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Training document for building biogas - vacvina digester

The center for rural communities research and development

Chapter I Biogas technology Instructions for the construction of improved VACVINA biogas plants
I. INTRODUCTION: Organic substances exist in a wide variety of forms from living beings to dead organisms and even animal droppings. Organic matter is composed mostly of carbon (C), combined with such other elements as hydrogen (H), oxygen (O), nitrogen (N), sulphur (S), etc. to form organic compounds such as carbohydrates, proteins and lipids. In nature, dead and inert organic matter is quickly disposed of by micro organisms, mainly bacteria 1 , through a digestion process that breaks the complex carbon chains into smaller substances. The digestion process occurring in presence of oxygen is called aerobic digestion and produces a mixture of gases having for component carbon dioxide (CO2). The chemical equation can be expressed as:
n(C6H10 O5) + nH2O + n6O2
Aerobic bacteria

n (6CO2+6H2O) + Q Kcalories.

The digestion process occurring without oxygen is called anaerobic digestion and generates a mixture of gases having for main component methane (CH4) The chemical equation can be expressed as:
n (C6 H10O5) + nH2O
Anaerobic bacteria

n (3CH4+ 3CO2)

Biogas is the name given to the mixture of gases generated by the bio-degradation of organic substances under anaerobic conditions. Composed mostly of methane, biogas produces 5200-5800 Kj/m3 burned at normal temperature, and thus represents a viable environmentally friendly energy source to replace fossil fuel. II. ADVANTAGES OF BIOGAS TECHNOLOGY Sewage and agricultural waste contain organic substances with high molecular compounds. Given the proper temperature and humidity conditions, these substances are broken into lower molecular compound material, inorganic matter and gases. In high concentration, this process creates pollution and adverse hygienic conditions for humans and animals. On the other hand, by properly treating the waste, useful renewable energy can be obtained as well as organic fertilizer, thus effectively changing waste into money. This technique becomes an important addition to the Vietnamese integrated agricultural model VAC 2 . Biogas technology can bring many benefits to farmers, among which: 1. The production of clean and inexpensive renewable cooking fuel. 2. Improved hygiene and health conditions in the household compounds (elimination of raw and untreated animal manure and night soil, elimination of the bad smell caused by pigs, reduction in the
These include fat-decomposing bacteria, cellulose-decomposing bacteria, protein-decomposing bacteria, acid-producing bacteria and methane-producing bacteria. 2 VAC is an acronym formed by three Vietnamese words (Vuon, Ao, Chuong) meaning Garden, Pond and Stable and refers to a model of small-scale bio intensive farming where gardening, fish rearing and animal husbandry are closely integrated. VAC makes optimal use of land, water and solar energy to achieve high economic efficiency with low capital investment. 1
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number of flies and parasites around the house, cleaner animal pens, elimination of toxic wood and coal smoke in the kitchen area). The introduction of biogas plants is also a mean to raise overall awareness on the importance of environmental issues and sustainable agricultural practices. 3. Reduction in CO2 emission and reduced deforestation pressure in the midlands and mountainous areas by substituting wood with biogas as cooking fuel. 4. Long-term improvement in the financial situation of households by reducing or eliminating cooking fuel expenses. 5. Reduction in soil degradation, improvement of soil fertility and agricultural production by the use of digested effluent as organic fertilizer in replacement of chemical fertilizers. 6. Facilitates animal husbandry activities especially in crowded and peri-urban areas. 7. Reduces the workload of women for fuel gathering and cleaning of pots and pans. III. STATUS OF BIOGAS TECHNOLOGY IN VIETNAM Family-sized affordable biogas technology was introduced in Vietnam in the early nineties. Since then, various models have been implemented, evaluated and modified, including some indigenous biodigester designs. Flow-through bio-digesters in usage in Vietnam can be broadly divided into two main types: fixed dome and plastic bag. Recently, with the introduction of VACVINAs HTASC model, a third category has emerged. 1 Fixed dome biogas plant Developed mostly in China and India, the fixed dome bio-digester is composed of several interconnected elements:

Figure 1: Scheme of Chinese fixed dome digester

Figure 1b: Construction of a fixed dome digester

An underground digestion chamber (in yellow) topped by a dome structure where the gas accumulates. The top can be made of brick, Ferro-concrete or composite. The inlet system (red arrow) where input material is mixed and fed into the digester. The outlet system (blue arrow) to retain the digested slurry.

