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Design of a Biogas Generator

Article in Concurrent Engineering Research and Applications · November 2013

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 Ogur, E. O et al Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 3, Issue 6, Nov-Dec 2013, pp.630-635

RESEARCH ARTICLE OPEN ACCESS

Design of a Biogas Generator

Ogur, E. O1and Irungu, P.2
1
Department of Mechanical and Mechatronic Engineering, Technical University of Kenya, P.O. Box 52428 –
00200, Nairobi
2
Murang’a University College, P.O. Box 75 - 10200, Murang’a Department of Mechanical Engineering,

Abstract
The world is facing an energy crisis due to depletion of fossil fuels. Therefore the need to search for
renewable alternative energy is a major concern for stakeholders around the world. Biogas is a combination of
gases produced during anaerobic decomposition of organic material of plant origin. This study’s main objective
was to design a biogas generator which utilizes animal waste to generate biogas for use in Murang’a
University College. Cow dung gas is 55-65% methane, 30-35% carbon dioxide, with some hydrogen, nitrogen
3
and other traces. Its heating value is around 600 Btu/ft . The daily energy required for both lighting and
cooking was calculated and the volume of biogas required from animal waste was determined. From this a
cylindrical shaped digester with a spherical gas holding top was selected having the dimensions for both the
cylinder and sphere arrived at mathematically. As this paper will show, the digester was found to be 5 metres in
diameter, with the top dome for holding the gas equivalent to be 3.7 metres high.
Keywords: Biogas, animal waste, anaerobic, aerobic, organic fertilizer

I. Introduction depends on firewood for cooking. Electricity is used

As the demand for the world’s fuel for lighting and for running machines in the
increases, their prices rise. Thus interest is now mechanical workshop. Firewood is not a good option
rightly focused on the development of renewable as the forest cover is reducing at an alarming rate. In
energy sources. Renewable sources of energy often view of the above, an alternative source of power is
offer the most potential energy conservation and urgently required. MUC has a number of cows plus a
development options for the future. The use of these lot of food waste from the kitchen. This would be a
energy sources can meet considerable energy good source of raw material for a biogas generator.
demands for our institutions and villages across the The unit would supply the much needed energy for
country. Amongst the renewable sources of energy, cooking, lighting and any other use that could require
biomass is the most promising. Biomass refers to the heating.
different forms of organic matter including crop
residues, agro-industrial by products, urban and 1.2 Objectives of the study
municipal wastes, animal dung. This may be The main objective of this study was to
transformed by physical, chemical and biological design a biogas generator unit suitable for MUC. The
processes to bio-fuels. In chemical form biomass is design of the digester was for meeting the energy
stored solar energy and can be converted into solid, requirements of the institution.
liquid and gaseous energy. A detailed study of energy
demands in Kenya indicates that firewood, charcoal 1.3 Significance of the Study
and crop residues accounts for more than 75% of the In the exploitation of alternative energy,
total energy consumed. This implies that the forest biogas holds the greatest promise as a cheap source of
cover is being depleted at a faster rate than are efforts energy because it is renewable, simple to generate and
at growing trees. Electrical power cannot also be convenient to use. MUC has a herd of cows used for
relied on not only because of the cost implication, but milk production, and pigs for meat. At present, the
also because of the very unpredictable weather waste from these animals is not used.
patterns largely attributed to global warming [1,2].
II. Materials and Methods
1.1 Statement of the Problem 2.1 Materials
Electricity is very important in our day to Cow dung gas is made up of 55-65%
day life; however, electrical power is very expensive methane, 30-35% carbon dioxide, with some
for rural Kenyans. Thus a lot of money is spent hydrogen, nitrogen and other traces. Its heating value
annually on electricity bills. In Murang’a University 3
is around 600 Btu/ft . Biogas yield can be enhanced
College (MUC), water heaters and electrical cookers by filtering it through lime water to remove carbon
were removed to try to save on cost. MUC now dioxide, iron filing to absorb corrosive hydrogen

