BA's commitment towards capacity building & awareness dissemination Feed preparation for biogas plant. ‘ Waste management for better revenue —_ generation Innovative semi-aerobic hydrolysis pretreatment technology for fibrous substrate. Indi: vbaln powerol Fontyog tony |Association by Mahindra(| RAMA CYLINDERS HIGH PRESSURE BIO-CNG STORAGE CASCADE AN ISO 9001, ISO 14001 & TS 16949-2009, OHSAS 18001 CERTIFIED COMPANY CASCADE STORAGE CAPACITY: 300 Liter to 4500 Liter WATER CAPACITY CASCADE WORKING PRESSURE: 250BAR CAPACITY : Rama Cylinders Pvt. Ltd. PRODUCTION CAPACITY 480000 CYLINDERS PER ANNUM. o 181 Maker Tower-E, Cuffe Parade, Mumbai, INDIA. QUALITY ASSURANCE & CERTIFIED BY : INSPECTION AGENCIES SUCH AS BIS/PESO, SGS, ® Tel. No.: +91 22 221623 44—45 BUREAU VERITAS & VCA, UK Fax No.: +91 22 22154294 Mob. 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Wahi Sana ors aie cm THAI (=a 4 Bb ded =) ae ICIENT, SAFER AND MORE ee er ro) Ve) se cael INDUSTRIES bsite: www.acegasconversions.com phone: +91 77095 74555 rai di@aceenertech.com / vs@aceenertech.com phone: +91 98217 33621www.biogas-india‘com Biogas Magazine | Edition 111 4 Index IBA News IBAs commitment towards capacity building and awareness dissemination os National Corner India's nascent bioma supply Industry turning reliable and organised 2 Feed pr ation for biogas plant 16 Waste management eration 22 for better revenus fative semi-aerobic hydrolysis pretreatment technology for fibrous substrate 25 International Corner Digestate a valuable rest product from biogas production 32 Operation and Maintenance Essence of Operation and Maintenance in Biogas industry ae in India 36 tba Biogas and Development oles BIOGAS Partner of German Business ‘Association Indian ‘= SOGUO scm LA S Fachverbandthe guidelin 04 pread of the pandemic ca x Corona virus’. As a responsible citizen, nrich your B per Ind look forwar continue doing the same. svilion india Ic f the indus his mag: channels including the Biogas fed website. The p: on along with effective utilize n estate, which in turn ensures fir Atma Ram Shukla PresidentIndian Biogas Association & ONLINE on BIOGAS TRAINING e Learn from anywhere e Easy on pocket e Instructor-led Interac- e@ Online support -tive training e Easy accessibility © Self-based learning MODULES TO BE COVERED 01 Basic concepts of Biogas 02 Biogas Technologies 03 Biogas in India 04 Digestate as Fertilizer 05 Design and Control 06 Planning, O&™ and safety Seats Filling Up Fast, Book Your Seat Now! Register at: https://biogas-india.com/?service=online-biogas-training al@biogas-india.comClarke Energy° KOHLER COPY INNIO "2" In order to treat waste water and meet the discharge permit requirement, we have to use ‘energy; quite alot of it. As the cost of energy rises and emphasis on renewable energy increases, local authorities and municipalities in india are ‘seeking solutions that save money and meet renewable requirements, Clarke Energy's office in India using INNIO’s Jenbacher gas engines provide a renewable energy solution that results in long- term savings for wastewater treatment plants. ‘Sian, Peto, 8, Ema aiclarhe-eongy comactive ticipating in various national and international confere In the recently concluded several conferen ~ be it 2nd Global Summit on Waste M agement on 3ist January 2020, MSMECCI ntech Asia Exhibition on 3rd February ) or World Future Fuel Summit 2020 on 16 February 2020, we specifially debated and put forward Biogas case in a positive man ner and emphasizing on the fact that the cir: cular economy is incom jout Biogas incorpration. Dr. A.R. always in the opinion that if we play our card properly then le to even replace the ith Biogas. Beginning 2020, the capacity of the commissioned biogas labo ratory at IIT-BHU, Varanasi has been further augmented, and presently its scaled to car- arger volume of tests simultaneously The Biogas Lab 4 he premier institute was set up by the institute in collaboration with the Indian Biogas Association and the Ger man Biogas Association. The lab, which was set up in 2018, is equipped comprehensively with contemporary testing facilities, like de- ition and yield from laboratory fermentatio of co-substrates, determining environmental and nutrient requirements for substrat radation, potential inhibitors in jas processes, evaluation and interpreta tion of the analysis results, and so on The Indi. with its interes! yas Associ an Bi has taken up the pursuit to provide the need ful thrust towards capacity building in th ield of biogas/CBG. IBA in collaboration wit! BA plans to organize a training tour on “B: sics of Biogas” in Kolkata, and Bhubaneshwar rom 18th -20th 2020. The exact venuand dates will be announced soon and infor spread the awareness about the Bio-Ener mation on same shall be updated on our wet ay sector along with increased visibility of site. Continuing its trend of organising the the sector upon convergence of corporates, event, previously in the Western and South ern parts of India, the idea this time around tions, lending institutions, and investors. is reaching out to the eastern parts of India__—This initiative is aimed at streamline scien: d disseminate awareness about biogas/ tific waste management practices, which is preneurs, academicians, Social organi CBG in the region. Corporate Professional presently supported by various government aspiring Entrepreneurs, Policy Makers, Finan schemes like Swachh Bharat, Sustainable Al cial Institutions, Environmental enthusiasts, ternative Technology for Affordable Trans research scholars, ac: s and NGOs, portation (SATAT), New National as can enhance their elementary the bic mationon and Organic Manure Program (NNEOMP), gas, Waste-to-energy scheme, Ethanol Blending gram, Compost promotional scheme, and ther relevant sche - IBA is coming up with the Bio-Energy Conference and Bio-En- ergy Pavilion in from 23rd to 25th Sept 2020 at RE! Expo, Greater Noida. IBA have been of ganizing the bio-pavilion since last two years, Indian with Further ithas gathered wide oD Biogas Tance fom parscipante'm wre eww, «= ECD EL|Biog The pavilion and conference is expected to —Fuklying Ey | ASSociation Last Year Photos Biogas Training Tour250+ PAVI ie ON Ss 2020 #bioindia2020 23,24, 25 Are you seed ignoring biggest ja ine ieee “Three new Bio-CNG plants per day are planned” Goverment of india 