J.Joseph

Scientist

Indian Institute of Chemical Technology

Hyderabad

HIGH RATE MODULAR BIO-DIGESTER

CURRENT PRACTISES FOR GARBAGE DISPOSAL

• LAND FILLS

• INCINERATION

• COMPOSTING

• ANAEROBIC DIGESTION

PROCESS EFFICIENCY FOR SOLID WASTE

MANAGEMENT

EXPRESSED AS PERCENTAGE SOLID REDUCTION /

DESTRUCTION

• LAND FILLING 100%

• INCINERATION 95%

• ANAEROBIC DIGESTION 95 % (high rate)

50% (conventional)

• COMPOSTING 50%

CLASSIFICATION & END PRODUCTS

LAND

FILL

INCINERATION ANAEROBIC

DIGESTION

COMPOSTING

• RDF

• PYROLYSIS

• PLASMA

• MICROBIAL

• VERMI -

COMPOST

• CONVENTIONAL

• HIGH RATE

• STEAM / POWER

• FUEL OIL / POWER

• BIOGAS

• BIOMANURE

EMISSION PROBLEMS

ENVIRONMENT FRIENDLY /

SUITABLE FOR BIODEGRADABLES

BIOMANURE

Treatment of garbage at source of generation is

the best option to reduce pollution load of a city

As the first step garbage must be segregated at

its source of generation

SOLID WASTE MANAGEMENT

SEGREGATION

PLASTIC (6%)

METAL (3 %)

GLASS (6%)

RECYCLE

ORGANIC

FRACTION

65 + 8 = 73%

DIGESTION

INERT

FRACTION

12%

INCINERATE

OR

LANDFILL

HIGH RATE MODULAR BIO-DIGESTER

• Capacity – 50 kg/day

• Biogas used as cooking fuel

• Working for ONE year without complaint

• No technical expertise required for operation

• Subjected to actual field conditions

SEGREGATION

Collection Sorting

SEGREGATION

Cartons Tetra packs & Waste paper

SEGREGATION

Plastics

PET

Carry bags

Metals

Aluminium cans

Foils, Caps

Crowning cork etc.

Glass

SEGREGATION

Recyclables packed

for sale Organic fraction need

transportation cost

INSTALLATION

SUMMARY OF CASE STUDY-1

Individual Family

• Pay Rs. 50/month to garbage collector

• Invested Rs. 3.5k for DIGESTER installation

Garbage Collector

• Collects total 90-100 kg/day from 85 families

• Gets Rs.5k / month for collection

• Gets Rs.5k / month for sale of recyclables (40 kg/day)

Watchman

• Save 1 litre kerosine /day

• Operates digester religiously

Digester

• Generates energy equivalent to 1 kg LPG

• Capture nearly 580 kg Methane annually

CONCLUSIONS / CASE STUDY-1

Total waste generation is 90 kg/day (Organic fraction 50kg)

MODULAR DIGESTER of capacity 50 kg/day installed

Rs. 3 Lakhs invested for 85 families (Rs.3500/family)

Generates 3.5 cu.m of biogas daily ( Equivalent to 1 kg LPG)

Biogas used by two families for cooking (Watch men)

Gunrock Enclave do not generate garbage for GHMC

PRESS RELEASE

SEGREGATION

Collection Sorting

HIGH RATE MODULAR BIO-DIGESTER - KOCHI

Easy to operate / No odor / clean & tidy

Capacity – 50 kg/day / 95% efficiency in waste destruction

Environmentally safe & No operational problems

Minimum space required ( 3 m x 1.2 m)

Working for 8 months without complaint

UNDERLYING PROCESS

ANAEROBIC DIGESTION

OR

BIOMETHANATION

BIOMETHANATION

CONVENTIONAL

DIGESTERS

HIGH RATE

DIGESTERS

GOBER GAS

PLANT

KVIC / CHINESE

DEENABANDHU

SHORT RETENTION

TIME

HIGH LOADING

RATE

HIGH TREATMENT

EFFICIENCY

MULTITUDE OF

PROBLEMSRELATIVELY NEW

IN INDIA

CONVENTIONAL DIGESTERS HIGH RATE DIGESTERS

Requires 50 to 60 days to

complete the digestion

Digestion completes within 15 days

Treatment efficiency less

than 50%

Efficiency in terms of solids digestion is 95%

Choking, Scum formation &

many operational problems

No operational problems

Suitable ONLY for small

installations

Suitable for any size

High water consumption and

generate secondary effluents

No water consumption and no secondary effluents

Entire operations manual NO MANUAL OPERATIONS

Loading rate less than 1 kg

per m3 of digester volume

Loading rate up to 10 kg per m3 of digester volume

CONVENTIONAL DIGESTER - INDIA

Multitude of operational problems & digesters are abandoned after

a few years of use

No engineering principles applied in the design to increase

process efficiency

Popularly known as “GOBERGAS” plant (Floating dome KVIC

design)

First invented by British missionaries and installed at leper’s

colony in Maharastra in 1895

IMPORTANCE OF MIXING

Inorganic substances and sludge accumulates in the bottom leads to choking

MANY DIGESTERS ARE ABANDONED AFTER A FEW YEARS OF USE

Slurry separates into three phases

Bacteria form clusters

CONVENTIONAL MODUALR DIGESTERS - INDIA

Size : 1-2 cu.m

Capacity : 1- 2 kg/day

Efficiency < 50%

Only for single house

Cost INR 25,000

Feed require grinding

Generates slurry

ALL HAVE SAME

DESIGN

No driving force for feed

No driving force for outlet

Chokes feed & Outlet

Need periodical flushing

Gas production too less

Feed restrictions

Odor / Insects problems

Failed field test

Rejected in marketSINTEX

BIOTECH

ARTI SYNOD

FEEDING SOLID WASTE …..THROUGH PIPE ???

