BiogasPlantConstructionManual

FixeddomeDeenbandhumodeldigester:2to6cubicmeterbiogasgenerationperday

 SKGSangha,EgyptJanuary2013



Forward

TheBiomassforSustainableRuralDevelopmentprojectisajointprogrammebetweenthe
EgyptianEnvironmentalAffairsAgency(EEAA),MinistryofStateforEnvironmentalAffairs,
GlobalEnvironmentalFacility(GEF)andtheUnitedNationsDevelopmentProgramme(UNDP)
Theprojectistofacilitateandacceleratethemarketdevelopmentfornewbioenergy
technologiesinEgypttoremovecertaintechnologicalandcapacitybarriersindevelopmentof
biogasprojectforEgypt.SKGSangha(SKGS)hasbeenselectedtoinstall100domesticbiogas
plantsintwogovernorates,FayoumandAssiyutinthehouseholdsselectedbytheBiomass
Project.SKGSwillinstall,monitorandmaintainunitsforaperiodoftenmonths.Duringthe
courseofplantsinstallationtrainlocalmasons,selectedbytheBiomassProjecton
construction,trainsupervisorystaff,againselectedbytheBiomassProjectondesign
parameters,monitoringandmaintenance.Thedesignoftheplantwillbeafixeddomeonthe
linesofDeenbandhumodelspecificallydesignedbySKGSsuitableforEgyptianconditions.As
themeantemperatureoftheEgyptisabout21degreesCelsiustheplanthasbeendesigned
with50dayshydraulicretentiontime(HRT).TheprojectwillbeimplementedbySKGSand
monitoredbytheBiomassProject.Aprimarylistofprobablebeneficiarieswillbemadebythe
localbodyofthegovernorateandwillbescrutinizedbythebiomassprojectandwillbesentto
SKGSforfinalselectionofbeneficiaries.Theselectedbeneficiarieswillbeprovidedwitha
suitablesizebiogasplantbasedonthecattlepopulationandnumberofmembersinthe
household.

KiranKumarK
Secretary
SKGSangha
skgsegypt@gmail.com
www.skgsangha.org

TableofContents

1.Introduction.................................................................................................................. 5
2.SelectionofConstructionMaterials.............................................................................. 6
2.1 Cement. 6
2.2 Sand 6
2.3 StoneAggregates .. 7

2.4 Apipetoconnectthedigesterandtheinlettank . 8

2.5 Bracketsweldedgalvanizedironpipe .. 8

2.6 Valvetocontrolthegasflow .. 8
2.7 Bricks .. 8
2.8 HighDensityPolyEthylenePipe(HDPE)pipe.. 9
2.9 RubberHose . 9
2.10 BrassNipple .. 9
2.11 BiogasBurner... 9
2.12 Water. 9
3.DeterminingPlantSize. 10
4.ConstructionSiteSelection.......................................................................................... 10
5.Planlayoutforexcavationofpit................................................................................. 11
6.Excavationofpitforplantinstallation........................................................................ 11
7.Castingthebedconcrete 13
8.Constructionofcentrepillar. 13
9.Guidepole. 14
10.Fixingfirstlayerofbricks. 14
11.Startingconstructionofthedigester.. 15
12.Placingofinletpipe. 15
13.Plasteringtheoutsideofthepartlyconstructeddigester 16
14.Layingofbricklayerastopofthedigesterslurryflowdoor.. 16
15.Pouringofcementwatertosealanypoursintheconstructeddigester.. 17
16.Excavationofearthforconstructionofdisplacementchamber.. 17
17.Layingoffoundationforthedisplacementchamber 18
3

18.FixingofGInippleatthezenithofthedigester.. 18
19.PouringofCementwaterontopofthedigesterandplastering. 19
20.RemovalofARAVANAfixedinsidethedigester. 19
21.Plasteringofdigesterinsideportion.. 19
22.Applicationofcementpasteontheinsideportionofthedigester.. 19
23.Applicationofcementcoat 19
24.Constructionofdisplacementtank. 20
25.Castingofconcreteslabs/platesmeantforcoveringthedisplacementtank. 20
26.Constructionofinlettank.. 20
27.Curingofcivilworkswithwater 20
28.Compactingofthecivilworkswithsoil 21
29.Diggingofpittocollectspentslurry.. 21
30.Initialfeedingofplant.. 21
31.Requiredphysiochemicalconditionsforoptimumproductionofbiogas. 21
32.Constructionmeasurementsofthebiogasplant.. 22
33.Designofthebiogasplant. 23
34.Materialrequirementforthebiogasplant 24
35.Deviationsfromthedesign.. 25

Attachment:OperationandMaintenanceofBiogasPlant

Tables
Table:31.PhsioChemicalconditionsforoptimumproductionofbiogas.. 20
Table:32.ConstructionMeasurementsofbiogasplant.. 21
Table:34.Requiredmaterialforbiogasplantinstallation.. 23

Figures
Figure:5.1PitLayouts......... 10
Figure:6.1Excavationofapitforplantinstallationusingmachine. 11
Figure:6.2Atrimmedpitreadyforbedconcrete
Figure:7.1Maintainlevelofbedconcretealltheroundusingplastictubefilled
withwater.. 12
Figure:8.1Constructionofcentrepillar.. 12
Figure:9.1Guidepoll. 13
Figure:9.2Guidepoll. 13
Figure:10.1Placingfirstlayerofbricks............................................................. 13
Figure:10.2Spacingfirstlayerofbricks 13
Figure:11.1Startingconstructionofthedigester. 14
Figure:12.1Placingofinletpipe. 14
Figure:12.2Placingofinletpipe. 14
Figure:12.4Fixingofinletpipe 15
Figure:12.4Fixingofinletpipelowerthantheslurryflowgateheight. 15
Figure:14.1Supportplankforboxtankceilinglayer.. 16
4

