Mekelle University

Ethiopian Institute of Technology (EIT-M)

Department of Mechanical Engineering

Final Report on:

Performance Analysis of Biogas Digester at MU Campus

For the Course

Energy Technology Project (MEng 6233)

By: Michael G.yesus Advisors: Mussie T. (M.Sc) Ashenafi K. (M.Sc)

January, 2012 Mekelle 1

I. Acknowledgment
I am highly indebted to God almighty for his special grace, strength and protection towards me. In the preparation of this report I received much generous help and encouragements from teammates of the project, friends, and especially from the staff of Mechanical Engineering Department. I truly appreciate the patience, time, kindness shown me by the department members and giving me valuable feedbacks. I would like to express my deepest gratitude to my advisors (Mr. Mussie T. and Mr. Ashenafi K.) for their Constructive feedback and continuous support. GOD BLESS YOU ALL!!

II. Abstract
Recent construction of a number of successful biogas systems for livestock manures and an increased awareness of their merits has produced an increased level of interest. Thus, a 27.86 m3 Nepal type fixed dome biogas plant has been designed and constructed at Mekelle University, main campus, by Mechanical Engineering staff. Thus, this paper reports the performance of the biogas plant characterized through measurements of its actual volume, analytical relations and gas yield. The digestion of the slurries was undertaken in a continuous operation. The parameters necessary for gas production were measured and recorded. Anaerobic digestion of cow dung using the plant is carried out. The plant waste utilization is determined by giving waste to water ratio of 1:1. The density of the feed stock is 1111 kg/m3. The volume of gas production at full capacity of the plant is estimated. It was discovered that the waste has a longer hydraulic retention time (62.5 days). The conditions within the digester suitable for the anaerobic microbes were under mesophllic temperatures (20-450C) and the PH of the digester was found ranging 7.16 7.22 which is the range at which the methanogenic bacteria lives and reproduces comfortably.

List of Tables and Figures

Table 1: Typical biogas composition Table 2: Approximate biogas production rates of different waste Table 3: Approximate biogas consumption rates Figure.1. Schematic of biogas reaction Figure.2 Biogas Under analysis Figure.3 Instruments used to measure PH and determine density Figure.4 Nepal type fixed dome biogas plant Figure.5 Digester volume Vs time Figure.6 Temperature of the digester Figure.7 PH Measurment of the reactor Figure.8 Gas Production Figure. 9 Pressure of the gas in the digester Figure.10 Biogas Burner/stove Figure.11. Water Boiling rate of the Biogas

III. TABLE OF CONTENTS ACKNOWLEDGEMENTS..2 ABSTRACT3

List of Tables and Figures.4

TABLE OF CONTENTS..5 1. INTRODUCTION.6

1.1 Locations of the Anaerobic Digesters 7 1.2 Biogas digesters....8 1.3 Fixed-dome digester (Over-view)..8 1.4 Biogas mechanics..9
2.

Materials and Methods....10

2.1 Sources of Waste ..10 2.2 Preparation of the waste.10 2.3 Methodology..11 2.4 Measurements of the fixed dome biogas plant12

3. DATA ANALYSIS...14 3.1 Biogas Production and Parameter Comparison...17 3.2 Gas demand..18 3.3 Biogas burners.19 3.4 Water Boiling Rate of the Biogas and stove Performance.20

