Integrated Farming System Biogas Guide
Integrated Farming System Biogas Guide
Bio-gas: In farm waste such as dung is mixed with straw, grass, leaves and kitchen waste were
kept in anaerobic environment produced gas is called as bio-gas. Biogas is somewhat lighter
than air and has an ignition temperature of approximately 700 °C (diesel oil 350 °C; petrol and
propane about 500 °C). The temperature of the flame is 870 °C.
Composition of bio-gas:
Biogas consists of about 55 to 60 % methane (CH4), 40 % carbon dioxide (CO2), 1% hydrogen
sulphide (H2S) and other substances.
The methane content and hence the calorific value is higher the longer the digestion process.
The methane content falls to as little as 50% if retention time is short. If the methane content
is considerably below 50%, biogas is no longer combustile. The first gas from a newly filled
biogas plant contains too little methane. The gas formed in the first three to five days must
therefore be discharged unused. The methane content depends on the digestion temperature.
Low digestion temperatures give high methane content, but less gas is then produced.
The methane content depends on the feed material. Some typical values are as follows:
• Cattle manure - 65%
• Poultry manure - 60%
• Pig manure - 67%
• Farmyard manure - 55%
• Straw- 59%
• Grass- 70%
• Leaves- 58%
• Kitchen waste - 50%
• Algae- 63%
• Water hyacinths- 52%
Uses and features:
1. Accumulation of moist dung in heap will produce various pathogens and this will be avoided
by biogas production.
2. Because of smoke free it can be used for cooking. Speedy in cooking time. In the cooking
protect the utensils from carbon sedimentation.
3. It can be used to generate electricity and to run the engine. Saves 70-80% diesel requirement.
4. Well digested and odourless dung liquid is called as slurry - used for land reclamation and
enrichment.
5. If weeds and seeds by fermentation reduced capacity and in field production of weeds
reduced.
6. Used wastes as food to fish and pig.
7. Used to make compost.
8. Used to make Asola fertilizer.
9. If gas leak may occurred means cause major casualities. Bio gas is very safe for the womens
those who are all cooking.
10. Every time we have to spend money when buying a cylinder. Once the construction
completed and start to functioning no need to spend money.
11. Production of bio gas through integrated farming system will reduce the production cost with
increased income.
Vessel Size: One cubic meter of container is required to set up at least 3 cows.
• 6 cubic meters - 15 cows
• 10 cubic meters - 25-30 cows
• 25 cubic meters - 60-65 cows
Gas tank
It is a circular-shaped iron box. Above ledger fit in reverse. The mouth should be immersed in
the mixture.
Pipe system
The digester barrel above the gas vessel is shut off it. The standard of the gas coming through
fermentation will collected. The correct pressure for the gas and pass through gas pipe. Gas
usages places like gas stove, and gas engines receives gas through gas pipe without reduction
in pressure. The tubes are made to carry gases should be made of Iron or black polythene. The
internal diameter should not be less than 1 inch or 32 mm. Thickness should not less than 4.7
mm. Polyethylene pipes are cheaper one. Easy installation. Inside house ½ inch or ¾ inch GI
pipes should be used.
Feed methods
A distinction is made between batch and continuous plants.
a) Batch plant
Batch plants are filled completely and then emptied completely after a fixed retention time.
Each design and each fermentation material are suitable for batch filling. Large gasholders or
a number of digesters are required for uniform gas supply from batch plants.
b) Continuous plants
Continuous plants are filled and emptied regularly -normally daily. Each design is suitable for
continuous operation, but the feed material must be flowable and uniform. Continuous plants
empty automatically through the overflow. It is more suitable for rural households. The
necessary work fits better. into the daily round. Gas production is constant, and somewhat
higher than in batch plants.
Method of usage
• Preserve it with two to three weeks by pouring water and then pour cow dung slurry.
• Initially full capacity of the tank should be filled with slurry, so collect cow dung when
starting the construction of tank. Dung and water to be mixed in the proportion of 1: 1
ratio to fill the tank.
• Once the biogas begun to come pour the cow dung slurry continuously then only it will
supply gas continously.
• Every time when pouring cow dung mixture slurry also come out from the tank. Tank gas
pressure is sufficient to remove the slurry. Gas come out from the tank will be transferred
to gas stove through adopter.
Measures to be considered
• In coastal area due to salinity the gas tank should be line with plastic.
• The gas production was higher in the summer, less in winter to prevent this, dissolve cow
dung in medium warm water.
• Sometimes fermentor walls bursts due to poor quality cement.
• In some cases, mixture in the vessel likely to sediment and it will be avoided by
frequent stirring.
