FACULTY OF ENGINEERING, TECHNOLOGY, APPLIED DESIGN AND FINE

ART
DEPARTMENT OF MECHANICAL ENGINEERING
A PRACTICAL REPORT ON THE FABRICATION OF BIOGAS DIGESTER TANK
BY
GROUP II (MEC II)

S/NO NAME OF STUDENTS REGISTRATION NUMBER

1 ENDREONZI GILBERT
2 TUMUSIIME SAMUEL
3 AGABA TYSON
4 SALIM SALEH
5 ODONG JAMES
6 OYESIGYE COLLINS
7 OKECH ESAU FELIX
8 MASEREKA RODRICK
2022/A/KME/0455/F
2022/A/KME/1703/F
2022/A/KME/0961/G/F
2022/A/KME/0940/G/F
2022/A/KME/0959/G/F
2022/A/KME/0458/F
2022/A/KME/0962/G/F
2021/A/KME/2037/F

A REPORT SUBMITTED TO KABALE UNIVERSITY, DEPARTMENT OF MECHANICAL

ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING OF KABALE
UNIVERSITY.
APPROVAL
This industrial training report was submitted to Kabale University, Department of
Mechanical Engineering after the approval of the following:

MRS.STELLA KIZANYE
LECTURER, WELDING AND FABRICATION TECHNOLOGY
KABALE UNIVERSITY

Signature: Date:

MR. BRUNO BERENTI

PRACTICAL SUPERVISOR
KABALE UNIVERSITY

Signature: Date:

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ACKNOWLEDGEMENT
First and foremost, we express our sincere gratitude to God for His unconditional love,
guidance and protection; and for making the project a success. It is entirely by His
grace that we have reached this far in life in general and the academic journey in
particular. Praise, glory and honor be to Him!

Special thanks also go to the Mechanical Engineering Department of Kabale University

especially our lecturer Mr. Robert Kakebe and Mr. Berenti Bruno for their constant
advice and guidance regarding the project as well as availing us with this study time so
as to apply the theoretical skills learnt in class into real life problem-solving situations
and understanding of the Mechanical Engineering profession at large.

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ABSTRACT
This report focuses on the fabrication of a biogas digester tank, which is an essential
component in the process of producing biogas from organic waste. The primary
objective of the report is to provide an overview of the various metal forming processes
involved in the fabrication of biogas digester tanks. The report discusses the common
metal forming techniques such as rolling, welding, cutting, bending, punching, and
surface treatment, and their importance in ensuring the durability and leak-proof nature
of the tanks. The report also highlights the significance of proper fabrication techniques
in ensuring the efficiency, safety, and sustainability of the biogas production process.

The report offers a comprehensive overview of the various steps involved in the
fabrication process, including material selection, design considerations, and construction
techniques. Additionally, it explores the factors influencing the performance and
efficiency of the biogas digester tank. The results of this study contribute to the existing
knowledge in the field of renewable energy and sustainable waste management.

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TABLE OF CONTENT

Contents
APPROVAL ...................................................................................................................................................... i
ACKNOWLEDGEMENT ................................................................................................................................... ii
ABSTRACT ..................................................................................................................................................... iii
FABRICATION OF A BIOGAS DIGESTER TANK ................................................................................................. 1
1.1: Introduction ....................................................................................................................................... 1
1.1.1: Major steps involved in fabrication of biogas digester tank ....................................................... 2
1.2: MAJOR COMPONENTS OF THE BIOGAS DIGESTER TANK ................................................................... 2
1.2.1: The main components of a biogas digester tank include: .......................................................... 2
1.2.2: Key features of a biogas digester tank include: .......................................................................... 3
1.3: MATERIAL SELECTION ........................................................................................................................ 3
1.4: METHODS OF JOINING THE MATERIALS ............................................................................................ 5
1.4.1: Type of welding chosen............................................................................................................... 5
1.4.2: Advantages of MIG ...................................................................................................................... 6
1.4.3: Types of welds ............................................................................................................................. 7
1.4.4: Welding Consumables ................................................................................................................. 7
1.5: METAL FORMIMG............................................................................................................................... 8
1.5.1: Steps of Metal Forming Processes .............................................................................................. 8
1.5.2: Development of the Biogas Tank ................................................................................................ 9
1.6: DESIGN CALCULATIONS .................................................................................................................... 10
1.7: MAINTENANCE AND REPAIR OF THE BIOGAS DIGESTER TANK ........................................................ 12
2.0: CHALLENGES FACED ............................................................................................................................. 14
3.0: CONCLUSION ........................................................................................................................................ 15
4.0: REFERENCES ......................................................................................................................................... 16