4. RESULTS and DISCUSSION 21 5. LIMITATIONS22 6. SAFTEY ..23 7. CONCLUSIONS ..25

8. RECOMMENDATION......26 9. REFERENCES ...27

10. ANNEXES .....28

1. Introduction
The importance of energy in national development cannot be over-emphasized. Energy is the hub around which the development and industrialization of any nation revolve. It is a fact that any distortion in energy supply chain at any point in time results into serious economic and social hardship. The significance of energy in the provision of goods and services and in the elevation of the standard of living of mankind, and the role it plays in industries for sustainability of production is a well known fact (Sambo, 2005). Biogas is one of the renewable energy sources with lowest financial inputs per Kwh of output. Biogas was first discovered by Alessandro Volta in 1776 and Humphrey Davy was the first to pronounce of combustible gas methane in the farmyard manure in as early as 1880. The technology of scientifically harnessing this gas from any biodegradable material (organic matter) under artificially created conditions is known as biogas technology. The economic prosperity and quality of life of a country are closely linked to the level of its per capita energy consumption and the strategy adopted to use energy as a fundamental tool to achieve the same. The per capita energy utilization in Ethiopia is less than one seventh of the world average. In the country side, it is extremely below the required level, where Ethiopia is not in a position to meet the energy input levels to agriculture at par with advanced countries due to the rapidly depleting sources of conventional energy, high energy cost etc. the realizations that conventional sources of energy are finite in nature has forced the world community to seek fuel efficient and environmentally viable alternatives for many of the traditional energy consumption approaches and focus on exploiting the infinite non-conventional energy sources for meeting day to day energy requirements. In a country like Ethiopia, where more than 70% of the total populations inhabit in rural areas, one such alternative is the use of Biogas as cooking fuel, which can be easily obtained by anaerobic digestion of domestic and farm wastes, like cattle dung, abundantly available in the country side. Cattle dung is predominantly being used either by composting it for preparing farm yard manure or directly preparing dung cakes for burning as cooking fuels. Both these means are highly uneconomical and unhygienic. Anaerobic digestion of cattle dung not only provides valuable cooking fuel, i.e. biogas, and enhances the manurial value of the waste but also provides a convenient, safe and aesthetic waste disposal. 6

For improving the rural economy and enabling the best use of cattle dung to provide smoke free cooking fuel, the cattle dung is put into a specially designed structure called a Biogas Plant where, after anaerobic digestion of the same, biogas is produced. The remaining material, called Slurry , containing about 2.1% nitrogen, 0.046% phosphorous and 2.2% potassium is used as manure for crop production as a fertilizer.

An added benefit of anaerobic digestion is that potentially negative impacts of these wastes on air and water quality are reduced. This includes but is not limited to reducing emissions of methane, a greenhouse gas, when manure decomposes anaerobically under uncontrolled conditions. Methane has approximately 21 times the heat trapping capacity of carbon dioxide. In addition, producing, capturing, and using biogas as a fuel reduces emissions of carbon dioxide and various pollutants from fossil fuel combustion to generate electricity or produce heat.

1.1 Location of the Anaerobic Digester

The Biogas plant in this study is located in the eastern side of Mekelle University near by the diary farm of the Animal Science Department. The Dairy has roughly 25 head of cattle on the farm, out of which 16 in milk production. The biogas constructed in the Dairy farm has a mesophilic, single tank, below ground, complete mix anaerobic digester system. The biogas produced is to be utilized for water heating purposes used to wash cow breasts, wash the diary utensils and for sterilization of some instruments. To increase the temperature of the substrate, sunny location (i.e. away from trees or shade) is selected for biogas digester. As a precaution for (unintended) leaching, the digester is situated at least 30m away from any water source or stream. There are No any permanent structures or through ways on the ground above the digester. Hence; the location where the biogas plant was constructed is good.

1.2 Biogas digesters

Several different designs of biogas plants have been built but the two most popular are the floating gas holder and the fixed dome digester. There are different operations of biogas plants and they may be classified under two headings: 1) The continuous plant in which the feeding is done every day and 2) The batch plant in which feeding is done at intervals. Although the designs differ in detail each has three common parts which will be detailed in terms of design and construction for each type of generator: 1. Digester where biomass (slurry) is stored and broken down by bacteria to produce biogas 2. Biogas holder an area where the biogas is stored under pressure and can be tapped off (could be part of the digester) 3. Displacement tank/Slurry overflow method of removing fully digested slurry and prevention of over pressurization of biogas

1.3 Fixed-dome digester (Over-view)

The biogas in my study is fixed dome type. The Waste matter is fed into the digester where it collects and is broken down, producing biogas which is stored in the gas holder part of the hemispherical digester. As the pressure of the biogas increases, the volume of slurry increases which is displaced into the displacement tank. Excess slurry from the displacement tank will be removed, dried or composted and used for fertiliser or will overflow into a sewage outlet or slurry/composting bed. Biogas is removed from the gas holder and can be used for cooking, lighting and heating (as detailed). When the gas is used some of the slurry moves back from the displacement tank into the digester causing mixing. The fixed-dome generator is commonly known as the Chinese design and can be used in small scale (household) or larger scale (community) services. 8