Balloon Plants
A balloon plant consists of a plastic or rubber digester bag, in the upper part of which the gas
is stored. The inlet and outlet are attached direct to the skin of the balloon. When the gas space
is full, the plant works like a fixed-dome plant - i.e., the balloon is not inflated; it is not very
elastic. The fermentation slurry is agitated slightly by the movement of the balloon skin. This
is favourable to the digestion process. Even difficult feed materials, such as water hyacinths,
can be used in a balloon plant. The balloon material must be UV-resistant.
Fixed-Dome Plants
A fixed-dome plant consists of an enclosed digester with a fixed, non-movable gas space. The
gas is stored in the upper part of the digester. When gas production commences, the slurry is
displaced into the compensating tank. Gas pressure increases with the volume of gas stored,
therefore the volume of the digester should not exceed 20 m³. If there is little gas in the
holder, the gas pressure is low.
Fixed-dome plant
[Link] tank with inlet pipe. 2. Digester. 3. Compensating and removal tank. 4. Gasholder. 5.
Gaspipe. 6. Entry hatch, with gaslight seal and weighted. 7. Difference in level = gas pressure
in cm WC. 8. Supernatant scum; broken up by varying level. 9. Accumulation of thick sludge.
10. Accumulation of grit and stones. 11. Zero line: filling height without gas pressure.
Floating-Drum Plants
Floating-drum plants consist of a digester and a moving gasholder. The gasholder floats either
direct on the fermentation slurry or in a water jacket of its own. The gas collects in the gas
drum, which thereby rises. If gas is drawn off, it falls again. The gas drum is prevented from
tilting by a guide frame.
Floating-drum plant
Mixing tank with inlet pipe. 2. Digester. 3. Overflow on outlet pipe. [Link] with braces
for breaking up surface scum. 5. Gas outlet with main cock. 6. Gas drum guide structure. 7.
Difference in level = gas pressure in cm WC. 8. Floating scum in the case of fibrous feed
material. 9. Accumulation of thick sludge. 10. Accumulation of grit and stones. 11. Water jacket
with oil film.
• Bottom of the cell in the shape of football constructed with concrete mix. It’s minimizing
building cost. Building to be built at the top (capacity) is reduced. Concrete covered as half
ball shape from the top will reduce the cost. There is no chance of mistakes in measurement.
• Pouring dung in the 6-inch pipe and construct cow dung mixing tank on top of this pipe.
• The tank will be built on a large scale is necessary for the outlet of cow dung. Because, when
large amounts of gas produced in excess of the tank dung liquid could raise on the roof of
the plant.
• Thus, the level of dung will be come down when the gas used for burning. Cow dung mixture
climbing up and down from the level in cow dung outlet tank indicates the system operates
in good condition.
Funding agency: The central government's Energy Resources Department, for setting up
the gas plant release the subsidy through KVIC. This subsidy amount will change according to
capacity, place (hill or plain area) and person (small, marginal farmers and landless worker).
The subsidy will be determined each year by the central government. Any farmer having three
cows, sufficient space to set up the plant can approach the Khadi Commision or Sarvodaya
Association Khadhar Bawan in the respective districts.
Earthworms have been on the Earth for over 20 million years. In this time, they have faithfully
done their part to keep the cycle of life continuously moving. Their purpose is simple but very
important. They are nature’s way of recycling organic nutrients from dead tissues back to living
organisms. Earthworms live in the soil and feed on decaying organic material. After digestion,
the undigested material moves through the alimentary canal of the earthworm, a thin layer of
oil is deposited on the castings. This layer erodes over a period of 2 months. So, although the
plant nutrients are immediately available, they are slowly released to last longer. The process
in the alimentary canal of the earthworm transforms organic waste to natural fertilizer. The
chemical changes that organic wastes undergo include deodorizing and neutralizing. This
means that the pH of the castings is 7 (neutral) and the castings are odorless. The worm
castings also contain bacteria, so the process is continued in the soil, and microbiological
activity is promoted.
Vermicomposting is the process of turning organic debris into worm castings. Vermicompost
is nothing but the excreta of earthworms, which is rich in humus and nutrients. The worm
castings are very important to the fertility of the soil. The castings contain high amounts of
nitrogen, potassium, phosphorus, calcium, and magnesium. Castings contain: 5 times the
available nitrogen, 7 times the available potash, and 1 ½ times more calcium than found
in good topsoil. Several researchers have demonstrated that earthworm castings have excellent
aeration, porosity, structure, drainage, and moisture-holding capacity. The content of the
earthworm castings, along with the natural tillage by the worms burrowing action, enhances
the permeability of water in the soil. Worm castings can hold close to nine times their weight
in water. “Vermiconversion,” or using earthworms to convert waste into soil additives, has
been done on a relatively small scale for some time.
