TANZANIA DOMESTIC BIOGAS PROGRAMME

The Modified-‘CAMARTEC’ Biogas Plants

Construction Training Manual

TDBP - Mason’s handbook-1st Edition- ‘December 2009’

 Table of Contents

Table of Contents ........................................................................................................................................ ii

1.0 INTRODUCTION .......................................................................................................................................... 1

1.1 Biogas and its composition ................................................................................................................... 1
1.2 Benefits of biogas ................................................................................................................................ 1
1.3 Uses of biogas .................................................................................................................................... 2
1.4 Different components of a biogas plant and the system of the fixed dome plant ......................................... 2
1.5 Importance of training local masons....................................................................................................... 3

2.0 OBJECTIVES OF THE TRAINING ................................................................................................................. 3

2.1 General objective: ................................................................................................................................ 3
2.2 Specific objectives: .............................................................................................................................. 3
2.3 Expected outputs: ................................................................................................................................ 3

3.0 FACTORS TO BE CONSIDERED IN BIOGAS SITE SELECTION ..................................................................... 4

3.1 Client’s personal information: ................................................................................................................ 4
3.2 Biogas plant site location: ..................................................................................................................... 4

4.0 GUIDELINE FOR SELECTING THE APPROPRIATE SIZE BIOGAS PLANT: .................................................... 4
4.1 Design parameters:.............................................................................................................................. 4

5.0 QUALITY STANDARDS OF CONSTRUCTION MATERIALS ........................................................................... 5

6.0 BIOGAS PLANT CONSTRUCTION PROCEDURE .......................................................................................... 5

6.1 Setting out a Biogas Plant .................................................................................................................... 5
6.2 The Importance of the Reference Line ................................................................................................... 6
6.2.1 Steps for setting the reference line ...................................................................................................... 6
6.3 Excavation of the biogas plant pits......................................................................................................... 7
6.4 Preparation of Radius Stick and its importance in the dome construction ................................................... 7
6.5 Fixation of the centre (radius) point ........................................................................................................ 7
6.6 Excavation and pouring concrete of a foundation base (steps to be followed) ............................................ 8
6.7 Construction of a spherical wall up to the strong ring ............................................................................... 9
6.7.1 Specification of brick’s size and dimensions......................................................................................... 9
6.7.2 Steps for constructing a spherical wall up to the strong ring ................................................................. 10
6.7.3 Fixation of the inlet pipe(s) ............................................................................................................... 12
6.7.4 Construction of the strong ring.......................................................................................................... 13
6.7.5 Slurry outlet opening beam .............................................................................................................. 14
6.7.6 Soil backfilling on the lower part of the digester .................................................................................. 14
6.8 Construction of the spherical wall on the upper part (above strong ring) to the closure of the dome ............ 14
6.9 Placement of the Dome gas pipe: ........................................................................................................ 15
6.10 Placement of the chicken wire on the upper part and the construction of the test unit chamber ................ 17
6.11 Plastering the outside upper part of the digester: ................................................................................. 17
6.12 Plastering the inside upper part of the digester (gas tightness plasters) ................................................. 17
6.13 Flooring .......................................................................................................................................... 18
6.14 Construction of the expansion/compensating chamber ........................................................................ 18
6:15 Soil back filling above the strong ring, on the upper part of the digester ................................................. 19
6.16 Construction of a mixing chamber ...................................................................................................... 19

7.0 GAS PIPE LINE .......................................................................................................................................... 20

7.1 Fixation of the main gas line (alignment and digging of trench) ............................................................... 20
7.2 Procedure of fixing the main gas pipe line ............................................................................................ 20
7.2 INDOOR PIPING ............................................................................................................................... 22

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 7.3 CHECKING FOR LEAKAGES ............................................................................................................. 22

8.0 INSTALLATION OF GAS APPLIANCES ...................................................................................................... 23

8.1 Fixation of gas taps, rubber hosepipe, stove and lamps: ........................................................................ 23
8.2 Some technologies and modifications of gas appliances ........................................................................ 23

9.0 FINISHING WORKS .................................................................................................................................... 24

10.0 GAS UTILIZATION (Cooking and Lighting) ............................................................................................... 25

10.1 Gas stove:....................................................................................................................................... 25
10.2 Gas lamps....................................................................................................................................... 25

11.0 BIO-SLURRY UTILIZATION ...................................................................................................................... 26

11.1 Slurry Canal .................................................................................................................................... 26
11. 2 Importance of composting and shading of pits.................................................................................... 26

12.0 OPERATION OF THE BIOGAS PLANT ...................................................................................................... 27

12.1 Operation and maintenance .............................................................................................................. 27
12.2 Initial and regular filling of the digester ............................................................................................... 27
12.3 Potential problems and likely solutions (Trouble shooting): ................................................................... 27
12.4 BIOGAS PLANT DRAWINGS ........................................................................................................... 29

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1.0 INTRODUCTION
1.1 Biogas and its composition
Biogas is a combustible gas produced by anaerobic digestion of organic materials like animal dung, agricultural wastes and human
excreta.
During the anaerobic digestion process, methane (CH4), carbon dioxide (CO2) and traces of hydrogen sulphide are produced as
by-products.
The gas is only combustible if the quantity of methane in the mixture is above 50%. After these organic materials have been
digested, they go out as slurry, which is a rich fertilizer for agricultural production.

Organic feeding
material + urine/water

Anaerobic
digestion process

Biogas Liquid overflow Bio-slurry

Energy Post treatment

Plants

1.2 Benefits of biogas

1. Low cost energy for cooking and lighting
o Savings of up to 375,000 TShs ($ 300) on annual energy expenditure for an average household by replacing
firewood and charcoal.
2. Less Laborious
o Women in rural areas will be spared the burden and time together firewood up to two hours daily for other economic
activities.
3. No smoke or odour
o Reduce indoor pollution avoiding respiratory and eye diseases caused by the smoke inherent to traditional cooking.
4. Job creation
o Masons will be trained in biogas plant construction, after sales management and business development support.

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 5. Improved Agriculture:
o Bio-slurry is a powerful fertilizer, which is better than cow manure and expensive industrial fertilizers.
6. Sanitation and Improvement:
o Cattle dung is no longer stored in the farm yard, but is fed directly to the biogas digester
7. Environmental Protection:
o Reducing fire wood use and emissions of green house gas
o Cattle under zero –grazing condition reduce overgrazing

1.3 Uses of biogas

 Cooking using special domestic biogas stoves or modified conventional stoves
 Baking ovens
 Lighting using biogas lamps
 Refrigeration
 Motive power - converted into mechanical energy for various uses, i.e generation of electricity, water pumping, etc.
 Chicken incubators and brooders - replacing kerosene and electricity
 House warming and heating

1.4 Different components of a biogas plant and the system of the fixed dome plant
A biogas plant is the hemispherical masonry structure-dome shaped which is constructed underground and guided by the
respective vertical and horizontal dimensions as per technical drawing details provided.
Fig: 1 Basic components of the MCD-Biogas plant

Mixing chamber 5 4 1 Expansion chamber 6

Overflow point & opening

9 8

3 7

Foundation ring Concrete base Slurry outlet opening

The digester (1) is filled via the inlet pipe (2) up to the bottom level of the expansion chamber (3).
The level of original filling is called the zero line (9).
Under the airless (anaerobic) condition, biogas is produced. When the gas valve at the test unit chamber (4) is closed,
biogas collects in the upper part of the digester, called the gas storage part (5). The accumulating gas displaces part of the

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slurry into the expansion chamber. When the expansion chamber is full, slurry overflows into the slurry drain for use as
manure. When the main valve (4) is opened, the gas escapes off the gas storage part until the slurry levels inside the
digester and inside the expansion chamber balances. The gas pressure "p" depends on the prevailing difference of the
slurry levels (6-HSL) and (7-LSL). The slurry outlet opening beam/lintel (8), reinforced with round iron bars.