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FABRICATION OF A BIOGAS DIGESTER TANK
1.1: Introduction
The fabrication of a biogas tank digester serves as a pivotal component in the field of
renewable energy and waste management. As the world grapples with the dual
challenges of energy sustainability and waste management, biogas tank digesters offer
a promising solution by harnessing the power of organic waste to generate clean and
renewable energy.

A biogas tank digester is an anaerobic digestion system that converts organic matter,
such as agricultural waste, food waste, and sewage, into biogas through a natural
decomposition process. This biogas, consisting mainly of methane and carbon dioxide,
can be harnessed as a source of renewable energy for cooking, heating, and electricity
generation. Additionally, the byproduct of this process, known as digestate, can be used
as a nutrient-rich fertilizer.

The fabrication of a biogas tank digester involves a series of crucial steps, ranging from
the selection of materials and design considerations to construction techniques and
quality assurance measures. It requires adherence to industry codes and standards to
ensure the safe and efficient operation of the digester.

The design and layout of a biogas tank digester take into account factors such as the
quantity and quality of feedstock, retention time, temperature control, and gas storage
capacity. It requires careful modeling and engineering expertise to optimize the
performance and methane production of the plant.

The fabrication process typically involves selecting appropriate materials, such as high-
density polyethylene (HDPE), reinforced concrete, or steel, which can withstand the
corrosive and harsh conditions inside the digester. Special considerations are given to
factors such as chemical resistance, durability, and structural integrity.

Moreover, the fabrication of a biogas tank digester necessitates compliance with specific
codes and standards set by regulatory bodies and relevant organizations. These codes
ensure a high level of safety, efficiency, and environmental sustainability in the
fabrication and operation of the digester.

Throughout this report, we will explore in detail the various aspects of fabricating a
biogas tank digester, including material selection, design considerations, construction
techniques, quality control, and compliance with industry codes. By understanding the
intricacies involved in the fabrication process, we aim to gain insights into the critical
role played by biogas tank digesters in achieving sustainable and eco-friendly waste
management practices while harnessing renewable energy.

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1.1.1: Major steps involved in fabrication of biogas digester tank

 Cutting of mild steel metal according to the design fabrication

 Cutting of angle bar into dimensions required
 Rolling of sheet metal into shape
 Welding of sheet metal
 Making of sheet metal
 Making indentation of the substrate inlet cover
 Drilling holes for inlet and outlet port
 Painting of the digester

1.2: MAJOR COMPONENTS OF THE BIOGAS DIGESTER TANK

A biogas digester tank is an infrastructure designed to efficiently produce and harness
biogas through the process of anaerobic digestion. This technology is an excellent
example of renewable energy generation and waste management, as it converts
organic waste materials into valuable resources.

1.2.1: The main components of a biogas digester tank include:

Inlet: This is the entry point where organic waste such as animal manure, crop
residues, food waste, or sewage sludge is introduced into the digester. It is important
to ensure a controlled and balanced supply of feedstock to maintain optimal conditions
for digestion.

Digester Chamber: This is the core component of the tank, where anaerobic digestion
takes place. The digester chamber is specifically designed to create an oxygen-free
environment, allowing the growth of anaerobic bacteria responsible for the breakdown
of organic matter. The tank is typically made of concrete, steel, or reinforced fiberglass
to ensure durability and minimize leaks.

Mixing System: Many biogas digester tanks employ mechanical or hydraulic mixers to
promote the intimate contact between the organic feedstock and the bacteria. Mixing
helps in maximizing the digestion efficiency by breaking down larger organic particles,
preventing the formation of scum or solids accumulation, and maintaining a
homogenous mixture for optimal biogas production.

