Tanzania Traditional Energy Development and Environment Organization

(TaTEDO)











Cooking using biogas

BIOGAS TECHNOLOGY
Construction, Utilization and Operation Manual
TaTEDO
Off Shekilango Road, Kijitonyama
P.O.Box 32794
Dar Es Salaam Tanzania
Tel: +255 22 2700 438
+255 22 2700 771
Fax: +255 22 2774 400
E-mail: energy@tatedo.org
Website: www.tatedo.org

TABLE OF CONTENTS

CHAPETR ONE........................................................................................................................................... 3
1.0 BIOGAS TECHNOLOGY............................................................................................................ 3
1.2 BASIC PRINCIPLES OF BIOGAS PRODUCTION.......................................................................... 3
1.3 THE ANAEROBIC ENVIRONMENT................................................................................................. 3
1.4 Factors affecting yield and production of Biogas................................................................................. 4
CHAPTER TWO.......................................................................................................................................... 7
2.0 UTILIZATION OF BIOGAS................................................................................................................ 7
2.1 COOKING.............................................................................................................................................. 7
2.2 LIGHTING............................................................................................................................................. 9
2.3 GENERATION OF POWER.............................................................................................................. 10
2.4 COMPRESSION OF GAS................................................................................................................... 11
2.5 COMPARISON BETWEEN DIGESTED SLURRY AND FARMYARD MANURE.................... 11
2.6 UTILITY............................................................................................................................................... 11
CHAPTER THREE.................................................................................................................................... 14
3.0 THE VACVINA BIOGAS MODEL................................................................................................... 14
Advantage of VACVINA BIOGAS SYSTEM.......................................................................................... 14
CHAPTER FOUR...................................................................................................................................... 18
4.0 HOW TO CALCULATE REQUIRED DIGESTER VOLUME............................................. 18
4.1. Preparation of Construction Materials and Appliances .................................................................. 19
4.2. Digester construction............................................................................................................................. 21
4.2.1. Digging............................................................................................................................................... 21
4.2.2. Making digester foundation................................................................................................................ 21
4.2.3. Bricklaying of the walls...................................................................................................................... 22
4.2.4. Mortar and cement liquid plastering................................................................................................... 24
4.2.5. Making digester concrete.................................................................................................................... 25
CHAPTER FIVE........................................................................................................................................ 28
OPERATION AND MAINTENANCE..................................................................................................... 28
FEEDING OF BIODESTER..................................................................................................................... 28
5.1 Initial cleaning and verification of the system........................................................................................ 28
5.1.1. Initial feeding of bio-digester ............................................................................................................. 28
5.1.2. Daily feeding of manure..................................................................................................................... 28
5.2. Operation of biodigester ........................................................................................................................ 29
5.2.2. When gas burners in operation ........................................................................................................... 30
5.2.3. When whole system in use ................................................................................................................. 30
5.2.4. Warning of chemical into digester...................................................................................................... 30
CHAPTER SIX........................................................................................................................................... 31
MAINTENANCE AND TROUBLE SHOOTING................................................................................... 31
6.1.1 Common problems and Solutions........................................................................................................ 31
CHAPTER SEVEN.................................................................................................................................... 33
7.1. Practical exercise in calculation of total volume of a digester, construction materials and
investment cost............................................................................................................................................ 33











CHAPETR ONE


1.0 BIOGAS TECHNOLOGY
Biogas is the name given to the mixture of gases generated by the bio-degradation of
organic substances under the anaerobic conditions.

Sewage and agriculture waste contain organic substances with high molecular
compounds. In nature, given the proper temperature and humidity conditions, these
substances are broken into lower molecular compound material, inorganic matter and
gases. In high concentration, this process creates pollution and adverse hygienic
conditions for humans and animal. On the other hand, by properly treating the waste,
useful renewable energy can be obtained as well as organic fertilizer, thus effectively
changing waste into money.

1.2 BASIC PRINCIPLES OF BIOGAS PRODUCTION
Conversion of organic Substances into Biogas
Organic substances exist in wide variety of forms from living beings to dead organisms
and even animal droppings. Organic matters is composed mostly of carbon(C), combined
with other elements such as hydrogen (H), Oxygen (O), Nitrogen (N), Sulphur (S) to
form organic compounds such as carbohydrates, proteins and lipids.
In nature Microorganisms, mainly bacteria, through a digestion process break the
complex carbon into smaller substances

The digestion process occurring in presence of Oxygen is called aerobic digestion and
produces mixtures of gases having carbon dioxide (CO2), one of the main green houses
responsible for global warming

.
The digestion process occurring without oxygen is called anaerobic digestion and
generates mixtures of gases with main contents is methane (CH
4
) .The gas produced
which is mainly methane produces 5200-5800 KJ/m
3
when burned at normal temperature
and thus presents a viable environmentally friendly energy source to replace a fossil fuel


1.3 THE ANAEROBIC ENVIRONMENT
Anaerobic environment also called Methanogens-are essential for the production of
combustible biogas. These bacteria are very sensitive to the presence of oxygen and will
effectively operate only in anaerobic conditions
1
.

Hence the importance of designing an
air tight chamber, when constructing biogas plants






1.4 FACTORS AFFECTING YIELD AND PRODUCTION OF BIOGAS

Many factors affecting the fermentation process of organic substances under anaerobic
condition
The quantity and nature of organic matter
The temperature
Acidity and alkanity (PH value) of substrate
The flow and dilution of material

During the initial feeding of organic material or after adding new material, small
quantities of oxygen as well as aerobic bacteria will enter the digester. These aerobic
bacteria, along with some oxygen tolerant anaerobic bacteria present in the fermented
matter will burn the oxygen present and thus help restore and maintain anaerobic
condition

All have an important influence on the action of anaerobic bacteria responsible for the
bio-degradation process. Thus its important to understand their effects in order to design
effective man-made bio-digesters.

Temperature
The action of methane producing bacteria is strongly affected by the ambient
temperature. Though the biogas fermentation can occur at temperature ranging from 0

to
70
0
C, the effective methane producing occurs at temperature ranging from 25
0
C to 40
0
C
with 35
0
C as optimum temperature (see table 1) Keeping the digestion chamber at near-
constant temperature is important; constructing the digester chamber underground and /
or insulating it when in cold environment achieve this

Table 1: Biogas yield at various temperatures

















Temperature Biogas yield
(m
3
/1 ton of
dung/day)
15 0.150
20 0.300
25 0.600
30 1.000
35 2.000
40 0.700
45 0.320
The PH value
Methanogenic bacteria require a neutral environment (PH values between 6.5 and 8).
Higher values significantly impede the fermentation process (see table 2)

Table 2: Effective of PH on methane production
From 5 6 7 8 9 10 PH value
To 6 7 7 7.5 7 7
Biogas
yield
12.7 14.8 22.5 24.6 17.8 10.2

Carbon to Nitrogen ratio (C/N ratio)
Different organic matters contain different concentrations of carbon (C) and nitrogen (N),
these two elements being the bacterias most important nutrients.

Normally, fermentative bacteria will require thirty times more carbon than nitrogen.
Therefore the optimum carbon-nitrogen ratio (C/N) ratio of the digester input is 30/1.

Plant material such as weed and straw tend to have a very high C/N ratio resulting in
carbon redundancy and very slow decomposition. The C/N ratio of pig and cattle manure
is more suitable for biogas

Using both animal dung and plant materials input for the bio digester is NOT
recommended as it will reduce the fermentation process and result in incomplete
decomposition of the vegetal portion

Total solid Concentration
Total solid concentration (TS %) is a measure of the dilution ratio of the input material.
Its calculated by dividing the weight of the remaining portion after drying at temperature
of 105C (to constant weight) by the original weight.