The substrate is filled daily so that slurry flows out daily at the time when large amount of gas is stored.
Regular gas consumption requires a significantly optimum gas storage space, i.e. 60% of the total gas production.
Consequently the zero-line will rise.
While daily feeding of the plant continues, gas is released before the slurry reaches the overflow level, i.e. as soon as the
slurry covers all the openings (Inlet pipe(s) and the slurry outlet opening) or the initial feeding up to the zero-line has been
fulfilled.
The slurry level rises also when there is a gas leakage along the gas line.
The level in the expansion chamber at zero gas pressure (on the expansion chamber floor) indicates the level of the zero
line.
The volume of slurry above the zero line inside the expansion chamber is equal to the gas storage space.

1.5 Importance of training local masons

This handbook is designed for Tanzanian masons willing to make a living out of building biogas digesters. After going through a
thorough training course set up by TDBP, masons are encouraged to form Biogas Construction Enterprises (BCEs)/associations
that will act as commercial entities. This private-sector led approach driven by mason associations/companies will provide biogas
construction services to the general population. This approach will spread biogas technology through various promotions efforts,
extension work and lead to the development of a sustainable yet commercial biogas sector in Tanzania.

2.0 OBJECTIVES OF THE TRAINING

2.1 General objective:
To build the technical capacity of individual masons and artisans to construct biogas plants and further the use of simple biogas
technology as a source of energy that will substitute the use of traditional fuels such as firewood and other relatively expensive and
polluting sources.
2.2 Specific objectives:
a) To build technical capacity to groups of masons/artisans/technicians so that they get involved in the construction of biogas
plants for their own income-generation.
b) To strengthen TDBP’s capacity for creating a commercial biogas sector by promoting domestic biogas plants and provide
biogas construction services across the country.
c) To train the biogas end users on how to operate and maintain their biogas plants efficiently.
2.3 Expected outputs:
At the end of the training, we expect all participants:
 To be familiar with the Tanzania Domestic Biogas Programme
 To acquire detailed knowledge on biogas technology, its advantages, and the use of biogas plant products i.e. biogas and bio-
slurry.
 To be able to adequately construct quality domestic biogas plants, in line with the steps set out in this training manual through;
- Reading technical biogas plant drawings and interpreting the dimensions onto the ground precisely
- Selection of appropriate plant size, construction sites and materials
- Advising the client and signing official TDBP contracts and Bill of Quantity (BoQ) with clients
- Plant lay out and excavation of pits

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 - Construction of entire biogas plant (as per the guidelines set out in this manual)
- Laying of gas pipelines and installation of appliances
- Advice on the use of bio-slurry as fertilizer
- Carry out & guide households on how to operate and maintain the biogas system
- Provide independent after-sales services
 Masons should be familiar with their supervisory roles and responsibilities related to Promotion (various promotion activities),
Quality Management (ensuring a fully operational plant, continued maintenance and after-sales service) and Extension
(biogas slurry user).

3.0 FACTORS TO BE CONSIDERED IN BIOGAS SITE SELECTION

3.1 Client’s personal information:
 Client’s energy requirement (family size to be served)
 Client’s priority plans and future prospects
 The quantity of organic material/feed stock available for daily feeding of the plant (see chapter 4.0 for more details)
 Animal rearing system (zero-grazed, semi-grazed or outdoor grazing)
 Slurry utilization/disposal
 The size of the farm
 Hygienic and sanitation conditions to be achieved
 Clients own income (i.e. the biogas plant costs vs. the affordability by the client)

3.2 Biogas plant site location:

 Selected site for the plant should be as closely proximate to ensure simple and quick feeding into the digester.
 Take into consideration existing structure at the site and how they can be incorporated in the biogas system e.g. current
cowshed, kitchen stove, and other infrastructures around the site like roads, rivers, rocks, obstacles like big trees, etc.
 Consider the land terrain & the existing natural slope for the gravitational flow of slurry.
NOTE: A level ground will have a different approach from the one with a defined slope. Where there is no slope, the slurry will
be considered for storage (slurry pit), drying or composting.
 Consider the gas consumption points in terms of distance and slope direction in relation to piping costs and position of water
traps respectively.
 Consider client’s future plans, such as house expansion / new construction, increasing number of animals, etc.
Where these structures do not exist, and a biogas plant is required, it is necessary to consider them in the initial planning.
 Cowshed/Pigsties: depending on the animal shed to be connected to the plant, the direction for slurry flow should be
determined firstly. In the case of a biogas plant connected to toilets, it does not only solve the problem of emptying the filled
up pits, but it also brings about a better and safe use of human wastes for agricultural production.
 It is important that the slurry outlet is always placed at a lower point than the digester.

After all these factors have been considered, then the physical setting out of the biogas plant can start.

4.0 GUIDELINE FOR SELECTING THE APPROPRIATE SIZE BIOGAS PLANT:

4.1 Design parameters:
- Hydraulic retention time = 50 days
- Ambient temperature range = 200C – 250C
- 1 adult cow produces an average of 15 kgs of dung per day (zero-grazed cows)
- Mixing ratio of dung to water/urine = 1:1 (consistency)
- 1 kg of cow dung produces 40 litres of gas per day

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 - Digester’s gas storage capacity (%) ~ 60%

 VD Daily gas Daily dung Water / urine # of H/H stoves & # of lamps &
 production feeding to mix with running time at a running time at a
 rate: rate:
 (m3) Lts/day Kg/day Lts/day 200-350 lts/hr. 120-180 lts/hr.
4 1108 30 (30 – 40) 30 1 (3 hours) 1 (2 hours)
6 1772 45 (41 – 60) 45 1 (4 hours) 1 (4.5 hours)
9 2788 70 (61 – 90) 70 1 (6 hours) 2 (3.5 hours)
13 4172 105 (91 – 130) 105 1 (6 hours) 3 (6 hours)

Observations:
 If cows are out-door/semi-grazed, multiply the number of cows (zero-grazed) by 3 in order to get the required number.
 Pigs and poultry manure can equally be used and provides more gas than cow dung.
 Goat manure…require special treatment before feeding into the digester
 Based on energy household research, Tanzanian household’s use about 6 hours for cooking all meals per day.

5.0 QUALITY STANDARDS OF CONSTRUCTION MATERIALS

CEMENT Cement should be of good and high quality; Portland cement has a good reputation and is recommended. It should
be stored away from the walls and in cool dry places, i.e under the shades and on a raised platform.

SAND Sand should be clean and well sieved; it should not contain soil or any unwanted material, however fine river sand of
good quality is recommended for all the constructional works.

GRAVEL The gravel should be clean, hard and angular shaped - if dirty it should be cleaned first before use. The size range of
gravel should be ½”- ¾” (i.e. 25 mm – 38 mm).

BRICKS Bricks should be of high quality, hard and well shaped, the recommended size is 23cm x 11cm x 7cm.
TIP: In some areas where burnt bricks are not available, you can easily make and
use cement/sand bricks of the same size, made with the ratio of 1:8 (cement: sand)
and one bag of cement (50 kg) will give about 150 bricks.

The quantity and requirements of construction materials (Bill of Quantity-BoQ) depends on the size of the plant, i.e 4m3-13m3.
Please refer to the appendices for the BoQ, listing the required materials needed.