Gas Storage Area: The biogas produced during the anaerobic digestion process is
stored in a separate chamber or vessel. This area is designed to safely collect and
contain the produced biogas, which primarily consists of methane (CH4) and carbon
dioxide (CO2). It is important to incorporate safety measures, such as pressure relief

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valves and gas meters, to prevent hazardous conditions and facilitate gas utilization or
subsequent treatment.

Outlet: After the digestion process is complete, the remaining digestate, also known as
effluent, exits the tank through an outlet. This nutrient-rich liquid can be used as a
high-quality fertilizer for agriculture or horticulture purposes due to its abundant
availability of essential plant nutrients.

1.2.2: Key features of a biogas digester tank include:

Insulation: To maintain stable and optimized operating conditions, some digester tanks
are insulated to regulate temperature variations. Proper insulation helps sustain the
desired microbial activity and enhances biogas production.

Temperature Control: Certain digester designs incorporate heating or cooling systems

to maintain the ideal temperature range for the growth and activity of the anaerobic
bacteria. This control ensures more efficient degradation of organic waste and
maximizes biogas composition and yield.

Substrate Loading and Unloading Mechanisms: Biogas tanks can be equipped with
systems that facilitate the loading and unloading of feedstock and digestate. These
mechanisms, such as pumps, conveyors, or agitators, enable efficient and convenient
operations, minimizing manual labor and improving overall system productivity.

Gas Utilization: Biogas produced in the digester tank can be harnessed for various
applications. Common utilization methods include generating electricity through biogas-
powered generators, direct burners for cooking or heating, or upgrading and injecting
biogas into the natural gas grid.

1.3: MATERIAL SELECTION

The material selected for the fabrication of the digester was a 3mm stainless steel sheet
for the inner layer because of the following reasons;

Corrosion resistance: Stainless steel is highly resistant to corrosion, making it ideal for
storing biogas, which is often rich in corrosive gases such as hydrogen sulfide (H2S).
This resistance to corrosion ensures the tank has a longer lifespan compared to other
materials like carbon steel.

Durability: Stainless steel is known for its durability and strength. It can withstand
extreme temperatures, pressure, and environmental conditions commonly encountered

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in biogas production facilities. This durability ensures the tank remains intact and
functional over an extended period.

Hygienic properties: Stainless steel has smooth and non-porous surfaces, making it
easy to clean and resistant to bacteria buildup. This is particularly important in biogas
tanks where organic matter can accumulate and cause biological degradation. The
hygienic properties of stainless steel ensure the biogas produced remains clean and
uncontaminated.

Gas-tightness: Stainless steel tanks can be manufactured with precision welding

techniques, resulting in a gas-tight structure. This is crucial in biogas production, as it
helps prevent any leaks or losses of biogas from the tank. The gas-tightness of stainless
steel tanks ensures maximum gas retention and efficiency

Flexibility in design: Stainless steel tanks are highly flexible when it comes to design
and customization. They can be constructed in various sizes and shapes, allowing for
optimal utilization of available space and easy integration into existing biogas
production systems. This flexibility enables the tank to be tailored to specific project
requirements.

Resistance to external factors: Stainless steel tanks have excellent resistance to external
factors like ultraviolet (UV) radiation, weather conditions, and chemicals. This ensures
the tank remains unaffected by these factors, maintaining its structural integrity and
extended lifespan.

Sustainability: Stainless steel is a highly sustainable material. It is 100% recyclable, and

the production processes require less energy and generate fewer emissions compared
to other materials. Using stainless steel in biogas tank construction aligns with
sustainability goals and reduces the environmental impact of the project.

The material selected for the fabrication of the digester was a 3mm mild steel sheet for
the outer layer because of the following reasons;

Mild steel is a commonly used material for making biogas tanks due to its numerous
advantages. Here are some of the key advantages:

Strength and Durability: Mild steel is known for its high tensile strength, which makes it
sturdy and durable. This strength enables the tank to withstand the pressure exerted by
the biogas inside without deformation or rupture, ensuring the safety of the system.

Corrosion Resistance: Biogas is a mixture of gases, including methane and carbon

dioxide, along with traces of water vapor and hydrogen sulfide. These components can

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be highly corrosive to certain metals. However, mild steel holds good resistance against
corrosion, especially when coated with corrosion-resistant materials, such as paint or
epoxy.