Figure:16.1Sandfillingtoraisetheareatorequiredheight.... 17
Figure:17.1Firstlayerofbricks 17
Figure:17.2Brickshavetobefixedatrequiredmeasurements.. 17
Figure:33.1:Planandsectionaldiagramofthebiogasplant. 22

1.Introduction

Biogasplantisananaerobiccivilconstruction.Alltypesofsoftwastescanbefedintothisplant.
Differenttypesofbacteriawilldecomposethisfeedmaterialandgeneratebiogas.Biogasisa
combinationoffewgaseslikeMethane,carbondioxideandHydrogensulfide.Predominantlybiogas
containsabout65%methaneandabout35%carbondioxidewithtracesofothergases.Thetreated
wastewhichcomesoutofbiogasplantisrichwithusefulbacteriaandalsomajorandmicronutrients.
Biogasplantsarepreferredthroughouttheworldasanalternativesourceofenergysupplyandto
createwellfermentedslurrytobeusedasliquid/solidmanureintheagriculturalsoilsandalsoto
createsanitation.Sofarmillionsofbiogasplantshavebeeninstalledmainlytoprovidesustainable
energytoruralhouseholdsandoverallimprovementofhumanhealthandtheenvironment.Chinaand
Indiaareleadersintheline.Thebiogasplantsarepreferredasanalternativetoburningdriedanimal
dungcakes,fuelwoodandinsomecasesLPGfordailycookingneeds.Feedmaterialforthesebiogas
plantsarehumanwaste,meatandvegetablemarketwastes,foodprocessingfactorieswasteand
almostalltypesofanimaldung.

Manyfactorslikequantityoffeedstockavailableondailybasis,typeofwaste,wateravailability,space
availability,typeofsoilandgroundwatertableleveletc.,havetobestudiedbeforeinstallationofa
biogasplant.

Biogasplantespeciallythefixeddomemodelbiogasplantinstallationrequireswelltrainedand
experiencedmasonsapartfromqualitymaterial.Strictfollowingofdesignmeasurementsassuresa
longlastingbiogasplant.Successorfailureofbiogasplantsmainlydependsuponhowandbywhomit
hasbeeninstalledandwhattypeofqualitymaterialhasbeenusedapartfrommaintenancefactors.

Therearemanyadvantagesofafixedmodelbiogasplant.Itisunderground,savesspaceand
somewhatimmunetoclimaticconditions.Therearenomovingpartsandhencelesserwareandtare.
Almostnomaintenanceanditcostlessthanotherdesigns.

ThemanualhasbeenpreparedbySKGSangha(www.skgsangha.org)withitsvastexperiencein
constructionoffixedmodelbiogasplants(morethan105,000)fortheuseofmanagerialpersonnel
trainedonsiteandinprojectforfurtherpropagationofbiogasplantsinEgypt.

Thismanualhasbeendesignedinsuchwaythatitcanbeusedbyalayman,providedanexperienced
masonisavailabletoconstructafixedmodelbiogasplant.Stepbystepdescriptionalongwithfigures
andphotosprovidesaclearunderstandingandmethodsforinstallationoftheunit.










2.Selectionofconstructionmaterials:

MaterialAvailability:Almostallofthematerialsareavailablelocallybutfindingthemisaherculean
task.Thefollowingmaterialisrequiredforconstructionanduseoffixeddomemodelbiogasplant:

1. Cement
2. Sand
3. Stoneaggregates

4. Apipetoconnectthedigesterandtheinlettank

5. Bracketsweldedgalvanizedironpipe

6. Valvetocontrolthegasflow
7. Bricks
8. Highdensitypolyethylene(HDPE)pipe
9. Rubberhose
10. Brassnipple
11. Biogasburner
12. Water

2.1 Cement:Thisisavailablelocallyandcanbeboughtatanyquantitybutthemixofcement
whenitwasmadeisnotknown.Cementgraduallylosesitsbindingpowerduringthe

 prolongedstorage.Alwaysitisbettertousethefreshcementforbetterresults.A
wholesalerwhogetsfreshloadsfromfactoryeveryfewdaysmaybeidentifiedandcement
canbefromthisestablishment.LocallyavailableordinaryPortland42.5gradecementis
selectedforconstructionofplants.

2.2 Sand:SandisavailableinEgyptbutthesandparticlesizeistoosmalltouseitincivilworks.
Soasupplierwhocansupplybiggerparticlesizesandistobesoughtouttoprocuresand.
Thissandcontainslotsofpebblesandstonessizestartingfrom10mmto500mm.Thishas
tobesievedbeforeuse.Sandshouldbefreeofearthandclaytobeusedforbiogasplant
construction.

2.3 Stoneaggregates: Riverbedpebblesarepredominantlyusedinconcreteinthese

governoratesofEgypt.Thepebblesurfaceissmoothandcannotholdthecementinthe
concretemix.Highersurfaceareasareneededforconcreting.Eventhoughifwebreakthe
pebblestogetmoresurfaceareaagainthesmoothnessofthesurfaceposesproblemof
cementbinding.Astrong,hard,roughsurfacedstoneaggregatesareneededforconcreting.
Thiskindofmaterialisnotavailableinthevicinityofthemanyareas.Searchforgranite
stoneaggregatesupplierhastobelaunched.Thismaterialhastobebroughtfroma
farawayplaceandtobeboughtinhigherquantities,37M3atatime.Eventhoughtheprice
ofthismaterialishigh,almosttriplethecostofpebblesthismaterialistobeused.The
granitestonepiecesof2025mmsizearepreferred.

2.4 Pipetoconnectdigesterandinlettank: Manytypesofpipescanbeusedforthis

purposestartingfromplastictostoneware.15centimeterdiameterhigherthicknessPoly
VinylChloride(PVC)pipemaybeusedforthepurposeofconnectingtheinlettothe
digester.Thesepipesarelocallyavailablebuthavetobeorderedinadvancetogethigher
thicknesspipes.46mmthickPVCpipeispreferred.