Phase 2 : Pre-digestion of organic waste for twenty days by heaping the material
along with cattle dung slurry. This process partially digests the material
and fit for earthworm consumption. Cattle dung and biogas slurry may
be used after drying. Wet dung should not be used for vermicompost
production.
Phase 3 : Preparation of earthworm bed. A concrete base is required to put the waste
for vermicompost preparation. Loose soil will allow the worms to go into
soil and also while watering, all the dissolvable nutrients go into the soil
along with water.
Phase 4 : Collection of earthworm after vermicompost collection. Sieving the
composted material to separate fully composted material. The partially
composted material will be again put into vermicompost bed.
Phase 5 : Storing the vermicompost in proper place to maintain moisture and allow
the beneficial microorganisms to grow.
Sheltered culturing of worms is recommended to protect the worms from excessive sunlight
and rain. Vermicompost can be produced in any place with shade, high humidity and cool.
Abandoned cattle shed or poultry shed or unused buildings can be used. If it is to be produced
in open area, shady place is selected. A thatched roof may be provided to protect the process
from direct sunlight and rain. The waste heaped for vermicompost production should be
covered with moist gunny bags.
Sugarcane
Cement tub Coir waste Saw dust
trash
Worms can be enormously productive and reproductive. Good bedding mixtures are an
essential element in meeting those needs. They provide protection from extremes in
temperature, the necessary levels and consistency of moisture, and an adequate supply of
oxygen. Mixing beddings can be done by hand with a pitchfork (small operations), with a
tractor bucket (larger operations), or, if one is available, with an agricultural feed mixer. Please
note that the latter would only be appropriate for large commercial vermicomposting operations
where high efficiency levels and consistent product quality is required.
This habitat must have the following characteristics:
High absorbency: Worms breathe through their skins and therefore must have a moist
environment in which to live. If a worm’s skin dries out, it dies. The bedding must be able to
absorb and retain water fairly well if the worms are to thrive.
Good bulking potential: If the material is too dense to begin with, or packs too tightly, then
the flow of air is reduced or eliminated. Worms require oxygen to live, just as we do. Different
materials affect the overall porosity of the bedding through a variety of factors, including the
range of particle size and shape, the texture, and the strength and rigidity of its structure.
The overall effect is referred to in this document as the material’s bulking potential.
Low protein and/or nitrogen content (high Carbon: Nitrogen ratio): Although the worms
do consume their bedding as it breaks down, it is very important that this be a slow process.
High protein/nitrogen levels can result in rapid degradation and its associated heating, creating
inhospitable, often fatal, conditions. Heating can occur safely in the food layers of the
vermiculture or vermicomposting system, but not in the bedding.
Shredded paper or cardboard makes an excellent bedding, particularly when combined with
typical on-farm organic resources such as straw and hay. Organic producers, however, must be
careful to ensure that such materials are not restricted under their organic certification
standards. Paper or cardboard fibre collected in municipal waste programs cannot be
approved for certification purposes. Another material in this category is paper-mill sludge,
which has the high absorbency and small particle size that so well complements the high
C:N ratios and good bulking properties of straw, bark, shipped brush or wood shavings. Again,
the sludge must be approved if the user has organic certification.
v) Worm Food
Any types of biodegradable wastes:
1. Crop residues
2. Weed biomass
3. Vegetable waste
4. Leaf litter
5. Hotel refuse
6. Waste from agro-industries
7. Biodegradable portion of urban and rural wastes
Compost worms are big eaters. Under ideal conditions, they are able to consume in excess of
their body weight each day, although the general rule-of-thumb is ½ of their body weight
per day. They will eat almost anything organic (that is, of plant or animal origin), but they
definitely prefer some foods to others. Manures are the most commonly used worm feedstock,
with dairy and beef manures generally considered the best natural food for Eisenia. The
former, being more often available in large quantities, is the feed most often used.
Pre-composted Good nutrition; partial Nutrition less than with fresh food
food wastes decomposition makes digestion wastes.
by worms easier and faster; can
include meat and other greasy
wastes; less tendency to
overheat.
