Detailed Project Report of

Biogas Project for

Thermal Applications

Prepared by

Dr. Sarbjit Singh Sooch,

Principal Scientist (REE)
Email Id: sssooch@[Link]
Mobile No.: 95010-34513

Department of Renewable Energy Engineering,

PUNJAB AGRICULTURAL UNIVERSITY,
LUDHIANA – 141004

2020
 INDEX
Chapter Title Page No.

No.

1. Salient features of the project 1–2

2. General information of biogas technology 3 – 13

3. Estimated cost of the project 14 – 16

4. Feasibility report of the project 17

5. Commercial terms & conditions 18 – 20

 CHAPTER – I

SALIENT FEATURES OF THE PROJECT

1. Name of firm
2. Type of concern
3. Location
4. Contact No.
5. Basic raw material Cow Dung
6. No. of cattle available with the firm 250
7. Quantity of cattle dung available 2500 Kg./2.5 Ton
8. Proposed capacity of biogas plant 100 m3 /day
9. Design of Biogas Plant Modified fixed dome PAU Janta
(a)
model Biogas Plant
(b)
10. Space required for construction of biogas plant 252 Sq. m. (13.00 Marla)
11. Land / cattle dung / water / power / Client
transportation of the dung to the plant
12. Proposed operational hours per day entirely 10 – 11 hours
based on Biogas
13. Estimated cost of the project Rs. 19.50 Lacs
14. Subsidy from MNRE Rs. 1.75 Lacs
15. Means of Finance Own expenses
16. Technical know – how Dr. Sarbjit Singh Sooch, He is
having 26 years experience in the
field of Biogas Technology.

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Note:
(a)
Salient design features of Modified fixed dome PAU Janta model Biogas
Plant

 This biogas plant has been designed and developed by PAU, Ludhiana.
 The constr uction of this type of plant is easy and is not very difficult.
 This biogas plant is an all brick masonry structure.
 The design is suitable for all regions of the country.
 The single digester of this plant may be designed for any rated capacity from 20 to 500
m3 /day.
 Maintenance requirements of this plant are far lesser than the floating drum biogas
plants.
 The cost of this plant is 60 – 70% as compared to the cost of KVIC model biogas plant.

(b)
Refer Annexure – I.

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 CHAPTER – II

GENERAL INFORMATION OF BIOGAS TECHNOLOGY

BIOGAS

 A product of anaerobic digestion of organic wastes / materials.

 Animal waste / crops / crop residues, kitchen waste etc.
 Suitable fuel for cooking / lighting / electricity generation / bottling.
 Enhances the fertilizer value of the waste.
 A safe, aesthetical and economical waste disposal method.

BIOGAS PRODUCTION & UTILIZATION

COMPOSITION OF BIOGAS

Biogas is a mixture of gases whose composition is as follows:

(i) Methane (CH4 ) 50-65%
(ii) Carbon dioxide (CO 2 ) 30-40%
(iii) Hydrogen (H2 ) 1-5%
(iv) Nitrogen (N 2 ) 1%
(v) Hydrogen sulphide (H2 S) 0.1%
(vi) Oxygen (O 2 ) 0.1%
(vii) Water vapors (H2 O) 0.1%

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BIOGAS IN INDIA – POTENTIAL

 India has a potential of generating 6.38 X 10 10 m3 of biogas from 980 million tones of
cattle dung produced annually from 300 million cattle population.
 The heat value of this gas amounts to 1.3 X 10 12 MJ. In addition, 350 million tones of
manure would also produce along with biogas.
 Apart from the 4.5 million domestic biogas plants installed in India against the potential
of 12 million, there is a huge potential of installation of medium and large scale biogas
plants installation in India in small scale industries, animal rearing farms, poultry farms,
distilleries, tanneries, hotels, restaurants, military barracks etc.
 India produces about 2.07 billion m3 /year of biogas, while it’s estimated that it could
produce as much as 48 billion m3 /year.
 Equivalent to 6.6 crore domestic LPG cylinders.