2.5 Bracketsweldedgalvanizedironpipe: Thispipe,diametertopsidemalethreaded

isneededtofixitonzenithofthesemisphericaldigester.Tomakeitunmovabletwoiron
wirepieceswereweldedonbothsidesofthepipeofabout30centimeterslongataheight
frombottom3centimeters.Theseweldedironpieceswillholdtheconstructionmaterial
andmakesthepipenotmovable.Pipeisavailableinthelocalmarketandgetitweldedata
localweldingshop.Bclass,pipemarkedwithbluecolourpaintispreferred.

2.6 Valvetocontrolthegasflow: Thisdiametervalveisfittedtothebracketswelded

galvanizedpipefixedontopofthedigester.Thisvalvemaybemadewithanymaterial,iron,
gunmetal,plastic,PVC,brassetc.Manyofthemetalvalvesareleakingafterfewtimesof
operation.PVCvalvesarehavingnylonoringsandarelastingforlongtimewithoutgas
leakage.Thesevalvesarefragileandmaybreakbutleakproof.ThesePVCvalvesmaybe
usedintheproject.Thegasoutletpipeisthemostpronetodamagesasitisatthezenith
ofthedigester.Intheruralscenechildren,animalsandinsomecaseswindalsomovesthe
overheadpipelineandmaybreakthegatevalve.Ifametalvalveisusedthenthe
movementofthepipewillbetransferredtothebracketsweldedgalvanizedpipeandmay
causelooseningofthefixing.Ifithappensitisdifficulttofixthispipeasithastobefixed
frominsidethedigester.PVCvalvesarepreferredtoavoidthiseventuality.Avalvecanbe
replacedatanytimewithease.

2.7 Bricks: Anytypeofbricksorareinforcedconcretecanbeusedforfloatinggas

holdermodelbiogasplants.Forfixedmodelbiogasplantasitisasphericalstructurealarge
surfacedcementmortarholdingbricksareneeded.Wellburntmudbrickswillholdthe
cementwell.ManypartsofEgypthallomudbricksareinuse.Thesebrickswillhaveholes
throughthebrickandgoodforverticalstructuresandlightweighttoo.Astheyhavelesser
surfaceareaandchanceofremainedhallospaces,thesphericalstructureofthebiogas
plantbecomesweakandmaybreakwithslighttensilepressure.Thatiswhysolidbricksare
preferredforfixedmodelbiogasplantsconstruction.Solidbricksarenotmadeinmany
places.Athoroughsearchhastobemadeintheprojectandadjoiningareastofindabrick
factorythatmakessolidmudbricks.Thebrickhastobewellburntandwellcompactedto
beusedforthebiogasplant.Thefactoryownersmaybeexplainedformakinghighquality
solidmudbricks.Thesizesofthesebricksare22centimeterlong,10centimeterwideand7
centimeterthick.

2.8 HighDensityPolyEthylene(HDPE)Pipe:Apipeisneededtoconnectthedigesterandthe
biogasburner.Thispipewillbelaidoverhead.Soitshouldhavecertaincharacterstickslike,
shouldnotbend,lastlong,nottocompresswithpressure,shouldnotbreakandetc.,.HDPE
pipeishavingallthesecharactersticks.EventhoughthereareHDPEproductsinthe
Egyptianmarkettheparticularpipeisnotavailable.Manyfactorieswerecontactedand
exceptonerefusedtomakethepipe.OneHDPEproductmanufacturerprincipallyagreedto
makethepipewithspecificthicknessbutaskedtogivehigherquantityorderastheyhave
tomakethenecessarymoldstomanufacturethepipe.Asthereisnootheralternativea

 5000meterorderwasplacedandtakenthedelivery.Thispipeishavingabout3millimeter
thicknessand20millimeterdiameter.

2.9 Rubberhose: ThisisneededtoconnectthebiogasburnerandtheHDPEpipecoming

fromthedigester.Thisshouldhaveaspecificinnerdiameterassuitabletoconnectthe
biogasburnermetalpipe.Thisspecificsizeisnotavailableinthelocalmarketanditcanbe
broughtalongwiththebiogasburner.

2.10 Brassnipple: Apipenippleisneededtoconnectthegalvanized

ironpipeconnectedtotheHDPEpipeandtherubberhose.Thiswillhaveafemalethread
ononesideandmalegrovesontheotherside.Thismalegrovessizeisequaltothesizeof
thebiogasburnermetalpipe.Asthisnippleishavingspecificsizeoftheburnerbettertoget
italongwiththebiogasburner.

2.11 Biogasburner: LiquefiedPetroleumGas(LPG)burnersarenotsuitablefor

biogasburning.Biogasrequiresaspecificburnerasitishavingadifferentcompositionof
gases,differentpressureanddifferentcalorificvalues.Thesebiogasburnersarenot
availableinEgyptianmarket.Whenthereisaprojecttoinstallhighernumberofbiogas
unitsthenalocalLPGstovemanufacturercanbetrainedonmakingbiogasburners.The
stovebodyandthegasmixingtubesaresameastheLPGforbiogasburner.Burnertops,
controlvalvesandgasjetsarethethreepartsthathavetobemadeseparatelyforthe
biogas.Eitherthesepartscanbeimportedormadelocallytomakethebiogasstoves.For
thepresentprojectbiogasburnersareimportedfromIndia.