The TS ratio is another important factor in the production of the biogas. Below an
optimal value, the lower the total TS concentration, the lower the yield of biogas. On the
other hand, when the total solid concentration values exceed the optimal point; the yield
of the biogas also decreases and the result mixture become too dense to effectively flow
through the bio-digester, the optimum dilution ratio for cattle manure is 1 part of manure
for 5 parts of water. Research conducted in China has shown that temperature and the
total solid concentration have an interdependent effect on the biogas yield (see table 3)
Use less water during the colder months of the year to increase biogas production

Table 3: interrelated effects of temperature and total solid concentration on the biogas
Total yield (ml) Total solid concentration (TS)-%
2 4 6 8 10 12
25-27C (summer
and autumn)
2915 3500 6295 4090 3960 2510
18-23C (winter
and spring)
1030 1080 1140 1380 2580 1850

The table shows that in winter months, the optimum total solid concentration is 6% and
figure increase to 10% in winter time

Retention time
In flow retention biogas systems (such as the VACVINA model), material is fed daily
into the digester, with the fermented materials being pushed towards the systems outlet.

Retention time is defined as the total time taken by material to travel from the inlet to
outlet. This represents the time allowed to the fermentation and gas production process.
Retention time is normally calculated using the total volume of the slurry in the digestion
chamber and slurry volume of the input materials

The higher the retention time the longer the materials stay in the digester and thus more
Biogas can be extracted. Although 50 days ensures almost complete digestion and gas
extraction (97.3-99.1%) for optimal cost-benefit ratio, bio digester volumes are usually
reduced to provide retention times of 40 days.

Table 4: Retention time and biogas produced for different input material
% of biogas extracted for different retention times
Material/Days 10 20 30 40 50 60
Human excreta 40.7 81.5 94.1 98.2 98.7 100
Pig manure 46.0 78.1 93.9 97.5 99.1 100
Poultry manure 34.4 74.6 86.2 92.7 97.3 100

Table 5: Optimal values for biogas production using
animal manure
Factor Optimal value
Temperature (C) 25-40
PH 7
C/N ratio 30
Total solid concentration % 6
Retention time (days) 40-50


Toxicity
Products such as pesticides, antibiotics, soap and rain water are not allowed to be fed into
the digester





CHAPTER TWO

2.0 UTILIZATION OF BIOGAS

Biogas is a valuable vehicle of energy containing 55 70% methane and 30 45%
carbon dioxide as well as small quantities of various gases. It is almost 20% lighter than
air and has an ignition temperature of 650 750C. Its calorific value is 20 mega joules
per cubic meter (or 4700 kcal)

Biogas is a cheap and clean fuel. It burns with a blue flame, which is soot-free. When it is
burnt in silk mantle lamps, it illuminates better than kerosene in patrolman lantern.
Biogas can replace petrol and diesel in engines. The quantity of biogas required for
different application is shown below.

Possible applications of biogas

















2.1 COOKING
The best use of biogas is for cooking. In order to get maximum heat value of the gas, it
should be burnt in properly designed stove. For a typical 0.45 m3 (16 cubic feet) per hour
stove, which is popular family type, the dimensions are as under:

Jet size 2 mm diameter
Area of jet: 3.98 mm2
Flame port size: 6.0 mm diameter
Number of port: 20
Total area of ports 565 mm2
Ratio of jet area to flame port area: 1:142

4 m
3

BIOGAS
5 kW
Electricity
Cooking
for 25
persons
Mantle
lamp 25
28 hours
5 hp engine for
one hour and
thirty minutes
Length of gas mixing pipe: 20 mm

It may be noted that biogas stove have large flame port diameter than stoves using
liquefied petroleum gas:

The procedure for the use of biogas stove is as follows:

i. Connect the stove to the gas tap by using a rubber pressure tube.
ii. The air adjuster should be closed fully.
iii. Light a match and keep it near the flame ports. Then open the gas tap and place
cooking vessels on the stove. The flame will be weak and long, which is an
inefficient way of burning the gas.
iv Now open the air adjuster to admit air up to the point when the burning gas creates
a noise. The adjuster may then be closed a little only to subside the noise and the flame
will be about 25 to 30 mm high. The upper cone of flame should touch the vessels; the
burner can only be adjusted for maximum efficiency when there is a cooking vessel on
the burner

Precautions
i. When necessary, the flame ports should be cleaned by using a jet of water.
ii. Whenever a smell emanates from the burning gas, the flow of air into the gas jet
should be checked. The smell should stop immediately if the supply of air is
increased.
iii. Keep the nozzle of the burner clean. Sometimes carbon particles get deposited on
the nozzle, which should be removed by erasing with sand paper. Or cleaning
with soap water.
iv. In a fixed dome type plant, when the gas pressure is high, the gas cock should
not be opened full so the flame may attain a height of 25 cm and cause accidental
burning of face, hair, et
2.2 LIGHTING
There is a big demand for biogas lamps in unelectrified rural areas. However, the
light produced is not as good as that from an electric bulb. Biogas lamps are
expensive and they consume large quantities of gas. Regular servicing of lamps
and good supply of mantles is required.

Single mantle biogas lamps for use inside and outside houses are available in the
market. Different types of biogas lamps are operated in the following manner:
i. Open the lamp and fit the clay Nozzle, also called a venturi. Make a hollow
ball of the mantle and tie it to the venturi. Close the lamp.
ii. Fix the lamp at an appropriate height. Care should be taken that it is not fixed
near thatched roof; otherwise there could be danger of fire.
iii. Connect the lamp with the gas tap using a rubber tube.
iv. Open the gas cock fully and also the gas regulator.
V Light the mantle and allow the gas to burn.
Vi The lamp should be allowed to heat up until it makes a noise. Then the gas
regulator should be adjusted so that the mantle is at its brightest illumination

Vii To turn the lump, only the gas cock should be closed.

Viii To relight the lamp, first a lighted match should be held close to the mantle,
through the hole in the bottom of the glass globe. Then turn on the gas immediately.

Precautions
i. Be careful that the sequence mentioned above is not reversed, otherwise there
will be a minor explosion and mantle will break. Allow the lamp to heat up until
it makes a noise and gives steady and good light.
ii. The clay nozzle and venture tube should be cleaned to remove dirt, carbon
particles, insects, etc whenever a new mantle is fitted.
iii. The glass globe should be cleaned with soap and water whenever necessary;
otherwise the glass will crack.
iv. The common reason for a lamp not working well is a defective needle in the gas
regulator. The needle must be long, thin and have fine point. It must come down
low enough to protrude through the jet and shut it off (Fig 8.7) If the needle
doesnt come down low enough, then file a whole (A) And make a slot so that it
can come down far enough. The gas regulator lever fits into thin hole.










10
2.3 GENERATION OF POWER

Biogas is an excellent and economic fuel for both petrol and diesel engine. However
the power obtained is less than that obtained when liquid fuel alone is used. As engine
using biogas become hotter than those on liquid fuels, their cooling has to be kept in
good condition.

Petrol engine can be run 100% on biogas except that little petrol is consumed for
starting up.

Diesel engine are modified to dual- fuel engine which use both biogas and diesel oil.

Biogas is introduced in the inlet pipe after it passes through the air filter. (Fig..) Gas
inlet devices are designed to suit different engine designs and inlet pipe and in order to
give the proper biogas/air mixture.

Injection of a little diesel oil to ignite the gas mixture in each stroke is essential for
normal running of the engine. This is because in diesel engine the temperature at the
end of the compression stroke is usually not over 700
o
c, where as the ignition
temperature of a methane/air mixture is 814
o
C.