Biosolids Excellent nutrition and Heavy metal and/or chemical
(human waste) excellent product; can be contam-ination (if from municipal
activated or non-activated sources); odour during application
sludge, septic sludge; to beds (worms control fairly
possibility of waste quickly); possibility of pathogen
management revenues survival if process not complete
Legume hays Higher N content makes these Moisture levels not as high as
good feed as well as reasonable other feeds, requires more input
bedding. and monitoring
Corrugated Excellent nutrition (due to high- Must be shredded (waxed variety)
cardboard protein glue used to hold layers and/or soaked (non-waxed) prior
(including together); worms like this to feeding
waxed) material; possible revenue
source from WM fees
Fish, poultry High N content provides good Must be pre-composted until past
offal; blood nutrition; opportunity to turn thermophillic stage
wastes; animal problematic wastes into high-
mortalities quality product
x) Harvesting earthworm
After the vermicompost production, the earthworm present in the tub/small bed may be
harvested by trapping method. In the vermibed, before harvesting the compost, small, fresh
cow dung ball is made and inserted inside the bed in five or six places. After 24 hours, the cow
dung ball is removed. All the worms will be adhered into the ball. Putting the cow dung ball
in a bucket of water will separate this adhered worm. The collected worms will be used for
next batch of composting.
Worm harvesting is usually carried out in order to sell the worms, rather than to start new worm
beds. To accomplish this, the worms must first be separated from the bedding and
vermicompost. There are three basic categories of methods used by growers to harvest worms:
manual, migration, and mechanical.
a) Manual Methods: Manual methods are the ones used by smaller-scale growers, particularly
those who sell worms to the home-vermicomposting or bait market. In essence, manual
harvesting involves hand-sorting, or picking the worms directly from the compost by hand.
This process can be facilitated by taking advantage of the fact that worms avoid light. If
material containing worms is dumped in a pile on a flat surface with a light above, the worms
will quickly dive below the surface. The harvester can then remove a layer of compost, stopping
when worms become visible again. This process is repeated several times until there is nothing
left on the table except a huddled mass of worms under a thin covering of compost. These
worms can then be quickly scooped into a container, weighed, and prepared for delivery. They
are all labour-intensive, however, and only make sense if the operation is small and the value
of the worms is high.
b) Self-Harvesting (Migration) methods: These methods, like some of the methods used in
vermicomposting, are based on the worms tendency to migrate to new regions, either to find
new food or to avoid undesirable conditions, such as dryness or light. Unlike the manual
methods described above, however, they often make use of simple mechanisms, such as screens
or onion bags.
The screen method is very common and easy to use. A box is constructed with a screen bottom.
The mesh is usually ¼”, although 1/8” can be used as well. There are two different approaches.
The downward-migration system is similar to the manual system, in that the worms are forced
downward by strong light. The difference with the screen system is that the worms go down
through the screen into a prepared, pre-weighed container of moist peat moss. Once the worms
have all gone through, the compost in the box is removed and a new batch of worm-rich
compost is put in. The process is repeated until the box with the peat moss has reached the
desired weight. Like the manual method, this system can be set up in a number of locations at
once, so that the worm harvester can move from one box to the next, with no time wasted
waiting for the worms to migrate.
The upward-migration system is similar, except that the box with the mesh bottom is placed
directly on the worm bed. It has been filled with a few centimetres of damp peat moss and
then sprinkled with a food attractive to worms, such as chicken mash, coffee grounds, or
fresh cattle manure. The box is removed and weighed after visual inspection indicates that
sufficient worms have moved up into the material. This system is used extensively in Cuba,
with the difference that large onion bags are used instead of boxes. The advantage of this system
is that the worm beds are not disturbed. The main disadvantage is that the harvested worms are
in material that contains a fair amount of unprocessed food, making the material messier and
opening up the possibility of heating inside the package if the worms are shipped. The latter
problem can be avoided by removing any obvious food and allowing a bit of time for the worms
to consume what is left before packaging.
4. Advantages of vermicompost
• Vermicompost is rich in all essential plant nutrients.
• Provides excellent effect on overall plant growth, encourages the growth of new shoots /
leaves and improves the quality and shelf life of the produce.
• Vermicompost is free flowing, easy to apply, handle and store and does not have bad odour.
• It improves soil structure, texture, aeration, and waterholding capacity and prevents soil
erosion.
• Vermicompost is rich in beneficial micro flora such as a fixers P- solubilizers, cellulose
decomposing micro-flora etc in addition to improve soil environment.
• Vermicompost contains earthworm cocoons and increases the population and activity of
earthworm in the soil.
• It neutralizes the soil protection.
• It prevents nutrient losses and increases the use efficiency of chemical fertilizers.
• Vermicompost is free from pathogens, toxic elements, weed seeds etc.
• Vermicompost minimizes the incidence of pest and diseases.
• It enhances the decomposition of organic matter in soil.
• It contains valuable vitamins, enzymes and hormones like auxins, gibberellins etc.