Recyclability: Mild steel is recyclable, which means it can be reused or recycled once its
life cycle is complete. This makes it an environmentally friendly choice for biogas tanks
and aligns with sustainable practices.

Cost-effective: Mild steel is relatively inexpensive compared to other materials like

stainless steel. This cost advantage makes it a popular choice for constructing biogas
tanks, especially for smaller scale projects or when cost-effectiveness is a priority.

Weldability: Mild steel is highly weldable, meaning it can be easily joined together using
various welding techniques. This facilitates the construction process and allows for
customization of tank shapes and sizes to suit the specific requirements of the biogas
plant.

Availability and Versatility: Mild steel is a widely available material making it easily
accessible and convenient for construction purposes. It can be readily sourced from
numerous suppliers, ensuring the ease of procurement. Additionally, mild steel can be
fabricated into different shapes and sizes, making it versatile for creating tanks with
varied capacities

1.4: METHODS OF JOINING THE MATERIALS

During fabrication of biogas digester tank, the metal sheets have to be connected
together using a suitable joining methods and in this case welding is the most
appropriate and recommended methods due to its good finish, durability, and easy
operation,

1.4.1: Type of welding chosen

The type of welding chosen was metal inert-gas (MIG) welding which is an arc welding
process in which the heat for welding is generated by an arc between a consumable
electrode and the work metal. The consumable bare wire is fed automatically through a
nozzle into the weld arc by a wire-feed drive motor. In GMAW, the weld area is shielded
by an effectively inert atmosphere of argon, helium, carbon dioxide or various other gas
mixtures.

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1.4.2: Advantages of MIG

We decided to use Metal Inert Gas (MIG) welding, also known as Gas Metal Arc Welding
(GMAW), since it offers several advantages when it comes to the construction of biogas
digester tanks.

High Efficiency: MIG welding is a highly efficient welding process where a continuously
fed electrode wire melts and fuses the metal together. This results in a fast welding
speed, allowing for increased productivity during biogas digester tank construction.

Versatility: MIG welding can be used to weld a wide range of materials such as carbon
steel, stainless steel, and aluminum, making it a versatile choice for constructing biogas
digester tanks. Additionally, it can easily adapt to different thicknesses, ensuring
structural integrity throughout the tank.

Smaller Heat-Affected Zone: MIG welding produces a smaller and more controlled heat-
affected zone (HAZ) compared to other welding techniques. As a result, there is less
distortion, warping, or damage to the surrounding structure of the biogas digester tank,
ensuring its durability and longevity.

Better Control and Precision: MIG welding offers excellent control and precision,
allowing for precise welding of intricate joints, seams, and connections in the biogas
digester tank. This ensures high-quality welds, enhancing the overall strength and
performance of the tank.

Weld Quality: MIG welding produces high-quality, clean, and aesthetically pleasing
welds. The process involves shielding the weld pool with an inert gas (e.g., argon or
helium), which helps to protect the weld from atmospheric contamination, resulting in
strong and reliable welds. This is crucial for the integrity and safety of the biogas
digester tank.

Less Spatter and Fumes: MIG welding generates minimal spatter, which reduces the
need for post-weld clean-up and saves time during the construction process.
Additionally, MIG welding produces fewer fumes compared to other welding techniques,
creating a healthier and safer working environment for the construction workers.

Easy to Automate: MIG welding can be easily automated using robotic systems. This
lends itself well to the construction of biogas digester tanks, where consistent and
repetitive welding tasks can be efficiently carried out by robots. Automation increases
precision, productivity, and reduces labor costs.

Cost-Effectiveness: MIG welding is a cost-effective welding process due to its high

deposition rate and efficient use of materials. The continuous wire feed system ensures

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minimal waste, reducing material costs. Additionally, the high efficiency and productivity
of MIG welding save construction time, leading to overall cost savings.

1.4.3: Types of welds

To construct a biogas tank digester, one of the crucial steps is welding. Welding is the
process of joining two or more metal components by melting them together into a
single, solid structure. Various types of welds are commonly used in the fabrication of
biogas tank digesters, depending on the specific requirements and the materials being
used.

Fillet Weld: This is the most common type of weld in biogas tank digester fabrication. It
involves joining two metal components along their edges, forming a triangular cross-
section. Fillet welds provide good strength and are relatively easy to achieve, making
them suitable for connecting structural components of the digester.