Dual - fuel engines are marketed as gobar gas engine. The capacities of that engines
range from 3 to 96 H.P. (British Horse Power)

As the consumption of biogas in diesel is a bout 0.50 m3 gases per hour per P.H.B. or
0.65 m
3
gas per hour per KW electricity, large size biogas units are required to run
engine. The quantity of diesel oil saved by using biogas produced from different size
of biogas unit is indicated in Table .

Table Quantity of diesel oil saved by running a 5 hp dual fuel engine on
biogas

Table Quantity of diesel oil saved by running a
5hp dual fuel engine on biogas
Size of
biogas unit
(cm
3
)
Tie period for
which a 5 H.P
engine is run twice
a day
Quantity of
diesel oil saved
(litres/day)
8 4hr 3.6
15 6hr 30 minutes 5.8
25 12hr 10.8

The monetary benefit that accrues from the use of biogas for running diesel engine is
very attractive.

Operational of dual fuel is easy. After the engine has run with diesel oil for a while, the
biogas valve is opened slowly. This should automatically reduce the supply of diesel oil
11
through the action of the speed governor. In order to stop the engine, the biogas valve
should be closed first and then the throttle valve.

The gas produced from nightsoil alone or nightsoil in combination with dung contain a
high concentration of hydrogen sulphide. Such a gas can be used in diesel engine only
after passing it through a tube fitted with iron fillings. The iron fillings can be regenerated
by open-air storage.

It is important to operate the engine according to the instructions given in the manual
provided by the manufacturing firm. In case there is any problem, the servicing facilities
provided by the dealer or manufacturing firm should be availed of.

A dual fuel engine can be used for running an irrigation pump, flour mill, chaff cutter
thresher, etc.

Dual fuel generators helps in the production of electricity from biogas . Generators of
capacities ranging from 3.5 to 7.5 KVA are available in the market.


2.4 COMPRESSION OF GAS
Methane gas is unlike commercial available bottled butane or propane gas. It liquefies at
a pressure of about 47.4 kg per cm
2
at a critical temperature of 82.1
o
c. Further, it has to
be cleaned of all hydrogen sulphide as this would corrode the storage bottles. It should be
also cleaned of carbon dioxide as there is no advantage in compressing this. Considering
the cost of cleaning the gas, compressing it, purchasing a special high-pressure storage
bottle and transporting these heavy bottles, it is obvious that such a proposition is neither
economical nor practical.


2.5 COMPARISON BETWEEN DIGESTED SLURRY AND FARMYARD MANURE

The quantity of manure after processing through a biogas plant is more than farm yard
manure. About 25 30% of organic matter is lost in open pit composting as carbon
dioxide. Thus a bout 20 25% more quantity of manure is produced through a biogas
unit. Digested slurry is better manure than farmyard manure. Its nitrogen content can be
improved further by using cattle urine for dilution and preparation of dung slurry before
addition to a biogas unit or nightsoil by attaching a latrine directly to biogas unit.

2.6 UTILITY
Digested slurry can be used for manuring crops or fish ponds.

Manuring crops
Like compost and farm yard manure, the application of digested slurry to soil helps in
improving soil fertility. It provides humus which is an essential component of fertile
soils. It increases soil porosity and water holdings capacity. It supports the activities of
12
useful micro organisms which facilitate the release of nutrients to crop plants. All these
benefit add up to increasing crop production.

Digested slurry can be used effectively in any type of soil and for any crop. The
recommended application of manure is 10 tones per hectare in irrigated areas and 5 tones
per hectare in dry land areas. However the response of crops would vary. The increase in
crop yield is about 10 to 20%. Most responsive crops are vegetables, in particular root
crops such as carrot, radish, sweet potato, fruit trees, tea, coffee, sugarcane, rice and jute.

Digested slurry can use as fertilizer for crops by any one or the followings methods:

Liquid form
Maximum benefits are obtained when the slurry is used in liquid forms as it comes out of
a plant. It can be easily distributed in the field in the slurry outlet of the plant is linked
with the main irrigation channel. This would be possible only if the biogas unit is
installed on the farm. Otherwise slurry can be transported in discarded oil drums or
buckets, by wheelbarrow or bullock cart, which is more cumbersome.

Compost
Digested slurry is an excellent material for hastening the rate of composting of refuse
crop wastes, garbage, etc. It also provides moisture to the compostable biomass.

Two or three rectangular pits (common dimension 3m length x 2 m breadth x 1.5 m
height) or circular pits are dug. First, a layer or straw, animal bedding, leaves, garbage
etc. is put in the pit. Slurry is allowed to flow n to the pit. Alternate layer of refuse and
slurry are made until one pit is full. It is an advantageous to place bamboo poles having
holes 10 cm apart in the compost able materials for aeration. (Fig.). Finally the pit
should be plastered with mud layer. This will minimizes loss of nitrogen from the pit.
After about three or four months the compost will be ready for application in the fields
After one pits is field up, the same procedure should be repeated for filling another pit.
Composting is done in heaps, particularly in high rainfall areas. Digested slurry and
refuse are first mixed in equal proportion and a pile is built about 2 3 m in width at the
base, 1.0 m in height and 3-5 m in length. The sides are tapered so that the tip is about 0.5
m narrower in length and width than the base. Then the heap is plastered with a thin layer
of soil. (Fig..) It may be kept under a tree to protect it form rain. The compost will be
ready about three or four months. If possible, the heap can be turn up side down after 15
days of initial filling and for a second time after another 15 days. During this process,
water may be added if the materials look too dry. In this way, the compost will be ready
in two months. Composting of slurry with other refuse is a Common practice. However,
it requires availability of adequate land near the biogas plant.

Semi dried
The slurry may be spread in shallow pits and allowed to dry partially. It is then scraped
and stored in piles which should be covered with plastic sheets or mats until applied to
the field. Complete drying of slurry under the sun should be avoided.
13
A slurry filter bed made near a plant can help in quick drying. The dimension of such a
bed for a 4 m3 size plant would be 3m long, 1.2 m broad and 0.6 m deep with an opening
at opposite end of the sloping bottom (Fig..). The digested slurry is lead through a
channel to flow and cover a 15 cm compact layer of green or dry leaves filled in the bed.
Water from the slurry filters downs and flows out of the opening into a pit. This water
can be reused for preparing fresh dung slurry for feeding the plant. Semi solid residue left
on top of the bed has the consistency of fresh dung and can be transported easily to field
for application as top dressing for crops in particular potato and sugarcane.

Manuring Fish ponds
Digested slurry can also be used as fertilizer for fish ponds. An ideal feed for Singi, an air
breathing cat fish, may contain equal quantities of mustard oil seed cake, bran and
digested slurry. This supplementary diet should be providing at a rate of 3 5% of the
body weight of the fish. Utilization of digested slurry in pisciculture helps in the
reduction of cost of supplementary fish feed.






























14
CHAPTER THREE

3.0 THE VACVINA BIOGAS MODEL

The system consist of a flat-top rectangular underground digestion chamber with external
plastic gas reservoirs, inexpensive siphons, inlet mixture tank and slurry output tank

3.1 ADVANTAGE OF VACVINA BIOGAS SYSTEM

The gas plant provides comfort and saves expenditure by supplying Clean and
inexpensive renewable energy fuel for cooking and lighting
Improved hygiene and health conditions in the household compound [eliminating
raw and untreated animal manure and night soil] this reduce bad smell, flies and
parasites around the house.
With improved biogas stove reduce smoke from the fuel wood and leaves all
family especially women from eyes problem caused by smoke
Reduction in CO
2
emissions and deforestation pressure by substituting fossil fuel
with biogas
Long-term improvement in the financial situation of house holds by reducing fuel
and chemical fertilizer expenses
Improved of soil fertility and reduction of soil degradation by the use of the bio
digesters digested effluent as organic fertilizer
Allows for safer and cleaner animal husbandry activities especially in crowded
and peri-urban areas
Reduce workload of women for fuel gathering, cleaning of pots and pans


15

Fig 1: VACVINA model




The digester
The main digestion chamber is an underground rectangular tank made of bricks and
motor fig 1. However, the shape of the tank can be adjusted to the specific configuration
and meet the constraints of the family compound while retaining the sufficient volume.

