• Village: BHITBUDRAK

• Taluka: UCHHAL

• District: SURAT

• State: GUJARAT

• Country: INDIA

Jilla /TalukaPanchayatSurat

Bhint BudrakVillage

Presently most of the Biogas plants installed traditionally are either

defunct or working unsatisfactorily and inefficiently.

The studies reveal following reasons for the above status:

1. The Digester loadings such as cattle dung and water are

not thoroughly mixed which results into either non-generation of gas or

lesser quantity gas production.

2. Due to the quality and pressure of the gas produced is being

insufficient, it cannot be transported to far of houses with required

pressure.

The above constraints and defects were rectified and corrected by Gram Vikas Trust.

The mixture of cattle dung and water are stirred in required

proportion uniformly and thoroughly by a mixing mechanism

with proper air circulation.

This results into maximum generation of the gas and utilization of

the plant capacity.

As such, with the help of pressure regulating tank and

mechanism, the gas can be distributed to individual households

with uniform pressure as is done in case of CNG in major cities.

Recently, Gram Vikas Trust, introduced GOBAR BANK concept and has

manufactured, installed and commissioned 2 Gobargas Plants in

Bhintbudrak village in Uchhal Taluka, Dist. Surat.

The plants are of 85 M3 capacity each totaling to 170 M3 of biogas

generation per day.

The gas is further purified and distributed satisfactorily to 121 houses

through pipeline. The design of the plant emphasizes the use of

minimum motive power as compared to plant total power output.

Apart from the above application, the purified biogas with maximum

content of Methane can be used to generate electricity through gas

generators and also can be bottled and used to run the vehicles. The gas

purification systems are developed by Gram Vikas Trust.

(1) Loading Platform

• The Gobar Bank

members bring the dung

everyday to the

community biogas plant

which is weighed and

accounted for in their

pass books.

(2) Slurry Preparation

• The cattle dung taken from dung loading platform area is delivered to feed preparation tank section.

• The fed dung is mixed with water for maintaining ratio of 1:1 for fresh cattle dung and 1:1.25 for stale (hard) cattle dung.

• The mixture is then mechanically mixed to have homogeneous slurry.

(3) Anaerobic Digestion

• Anaerobic digestion tank (biogas digester) creates an anaerobic condition to generate methane gas by methanogenic bacteria.

• The digester employed here is mostly KVIC model with floating dome & water jacket.

• The water jacket helps in curbing the methane leakage and wastage.

(4) Common Collecting Tank

An intermediate gas storage before Pressure regulating tank for

distribution to concerned beneficiaries.

(5) Pressure Regulating Tank

• Gas is compressed by blower and fed to the pressure regulating tank where gas is upgraded due to the passage of pressure

ENVIRONMENTAL NUISANCE – SMOKE FROM WOOD BURNING

EARLIER

An happy villager with her biogas connection and equipment

NOW

The Slurry being transported to composting pits.

The Compost.

The slurry generated by these biogasplants are being converted into Vermi-Compost for Organic Farming.

This Compost is very good fertilizer for theagriculture having rich nutrient values.

Vermi- Compost Unit

Entrepreneurship Models on Biogas for Rural AreasLarge Scale/ Community level Biogas Enterprises forCooking needs- Pipeline supply and Rural Sanitation andbio manure production

I. Size of Biogas Plant- 85 m3/day• No. of families Beneficiaries—50

• Cow dung required—2 Tons/day- Rs 250/Ton

• A complex of 20 community toilets

• Gas utilization—Cooking

• If for Cooking – 2 hrs. morning & 2 hrs. evening(1.5 m3/familyper day)

• Pipeline length—up to 1km. distance

• Pipe quality—HDPE, pressurize system—0.3 kg./cm2(Rs. 2.5lacs cost)

• Gas charge—150/month-family

II. Raw material—Cow dung+ Toilet (community-20 toilets costs 1.5lacs)

III. Slurry Management—Biogas digested slurry

Four options-

1. Liquid slurry

2. Recycle water (upto 40 to 50% only)

3. Dry slurry

4. Semi dry

750 kg semi dry slurry @ Rs 2/- per kg costs Rs 1500/day

•Local consumption of slurry is advised

•Quality of slurry should be maintained

Cost

• Plant Cost – Rs 4,50,000/-

• Pipe Line Cost – Rs 1,50,000

• Appliances 50*400 – Rs 20,000

• Pressurizing System – Rs 2,00,000

• Manpower ( Mechanic – 5000, Helper -3000 ) – 96,000

Income-

• Gas – 150*50 – Rs 7500/ month = Rs 90,000/yr

• Slurry – Rs 1500/day = Rs 5,00,000/yr

• CDM Benefits – Rs 71,000/yr

Cost estimates

• Non- recurring cost—Rs. 8,20,000 ($ 20,500)

• Recurring/ Variable cost—Rs. 2,12,000 ($ 5300)

• Manpower-- Rs.96,000 ($ 2400)

• Depreciation—Rs.80,000 ($ 2000)

• Sum of recurring cost- 3,88,000 ($ 9700)

• Revenue generation- 5,90,000-3,88,000=Rs.2,02,000 (& 5050)

Note- In addition to this Carbon credit benefit to thetune of Rs.71,000/yr. ($ 1775) will also be available.

