SEMINAR ON

BIOGAS PLANT OPERATION AND

MAINTENANCE
SUBMITTED TO
DEPARTMENT OFALCOHOL TECHNOLOGY
VASANDADA SUGAR INSTITUTE
MANJARI [BK.]
Pune,
1.0 Introduction:

Molasses based distilleries: Classified as “ Red

Category ” by CPCB.

CREP :

CPCB :

ZLD :
Fermentation :
• Batch
• Fed-batch
• Cascade continuous
• Bio still continuous
Distillation :
• Atmospheric distillation
• Multi –pressure distillation
(6 liter to 15 liter per liter of alcohol )
Table1.0 General characteristics of raw spent
wash :

SR.NO PARAMETER BATCH CASCADE PROCESS BIOTILL PROCESS

PROCESS
1 Volume alcohol L/L 14-16 10-12 8-10

2. COLOUR Dark brown Dark brown Dark brown

3. pH 3.7 – 4.5 4.0 -4.3 4.0 -4.2

4. COD 80,000-1,10,000ppm 1,10,000-1,30,000 1,40,000-1,60,000

5. BOD 45,000-50,000ppm 55,000-65,000ppm 60,000-70,000ppm

6. Total solid 90,000mg/l 1,30,000mg/l 1,60,000mg/l

7. Total volatile 1,20000mg/l 1,60,000mg/l 2,10,000mg/l

8. Inorganic Dissolved 60000-70000 60,000-75,000 80,000-90,000

30000-40000mg/l 35,000-45,000mg/l 60,000-90,000mg/l

9. Chlorides 5000-6000mg/l 6000-7500mg/l 10,000-12,000mg/l

10. Sulphates 4000-8000mg/l 4500-8500mg/l 8000-10,000mg/l

11. Phosphates 200-300mg/l 300-500mg/l 1600-2000mg/l

12. Potassium 8000-12000mg/l 10,000-14,000mg/l 20,000-22,000mg/l

13. Sodium 400-600mg/l 1400-1500mg/l 1200-1500mg/l

14. Calcium 2000-3500mg/l 4500-6000mg/l 5000-6500mg/l

 2.0 Biomethanization or
Anaerobic Digestion :

2.1 Definition:
“ Anaerobic digestion is the biological
decomposition of organic matter in the
absence of oxygen.”
Two different stages:
(a) Acidogenesis
(b) Methanogenesis
Theory of Biodegradation :

When organic matter is removed from solution

by consortium of microorganisms two basic
phenomenam occur.

Oxygen is consumed by the microorganisms for

energy and new cell mass synthesized.

The microorganisms also undergo progressive

auto oxidation in their cellular mass.
 4H2 + CO2  CH4 + 2H2O

4HCOOH  CH4 + 3CO2 + 2H2O

CH3CH2OH + H2O  CH3COOH + 2H2

 Table 1.1Bio chemical steps in biomethaisation:

SR CORE PROCESS TYPE OF

NO. REACTIONS BACTERIA

1. Hydrolysis Fermentation of complex organics Fermentative

to soluble organics

2. Acidogensis Soluble organics converted to Acidogenic

volatile fatty acids (VFAs) and
alcohols .

3. Acetogensis VFAs and alcohols converted to Acetogenic

acetic acid , CO2 and H2

4. Methanogenesis Acetic acid converted to methane Methanogenic

and CO2,H2 converted to CH4 and
water
3.0 Factors Effecting Anaerobic
Treatment:-
Five basis factors affect anaerobic treatment
are

•Bacteria

•Food

•Loading

•Contact (mixing)

•Environment
3.1 Bacteria:
In fixed films reactor bacteria are retained and
immobilized on the plastic media , thus giving the
retention time for bacteria more than 100 days .
Many bacteria are present in reactor in suspected
form , volatile fraction of total suspended solid can
be used as an indicated of bacterial population in
suspension in the treated spent wash and should
not vary significantly from day to day . sudden
increase in this value would mean wash out of the
bacterial film inside the reactor.
3.2 Food:

Soluble organic matter in the spent wash is the

food for the bacteria .the ease with which bacteria
can utilize the organic matter varies from waste to
waste and also depend up on the initial
concentration of the organic matter .
3.3 Loading:
Loading rate can be controlled by the operator.
Loading rate can be control by
a)The regulating the flow of the incoming spent
wash.
b)The amount of COD per unit media volume
3.4 Contact (Mixing):
Waste stabilization can not occur unless the
bacteria are brought contact with the food .the
goals are so expose the bacteria to the maximum
amount of food and also to distribute the
Alkalinity generated or added thought out the
reactor. The benefits of mixing are speeding up
the process of the COD reduction and increasing
the amount of the gas production. Mixing is done
two ways.
3.5 Gas Evolution:
As gas is produced forms in pockets then gas
loose and rises to the surface. This action creates a
boiling effect resulting in some mixing.
4.0 Optimum/operating conditions of
anaerobic treatment:

•pH

•Temperature

•Alkalinity

•Volatile acids

•Toxicity
4.1 pH :-
One of the most important environmental
requirements is the proper pH . The acid workers
can function at any pH level above 5. But the
methane workers are inhibited when the pH falls
below 6.5. in reactor operation ,slight decrease in
pH will seriously inhibit the activity of the methane
workers .
Best operation range :- 7.0 – 7.3
Tolerable range :- 6.8 -7.5
The pH of the liquid under goinganerobic digestion
is controlled the amount of volatile acids produced
and the alkalinity in the reactor.
4.2 Temperature :-