600+ , | Business Meeting i z= SO+ Companies 10,000+ Visitors 2000+ Wer petreny Pstrrey ra Cee CCC) eT ue eee You) CeCe See ee earn SURI E EC re} texected figures should nt be tajen as guaranted figures.BIOGAS COMPRESSORS ee er ae raee ga Re ee ie eo Capacity - upto 2400 Nm3/hr Suction pressure - upto 15 Barg Discharge Pressure - upto 250 Barg Cooling - Air/ Water Cooled F , Compressor Type : Reciprocating & Screw Un JYOTECH Packager & Authorized Dealer JYOTECH ENGG. & MKTG. CONSULTANTS G-141, Se 63, Noida 201301 U.P India (T) : 9312004352, 8920462800 (R) :0120-4711300 (E) : sales@jyotech.com, vipinv@jyotech.comwww.biogas-indiacom Biogas Magazine | Edition 11| 12 India’s nascent biomass supply industry turning reliable and organised he utilisation of cereal straws, like that of paddy, has always grabbed the headlines and attention of Biogas/ BIOCNG sector owing to its vast potential to reshape the whole sector. Now, attempts to use crop residues, like Paddy Straw, for the Purpose of BioCNG production have started gaining commercial traction, and the indus- try's attempt to make it a major raw mate- rial, complemented with other biomass; like presmud, steadily looks achievable. Given the fact that Punjab and Haryana, the two major agrarian states adjacent to the capital city of India, together generates around 30 Million Tonnes of crop residue each year, thus mak- ing its availability in abundance wart its de- mand by industries. Furthermore, this makes it a very low-cost fuel with moderate-to-high calorific value and a relatively stable price, in comparison with other CBG raw materials. The irony is that such a resourceful fuel is be- ing openly burnt, and causing lethal air pol- lution in its catchment areas, due to lack of economic alternatives with farmers to man- age it. These economical & ecological dy- namics have led to the encouragement by in- dustry and government for setting-up a large number of BioCNG, Biofuel plants and other industries to channelise the vast amount of crop residue into productive use and pre- vent its open burning. The push from Pub- lic Oil Marketing Companies, like HPCL and IOCL, to utilise crop residues in Bioethanol and BioCNG sectors is also fuelled by the concerns arising from high oil and gas import dependency of India But, here in India, these crop residue-based industries have not been able to achieve the economic potential they possess, primarily ‘owing to the lack of a reliable and integrat- ed supply chain mechanism, which is quint- essential for any bio-based industry to suc-ceed. As reported by ‘Task Force on Biomass Management’, set-up by the Government of India’s think tank - NITI Ayog, power plants and industries are unable to utilise this res- idue due to fragmented and mismanaged biomass supply chain. The biomass supply sector in India has largely remained depen- dent on unorganised and unprofessional local players, who operate with a very low degree of reliability and supply inexpertly processed biomass thus negatively impacting its quality and thus energy output from the plants. This has caused viability issues for several major plants and subsequent shutdowns. While the currently operating plants are forced to oper- ate at a very low capacity utilisation, at times, they are dependent on expensive alternate fuels, due to huge commodity price risk asso- ciated with biomass fuels. But, now all these upcoming emboldened plants and industries have a solution in sight, as the biomass supply chain industry has started becoming professional and organised with the entry of innovative players like, RY Energies and others, providing reliable and integrated supply chain services. These com- panies undertake the responsibility of es- tablishing the supply chain infrastructure in the vicinity of the plants and enable them to conveniently procure biomass at sustainable prices, with zero capital investment and zero downtime with assured biomass availabil ty. This leads to an increase in profits of AD plants and enables them to fulfil their Renew- able Purchase Obligations (RPOs). The supply chain companies work in close collaboration with farmers and regional agi cultural departments to procure the biomass in a timely manner and prevent open burn- ing of the crop residue, thus contributing to a greener and cleaner environmentDirector ol ah ia BIOGAS APP e Point Solution for Biog Lar Scan & Download The Biogas AppAISIN Aisin Automotive Haryana Pvt. Ltd. se Biogas to Electricity Generatio (Empowering RURAL COMMUNITIES to be Self-sufficient & Self-sustainable for their Electricity Needs) Dis ein denne wil ee a tous eins sig Vrumlng > Cstocran cys dig sto en Benefits of Aisin Bi wer generation system: * Availability of power for 24x7 (5Kw per hour per engine) Type 4-stroke OHV * Reduces reliance on fossil fuels & Pollution # Improves living standards in rural areas No.of cylinder Single cylinder # Produces good quality enriched manure to improve soi fertiity Cooling system Woter-cooled * Effective and convenient way for sanitary disposal of organic wastes (food, animals, Swept volume — 245cc Blane) Rated power * Improving the hygienic conditions & reduces global warming output perhour —_PSKVA Highlights : | + Aisin is providing a complete solution for Biogas Power generation system (Digester, Desulphurizer, Generators) for Grid & off-Grid applications for animal waste * Generated biogas can be utilized for electrification, cooking, heating, etc. * The CO, from exhaust can be utilized for photosynthesis inside green houses. * The heat coming out from the engine can be utilized for heating the digester at winter conditions Plot No.7,8 & 9, Sector-30B, IMT Rothak, Rohtak (Haryana), India Ras Contact: Rejeesh, aa Mob: +91-7082828250 // E-Mail: rejeesh.k@aisin-ahl.co.in //https://aisinindia.com gery Demo Site, Bangalore : https://goo.gl/maps/3RitBBfuIM12 neewww.biogas-indiacom Biogas Magazine | Edition 11116 Feed preparation for biogas plant overnment of India is pushing vision of G establishing 5000 Compressed Biogas plants in a phased manner by 2025 Such large capacity Biogas plants will require huge quantity of raw material as feedstock, so the plant operators have to get acquaint- ed with various feedstock having potential for biogas generation. It will be imperative for the plant operators to set-up pre-treatment/ feed