Groove Weld: Groove welds are used when two metal components, with a gap between
them, need to be joined. The gap is filled with molten metal during the welding
process, resulting in a strong and continuous weld. Groove welds are typically used for
sealing joints and connecting plates in biogas tank digesters.

Plug Weld: Plug welds are similar to spot welds and are often used to connect
overlapping metal components. A hole is made in the upper component, and the lower
component is welded to it, creating a strong joint. Plug welds offer good load-carrying
capacity and are commonly employed in biogas tank digester construction.

1.4.4: Welding Consumables

When it comes to welding consumables, choosing the right materials is crucial to ensure
the quality and integrity of the welds. Commonly used welding consumables in biogas
tank digester fabrication include:

Welding Electrodes: These are solid metal wires coated with flux, providing a protective
layer during the welding process. Welding electrodes are typically classified based on
their composition and intended application. For biogas tank digester fabrication,
electrodes with high strength and corrosion resistance, such as stainless steel
electrodes, are often used.

Welding Filler Wire: Filler wires are used to add additional material to the weld joint,
enhancing its strength and durability. The choice of filler wire depends on the base
metal being welded. In biogas tank digester fabrication, filler wires made of materials
like stainless steel or low-alloy steel are commonly utilized.

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Flux: Flux is a chemical substance used to clean the welding surface, prevent oxidation,
and improve the quality of the weld. It is typically applied in the form of a powder or
paste. Flux selection depends on the welding process and the materials being joined.

1.5: METAL FORMIMG

Metal forming processes play a crucial role in various industries, including the
fabrication of a biogas tank digester. These processes involve shaping and altering
metal materials into desired forms and configurations. Through the application of force,
heat, or a combination of both, metal forming enables the manufacturing of complex
components with superior strength, durability, and functionality.
The fabrication of a biogas tank digester involves the utilization of metal forming
processes to create a robust and efficient structure that can withstand the unique
demands of biogas production. Biogas, a renewable energy source derived from organic
materials, necessitates a specialized containment system to store and process the gas
generated during the anaerobic digestion process.
Metal forming enables the production of biogas tank digesters with specific
characteristics suited to their function. Tanks must be resistant to corrosion, leakages,
and mechanical stress to ensure the safe and effective storage of biogas. Moreover, the
geometry of the tank, including its shape, size, and internal features, directly impacts
the efficiency and performance of the biogas production process.

1.5.1: Steps of Metal Forming Processes

The metal forming process for the construction of a biogas digester tank involves
several steps. Here is a detailed explanation:

Design and material selection: The first step is to design the biogas digester tank based
on its intended capacity and purpose. Once the design is finalized, the appropriate
material for construction is selected. Common materials used for biogas digester tanks
include stainless steel, carbon steel, and sometimes aluminum.

Cutting and shearing: The selected metal sheets are cut into the required sizes and
shapes. This can be done by using mechanical cutting tools such as shears or by
employing more advanced methods like laser cutting or plasma cutting for precise and
clean cuts.

Forming and bending: The cut metal sheets are then passed through a forming and
bending process to shape them into the desired configuration for the biogas digester

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tank. This can be done using various methods such as press bending, hydraulic
bending, or roll forming, depending on the complexity and size of the tank.

Welding: The bent metal sheets are welded together to create the tank structure.
Different welding techniques can be used, such as gas metal arc welding (GMAW),
shielded metal arc welding (SMAW), or tungsten inert gas (TIG) welding. Welding
ensures that the tank components are securely joined and can withstand the pressure
and gases within the digester.

Surface treatment: After the welding process, the tank is subjected to surface treatment
to improve its durability and corrosion resistance. This may involve methods such as
sandblasting, shot blasting, or applying a protective coating or paint to the tank’s
exterior and interior surfaces.

Assembly and finishing: Once the individual tank components are ready, they are
assembled together to create the complete biogas digester tank. This includes attaching
any necessary valves, fittings, or access ports. The tank is then thoroughly inspected
for any defects or leaks and necessary adjustments are made.

Testing and quality control: Before the biogas digester tank is ready for use, it
undergoes rigorous testing and quality control procedures. This may involve pressure
testing to ensure its structural integrity and leak-free operation. The tank is also
inspected for any visual defects, such as welding flaws or surface imperfections.