As organic material is fed into the digester, gas is produced and accumulates in the dome. As gas formation increases, the liquid in the digestion chamber is forced down and overflows in the retention tank compressing the gas in the upper part of the chamber. Normally a fixed dome plant will produce constant pressures equivalent up to 80 cm of water column. As the gas is used, the liquid in outlet tank will flow back to the digester. This simple hydraulic system ensures a regular flow of gas at good pressure levels. However, the fixed-dome bio-digester model has a number of disadvantages when applied in Vietnams rural areas. The model is rather complicated to build given the current construction skills and work practice of rural masons. Overall construction, especially of the dome, must be of high quality, otherwise, cracks can develop leading to gas leakage and reduction of pressure. Quality control becomes of utmost importance but is unfortunately still difficult to implement. In addition, investment cost is still rather high
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in comparison with income of households. The cost of the system, already rather high, is increased by the fact that the foundation of the digestion chamber must be meticulously compacted before casting. Over time, in the digestion chamber, a layer of scum can accumulate which will prevent gas from escaping to the dome. Yearly cleaning and maintenance is required. These conditions might explain the fact that many farmers who decided to build such biogas plants by themselves have run into problems with their system breaking down after a short time of operation. 4.2 Plastic bag bio-digesters This model was first introduced from Columbia to Vietnam in 1994 by doctor Reg Preston, rector of the University of Tropical Agriculture.
Gas reservoir Inlet

Outlet

Digestion bag Figure 2: Plastic bag biodigester

The system consists of a long digestion bag or fermentation bag (Fig.2) and a gas reservoir bag. Both are made of two or three layers of polyethylene tubing, 21c thick and 1m in diameter. The length of the main bag determines the total digestion chamber volume (a 10 m bag results in a 7 cubic meter digestion chamber). The digestion bag is half buried in a trench and is connected at one end to a small mixing and collection tank and at the other end to a slurry holding pit. The gas reservoir has a capacity of 1,8 m3 and is usually suspended either in the kitchen or the stable (Fig. 3).

Figure 3: Plastic bag biodigester

As organic material is fed into the digestion bag, it slowly travels down the length of the tube while the fermentation process occurs and is then expelled at the other end as digested slurry. The biogas produced accumulates in the main bag and, through gravity as well as pressure, finds its way to the gas reservoirs. Thus biogas is stored partly in the digestion bag and partly in the gas reservoir. Users can easily judge the quantity of gas available by the level of inflation of the bags. Plastic bag digesters are inexpensive, easy to install and operate and scum formation can be controlled easily by gently slapping the scum to make it sink to the bottom. On the other hand, the polyethylene bags are somewhat fragile they can be perforated or torn and their life expectancy is but 3-5 years. They must be protected from wandering animals and also from sunlight as UV rays will degrade the plastic. In addition, the model requires a large area of 10-15m2 near the animal stable. This is a problem for many households in the Red River Delta where household compound is not large enough to allow its installation. 4.3 The VACVINA biogas model OBJECTIVE: The VACVINA biogas digester was designed with the following objectives:
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Simple design and construction with high tolerance to construction flaws and defects. Making the best use possible of the restricted compound space. Long life expectancy. As low cost as possible without sacrificing life expectancy Constant gas production over time by controlling the formation of scum. Low maintenance and adapted to the habits and perceptions of the intended users. Taking the best elements of the fixed dome digester, with those of the plastic bag digester and using the common and widespread construction technology of septic tanks, the first VACVINA biogas units were built in May 1998.
CH4 Gas reservoir

Inlet Fixed dome Biodigester

Toilet

Septic tank

Digestion tank

Outlet

Plastic bag biodigester

Figure 4: Improved VACVINA Biodigester

Although no one model is perfect, the improved VACVINA biodigester has proved to be a good compromise between simplicity, low cost and effectiveness. Designed with the Vietnamese mentality and context in mind, it has been well received by farmers and has maintained a very good success rate. THE DESIGN & WORKING PRINCIPLES: The design and working principles of the VACVINA biodigester is illustrated in Fig. 4 and Fig.5.