2.12 Water:Waterisavailableatmanyplacesforconstruction.Whereeveritisavailablethe
irrigationcanalwaterorthegroundwateraccumulatinginthedigesterbottomisusedfor
constructionandcuring.Itisthepipedwaterthatisusedinothercases.Beneficiariesused
thepipedwaterforinitialfeedingofdungandareusingthesamefordailyfeedingofplant.
Thepipedwaterisfilteredandchlorinated.Thechlorineinthewaterisantibacterial.
Becauseofthischlorinecontenttheplantsaretakingunusuallylongtimetogenerate
maturedbiogasinitially.Facultativebacteriawhichareaerobic/anaerobicmultiplyfaster
thananaerobicbacteriacansurvivethischlorinecontentinthewateranddowork.
Whereasanaerobicbacteriawhichareslowgrowingandsensitive,growslowanddonot
workinunfavorableconditions.Thisisthereasonforprolongeddaysofsmellygas
generation.Theplantswhicharefedwithmorewaterandlessdungwilltakeverylongtime
togeneratecompletefermentedgas.Manyofthetimesbeneficiariesweretoldtorecycle
thespentwaterfordailyfeedingand/useanimalurinefordailyfeedmaterial,dung
mixing.Itisbettertousecanalwaterwhereeveritisavailablefordailyfeeding.Otherwise

 tapwatercanbestoredinwidemouthedopencontainersatleastfortwodayswith
occasionalmixingfordailyfeeding.Aerationofwaterwilllessenthechlorineeffectbecause
ofevaporation.Allthebeneficiariesweretoldaboutthisproblemandhavebeenadvisedto
useonlythecanalwater.Beneficiarieshavetobeeducatedonthisissuefurtherduringthe
monitoringvisitsandtrainingprogrammes.

3.DeterminingPlantSize

Thismanualismeantforhouseholdfixedmodel26cubicmeterbiogasgenerationcapacity50
daysHRTbiogasplantsinstallationinruralhouseholdsofEgypt.Othersizesofbiogasplantswith
differentparameterslike50%gasstorage,lesserHRTandetc.,arealsoavailable.Aqualifiedperson
whoishavingexperienceinthislinecandesignothertypesofplants.Asallthetraineesunderthis
projectareamateursitisbettertosticktotheconstructionmanualguidelines.Evenifafamilyof5
membersownsmorethan8animalsa2cubicmeterbiogasgenerationunitwillbeinstalled.Ifafamily
of10arehavingonly4animalsthenalsoa2cubicmeterbiogasgenerationunitwillbeinstalled.
Numberoffamilymembers,numberofanimalstheyownandbothinclusivewilldecidetheplantsize.
10kgofdungperanimalperdaymaybetakenasathumbruletoquantifythedungavailability.0.4M3
perpersonperdaymaybetakentoquantifythebiogasdemand.

4.Constructionsiteselection

Constructionsiteselectionisanimportantaspectofbiogasplantinstallation.Iftheplantis
awayfromsourceoffeedmaterialitisdifficulttofeedtheplantondailybasis.Ifitisfartherawayfrom
thegasutilizationpointthecostofpipelinewillincreaseandpipelinelyingwithoutsaggingbecomes
difficult.Andthewateravailabilityatthesiteisalsoanimportantfactortobeconsidered.Theplant
shouldnotbenearertoawatersourceandbigtrees.Consideringallthesefactorsacompromising
placehastobedecidedfortheinstallationofthebiogasplant.Fixedmodelbiogasplantsgenerate
highergaspressurehenceitisnotdifficulttocarrythegastotheutilizationpoint.Moreoverthecost
ofthepipelineisaonetimecost.Itisalwaysbettertoselectthesitenearertothesourceoffeed
material,sideoftheanimalconfinement.Insomecasesplantsinstalledinsidethehousesandunder
theroofarealsofunctioningwell.Thebeneficiaryconvenienceandeaseofdailyfeedingarethe
guidingrulesforsiteselection.

5.Planlayoutforexcavationofpit

Oncethesiteisselectedfortheplantinstallationalayouthastobemadefortheexcavationof
thepit.Wheretoconstructtheinlettankandwhereandhowtoplacethedisplacementchamberare
theimportantfactorstobetakencareatthisstage.Archtankandfeeding/inlettankshavetobe
constructeddiagonallyoppositetoeachother.Displacementchamber/outlettankhastobe
constructedwheretransportationofspentslurrybecomeseasy.Accordinglythepithastobe
excavated.

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Figure:5.1PitLayouts

Awoodenormetalpeghastobeinsertedintothesoilatthecentreandaropehavingequal
outsidelengthofthedigesterbasementconcretehastobetiedtothepegtodrawacirclefor
excavation.Arectangularportionfordisplacementchamberalsohastobemarkedonthegroundjust
touchingthedigestercircleusingrockdustoranyotherpowdertobevisibletothemachineoperator
orthemenwhowilldigthepit.


6.Excavationofpitforpantconstruction

Ifavailableanexcavationmachinewillbeengagedtodigoutthepit.Itsavesthelabourcost
andmoreovernumberofpitscanbemadeinaday.Fixeddomebiogasplantisasphericalstructure
sothepitshouldbeinacylindricalshape.Inmostofthecasesitisdifficultfortheexcavatingmachines
tomakeacylindricalpithencearectangularpitmaybemade.Manuallabourisrequiredtotrimthe
machinemadepitandtoexcavatethebottomportionofthepit.Ifthemanuallabourisengagedtodig
thepitthenacylindricalpitispreferredtolessentheburdenofunnecessarysoilexcavationand
shifting.Allthesoilexcavatedshouldbekeptaroundthepitforlaterbackfillingaroundandontopof
theinstalledunit.

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Figure:6.1Excavationofapitforplantinstallationusingmachine

Thebottomcurvedportionhastobeexcavatedbymanuallabourtotheexactsize.
Thedepthandradiusofbottomcurvedportionvariesaccordingtothesizeoftheplant.Moreoverthe
displacementchamberportionalsohavetobeexcavatedaccordingtothedesignparameters.After
completionthepitlookslikeasshowninthebelowphoto:

Figure:6.2Atrimmedpitreadyforbedconcrete

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7.Castingthebedconcrete

Bedconcreteislaidwith1:2:4or1:1:3mixofcement,sandandstoneaggregatesrespectively.The
mixofmaterialdependsupontheoilcondition.Ifthesoilishavingmoreorganicfractionthentherich
mixof1:1:3maybeusedandinothercasesmildmixof1:2:4maybeused.Inblackcottonsoilsthe
concretehastobereenforcedwithironwireof6mmdiameter.Theconcretehastobewell
compactedtoattainmorestrength.Concretehastobelaidaccordingtothedesignparameter.Care
hastobetakentomaintainthelevelonallroundusingthewaterfilledplastictube.