FEEDSTOCK FOR PRODUCTION OF BIOGAS

 Cattle Waste
 Poultry Waste
 Crop / Agricultural Residue
 Agro-industrial Waste
 Vegetable Market Waste (Mandi waste)
 Food waste / Canteen Waste
 Human Waste / Community Toilets / Sewage
 Municipal Waste (Housing Societies)

ADVANTAGES OF BIOGAS TECHNOLOGY

 The use of biogas in the kitchen saves other fuels such as cattle dung cakes, kerosene
oil, coal, firewood, Liquid Petroleum Gas (LPG).
 All objectionable odour from the bio wastes is removed and most harmful organisms
are killed in biogas plant digested wastes, therefore the use of pesticides, weedicides
can be reduced when bio-digested slurry is used for the crops as fertilizer.

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 The digestion of carbonaceous material in the organic matter anaerobically will make
richer in nitrogen, phosphorus and potassium than the compost fertilizer and so is a
superior fertilizer.
 The use of biogas prevents chances of eye diseases and respiratory diseases from the
kitchen.
 Biogas is more efficient and clean fuel than cow dung cakes and firewood in the
kitchen.
 Bio – digested slurry can be applied to the fields along with the irrigation water, so
there is saving of labour for applying the digested slurry to the fields.
 Latrine can be attached with the biogas plant. Thus, there is a saving of money for
construction of a separate septic tank.
 The use of biogas technology controls environmental pollution because the biogas is a
smokeless fuel, so the utensils and kitchens are remained clean.

IMPORTANCE OF BIOGAS

1 m3 of biogas = 3.50 kg of wood / 12.30 kg of cattle dung cakes / 0.43 kg of

LPG / 0.62 litre of kerosene oil / 1.6 kg of coal / 1.46 kg of
charcoal / 0.52 litre of diesel / 1.25 kW of electricity

CALORIFIC VALUE AND THERMAL EFFICIENCY OF VARIOUS FUELS

Sr. Name of fuel Calorific Mode of burning Thermal Effective

No. value efficiency heat
(KCal) (%) (KCal)
1. Biogas (m3 ) 4713 In standard burner 60 2828
2. Kerosene (Litre) 9122 Pressure stove 50 4561
3. Fire wood (kg) 4708 In open chulla 17.3 814
4. Cow dung cakes (kg) 2092 In open chulla 17.3 230
5. Charcoal (kg) 6930 In open chulla 28 1940
6. Soft coke (kg) 6292 In open chulla 28 1762
7. LPG [Butane gas] (kg) 10882 In standard burner 60 6529
8. Furnace oil (litre) 9041 In water tube boiler 75 6781
9. Coal gas (m3 ) 4004 In standard burner 60 2402
10. Electricity (kwh) 860 Hot plate 70 602

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ANIMAL WASTE AND THEIR POTENTIAL TO PRODUCE BIOGAS

Sr. No. Type of waste Comparative potential Average excreta

of biogas production Fresh wt. Dry wt.
(%) (kg/day) (kg/day)
1. Cow dung 100 15.0 3.00
2. Buffalo dung 100 20.0 4.00
3. Goat droppings 308 1.0 0.35
4. Horse dung 258 10.0 3.5
5. Piggery waste 391 2.5 0.5
6. Poultry droppings 616 0.07 0.025

OPTIMUM FACTORS FOR BIOGAS PRODUCTION

 Temperature ( 35ᵒ-37ᵒ C Mesophilic condition )

 C/N ratio optimum between 25:1 to 30:1)
 pH ( optimally pH between 6.8-7.2)
 Solid content ( feed material should have approx. 10:1 )
 Should not have toxic material/ harmful material to bacteria in digester
 HRT ( Hydraulic Retention Time – 30, 40, 55 days)
 Loading rate

SELECTION OF PROPER SIZE OF BIOGAS PLANTS

 The size (capacity) of biogas plant means the quantity of biogas (in cubic metres)
which we can get from it in 24 hours.
 An average of 15 kg of cattle dung is collected from an animal.
 1 kg of cattle dung generates about 0.04 m3 of biogas.
 From 25 kg of cattle dung about 1.0 m3 of biogas is collected.
REQUIREMENT OF NUMBER OF ANIMALS AND DUNG FOR DIFFERENT SIZE
OF BIOGAS PLANTS
Capacity of biogas No. of animals Quantity of dung Cooking for
plant (m3 ) required required (kg) number of persons
1 2-3 25 2-3
2 3-4 50 4-5
3 5-6 75 7-8
4 7-8 100 10-11
6 10-12 150 14-16

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 Biogas plant can also be operated on human excreta (night- soil).
 An average of 0.4 kg of human excreta is collected from an adult human.

