Designing a Biogas System

Technical Note No. SAN. 3.D.4

A biogas system is a means of digesting animal manure anaerobically to produce methane gas which is burned to provide heat or light. The system consists of one or more digester tanks, a gas holder, an arrangement of gas and one or more fixtures to burn pipes, the gas. Designing a biogas system requires the services of a project designer experienced with these systems. Designing involves selecting a location; calculating the size of the digesters and the gas holder; and determining the labor, materials, and tools needed for construction. The products of the design process are: (1) a location map, (2) design drawings of the system, and (3) a detailed materials list. These products will be given to the construction foreman prior to construction. This technical note describes how to design a biogas system. Read the entire technical note before beginning the design process.
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General A biogas system requires a constant A system and large supply of manure. serving one family needs the daily manure production of either lo-15 pigs, two or three horses, or two cows. All components of a biogas system must be gas-tight. Gas leaks are dangerous because certain mixtures of methane gas and air are explosive. the design, construction, Therefore, and operation of these systems should be undertaken only by experienced or There carefully trained personnel. are a number of types of biogas One design requires at least systems. two digesters to ensure continuous gas While one digester is proproduction. ducing gas, the other can be emptied of digested material and reloaded with fresh manure and water. Some components of the system may be The built but some must be purchased. digesters and the floor and walls of the gas holder are generally made from reinforced concrete and usually are However, the gas built on the site. holder is typically circular and requires special construction skills to build. Components which must be purchased include the metal cover for the gas holder, guide wheels, guide posts, gas pipes, valves, petcocks, and These fixtures used to burn the gas. items make a biogas system relatively costly. The gas holder and digesters are designed to be Installed partially This is done for ease of underground. loading and maintenance, while allowing

Useful Definition when organic METHANE - A gas produced material such an manure decomposes in an airless environment; methane burns with a violet flame without smoke; it is explosive.

Materials Needed Measuring tape - To obtain accurate field Information for a location map. Ruler - To produce a location map.

a portion of the system to be exposed In temperate climates, to sunlight. this kind of installation helps keep the temperature in the digester more uniform. Selecting a location The system should be located:

/ Table 1. Approximate Gas Requirements

Activity Cooking for a family of 5 or 6 persons Heating lOO-liter Lighting water in a tank one lamp

Volume of Gas 2m3 per day

l alongside the stable, pig sty, or other manure source to avoid excessive handling of manure, l near the dwelling amount of gas piping,

3m3 per

day

to minimize

the O.l-0.15m3 per hour 0.91113 per hour

in an unshaded area of the maximum available sun.

to make use heat from the Operating a twohorsepower stationary engine

When a location has been selected, draw a location map similar to Figure and give It to the construction foreman.

To estimate the volume of the gas add together the gas needed holder, For for each expected activity. if the family expects to burn example, one lamp for two methane to cook, light hours each night, and operate a twohorsepower engine for two hours each should day, the size of the gas holder be: 2m3 + (2 x O.lm3) + (2 x 0 9m3) = 2m3 + 0.2m3 + 1.8m3 = 4.Omj The floating cover of the gas holder should have a volume equal to at least 4.Om3, The volume of a circular cover equals 3.1 times the radius squared times the height. One configuration which would contain the required volume would be 1.6m In diameter and 2.02m in height: = dia;eter so radius = 1.6m = radius
2

Figure 1. Location

Map

Calculating

Size

0.8m
3.1 x 0.8m x 0.8m x 2.02m = 4.0m3 Worksheet A, Lines l-5

The size of the system depends on the desired volume of daily gas production. The volume of the gas holder should equal one day's gas production, with a minimum size of 2m3. Table 1 provides approximate quantities of gas required for some domestic activities.

The actual height of the cover equals the calculated height plus 150mm to allow for placement of the weepwhich will provide an escape for holes, an excessive amount of gas.

Worksheet A. Calculating

Dimensions of a Biogas System

1. Expected

daily

volume

of gas = gfo = Line cover

m3 1 = 90 = /.6
2

2. Minimum volume 3. Proposed 4. Proposed 5. Calculated (*O 3.1 x (a.8 6. Design 7. Inside 8. Inside
2 x

of gas holder of floating of cover of cover

m3 m

diameter radius height m3 m> x ( 0.8 height height diameter

= Line =

3 = ( /.b

m) = 0.8

m =

3.1

Line 2 x Line 4 x Line

= ( 9.0 m3) = 2.0X. ma ( y.98 m2) m) = Line 5 + 0.15m = 2.OZ.m + 0.15m = U./y = Line = Line should m m = 11 (A.0 (8.0 m3) ml x (2.0 = m> 6 + 0.25m = ,A.7 3 + 0.15m = /6 not exceed m

of cover

of gas holder of gas holder

m + 0.25m = z.qzrn m + 0.15m = /.7srn 1 =

9. Volume of each digester q.0 m3 = g:O m3 length width

volume

8.Om3 = 2 x Line

10. Proposed 11. Proposed 12. Height

of digester of digester = Line

= a.0 = 2.0 Line 9 10 x Line

of digester m

( 8.0 m3) = 2.0 ( y.0 m*)