Note: 1. Inlet, 2. Digestion tank, 3. Outlet, 4. Gas reservoir

Figure 5: General Scheme of VACVINA Biodigester

It consists of a flat-top rectangular underground digestion chamber with external plastic gas reservoirs. An ingenious system of inlet siphon allows the new material to be dropped unto the surface of the fermenting liquid thus breaking any accumulated scum. 1.The inlet The inlet is a simple inexpensive off-the-shelf siphon pipe (also called rabbit joint) made of glazed-terra cotta (Fig.6).
Animal dung

Figure 6: The inlet siphon (by glazed terracotta ) allows animal dung to be fed into the digestion chamber

The system normally comprises two or three siphon inlets and can also be fed by the lavatory pan. These inlets play an important role in preventing the formation of a hardened scum layer by allowing the new material to drop on top of the liquid surface, thus wetting and breaking the top layer. As new material is fed daily the surface is continually stirred and broken. In addition, the siphons also act as pressure safety valves. With 15 cm of water column, they effectively ensure gas tightness of the main chamber but, should the internal pressure increase over this limit, excess gas will bubble out. (Fig. 5, on the right). 2. The digester The main digestion chamber is an underground rectangular tank made of bricks and mortar (Fig.7). However, the shape of the tank can be adjusted to the specific configuration and constraints of the family compound while retaining a sufficient volume. One of the great advantages of this model is that the concrete flat top of the digester can provide a clean and dry floor for the pigsty or stable. .

Figure 7: The costructing digester

3.The outlet The outlet system consists of a straight pipe, normally made of PVC, 110mm diameter and 1m long, inserted at a 45o angle in the digestion chamber. Its function is to drain the effluent (liquid form) from the digester to the slurry pit and to set the level of liquid in the digester. The outlet pipe must therefore be positioned lower than the inlet pipe, with its end opening about 35 cm lower than the digester cover. To ensure gas tightness of the digester, the other end of the pipe should extend deep under the static surface of liquid in the digestion chamber (Fig.34). 4. Slurry pit The slurry retention pit is constructed near the outlet of the digestion chamber and is used to store the systems effluent for later use (Fig.28). The amount of effluent flowing into the slurry pit is equivalent to that of the input fed into the digester. However, the volume of slurry retention pit must be calculated according to the intended usage of the slurry. It is important to remember that, in order to ensure the normal functioning of the system, the slurry level must always be kept lower than the digesters outlet. 5. Gas reservoir The external gas reservoirs are used to collect and store the biogas before being used as cooking fuel (Fig 8). One gas reservoir should be enough for a normal family. However, if the household has a large number of animals, more gas will be generated and more storage bags will be required. The bags are made of two layers of 20 mc thick polyethylene tubing, and have a storage capacity of 1.5 2 cubic meters. In order to increase the gas pressure during cooking, a rubber band is tightened around the reservoir and then loosened again after finished using the burner to allow the bag to re-inflate itself.

Chapter 2
Instructions for the construction of improved VACVINA biogas plants

Objective Participants will gain practical knowledge and skills on the techniques required for the construction of improved VACVINA biogas plants, namely: The design of biogas plants adapted to different topographies and animal husbandry situation. The construction steps The installation procedures The operation and utilization I. PREPARATION 1.1 Calculating the digestion chamber volume The size of any biodigester plant must be based on the number and species of animals owned by the family. The calculations take into consideration the following basic parameters: daily amount of collectable animal dung, minimum required retention time of the slurry in the digester, and dilution ratio of manure to water (TS content). For the improved VACVINA biogas plants, actual volumes can be derived through the following formulas: V = Vgas + Vdig (1) (Figure 9) Where Vgas:Gas volume in the digestion chamber Vdig: Slurry volume in the digestion chamber And, Where Vdig = T x Vdm (2) S Vgas h1 h2
Figure 9: Volum of Biodigester

Vdig

Vck

T: Retention time of slurry in the digester (e.g. 40 50 days) Vdm: Daily amount of water and dung (liter/day) And, Where Vck = h1S