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sulphide and calcium chloride to extract water vapour b) Digester

after the other two processes [3]. Cow dung slurry is This is the reservoir of organic wastes in
composed of 1.8-2.4% nitrogen (N2) 1.0-1.2% which the substrate is acted on by anaerobic micro
phosphorus (P2O5), 0.6-0.8% potassium (K2O) and organisms to produce biogas.
50-75% organic humus. About one cubic foot of gas
may be generated from one pound of cow manure at c) Gas Storage /Reservoir
around 28o C, an adequate amount to cook a day’s Depending on the proposed design, this may
3
meal for 4 - 6 people. About 1.7 m of biogas equals be simply an empty but enclosed space above the
one litre of gasoline. The manure produced by one slurry in the digester, an inverted floating drum whose
cow in one year can be converted to methane which is diameter is just slightly smaller than that of the
the equivalent of over 200 litres of gasoline [4]. cylindrical digester or an air tight polythene tube with
an inlet –outlet outfit.
The Biogas Production System
A biogas production system consists of the d) Gas Burner
following features: This may be a special lighting lamp or a
modified burner for cooking.
a) Substrate inlet
This consists of a receptacle for the raw e) Exhaust outlet
fresh organic waste and pipe of at least 10 cm This consists of a pipe of similar size to the
diameter leading to the digester. The connection inlet pipe connected to the digester at a slightly lower
between the inlet pipe and the digester must be air level than the inlet pipe to facilitate outflow of
tight. exhausted slurry.

To
kitchen

Reservoir Gas pipe

Water
trap

Outlet Digester Inlet

Fig.1: Biogas Production System

2.2 Methods
Biogas can be obtained from any organic 1. First Stage
material after anaerobic fermentation by three main Complex organic compounds are attacked by
phases. The fermentation of organic wastes under hydrolytic and fermentative bacteria, which secrete
anaerobic conditions to produce biogas occurs in the enzymes and ferment hydrolyzed compounds into
following three stages:- acetate and hydrogen .A small amount of the carbon
converted will end up as volatile fatty acids, primarily
propionic and butyric acids.

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Ogur, E. O et al Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 3, Issue 6, Nov-Dec 2013, pp.630-635

Hydrolyze and ferments organic substance

Cellulose Protein decomposing Fat decomposing bacteria

decomposing bacteria
bacteria

Saccharides Amino acids Fatty acids

Volatile acids H2 and CO2

Fig. 2: Fermentative Bacteria

volatile fatty acids into acetate and hydrogen
2. Second Stage producing acetogenic bacteria.
The hydrogen- producing acetogenic
bacteria continue decomposing by converting the

Decompose the substances Acetic acid,H2 and CO2

produced in the first stage
Fig.3: Decomposition of Fatty Acids

3. Third Stage  The purpose or performance goal

Methane –producing bacteria convert the The size of the digester is based on;
hydrogen and acetate into methane .There is a certain a) Size based on health criteria
amount of specialization in that different bacteria act If the primary purpose is for health i.e. reduction
on different substrates .In order for these bacteria to of the possible transmission of the diseases then
work properly and achieve the desired end products, temperature and retention time are very important
the following conditions have to be well balanced . criteria.
 The dilution of the substrate i.e. amount of water b) Size based on production of soil conditioner
to dilute the animal waste. If the purpose of the system is to produce
 The optimum temperature which should be 350C primarily a soil conditioner, then the breakdown,
 Type of substrate (due to their suitable carbon to stabilization, and storage of the organism and
Nitrogen (C: N) ratio and total solid content nutrients will govern the system.
cattle, pig and poultry manures are c) Size based on energy.
recommended). If the production of energy is the most
 Rate of feeding the digester (overfeeding can important objective, the gas production should be
lead to accumulation of volatile fatty acids). optimized then the primary variables that affect
production of the gas are:
2.2.1 Design and Construction of Biogas Plants  Biodegradability of the materials
2.2.1.1 Design of Generator (Based on Methane  Concentration of the feed.
Production Rate)  Kinetic constants.
In designing the digester two terms must be  Retention time.
taken into consideration
 Type of digester that will be used

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ISSN : 2248-9622, Vol. 3, Issue 6, Nov-Dec 2013, pp.01-05

