell piece

12.5mm barell piece

2 saw blades

Teflon tape

Adhesive

M seal

Stove

~ 17 ~

4.3 COST ANALYSIS

MATERIAL

QUANTITY

VENDOR 1

VENDOR 2

Tank 1000 litres

3200

3000

Tank 750 litres

2400

2250

90 mm T

30

30

90 mm female adapter

140

130

90 mm male adapter

45

50

90 mm ailed cap

150

145

PVC pipe 90mm dia 2m

40

50

Elbow 63 mm

140

150

Checknut 63 mm

120

120

63 mm male adapter

75

75

PVC pipe 63mm dia 1 m

20

20

12.5 mm pvc male adaper

15

15

100

100

12.5 mm galvanised iron 1

elbow
Brass gascock

120

120

Ball valve 15 mm dia

90

90

MATERIAL

QUANTITY

VENDOR 1

VENDOR 2

~ 18 ~

90mm barell piece

120

120

63mm barell piece

100

100

50mm barell piece

80

80

12.5 mm barell piece

45

50

Teflon tape

15

15

Saw blades

100

100

Adhesive (50 gm)

10

M seal

40

60

Pressure gauge

400

400

300

300

220

220

8020

7720

Transportation
Cylinder pipe
TOTAL

~ 19 ~

4.4 FABRICATION OF BIOGAS UNIT

The fabrication of home based biogas unit is done using simple plumbing equipment
available from any paint shop.
Steps for fabrication are as follows:Step 1: Remove the upper portion of 1000 litre water tank as shown in fig 5 in such a way
that the 750 litre tank slides into the bigger tank.
Step 2: Remove the upper part of the 750 litre tank as shown in fig 4 to make it a digester
tank.

FIG 3 (Fermenter)

FIG 4 (Digester)

FIG 5 (other)

~ 20 ~

FIG 6 (Fermenter 2)
Step 3: Make 2 holes in the lower portion of the digester tank to make feed inlet and slurry
outlet using 90 mm and 63 mm barell piece respectively.
Step 4: Attach 90 mm T at the bottom of the tank using male and female adapter and along
with that attach a 2m long PVC pipe to make feed inlet valve as shown in fig 7 and attach a
ailed cap on it.
Step 5: Attach a 63 mm ball valve in the lower hole of 63mm using male adapter for slurry
outlet valve as shown in fig 8.
Step 6: Make a hole in the upper part of the fermenter tank of 63mm using 63mm male
adapter and a check nut as shown in fig 8.
Step 7: Make a hole of size 12.5 mm in the upper portion of the digester tank and attach a
gascock on it with the help of male adapter and a galvanised iron elbow as shown in fig 9.
Step 8: Make all joints tight using Teflon tape to avoid leakage.
Step 9: Check all the joints for leakage using soap solution.
Step 10: Put 40 kg of cow dung an 200 litres of water and leave for 25 days.
Step 11: The final setup is shown in fig 10.

~ 21 ~

FIG 7 (FEED PIPE)

FIG 8 (OUTLET VALVE)

~ 22 ~

FIG 9 (OVERFLOW PIPE)

FIG 10 (GAS OUTLET VALVE)

~ 23 ~

~ 24 ~

FIG 11 (FINAL SETUP)

~ 25 ~

4.5 PREPRATION
For getting daily supply of methane gas we had to put a considerable amount of waste food
in the digester tank in the form of slurry which contains equal amount of food and water
mixed with each other in such a way that there are no chunks of food left in the slurry and
it should be in the liquid form but before getting the regular production we first had to start
the plant by putting 30-40 kg of cow dung mixed with about 250-300 litre of water in it to
provide the environment for the growth of bacteria that is used for fermentation. The
bacteria is only found in the stomach of cows and buffalos, so we had to use cow dung for
the germination of bacteria, the process will take 30-30 days.

4.6 PROCESS
After the germination of bacteria in the digester tank, feed the leftover food stock mixing it
with equal amount of water forming liquid slurry into the digester tank from the feed pipe.
The bacteria start working on it and break the waste food to produce slurry, carbon dioxide
and methane gas. The methane gas being lighter is collected in the collecting tank which is
floating upon the digester tank (partially immersed in it) and the carbondioxide being
heavier comes down. After collecting the gas in the collecting tank, the tank rises up and
the gas collected gets stored in the tank. The brass gascock is used for transmitting
methane gas from the colletor tank to the stove using PVC or rubber pipe. Open the gas
valve and light the stove for making food. Remove the slurry left from the outlet pipe
which can be further used as manure in the garden.