1.5.2: Development of the Biogas Tank

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1.6: DESIGN CALCULATIONS

Parameter Symbols Values(units)

Volume of the digester Vd 4.0 m3
Volume of Gasholder Vg 1 m3
Volume of Gas collecting chamber Vc 0.21 m3
Volume of fermentation chamber Vf 2.36 m3
Height of the digester HD 1.63 m3
Height of Gas collecting chamber HC 0.3 m
Height of fermentation chamber hf 1.33 m
Diameter of cylinder Dc 1.5 m

a). Amount of Total Solid (TS) in the slurry:

TS= 8.5% of slurry
A mount of Volatile Solid (VS) in the slurry: VS= 0.8TS
Where TS = amount of Total Solid in the slurry
b). Substrate input (𝑺𝒅 ):
𝑆𝑑 = B + w (m3/d) Where 𝑆𝑑 = Substrate input B = Biomass (organic matter) and w =
water
c). Digester volume (𝑽𝒅 ):
𝑉𝑑 = Sd x RT (m3/day x number
Where 𝑆𝑑 = daily substrate input quantity
RT= chosen retention time.
d). Daily gas production, G
The amount of gas generated each day, G (m3gas/d), was calculated on the basis of
the specific gas yield, Gy of the substrate and the daily substrate input, 𝑆𝑑 . The
calculation was based on standard gas yield values.
G = 𝑥 × 𝑦 × 𝑧 where G = Daily gas production, x = No. of cow that generate the
biomass (organic matter) for the study, y = average wt. of organic matter estimated to
be produced by on daily basis.
e). Specific gas production 𝑮𝒑

It was calculated according to the following equation

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 𝑚3
𝐺
𝐺𝑝 = ( 𝑑3 )
𝑉𝑑 𝑚

Where 𝐺𝑝 = Specific gas production, G = daily gas production,

𝑉𝑑 = Digestive volume.

f). Digester loading, 𝑳𝒅𝑻

The digester loading, 𝐿𝑑𝑇 was calculated from the daily total solid input
𝑇𝑆
𝑘𝑔
𝐿𝑑𝑇 = 𝑑
(𝑚3 𝑑) Where 𝐿𝑑𝑇 =Digester Loading, 𝑇𝑆 = daily total solids input, 𝑉𝑑 =
𝑉𝑑
digestive volume.
g). Volume of gas holder 𝑉𝑔
𝑉𝑔
Gas holder capacity (C) = Where C = Gas holder capacity, Vg = Gasholder
𝐺
volume, G = daily gas production.
f). Biogas yield
Biogas yield was determined using the equation reported by Arthur (2004), expressed
as:
𝑉𝑑
𝐺𝑦 = Where Gy = Biogas yield , 𝑉𝑑 = Digestive volume ( ), and 𝐹𝑠 = Mass of feed
𝐹𝑠
stock (kg)
h). Volumetric capacity 𝑽𝒅
𝑉𝑑 = 𝜋𝑟 2 ℎ where 𝑉𝑑 = volume in cubic meters, 𝑟 = radius (m) , and ℎ = height in
meters.
i). Cylindrical volume of digester
𝐶𝑦 = 𝜋𝑟 2 ℎ

j). Conical volume of the digester

1
𝑉𝐶𝐷 = (𝜋𝑟 2 ℎ)
3

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1.7: MAINTENANCE AND REPAIR OF THE BIOGAS DIGESTER TANK
Maintenance and repair of a biogas digester tank are crucial to ensure its efficient and
long-lasting operation. Here are the steps involved in maintaining and repairing a
biogas digester tank:

Regular inspections: It is essential to conduct routine inspections of the digester tank to

identify any signs of damage, corrosion, or leaks. This can be done by checking for
visible cracks, leaks, or bulges in the tank walls. Inspect the joints, valves, and pipes for
any wear and tear or loose connections. Inspections should be carried out at least once
a month.

Cleaning: Regular cleaning of the digester tank is important to prevent the buildup of
sludge and other sediments that may hinder the proper functioning of the tank. The
tank can be cleaned by removing any accumulated solids and cleaning the interior with
water or a mild detergent. It is important to avoid using abrasive cleaners or harsh
chemicals that could damage the tank material.