3
From 1 kg of huma n excreta, 0.07 m of biogas is collected.
 Biogas plant can also be operated on poultry droppings.
 Droppings from 250 – 300 poultry birds are required per m3 capacity of biogas plant
but the gas production from this plant can be increased upto 1.5 – 2 times.

USES OF BIOGAS FOR

(i) Cooking Purposes
 Biogas provides a clean and efficient fuel for the kitchen. A special biogas burner
(stove) other than L.P. burner is used for cooking purposes.

(ii) Operating dual fuel engines

 To run diesel engine on biogas, the biogas pipe is joined with the air cleaner of the
engine to prepare the mixture of biogas and air.
 In the first stroke of the piston, the engine sucks biogas and air and it catches fire after
injecting the diesel by the nozzle.
 A special and simple instrument shown in the Fig. 1 below can also be used to prepare
the mixture of biogas and air and is joined with the diesel engine at modified inlet.
 The control of biogas is being done with the help of gate valve attached to this
instrument.

Fig.1 Carburettor for Diesel Engine running on Biogas

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(iii) Electricity generation
 Biogas can be used to produce electricity by coupling a dual-fuel / 100% biogas based
engine to an generator.
 Normal consumption rate of biogas for running dual-fuel engines is 0.45 to 0.54 m3 /
hour / H.P. or 0.60 to 0.70 m3 / hour kW if used for power generation.
 One m3 of biogas can generate 1.25kWh electricity thorough the genset coupled with
100% biogas based engine.

(iv) Bottling of Biogas

 Biogas comprises of 50-65% methane, 35-40% carbon dioxide, 0.5-1.0 % hydrogen
sulphide and traces of water vapour.
 It is almost 20% lighter than air and has ignition temperature of 650-750 ºC.
 Its calorific value is 20 MJ (4713 Kcal) per cubic meter.
 Biogas, like Liquefied Petroleum Gas (LPG) cannot be converted to liquid state under
normal pressure and temperature.
 Critical temperature for liquefaction of methane is - 82.1 ºC at 4.71 MPa pressure.
 In such situations, removing carbon dioxide and compressing it into cylinders makes it
easily usable for transport applications, three wheelers, cars, pick up vans etc and also
for stationary engines for various applications at remote locations. Since CNG
technology has already been in use, therefore, bio-methane (upgraded biogas) which is
nearly same as CNG, can be used for all applications for which CNG is being used.
 The upgraded biogas (without CO 2 ) has its calorific value as 34 MJ/m against 20 MJ/m3
of raw biogas.
 Upgraded biogas can be successfully used as a substitute of CNG in internal
combustion engines.

REQUIRED QUAN TITY OF BIOGAS FOR DIFFERENT USES

Sr. Purp ose Use Require d quantity of
No. biogas (m3 )
1. Cooking/Burners Per person/day 0.34-0.42
2. Lighting/Lamps 100 candle power 0.13
(60W) lamp /hr
3. Diese l Engine/Engine 1 H.P./hr 0.45-0.51

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IMPORTANCE OF BIO-DIGESTED SLURRY

The bio-digested slurry coming out of the biogas plant has various uses (as per Fig. 2)
as below:

Fig.2 Various uses of Bio-digested Slurry

 During fermentation in the biogas plant, about 25% of the added cattle dung
(on the dry matter [DM] or total solids [TS] content basis of the fresh dung) is
digested and a residue containing 75% of TS becomes available for use as manure.
 From a small family size biogas plant of 2m3 capacity, using 50 kg fresh dung every
day (or 18.25 tonnes annually), we can get approximately 9 tonnes of good quality
organic manure in a year.
 One tonne of biogas slurry provides 44 kg of nutrients as compared to 19 kg through
farmyard manure and 27 kg by compost.
 Micronutrients such as zinc (Zn), copper (Cu) and manganese (Mn) present in the
original material are also recovered in biogas slurry and can prove useful to crops.