preparation system which can process the feed to the digestor on required large scale basis. Such systems should be capable of handling various raw materials so as the plant operator do not have to depend heavily (on seasonal availability of particular raw ma- terial or shortage of raw material. Biogas has distinct advantage of being much greener bio-fuel compared to Ethanol and Biodiesel. Ethanol production requires specif- ic feedstock with high fermentable carbohy- drate level e.g. corn, sugarcane, sugar beet, cassava. Biodiesel production requires feed- stock with high oil content (e.g. jatropha or any oil seed crop). Both technologies require complex feed preparation and extract yield only from portion of the feedstock. Biogas production uses wide range of agriculture waste as well as municipal sewage waste, with relatively simple feed preparation. Prop- er design and planning should be done for the feed preparation to run the Biogas pro- duction efficiently on continuous basis with better yields. Biogas production traditionally started from dairy manure and sewage sludge. Though being easy digestible, the energy potential of manure/sewage/poultry litter is limited as animals have already consumed much of energy. This is the reason, various other feedstocks having high eneroy potential like grass, silage, food waste are used as co-di- gestion materials in modern Biogas plants. More than 2 or 3 substrates could be used at a time for co-fermentation. Table 1 shows en- ergy potential for various raw materials. Any agricultural substrate or organic waste is fit for use in Biogas plant. Woody materials are not preferred due to high lignin content, which is resistant to decay in anaerobic di gestion. Most Biogas plants use CSTR type anaerobic digestor with dry material content of 69 to 15%. It is preferred practice to mix manure/ poultry litter having better digestibility withwww.biogas-indiacom high energy potential mate- I from agriculture origi (grass, silage etc). As gen- eration of Biogas depends ‘on anaerobic digestion of raw material, it is essential to pre-treat the feed to increase digestibility and in turn in- crease in yield of Biogas. BHS-Sonthofen GmbH have been working closely with European Biogas industry since last 10 years for the feed pre-treatment solutions. German Biogas plant owners were first to use Rotary Mill from BHS crushing equipment range for selective size re- duction of the feed material. Aim of the selective size re- duction of the raw material is to achieve defibering as well as comminute the material, which facilitates fast uptake of nutrients by the micro-organisms and achieve flocculent mass for better handling of the slurry. Based on contin- uous feedback from the Biogas industry, BHS developed Bio-Grinder which meets demands of Biogas industry for pretreatment for wide range of feed materials. BHS Biogrinder is based on rotary hammer mill principle, but with special design features to process substrates. Features like large opening allows feeding of substrates of various sizes. Crushing chamber is designed such as to facilitate maximum defibering and size reduction and Poeun Biogas Magazine | Edition 11117 2 Neelesh Desai Managing Director BHS Sonthofen Methane errenywww.biogas-india‘com Biogas Magazine | Edition 11|18 1.000 = 0 2 3 S wo 2 m 5 oo 3 ZB 400 & 0 7 wes youn Boga 2p | — Gas yield with Biogrinder S mm | — Gas yield without Biogrinder iS gg ° 3 2 : 5 2 2 . 5 Date (period of operation) run continuously choke free operation, even with moist substrates. There is possibility to use two different kind of hammers as well as change number of hammers to influence crushing result with variety of substrates. Motor KW power can be selected depend- ing on the capacity required, customers have option to use VFD to change rotor speed to influence the output. Advantages of using Biogrinder for substrate pretreatment 1) Substantial increase in gas yield vis-a-vis normal cut feed materials. Refer Graph 1. 2) Stable fermentation process due to homo- geneous mix, layer formation is avoided in the digester. 3) Less stirring power required due to easy and homogeneous mix of feed. 4) Short crushing time means all energy used for selective crushing. 5) Impurities like soil clods or stones also gets Figure 3 Graph 1 Yield Comparison crushed without any harm to the Biogrinder. 6) Biogrinder works on continuous process, thus meeting important aspect of integrating feed preparation with Continuous Digestors as well as providing large capacity handling of substrates. 7) Future proof investment as Biogrinder can be used for pre-treatment of varieties of sub- strate treatment, plant owners do not have to be dependent on just one feedstock material. Biogrinder in India:- BHS have supplied first Biogrinder in india in 2019 near Ambala for plant operated by Source Facility. This plant uses dairy manure for Biogas production. The plant operator have started processing vege- table waste from Agriculture market as ad tional feed material through the Biogrinder. This installation has successfully increased yield of Biogas from the plant with low oper- ational cost. Increase in solid content also im- proved yield for digestate which can be used as a fertilizerwww.biogas-indiacom Various Substrates Input vs Output from Biogrinder ae Biogas Magazine | Edition 11|19 igure 5: Vegetable waste rout - OutputON BOOKING ADVERTISEMENT IN NEXT FOUR EDITIONS OF IBA MAGAZINEGREEN PUMPS & EQUIPMENTS PVT LTD SUBMERSIBLE SEWAGE PUMP a ekaaeler las] Dewatering Pump Green Pumps & Equipments Pvt. Ltd. o 1941, Ghotawade Phata,Pirangut,Tal Mulshi, Dist Pune 412 108 9637867412 , 09422776152, 9422080447, 7057124230 prasadegreenpumps.co.in pum PSs aie 5 fn www.greenpumpsandequipments.comndustrialization, urban ization and changes in the pattern of ompany the process of life, which ac economic growth, give rise to generation increasing quantities of wastes leading to i creased threats to the environment. In recent years, technologies have been developed that not only help in generating substantial quantity of decentralized energy but also in reducing the quantity of waste for its safe disposal or rather use it for better revenue generation. The definition of waste,” which is useful resource laying at wrong place ‘itself suggests that it must be utilized properly. In