One of the great advantages of these models the concrete flat top of the digester can
provide a clean and dry floor for the cattle stable.

The inlet
The inlet is a simple inexpensive off-the shelf siphon pipe made of glazed-terra cotta

16


Fig 2 the inlet siphon allows animal dung to be fed into the digestion chamber

The system normally comprises two or three siphon inlets allowing the lavatory pan and
the latrine to be connected in addition to cattle stable. These inlets play an important role
in preventing the formation of a hardened scum layer by allowing the new material to
drop on top of the liquid surface, thus wetting and breaking the top layer. As new
material fed daily the surface is continuously stirred and broken.
In additional siphons also act as the safety valve with 15cm of water column, they
effectively ensure gas tightness of the main chamber.
2. Mixing
tank
1. Digestion tank
3.Technical
top
4. Slurry tank
5.Toilet
1. Digestion tank
2. Mixing
tank
3. Technical
top/hole
4. Slurry tank


Fig 3: VACVINA digester

The outlet

The outlet consist of straight pipe, normally made of PVC 110mm diameter and 1 meter
long, at an angle of 45C incline in the digestion chamber. Its function is to drain the
effluent (liquid form) from the digester to the slurry pit and set the level of the liquid in
the digester

The outlet pipe should be positioned lower than the inlet pipe, with its end opening about
35cm lower than the digester cover. To ensure gas tightness of the digester, the other end
of the pipe should deep extend deep under the static surface of the liquid in the digestion
chamber (see fig4)

17

Fig 4: The outlet

The slurry pit
The slurry retention pit is constructed near the outlet of the digestion chamber and is used
to store the systems effluent for later use.

The amount of effluent flowing into the slurry pit is equivalent to the input fed into the
digester.

However the volume of the slurry retention pit must be calculated according the intended
usage of the slurry.

Its important to remember that, in order to ensure the normal functioning of the system,
the slurry level must always be kept lower than the digester outlet


Gas reservoir
The external gas reservoirs are used to collect and store the biogas before being used as
cooking fuel see fig 5. One gas reservoir should be enough for a normal family. However
if the household has the larger number of animals, more gases will be generated and more
gas will be required
18
The bags are made of two layers of 20c thick polythene tubing and have the storage
capacity 1.5-2 cubic meters.
In order to increase the gas pressure, rubber bands is tightened around the reservoir and
then loosen again after finished using the burner to allow the bag to inflate it-self.

Fig 5 Reservoir




CHAPTER FOUR

4.0 HOW TO CALCULATE REQUIRED DIGESTER VOLUME
The size of a biogas plant which can be used for storing manures collected from
husbandry activities is calculated based on the number of cattle raised by each household

In general, the calculation of the volume of a bio-digester (fed with animal manure,
urine) depend closely on daily feeding of manures by each household, retention time,
concentration of manure and water solution before being fed into the digester through
siphon inlets, etc.

For a VACVINA biogas plants, actual volumes (V) can be derived through the following
formulas:


Fig 6 Digester volume

V= V
gas +
V
dig..
(1) (See Fig. 6)
Vdm
Vgas
Gas
Reservoirs
19
Where
V
gas
: Gas volume in the digestion chamber
V
dig
: Slurry volume in the digestion chamber

And V
dig
= T x V
dm..
(2)
Where
T: retention time of the slurry in the digester (i.e. 40 days)
Vdm: daily amount of water and dung (liter/day) fed in the digester

And V
gas
= h
1
S
Where S: Ares of the Flat bottom slab of the digester (m
2
)
h
1
: Distance between the bottom of the cover slab and the static liquid surface in
the digester (m), normally be 35-40cm

When use cattle manure Vdm can be calculated as follows
Vdm= (w + nL) T (3)
Where
W: the amount of water to dilute the dung of n cattle
L: The daily average amount of dung per cattle (l/day)
The optimal dilution ratio of input material is 1:5 (one part of manure for five parts of
water)
Put w= 5nL into (3) and from (1), (2), and (3) we have
V= V
gas
+ (5nL + nL) T= V
gas
+ 6nLT
Hence
V= h
1
S+ 6nLT.. (4)
Where n: Regular number of Cattle
L: Daily average amount of dung per animal (2litre/head/day)
T: Retention time (Days)
h
1
: Distance between the bottom of the cover slab and the static liquid surface in the
digester (m), normally be 40cm (h
1
=0.4m)
S: Ares of the Flat bottom slab of the digester (m
2
)
For Retention time of 40 days (T=40)
V= 0.4S + 240nL

Fig 6. Digester volume


4.1. Preparation of Construction Materials and Appliances
The materials and appliances for construction of a standard 7-m
3
biodigester
VACVINA mode are given in the following table:
No. Description Unit Quantity
1 Solid brick small size piece 1,400
2 Cement kg 600
3 Yellow sand (not mixed with silt)
m
3

1.5
4 Gravel or small stone (1 x 2 cm)
m
3

0.5
20
5 Iron bar (diameter of 8 mm and
smooth)
kg 30
6 Metal pipe piece 1
7 PVC pipe (diameter of 21 mm) m 4
8 Valve & metal connector set 15
9 Plastic gas-conducted pipe ( 21) m 15
10 Gas reservoir polythene bag bag 2
11 Siphon pipe set 2
12 Biogas burner set 2
13 Glue and paper tape
14 Hoe, digging hoe, shovel, pickax, ax, rotten
bucket, pounder for compacting soil, crowbar,
hacksaw, saw, trowel, mortarboard for
plastering, water hose, plastic bucket, mortar
bucket, drum, zinc sheet, palm broom, brush for
plastering mortar, water container, tent, motor
rubber tube, wooden pole, torch, vibrator, jack,
cow string, nail, measuring tap, metal-cutting
scissors, pliers, Adjustable spanner and wooden
mold.
21
4.2. Digester construction

Construction site selection
The biodigester for every household should be constructed at the most favorable location
which makes it easy for transportation of manure from animal farms to feed in the tank.
The biodigester, therefore, should be placed nearby or beneath pigsty, while its shape
should be designed according to the area condition or situation.

4.2.1. Digging
After the selection of the construction site and design, we start digging a digester pit and
its size must be a bit larger the required tank that makes us convenient for construction.

In determining the size of a digester, it depends on the actual condition of the land area
for construction. However, in order to smoothly run the household investment in
biodigester building, it would be ideal to be pay attention to the following characteristics:
the digester depth ranging from 1.5 to 5 metres, most favorably from 1.8 to 2 metres,
width of less than 2 metres, and length depending on capacity desired.

Remark: If the dug pit is by chance in area with low level of underground water, it is
necessary another small pit be prepared to temporarily store it and then pump or remove
it so as to make the foundation work convenient.


4.2.2. Making digester foundation
After the digging is completed with the accurate determination of dimensions of a tank,
we continue to construct its supportive foundation as following steps:
Lay pieces of broken bricks or small stones (diameter of 4 x 6 cm) for 10 cm layers and
then compact and spread them evenly;
Apply gravel or small stone (diameter of 1 x 2 cm) for another layer of 3 cm thickness;
and
Make 5 cm thick concrete at ratio: 1 cement, 2 sands and 3 small stones (dia. of 1 x 2
cm).


22







Fig 7 digester hole and underground

In case there is too much underground water while conducting the concrete work, it needs
to be gradually pumped out of the pit, or a plastic sheet needs to be laid over the
foundation area, in order to protect leakage or disturbance from the water.