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NUTRIENT COMPOSITION OF BIO-DIGESTED SLURRY
Sr. No. Parameter Amount

1. Total Nitrogen (%) 1.40-1.84

2. Total Phosphorus (%) 1.10-1.72

3. Total Potash (%) 0.84-1.34

4. Organic carbon (%) 35.0-38.4

5. Zinc (mg/kg) 103-116

6. Copper (mg/kg) 51-68

7. Manganese (mg/kg) 231-295

 The digested slurry can be fed directly to the crop through the irrigation channels or it
can be stored and used late whenever required.
 To derive maximum benefits from the stored digested slurry, it is essential to prevent its
exposure to the sun as any such exposure would result in loss of ammonical nitrogen
content of the slurry.
 It is advisable to dig, two or three manure pits near the biogas plant.
 The digested slurry can also be used for composting. During the process of composting,
it helps in faster decomposition of organic materials, wastes etc. put in the composting
pits.

IMPORTANT TIPS FOR EFFICIENT USE OF BIOGAS PLANTS

 Cover the top of the inlet and outlet tank opening with wooden, stone or RCC cover, to
avoid accidental falling of cattle/children.
 Feed the biogas plant with cattle dung and water mixture in the right proportion (1:1
ratio) to make a homogeneous mixture.
 Do not allow soil / sand / gravel / wooden particles to enter into the digester.
 No foreign material should like urea, any powder, lassi, jaggary waste etc. be added in
the plant especially in winter season to increase gas production.
 In winter, the gas production can be increased by covering the top of biogas plant with
paddy straw, wheat straw etc. / increase in quantity of cattle dung / adding urine of

Page | 10
 cattle to biogas plant / addition of poultry droppings if any in the plant / using bio-
digested slurry along with the fresh cattle dung.
 Do not burn the gas directly, i.e. from the gas outlet pipe even for the testing purpose as
it can be dangerous.
 Do not let any water accumulate in the gas pipeline; otherwise the required pressure of
gas will not be maintained and the flame will sputter.

POLLUTION CONTROL THROUGH ANAEROBIC DIGESTION

 Anaerobic digestion is one of the methods for treatment of strong industrial or
agricultural wastes.
 Methane is produced in anaerobic digestion while aerobic digestion produces only CO 2 .
 The remaining sludge has no offensive smell.
 Anaerobic digestion reduces the number of pathogenic organisms.
 The simple reason for this reduction is, the fact that the waste is kept without oxygen
for a length of time around 40 days at about 30 0 C to 350 C.
 An average small – scale biogas plant can save up to 4.7 tonnes of carbon dioxide
emissions per year.
 The contribution of a methane molecule to the greenhouse effect is 21 times greater
than that of a carbon dioxide molecule.
 Therefore, burning methane, even though producing CO 2 , reduces its impact on the
environment.

FINANCIAL INCENTIVES AVAILABLE FROM MINISTRY OF NEW AND

RENEWABLE ENERGY (MNRE), NEW DELHI
The MNRE is promoting setting up of biogas plants under three Central Sector
Schemes:
i) National Biogas and Manure Management Programme: (1 m3 to 25 m3 per day).

Rates of Central Financial Assistance (CFA) upto March, 2021 for different States /
UTs, Regions & Categories of Beneficiaries

A. Central Subsidy Rates Size / capacity of biogas plant

Applicable (in Rs. Per Plant) 1 m3 2 – 6 m3 8 – 10 m3 15 m3 20 – 25 m3
1. NER States, including Sikkim 17,000 22,000 24,000 25,000 35,000
and including SC and ST

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 Categories of NER.
2. Special Category States (Jammu 10,000 13,000 18,000 21,000 28,000
& Kashmir, Himachal Pradesh,
Uttarakhand and Andaman &
Nicobar Islands) and Scheduled
Castes / Scheduled Tribes of all
other States.
3. All other States (General 7,500 12,000 16,000 20,000 25,000
Category)
B. Additional Subsidy for cattle 1,600 1,600 1,600 Nil Nil
dung based biogas plants if
linked with sanitary toilets,
only for individual households
(Rs. Per Biogas Plant) fixed

ii) Biogas Power Generation (off ‐ grid) Programme:

 Setting up of biogas plants in the size range of 25m3 to 2000 m3 per day or 3kW to

250 kW power generation from biogas or thermal applications

Financial assistant for installation of large capacity biogas plants for power generation /
thermal applications

Sr. Power generating CFA / subsidy limited to the following Contact Agency for
No. capacity ceiling or 40% of the cost of the Punjab State
system whichever is less
Power generation Thermal
applications
1. 3 – 20 kW Rs. 35,000 per kW Rs. 17,500 per kW Punjab Agricultural
University, Ludhiana
2. > 20 kW to 100 kW Rs. 30,000 per kW Rs. 15,000 per kW Or
Punjab Energy

3. >100 kW to 250 kW Rs. 25,000 per kW Rs. 12,500 per kW Development Agency,
Chandigarh

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iii) Waste to Energy recovery programme:
 Setting up of large size biogas plants to recover energy from Urban, Industrial and
agriculture wastes / residues.

Central Financial Assistance (CFA) for different categories of projects

Sr. Output Capital Subsidy Description

No.
1. Biogas Rs. 1.0 crore per 12000 Biogas generation from Urban waste /
m3 Biogas / day. (Max. Agricultural Waste / Industrial wastes /
Rs.10 crore / project ) Effluents or mix of these wastes.
(Distillery effluent is excluded)
2. Power Rs 3.0 crore. Per MW. Power generation based on Biogas
(Max. Rs.10 crore / generated from Urban waste /
project) Agricultural Waste / Industrial wastes /
Effluents or mix of these wastes. In case,
developer wants to set up power
generating unit at already existing Biogas
generation unit, in that case, the
applicable CFA will be only Rs. 2.0 crore
per MW.
3. Bio-CNG / Rs 4.0 crore. Per 4800 kgs BioCNG generation based on Biogas
Enriched of BioCNG / day generated from Urban waste /
Biogas generated from 12000 m3 Agricultural Waste / Industrial
Biogas / day. (Max. Rs.10 wastes/Effluents or mix of these wastes.
crore / project) In case developer wants to set up
BioCNG generating unit at already
existing Biogas generation unit,
applicable CFA will be Rs. 3.0 crore.

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 CHAPTER – III

ESTIMATED COST OF THE PROJECT

 The detailed dimensions of modified fixed dome PAU Janta model biogas plant of
capacity 100 m3 /day (as per Fig. 3) are as below:

Fig.3 Dimensions of Modified Fixed Dome PAU Janta Model Biogas Plant

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 Cost for Construction of Biogas Plant for Off-grid Power Generation
(Capacity 100 m3 )

A. Cost for construction materials

S. Details of the material Unit Quantity Rate Amount

No. (Rs.) (Rs. in lacs)
1. Bricks Nos. 27000 6.0 1.620
2. Cement Bags 220 420 0.924
3
3. Stone ballast m 13 1100 0.143
3
4. Sand m 32 1000 0.320
5. Inlet pipe (PVC) having 300 mm m 6.25 1000 0.062
diameter
6. Steel required for slabs to cover the Kg 550 50 0.275
outlet chamber
7. Cost of digging the pit Lump sum 1 1.25 1.250
8. Cost of shuttering required for Lump sum 1 0.50 0.500
construction work
9. Cost of labour to construct the biogas Lump sum 1 1.50 1.500
plant
Total Cost Rs. 6.594 Lacs. = Rs. 6.50 Lacs. (say)

B. Cost for manufacturing parts of the project

S. Details of the material Unit Quantity Rate Amount

No. (Rs.) (Rs. in
lacs)
1. Mixing arrangement for feeding Lump sum. 1 2.00 2.00
material
2. Gas pipe line system Lump sum 1 0.50 0.50
3. Gas Flow Meter Lump sum 2 1.00 1.00
4. Moisture Scrubber Lump sum 1 0.50 0.50
Total Cost Rs. 4.00 Lacs.

C. Cost of bio-digested slurry disposal system for the project

S. Details of the material Unit Quantity Rate Amount

No. (Rs.) (Rs. in lacs)
1. Construction cost for Storage for bio- Lump sum 1 4.00 4.00
digested slurry
2. Cost of tanker (having capacity 5000 Lump sum 1 3.50 3.50
Ltr) along with submersible slurry
pump for bio-digested slurry
Total Cost Rs. 7.50 Lacs.