Gas outlet and inlet maintenance: The gas outlet and inlet pipes should be checked for
any blockages or obstruction. Clean or replace any filters or screens that may have
accumulated debris, thus obstructing the gas flow. Ensure that valves are properly
functioning and not leaking gas.

Gas pressure monitoring: The pressure inside the digester tank should be monitored
regularly gas storage system: If the biogas is being stored for use later, ensure that the
storage system is well-maintained. Regularly check the gas holder for any damage or
leaks. Monitor gas levels and ensure proper venting to prevent gas buildup. Check and
maintain gas pipelines, regulators, and valves to ensure they are functioning properly.

Repairing leaks or damages: If any leaks, cracks, or damages are identified during
inspections, they should be repaired promptly to avoid any further deterioration or
potential safety risks. The damaged area should be cleaned thoroughly and patched
using appropriate repair excessive pressure can damage the tank, while low pressure
may indicate a problem with the gas production. Install pressure gauges at appropriate
points to monitor and regulate the gas pressure within safe limits.

Temperature monitoring: Biogas digesters operate optimally within specific temperature

ranges. Regularly check the temperature levels inside the digester tank, as both
excessively high or low temperatures can impact the microbial activity and digestion
process. Maintain the desired temperature range by using insulation or heating/cooling
systems if necessary.

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Check and maintain the grinders, mixers, and other equipment involved in the substrate
preparation and feeding process.

Keep records: Maintain proper documentation of all maintenance activities, repairs, and
modifications done to the digester tank. This will help in tracking the tank’s
performance, identifying recurring issues, and planning future maintenance or
upgrades.

Regular maintenance and prompt repairs are essential to ensure the smooth operation
and longevity of a biogas digester tank. By following these steps and adhering to
manufacturer guidelines, the digester tank can operate efficiently, optimizing biogas -
materials compatible with the tank’s construction material. Seek professional assistance
if needed.

Regular maintenance of accessories: Various accessories, such as mixers, agitators,

pumps, or sensors, may be attached to the digester tank. These should also be
routinely checked, maintained, and repaired if necessary. Follow the manufacturer’s
instructions and guidelines for their upkeep.

Regular maintenance of the substrate feeding system: If the digester tank is being fed
with substrates, ensure that the feeding system is well-maintained. This includes
checking and cleaning feed pipes, as production and minimizing downtime.

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2.0: CHALLENGES FACED
The major challenge we had was inadequate practical skill about the whole process of
making the biogas digester tank. We never did this practically and only relied on the
basics of theoretical part and this caused much doubts amongst the group members
since we never had practical proofs on our ideas to visualize the points.

The time frame given was not proportional to the project. We needed more time for
research and discussion to come up with a detailed and proper biogas digester tank.

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3.0: CONCLUSION
In conclusion, the fabrication of biogas digester tanks involves a range of metal forming
processes that are crucial in ensuring the durability, leak-proof nature, and efficiency of
the tanks. The appropriate selection and application of metal forming techniques such
as rolling, welding, cutting, bending, punching, and surface treatment are essential for
producing high-quality tanks that can withstand the harsh conditions of biogas
production. The proper fabrication techniques also play a significant role in ensuring the
safety and sustainability of the biogas production process. Therefore, it Is crucial to
ensure that appropriate fabrication techniques are used and that the tanks are regularly
maintained to ensure optimal performance and longevity. With the increasing demand
for sustainable energy, the fabrication of biogas digester tanks will continue to be
critical in promoting a cleaner environment and reducing dependence on fossil fuels.

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4.0: REFERENCES
Arthur M (2004). Biogas Production from Stillage (Scientific, Technical and Economic
Aspects): University of Luneburg, Germany. Available at www.hachlange.com.
Babatola JO (2008). Comparative Study of Biogas Yield Pattern in Some Animal and
Household Wastes, African Research Review. An International Multi-Disciplinary Journal
2(4):54-68.
Mitel KM (1996). Biogas Systems-Principle and Application: New Age International
Publishers Ltd., New York; 6:9-12.
Mshandete AM, Parawira W (2009). Biogas Technology Research in selected Sub-
Saharan African Countries - A review. African Journal of Biotechnology 8:116-125.
Lecture notes

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