6.0 BIOGAS PLANT CONSTRUCTION PROCEDURE

6.1 Setting out a Biogas Plant
1. Locate a suitable position for the biogas plant (see Section 3.2 for details)
2. Fix the relative positions of mixing chamber / inlet, digester, manhole, expansion chamber and slurry pits.
3. Use the respective drawing and their horizontal dimensions; add 45 cm to the digester and expansion chamber radii to allow a
working space inside the pits.
4. Use colored powder to demarcate the locations-boundaries and centre points of the respective components.

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6.2 The Importance of the Reference Line
o Reference line can be defined as a thin string tightly connecting two leveled points passing across the centre of a biogas plant
from which all vertical measurements are taken (measured vertically downwards).
o All the vertical measurements for the biogas plant in relation to the reference line are clearly shown on the attached technical
drawings.
o The reference line is placed 40 cm ± 10 cm above the ground level at the overflow point of the expansion chamber.
o Tools required: strong pegs, string, nails, hammer, spirit level, measuring tape.
6.2.1 Steps for setting the reference line
Step 1: After setting the demarcation of the plant, fix a peg (peg number 1) at the lowest point of the stable floor.
Step 2: Position another peg (peg number 2) at point of slurry overflow.
Step 3: Measure at least 40 cm above the ground level at peg number 2 and tie a string at that point.
Step 4: Use spirit level to get a point at peg number 1.
Step 5: Fix a string between peg number 1 and 2 in horizontal position passing across the center of the digester.
Step 6: Verify if lowest point at the inlet’s ground level (peg number 1) from the reference line is ≤30 cm, this is to be sure that
the difference in level between the inlet and overflow points is ≥20 cm, and the height at peg number 2 is about 40 cm
± 10 cm (30-50 cm) above average ground level.
Step 7: If the measurement from the reference line to the inlet point (at peg 1) on ground level is more than 20±10 cm relative to
40±10 cm (at peg 2) then reposition the later till you get the difference of at least ≥20 cm.
Step 8: Indicate both center points for the digester and expansion chamber on the reference line by fixing small nails on those
points. In order not to lose the level of the reference line it is advisable to also mark it on a permanent structure like a
tree or building near to the biogas plant.
If the biogas plant site is sloping, then setting of reference line should be along the contour/across the slope, and the same
difference of ≥20 cm between inlet and overflow points should be considered in all terrains, i.e. flat, gentle and steep slopes.

Fig 2: Illustrating the setting of a Reference line and the important vertical and horizontal dimensions for the digester and
expansion chamber pits

40±10cm above
Cow CD CEC ground level
Shed

Reference line
Peg1
Ground level
Expansion chamber pit Peg 2

Digester pit Radius point

measured
from R.Line
reference
line

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6.3 Excavation of the biogas plant pits
Further tools required; Radius stick, peg, plumb bob, spade, martel
o Digging the pits has to be done according to the layout marked on the ground during the planning stages.
o The pit’s vertical depth has to follow the vertical measurements taken from the reference line, depending on the digester size.
These measurements are clearly shown on the technical drawings attached for each digester size.
o The radius of any digester is increased by 45 cm to allow a working area around the digester. See Fig. 3 below.

Fig 3: Radius of the digester pit

Digester radius-RD

45 cm

Pit radius=RD + 45 cm

o Where the ground water table is high, a small pit is dug aside the
digester pit to allow water to collect so that it can be pumped out while
digging or construction works continue (removal of water can be done
manually or by a motorized pump). See Diagram alongside.
o The walls of the pit should be shaped according to the soil properties.
In case of loose soil the pit should be dug with slanting walls to avoid
collapsing down onto the pit.
o Enough space for dumping the soil is also necessary; keep this soil
away from the pit edge. Soil scooped out of the pit should be placed at
(5) concrete floor, (6) centre radius
least 1 meter away from the edge of the pit to allow free movement around the sites.
It is advisable that digging should not be done during rainy seasons.

6.4 Preparation of Radius Stick and its importance in the dome construction
o The Radius Stick is a tool used as a guide stick, its length is measured specifically for controlling the radius of the digester and
also controls the brick domes’ hemispherical shape while constructing.
It gives the measurement from the radius point to the inner wall of the hemispherical digester.
o The radius stick can be made by simply marking the length of the radius of the digester with a nail at the end of a piece of
timber, steel or bamboo. This will ensure standardized measurement to ensure that all bricks go round on a given radius and
maintains a dome shape.
o The radius point can be the head of a strong nail firmly attached to a wooden peg or a piece of round iron bar fixed to the base
of the pit.
o The radius stick end can spin around the nail or round iron bar and can be fixed with binding wire or manila rope.

6.5 Fixation of the centre (radius) point

Tools required; Radius stick, peg, plumb bob, string

o For the construction of the dome, the radius point has to be defined in the middle of the excavated pit below the reference line.
o The various vertical dimensions from the reference line are given in the attached drawings.
o The radius stick is used from the center point to get the actual diameter of the digester.

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6.6 Excavation and pouring concrete of a foundation base (steps to be followed)
Tools required; Radius stick, brick trowel, spade, mattock, hoe, wheel barrow, measuring boxes.

Step1: Use a radius stick to establish the foundation ring as per Fig 4 below.

Fig 4: Layout of a foundation ring

Reference Line

Peg 2 Peg 1 (extended)

Radius
Point

Center-slurry outlet CSO

Step 2 centre point-CC
Digester

Step 2: Excavating the foundation ring at 20cm deep Step 3: Hard core packing, stones with thickness of 15cm are
and 30cm wide, as per Fig 5. used, as per Fig 6.
Fig 5: Excavation of the foundation ring Fig 6: Stone packing (Hard core)
Foundation ring Hard core

Step 4: Pour concrete on the foundation ring/trench for the remaining 5cm together with the floor of the digester (Site concrete).
The concrete mixing ratio for the foundation ring is 1:3:5, (Cement 1: Sand 3: Aggregate 5). See fig 7 below.
Fig 7: Concrete pouring on the foundation ring
Concrete

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Step 5: Use the radius stick, and immediately after, lay one or more courses of bricks on the same day.
Step 6: The first course of bricks is laid ½ brick while the rest are laid ¼ brick, the ratio for mortar is 1: ¼: 4 (cement: lime: sand)

Fig 8: a) Laying half brick (First course)

Radius stick

11 cm

Fig: b) Photograph showing laying of the first course of the brick in the dome construction
NOTE:
It is important to use the technical drawing right from the beginning
in order to have all the dimensions in place.

1st course of bricks

6.7 Construction of a spherical wall up to the strong ring

6.7.1 Specification of brick’s size and dimensions

o For the construction of the dome wall, good quality burnt bricks must be used.
o The correct size of bricks is approximately 7cm x 11cm x 23cm, see Fig. 10
o As an alternative in areas where burnt bricks are not available, cement & sand bricks with the same dimensions can be used;
the mixing ratio being 1:8 (Cement 1: Sand 8)
o Any other sizes available can be considered but it means that probably more cement and sand are required, a tolerance of -1
cm and +1 cm is allowed, i.e. 6cm x 10cm x 22cm and 8cm x 12cm x 24cm respectively.

Fig 9: Brick dimensions

7 cm
23 cm

11 cm

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6.7.2 Steps for constructing a spherical wall up to the strong ring
Tools required; Radius stick, spade, brick trowel, bucket, hoe, wheel barrow, measuring boxes
NOTE: For the domestic biogas plants the bricks are laid as “half bricks” for the first course and “quarter bricks” for the rest, forming a
wall thickness of 7 cm (without inner and outer plaster).