current scenario, environmental concerns rather than energy recovery is the prime r tivator for waste-to-energy facilities, whi help in treating and disposing / reusing of wastes. Eneray in the form of biogas, heat or power is seen as a bonus, which improves the viability of such projects. A common feature in most developed countries is that the entire waste management system is being handled as a profitable venture by private industry or non-government organizations with tipping fee for treatment of waste being one of the revenue streams. The major advantag- for adopting technologies for recovery of jergy from urban wastes is to reduce the quantity of waste and net reduction in en vironmental pollution, besides generation of substantial quantity of energy. Poultry industry is major food supplement provider in India and across the world, it’s a major boost to farmers also for side business and earn good money out of it. As per recen census The total poultry livestock in the coun try is 851.81 million in 2019, and registered an increase of 16.8% in the total poultry. The to- tal birds in the backyard poultry in the coun- try is 317.07 million. The backyard poultry has increased by around 46% as compared to previous Census. The total Commercial Poul- try in the country is 534.74 million in 2019, in- creased by 4.5% over previous Census. But in recent period this industry is facing se- rious challenges due to increase in feed rate wer rate , very less production of feed due to draught , heavy rain , steep drop in selling prices of eggs , meat etc. The social nuisance of near by villagers ( to the poultry set up ) is also reached to alarming level.M/s. AVEE Broilers, Nashik also face those serious issues and find it diffi cult to focus on daily activities and rather scratch head from those non value added activities. AVEE Broil- ers came in contact M/s. Uria Bio System Pvt Ltd, Pune with one of major player in waste management system provider. After a fruitful discussion, it was agreed to set up Biomethanation plant at Broilers prem- ses. Based on the available 2,00,000 birds, he proposed for 22 TPD litter based biogas plant. The plant is set up for 22 TPD litter which is able to generate @ 2000 m*/day raw biogas This litter initially undergoes suitable prima- ry treatment, basically the challenge in litter is its heavier silica (grit) and lighter feath- er content, Urja has made in built design handle such problems and sorted out this is sue and also facts for needful provisions for their anticipated challenges. Thus, a proper well functional plant is set up at the site. The farm is being provided with 2500 kWH/day electricity (200 kw x 14-16 hrs per day), thus reducing major dependency on MSEB (State Electricity Board Power), which provided interrupt, power supply leading to usage of diese! gensets. The digested slurry also bringing very good revenue, as the Broiler is generating @ 7 TPD dry manure, which is very good soil conditioner and useful for bat crop. The heavy monetary loss due to usage of diesel genset is completely stopped, which was draining @ 25,000 Rs per day. 1. Completely stopped the social nuisance nearby people who were always con about the obnoxious litter smell. 2. Zero requirement of diesel in genset. 3. Usage of green power, which brings good subsidy from state as well as central govt. 4. Better revenue generation through sale of digested slurry as organic manure. Seeing the better revenue generation model through, manure sale, Avee Broilers is further planning to go for value added organic fertilizer plant. Managing Director Urja Bio System Pvt. Ltd,Renewable Energy Oj informa markets India Expo 23 - 25 SEPTEMBER 2020 India Expo Centre, Greater Noida YOUR MOST POWERFULSOURCE OF LIMITLESS ENERGY. — ASIA'S LARGEST AND MOST. INFLUENTIAL RENEWABLE ENERGY EXPO SHOW HIGHLIGHTS . c0- LocaTED WITH 2 70 ® & @ THE BATTERY SHOW ee ee ee ees NDIA a Se EE, eR Fou , a iy electric wm Ga ra Munn paxmicnarion 000050.MTRS. MUMTIBLE rua & hybrid | india enanst Wgeseess | giz | foe | ign: | REE-|@ | Go ames alan Pare vor | amped Peroee | Wate Bote Peer PE PREMIER areas 2¢solis www.renewableenergyindiaexpo.comwww.biogas-indiacom Biogas Magazine | Edition 11| 25 Innovative semi-aerobic hydrolysis pretreatment technology for fibrous substrate iogas has emerged as a promising re- B newatletochclogy tocomert apr tural, animal, industrial and municipal wastes into energy. Quite like any renewable energy technology, biogas offers a range of benefits such as reduction in Greenhouse Gas Emissions (GHG), ensures energy security and offers a sustainable alternative to con- ventional energy sources. Stubble burning in the regions of Punjab and Haryana is one of the major sources for Delhi Air Pollution. Con- verting bio-mass to compressed biogas and bio-CNG will not only help curb the menace of stubble burning but also create additional income for farmers. India consumed close to 20 million tonnes of LPG in 2016-17 and is expected to grow to at whopping rate 23.7 in the next upcoming years. Of the total consumption in 2016-17, close to 11 million tonnes was imported, Bio- gas can serve to offset a significant portion of this import requirement. The current bio- gas potential is estimated at 60,443 million m3 (raw biogas) which is equivalent to 26 million tonne LPG per year. Biogas produced is further purified and processed, to bio-com- pressed natural gas (bio-CNG) which is simi lar to natural gas in terms of its composition and properties, and is a cleaner alternative to fuels such as petrol and diesel Thus Fuel from Agrowaste can be a better al- ternative to LPG and other fossil liquid fuels (Petrol and diesel) Supporting policies in india - BioCNG It is planned to roll out 5,000 CBG plants across India in a phased manner; 250 plants by the year 2020, 1,000 plants by 2022, and 5,000 plants by 2025 with expected produc- tion of 15 million tonnes of CBG per annum, which is about 40 per cent of current CNG consumption of 44 million tonnes per annum in the country. The National Policy on Biofuels, 2018, empha- sised on active promotion of advanced bio- fuels, including CBG. The Government had launched the GOBAR-DHAN (Galvanising Or- ganic Bio-Agro Resources) scheme earlier to convert cattle dung and solid waste in farms to CBG and compost. The scheme proposed