S: Area of the flat bottom slab of the digester (m2) h1: Distance between the bottom of the cover slab and the static liquid surface in the digester (m) When using mainly pig manure, Vdm can be calculated as follows: Where Vdm = (w + nL)T (3) w: The amount water to dilute the dung of n pigs (l) L: The daily average amount of dung per pig (l/day) The optimal dilution ratio of the input material is 1:5 (one part of manure for five parts of water)
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Put w = 5nL into (3), and from (1), (2) and (3) we have: V= Vck + (5nL + nL)T = Vck + 6nLT As a result, the formula for calculating the digester volume for pig farming is Where n: Regular number of pigs (pig) L: Daily average amount of dung per animal (2 liters/head/day) T: Retention time (day) For a retention time of 40 days (T = 40), V = Vck + 240nL 1.2 Construction material The construction material required to build a 7 cubic meter VACVINA biogas digester is detailed in the following table: Table 9: The construction material required to build a 7 m3 VACVINA biogas digester Item
1 2 3 4 5 6 7 8 9 A- standard solid brick Cement Coarse yellow sand Gravel Iron bars (8) Zinc joint pipe PVC pipe (21) Valve, joints Plastic pipe (21)

V= Vck + 6nLT (4)

Unit of measure
piece kg m
3 3

Quantity
1.400 600 1,5 0.5 30 1 4 15 15 1 1 2 2

m kg piece m piece m m piece piece piece

10 PVC pipe (110) 11 Polyethylene bag 12 Siphon pipe 13 Single burner stove 14 Glue, rubber strips 15 Hoe, shovel, knife, trowel and other masonry tools...

II. TECHNICAL CONSTRUCTION OF DIGESTION TANK

The construction steps are as the followings: 2.1 Use canvas to cover the construction site If the digester is erected outside the animal stable, the first thing to is to install a large canvas covering the construction site (Fig.1). This will reduce the overall construction time by sheltering the site from bad weather and will also ensure a better quality of work. 2.2 Excavating the pit
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Selecting the construction site: The location of the digester is determined by the current installations in the household compound. With its flat concrete top, the most suitable place for the system is under (or near) the pigsty or animal stable. The shape of the digester does not necessarily have to be rectangular and can be designed to accommodate the disposition and topography of the family plot. Excavating the pit: After careful selection of the construction site, excavation is started. The dimensions of the pit must be larger than those of digester so as to facilitate the execution of the work. The dimensions of the digester can be tailored to specific configurations. However, to minimize investment and maximize efficiency and ease of operation, it is suggested to keep the depth to 2m, the width to 1.5 2 m and to adjust the length to obtain the total volume required. Note: When excavation is carried out in an area of high water level, it is necessary to dig a ditch. Water accumulated in the ditch can be pumped out during the construction of the Figure 11: Drainage ditch digester base. (Fig. 11) 2.3 Building the base (foundation) of the digester After completing the excavation of the pit, the following steps are required to build the base: - Prepare a first 15 cm layer of tightly compacted broken bricks or crushed stone (4 x 6cm) - Pour the foundation of 5 cm concrete mix (1 part cement, 2 parts yellow sand and 3 parts crushed stone) (Fig.12).
Note: -Where the soil is of weak bearing capacity, metal rods (rebar) 10 should be used for the concrete layer. Any accumulated water must be pumped regularly. It is possible to use inexpensive plastic sheeting to protect the base from water. -Use inexpensive plastic sheets to protect the base from high water levels (Fig.13, left). Add metal rods (rebars) in the concrete slab when the soil has weak bearing capacity.

Concrete 5cm

Crushed stone Figure 12: The concrete base

2.4 Building the walls of the digester Walls are constructed after the base is completed. The thickness of the walls is the standard 10 (i.e. the thickness of a brick plus plaster Fig.15). The bricks used must be solid grade A. The mortar is made of 1 part cement to 4 parts coarse sand. While laying bricks, ensure that the space (joints) between them is well compacted with mortar.