??

OPERATIONAL DIFFICULTY

Feed require

grinding

Generates slurry

CONVENTIONAL MODUALR DIGESTERS - INDIA

Most of the digesters are abandoned by its users

BIO-GAS GENERATION

1 kg dry matter generate 0.250 kg of BIOGAS

Burner will work less than 10 minutes in a day

Calorific value of BIOGAS is ¼ th of LPG

2 kg garbage / day

400 gm dry matter

200 gm total carbon

1 cu.m BIOGAS

0.86 kg BIOGAS

482 gm total carbon

0.52 kg CH4 + 0.34 kg CO2

APPLICATION

Decentralized system for disposal of garbage at its

source to reduce pollution load of a city

HIGHLIGHTS

• Advanced engineering principles in the design

• Aided with electronic process control system

• Process efficiency in world class standards

• Totally free from operational problems

• Minimum water & power consumption

• Perfectly user friendly & Environment friendly

ALLOWED FEED STOCK

Fish & Meat waste (with bones)

Slaughter house waste

Fruits & Vegetable waste

Food waste (with fats & oils)

Dry & Green Leaves

Paper Plates & Cups

Packaging boxes (paper)

Any Excrements

Plastics, Metal & Glass

Thermocol (polystyrene)

Coconut husk & Shell

Wood & Gunny bags

Cloths & Sanitary napkin

Rubber & Leather

products

Used broom sticks

Sand and Stones

RESTRICTED ITEMS

BULK PRODUCERS OF GARBAGE

1. Fruits, Vegetable, Fish, Meat & Poultry

marketing Centers

2. Food processing industries

3. Slaughter Houses / Tanneries

4. Industrial & Institutional Canteens

5. Apartments & Residential Colonies

6. Restaurants, Hotels & Resorts

7. Pilgrim Centers

8. Agricultural Farms

9. Municipal Corporations (for organic fraction)

TECHNOLOGY

Multistage & Two phase digestion

Particle size control without grinder

Intense mixing without mechanical stirrer (self mixing)

Delinking HRT & SRT without filters

Unique hydrodynamics without pump

Biogas pr. as driving force for entire process

High Rate Biomethanation

DESIGN FEATURES TO INCREASE

PROCESS EFFICIENCY

TECHNOLOGY

• Capacity 25 kg/day, 50 kg/day, 75 kg/day, 100 kg/day

(In-situ construction required for scale-up to larger capacity)

• Size 2, 4, 6, 8 (all cu.m) & equivalent gas production/day

• Space requirement 2, 3, 4 & 5 ( all sq.m )

• Material of construction 5 mm TATA steel / 1 mm epoxy coat

• 95 % Solids reduction / Fully automatic / No manual operations

• Waste can be dropped directly into wide mouth feed tank

Any biodegradable material can be added without grinding

• No water consumption & negligible power consumption

SALIENT FEATURES (Modular design)

Existing modular digester High rate modular digester

Same as conventional gobergas plant Based on high rate biomethanation

Capacity – 2 kg/d maximum Capacity – 50 kg/day & above

Treatment efficiency < 50% 95% solids reduction

Garbage need grinding Garbage directly dropped into digester

Single stage digestion Multistage digestion

Insignificant Biogas production 2 to 3 cum/d (5000 kcals and above)

Choking , plugging & scum formation Free from operational problems

Entire operations manual Fully automatic

Water consumption 10 lit/kg 2 lit /kg water consumption

Generates large quantity thick slurry Thin liquid ( safe to dispose to drain)

Not sealed (odor / insects / rodents) Fully sealed & free from odor /insects

Failed field testing Field tested successfully

Not suitable for scale-up Can be scaled up

HIGH RATE DIGESTERS IN EUROPE FOR MSW

DRANCO

VALORGA

DRANCO

HIGH RATE DIGESTER INSTALLATIONS IN INDIA

FOR CATTLE DUNG

LUDHIANA

FOR VEGETABLE MARKET

CHENNAI

BIMA TECHNOLOGY FROM AUSTRIA

Installed at agriculture university Hyderabad for

poultry litter treatment

Working continuously for FIVE years

Project sponsored by DBT

HIGH RATE BIOMETHANATION PLANT – IICT

Popularly known as

FIXED DOME /

DEENABHANDU model

Relatively better than

floating dome model

Two stage digestion /

slight mixing takes place

during process

Battery of digesters are

required for scale-up

CONVENTIONAL DIGESTER - CHINA

Extensive field testing done using prototypes

Research started in 2008 and funded by MNRE , DST , DBT & CSIR

PROTOTYPES AND PRODUCT DEVELOPMENT

THANK YOUFor LIVE DEMO & More details, Contact:

Johny Joseph

Senior Principal Scientist

Bio-engg & Environmental Centre

Indian Institute of Chemical Technology

Hyderabad

Mobile: 09347569790

Email: johnyiict@yahoo.co.in