In the example design height is:

given,

the

actual,

or

2.02m + 0.15m = 2.17m Worksheet A, Line 6 The inside height of the gas holder equals the design height of the floating cover plus 25Omm. The inside height for this example is: f c ! i 2.17m + 0.25m = 2.42m Worksheet A, Line 7 The Inside diameter of the gas holder equals the diameter of the cover plus 150mm. The Inside diameter for this example is: 1.6m t 0.15m = 1.75m Worksheet A, Line 8

When the dimensions of the gas holder have been calculated, prepare a design drawing similar to Figure 2 and give it to the construction foreman. The volume of each digester should equal twice the volume of the gas holder, with a maximum size of 8.Om3. In the example given, the volume of the gas holder is 4.0m3. Twice this 2 x 4.Om3 = 8.Om3. volume equals: Each This does not exceed the maximum. digester should have a volume of 8.0m3. One configuration that has this volume is 2.0m wide by 2.0m long by 2.0m high: 2.Om x 2.Om x 2.Om = 8.Om3 Worksheet A, Lines 9-12

Top View

Guide post and guide wheel

s Brace for ouide post

Cross brace

Guide post -

I-

Cover diameter /I

Gas holderwall

i,> . . .a :; I. *.

7 ..1 .a . .: ; : ! .. : .. ;:

Guide wheel

T EE
r

*. .. I . 1. , ! ..;

.. ..

# .

Weephole

-<

: .. .. s:

Gas pipe from digester

.. 0 A

Figure 2. Design

of Gas Holder

Side View

When the dimensions of the digesters have been determined, prepare a design drawing similar to Figure 3 and give it to the construction foreman. The digesters and the gas holder, not including the cover, are made from reinforced concrete. The thickness of the concrete is summarized in Table 2. Add this information to Figures 2 and
3.
Side View \
75mm

/ Table 2. Concrete Thicknesses

Feature Digester: wal. 1.s floor top Gas Holder:

Thickness

150mm

175mm 175mm

Top

walls floor

150mm 250mm

. E all + : -c ol 75mm . I Ick -. .I. ., + : + 75mm .S.. ~

.. 175mm+ . .c .a .., E g I +

, .: +175mm

Length ., :

-, .. ,I,.

I.. . + .,-..,:...

Length

_ .-,,.::

.i :.. 1 C. ,, J

Top View
rOverall length ~1

The floating cover for the gas holder is made from sheet iron 2-3m thick, reinforced with angle iron or Because of its strict cross-braces. design specifications, it must be purchased unless an exceptionally skilled sheet metal worker can be found. Gas and are iron. at key lines. needed, cocks, drawing layout pipes are 12-25mm in diameter made from copper or galvanized Valves and petcocks are placed control points along the gas To determine the amount of pipe and the number of valves, petand pipe-fittings, prepare a similar to Figure 4 showing the of the system.

Manhole 7

To gas holder

Fixtures are needed to burn the methane gas. These are generally purchased. Materials for reinforced concrete include cement, sand, gravel, water, reinforcing material, and materials to build forms. For complete details see "Designing Septic Tanks," SAN.2.D.3. Tools needed include picks and shovels for excavation; hammer and saw for building forms; trowel for working concrete; wrenches, hacksaw, and threading tool for installing gas and a device for checking pipes, leaks. When a31. determination for labor, materials, and tools have been made, prepare a materials list similar to Table 3 and give it to the construction foreman.

Figure 3. Design

of Digesters

Determining

Labor, Materials,

and Tools

The primary labor requirement is a construction foreman familiar with these systems. An experienced pipefitter is needed to install the gas At least one worker should pipes. have some experience with reinforced concrete. Unskilled labor can be used for making excavations, mixing concrete, and hauling materials.

Side View

Petcock

Dwelling

Digesters

trap

Gas holder

Petcock

Top View

Digesters

Figure 4. Typical

Gas Pipe Arrangement

In summary, give the construction foreman a location map similar to similar to Figure 1, design drawings

Figures 2 and 3, a system layout lar to Figure 4, and a materials similar to Table 3.

similist

Table 3. Sample Materials List

Item Labor

Description Construction foreman experienced with biogas Worker experienced with pipe fitting Worker experienced with reinforced concrete Unskilled workers Prefabricated floating cover: 3mm thick sheet iron; 1.60m diameter; 2.17m high Guide posts; galvanized iron Guide wheels Gas pipe: 18mm diameter Valves Petcocks "T" fittings "L" fittings Fixtures Concrete mix Reinforcing material Material for forms Sealer for digester manholes Other Shovels Picks Hammers Saw Trowels Wheelbarrow Containers: Pipe wrench Threader Hacksaw Other

Quantity

Estimated

Cost

Supplies

Tools

for

mixing

concrete

Total

Estimated

Cost =