Figure:7.1maintainthelevelofbedconcretealltheroundusingplastictubefilledwithwater

8.Constructionofcentrepillar

Thecentrepillarhastobeconstructedwith1:10cementmortarasithastoberemovedlater.A6mm
ironwirehastobeplacedinthemiddleofthepillarprotruding5centimetersabovethepillarwhile
constructingit.Theheightofthepillarhastobemaintainedonparwiththeheightofthebed
concrete.Thispillarhastobeconstructedimmediatelyafterthecastingthebedconcrete.

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Figure:8.1Constructionofcentrepillar

9.Guidepole

Guidepolecanbeawoodenplankof5centimeterwideand2centimeterthick.Thisisthepolewhich
guidesthemasontomaintainthefixedradiustoconstructthehalfsphere.Anailisputthroughthe
plankattheprescribedlength(2centimeterlongerthanthedigesteractualradius)comingthroughthe
plankuptoalengthof5centimeters.Theguidepolewillhaveabout5centimeterlongerthanthe
requiredinnerradiusoftheplant.Theprojectionofnailandplankwillholdthefreshlylaidbrickfrom
fallinguntilthenextbrickisputinline.2centimeterhigherlengthofthenailontheplankthanthe
actualradiusofthedigesteristocompensatethe12mmthickplaster,cementpasteandcementcoats
appliedinsidethedigesterwallsafterbrickconstruction.

Figure:9.1Guidepoll Figure:9.2Guidepoll

10.Layingofbricksasreinforcementlayer

Oncetheconcreteiscastedandcenterpillarisconstructedthefirstlayerofbrickshavetobelaidon
thewetconcreteforthedigesterandslurryexitpassageboxtank.Thefirstlayerofbrickshastobe
laidinsuchawaythatthedigesterconstructionbrickswillcomeinthecentreofthislayer.Thebricks
arelaidvertically22/23centimeterlongand11/10centimeterhigh.Thebricksarekeptinsuchaway
thatthegapbetweenthebrickshavetobenotmorethanabout1to1centimeters.Athinlayerof
cementmortarof1:4willbeappliedontheconcretefloorbeforeplacingthebricksandthegaps
betweenthebrickshavetobefilledwithcementmortar.Oncetheconcreteislaidandfirstlayerof
brickswerefixedtheworkhastobestoppedfortheconcretetoattainstrength.Thestructurehasto
14

becuredafter12hourswithwateruntilthenextportionofworkhasbeenstarted.Theremainingbrick
afterthereinforcedlayerwhichweresourcedforplantconstructionhavetobewettedwithwater.
Cleanwatercanbepouredontopofthepileuntilallbricksgetwet.

Figure:10.1Layingof1stlayerofbricksFigure10.2:Spacingfirstlayerofbricks

11.Startingconstructionofthedigester

Constructionofmaindigesteralongwithslurryflowchamberboxcanbestartedafter24hoursof
fixingoffirstlayerofbricks.Ifthebottomconcreteislaidwithreenforcedconcretethenthiswork
hastobestartedafter72hoursofconcreting.Beforestartingofconstruction70%ofbricksrequired
fortheunithavetobeplacedinthewellofthedigester.Thiswillhelpthemasontoaccessthebricks
easily.Dependinguponthesizeoftheplantthethicknessofthedigesterwallvariesandaccordingto
thedesignthedigesterhasbeconstructed.Guidepolehastobeusedtomaintaintheradiuswhile
constructingthedigester.Cementmortarof1:4maybeusedforconstructionofthedigesteruntilthe
heightofthearch.Graduallythecementquantityinthemortarhastobeincreasedto1:2oncethe
digesterheightisincreasing.Carehastobetakentoavoidjointsoftwoormorelayersofbrickscome
inthestraightline.Brickshavetobecompacteddownwordsandsidewisealso.Trowelhandletipbe
usedtocompactthebricks.

Figure:11.1startingconstructionofthedigester

12. Placingofinletpipe

Inletpipewillbeplacedatthestipulatedheight.TheloweredgeofthePVCpipeshouldrestonthe
lowersideedgeofthebricksothatitwillnotslipdown.ThebindingofPVCandcementisnotstrong
sothepipehastobescratchedusingsawbladeteethhorizontallyi.e.thelinesshouldformaroundthe
15

pipetotheextentofthepipecoveredinthedigesterwall.Arichmixofmortarshouldbeusedatthese
jointsandbrickpiecesshouldbeplacedintheloweranduppertriangularjoints.Theinletpipeshould
beplacedinsuchawaythattheinletpipetopedge,thecentrepillarandthecentreoftheoutletbox
tankshouldbeinastraightline.Theinletpipeinneredgeshouldbeat45centimetersawayfromthe
outsideofthefirstlayerofbricksataheightoftheguidepoleplacedverticallyonthecentrepillar.The
guidingrulefortheinletpipeplacingis:inletpipelowertopedgeshouldbebelowtheheightofthe
slurryflowrectangletopintheboxtank.

Figure:12.1Placingofinletpipe1 Figure:12.2.Placingofinletpipe

Figure:12.3Fixingofinletpipe Figure:12.4Fixingofinletpipelower
thantheslurryflowgateheight

13. Plasteringtheoutsideofthepartlyconstructeddigester

Oncethedigesterisconstructedtotheheightoftheboxtanktoptheconstructedportionofthe
digesteroutsidecanbeplasteredwith12mmthick1:4mixmortar.Digesterconstructionwillbe
continueduntiltheplasterofmortarisdried.Oncethemortarplasterisdriedandfixedthenthe
plasteredportionofthedigestercanbecompactedwithexcavatedearthuntiltheheightofthe

16

plasteredarea.Backfillingofsoilaroundthedigester,apartfromcreatingmoreworkingspaceforthe
workerstomovebutalsocompactsthesoilaroundthedigester.