to cover 700 projects across the country in 2018-19. CBG networks can be integrated with city gas distribution (CGD) networks. Later, the retailing from OMC fuel stations could be injected into CGD pipelines, too, for efficient distribution and access. The poten- tial for CBG production from various sourc- €5 in India is estimated at about 62 million tonnes per annum. Problems Associated with Feedstock Most of the agro wastes like Paddy straw are highly fibrous, which makes it difficult to di-www.biogas-indiacom Biogas Magazine | Edition 11| 26 gest as they are highly resistant to anaerobic diges- tion. The fibrous feedstock contains non-edible plant material so called lignocelluloses and is mainly com- posed of cellulose, hemicellulose, and lignin. Hemi- celluloses is present as the matrix that surrounds the cellulose skeleton, while lignin is present as an encrusting material and serves as a protective layer. All three components have covalent cross-linkages between the polysaccharides and lignin, therefore, making biomass a composite material Macrotibat - oe pe pmo a #8 : Cotulose Hemicetiuiose (14-8-0-gucany Fibrous Feedstock Different Feedstock and their composition =z_—i Rice straw 33-40 20-30 410 FB 60 22 18 Maize straw 30-50 20-35 12-30 The retention time and the speed of decomposition vary greatly based on the composition of feed. As per the graph, the fibrous material which has higher portion of lingo-cellulose requires more retention time to decompose. Beet (5-10 days) Maize, Sorghum, te 4 Hybrid Rye feces (60-90 days) ‘Speed of fermentation (rel) s se & © - & Retention time for substrate fermentation (days)Anaerobic digestion has been extensive- ly used for treating highly biodegradable wastes like fibrous waste. Pretreatment is an important tool for cellulose conversion pro- cesses, and is essential to change the struc- ture of cellulosic biomass to make cellulose more available tothe enzymes that convert the carbohydrate polymers into fermentable sugars. The pretreatment step is referred to as the technological bottleneck and is cost effective, Available Pretreatment Methods Several pretreatment methods have been followed to decompose fibrous rich agro waste. cays SPL + Physical + Chemical + Biological Pretreatment Fibers in Lignocellulos Materi Atleast 20% of the total production cost is represented by the pretreatment phase Long decomposition time, Low biogas con- version rate, particularly less gas yield rate, formation of the floating layer in the system and clogging problems makes it less feasible for anaerobic digestion and no suitable diges- tion technologies for pure straw substrate. Physical pretreatment Physical pretreatment methods, including Biogas CHytCOy Anaerobic Digestion (AD) = Lignin “~% Hemicellulose — Cellulose @ Microorsanism mechanical operations, different types of ir- radiation and ultrasonic pretreatment, have been utilized to enhance the accessibility to hydrolysable polymers within lignocellulosic material. Among the physical pretreatments, (below beneath) mechanical pretreatment is widely used for waste materials, such as agri- cultural residues or any other crops and for- estry residues. 1. Mechanical Treatment 2. Steam Explosion 3. Microwave radiation Physio Chemical pretreatment Steam explosion Steam explosion (SE) is a well-known tech- nique for the pretreatment of various biomass feedstocks. During SE pretreatment, lignocel- lulosic material is exposed to ahigh-pressure saturated steam at a temperature of 160-260 *C and a corresponding pressure of 5-50 atm for afew minutes. The pressure is gradually released, and the steam expands within the lignocellulosic matrix, causing individual fi- bers to separate and the cell wall structure towww.biogas-india‘com be disrupted. Acid can be added as a catalyst during steam explosion Chemical pretreatment Chemical treatment methods are used more than biological or physical pretreatment methods because they are more effective and enhance the biodegradation of complex materials. Common chemicals used in chem- I pretreatment methods for improving the AD performance of agricultural residues are sulfuric acid (H2SO,), hydrochloric acid (HCacetic acid (CH,COOH), sodium hy- droxide (NaOH),potassium hydroxide (KOH), lime (Ca(OH),), aqueous ammonia (NH,H,O). Biogas Magazine | Edition 11| 28 and hydrogen peroxide. 1. Alkali pretreatment 2. Acid hydrolysis Biological pretreatment The deconstruction of lignin structures in the cell wall using microbes and/or enzymes as catalysts is usually referred to as biological pretreatment and occurs in the first stage of hydrolysis with other pretreatment process- es. It can be done by manure addition as well as by adding certain microbes like actinomy- cetes 1 Microbiological treatment 2. Manure Addition The table shows the increased gas generation rate of anaerobic digestion based on the type of pre-treatment method preferred Pre-treatment Type Peres ets atelg t-te CT generating Capacity (%) Mechanical Pre treatment 13 Chemical Treatment (Various on type 4075 of Method) Biological Treatment 407 (Adding Manure) - Our Technology - Semi Aerobic Hydrolysis The fibrous raw materials are being decom- posed step by step into simpler compounds using a multistage microbiological process. The first two stages, pre-digest and acidifica- tion are usually often described as hydrolysis. Process Flow Solid feeder Semi-aerobic pre-digestion is the microbio- logical pre-decomposition of the hardly ac- cessible parts, especially of the fibers in the substrates. Thereby the gas yield is being in- creased and the use of fibrous substrates is made more economical. ication Pump room Hydrolysis tank CSTR.www.biogas-indiacom Working Principle ‘The Semi aerobic hydrolysis unit provides an aerobic and anaerobic mixed flora (faculta- tive species) with different biochemical re- actions in which the Aerobic and anaerobic bacteria could work together to decompose the lingo-cellulose structure 1. Support aerobic microorganisms to rapidly secrete large amounts of hydrolase to con- vert cellulose into soluble sugar 2. Support anaerobic microorganisms to pro- duce small amounts of alcohol 3. Support aerobic production of acetic acid 4, Supports the internal disintegration of mo- lecular chains and reduces material viscosity while rapid polymer degradation In the