1.4 Biogas mechanics

Fig.1. Schematic of biogas reaction Stage 1 Hydrolysis Bacteria decompose long chains of complex carbohydrates and proteins in the biomass into smaller molecules. Stage 2 Acidification Acid-producing bacteria convert the smaller molecules produced in the first step into acetic acid (CH3COOH), hydrogen (H2) and carbon dioxide (CO2). Stage 3 Methane formation (Anaerobic) Methane-producing bacteria convert the acetic acid (CH3COOH), hydrogen (H2) and carbon dioxide (CO2) into methane (CH4) and carbon dioxide (CO2). This mixture of gas is known as biogas. Table 1: Typical biogas composition Compound Methane Carbon dioxide Hydrogen Nitrogen Other gases

Symbol CH4 CO2 H2 N2 H2O, H2S

Presence 50%-70% 30%-40% 5%-10% 1%-2% Trace 9

2. Materials and Methods 2.1 Sources of Waste

The wastes used in this study were the animal dung from the diary farm of Animal Science Department, Mekelle University. 180 liters Geepee (G.P) tank made from plastic/synthetic materials was used to measure the daily intake volume of raw material for this experiment at mesophllic temperatures. Other materials utilized were digital PH meter, thermometer, pressure gauge, hose pipes, measuring tap, pots, biogas burner constructed locally, glass flasks, and digital weight measurement.

2.2 Preparation of the waste

It was ensured that foreign materials like earth, sand, gravel, sawdust, soap, detergents, etc. did not enter the digester or plant. The slurry was prepared by measuring the animal dung and water using a 20 liter volume jar and each weighed sample was poured into the 180 liter GP tank in the ratio of 1:1 (waste to water). The slurry was fully stirred manually with a piece of wood until there were no lumps. The waste was transferred to the biogas digester.

Fig.2 the Biogas Under analysis

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2.3 Methodology
The Performance analysis is performed in accordance to a set protocol written by Dr. John Martin. The protocol A Protocol for Quantifying and Reporting the Performance of Anaerobic Digestion Systems for Livestock Manures (2007) was written to provide farm operators and system developers a standard approach for quantifying the performance of their systems and to support claims in order to receive acceptance as credible. The protocol specifies prerequisites for performance evaluations and required assembly of background information. It also describes acceptable methods for data collection to characterize system performance with respect to waste stabilization, biogas production, and utilization. Additionally, Analytical Procedures and practical Measurements is taken and used to collect data and evaluate the performance of the biogas digester. A Digital pH meter was used to measure the pH every day for a week. It ranged from 7.16 -7.22. The temperature of the slurry was observed daily through the thermocouple wire that was inserted into the digester: the thermocouple wires were connected to the thermocouple digital thermometer which measured the slurry temperature. The ambient temperature was also measured with the digital thermocouple thermometer. These temperature readings fall within (20-45oC) which corresponds to the mesophyllic range. The density was determined by taking a sample of the slurry and measured its volume and mass using volume flask and digital weight measurement respectively; and the density was found to be 1111Kg/m3. To determine the total volatiles out of the slurry, a sample was taken and measured its mass. Then the known mass was dried in the sun and weighed again. By subtracting the later mass from the 1st weighed mass, the percentage of total solids was estimated, and was found to be 16.8%.

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Fig.3 instruments used to measure PH and determine density

2.4 Measurements of the fixed dome biogas plant

The inside of the plant was thoroughly cleaned with water and measurement was taken with a standard measuring tape. The sketch of the plant with simple formula for the calculations of its volume is shown in the figure below:

Fig.4 Nepal type fixed dome biogas plant

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On the sketch above H1 = 1.15m, H2 = 0.88m and r=2.33m Where: H1 - height of fermentation chamber H2 - Height of upper arc r Radius of the cylinder The equations used in calculating the volume of the digester are given as; V1= ( * r2 * H1) m3 =3.14*(2.33)2*1.15 =19.60 m3 V2= [/6 * H2 (3r2 * H22)] m3 =3.14/6 * 0.88 (3*(2.33)2 * (0.88)2 =7.85 m3 V3= (H1* 0.6*0.6*) m3 =1.15*0.6*0.6 m3 = 0.041 m3 The total volume of the digester is then; =V1+V2 + V3
= (19.60 +7.85 +0.41) =27.86 m
3