4.2.3. Bricklaying of the walls
While the digester foundation work is finished, we commence to lay bricks to construct
the walls. In construction of the tank walls which is similar to that of high buildings with
their thickness of 10 cm (i.e. thickness of single brick), high quality solid bricks are used
together with cement and sand at ration of 1 cement and 4 sands.

Notice: While doing the bricklaying, holes are technically determined for installing some
materials such as inlets and outlet (see figure 3).
Inlets are fixed at place, which is closed to the top edge of the digester wall, and the
dimension of an inlet is 30 cm high and 15 cm wide. However, they can be positioned
apart.
Remark:
If the plant is built on soft and wet land (bad condition), iron bars should be added
in the concrete to increase strength of the foundation. The iron bars should be 8 mm in
diameter and cast in checked pattern with gaps of 20 cm.
23
The position of an outlet is at 30 cm away from the top edge of the digester wall, and it
must be 30 cm high and 15 cm wide.







24
Fig 3: Position for installing inlets and outlet


4.2.4. Mortar and cement liquid plastering

Mortar and cement plastering work has the most significant role in ensuring the
construction quality standard by which the tank must be waterproof and airtight, thus
internally plastered mortar must be firm. The sand mixed with cement for plastering the
walls must be purified so that it is well mixed with the cement at ratio: 1 cement-3 sands.
It is overall suggested the thickness of plastered cement and sand should be even, and the
plastering should be pressed firm and smooth. At the corner of the walls, inward corns
are recommended.

The plastering of mortar and cement liquid should be carried out the following steps:
First, the interior wall faces should be cleaned with clean water; Solution of cement (at
medium rate), then, needs to be smoothly applied on the wall faces at the thickness of 1
mm (considered as the 1
st
layer);

After that, one more layer of mortar (cement and sand) at 1 cm thickness should be
made and then left it a bit dry on surface before it is evenly smoothed (2
nd
layer); Wait for
1-2 hours after plastering of the first and second layers to let them a bit dry, and then the
cement solution is additionally spread at thickness of 1 mm in which the application
method is similar to that of the first layer (3
rd
layer); and One hour later, cement solution
needs to be applied at thickness of 1 mm ((4
th
layer).

While plastering the mortar over the wall faces, 5 cm gap down from the peak of every
wall is left blank to connect with the digester concrete cover later. After the top concrete
is made, parts with shortage of mortar must be additionally sealed. The corners between
the digester cover and the walls must be conically sealed with mortar inward to ensure
airtight (figure 4).






25
39
Plastering the face of tank wall
by mortar of cement & sand
2
1
2
Hole for Inlet
Hole for Outlet




Fig 4: Plastering mortar inside the tank to protect leakage

4.2.5. Making digester concrete
After the walls are built and plastered with mortar and cement solution, a top reinforced
concrete is made to construct the digester cover.
As the tank concrete has the role to serve not only as a cover to create airtight but also as
a flat floor for animal rising, the concrete must be 8-10 cm thick (according to the type of
animals raised).
The surface of the concrete must be flat, and it must be made directly by the mold
assembled at the construction site (Any reinforced concrete produced at the factory is not
recommended for used in this purpose).

The preparation as well as construction technique are carried out in the same way as
those of constructing tall buildings or houses we are staying in (fig 5). The construction
process is as follows:
26
a. How to assemble mold and install supporters of the mold to construct digester
concrete
The concrete mold and its supporters must be firmly and technically installed (the mold
frame must have its strong supporters).


Fig 5: Assembling wooden mold and its supporters

b. How to determine and make the technical hole during construction of top
concrete
A technical hole with the dimension of 70 x 70 cm on top must be readily made by a
mold, which had already been prepared with small wooden pieces and shaped in a semi-
cylinder frame with the dimension of 70 x 70 cm on top, 50 x 50 cm at bottom, and 10
cm high (Fig 6). Iron bars used to construct the technical hole should be 8 mm in
diameter and cast in square pattern of 10 cm
2
.




Fig 6: Technical hole

Assembling wooden mold and supporters for concrete
27
To serve as a hole to go in and out of the tank to remove the wooden floor and supporters
of the mold from interior digester when the concrete is, according to the determined
construction technical standard (7 days), dry and firm enough. Also, it acts as a hole to
enter and get out of the tank to complete the last work such as installation of the inlets
and outlet, etc.
To be a hole for cleaning the digester when there is blockage or after it has been operated
for years (normally estimated 7-10 years).
The position of the technical hole should be analytically and appropriately determined to
enable convenient operation (while going in or out of the digester, ensure that it doesnt
affect the outlet and inlets ), and it must not disturb or interrupt animal raising
activities.



























28
CHAPTER FIVE

OPERATION AND MAINTENANCE

FEEDING OF BIODESTER
5.1 Initial cleaning and verification of the system
Before operation is started, clean interior digester and after that recheck the installed
system to ensure airtight or leakage proof. In addition all components of the system must
be checked to ensure gas-tightness, includes
Sufficient amount of water in the safety valves
All siphons filled with water
Lavatory pan siphon (if any) filled with water
All gas valves (main gas valve, stove tap) closed

5.1.1. Initial feeding of bio-digester
Once the construction of biodigester and installation of appliances are complete the bio-
digesters should be operated immediately. To kick start the anaerobic process and ensure
proper colonization of methanogenic bacteria, the most appropriate in put are cattle,
poultry or pig manure. In order to obtain biogas faster, 800-1,000 kg of fresh manure
[collected and stored not more than 7 days] should be prepared in advance as raw
material for the first feeding, and water is filled together with manure until it is seen
flowing out through outlet.

Once the gas reservoirs start to inflate, the biogas can be used for cooking. Initially, the
gas will contain some amount of air that will be flushed out as the system usedThe
process of bio-degradation and biogas generation will take 5-10 days. [Slightly more days
in cold temperatures].
5.1.2. Daily feeding of manure
To ensure durable and sustainable operation of biodigester, it is necessary to daily feed
the digester with raw materials collected from cattle shed or pigsty and toilet. Fresh
material must be fed daily in the digester to sustain the cooking fuel need of the family.

Its important to ensure that the following materials are NOT fed in the digester:
- Soil, sand and stones
- Branches, twigs and straws
- Soaps and detergent solution, cleaning chemicals, antiseptic products and rain
water
For a family of 7 persons, an average of 15-20Kg of cattle dung must be fed daily.
Together with the above-mentioned manure, water is added at ratio of 1manure to 5
waters.



29
If water is overfed, then some amount of non-digested manure is flown out through
outlet, since its digestion is limited, resulting in less gas production and the environment
problem cannot be all solved, meaning manure still carries bad odor and diseases.

In this case, water for bathing cattle during hot weather should not be directed into the
digester but through canals prepared by the owner upon request in order to avoid excess
water in the tank.
Taking full advantages of the VAVCVINA flat-top design with multiple inlets siphons
inlets, a latrine is often constructed at the same time as the bio-digester. Water used to
clean latrine must be taken into account when calculating overall water-dung ratio.

5.2. Operation of biodigester

5.2.1. When reservoir is full of gas
We can start to use biogas for cooking. At the beginning, if gas cant be ignited due to the
reason that it is not of high quality as it contains a lot of carbonic dioxide resulting from
digestion of manure with oxygen remaining before closing the tank, first gas should be
released from the reservoir, and wait until the next gas comes in which the balloon is
refilled.
Keep in mind to turn off gas valve soon after operation is ceased. To start fire, first ignite
fire-distributing device of the burner with lighter, and then adjust gas flow and flame to
the desired level by the valve.
To obtain evenly distributed flame while operation, fire-distributing device made of
copper should be frequently cleaned.