inlet

Outlet

Figure 14: Positioning the inlet and outlet

Picture 15: Building the walls of the digester 8

Note: During the construction of the walls, remember to leave the technical openings for the installation of inlet/outlet pipes as indicated in figure 14. - The hole for the inlet pipe is 30cm diameter and starts from the top of the wall. It can be located on any wall. - The hole for the outlet pipe is 30cm high by 25 cm wide and is located 30cm below the upper edge of the wall. 2.5 Plastering the walls The plaster applied on the inner side of the digester plays a very important role in ensuring permanent gas and water tightness. Plastering mortar is made of clean fine yellow sand mixed thoroughly with cement (1 part cement to 3 parts sand). Special care must be taken to ensure even thickness of the plastering layer. The surface must be smooth and regular and all edges must be rounded. The following steps must be followed: a) Clean and scrub the entire surface to be plastered b) Plaster a 1 cm thick layer. Wait for this layer to dry slightly and use the hand trowel to press the entire surface evenly c) Wait 1-2 hours for the layer to dry then plaster a second layer in the same manner. Polish this final layer with pure cement solution.
5cm

Plastering layer

Figure 16: Plastering the walls

Important: The top 5 cm of each wall must not be plastered. This wall surface will be plastered once the digester cover is installed. This final plastering must be applied properly at the connection area between the wall and the cover (with rounded edges) to ensure proper gas tightness (Fig.16). 2.6 Casting the ferro-concrete digester cover After plastering and polishing the walls, it is time to construct the digester cover. Because the flat-top cover is used to support the pigsty, animal stable and/or latrine, it must be 10cm thick, flat shaped and casted in place (DO NOT use a precast concrete slab). The procedure is the same as that used to build a house foundation and comprises the following steps: a) Prepare a solid formwork for casting the concrete cover. Use scaffoldings to support the wooden framework (Fig.17, Fig.18). b) Define the location of the manhole to provide easy access to the digestion chamber while not interrupting animal production activities (Fig.19). Prepare a wooden mould shaped as a truncated V9

Figure 17: formwork for casting the concrete cover

shaped rectangular column with upper dimensions of 50 cm x 50 cm, lower dimensions of 45 cm x 45 cm, and a height of 10cm (Fig.20).

Figure 19: Positioning the Manhole

Figure 20: Wooden mould for the manhole (technical opening)

The manhole performs the following functions: - Provides access to the digester inner chamber to remove the formwork after the concrete has settled and to install the accessories (inlet/outlet pipes, gas pipe...). - Provides access to the digester to remove accumulated waste and grit (normally after 7-10 years of use). c) Prepare a 15cm x 15cm mesh of 8 steel rods, with hooks at both ends of the rods (Fig.21). Position the shorter steel rods under the longer ones for better solidity. If the width of the cover exceeds 2.5 m, a construction engineer must be consulted to design the proper reinforced mesh configuration. Attention: Additional reinforcing rods must be installed around the manhole to increase the bearing capacity.

Figure 21: Binding steel rods

d) Cast the concrete cover with 200-marked concrete : The basically proportions of construction materials 1cement /2sand /3 gravel(Fig.22) could be used for casting the concrete cover with 200-marked concrete . To ensure even thickness of the cover, several 10cm wooden pegs are used. Once the thickness of the concrete layer is evenly compacted, remove the pegs. e) The main gas pipe must be fitted during casting. Made up of iron 21 diameter, it is fitted right beside the wall of the animal stable so as not to disturb the animal production activities in the future. f) Compact and sprinkle the concrete. g) After 2 to 3 hours, once the surface of concrete has taken shape, the wooden mould for the manhole cover can be removed. Smooth and press thoroughly the edges of the opening. h) The first manhole cover is then casted in place (pay particular attention to this technique during practice). Coat the surface and lateral side of the manhole opening with cement paper, lay the steel rod mesh and cast the concrete (thickness of 5 cm). The steel mesh uses masonry 8 rods spaced at 10cm intervals with end-hooks. To provide a convenient way to remove the cover, two carrying handles made up of 10 rods are inserted. i) A second manhole cover 55cm x 55cm is prepared. After the first cover is placed and sealed with clay and water, the second cap will be placed on top to provide a flat and dry final surface. j) To save construction time, a stove platform should be casted at the same time as the concrete digester cover. This concrete platform will support the stove burner. It is made of 6-8cm of concrete reinforced by a steel mesh of 20cm x 20cm 8 rods with end-hooks. The breadth and length of platform are 60cm
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and 120cm respectively. For maximum convenience, it is recommend fixing the platform 75 cm above the kitchen floor (Fig.29).
Two holes are placed when casting stove form for installing the gas pipes coming from beneath the platform