Step 1: All the bricks are dipped in water to clean and improve binding before they are used for construction.
Step 2: Lay the bricks in a quarter position guided by the radius stick as a gauge, see Fig 10 and 11.

Fig 10: Laying quarter brick (rest of the courses)

Radius stick

7 cm

Fig 11: Brick work and the use of radius sick in the construction of the dome

Radius stick Centre peg

Step 3: Construction of slurry outlet manhole of 70 cm diameter (see Fig 12 and 13) is done simultaneously and use spirit level or
plumb bob to assure vertical walls. Half cut bricks should be used.
Fig 12: Section of the slurry outlet opening Fig 13: Construction of the slurry outlet opening

Slurry outlet opening

Slurry outlet opening

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 Step 4: Place chicken wire around the dome using 2” nails at the outside. See Fig 14 below:

Fig 14: Placement of a chicken wire on the outside Fig 15: Plastering the outside lower part of the
lower part of the digester digester

Chicken wire Plaster

Step 5: Plastering the lower part of the digester, see Fig 15 above:
- On the outside of the digester, the plaster of 2 cm thickness, covering the chicken wire with a ratio of 1: ¼: 4 should be
applied.
- On the inside of the digester, the plaster with same thickness 2 cm, and ratio should be applied to make it strong and
prevent water seepage.

Step 6: Pour a lean supporting concrete on the outside lower part of the digester to 22 cm high and 15 cm wide, a mixing ratio of
1:3:5 is used, see Fig 16 below.
Fig 16: A lean supporting concrete poured on the outside lower part covering
a height of about 22 cm and a width of about 15 cm.
Lean concrete

Step 7: The brick wall should be watered daily in order to allow curing to take place.
Outline of Steps, See Fig 17.
Fig 17: Biogas Plant Construction to the strong ring
(1) Foundation ring concrete - 1: 3: 5;
(2) First layer of' bricks laid in cement-lime mortar 1:1/4 : 4;
(3) Supporting concrete ring 1: 3: 5;
(4) Brickwork up to the bottom of the weak ring laid in mortar 1:
1/4 : 4;
(5) 2 cm thick outside cement-lime plaster 1: 1/4 : 4;
(6) Backfilling soil rammed in layers of maximum height of 30
cm.
(7)The brickwork is erected with the help of a radius stick

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 (8) The radius stick is set at the centre of each brick.
(9) The surface of the brick follows the direction of' the radius stick. It rests with a groove at the nail of the centre point (CP).

6.7.3 Fixation of the inlet pipe(s)

o The plastic pipe with a 10 cm diameter is placed into the digester wall at a position (IPP) which should be at least 5-10 cm lower
than the lowest point of the slurry outlet opening beam (LSL) in order to allow stirring to take place within the expansion chamber
when the plant has reached its maximum gas pressure, allowing all surplus gas to escape through, and thus acting as a plant’s
pressure relief valve. The pipe end must be flush to the inside brick wall after plastering, therefore in case of any pipe protrusion
it must be cut off.
o Position of the inlet pipe (IPP) is directly in line opposite the slurry outlet opening.
o NOTE that this pipe connects the digester and the mixing/dung chamber at the cow shed, it is inclined at an angle of about 45°
upward from the central axis of the hemispherical radius centre through the centre of the slurry outlet opening, and horizontally it
has a tolerance angle of about 30° from the central axis to either of the sides, this angle gives a clearance for the connection of
the second pipe to the toilet.
o Thus the pipe is apparently aligned with the slurry outlet opening centre (CSO) through the centre of the digester (CC) and
reinforced with concrete/mortar on the outside. See Figures 18 and 19 for the above steps.

Fig 18: Biogas plant drawing showing an angle of Fig 19: Dome inlet pipe(s) position and the inside
inclination allowed for the inlet pipe(s) lower part plaster + toilet connection

o Incase of a toilet connection, the toilet inlet pipe should be installed exactly at the same level with the inlet pipe from mixing
chamber, placed 30 cm apart or 15 cm to each pipe from the central axis of the hemispherical radius centre through the centre
of the slurry outlet manhole and both pipes should not go above the lowest slurry level to avoid gas escaping through.
o Toilet attachment to the digester need to be constructed with a pan without siphon or trap to avoid excessive water inside the
digester affecting the hydraulic retention time (HRT) and total solids in the slurry. It is also not possible to de-block the pipe if
siphon is placed.
o The inlet pipe from the toilet should not discharge farther than 30° from the hart-line. Additionally the pan level of toilet should at
least be 60 cm above the overflow level in the outlet walls. See the diagrams below:

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 Fig 20: Construction details of a toilet Fig 21: Photograph illustrating toilet connection
plant – connected to a biogas plant to a bio-gas plant

The toilet floor (a) has a groove serving as the toilet pan.
The highest slurry level (b) and the lowest slurry level (c) depending on the gas storage requirements of the biogas plant.

There are a few but very important details to be observed:

(1) The toilet pan inlet consists of a piece of pipe of 6" diameter placed absolutely vertical in order to avoid soiling the sides.
(2) The bottom rim of the inlet piece is separated from the lower system in order to prevent worms from crawling out of the toilet.
(3) The inlet piece ends always above the highest slurry level.
(4) Below the inlet piece is a chamber of larger surface in order to avoid floating feces piling up in the pipe. Feces should drop
directly into the slurry but never on parts of the structure which are normally above the slurry level.
(5) On the other hand, the dropping chamber should be as small as possible in order to release fresh feces as quickly as possible
into the biogas plant. This is important for avoiding bad odour and for producing the biogas there, where it can be collected and
utilized, which is the inside of the dome.
(6) The down pipe is straight and at least of the same diameter as the inlet piece
(7) 4” vent pipe ‘PVC’

6.7.4 Construction of the strong ring

o When the brickwork reaches the lowest slurry level, the strong ring mortar is placed. Use cement-sand mortar, reinforced with a
10 mm round iron bar all around the top of the brick wall, see Fig 22a & b.
o The round iron bar must pass through the slurry outlet manhole beam, and covered by a 2 cm thick cement/sand mortar.
o The ratio of the strong ring mixture is cement : lime: sand = 1: ¼ : 4
Fig: 22 (a) Placement of the strong ring Fig: 22 (b) Fabrication of the slurry outlet beam

Strong ring-10mm

Slurry outlet beam

13
6.7.5 Slurry outlet opening beam
o Pouring concrete of the Beam/lintel at the slurry outlet opening:
At this point where the slurry outlet opening and the dome walls separate from the digester (just above the beam), a reinforced
concrete beam in the form of a lintel has to be placed, with a length of 90 cm reinforced with 2 pieces of 10mm iron bar.
See Fig. 22b and 23.
CAUTION: The slurry outlet beam must be fabricated right at its position, and therefore a form work has to be made in advance
using timber and nails. Note that fabricating a beam separately should not be practiced as it will hinder the passage of a strong ring
iron bar through.

Fig 23: Separation of the dome wall and the slurry outlet Fig 24: Soil back filling on the lower part
Dome wall Slurry outlet

(6) Backfilled soil rammed in layers of 30 cm height

6.7.6 Soil backfilling on the lower part of the digester
o Soil backfilling and compaction around the lower part of the digester should be done up to the strong ring, see Fig. 24.
o Proper compaction should be carried out around the slurry outlet manhole.
o Compaction is done in stages, i.e. at every soil depth of 30 cm.
o Water is put onto the backfilled soil to ease the compaction work.
o Soil compaction is important, and it must be properly done because once the digester is in use, the brick wall is subjected to
high pressure from inside, and therefore it must be supported from the outside.