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 D. Consultancy charges for installation of the project

S. Details of the material Unit Quantity Rate Amount

No. (Rs.) (Rs. in
lacs)
1. Consultancy charges for Preparation Lump sum 1 0.25 0.25
and Supply of Detailed Project Report
(DPR)
2. Consultancy charges for installation of Lump sum 1 1.25 1.25
the project
Total Cost Rs. 1.50 Lacs.

Thus, total cost for installation of 100 m3 biogas plant

= Part – A + Part – B + Part – C + Part – D
= 6.50 + 4.00 + 7.50 + 1.50
= Rs. 19.50 Lacs.

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 CHAPTER – IV
FEASIBILITY REPORT OF THE PROJECT
PROJECT COST
Sr. CAPITAL COST HEAD Amount
No. (Rs. In Lakhs)
A Project Cost
1. Cost of civil construction 6.50
2. Cost for manufacturing parts 4.00
3. Cost of bio-digested slurry disposal system for the project 7.50
4. Consultancy charges for installation of the project 1.50
Total Project Cost 19.50
Subsidy from MNRE 1.75
Net project Cost 17.75

PRFOTIBILITY ESTIMATES ON 100% BASIS

Projections Unit rate Unit Annual Amount
(Rs.) quantity (Rs. In lakhs)
B INCOME
1. Income in terms of L.P.G. 650 Cylinder 1,004 6.52
2. Income from bio-digested slurry 0.2 Ltr. 13,68,750 2.74
Gross Annual Income 9.26
C OPERATING EXPENSES
1. Depreciation of the project (25 years 0.78
of life) @ 4 %
2. Worke rs Wages
Un-Skilled Worker – 2 Rs. 9,000 Rs. per month - 2.16
3. Annual Maintenance Charges Rs. 1% of Project - 0.18
Cost
Total Expenses 3.12
Net Profits = 9.26 – 3.12 = 6.14 Lacs.

17,75,000
Payback period of the project = ----------------- = 2.89 years = 3.00 years (say)
6,14,000 (subjected to availing subsidy from MNRE)

19,50,000
Otherwise, payback period of the project = ------------- = 3.18 years = 3.25 years (say)
6,14,000

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 CHAPTER – V

COMMERCIAL TERMS & C ONDITIONS

I. Price basis:
The prices offered are on Ex-works supplier or sub-contractor works basis and
packing & forwarding, taxes, duties, levies, freight, insurance etc.

II. Packing & forwarding:

GST Tax - Extra applicable as per government.

III. Acceptance :
The Purchase Order will be accepted by us on the basis of our valid quotation.

IV. Installation and commissioning:

Up to 3 Months after clearness and receipt of material at site depending on site
readiness.

V. Delivery:
4-5 months from date of clear, signed purchase order with advance and drawing
approvals.

VI. Payme nt terms :

a) 100% of Consultancy Charges in-advance for Preparation and Delivering of
vetted Detailed Project Report (DPR).
b) 75% of Consultancy Charges for Technical know – how in-advance along with the
work order.
c) 15% of Consultancy Charges for Technical know – how after completion of 50%
construction work of the project.
d) 5% of Consultancy Charges for Technical know – how after completion of 100%
construction work of the project.
e) 5 % after complete Installation, Commissioning and Trial Production or after a period of
one month of completion of the project in all respects.

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VII. Validity:
This quotation is valid for a period of 60 days.

VIII. Warranty:
12 months from date of commissioning of the project. Warranty shall not be
applicable if installation and commissioning is not done as per standard procedure
prescribed by PAU, Ludhiana.

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 ANNEXURE – I

SPACE REQUIRED FOR CONSTRUCTION OF BIOGAS PLANT

Fig. Space required for construction of biogas plant

Capacity of Biogas Space Required for Biogas Plant

3
Plant (m /d) Length Width Area in
ft ft Sq. ft. Marla
(m) (m) (Sq. m.) (In Punjab)
80 35 2800
100 13.00
(24.0) (10.5) (252)

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