Position of 2 stove burners installed on stove platform

Figure 28: The stove platform

Note: While constructing the stove platform, two holes 25 cm in diameter must be made. The holes are placed 10 cm from the edge of platform and the distance between the holes is 50 cm. These will be used to install the gas pipes coming from beneath the platform (Fig. 28).
III. INSTALLATION: INLET, OUTLET, EQUIPMENTS

After constructing the digester cover, manhole cap and stove platform, the entire concrete work must be protected and maintained in proper conditions to ensure drying and curing. The formwork is removed after 7 days, and the inlet and outlet pipes are then installed. Important: as the concrete has not yet reached its load capacity, weight must not be applied yet to the surface of the cover. 3.1 The inlet system The inlet system of the digester consists of a mixing tank connected to the main reservoir by one or more siphon pipe (also called U-band, rabbit-shaped joint, cattail-shaped joint) The mixing tank is usually located close to the digester and at the corner of the animal stable. The standard dimensions of the mixing tank are 0.2 m x 0.4 m with a depth of 0.3 m (Fig.6). This system prevents the formation of a scum layer by regularly wetting and mixing the surface with fresh input. The number of pipes is based upon the size of digester, commonly 2-3 pipes per digester. The latrine can also be linked to the input system (Fig. 31 and Fig.32).
Animal dung
5 cm

Figure 31: The correct position of siphon pipe in inlet of biodigester

Figure 32: Inlet including siphon pipes

As the siphon also acts as a water valve to prevent gas leakage, proper installation is very important.
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Once positioned in its proper place, the siphon pipe is slightly sloped at a 30o angle. This condition could be reached when the highest point of the pipe should be 5cm higher than the top of the opening (Fig.31). In this position, when water is poured to fill the siphon, it will start running at the other end as the level reaches the lip of the opening. Fix the pipe firmly in this position and seal the joint with mortar. The mixing tank is then constructed around the inlet. Its function is to collect and mix the fresh material before feeding it to the digester (Fig.32). It can be covered by a net to prevent larger debris and stones from entering the digester. Important: Do not place the siphon pipe before or during the construction of the digester cover. 3.2 The outlet system The outlet system consists of an outlet pipe and a slurry holding pit. The holding pit is commonly built alongside the outlet and its volume depends on the usage by the family of the digested slurry. However, irrespective of its dimensions, the top of the slurry pit will determine the level of slurry in the main chamber as the outlet pipe will rest upon its upper ledge. Hence, the level of slurry in the slurry pit should always be kept equal or below the outlet mouth. The outlet pipe allows the digested slurry to flow from the digester to the slurry pit. Its length and position are important as they determine the level of slurry in the digester. The PVC pipe is 110 150 mm in diameter with a length equal to one third of the slurry height (80 100 cm). It must be positioned at a 45o angle, making sure it extends under the surface of the slurry the equivalent of one third of the height of the slurry (Fig.34). For example, if the slurry in the main chamber is 1.50 m deep, the end of the pipe must extend 50cm below the surface.

Figure 34: Design of outlet system and Static slurry level

3.3 The gas pipeline The gas pipeline connects the gas outlet pipe with the gas reservoirs, the safety valve and the burner. Attention: Before the pipeline is fitted on the gas outlet pipe, the latter should be cleaned by poking a fixing the platform 75 cm above the kitchen floor 6 steel rod. 3.4 The safety valve Purpose: The safety valve is important to ensure that the gas pressure in the system does not exceed 15cm of water column. It consists of a 1 1.5 litre , 1 T-joint and 21 Tienphong plastic tubing (Fig.35). Installation: To install the safety valve, make a hole 1.5-2 cm in diameter at the neck of the bottle. Insert a short length of pipe into the bottle and connect the other end to the T-joint. Insert the T-joint as part of the main pipeline (Fig. 35). Operation: Pour water into the bottle to cover the end of the pipe by 10 cm. Mark the water level on the bottle as a guide to add water when necessary. If the pressure in the system reaches more than 10 cm of water column, gas will automatically bubble out of the pipe and of the water bottle. Location: position the safety valve in a well ventilated area and where it is easy to see the water level and add water when required.
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Important: Check the water level regularly. If le level falls below the 15 cm mark, water must be added immediately to prevent gas leakage and reduction in gas pressure.