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3. Data Analysis
The digester volume increases since the start day of filling the raw feedstock till the volume reaches 20.16m3; Then it keeps constant as the same amount to the intake displaces from the digester after it starts gas production. The sullery which was inside the digester moves to the outlet tank by the pressure difference between the digester and the environment and the density difference between the fresh charge of feedstock and the sullery which is inside the digester. This process continues as long as there is contineous feed supply.

Fig.5 Digester volume Vs time

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Fig.6 temperature of the digester The temperature range of the digester is found to be in the mesophllic temperatures (20-450C); which is the most convenient range for biogas production. In this temperature range the methanogenic bacteria lives comfortably and reproduces to the maximum extent which results in increased gas yield.

Fig.7 PH Measurment of the reactor The PH value of the digester is within the neutral range where the microorganisms live comfortably and facilitate the anaerobic digestion to increase biogas production. 15

Fig.8 Gas Production The Biogas gas production and accumulation increases with time as the consumption rate is zero. The gas production starts at the 63rd day after the feeding was started and the volume reaches 20.16 m3. Since then the volume of gas starts to increase from day to day because the feeding process was contineous the gas production continues every day and it was accumulating inside the gas holder to higher volume and pressure.

Fig. 9 pressure of the gas in the digester

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The pressure of the digester increases with time due to the contineous gas production and no consumption. But; this pressure doesnt represent the actual pressure of the digester because the pressure was measered after travelling a long small diameter pipe where huge pressure drop is there, and due to a reason that there is no access hole for measureing the actual digester, It was not measured from the digester but from the pipe.

3.1 Biogas production

The biogas production rate of animal dung is about 0.04m3/kg/day however the data varies greatly and is dependent on many variables (diet, food intake, water intake, climate, etc). GTZ suggest the following production rates of biogas from wastes of different animals per day in warm climates. Table 2: Approximate biogas production rates of different waste

Source 1kg Cattle dung 1kg Pig dung 1kg Chicken droppings 1kg Human excreta

Biogas per day (m3/day) 0.04 0.06 0.07 0.02-0.07

The gas production rate in the biogas considered is found to be 0.031m3/kg/day; because the temperature biogas digester was found to be around 250C. Even though the operating parameters (temperature and PH values) are found with the favorable range for biogas production, the temperature is a bit lower than the average (30 0C). Since the start of gas production in the digester, more than 200m3 biogas has been produced; and at this time around 7 m3 of biogas at a pressure of 3.9Kpa is available.

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3.2 Gas demand

In developing countries, the household energy demand is greatly influenced by eating and cooking habits. Gas demand for cooking is low in regions where the diet consists of vegetables, meat, milk products and small grain. The gas demand is higher in cultures with complicated cooking and where whole grain maize or beans are part of the daily nourishment. As a rule of thumb, the cooking energy demand is higher for well-to-do families than for poor families. Energy demand is also a function of the energy price. Expensive or scarce energy is used more carefully than energy that is effluent and free of charge. The gas consumption for cooking per person lies between 300 and 900 liter per day, the gas consumption per 5-member family for 2 cooked meals between 1500 and 2400 liter per day. In industrialized countries, biogas almost always replaces existing energy sources like electricity, diesel or other gases. The objective of biogas production may be less to satisfy a certain demand, but to produce biogas as much and as cheap as possible. Whatever surplus is available can be fed as electricity into the grid. The gas demand is market-driven, while in developing countries, the gas demand is needs-driven. The gas production of the biogas plant under consideration is 3.6m3/day and can supply gas demands for two households with 5-member family for 2 cooked meals with 1800 liters of gas per day. Some approximate biogas consumption rates are shown in Table 3. Table 3: Approximate biogas consumption rates Application Consumption per person per meal Boil 1 litre water Cook 0.5kg rice Cook 0.5kg vegetables Gas lamp lighting (1 hour) Volume biogas (m3) 0.15-0.30 0.03-0.04 0.12-0.14 0.16-0.19 0.07-0.20 18