~ 26 ~

5 Results, validation and Discussion

5.1 OBSERVATION AND CALCULATIONS
For 3 kg of sugar that is fed into the digester tank with 10 litre of water in the form of
slurry the observations are as follows
Radius of collector tank = 2 m
Rise in the level of collector tank = 6 cm = .06m
Density of methane gas at room temperature = .656 kg/m3
Volume of gas in the collector tank = .754 m3
Amount of methane gas produced = .754 * .656
= .4948 kg
= .5 kg (approx.)

FIG 12 (Burning of methane)

~ 27 ~

5.2 EFFICIENCY OF BIOGAS UNIT

Efficiency of biogas unit is calculated by taking the ratio of the amount of
methane produced to amount of feed stock supplied in kilogram,
Efficiency =

amount of methane produced (kg)/ amount of feed supplied

0.5 / 3

16.67% (approx)

5.3 Breakeven Analysis

For 1 kg of feed stock 250g of methane gas is produced
As per the data collected by college canteen, we can get around 6-8 kg of feed i.e. left over
food in one so we can produce 2 kg of methane gas in a day.
Total gas collected in a month = 2*20 = 40 kg
As we know that a LPG gas cylinder contains 14.6 kg of gas
No. of cylinders we can save in a month = 2.5 approx.
Cost cut down = 438*2.5 = 1095
Payback period = 7 months

6 Conclusions and Recommendations for future work

Based on the models and analysis presented in the previous sections, the following
conclusions can be drawn
1. For 1 kg of feed stock 250g of methane gas is produced
2. As per the data collected by college canteen, we can get around
6-8 kg of feed i.e. left over food in one so we can produce 2 kg of
methane gas in a day.
3. Total gas collected in a month = 2*20 = 40 kg
4. As we know that a LPG gas cylinder contains 14.6 kg of gas
5. No. of cylinders we can save in a month = 2.5 approx.
6. Cost cut down = 438*2.5 = 1095
7. Payback period = 7 months

~ 28 ~

RECOMMENDATIONS FOR FUTURE WORK

1. Different materials can be used such as bad fruits, vegetables, leaves
etc. and results can be studied in the future.
2. Design of the unit can be made better considering more safety
measures.

References
1. P.R. Bhat, H.N. Chanakya and N.H. Ravindranath (1990) Centre for
Application of Science and Technology for Rural Areas (ASTRA) and
Centre for Ecological Sciences Indian Institute of Science, Bangalore 560
012, India

2. K. Jatinder Singh a,*, Sarbjit Singh Sooch b a Oce of Director (Farm), Punjab
Agricultural University, Ludhiana 141 004, Punjab, India b Department of Civil
Engineering, Punjab Agricultural University, Ludhiana 141 004, Punjab, India
Received 7 June 2003; accepted 12 September 2003
3. H. PathakN. JainA. Bhatia S. MohantyNavindu Gupta
Received: 13 March 2008 / Accepted: 11 September 2008 / Published online: 9
October 2008 Springer Science + Business Media B.V. 2008
4. http://www.sciencedirect.com/science/article/pii/0961953495000518
5. http://www.sciencedirect.com/science/article/pii/S1364032110000936
6. TARA CHANDRA KANDPAL, BHARATI JOSHI and CHANDRA SHEKHAR
SINHAt Centre of Energy Studies, Indian Institute of Technology, Hauz Khas, New
Delhi-110 016, India
7. http://www.sciencedirect.com/science/article/pii/S096014810400383
8. http://www.sciencedirect.com/science/article/pii/S1364032105001048
9. http://www.sciencedirect.com/science/article/pii/S1364032110004132
10. http://www.cabdirect.org/abstracts/19862429294.html
11. http://www.sciencedirect.com/science/article/pii/0144456586900132
12. http://www.sciencedirect.com/science/article/pii/096085249290117G

~ 29 ~

13. http://www.sciencedirect.com/science/article/pii/S1364032108000488
14. http://www.sciencedirect.com/science/article/pii/S0961953405000693
15. http://www.sciencedirect.com/science/article/pii/S0960148101001276
16. http://www.sciencedirect.com/science/article/pii/0196890487900574
17. http://www.sciencedirect.com/science/article/pii/S0960852497001399
18. http://www.sciencedirect.com/science/article/pii/S09619
19. http://edugreen.teri.res.in/explore/solwaste/types.htm
20. https://en.wikipedia.org/wiki/Demolition_waste
21. https://practicegreenhealth.org/topics/waste/waste-categories-types
22. http://web.mit.edu/urbanupgrading/urbanenvironment/sectors/solid-wastesources.html
23. http://www3.epa.gov/climatechange/ghgemissions/ind-assumptions.html
24. https://www.carbonfund.org/reduce
25. http://www.carbonfootprint.com/calculator.aspx

~ 30 ~