14. Layingofbricklayerastopofthedigesterslurryflowdoor

Oncebackfillingofsoilaroundthepartlyconstructeddigesterisoverthenthecircularlayerwhich
coversthetankdoorcanbetakenup.Brickspiledinverticalcolumninbothsidesoftheboxtankwill
supportawoodenplankof60centimeterlong,10centimeterwideand23centimeterthick(seefigure
14.1).Woodenplankhastobeplaced1centimeterlesshighthanthedesignmeasurement.
Adjustmentofheightcanbedoneusingcementmortarontopoftheplank.Afteradjustingthecorrect
heightanewspaperorcementbagpaperhavetobeplacedonthewoodenplank.Arichmixmortar
layerhastobespreadand2fullbrickshavetobeplacedfromboththesidesofthedigesterwall.Care
hastobetakentoplacethesebricksabout2centimetersonthewallandtheremainingportiononthe
mortarontopofthepapercoveringthewoodenplank.Theremainingdistancemaybecoveredwitha
fullbrickoraportionofacutbrick.Compactthebricksusingrichmixmortar.Continueconstructionof
thedigester.Secondlayerofbricksontopofthefirstlayerontopofthewoodenplankalsoshouldbe
placedwithrichmixmortar.Oncethedigesterworkiscompletedandwhentheworkontheboxtank
isstartedthenthesupportingbricksandthewoodenplankcanberemovedcarefullynotdisturbing
thedigester.Oncethewoodenplankisremovedthencementpastecanbeusedonthebottomsideto
adjustheightaccuratelyaccordingtothedesign.

Figure:14.1Supportplankforboxtankceilinglayer

15. Pouringofcementwatertosealanypoursintheconstructeddigester

Plaincementwillbemixedwithdoublethequantityofwaterforthispurpose.Presentlythislayerof
cementwaterhastobeappliedontheoutsideportionoftheconstructeddigester.Bythetimethe5/6

17

layersofdigesterisconstructedontopoftheslurryflowdoortopthispouringofcementwateractivity
canbetakenup.Thiscementwatershouldcovertheentirenewlyconstructedoutsideportionofthe
digestercoveringallthejoints.Ifanyholesappearafterthiswaterapplicationtheholeshavetobe
coveredwithcementwaterormortariftheholesarebig.Plasteringofthisnewlyconstructedportion
canbetakenupimmediatelywhenthecementwaterisstillwet.Oncethisplasteringiscompletedand
theplasterissetthebackfillingofsoilaroundthedigestercanbetakenup.

16. Excavationofearthforconstructionofdisplacementchamber

Oncethedigesterconstructionabovetheboxtankdoorcoverlayeriscontinuingtheworkerscanstart
diggingtheareaneededfordisplacementtank.Theexcavatedsoilcanbeusedforbackfillingthepit
aroundthedigestertothebottomheightofthedisplacementtank.Accordingtothemeasurement
providedinthemanualthepithastobeexcavated.Carehastobetakenwhilecompactingsoilaround
theboxtankbynotdisturbingthestructureasitisconstructedwithathinlayerofbricksandstillitis
notattainedstrength.Waiteuntilthefilledupsoilattainscompaction.Thefilledupsoilwillgodown
bycompactionbythetimetheareareadyforconcrete.Sandmaybeusedontopofthesoiltoraise
theareatotherequiredheight.

Figure:16.1sandfillingtoraisetheareatorequiredheight

17. Layingoffoundationforthedisplacementchamber

Oncethesoilaroundthedigesterespeciallyaroundtheboxtankandspacerequiredforthe
displacementchamberiswellcompactedandsettledthenbaseconcretecanbelaid.Basingonthesoil
weightbearingcapacityironwiremaybeusedinthebedconcreteintheloosesoils(especiallyblack
cottonsoils).1:2:4mixofcement,sandandstoneaggregatesmaybeusedforthisbaseconcrete.10
centimeterswiderconcretebedisrequiredonallsidesthantheconstructingtankoutsidedimensions.
Oncetheconcreteislaidthefirstlayerofbricksforthedisplacementtankhastobefixedtothe
concreteusingcementmortar.Constructionoftankwillwaituntiltheconcreteattainsstrength.
Thicknessofthisconcretedependsuponthesizeoftheplantanddesignmeasurementhastobe
followed.Careshouldbetakentomaintaintheexactrectangleshapeofthedigester.

18


Figure:17.1FirstlayerofbricksFigure:17.2Brickshavetobefixedatrequiredmeasurements

18. FixingofGInippleatthezenithofthedigester

Whenthedigesterconstructionanglereachesmorethan45degreesthelayersofbricksmayfall.To
avoidthiscounterweightsmaybehangedasshowninthebelowdrawing.Oncethedigester
constructionreachesthefinalstage,whenonlyafewcentimeterdiameterofbrickconstructionisleft
outpreparationforfixingthebracketsweldedGInipplemaybetakenup.Removeonetoplayerof
bricksfromthecentrepillaratthewellofthebedconcrete.TakemortarcarryingironARAVANAand
covertheoutsidebottomportionofitwith2layersofanyoldnewspaperorcementpaperbag.Invert
theARAVANAandbalanceitontheguidepoleverticallyplacedonthecenterpillarandfixtightlythe
entiresetupcoveringtheleftoutdigesterholeatthezenith.Placingonelegonthedigester,pour
somedrycementontopofthepapercoveringtheARAVANAvisiblefromoutside.Keepthebrackets
weldedGInippleverticallyinthecentreoftheholeandporesomerichmixcementmortar.Fillthe
gapswithbrickpiecesandfixthemwithmorecementmortar.Poursomedrycementonthemortar.
Waiteforatleast10minutesuntilthearrangementisdriedandsettledbeforecontinuinganyworkon
thedigester.