3.3 Biogas burners

The heart of most gas appliances is a biogas burner. In my case, commercial and local atmospheric-type burners operating on premixed air/gas fuel are used. Due to complex conditions of flow and reaction kinetics, gas burners challenge precise calculation, so that the final design and adjustments must be arrived at experimentally. Compared to other gases, biogas needs less air for combustion. Therefore, conventional gas appliances need larger gas jets when they are used for biogas combustion. About 5.7 liters of air are required for the complete combustion of one liter of biogas, while for butane 30.9 liters and for propane 23.8 liters are required. The modification and adaptation of commercial-type burners is an experimental matter. With regard to butane and propane burners, i.e. the most readily available types, the following pointers are offered: o Butane/propane gas has up to three times the caloric value of biogas and almost twice its flame-propagation rate. o Conversion to biogas always results in lower performance values. Practical modification measures include: o Expanding the injector cross section by factor 2-4 in order to increase the flow of gas; o Modifying the combustion-air supply, particularly if a combustion-air controller is provided; o Increasing the size of the jet openings. The aim of all such measures is to obtain a stable, compact, slightly bluish flame.

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Fig.10 Biogas Burner/stove

3.4 Water Boiling Rate of the Biogas and Stove Efficiency

Water was boiled in a metallic pot with four liters and two liter capacity and look at the rate of boiling the water. The four liter water boils (980C) in 14 minutes and the 2 liter water boils (980C) in 9 minutes with the same flow rate (around 300L/hour) of gas. I have made tea and enjoyed it during the test. The boiling test was done outdoor, and the wind speed was very high and windy condition, thus it has affected greatly the boiling time to be longer. The gas production rate of our biogas is about 0.031m3/Kg/day and the biogas production rate of biogas plants working with animal dung is 0.04 m3/Kg/day operating in mesophelic process (from literature) range in the protocol. Thus the efficiency of the biogas under consideration is found to be around 77.5% (compared to the one given in the protocol for quantifying the gas production and anaerobic digester efficiency). The calorific efficiency of using biogas is 55% in stoves, 24% in engines, but only 3% in lamps. A biogas lamp is only half as efficient as a kerosene lamp. The use of biogas in stoves is the best way of exploiting biogas energy for farm households in developing countries.

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Fig.11. Water Boiling Test

4. Results and discussions

The measured temperature of the digester is in the mesophillic range but it is below the required average (300C) which has the maximum gas yield. The PH of the reactor is in the neutral and alkaline range where the methanogenic bacteria can reproduce to a greater population to facilitate the anaerobic fermentation which increases the gas production. To determine the gas production rate and to measure the amount of gas produced so far, the required instruments was not found. The gas composition was not determined due to lack of instruments but was estimated by relating the actual measured data and literatures and was found to be around 65% CH4 and 35% CO2 and other trace gases. The gas production rate of the biogas plant under consideration is 3.6m3/day by comparing with the requirement and affecting factors in the protocol used for quantifying and determine the performance of anaerobic digester and can supply gas demands for two households with 5-member family for 2 cooked meals with 1800 liters of gas per day.

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5. Limitation
I have faced difficulties to determine the biogas compositions and measure some influential parameters due to lack of equipments: like Gas chromatograph Orsat gas analyzer Gas flow meter To evaluate the performance of the digesters gas yield, different parameters like the flow rate of the gas production, the chemical composition and the digester inhibitors had to be measured and considered in the performance analysis. But due to lack of measuring instruments the needed data to analyze the digester performance is not collected. Rather the performance of the digester is compared with biogases from literatures by using the measured data and analytical relations.