Fig 20: Feeding manure



30
5.2.2. When gas burners in operation
If biogas doesnt supply sufficiently for cooking, rubber should be employed to tie across
the reservoir to increase pressure inside the reservoir. After cooking, attention should be
paid to remove rubber from the reservoir so that it can receive new biogas from the plant.

5.2.3. When whole system in use
If gas reservoir is seen loose, check the pipelines and gas reservoir system itself, valves
immediately for fear that they are bent or clogged, or control water in the bottle safety
valve or at siphon inlets that it could be empty. If so, repair must be done urgently.

5.2.4. Warning of chemical into digester
Chemicals that are not allowed into the digester are soap, paint, and rainwater as they
interrupt reaction of bacteria in anaerobic condition. Presence of those chemicals may
cause less biogas production or even stop production as a whole.
31
CHAPTER SIX
MAINTENANCE AND TROUBLE SHOOTING

6.1.0 Tips and techniques
During the first few days of operation, the biogas might contain other gas which
makes it not well flammable. If this is the case, discharge entire bagful of gases
and wait for a next day for a production of new biogas.
Make sue all gas valves are closed when not using biogas for cooking.
When using the stove, remember first light a flame then slowly open the gas valve
and adjust the flame height and intensity according to the cooking need.
To unsure a stable and clean flame, the copper regulator portion of the burner
must be cleaned at least once a week
If the gas pressure is too low, use a rubber band to constrict the gas reservoir fig
21, the band must be loosen after use to allow the bag to re-inflate.
The main gas should be installed out of reach of children and kept locked when
fuel is not in use




6.1.1 Common problems and Solutions
Problem Cause Potential solution
Bio- degradation process has not started Wait for few days for the
process to start
Insufficient bacteria content Wait for few days for the
process to start
No gas or not
enough gas
Feed the digester with pre-
treated material
32
Gas leakage Check the gas pipe line
Check the water level in the
safety valve
Check the water level in the
digestion chamber cover, in
the siphons and in the
lavatory pan


Not enough feeding material Feed as per
recommendation
Holes or tears in the bag Repair it with nylon
bandage or replace the bag
Gas reservoir
do not inflate
as they should Gas is leaking from the gas pipeline Repair the gas pipeline by
welding
Flush the gas reservoir and
wait for its replacement
with the new biogas
Gas does not
burn properly
Too much air or co
2

Add a small amount of lime
solution into the digester(
be very careful not to add
more)
Not enough gas pressure Constrict the gas reservoir
with a rubber band or install
a gas extracting device
The flame
often
extinguishes
Water has accumulated in gas pipeline Drain water from the gas
pipeline



















33
CHAPTER SEVEN
7.1. Practical exercise in calculation of total volume of a digester, construction
materials and investment cost

TaTEDO Center Goba Mbezi beach
There are 30cattle.
Retention time = 30 days given, length = 3.3 m, width = 2 m, depth?

Remark: 1 adult cattle quantity of manure per pig = 2 kg/day
Calculate total volume of the intended digester, number of bricks, cement, sand, small
stone and iron, and investment cost?
Solution

Steps:
1. Calculate digester volume and depth
2. Calculate the volume of foundation [Bear in mind to extended the exterior
dimension by 10 cm each]
3. Calculate the area surface of exterior walls
4. Calculate the volume of top concrete
5. Calculate the number of reinforcement steel
6. From all above you can have the quantity of cement, bricks, sand & gravel gravel


1. Digester Volume
Formula: V= Vgas+ 6nLT

V
dm

= 6nLT?
n = (total no. of Cattle) = 30 Cattle, L (amount of manure/Cattle/day) = 2 liters = 0.002
m
3

T (retention time) = 30 days
Hence, V
dm
= 6 x 30 x 0.002 x 30 = 10.8 m
3

Total volume of digester V

= V
gas
+ 10.8
But V
gas
= h
1
S=0.4 x 3.3 x 2 = 2.64 m
3
(Length = 3.3 m and width = 2 m)
Thus, V

= 2.64 + 10.8 = 13.44 m
3
13.5 m
3

And V

= 13.5 = 3.3 x 2 x Depth
Therefore, Depth = 13.5/ 6.6 2 m
Conclusion:
Interior length = 3.3 m or exterior length = 3.5 m [assume a brick of 10 x9x23cm] width]
Interior width = 2 m or exterior width = 2.2 m
Depth = 2 m
Digester volume = 13.44 m
3
13.5 m
3

Volume of Foundation

34














For 5cm layer concrete mixture and small stone and mixture of sand and gravel

Quantity of cement is found from the top layer concrete of 5cm

Volume =3,6mX 2.3mx0.05 m=0.414m
3








So 0.414m3 require 325 x 0.414 kg=134.55 cement=5.385 bucket [of 25litre oil/paint
bucket] 5.5 bucket

So cement: sand: gravel = 5.5: 11: 16.5 buckets
For remaining layer of 15cm, Volume is 0.15mx3.6mx2.3m= 1.242m
3

So quantity of gravel stone is 1.242 x 0.025m
3
=0.031m
3

So the quantity of gravel in bucket =0.031/0.02=1.55 bucket

Cement =5.5 bucket (1),
Sand=11 bucket (2)
Small stone {1x2cm} Gravel = [16.5bucket] (3i)
Small stone {1x2cm} Gravel=1.55 bucket (3ii)

2. Quantity of Bricks
Total area of wall faces?
Total area of wall faces = 2(3.5 x 2.00) + 2(2.2 x 2.00) = 22.80 m
2

Given 1m
3
requires 325 kg of B200 cement
And ratio is 1:2:3 cement: sand: gravel

1 sacs of 50kg cement =2 bucket of 25 litre [oil/paint bucket]
35

So, number of bricks for all wall faces = 24 bricks/m
2
x 22.80 m
2
= 550 bricks
And number of bricks for wall foundation = (1.2 x 2 + 1.2 x 2) x 24 = 116 bricks + 40
mixing tank brick= 156 bricks

Therefore, total of bricks = 550 + 156= 706 bricks for both digester, mixing tanks and
slurry
3. Quantity of Cement & Sand for Laying Bricks and Plastering Mortar for Walls, and
Small Stone for Top Concrete
a. Quantity of laying bricks & plastering mortar for walls = 22.80 m
2
x 25 kg/m
2
= 570 kg







So, 570 kg of cement for laying bricks and plastering walls = 570/ 25 =22.8 buckets




b. Amount of sand for laying bricks & plastering the walls = 22.8 x 3 = 64.8 buckets
Cement=22.8 bucket (4)
Sand= 64.8 bucket (5)


c. Quantity of cement for top concrete
Assume V
1
for volume of the top concrete and size of concrete is 8cm
So, V
1
= 0.08 x 3.30 x2.3 m
3
=0.644m
3

Given 1 m
3
of concrete = 322 kg of cement
Therefore, quantity of cement for concrete = 0.644 m
3
x 325 kg/m
3
209 kg
d. Quantity of sand & small stone for top concrete
We know, 1 bucket of cement = 25 kg
So, 276 kg of cement for concrete = 209: 25 9 buckets (6)

On the other hand, ratio of cement, sand and stone for concrete is 1: 2: 3
Then, Quantity of
Sand = 9 buckets x 2 = 18 buckets (7)
Small stone (1 x 2 cm) = 9 buckets x 3 = 27 buckets (8)
Given 1 m
2
of wall face requires 25 kg of cement
Given 1 m
2
= 24 solid bricks [SISPO] =48 KIDT=9 CEMENT BRICK
Note: this depend on the size of the brick
Given 1 sack of cement = 50 kg = 2 buckets
(paint bucket of 25liter)
(Given ratio of cement and sand for laying bricks and
plastering walls is 1cement: 3 sands)
36