19

 19. PouringofCementwaterontopofthedigesterandplastering

Followthestepsdescribedinpointno.15tocovertheremainingportionofthedigesterandplaster
theoutsideofthedigesterwith12mmthickcementmortarof1:4.Careshouldbetakennottotouch
andexertanypressureontheareawherethebracketsweldedGInippleisplacedwhileplasteringthe
digestertop.

20. RemovalofARAVANAfixedinsidethedigester

SlidetheguidepoleonthecentrepillarholdingtheARAVANAtoslackenthetightlyfixed
arrangement.OnceitisslackenedremovetheguidepoleandtheARAVANA.Paperontopofthe
ARAVANAmaysticktothemortarandhavetoberemovedcarefullynotleavinganypaperportion
onthedigester.Alongwiththisarrangementthecentrepillaralsowillberemovedentirely.

21. Plasteringofdigesterinsideportion

Preparethecementwatermixdescribedinpointno.15andapplythesameonallthesurfaceareaof
insidedigesterandplastertheentireareawith12mmthickand1:4mixofmortar.Smoothenthe
surfaceareabyrubbingtheplasteringwithwoodentrowel.Anyfallenmortaronthebedconcretecan
bepressedtothebedconcreteasaplasteringlayer.

22. Applicationofcementpasteontheinsideportionofthedigester

Thisisthemostcrucialpartofthebiogasplantconstructionwhichmakesthedigestergasleakproof.
Cementshouldbemadeintopastemixingwaterforthispurpose.Usually1:1ratioofwaterand
cementismixedtogettherequiredconsistency.Throughmixingofmaterialswillassurethelumpless
paste.Applyabout1to1mmthicklayerofthiscementpasteonalltheinsidesurfaceareaofthe
digesterusingthetrowel.Careshouldbetakennottoleaveanyportionwithoutthecementpaste.
Lightinginthedigesterisnotmuchwhiledoingthisactivitysoputawhitecolourplasticbagatthe
bottomoftheboxtanktoreflectthelightandtellpeoplewhoareonoutsidenottoblocklighting.1
5bagsofcementmaybeneededforthispurposedependinguponthesizeoftheplant.

23. Applicationofcementcoat

Thiscementcoatoninsidesurfaceareaofthedigesterwillbedonetwice.Oncewhenthecement
pasteappliedacquiredsomedrynessandsecondtimewhentheplantisreadyforinitialfeeding.
Cementmixedwithdoublequantityofwatermaybeusedforthispurpose.Anordinarypaintbrush
willbeusedforthispurpose.Justlikeanypaintingworkthiscementcoatalsoappliedontheentire
insidesurfaceareaofthedigesternotleavinganyportionuncovered.

24. Constructionofdisplacementtank

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Oncethebaseconcreteattainsstrengththedisplacementtankconstructioncanbetakenup.Ahole
forslurryexithastobeleftoutwhileconstructingthedisplacementtank.Thisexitholecanbekepton
anysideofthedisplacementtankdependingupontheneedofthehousehold.Untiltheheightofthe
slurryexitholearoughplasteringonoutsideportionandallremainingportionfineplasteringhastobe
done.

25. Castingofconcreteslabs/platesmeantforcoveringthedisplacementtank

Thisworkcanbetakenuponthedayofbedconcretelayingoranyotherconvenientdayofplant
installation.Eachplatewillhavetobecastedwith6070centimeterwidth,120140centimeter
lengthandwith68thickness.6mmironwirecuttotherequiredmeasureswillbeusedinthese
plates.Dependinguponthesizeoftheplant36platesarerequired.1:1:3mixofcement,sand
andstoneaggregatesmaybeusedfortheseslabs.4verticaland56horizontalironwiresare
requiredforeachplate.Clearanareatotheextentoftheplatesrequirementandleveltheground
usingshawl.Covertheareawith12centimeterthicksandlayer.Putemptypapercementbagsor2
layersofoldnewspapersonleveledandsandcoveredarea.Placebricksonoutsideofexactplate
dimensionsformingarectangle.Onelayerofbrickscanbeuseasonesidefor2plates.Coverthebricks
withpaperinsuchawaythattheconcretedonotsticktothem.Pourconcretemixtotheextentof2
centimeterthicknessandplacetheironwiresverticallyandhorizontallyandbindallthejointswith
thinironwire.Pourmoreconcretemixontopofthewiresandcompacttheconcretewithtrowel
initiallyandlaterwithawoodenplank.Alltherequiredplatescanbemadeatthesametime.

26. Constructionofinlettank

Whilethedisplacementtankisunderconstructionthearearequiredforinlettankhastoberaisedfor
layingofbedconcrete.Oncethissoiliscompactedandwellsettledthenbedconcretewith1:2:4mix
maybelaid.Atleast10centimetermorelengthyareathantheinlettankouterareaonallsideshasto
becoveredwithconcrete.Oncethisconcretehasattainedsufficientstrengththentheinlettank
constructioncanbetakenupaccordingtothemeasurementsmentionedinthemanual.

27. Curingofcivilworkswithwater

Thisisanotherimportantfactorforthelongevityoftheplants.Allcementstructuresattainstrength
whentheyarecuredwithwater.Allthecivilworksincludingtheconcreteplateshavetobecuredwith
waterfornotlessthan15days.Curinghastobetakenupinsuchawaythatthecivilworksdonotget
driedcompletely.Whenallthecivilworksoutsidesarecoveredwithsoilitbecomeseasytomaintain
moistureinthestructuresandlessentheburdenofapplicationofwaternumberoftimesinaday.

28. Compactingofthecivilworkswithsoil

Theinlettank,displacementtankandthedigestershouldbecompactedwithsoilonalloutside
portions.Thedigestertopshouldbeatleast10centimeterunderthesoilandsoilhastobecovered
21

aroundtheinlettankatleast15centimetershighonallsides.Exceptonthesidewheretheslurryexit
holeinthedisplacementchamberallothersidesshouldbecoveredwithsoiltotheheightofthetank.