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6. Safety
When operating a biogas plant special attention has to be paid to the following: Breathing in biogas in a high concentration and over longer periods of time can cause poisoning and death from suffocation. The hydrogen sulfide content of biogas is highly poisonous. Unpurified biogas has the typical smell of rotten eggs. Purified biogas is odorless and neutral. Therefore, all areas with biogas operating appliances should be well ventilated. Gas pipes and fittings should be checked regularly for their gas-tightness and be protected from damage. Gas appliances should always be under supervision during operation. Everybody dealing with biogas, in particular children should be instructed well and made aware of the potential dangers of biogas. Safety factors to consider include: o Location the generator should not be housed underneath or within any other permanent structure o Biogas piping system should be protected, clear and obvious (whether underground or above ground) o Careful installation and regular inspection is mandatory o Regular inspection of gas appliances o Good ventilation of rooms containing gas appliances without pilot lights o Installations of safety stop valves (at the plant and on each appliance) and venting valves (at the plant) o Educational factors to consider include: o Users must be aware of the dangerous nature of biogas when formed in the explosive mix of Oxygen (air) and biogas o Always close the gas and safety valves of each appliance properly and after each use o Close the generators safety valves over night or when the generator is unattended o Quick detection of gas leaks by watching for the conspicuous odour of unburned biogas

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If biogas is continuously produced but not constantly used, the capacity of the gasholder will be exceeded. There is hardly any danger for the dome to topple over, as the gasholder will be slightly lifted by the pressure of the gas. The abundant biogas can thus bubble out through the rim which is comparable to a safety pressure valve. Although hydrogen sulphide is a toxic gas, desulphurisation of the biogas at household level is not necessary. Since CH4 and CO2 are both odourless, the characteristic rotten egg smell of H2S can be helpful in detecting gas leakages.

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7. CONCLUSION
The results of the study have revealed that the location of the biogas is a very good site for biogas production and there is a great potential for anaerobic digestion of the organic fraction of animal waste in the dairy farm. The biogas system has proved to be effective in terms of operational parameters especially PH and temperatures. The PH values of the digester has been found to be within the range 7.16-7.22 which is in the neutral range where the methanogenic bacteria reproduces comfortably and the temperature of the reactor ranges 200C 420C (mesophillic process). The gas produced from cow manure in the mesophillic process is mostly composed of CH4 (65%) and CO2 and other trace gases (35%) from the protocol. But due to lack of instruments like gas chromatograph and orsat gas analyzer, the composition is not analyzed practically. Although the performance of the system regarding gas production seems good, the design of digester has to be improved. The most essential technical improvements concern digester and gasholder size. The biogas system has a good potential for being scaled up depending in particular. In view of this, larger generators of organic solid wastes such as schools and restaurants can easily adapt the system to match with the volume of waste they generate.

As there are currently no competing products on the Ethiopia market for anaerobic digestion system of organic solid waste at household level, the market potential of biogas system may therefore be regarded as good.

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8. Recommendation
The animal science department should start utilizing the biogas plant for their energy demand (hot water demand). Awareness of the technology: to encourage the use of biogas an awareness campaign for potential users in the diary farm should be under taken. The intake of the feedstock should be supplied continuously for continuous gas yield. Mekelle University should take active part in the biogas projects to utilize them effectively for different applications like the diary farm and cafeterias. Blocking of the inlet pipe seems to occur frequently as a result of the rather small diameter of the inlet pipe or the insufficient chopping or dilution of the feedstock. Therefore, the inlet pipe should permanently be covered to avoid clogging of the inlet pipe. A strong quality control system needs to be put in place to ensure that the installed biogas systems perform to the level, which is expected. To make the biogas system affordable to a wider application. The cost of installation has to come down considerably.

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9. References
1. A Protocol for Quantifying and Reporting the Performance of Anaerobic Digestio Systems for Livestock Manures, J.H. Martin, Jr. Hall Associates, Georgetown, DE 2. Process performance of biogas digesters incorporating pre-separated manure H.B. Mller, A.M. Nielsen, R. Nakakubo, H.J. Olsen, University of Aarhus, Department of Agricultural Engineering, Research Center Bygholm, P.O. Box 536, 8700 Horsens, Denmark 3. GTZ. Biogas Digest Volume 1 (Biogas Basics). (PDF Document) [Available online at] http://www.gtz.de/de/dokumente/en-biogas-volume1.pdf 4. Diaz L.F., Eggerth L.L., Savage G.M. (2007): Management of solid wastes in developing countries. IWWG Monograph. CISA publisher

5. Schmitz T.D. (2007): Feasibility study for a national domestic biogas programme in Tanzania. Published by GTZ, Eschborn

6.