T-joint from PVC material

Transparent Plastic bottle

Permanent water level

Figure 35: The Safety valve

3.5 The gas reservoirs Gas is stored in the gas reservoir until used for cooking. The plastic reservoirs are suspended under the stable roof or in an area where they are not subject to be punctured or affected by sunlight. In order to store enough gas for the 4-5 hours of daily cooking required by a typical family (of 5-6 persons and raising 6-7 pigs), 1 bag is needed. More gas reservoirs are needed in case if quantity of pigs is higher. The reservoir is made of two layers of 20-24c polyethylene tubing, 100cm in diameter and 2.5 m in length capable of storing 1.8m3 of gas. One end of bag is tightly tied while the other is connected to the pipeline with 21 plastic tubing.
T-joint

Figure 36: Gas reservoir, Conected to gas pipe using T-joint

Figure 37: Gas reservoir Suspended under the roof of the pigsty or kitchen

Installation: - The double layer is achieved by inserting two polyethylenes tubing one in the other making sure not to trap significant amount of air between the layers. - Binding technique: For the bag to inflate evenly when storing gas, the two ends of the bag are folded from the outer edge to the center of the bag (this technique will be demonstrated in detail during the practice sessions). Elastic rubber strips are used to tie the ends. - Insert a 30-cm-long T-shaped pipe made of PVC 21 (Fig.38) in the two layer bag to convey gas. The built-in pressure will ensure that gas flows automatically to the burner. - The gas reservoir should be hung tidily, out of harms way and in a convenient place for use. They are normally hung below the stable roof, not too far from the kitchen area where the gas is used.

Operation:
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An elastic rope can be tied around the bags to create a stable output of gas during cooking (Fig.38). Loosen the rope after usage to allow the reservoirs to inflate back to their original size.

Figure 38: An elastic rope can be tied around the bags to create a stable output of gas during cooking

Figure 39: The small gas-fan installed to help suck out gas from the digester and push it towards the burner

3.6 The burner VACVINA manufactures affordable and easy to use biogas burners (Fig.29). The burners are made of cast iron with copper regulation valve. Designed like the standard LPG burners, they are nonetheless much less costly. The burners are installed on the stove platform (see section II/6-j and Fig.41) once the installation of the gas pipeline and all the fittings has been completed.

Figure 41: Installation of the burners

The biogas burners are connected to the pipeline through a valve (Taiwan valve) fitted under the platform (Fig.30 and Fig.39 and Fig.41). Before fitting the valve, apply lubricant on the surface of the ball inside the valve to ensure smooth and easy operation. Important: For safety reasons, especially to prevent children from opening the burners, a main valve must be installed at the suitable elevation and near the platform. The main valve as well as the burner valve are closed when not using gas. Before using the burner, the main valve is opened first before the gas valve.. 3.7 Site filling After completing the construction and installation of the system, all remaining excavated areas must be carefully filled back. The best material to use is sand, especially around the digester outer walls. The sand layers should be sprinkled with water and tightly compacted.

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Chapter 3
Operation and maintenance of the VACVINA biogas plant