29. Diggingofpittocollectspentslurry

Aholeinthegroundhastobeexcavatedjustundertheslurryexitholeinthedisplacementchamberto
collecttheslurryflowingoutoftheplant.Thepitdimensionsvarydependinguponthesizeofthe
plant.Thepitshouldbeexcavatedinsuchawaythatitshouldholdatleast10daysfeedstock.A2
cubicbiogasgenerationperdaycapacityplantwillbefedwith50kgofdungandabout50litersof
watereverydayandhencetheslurrycollectingpitshouldhaveacapacitytohold1000litersofslurry.

30. Initialfeedingofplant

Theplantrequiresbigquantityoffreshanimaldungandwatertofeeditinitially.Theplantswere
installedwith50dayshydraulicretentiontimeandrequire50daysfeedstockasinitialfeed.A2cubic
metergasgenerationperdaycapacityplantrequires50kgdungperdayandhence50kgx50daysi.e.
2500kgofdungisrequiredforinitialfeedingoftheplant.Beneficiarieswereadvisedtopileupthe
dunggeneratedintheiranimalconfinementondailybasisstartingfromthedayofdecisiontoinstall
theplantinshadedarea.Therequireddungforinitialfeedingwillbeaccumulatedonsitebythetime
theplantisinstalledandcompletedcuring.Initialfeedingwillbedoneusingtheirrigationwaterbut
notthetapwaterasitcontainschorine,anantibacterialmaterial.

31. Requiredphysiochemicalconditionsforoptimumproductionofbiogas

Sl. Character Range comments
No.
1 pH 6.87.2
2 C/Nratio 1:2530
3 Temperature 3235 Canbecompensated
withHRT
4 Solidsconcentration 810
5 Toxicsubstances 0 25ppm
Table:31.PhsioChemicalconditionsforoptimumproductionofbiogas

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 32. Constructionmeasurementsofthebiogasplant

Sl. Description 2M3 3M3 4M3 6M3

No.
1 AHeightoftheMixingTank 60 60 60 60
2 BThicknessofDigesteratGINipplelevel 10 10 13 13
3 CWidthoftheDisplacementTank 100 100 120 120
4 DDisplacementtankheightabovethe 45 45 48 53
holebottom
5 EWidthofthemixingtankconcretebase 100 100 110 120
6 FWidthofmixingtank 60 60 70 80
7 GThicknessofdigestermasonrywork 7 7 10 10
8 HThicknessofbaseconcreteatdigester 7 8 10 15
base
9 JHeightofthetapperportionorheightof 55 60 65 80
thecentrepillar
10 KHeightoftheinletpipeinneredgefrom 30 45 50 60
thebaseconcrete
11 LHeightofthearchfromthebottominner 25 25 25 25
tipoftheinletpipe
12 MInitialslurrylevelheightfromthearch 72 90 100 110
13 NRadiusoftheDigester 132 150 165 190
14 PArchheightfromarchtankconcrete 48 63 68 75
base
15 QLengthofthearchtank 70 70 90 90
16 RThicknessofarchtankwallunderthe 22 22 22 22
displacementtankwall
17 SArchtankheightuntilthebottomofthe 56 76 84 90
concretebaseofthedisplacementtank
18 TDiameterofthedigester 264 600 660 380
19 UHeightoftheslurryexitholefromthe 40 40 45 55
bottomofthedisplacementtank
20 VWidthoftheconcreteunderthedigester 25 25 25 25
base
21 WLengthoftheDisplacementtank 175 250 280 300
Table:32.Constructionmeasurementsofbiogasplantincentimeters

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 33. Sectionandplanofthebiogasplant

Figure:33.1:Planandsectionaldiagramofthebiogasplant

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 34. Materialrequirementforthebiogasplant

Sl. Description 2M3 3M3 4M3 6M3

No.
1 Wellburntsolidmudbricksof22x10x7mm 1050 1250 1850 2650
2 Cementbagsof50kgeach,42.5gradeOPC 16 19 24 34
3 Sandcourseincubicmeters 1.5 2 2.5 4
4 Sandfineincubicmeters 1.5 2 2.5 4
5 Stoneaggregatesmadefromgranitestonein 1 1.5 2.5 3.5
Cubicmeters
6 6mmironwireinkilograms 8 10 20 25
7 Bindingironwireinkilograms 0.1 0.1 0.2 0.25
8 150mmdiameter6mmthickPVCpipein 1.5 1.75 1.9 2.2
meters
9 Bracketswelded1.2diameterGInippleof30 1 1 1 1
centimeterlong
10 PVCgatevalveof20mmdiameternos. 1 1 1 1
11 Stainlesssteelbodydoubleburnerbiogasstove 1 1 1 1
12 100mmlongGalvanizediron20mmdiameter 2 2 2 2
nipples
13 Femalethreadedbrassmetalpipenipple 1 1 1 1
14 Rubberhoseinmeters 1 1 1 1
15 HighDensityPolyEthylene(HDPE)pipeof20 50 50 50 50
mmdiameterinmeters
16 Plumberinmandays
17 Freshanimaldungforinitialfeedingintons 2.5 3.75 5 7.5
Table:34.Requiredmaterialforbiogasplantinstallation

35. Deviationsfromthedesign

Thismanualincludesdesignandconstructionmaterialquantitiesforthebiogasplantsof2,3,4and6
cubicmeterbiogasgenerationperdaywith50daysHRT.Designandsizeofaplantotherthan
mentionedaboveisfeasibleandaskilledengineershouldbeconsultedfordeviationsfromthe
provideddesigns.Thebiogasplantsizeisdependentontheaveragedailyfeedstockandexpected
hydraulicretentiontimeofthematerialinthebiogassystem.Generally,25kilogramsoffeedstock
complimentedwith25litersofwaterperdaywithahydraulicretentiontimeof50dayswillrequire
about2.5cubicmetersemisphericaldigester.

25