Production and Utilization of Biogas in Rural Areas of Industrialized and Developing Countries, Schriftenreihe der gtz, No. 97, pg. 63, after: Felix Maramba, Biogas and Waste Recycling - The Phillipine Experience; Metro Manila, Phillipines, 1978

7.

Performance Evaluation of Partial Mixing Anaerobic Digester; N. Stalin and H. J. Prabhu, Department of Chemical Engineering, National Institute of Technology, Trichy, Tamil Nadu, India

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10. Annexes
A. General information about biogas operations 1. Name of operation 2. Address (including county) 3. Type of operation (e.g. dairy, swine, layer, etc.) 4. If dairy, a. Breed (e.g. Holstein, Guernsey, etc.) b. Average milking herd size c. Average number of dry cows d. Average number of replacements e. Respective fraction of the manure from the milking herd, dry cows, and replacements collected for digestion f. Type(s) of manure collection systems (e.g. scrape, flush, etc.) and frequency of manure collection 5. If swine, a. Type of swine operation (e.g. farrow-to-wean, farrow plus nursery, farrow-to-finish, etc.) b. Average number of sows and pregnant gilts and number of litters per sow-year c. Average number of nursery pigs and number of nursery stage cycles per year d. Average number of feeder pigs and number of grow/finish cycles per year e. Type(s) of manure collection systems (e.g. flush, pull-plug pit, etc.) and frequency of manure collection 6. If layer, a. Average number of hens b. Type of manure collection system (e.g. scrape, flush or pull-plug pit) and frequency of manure collection 7. If another type of animal, a. Numbers and ages b. Type of manure collection system 28

B. Biogas system Information / Biogas Production 1. Type of digester (e.g. mixed, plug-flow, attached film, or covered lagoon) 2. Name of system designer, address, and other contact information 3. Digester design assumptions a. Number and type of animals b. For lactating cows, average live weight or average milk production c. For swine, type or types (e.g. gestating sows, lactating sows, feeder pigs, etc.) and average live weight d. Bedding type and estimated annual quantity used e. Manure volume, m /day f. Wastewater volume, m /day (e.g. none, milking center wastewater, confinement facility wash-down, etc.) g. Other waste volume(s), m /day (e.g. none, food processing wastes, etc.) with physical and chemical characteristics (e.g. concentrations of total solids, total volatile solids, chemical oxygen demand, etc.) h. Pretreatment before digestion (e.g. none, gravity settling, stationary screen, screw press, etc.) i. Treatment of digester effluent (e.g. none, solids separation by screening, etc. with details including use or method of disposal) j. Method of digester effluent storage (e.g. none, earthen pond, etc.) 4. Physical description a. General description including types of construction materials (e.g. partially below grade, concrete channel plug-flow with flexible cover, etc.) b. Dimensions (length and width or diameter and height or depth) c. Type(s), location(s), and thickness(s) of insulation d. Operating volume and ancillary biogas storage volume if present e. Design hydraulic retention time f. Design operating temperature g. Compliance, yes or no, with the applicable Natural Resources Conservation Service Conservation Practice Standard (No. 365: Anaerobic DigesterAmbient Temperature or No. 366: Anaerobic DigesterControlled Temperature)

3 3 3

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5. Monthly summaries of operational details a. Number and type of animals b. Other waste volume(s) and physical and chemical characteristics c. Frequency of waste addition (e.g. once per day, twice per day, etc.) d. Pretreatment of digester influent (e.g. none, solids separation by gravitational settling, screening, etc. with details) e. Average daily digester temperature and monthly range f. Use of monensin or any other antibacterial growth promoters that could affect biogas production