4. Total Amount of Construction Steel (D=8 mm) for Casting Concrete
Distance of steel cast in length of digester = 3.3 + 0.35 = 3.65 m (interior length = 3.3 m)
Distance of steel cast in width of digester = 2 + 0.35 m (interior width = 2 m)





So,
Number of steels cast in width of 2.35 m = (3.65/ 0.15) + 1 25 steels
Number of steels cast in length of 3.65 m = (2.35/ 0.20) + 1 13 steels





Therefore, total quantity of steel for casting concrete = [(25 x 2.35) + (13 x 3.65)] x 0.386
= (58.75 + 47.45) x 0.386 41 kg) OR








Given, a gap from one steel to another cast in width = 0.15 m
And 0.35 is an invariable coefficient for calculation of one length of steel
We know, 1 m of 8-mm diameter steel = 0.386 kg
1 length of 8mm diameter is 12 m long
Therefore,
Total of cement = (1) + (4) + (6) =5.5 + 22.8 + 9 37.3 buckets
Total of sand = (2) + (5) + (7) = 11 + 64.8 + 18 93.8 buckets
Total small stone (1 x 2 cm) = (3i) + (8) =16.5+27 44 buckets
Total medium stone = (3ii) =1.55 bucket
Number of length required = [(25X 2.35) + (13X3.65)] / 12=8.859 length
Conclusion
Investment Cost for a Bio-digester with Volume of 13.5 m
3

1. Total volume of digester V

= 13.5 m
3

2. Total number of bricks = 1,925 bricks
3. Total quantity of cement = 37.3 buckets (paint bucket) = 19 sacks of cement
4. Total quantity of sand = 94 buckets = 94 x 0.02 = 1.88 m
3
(1 bucket = 0.02 m
3
)
5. Total quantity of stone (size 1 x 2 cm) = 45 buckets = 45 buckets x 0.02 = 0.9 m
3
6. Total quantity of stone (size 8 x 10 cm) = 1.55x 0.02 = 0.031 m
3

37
Investment cost for 13.5 m3 biogas plant.
No. Description Unit Qty
Unit Price
(Tshs) Total
1 Cement
50kg
sacs 19 15,000 285,000
2 Steel (D = 8 mm) Length 9 11500 103,500
3 Sand m
3
1.88 18,000 33,840
4 Solid brick piece 706 250 176,500
5 Stone (size 1 x 2 cm) m
3
0.9 36,000 32,400
6 Stone (size 8 x 10 cm) m
3
0.03 16,000 480
7 Biogas burner set 2 8,000 16,000
9 Plastic pipe m 15 1,600 6,000
10 Plastic valve unit 1 1,200 1,200
11 Metal valve unit 2 2,500 5,000
12 Plastic reservoir m 7 2,500 17,500
13 Glue bottle 1 1,500 1,500
14 Paper glue roll 1 1,500 1,500
15 Ring (plastic) unit 10 800 8,000
16
Zinc pipe and clip ( = 20 mm, L =
2.5m) set 2,5 1,000 2,500
18 Metal pipe ( = 20 mm, L = 1 m) and
metal connector of 20 mm at one end
and of 27 mm at the other

m 1.5 2,800 4,200
19
Metal connector with gear at both
exterior ends

set 1 2,000 2,000
21 PVC pipe ( = 20 mm) 1 length 1 6,000 7,000
22 PVC L-shaped pipe ( =20 mm) unit 6 500 3,000
23 PVC T-shaped connector ( = 20 mm) unit 4 500 2,000
24 PVC siphon set 2 10,000 20,000
25 Adaptor set 1 20,000 20,000
26 Nail (L = 5 cm) kg 1 3,000 2,000
27 Nail (L = 8 cm) kg 0.5 2000 1000
28 Nail (L = 10 cm) kg 0.5 2000 1000
29 Labor cost for digging m
3
14.4 4,500 64,800
30
Labor cost for constructors and
technician Digester 1 300,000 300,000
Grand Total 1,117,920
Remark: US$ 1 = 1200 tshs on July 2008

38
5.1.2. Mr. George Ntenga
V=7.5 m
3
, Number of adult Cattle = 10, retention time = 40 days, available land 2mx6m
and 2m deep
Notice: 1 adult Cattle (manure), amount of manure/pig/day = 2 kg.

Calculate total quantity of bricks, cement, sand, small stone and construction steel and
investment cost?
Solution

From all above you can have the quantity of cement, bricks, sand & gravel gravel
1. Dimension of the bio-digester tank
V= 0.4S + 6nLT
Hence 7.5m
3
=0.4mxS + [6x10x0.002m
3
x40}
S=[7.5-4.8]/0.4=6.75m
2

By keeping the width at 2m length should be 3.4m
Conclusion 1:
Interior length = 3.4 m or exterior length = 3.6 m [assume a brick of 10 x9x23cm] width]
Interior width = 2 m or exterior width = 2.2 m
Depth = 2 m
Digester volume = 7.5 m
3


Foundation volume calculation

For 5cm layer concrete mixture and small stone and mixture of sand and gravel
Quantity of cement is found from the top layer concrete of 5cm
Add 10cm to the exterior dimension!!!
Volume =3,7mX 2.3mx0.05 m=0.425m
3








So 0.432m3 require 325 x 0.425 kg=138.2kg cement=5.5 bucket [of 25litre oil/paint
bucket] 5.6 bucket
So cement: sand: gravel = 5. 11. 16. Buckets
Given 1m
3
requires 325 kg of B200 cement
And ratio is 1:2:3 cement: sand: gravel

1 sacs of 50kg cement =2 bucket of 25 litre [oil/paint bucket]
Steps
Calculate the dimension of the biogas keep depth at 2m
Calculate the volume of foundation [Bear in mind to extended the exterior dimension
by 10 cm each]
Calculate the area surface of exterior walls
Calculate the volume of top concrete
Calculate the number of reinforcement steel
39

For remaining layer of 15cm, Volume is 0.15mx3.7mx2.3m= 1.276m
3

So quantity of gravel stone is 1.276 x 0.025m
3
=0.031m
3

So the quantity of gravel in bucket =0.031/0.02=1.6 bucket

Cement =5. Bucket (1),
Sand=11 bucket (2)
Small stone {1x2cm} Gravel = 16bucket (3i)
Small stone {1x2cm} Gravel=1.6 bucket (3ii)

2. Quantity of Bricks
Total area of wall faces?
Total area of wall faces = 2(3.6 x 2.00) + 2(2.2 x 2.00) = 23.2 m
2





So, number of bricks for all wall faces = 24 bricks/m
2
x 23.2 m
2
= 557bricks
And number of bricks for wall foundation = (1.2 x 2 + 1.2 x 2) m2 x 24bricks/m
2
=
116bricks + 40 bricks for mixing tank= 156 bricks

Therefore, total of bricks = 560 + 156= 716 bricks for both digester, mixing tanks and
slurry
3. Quantity of Cement & Sand for Laying Bricks and Plastering Mortar for Walls, and
Small Stone for Top Concrete
a. Quantity of laying bricks & plastering mortar for walls = 23.2 m
2
x 25 kg/m
2
= 580 kg








So,
580 kg of cement for laying bricks and plastering walls = 580/ 25 =23.2 buckets






b. Amount of sand for laying bricks & plastering the walls = 23.2 x 3 = 69.6 buckets