6.8 Construction of the spherical wall on the upper part (above strong ring) to the closure of the dome
Tools required; Radius stick, spade, brick trowel, bucket, hoe, wheel barrow, measuring boxes and brick hooks.
o Construction is done in similar way as the lower part of the digester with an additional use of hooks.
o When the spherical building reaches an angle that bricks tend to fall down (Common on the upper part of the dome, temporary
support hooks with a little bent in the centre have to be used. i.e. 6 to 8 mm. iron bar of 60 cm length have to be bent 10 cm
from each end by 90 ° in opposite direction, see Fig 25 ( a), (b), (c) & (d).

Fig: 25(a) A simple brick hook (b) A simple brick hook in use

Counterweight

14
 (c) Illustrating other types of hooks (d) Other types of hooks in construction work

For the construction work, at least 10 hooks of this shape have to be prepared and available at the site, see figure (A) and (C).
A brick is used as a counterweight and placed on the outer of the dome wall to keep the freshly placed brick in position, see Fig (B).

Fig 26: Completion of the brick course/ring

When a ring or brick course is completed, small stones will be hammered carefully in the joints as a wedge to put pressure on
the joints.

Cement/sand mortar

NOTE: Curing of the wall

To avoid cracking and encourage proper binding, routine sprinkling of water should be carried out for the minimum of 5 to 7 days.

6.9 Placement of the Dome gas pipe:

CAUTION: Fixation of the dome gas pipe is done before attempting any inside gas tight plastering (the inside upper part of the
digester).
Tools required; Grease, Seal tape, portable pipe vice, hacksaw / wheel cut, measuring tape, thread machine, main gas valve, wire
brush, pipe wrench, screw driver and oil can.
Pipe materials/accessories required - See Fig 27 below:
1. A piece of 25 cm galvanized pipe - 1” diameter
2. T-join t -1”
3. Plug - 1”
4. Reducer bush – 1” – ¾”
5. Hexagonal nipple - ¾”
6. Gate-Ball valve - ¾”

15
 Fig 27: Standard dome gas pipe fittings and assembly

4
1 2

Step 1: Thread one end of a galvanized pipe of 1 inch diameter with a length of 25 cm and mount a T-joint together with a plug.
It is advisable to grease the thread in advance to prevent corrosion.
Step 2: Weld a disc and some scrap pieces of iron bar 4 cm on the other end of the galvanized pipe.
Step 3: Join the other components of the testing unit to the galvanized pipe.
Step 4: Position the pipe on top of the digester and make sure that it protrudes about 2 cm inside the digester. See Fig 27.
Step 5: Reinforce with concrete of the mixture (1:3:3) including 4% of water proof cement.
Step 6: Provide temporary support to this mounted dome gas pipe till concrete is cured.
Step 7: Place main gas valve on the test unit.
NOTE: The welded disc prevents gas from escaping along the dome pipe wall and iron bars, act as an anchor and it gives
additional strength to the pipe fixed in the brickwork. Under normal operation the T-joints should remain sealed and closed with
plugs, and all threads are joined with seal/thread tapes, which as a rule of thumb should be applied in approximately eight turns.
See the lay out below on Fig 28:

Fig 28: Fixation of the dome gas pipe (mounted with two T-joints) at the digester for testing and monitoring purposes

Thread tape

Temporally support
till concrete is cured

The test unit chamber is a provision for gas leakage testing, measuring of the digester’s gas pressure and gas flow/consumption rate,
and this is where main gas pipe line is linked with a plant direct to the consumption point.
The test unit chamber, with a cover on top it also protects the main gas valve.

16
6.10 Placement of the chicken wire on the upper part and the construction of the test unit chamber
o Placement of a chicken wire on the outside upper part is done just like in the lower part.
o For the construction of the test unit chamber, i.e the internal dimensions are 30cm x 45cm dimensions x 20cm depth (refer to
the technical drawings in the annex), for the concrete base use the ratio 1:2:4 and for brick work-joint mortar use a ratio of
1:1/4:4 ..See fig 29

Fig 29: (a) The test unit chamber on top of the digester (b) Placement of the chicken wire

Test unit chamber

Chicken wire

6.11 Plastering the outside upper part of the digester:

o Only sieved and washed river sand should be used; a smooth plaster of 2 cm thickness with a ratio of 1: 1/4: 4
(cement: lime: sand) is applied all over up to the test unit chamber.
o The plaster should be allowed to harden before back-filling of soil is done.
o CAUTION: The plaster should be applied where whether is conducive, i.e not in the exposure of sunshine or during rainfall!!
o The outer plaster protects the brickwork against roots growing into the joints. It forms a smooth surface which reduces friction
between soil and the structure and thus, reduces static stress on the brickwork.

Fig 30: Photograph illustrating the plaster on the upper part of the digester
Plaster

6.12 Plastering the inside upper part of the digester (gas tightness plasters)
o The plaster of the inside upper part of the digester has a smooth surface for better gas-tightness.
o Sand for use in the gas tight plasters should be well sieved and it should not contain any dust or other course impurities.
o It is applied in seven (7) coats/layers. The two main plasters (4th and 6th layers) which consist of water proof cement must be
completed within 48 hours (2nd and 3rd day). All the plasters to be applied on the 3rd day must be applied consecutively, a
good reason behind this lies under the following fact: The plaster mortar has to be water/gas proof, and if the preceding layer
will be let to dry up, as a consequence there will be no bond with the next layer of plaster to be applied.

17
These layers of gas tight plaster should be applied systematically as follows:
DAY LAYER ACTIVITY MATERIAL TOOLS RATIO
1 1 Cement-water brushing Cement & water Bucket + brush Cement+ water
2 Cement-sand plastering Cement, sand & water Wooden float + spade 1: 2½
2 3 Cement-water brushing Cement & water Bucket + brush Cement+ water
4 Cement-lime plastering + water proof cement Cement, lime, sand & water Wooden float + spade 1: ¼ : 2½ +
proof cement Water proof
cement (WP)-5%
3 5 Cement-water brushing + water proof applied Cement, water & water proof Bucket + brush Cement+ water +
consecutively cement water proof
cement (WP)-5%
6 Cement-lime plastering + water proof cement Cement, lime, sand & water Wooden float + spade 1: ¼ : 2½
made of fine sieved sand applied proof cement Water proof
consecutively cement (WP)-5%
7 Cement-screed (cement-water paste+ water Cement, water proof cement Bucket + steel float + Cement-water
proof) applied consecutively & water brush paste+ WP at 5%

o CAUTION: This should be done after the outside upper part plaster of the digester and the installation of the gas outlet pipe
have been finished. The plant will be ready for initial filling 2 weeks after finishing the final gas tight plastering and flooring.

6.13 Flooring
o The first base for the digester flooring is formed by dropped mortar from bricklaying and plastering.
o A maximum thickness of 2 cm cement screed (mixture 1: 4) applied on top of site concrete would be strong enough to
withstand the internal liquid pressure exerted on the floor as well as forming a water proofing base, and this should be
standard in all soil conditions. If the structure itself is sound and solid, water losses will not occur, and in case of any slight
water seepage sludge particles will be able to seal the surface sufficiently.
o NOTE: In case of unstable soil, e.g. black cotton soil and a high ground water table, a water tight floor should be achieved
right from the beginning, and water losses should not be allowed (In such situation water proof cement should be applied).
o After the plant construction, i.e concrete, brick work, plastering and flooring works, the plant must be kept in moist condition by
pouring in some reasonable amount of water in order to allow curing to take place.