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C. Biogas Utilization 1. Biogas utilization (e.g. none, generation of electricity, use on-site as a boiler or furnace fuel, or sale to a third party) 2. If generation of electricity, a. Type of engine-generator set (e.g. internal combustion engine, micro turbine or fuel cell with the name of the manufacturer, model, power output rating (kW) for biogas, and nominal voltage b. Component integration (factory or owner) c. Origin of equipment controller (manufacturer integrated, third party off-the-shelf, or third party custom) d. System installer e. Stand-alone capacity (yes or no) f. Pretreatment of biogas (e.g. none, condensate trap, dryer, hydrogen sulfide removal, etc. with the names of manufacturers, models, etc.) g. Exhaust gas emission control (e.g. none, catalytic converter, etc.) h. If interconnected with an electric utility i. Name of the utility ii. Type of utility contract (e.g. sell all/buy all, surplus sale, or net metering) i. If engine-generator set waste heat utilization i. Heat source (e.g. cooling system or exhaust gas or both) and heat recovery capacity (KJ/hr) ii. Waste heat utilization (e.g. digester heating, water heating, space heating, etc.) 3. If use on-site as a boiler or furnace fuel, a description of the boiler or furnace including manufacturer, model, and rated capacity 4. If biogas sale to a third party, a description of the methods of processing, transport, and end use Cost Information 1. As built cost of total system 2. Cost basis (e.g. turnkey by a developer, owner acted as the general contractor, constructed with farm labor, etc.) 3. An itemized list component costs (e.g. the digester, the biogas utilization system, 31

Annual Manure Yield and Nutrient Content of Animal Excrements

Table 1: Annual manure yield and nutrient content of cow, pig and chicken excrements; compiled from various sources.

Source: Production and Utilization of Biogas in Rural Areas of Industrialized and Developing Countries, Schriftenreihe der gtz, No. 97, pp. 71-72; after: Rager, K. Th.: Abwassertechnische und wasserwirtschaftliche Probleme der Massentierhaltung; Darmstadt, FRG, 1971, p. 38
LSU = livestock unit (= 500 kg live weight) TS = Total solids VS = Volatile solids

32

Gas Yields and Methane Contents for Various Substrates

Table 2: Gas yields and methane contents for various substrates at the end of a 10-20 day retention time at a process temperature of roughly 30C

Source: Production and Utilization of Biogas in Rural Areas of Industrialized and Developing Countries, Schriftenreihe der gtz, No. 97, pg. 63, after: Felix Maramba, Biogas and Waste Recycling - The Phillipine Experience; Metro Manila, Phillipines, 1978

33

Methane production from animal manure

Table 3: Gas production as a function of intake volume and time Daily Intake Days 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Volume (Liter) 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 volume increment (liters/Days) 320 640 960 1280 1600 1920 2240 2560 2880 3200 3520 3840 4160 4480 4800 5120 5440 5760 6080 6400 6720 7040 7360 7680 8000 Volume in m
3

Gas Production (m3/Day) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 34 0.32 0.64 0.96 1.28 1.6 1.92 2.24 2.56 2.88 3.2 3.52 3.84 4.16 4.48 4.8 5.12 5.44 5.76 6.08 6.4 6.72 7.04 7.36 7.68 8

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320

8320 8640 8960 9280 9600 9920 10240 10560 10880 11200 11520 11840 12160 12480 12800 13120 13440 13760 14080 14400 14720 15040 15360 15680 16000 16320 16640 16960 17280 17600

8.32 8.64 8.96 9.28 9.6 9.92 10.24 10.56 10.88 11.2 11.52 11.84 12.16 12.48 12.8 13.12 13.44 13.76 14.08 14.4 14.72 15.04 15.36 15.68 16 16.32 16.64 16.96 17.28 17.6

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 35

56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85

320 320 320 320 320 320 320 320 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180

17920 18240 18560 18880 19200 19520 19840 20160 20340 20520 20700 20880 21060 21240 21420 21600 21780 21960 22140 22320 22500 22680 22860 23040 23220 23400 23580 23760 23940 24120

17.92 18.24 18.56 18.88 19.2 19.52 19.84 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16

0 0 0 0 0 0 0 0 7.2 14.4 21.6 28.8 36 43.2 50.4 57.6 64.8 72 79.2 86.4 93.6 100.8 108 115.2 122.4 129.6 136.8 144 151.2 158.4 36

86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

180 180 180 180 180 180 180 180 180 180 180 180 180 180 180

24300 24480 24660 24840 25020 25200 25380 25560 25740 25920 26100 26280 26460 26640 26820

20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16 20.16

165.6 172.8 180 187.2 194.4 201.6 208.8 216 223.2 230.4 237.6 244.8 252 259.2 266.4

37