conventional system, the hydrolyzed microorganism is a dedicated anaerobic mi croorganism, and its living environment is limited by the methanogen, and the amount of the enzyme capable of acting on the cellu- Results for Various Feedstocks Biogas Magazine | Edition 11| 29 lose is small and the activity is low. Technology - Advantages 1. No chemical agent added, lower operation cost 2. Hydrolysis completed within 1-2 days, hy- drolysate input to the digester and complete the biogas conversion within 25 days 3. Volume of digester decreased, lower in- vestment 4, Easily pumpable and less floating layer, lower agitating power consumption 5. Possible for gas conversion of pure dry straw, deeply utilize gas yield potential 6. A higher CH, concentration is obtained, as some CO, released from hydrolysis 7. Many inhibiting chemicals can be broken down in hydrolysis(such as phenols, Ammo- nia etc), keeping the digester(methane pro- duction) running more stable. Semi Aerobic Hydrolysis of Rice Straw - Case study Rice Straw ‘After Hydrolysis Pure dry Corn Straw Before Hydrolysis The normal anaerobic digestion of paddy straw produces very less biogas. Average specific biogas production is in the range of 248 m* /tonne of total solids fed to the plant whereas the semi aerobic Hydrolysis of Rice straw produced around 400 Nm*/tonne. After Hydrolysis, Biogas Output for 45 TPD Feed - 12000 Nm/day The semi hydrolysis treatment of Fibrous feedstock has proven to produce more bio- gas than general Anaerobic digestion Conclusionwww.biogas-india‘com Substrate Characteristics and feeding amount Pe Deg Biogas Magazine | Edition 11| 30 Ca ee Le ie a eT L P Say | SEEK C/E Cooa CTY Water | 2920000 | 80.00 0.00% ° 0.00% o Process | 199,500.00 | 300.00 2.00% 6.00 50.00% 3.00 Water Rice straw | 16,425.00 | 45.00 | 85.00% | 38.25 78.00% | 29.84 Pretreatment alters the various feedstock characteristics at the fiber, fibril and micro fibril level. The extent and rate of LM hydro- lysis are affected by biological pretreatment, chemical pretreatment, physical pretreat- ment, and its morphological characteristics. The mechanism behind semi aerobic hydro- lysis is initiated by the increased facultative bacteria growth rate and enzymatic activity and the greater cellulase production under micro aerobic conditions. and cost-effective pretreatment method that meets most of the requirements for industri- al applications, such as the formation of re- active cellulosic fiber for enzymatic attack, avoidance of the formation of possible inhib- itors to the fermenting microorganisms and hydrolytic enzymes, reduced energy demand and reduced cost of size reduction of the It is an efficient feedstock. Other benefits include the reduc- tion in the cost of material for construction of the pretreatment reactor and the generation of fewer residues due to zero consumption of chemicals, all of which makes this technology as one of the most promising and environ- mentally friendly techniques in the long run P. Dev Anand Chairman & MD Kankyo Group of SUPPORTED EVENTS Date & VENUE Presa 27 een) Crean) Tees en) CTOBER, 20 irae cone Te rane! IFAT Indiaon") RenewX O informamarkets Renewing Opportunities 4 = Energizing Growth South India’s Largest Renewable Energy Expo 16 - 17 JUNE 2020 Hitex, Hyderabad ESwww.biogas-indiacom Biogas Magazine | Edition 11| 32 Digestate - an undervalued resource turned problem? Experiences of a Norwegian researcher in India Norwegian Institute of Bioeconomy Re- search. One of the projects | work on is a collaboration between Norway and India. The research focus of the collaboration is use of digestate, the organic rest from biogas pro- duction, as a fertiliser in rice production. In Norway | have worked on use of digestate as fertiliser for other crops, primarily wheat. We have found that digestate is a good fertilis- er, with a lot of nutrients that are available to plants. And the biogas process improves the fertiliser value of animal manure, nutrients are mineralised and made plant available in the process. The Indian counterpart in the col- laboration is KIIT university in Bhubaneswar, Orissa. KIIT university runs a biogas training centre and helps farmers in the area set up and run household sized digestors. As part of the collaboration | have been taken out to see the digestors in two villages, Salepur and Kakatpur. This was very interesting for me. The digestors seem to be running well and provide clean burning fuel for cooking for the villagers, and the trainers from KIIT appear very satisfied. However, there has not been much attention to digestate. | noticed a few problems, and | think at least in some cases, simple and cheap measures could make a lot of difference. | am a Norwegian researcher working at the The most serious problem | noticed was that the digestate was stored in open tanks in most places (Figure 1). In my country all storage of manure and digestate needs to be covered, but digestate stored like this is particularly problematic because there will usually be some methane potential left in it. How much will vary, but for household sized digestors it is probably difficult to bal- ance the input to exactly match the need, so that sometimes there will be quite a bit left In many cases | could see bubbles forming (Figure 2), indicating that gas production was still going on. As methane is a power- ful greenhouse gas (about 21 times stronger than CO.), any climate benefit from the di- gestors are therefore quickly negated this way. Ammonia is also lost to the air. That rep- resents a loss of nutrients, and it can result in eutrophication elsewhere. In addition, open tanks could be a danger for children or a mals to fallin. Only in one place saw I the tank covered. The cover was made of some twigs partly covered with plastic (Figure 3). We do not know which cover is best, but any cover is a lot better than no cover. Farmers should be encouraged to cover their digestate storage tanks and keeping them covered as much as possible. They can use whatever is available to them to cover it, so that this should not need to incur large extra costIn the storage tank, the solid will sink to the bottom, so the solid is separated out to some extent. The liquid overflows at the top. At in- tervals, the tank is emptied and the solid taken ‘out from the bottom. This solid is composted