Temperature has a professional effect on the digestion Tti = the operating time of the device ‘i’ per day
since the kinetic constants are affected by changes in Then, Total energy content generated per day, Etg= ∑
temperature. Eti Tti +Ett
where, Ett=unutilized energy per day (Kj/day)
2.2.1.2 Design Based on End User Requirement If Eoti is the useful energy of the energy point device
The design involves the following and ti is the overall efficiency of the end point
parameters: device’i’
1. Input parameters E oti Tti
 Water availability. E tg    E tt
 Daily availability of raw materials.  ti
 Financial inputs. The procedure for determining the digester volume V r
 Climate of the region and its is
geographical location. a) Based on the useful energy output of the end
 Appropriate space availability. point device, Eoti
2. Output parameter: - The operating time of the device per day; T ti
 End use energy requirement(kWh) - The overall efficiency ti of the end point
and useful power requirements(kW) device energy per day may be suitably
of thermal and material energy assumed.
 Requirement of biogas or methane b) From Etg and Ytg , the volume Vr can be
(in energy units or m3 per day) determined.
c) Based on the Ymin and Ymax, Vrmin and Vrmax can be
3. Design parameter calculated.
 Optimum temperature range and d) Based on Ymin and Ymax , Eu can be computed.
heating.
Ymax  Ymin
 Retention period. Eu   Ymin
 C/N ratio of feed. 2
 PH of slurry. Digester Volume Vr =Vs+Vg+Vx
 Feed of water ratio (Vf/Vw). where, Vs= volume of the slurry space or digester
 Percent of total solid in feed 3
Volume in m , if Vx tends to zero, then
(T S %). Vr =Vs+Vg , Vs=trId ,
 Percent of volatile solids in feed Where, tr= residence time, days. Id=influent charge or
slurry per day,m3/day.
(V S %). 3 3
The fraction of the feed f (m of V s / m ) of
 Fraction of the methane in gas f

(F CH 4 ) slurry input is
3 3 Vf
 Gas yield (m /m of digester/day). fg 
 Ultimate gas yield (m3/m3 of V w Vf 
digester/total retention time).
1  Vw  V f 


2.3 Design Approach.
If Y = Biogas yield (m3 of biogas / m3/m3 of
f f  V f 

digester/day). But Vw/Vf = water Ts feed ratio, thus
Ymin = minimum yield in the year (m3of the biogas / 1
m3/m3 of digester/year) ff 
Ymax= maximum yield in the year (m3of the biogas / 1  WF
m3/m3 of digester/year) where W F is the water to feed ratio, Vf=Idff =volume
Y g methane yield (m3of methane/year / m3 of 3
flow rate of pure feed (m /day)
digester/year)
Then, Y g = Y x F CH 4 III. Results and Discussions
The numbers of classrooms were 40. With
The total methane yield from a reactor of volume V r each classroom having a florescent tube of 36W and
per day is Ytg= Yg.Vg an average lighting time of 10hrs,
The total energy content generated per day, Etg = Ytg . Power required = (10×40×9×36W)/1000=
Cf 129.6kWhr
3
Where, Vr= volume of the reactor (m ), Cf = calorific The workshops and laboratories with the number of
value of CH 4 tubes they contain are listed below.
If Eti = the energy consumption of a devices ’i’ per
Workshop and Laboratory Number of tubes
hour (e.g. lighting tubes, burner etc).
- Mechanical training w/s 50

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- Electrical training w/s The student halls of residence data was listed as
40 follows:
- Electrical lab - Block A
30 21
- Woodwork w/s - Block B
40 23
- Masonry w/s - Block C
10 20
- Plumbing w/s - Gal sheet
20 10
- Automotive w/s - Extension
20 10
- Mechanical production w/s - Canteen
30 6
- Chemistry lab - Milimani (A+B)
10 25
- Biology Total number of tubes
10 115
- Dressmaking w/s With an average lighting time of 10hrs,
10 Power required = (10×115×36)÷1000 = 44.4kWhr
- Food &Beverage restaurants The total power required for lighting daily,
20 = 129.6+75.6+23.04+34.2+90+41.4= 393.84kWhr.
- Food & Beverage kitchen Approximately 400kWhr
20 1kWhr = 3.6×106 joules, therefore the daily energy
- Total number of tubes requirement
210 tubes. = 400 ×3.6×106 = 1.44×109/day