6.14 Construction of the expansion/compensating chamber

o The function of the expansion chamber is to store the displaced digested slurry from the digester (equivalent to equal volume
of the gas produced), and thus developing pressure inside the plant.
o The slurry outlet opening allows slurry to flow in and out following the gas consumption and production rates respectively.
o The foundation for the expansion chamber is made out of concrete at the ratio of (1:3:5).
o Brick work below the overflow level is as well guided by the radius stick just like for the digester.
o When the overflow point is reached the radius stick must be reduced by 5 cm (for 4m3 and 6m3 Biogas plants) and by 7 cm
(for 9m3 and 13m3 Biogas plants) for each course of bricks up to the expansion chamber manhole collar.
o The expansion chamber needs to be reinforced with chicken wire on the outside and plastered with ratio 1:1/4:4 (cement: lime:
sand).
o Inside plaster should only be done from the bottom of the expansion chamber up to the highest slurry level/overflow point.
o At the top of the expansion chamber a provision for a manhole with an internal diameter of 60 cm should be provided.

NOTE: Using bricks with dimensions other than the ones specified, i.e. (23×11×7 cm) will affect the level of the expansion
chamber, and the mentioned reductions of radius stick measurements above the overflow level will not apply!

18
 CAUTION:
o The slurry overflow opening at the expansion chamber can be directed in any direction convenient for slurry utilization/disposal
by gravity, not necessarily in line with the inlet pipe.
o The brick work above the overflow point should continue only after finishing all the works inside the digester, this is to allow
sufficient light inside the digester.

Fig 31: Brickwork – ‘expansion chamber’ Fig 32: Expansion chamber’s inside plastering

6:15 Soil back filling above the strong ring, on the upper part of the digester
CAUTION: Soil backfilling on the upper part should strictly be carried out after finishing all the gas tight plasters inside the
digester, and it is done in the same way like in the lower part.

6.16 Construction of a mixing chamber

o The mixing chamber has been designed to easy a work of mixing dung with water/urine to achieve the required consistency.
o The foundation of the inlet pit should be placed in well rammed, hard and leveled surface.
o In this rammed surface first of all the rectangular base of mixing chamber is constructed. The height of the base should be
decided in such a manner that the floor of the mixing chamber is at least 20 cm above the outlet overflow level.
o The rectangular dung and urine mixing chambers internal dimensions are 70cm x 60cm and 55cm x 60cm respectively.
o At least 1 day after brick laying is done, both inside and outside of the chamber is plastered with cement mortar (1 part of
cement to 4 parts of sand), and finished with cement-screed.
o The position of the inlet pipe in the floor must be placed in such a way that a pole/rod can go through without obstructions,
preferably to be aligned diagonally.
o Two types of mixing chambers which are commonly incorporated in the system, depending on the grazing system are:
i) The rectangular type where both urine and dung chambers are connected direct to a cow shed, mostly suitable where
zero grazing is practiced.
ii) The cylindrical type, to be employed in areas where cattle are grazed outside.

19
 Fig 33 (a) Rectangular shaped mixing chamber (b) Dung and Urine chamber depths
connected to a cowshed-‘Zero grazing’
Dung
Urine/water
Urine/ 40 cm
water

70 cm

Cowshed

(c) Cylindrical mixing chamber-‘Semi-grazing’

Dung/Urine mixing chamber

7.0 GAS PIPE LINE

7.1 Fixation of the main gas line (alignment and digging of trench)
o The piping distance from the plant to consumption point can be several metres away, and yet its gas pressure will be
maintained, with insignificant loss in pressure.
o The piping system is a crucial part of biogas technology; therefore it must be undertaken with maximum precision and care.
o All outside piping (main gas line) is done in ¾” or ½” diameter, class ‘B’ PU-plastic or galvanized steel pipe, depending on the
length of the gas line and type of the soil.
o The selection of the size/diameter and make of the pipe (plastic or metal) depends primarily on the distance to the
consumption point, gas production v/s consumption (number of gas appliances) and the type of the soil (salinity).
o The selection on which type of pipe should be used is also based on other factors;
 affordability
 convenience
 availability

7.2 Procedure of fixing the main gas pipe line

Tools required; Grease, Seal tape, portable pipe vice, hacksaw / wheel cut, measuring tape, thread machine, water drain valve,
wire brush, pipe wrench, screw driver and oil can.

20
Step 1: Excavate a trench, minimum 45 cm depth and 30 cm width for both PU-plastic pipes and galvanized pipes.
Step 2: Use the appropriate tools and fittings to connect the main line with the testing unit.
Step 3: Determine the position of the water drain (Use spirit level to determine the slope), establish a water drain valve at a
T- joint mounted at the lowest point along the pipeline.
Just before the drain valve, an extension of about 25 cm. ½”/ ¾” pipe pointing downward should be employed. See Fig. 34

Fig 34: Illustrating the position of the water trap (drain valve type) along the main gas pipe line

25cm

Step 4: Construct protection chamber for the water drain valve, 50cm x 50cm include a cover/lid.
Step 5: Fixation of piping to the wall of the house near the utilisation point.
Step 6: Backfill the piping trench to complete the piping setup.

TIP: Draining should be carried out regularly, i.e. once in a month

NOTE: Bio-gas sites differ from one another due to different terrain and nature of topography to the gas consumption point i.e.
variable slopes. Such earmarked features include:
1. Flat terrain (level grounds),
2. Slope towards the consumption point,
3. Slope towards the bio-gas plant and
4. In case of long gas pipe line (depending on the topography of the respective site), the ground tends to be undulating, thus
going up and down.

The following drawings illustrate the right position for the water drain installation: preferably the drain valve should be mounted
either just after the plant or before the consumption point. This is shown on the drawing with a T-joint in place!

Fig 35: Position of the water collection point/trap in relation to the direction of the slope:

1. Slope towards the consumption point 2. Flat terrain

21
 3. a) Slope towards the bio-gas plant; b) Slope towards the Bio-gas plant;
where the digester is completely under the ground level where the digester is slightly higher than the ground level

4. Undulating terrain; Common cases with long gas pipe lines. Ground with variable slopes

7.2 INDOOR PIPING

Reduce the size from ¾” to ½” and pass it through a hole in the wall to the respective consumption point (s).

7.3 CHECKING FOR LEAKAGES

o After installation, each section of the piping system has to be pressure tested for gas leakages. For this purpose a pressure
indicator has to be used.
o A pressure indicator consists of a mouthpiece to blow pressure in the piping system and a transparent plastic U-pipe, which
has two sides of more than 100 cm length. The pipe is filled with water and installed at the kitchen.
o The set-up is connected to the T-joint at the test unit chamber, which is along the pipe line. All ends of the piping system are
closed and air is blown into the mouthpiece until the water in the transparent hose pipe raise to a height of 100 cm.
o If there is no drop in water level it shows that the pipe line is gas tight/leak proof.
o When the pressure drops, there must be a leakage somewhere, which has to be detected and fixed before the work on the
piping system continues.
o To detect a leakage, brush and soap water are used, in case of a leakage soap bubble will be formed.
o Leakages occur mainly at joints, unions and particularly where hosepipes are connected to the fixed piping system. Such
weak points need to be minimized and tightened.