I. FEEDING THE BIODIGESTER Before putting the biogas system into operation, the digester should be cleaned thoroughly to remove any spilled mortar or construction debris. In addition all components of the system should be tested to ensure gas-tightness. Feeding material Although all organic matter, from animal or vegetal origin can be biologically digested, the VACVINA biodigester was specially designed to recycle animal and human waste products, mainly fresh manure and night soil. 1.1 Initial feeding of the digester Once the construction of biodigester and the installation of appliances and accessories are completed, the biodigester can and should be operated immediately. To kick-start the anaerobic process and ensure a proper colonization of methanogenic bacteria, the most appropriate inputs are cattle, poultry or pig manure. In order to ensure a rapid production of gas for cooking, it is advisable to prepare 700-800 kg of fresh dung (to be collected and stored in a 7-day period) as initial input. The dung must be properly hydrated and flushed into the digester with sufficient amount of water to prevent clogging and scum formation in the digestion chamber. The chamber must be filled with at least enough material to cover the bottom of the outlet pipe. It is important to ensure that the following materials are not fed in the digester: - Soil, sand and stones. - Branches, twigs and straw. - Soap and detergent solution, cleaning chemical, antiseptic products, rain water. And all components must be checked to ensure gas-tightness: - Sufficient amount of water in safety valve. - All siphons filled with water. - Lavatory pan (if any) siphon filled with water. - All gas valves (main gas valve, stoves tap) closed. The process of bio-degradation and biogas generation will take 5-10 days (slightly more in cold temperatures). Once the gas reservoirs start to inflate, the biogas can be used for cooking. Initially, the gas will contain some amount of air that will be flushed out as the system is used. 1.2 Daily feeding of material The initial 700-800 kg of input material will kick-start the digestion process but is not sufficient to produce a large quantity of biogas for daily gas using. Fresh material must be fed daily in the digester to satisfy the cooking fuel needs of the family. To produce enough gas for a family of 7 persons, an average of 15-20 kg of pig or cattle dung must be fed daily. In addition, night soil will be added if a latrine is connected to the biogas system. Beside dung, water must be added daily in the ratio of 5 parts of water for each 1 part of dung. The proportion of water is an important factor for optimum biogas production. Adding too much water will flush partly-digested slurry out of the digestion chamber. Less gas will be produced and the slurry will not be sufficiently treated to remove all odour and parasites.
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When large quantities of water are used to clean the pigsty or bathe the pigs during the hot summer days, this excess water must be drained and prevented to enter the biodigester (Fig.42). A drainage ditch can be built to drain the excess water while feeding only the animal waste to the digester. The ditch and the inlet opening must be carefully designed to prevent rainwater from entering the digester. Taking full advantage of the VACVINA flat-top design with multiple siphon inlets, a latrine is often constructed at the same time as the biodigester. Water used for cleaning the latrine must be taken into account when calculating overall water-dung ratio. The siphon in the latrine must also be checked regularly and kept full at all times to prevent gas leakage. II. MAINTENNCE AND TROUBLESHOOTING 2.1 Using the biogas for cooking 1. When the gas reservoir is inflated, gas can be used for cooking. At he beginning, the biogas might contain too much air to be readily flammable. Discharge this first bagful of gas and wait one day for the production of new biogas. 2. When gas is not used, all gas valves should be closed. 3. When using the stove, remember to first light a flame then slowly open the gas valve and adjust the flame height and intensity according to the cooking need. 4. To ensure stable and clean combustion, the copper regulator must be cleaned at least once a week. 5. If the gas pressure is too low, use a rubber band to constrict the gas reservoir (Fig.38). The band must be loosened when finish cooking to allow the bag to re-inflate. A small gas-fan can also be used to extract more gas from the reservoir (Fig. 39, Fig.41). 6. A main gas valve should be installed out of reach of children this main valve should be kept locked when fuel is not needed. 2.2 Common Problems and Solutions
Problem 1. No gas or not enough gas Cause Bio-degradation process has not started Insufficient bacteria content Potential Solution Wait a few days for the process to start Feed the digester with the digested slurry of another digester Feed the digester with pre-treated material Check the gas pipeline Gas leakage Check the water level in the safety valve Check the water level on digestion chamber cover, in all siphons and in the lavatory pan Carefully close all gas valves after each use and make sure the are out of reach of children Not enough feeding material 2. Gas reservoir do not inflate as they should 3. Gas does not burn Holes or tears in the bag Gas is leaking from the gas pipeline Too much air or CO2 Feed as per recommendation Repair it with a nylon bandage or replace the bag, if possible. Repair the gas pipeline by welding Flush the gas reservoir and wait for its replenishment with new biogas
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properly 4. The Not enough gas flame often pressure extinguishes Water has accumulated in gas pipeline

Add a small amount of lime solution into the digester (be very careful) Constrict the gas reservoir with a rubber band or install a gas extracting device Drain water from the gas pipeline

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