With an average lighting time of 10hrs, Assumption:

Power required = (210×36×10)/ 1000 = 75.6 kWhr Production of Biogas /kg of fresh dung
Data for the main kitchen was listed as shown below. 3
=0.06m or a retention of 30 days.
- Dining hall Calorific value of the biogas produced = 20MJ/m3
12 Thus, the daily Biogas flow rate = daily energy
- Kitchen +store +offices requirement /calorific value of fuel.
20 = (1.44×10) ÷ (20×106)
Total number of tubes = 72m3/day
32
With an average lighting time of 20hrs, The institution’s kitchen uses 150 kg of
Power required = (32×36×20) ÷1000 = 23.03kWhr wood per day.
Other utilities were listed as shown below: Biogas equivalent = 0.18 m3/kg of wood
- Administration block Amount of biogas required = 0.18 m3×150
45 =
- Main hall 27 m3 Biogas per day
20 Therefore, the total amount of biogas required daily
- T.V room =72+27= 99 m3/day
8 The Quantity of cattle dung required = gas production
- Main stores per day/gas per kg of fresh dung
8 = 99/0.06
- Toilets = 1650kg of dung per
8 day
- Cyber cafe Average dung collection /adult animal/day = 10kg
8 Total number of cattle required = total dung/dung per
Total number of tubes animal
95 tubes =1650/10
With an average lighting time of 10hrs, = 165 heads of cattle
Power required = (95×36×9×10)÷1000 = 34.2 kWhr
Security lighting required 50 tubes with each tube DIGESTER DIMENSION CALCULATIONS
consuming 150 Watts and an average lighting time of Cow dung water mix ratio=1:1
12 hrs, Mass of slurry per day = mass of cow
Power required = (50×150×12)÷1000 = 90 kWhr dung + mass of water
= 1650×2

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ISSN : 2248-9622, Vol. 3, Issue 6, Nov-Dec 2013, pp.01-05

= 3300kg Biological Hydrogen Foundation: The

Density of the slurry = 1000kg/m3with Netherlands.
solid Concentrations of 8-10% [2] Drapcho, C.M., Nhuan, N.P. and Walker,
Volume of slurry = mass of the T.H. (2008), Biofuels Engineering Process
slurry/density of the slurry Technology, McGraw Hill, U.S.A.
= 3300/1090 [3] Zicari, S.M. (2003), Removal of Hydrogen
= 3.027 m3 Sulfide from Biogas Using Cow-manure
= 3 m3 Compost, MSc Thesis, Cornell University.
Let the retention time (assumed) to be 30 days [4] Planning and Installing Bioenergy Systems:
Digester volume = Volume of dairy charge × A Guide for Installers, Architects and
retention time = 3×30 = 90 m3 Engineers, James & James, U.K.
This is the minimum working volume. The actual
volume should be 10% more to provide some empty
space at the top for proper disengagement of the gas
Actual digester volume = 90×1.1 = 99 m3
A cylinder shape for the digester was chosen.
The height (H) to diameter (D) ratio was taken as
entity for any large capacity plant time
Thus H/D = 1 of the digester
 3
Digester volume, 99= D
4
Therefore the height was taken as = 5 m
Let the digester be dome shaped at the top to hold the
required daily gas,
Then,
   D 2 
Vd  d h 3   d h 
2

6   2  
where, Vd = daily gas volume required, Dh = Dome
height and D = Diameter of the cylinder part of the
digester
Therefore,
   5 2 
99  d h 3   d h 
2

6   2  
By the trial and error, the digester dome height, D h =
3.7m

IV. Conclusions
Based on the findings of this study, the
following conclusion can be drawn:
 The biogas digester is the best option to save cost
on power.
 It will provide sufficient energy for both cooking
and lighting.
 Any excess gas generated should be sold to the
neighbourhood.
 Organic fertilizers can be made from the
slurry generated after the biogas production
process. This can also be sold to generate
income for MUC.

References
[1] Reith, J. H., R. H. Wijffels, and H. Barren
(eds). 2003. Bio-methane and Bio-hydrogen:
Status and Perspectives of Biological
Methane and Hydrogen Production. Dutch

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