Fig 36: Manometer/Pressure indicator for detecting gas leakages and pressure testing

100 cm Water
column

22
8.0 INSTALLATION OF GAS APPLIANCES
Biogas is denser than air therefore a biogas lamp is installed in downward position to facilitate gas combustion. Biogas needs a lot
of air to burn, the burner must have air rationing mechanism to control the amount of air. Biogas contains about 35% Carbon
dioxide and therefore does not explode in a flame with air.

8.1 Fixation of gas taps, rubber hosepipe, stove and lamps:

o Gas lamps are usually hung on walls or the roof ceiling depending on the type of the lamp. A gas valve is also provided to
control the gas flow as well as the brightness, turning the device on and off.
o Stoves at the kitchen are connected to the gas line by using flexible hose pipes and put on a table or down on the floor,
depending on the user.
CAUTION: The lamp should not be installed directly above the stove area because it is very dangerous.

8.2 Some technologies and modifications of gas appliances

Special biogas stoves and lamps are provided at a cost by the programme. See Fig 37-40 below.

Fig 37: A single burner household biogas stove- Fig 38: A single burner household iron bio-gas stove
auto-ignition system ‘Chinese make’

Fig 39: A bio-gas lamp ‘Chinese type’ Fig 40: A modified conventional LPG-gas cooker

o Conventional LPG appliances like lamps/pressure lamps, stoves and refrigerators can be modified to use biogas.
o Different engines using diesel or petrol can be modified to utilize biogas.
NOTE: All modifications should be done by the skilled technicians.

23
9.0 FINISHING WORKS
o Fabrication of all chamber and manhole lids/covers:
 The lids should take the shape of the intended opening
 The size of the lid must be flush with the outside wall of the intended opening
 The thickness of the lid must be at least 7cm.

o Follow these steps for the fabrication of the lids/covers:-

Step 1: Set the base out of plastic sheet or used cement bags on a flat ground
Step 2: Use Bricks or a mould to make the desired shape (round or rectangular)
Step 3: Use welded mesh and 8mm round iron bars for reinforcement and handles in fabrication of the lids.
- The handles are mounted to the weld mesh using a binding wire, their lengths is about 8 cm.
Step 4: Mix Strong mortar/concrete in the ratio of 1:3 - cement: sand/1:3:3 – cement: sand: gravel
Step 5: Pour Strong mortar in the mould and allow it to set for at least 7 days.

o Clean the inside of the digester and expansion chamber

o Landscaping - make the place look attractive, ensuring proper soil backfilling, e.g. plant flowers or grass.
o Clean all the tools and equipments used
o Propose the improvement of the cow shed to the farmer if needed.
o Propose the construction of toilet if needed.

Function of the Test Unit Chamber

o The test unit chamber is used for quality management by masons and technicians.
o Apart from pressure tests and measurements, leakage detection in the piping, the test chamber is used for determining the
amount of gas in use through an installed gas flow meter.
o The gas meter measures the amount of gas going to consumption in litres/cubic metres.
o The gas meter is connected to the two T- fittings at the test unit chamber, by-passing the gas valve so as to allow gas flow
when in use.

Fig 41: A Test unit for monitoring the plant performance & gas leakage.

24
 1. Test unit chamber with lid 5. Measuring the plant gas pressure
2. Main gas valve 6. Pressure indicator (manometer)
3. A T fitting connected 7. Number 8,9,10 and 11 shows leakage testing along the gas line
4. A second T-joint. 8. No 12, 13 and 14-measurement of the gas flow/consumption rate

10.0 GAS UTILIZATION (Cooking and Lighting)

10.1 Gas stove:
o Decisive parts of a gas burner are:
 Jet or nozzle,
 Primary air intake
 Accessibility for the secondary air
 Exhaust gas, which has to disappear from the flame without hindering the secondary air to reach the flame.
o The flame can be adjusted comfortably to be stable and not too wind sensitive under the bottom of the pot. The highest
adjustment of the stove knob should not lead to a flame, which licks around the pot and burns the plastic handles. The
performance of the flame depends among others on the quality of the gas, the altitude of the location and the gas pressure in
the digester.
o For the performance tests, the flame burns better if a pot filled with water is sitting on the pot rest (or a bit above).
o The sketch below, Fig 42, shows the different parameters on the flame. The example shows the ideal case, small blue flames;
completely under the pot resulting in the best energy efficiency.

Fig 42: Efficient stove:

Jet or nozzle

Secondary air

Gas/Air mixture
Primary air

10.2 Gas lamps

o The working principle of a gas lamp is similar to that of the stove, where as in a stove the burning gas heats a pot, while in a
lamp the burning gas heats a mantle until it glows brightly.
o The secret behind a lamp is to adjust the flame in such a way that the hottest part of the flame exactly matches the form of the
mantle, and this can be achieved by adjusting the air intake.
o Proper air mixture and appropriate size of the mantle play the biggest roles.

25
 o The methane content of biogas sometimes changes, therefore brightness of the light will also change.
o There are several makes of lamps available worldwide; the ones commonly used in Tanzania include those of CAMARTEC
(See Fig 43 below)

Fig 43: The CAMARTEC lamp

Example of some biogas consumption rates in various applications

 Cooking:
Between 150 – 250 Its of biogas are used per hour for boiling 1 liter of water, depending on the efficiency of the burner.
 Lighting:
Between 120 – 180 Its of biogas are used per hour; a biogas lamp can produce light equivalent to a 75 watts bulb.
 Heating and industrial burners:
About 450 – 500 lts of biogas is used per hour.

 Refrigeration:
Refrigerators with 100 lts capacity can run on between 30 – 80 lts of biogas per hour.

 Engines (motive power):

- About 420 lts of biogas can be used in 1 hour.
- To produce 1 KWh of electricity about 700 lts of biogas is required.

11.0 BIO-SLURRY UTILIZATION

11.1 Slurry Canal
o Overflow point should have a 5 cm step to allow a free-fall flowing of slurry.
o The size of the slurry overflow opening should be 40 cm x 40cm.
o The length of the slurry canal should be at least 1 meter long, constructed out of concrete.
o The slope of the canal should be at least 3-4%.
o In the case of limited area for slurry use, the slurry canal can be connected with slurry pits.

11. 2 Importance of composting and shading of pits

o Slurry pits are optional in situations where land is limited.
o Slurry has high fertilizer potential more than fresh cow dung, use of slurry and slurry pits is recommended.
- Two parallel slurry pits which both have an access to the slurry canal from the expansion chamber with
measurements of 3m length 2m width 0.75m depth each is dug.
- The pit floor slants downward at 0.75m depth at the lowest point.
o The interested farmers can obtain advice on better slurry use from the extension officer, however the user manuals are also
provided by the programme for assistance. For more information contact the TDBP Office.

26
12.0 OPERATION OF THE BIOGAS PLANT
12.1 Operation and maintenance
o If operational short-comings are often reported, the set up of the system is not appropriate to the user. The main task of a
biogas expert is to design and construct a user-friendly biogas unit.
o Operation and necessary maintenance must be logical to the user and should not be a burden to the one attending the plant.
o A well designed biogas unit is easy to maintain, the ease of maintenance ensures constant attention by the farmer.
o However, even with a perfect design, a minimum of daily care is needed to receive a proper service from the unit.
o Once in a while the expansion chamber should be cleaned In order to avoid solids assembling in the corners and thus,
reducing the gas storage capacity.