in open piles (Figure 4). At present it is most- ly this compost that is used in the field as fer- tiliser or soil improver. This compost will con tain organic matter and organic nitrogen and therefore improve soil fertility in the longer term. However, the content of readily plant available nitrogen is relatively low. Itis the lia- uid digestate that contains the most readily available nutrients, in fact it is almost like di- luted mineral fertiliser. For big biogas plants it is often difficult to use the liquid optimally. The large volumes make transport to areas that need it expensive, and in many coun- tries, including India, there are restrictions on the use of it. The reason for the restrictions is mainly fear of spreading pathogens. Howev- er, in small farm-sized plants, these problems should be easy to overcome. There are no re- strictions on the use of it, because there is ll tle or no risk of spreading any pathogens the farm doesn’t already have. And the transport should also be a small problem as it is usual- ly not necessary to transport it more than a few hundred metres. Even with very simple means of transport that should be possible. Currently, the overflowing liquid digestate represent a problem because it flows into the surrounding environment (Figure 5), where it becomes a pollution problem. In many cas- es it was led directly into ponds or streams, and here it leads to eutrophication and over- growing (Figure 6). Some tanks were placed further away from water and close to trees ‘or banana plantations, and that reduces the problem as much of the nutrient can be tak- en up by the plant, as well as directly provid- ing nutrients to the crops. So that is the first thing to consider where the tank is placed. It should drain into a field with a large need for nutrient, and not be close open water.www.biogas-india‘com The most important is to still to try use the liquid better as fertliser. In India, farmers usu~ ally apply fertiliser multiple times during the growth of the crop. It should therefore be rec: ommended to take out the liquid digestate often and apply to the field as often as pos- sible. In this way farmers can also save mon- ey as liquid digestate can substitute mineral fertilisers. Farmers are sometimes reluctant to substitute mineral fertilisers with organic ones, because not all nutrients are immedi- ately available in organic fertiliser, and the fertiliser effect can therefore be difficult to predict. However, liquid digestate contains a lot of mineral nutrients. Substitution should be based on ammonium concentration, as this is known to be immediately available to the crop. In this way we can be sure that the crop will get at least as much nitrogen as with mineral fertilisers. Our project will provide better data on ammonium concentration and fertiliser value of this digestate. Our current JOIN NOW Indian Biogas Magazine | E data suggest 019-0.26 gN/L. In conclusion, | think these villages have man- aged the biogas production well, but there is still room for improvement when it comes to the management of the digestate. | believe they could improve it a lot at very low cost, or even at negative cost. It is important to al- ways think about the management of diges- tate when biogas plants or project of biogas introduction are planned. Biogas plants pro- duce two valuable resources, one is biogas energy, the other is digestate where the nu- trients have been made more plant available than in the feedstock. Making use of both resources will improve the economy of the plant. In this magazine, | have read a few arti- cles about how big plants can make market~ able products from digestate. However, for small plants it is actually much easier to turn this waste into a valuable resources, and this opportunity should not be wasted. Zz @L\Biogas Fotliying oy | Association MEMBERSHIP @8) Institutional Membership (Colleges, Universities, and Students) Annual Fee (INR) cluding taxes National International i ai 15000 46000 Cesare eae es or call us atEL abel ooo oe . Excellent Gas (methane) impermeobility Optimum UV resistance Excellent resisiance to climatic damage Flame retardancy treatment Several possible finishes: Antistatic (AS}, Oil Resistant (OR), Zero Emission (ZE) 100% recyclable through Texyloop ABOUT US SERGE FERRARI has its presence in oll five continents. Present in more than 30 countries. A SergeFerrari [ECTS APPLICATIONS Covers for: . ° Compositing silos/tanks Water purification and waste water treatment plants Methanization unit Gos Storage The group's indusiriel focility comprises 3 production sites:Le Tour du Pin (France),Eglisau (Switzerland) Emmenbriicke (Switzerland) Eight (8) subsidiaries in the USA, Germany, Japan, China, Brazil, Turkey and India More than 100 distribution partners. Contact Us : DLF South Court, Plot A-1, Office No. 306, Saket District Centre, Sector 6, Saket, New Delhi, Delhi 110017. Ph : 011 4800 9400, e-mail: TN ere eeu unswww.biogas-indiacom F Biogas Magazine | Edition 11| 36 ye in Biogas industry yood healt w to as complex as nur interdependent cilitated by a large variety ‘an be of microorganisms, whose functionin extremely sensitive to its exposed In other words, setting up a biogas plant is relatively easier than to run it efficiently and ‘osystem. effectively over its operating years. Thus, ap- iate O&M is a crucial factor for longer pre life and sustainability of biogas plants. Over the years, a typical biogas deterioration in its performance due to age: lant shows factor. The condition agravate further, proper O&M practices are not followe n its operation. The biogas plants in India display a wide spectrum of operational practices with out a well-planned, or no O&M strategy be: Essence of Operation and Maintenance ing in place leading to reduced plant perfor mance including efficiency, production, and he principal underlying reasons are inadequate planning at inception, no-feasibility studies); miss- Tk of a differentiated but common approach for each piece or category of equipment and inappropriate production plan, leading to in- creased equipment downtime in the long run; lack of returns to plough it back into the sys- tem; and organizational capacity utilization. i.e. improper or ing meti odological appro: absence concerns, ie. to be ycated with nake shift arrangement thus missing