Most Methenogenic bacteria have the temperature

optimum in the range of 30 to 40 0C. The methane
formers are effected by changes in temperature of
as little as 1 0C per day but the acid formers are
not as sensitive to temperature changes.
Temperature changes >20C will reduce methane
formers activity while acids are still forming .This
results in losing the buffering capacity and
possible in capacitating the reactor. The best
bacterial activity will occur in reactors operating at
a constant temperature some where between 35 0C
and 40 0C.
4.3 Volatile Acids :-

The production of organic acids is largely

dependents upon the volume of waste fed to the
reactor . In a normal or healthy reactor , acids will
be used as food by the methane formers at about
the same rate as they are produced under these
condition , The volatile acids of the digesting
reactor content usually runs in the range of 2500
ppm to 3500 ppm express as acetic acids. if the
same amount of waste is fed daily , a population
balance between the acid group and the methane
group will be maintained easily.
4.4 Alkalinity :-
Process stability depends largely on the reactor
ability to resist a change in pH. This is commonly
known as its buffering capacity measured as
alkalinity . During the digestion process the
methane moving also produced some buffering
material such as bio-carbonates , carbonates and
ammonia which goes in to solution . The amount of
buffer produced in this stage is usually enough to
balance the acid produce by the acid workers so
that the pH will remain constant . Alkaline buffers
come from two sources
Those all ready present in the incoming waste .
Those created as part of the digestion process .
4.5 Toxic Materials :-

It is important to keep toxic substance out of a

digester since they inhibit bacterial activity and
can cause complete failure.
5.0 Plant Maintenance :-
5.1 Process and operation of anaerobic digester :
Spent wash is generated in the distillery to collect the settling
tank. The spent wash is pumped from settling tank is inlet feed
pump. The inlet feed pumped is an above ground level. Spend
wash collect in the inlet feed pump is pumped though the heat
exchanger to maintain the temperature ,pressure gauge and the
temperature indicator provided in the delivery line. The flow
element fixed down in the steam heat exchanger to the
measure the spent wash flow rate to the digester. The flow is
electrically transmitted to flow indicator cum totaliser ,display
on the flow indicator.
5.1 Plate heat exchanger :
Heat exchanger of suitable capacity to cool SPENT WASH
from 350C to 370 C
5.2Bio gas digester:
The digester provided with lateral three agitator and one central agitator
for stirring continuous. First culture used for digester then spent wash
and lime water first used for reactor feed. In that reactor culture methane
gas producing bacteria present. The process is continued then only spend
wash is used for treatment the overflow of reactor is joined to the
degassing pond
In the anaerobic digester anaerobic micro organism decomposes
organic present in the spent wash to produce methane & carbon dioxide.
The digester sampling anaerobic ports shell be provided at every 2 meter
height. Retention time is 18 to 20 days.
5.3Agitator / Stirrer with A.C motor :
Central agitator:-

The specially designed agitator coupled with flame proof

motor is provided centrally to effectively mix the influent and
recycled sludge in the reactor.
5.4 Lateral agitator :
These specially designed laterally positioned
agitator in order to keep the biomass in suspended
state shall be coupled to flame proof. The agitator
design should be such that when agitator require repair
and maintenance liquidation of digester should not be
necessary.
Bio gas and sludge separation system and sludge
recycling arrangement is provided.
5.5 Degassing pond :
Here bubbling create i.e other then methane gases
is separate from culture. Here the culture from
degassing pond bottom is coming in lamella
clarifier.
5.6 Lamella clarifier :
In lamella clarifier the culture from degassing pond is
coming. In that arrangement is done as active culture
i.e biomass is settled down at bottom and overflow of
lamella is supplied for upper treated effluent out. The
active culture is recycled for digester from recycle
pump.
Thus recycling process occure in the technology i.e is
that active culture is not thrown out or removed means
active culture is supplied back to digester.
5.7 Gas holder :
The gas holder is dome shaped structure used for storage
or collection of gas from reactor from reactor top gas is
collected in gas holder by gas line from reactor to gas holder
first when we do not use the gas to boiler the gas is burned in
flare. In flare line and in gas line to boiler two flame arrester
were used. Gas outlet pipe from digester is connected to gas
holder – thought the purge pot. Gas flow is measured to an
orifice plate type gas flow meter. The outlet of from gas holder
is connected to gas compressor for boiler as a fuel. The gas
holder is the floating dome type with water seal. The floating
dome is filled with the flame arrester and pressure relief valve
service water line is provided to gas holder .
5.8 Bio gas blowers /compressor :
This shall be used to supply bio gas from gas holder to the
boiler. It shall be twin lobe with flame proof motors with inter-
connecting piping and valve.
This shall be of reputed make with required capacity and head
depending on boiler location. The MOC of impeller shell be
SS316/SS2205.
5.9 Safety device :
Various device to protect the plant and safety of human being
normally flame arrester, moisture traps, high level /low level
of pressure alarms for biogas control shall be provided as per
the norms of safety and to be approved by safety / factory
inspector.
Conclusion:-

Biomethanation of raw spent wash is noble method

to reduce the Biological Oxygen Demand (BOD)
and COD singnificantly. At the same time it
generates biogas which can be used for generation
of steam and power.
Rapid development are taking place in the
technologies and in future, Biogas plant with high
organic loading and low hydralic rention time, may
be available.
Reference Books:

Design of Anaerobic Process for the Treatment

Municipal wastes:

Author By: Frederic G. Pohland