2. Large Scale/ Community level Biogas Enterprises for Electricity

Generation and supply for domestic consumption, water supply and

community consumption and Rural sanitation

• 15 KVA Power Generating System from - 85 m3/day Biogas Plant

• No. of families Beneficiaries—50

• No. of Animals—200

• Cow dung required—2 Tons/day- Rs 250/Ton

• Gas utilization— Electricity

• Domestic connection—2CFL, 1 Fan= 100 Wt.*50=5000Wt.

• Water supply connection—4000 Wt.

• Community Hall—2 CFL, 2 Fan & 1 TV.= 500 Wt.

Cost

A. Non recurringPlant Cost – Rs 4,50,000Electricity distribution cost – Rs 2,00,000/-Genset Cost – 15 kW – Rs 1,00,000Genset Room Cost – Rs 1,00,000Sum - Rs 8,50,000

B. Recurring Manpower ( mechanic – 5000, helper – 3000) – Rs 90,000

Raw Material – 1,62,000Miscellaneous – 50,000Depreciation – 85,000Sum = 3,87,000

Cost estimates

A. Non recurring

Sum =8,50,000 ($ 21,250)

B. Recurring

Sum=3,87,000 ($ 9675)

Income—

Electricity supply 130 unit @ Rs.6 per unit *365 = Rs.2,84,700/yr. ($7117)

Slurry—Rs.1500/day= Rs.5,00,000/yr. ($ 12,500)

CDM benefits – Rs.71,000/yr. ($ 1775)

Sum= Rs.7,84,000 ($ 19,600)

Surplus—

Rs. 7,84,000-3,87,000= Rs. 3,97,000 ($ 9925)

Cylindering of methane available from biogas plant for

tractors and rural vehicles and production of bio manure

Feasibility analysis for a community biogas plant of 300 M3 per day capacity with biogas enrichment and bottling plant has been shown below.

Dung requirement -For 300 cum. Biogas Plant = 6000 Kgs.Assuming cost of Dung = 0.20 Rs/kg.Cost of Dung for Biogas plant = 1200 Rs. per day.CAPITAL COST –

1. Bio Gas Plant (Digester) Provided by Buyer (@Rs. 3000/- per cubic meter capacity, for 300 cubic meter capacity Rs. 900000/-)2. Cost of Scrubbing unit Rs. 6,00,000.003. Cost of Compressor Rs. 6,00,000.004. C.N.G. cylinders Rs. 2,00,000.005. Storage tank Rs. 1,00,000.006. Installation Exp. Rs. 2,00,000.00Total Rs. 17,00,000.00

OPERATION COST -A. Fixed operational cost-1. Interest on capital @ 10% per annum= 0.1x 14,00,000 = Rs. 1,40,000 per annum2. Depreciation @ 5% per annum = 0.05x 42,50,000= Rs.70,000 per annum.

Total cost = 2,10,000 per annum

B. Annual Running (Operational) Cost: -1. Dung cost 1200x350 = Rs. 4,20,000 P.A.2. Labors Cost (1 skilled and 2 unskilled labors) 300x 350 = Rs. 1,05,000 P.A.3. Electricity cost (10 kWh x12 hr) 360x350 @3/- unit = Rs. 1,26,000 P.A.4. Repair and Maintenance@ 2% capital cost on 14,00000 = Rs. 28,000 P.A.

Total cost = 6,79,000 per annum

Sum of Fixed Operation cost and annual running cost: =6,79,000+2,10,000 = 8,89,000.00

Cylindering of methane available from biogas plant for

tractors and rural vehicles and production of bio manure

• Biogas plant of 300 M3 per day capacity with enrichment and bottling

• CAPITAL COST – Rs. 28,00,000.00 ($ 70,000)

• OPERATION COST –

• A. Fixed operational cost-3,00,000 per annum ($ 7500)

• B. Annual Running (Operational) Cost: -12,00,000 per annum

• Total cost of Operation = Rs. 15,00,000 /- ($ 37,500)

• Income:-

• income generate by selling CBG and slurry = Rs. 22,00,000/- ($ 55,000)

• Profit = Rs. 7,00,000/- ($ 17,500)

• Payback Period = 4 years