futuristic vision. Of the ab tioned concerns, the most vital one relate t inefficient use of financial resources with mi- e-men nuscule fraction of entire budget allocated towards well planned O&M activitie 08M a all w its smooth functioning and long service life. It doesn't only encompass technical but also manageri ctivities of a biogas set-up includes rk and inspections needed to ensui issues, social, financial, and in- stitutional issues. Evidently, many failures a not technical ones, as they may result f oor planning, upfront. The ease of operawww.biogas-indiacom tion and maintenance of a facility is central to its sustainability and must be given caref consideration at the inception stage. Prefera- bly, a higher mix of indigenous components in overall plant set-up is suggested as it be- the necessity to hold as spare parts for onward maintenance. But, this should be well balanced with appropri- ate mix of import component, deemed nec- not jeopardised at any cost. After all, what's the point in saving few bucks upfront with nomical procurement that leads to exorbitant reav ostly inventory essary to ensure safety and reliability is 0. costs later Biogas Installations particularly require strengthened O&M practices, which includes periodic fating procedures, schedule standard op. preven technical and managerial skills of O&M pe el, and ni ive maint enhancement in ties improvement. These actions address un- certainty and risks associated with outages, reactive sary infrastructure /facili maintenance, abrupt start-ups and shut-downs, and ensures long term up-time, performance, and economic viability. Adgitionally, there lies a signifi int scope for mance of the un improving overall per Biogas Magazine | Edition 11| 37 performing biogas plants through strength- ening their O&M practices. Improving per- through interventions aimed at O&M practices is the quick: and least cost alternative, rather than fix- ing the situation with frest Although, such restoring exercise would re quire multiple interventions across various aspects, as per the situation, including peo- technology, F formance strengthening pital investment ess and infrastructure Underneath is highlighted few aspects, which are necessary for efficient O&M management in biogas projects: * Appropriate accountability mechanisms h an organised O&M strategy - Account- ability is essential to the success of any bio: gas project. Having a written O&M plan, man ual, or similar guidance in place that management is aware of and can be held accountable for O&M responsibilities, which in turn ensure the long-term viability of a project. helps ensure + Sturdy Documentation and tracking sys Jing systems, such as maintaining tems -Trai log books, keeping records, trend analysis of process parameters not only ensures that a given project is performing as designed, bwww.biogas-india‘com facilitates continual improvement of O&M ac- tivities, by identifying opportunities for more effective strategies. = Training and capacity building - Local tech- nicians and operators need to be trained for the proper operation of a given biogas set- up, more so for a new installation. Hands-on training is desired to ensure full understand- ing and the implications of the new system. In-house operators or outsources local en- gineering companies, whomsoever will take care of the maintenance of the systems, should be also trained in the type of mainte- nance activities that have to be carried out periodically. Effective O&M training should be provided in an easy-to-understand for- mat, should occur at regular intervals, and is targeted to the relevant employees or volun- teers, who are expected to carry out the cor- responding activities, = Outsourcing of O&M - Sometimes, it makes sense to bring on board experienced O&M providers, who are fully equipped to pro- vide ongoing operations and maintenance services to ensure peak efficiency of biogas plants. Such engagement ensure that the necessary resources are in place. There are several models like BOO, BOOT, BOWT that can be judiciously carved out to meet the re- quirement of a given project. + Establishing vehicles for compliance assur- ance ~ Its recommended to have some type of cross-functional team (including mechan- ical, electrical, instrumentation, process op- eration, fire and safety) in place to monitor and ensure that needful activities are being performed without any discrimination across departments. * Dedicated funding/ budgetary allocation for O&M: A dedicated source of fund or allo- cation of needful budget shall provide means to cover justified costs pertaining to prudent- ly adopted O&M strategy. Often, in the Indian scenario, appropriate O&M practices in biogas set-up has been completely ignored in past, or in some cas- es introduced only after compulsion to do Biogas Magazine | Edition 11| 38 so. This neglect or delay in applying proper O&M has adversely affected the credibility of the investments made, the functioning of the services, the well-being of residents in vicin- ity, and most importantly loss of prospective projects. This turns out to be a vicious cycle. A comprehensive approach needs to be ad- opted, emphasising not only on the design and construction in the beginning, but also appropriate planning towards post-construc- tion activities in form of an appropriate O&M strategy, upfront in the planning stage. Abhijeet Mukherjee Project Head Indian Biogas Associationpowerol GENERATE ECONOMICAL ELECTRICITY FROM BIO GAS Efficient Gas Gensets by Mahindra Powerol INDORE Actual site images of Bio Gas plant. with 125 kVA Gas Genset www.mahindrapoweral.com | Toll Free No.: 1800 419 1999First-class technologies for handling digestate from anaerobic digesters For more than 25,000 biogas plants operating worldwide, SEPCOM’ has on offer first-class technologies for the separation of digestate from anaerobic digesters. Micro-filtration treatment of the same diges- tate provides its maximum enhancement in fertigation as well as for the complex issue of nutrient distribution and treatment. & The mixing and pumping equipment com- re omer Tech ead pletes the biogas sector range. tarot WAM India Pvt. Ltd. 401 United Business Park Phone: +#91/22/ 25808888 Road No. 11, Wagle Industrial Estate info@wamgroup.in iy” WAM* thane - 400604 - India www.wamgroup.in SP voncror-