Cement=23.2 bucket (4)
Given 1 m
2
of wall face requires 25 kg of cement for
laying brick and plastering
Given 1 m
2
= 24 solid bricks (SISPO) =48 KIDT=9 cement brick
Note: this depend on the size of the brick
Given 1 sack of cement = 50 kg = 2 buckets (paint
bucket of 25liter)
(Given ratio of cement and sand for laying bricks and
plastering walls is 1cement: 3 sands)
40
Sand= 69.6 bucket (5)
. Quantity of cement for top concrete
Assume V
1
for volume of the top concrete and size of concrete is 8cm
So, V
1
= 0.08 x 3.6 x2.2 m
3
=0.64m
3

Given 1 m
3
of concrete = 322 kg of cement
Therefore, quantity of cement for concrete = 0.644 m
3
x 325 kg/m
3
207 kg

d. Quantity of sand & small stone for top concrete
We know, 1 bucket of cement = 25 kg
So, 207 kg of cement for concrete = 207: 25 9 buckets (6)

On the other hand, ratio of cement, sand and stone for concrete is 1: 2: 3
Then, Quantity of
Sand = 9 buckets x 2 = 18 buckets (7)
Small stone (1 x 2 cm) = 9 buckets x 3 = 27 buckets (8)








4. Total Amount of Construction Steel (D=8 mm) for Casting Concrete
Distance of steel cast in length of digester = 3.5 + 0.35 = 3.85 m (interior length = 3.5 m)
Distance of steel cast in width of digester = 2 + 0.35 m =2.35m (interior width = 2.0 m)





So,
Number of steels cast in width of 2.35 m = (3.85/ 0.15) + 1 27 steels
Number of steels cast in length of 3.85 m = (2.35/ 0.20) + 1 13 steels








Therefore, total quantity of steel for casting concrete = [(27 x 2.35) + (13 x 3.85)] x 0.386
= (63.45 + 50.05) x 0.386 44 kg) OR

Given, a gap from one steel to another cast in width = 0.15 m
And 0.35 is an invariable coefficient for calculation of one length of steel
We know, 1 m of 8-mm diameter steel = 0.386 kg
1 length of 8mm diameter is 12 m long
Therefore,
Total of cement = (1) + (4) + (6) =5 + 23.2 + 9 37.2 buckets
Total of sand = (2) + (5) + (7) = 11 + 69.64 + 18 98.6 buckets
Total small stone (1 x 2 cm) = (3i) + (8) =16+27 43 buckets
Total medium stone = (3ii) =1.6 bucket
Number of length required = [(27X 2.35) + (13X3.85)] / 12=9.4510 length
41
































Conclusion
Investment Cost for a Bio-digester with Volume of 7.5 m
3

1. Total volume of digester V

= 7.5 m
3

2. Total number of bricks = 1,950 bricks
3. Total quantity of cement = 37.2 buckets (paint bucket) = 19 sacks of cement
4. Total quantity of sand = 98.6 buckets = 98.6 x 0.02 = 1.97 m
3
(1 bucket = 0.02 m
3
)
5. Total quantity of stone (size 1 x 2 cm) = 43 buckets = 43 buckets x 0.02 = 0.9 m
3

6. Total quantity of stone (size 8 x 10 cm) = 1.5x 0.02 = 0.03 m
3
42
REFERENCES

1. Khandelwal, K. C. , Mahdi S.S, Biogas technology, a practical handbook. Tata
McGrawhill Publishing Company Limited, New Delhi, 1986
2. Luwid Sasse, Christopher Kellner, Ainea Kimaro, Improved Biogas Unit for
Developing Countries published in Germany in 1991
3. MIGESADO, Mtambo wa gesi ya samadi, maelezo na utunzaji, Ecoprint Ltd, Dar Es
Salaam, 1997
4. Singh, JB, Myles, R. Dhussa, A., Manual on Deenbandhu biogas plant, Tata McGraw-
Hill Publishing Company Limited, 1993
5. Thanh, Pham Van, Biogas Technology and the improved VACVINA biogas plants
Social Labour Publishing House, Hanoi, 2007


































43
ATTACHMENTS

1. Sample cost estimate of a 7.5 m
3
biogas plant

Material required for 7.5m
3
biogas plant
No. Description Unit Qty
Unit Price
(Tshs) Total
1 Cement
50kg
sacs 19 15,000 285,000
2 Steel (D = 8 mm) Length 10 11500 115,000
3 Sand m
3
1.97 18,000 35,460
4 Solid brick piece 660 250 165,000
5 Stone (size 1 x 2 cm) m
3
0.9 36,000 32,400
6 Stone (size 8 x 10 cm) m
3
0.03 16,000 480
7 Biogas burner set 2 8,000 16,000
9 Plastic pipe m 15 1,600 6,000
10 Plastic valve unit 1 1,200 1,200
11 Metal valve unit 2 2,500 5,000
12 Plastic reservoir m 7 2,500 17,500
13 Glue bottle 1 1,500 1,500
14 Paper glue roll 1 1,500 1,500
15 Ring (plastic) unit 10 800 8,000
16
Zinc pipe and clip ( = 20 mm, L =
2.5m) set 2,5 1,000 2,500
17 Metal pipe ( = 20 mm, L = 1 m) and
metal connector of 20 mm at one end
and of 27 mm at the other

m 1.5 2,800 4,200
18
Metal connector with gear at both exterior
ends

set 1 2,000 2,000
19 PVC pipe ( = 20 mm) 1 length 1 6,000 7,000
20 PVC L-shaped pipe ( =20 mm) unit 6 500 3,000
21 PVC T-shaped connector ( = 20 mm) unit 4 500 2,000
22 PVC siphon set 2 10,000 20,000
23 Adaptor set 1 20,000 20,000
24 Nail (L = 5 cm) kg 1 3,000 2,000
25 Nail (L = 8 cm) kg 0.5 2000 1000
27 Nail (L = 10 cm) kg 0.5 2000 1000
28 Labor cost for digging m
3
14.4 4,500 64,800
29 Labor cost for constructors and technician digester 1 300,000 300,000
44
2. Technical drawings for a 9 m
3
biogas plant at TaTEDO SEDC

Location: TaTEDO Center for Sustainable Energy
Address : Mbezi Juu, Dar es Salaam, Tanzania
Capacity: 9m
3
TECHNICAL PLAN







































45
Plan for construction Steels for the top of the
digestion tank














46
Category
Quantity of
bar Length/Bar Total for category
S1 (8) 21 3,15 66,15 m
S2 (8) 11 3,65 40,15 m
S3 (8) for technical hole 16 0,50 8,00 m
Total steel 8 for theTop 115 m

- Quantity of Brick: 320 units
- Cement: 1.2 tons
- Sand: 2.5 m,
- Small Stone (2-3cm): 2 m
3


POSITION OF INLET & OUTLET
























47











































A
A
B
B
48
Plan of mixing tank integrated to Inlet Siphone












































Section 1 - 1
Detail of
Mixing tank Door
The Door of the mixing tank is made by
wood material with the thickness of 2cm
(22 x 42 x 2cm). A steel hook is placed
on top for facilitating its Open/Close
when needed.

49
GENERAL ILLUSTRATION OF A VACVINA BIOGAS PLANT










































50
3. Technical drawings for a 12 m3 biogas plant at George Ntengas house at Goba
VACVINA BIOGAS PLANT

Location: Family of George Ntenga
Address: Mbezi Juu, Dar es Salaam, Tanzania
Capacity: 12 m
3

TECHNICAL PLAN





































51











































The Top of the digestion Tank
52

Category
Quantity of
bar Length/Bar Total for category
S1 (8) 28 2,15 60,20 m
S2 (8) 11 4,15 45,65 m
S3 (8) for technical hole 16 0,50 8,00 m
Total steel 8 for the Top 113,85 m

- Quantity of Brick: 250 units (Dimension: 15 x 23 x 45,5cm)
- Cement: 1.0 tons
- Sand: 2.0 m
3
,
- Small Stone (2-3cm): 2.0 m
3