12.2 Initial and regular filling of the digester

Filling up of the digester with feedstock:
o The initial feeding of digester can start 14 days after finishing the last layer of gas tight plaster and floor inside the digester.
o Cow dung should continue to be collected during the construction of the biogas plant to quicken the initial feeding.
o While filling the digester make sure that the cow dung is clean, free from sand, trash, wood, grass, household waste,
goat/sheep droppings and other impurities in order to avoid scum formation and blockage of the inlet pipe.
o After removing all impurities from the dung, add sufficiently equal quantity of water/urine to achieve a paste with a good
consistency.
o The dung is mixed with urine/water at a ratio (1:1)
o The plant must be fed daily in order to achieve a constant gas production.

12.3 Potential problems and likely solutions (Trouble shooting):

Problem Possible cause Remedy/Solution:
Insufficient gas pressure, maximum - Gas leakage along the pipe line - Check for any gas leakage and solve the
plant pressure not reached problem,
- Under feeding of the plant. - Follow the feeding instruction carefully

Gas production has declined and is - Underfeeding of the plant, - Ensure the feeding instruction is followed
less than before - Leakages through gas tight zone, and daily feeding is done for a constant gas
- Possible gas leakages along the gas production,
pipe line, - Check for gas leakages and gas tightness
- Scum formation inside the digester, inside the plant, when necessary emptying
- Dung/water mixture not at the right of the plant should be performed in order to
proportion to the one incorporated in the inspect and solve the problem.
digester design,
- Accumulation of inorganic solids inside
the digester.
Bio-effluent smelling at the expansion - Over feeding of the digester, - Follow feeding instruction to ensure a good
chamber & slurry canal consistency of the mixture

Gas stove not burning well - Blocked primary air ducts, - Clean all the air ducts and burner holes
- Blocked flame holes, regularly to prevent blockages,

- Incorrect gas/air mixing ratio - Adjust the primary air knob in order to get the
right mixture,
- Presence of water in the pipe line, - Open the water drain valve to remove any
water condensed inside.
- Poor stove design - Purchase better stove

27
The lamp does not give bright light - Dirt glass screen, - Clean the lamp glass screen regularly,
- Cracked or destroyed mantle, - Replace the cracked mantle,
- Incorrect gas/air mixing ratio - Adjust the primary air knob in order to get the
- Presence of water in the system right mixture,
- Open water drain valve to remove any water.
- Blockage of the mantle holder hole - Clean the mantle holder hole
Maximum gas pressure achieved but - Under feeding or irregular feeding - Ensure that daily feeding is done in
still gas quantity is not as expected sufficient quantity
- Ensure that mixing is done properly and all
the unwanted material are removed
- Scum formation inside the digester - Empty the plant, remove the scum and stir
the inside slurry
No gas reaching the appliances - Water has blocked the gas passage - Check for the presence of water along the
along the pipe line gas line and drain it
- No any gas being produced inside the - Check for gas leakages in the pipe line and
digester solve them
- Disconnected gas pipe line - Check for any pipe disconnection and
reconnect it
- Closed main gas valve at the test unit - Check the main gas valve and reopen it
chamber.
- Inhibiting substances have entered into - Remove the inhibiting substances or
the digester chemicals from the digester by emptying it
The feeding materials are not - Blocked inlet pipe - Poke through the inlet pipe,
entering into the digester - Position of the inlet mixing chamber - Ensure right vertical dimensions are used to
placed below the overflow point. avoid wrong placement of the mixing
chamber.
Bio-effluent too thick at the expansion - Incorrect dung/water mixing ratio - Ensure good mixing consistency at feeding,
chamber/overflow point (less water/urine),
- No hydraulic movement inside the - Make sure that the gas is used daily to allow
digester, hydraulic movement to take place inside the
digester

- Water leakage at the expansion - Check for water leakages inside the plant
chamber base and expansion chamber and reseal them

- Water leakage on the lower part of the - Empty the plant and reseal the cracks or
digester, renew the base/floor
Slurry entering the gas pipe line - Gas outlet pipe placed below the over - Check slurry overflow point if it is not / or was
flow point blocked.
- Reduce slurry overflow point to a lower level.

NOTE: If problems persist, contact the TDBP Office for assistance urgently.

28
12.4 BIOGAS PLANT DRAWINGS
4 m3 Biogas Plant:

29
6 m3 Biogas Plant:

30
9 m3 Biogas Plant:

31
13 m3 Biogas Plant:

32
Modified CAMARTEC domestic biogas installation 4m3
BoQ - Bill of Quantities and pricing

qty unit rate household TDBP

Subsidy
1 General bulk materials
1.1 Sand 2.2 [m3]
1.2 Gravel 1.2 [m3]
1.3 Stones 1 [m3]
1.4 Cement 12 [bags 50 kg]
1.5 Bricks 23x11x7 cm 700 [piece]
1.6 Lime 2 [bags 50 kg]
1.7 Cement waterproofing 3 [kg]
1.8 Chicken wire (1 mtr wide) 30 [mtr]
1.9 Welded / square mesh 1 [pcs]
1.10 Round bar 1 [length]
2 Fittings
2.1 Dome pipe 1 [pcs] 12,000 0 12,000
2.2 PVC pipe 4" 1 [length]
2.3 GS pipe 3/4" [length]
2.4 GS pipe 1/2" [length]
2.5 Main gas valve 1 [pcs]
2.6 Stove tap [pcs]
2.7 Lamp tap 1 [pcs]
2.8 Water trap 1 [pcs]
3 Appliances
3.1 Single biogas stove 1 [pcs] 40,000 0 40,000
3.2 Double biogas stove [pcs] 70,000
3.3 Biogas lamp 1 [pcs] 35,000 0 35,000
3.4 Pressure meter 1 [pcs] 5,000 0 5,000
3.5 Fitting material & sundry 1 [set price] 20,000 0 20,000
3.6 Repair & maintenance set 1 [set price] 8,000 0 8,000
4 Labour
4.1 Excavation, site preparation
5 Company services & fees
5.1 Construction fee [ls] 0 160,000
5.2 Annual maintenance fee [ls] 0 20,000
Household Total
Subsidy 300,000
Plant Cost including subsidy
Agreed on: day month year
date:
Company: name:
signature
Household: name:

signature

33
Modified CAMARTEC domestic biogas installation 6m3
BoQ - Bill of Quantities and pricing

qty unit rate household TDBP

Subsidy
1 General bulk materials
1.1 Sand 3.00 [m3]
1.2 Gravel 2.00 [m3]
1.3 Stones 1.25 [m3]
1.4 Cement 15 [bags 50 kg]
1.5 Bricks 23x11x7 cm 850 [piece]
1.6 Lime 2 [bags 50 kg]
1.7 Cement waterproofing 4 [kg]
1.8 Chicken wire (1 mtr wide) 35 [mtr]
1.9 Welded / square mesh 1 [pcs]
1.10 Round bar 1 [length]
2 Fittings
2.1 Dome pipe 1 [pcs] 12,000 0 12,000
2.2 PVC pipe 4" 1 [length]
2.3 GS pipe 3/4" [length]
2.4 GS pipe 1/2" [length]
2.5 Main gas valve 1 [pcs]
2.6 Stove tap [pcs]
2.7 Lamp tap 1 [pcs]
2.8 Water trap 1 [pcs]
3 Appliances
3.1 Single biogas stove 1 [pcs] 40,000 0 40,000
3.2 Double biogas stove [pcs] 70,000
3.3 Biogas lamp 1 [pcs] 35,000
3.4 Pressure meter 1 [pcs] 5,000
3.5 Fitting material & sundry 1 [set price] 20,000 0 20,000
3.6 Repair & maintenance set 1 [set price] 8,000 0 8,000
4 Labour
4.1 Excavation, site preparation
5 Company services & fees
5.1 Construction fee [ls] 0 200,000
5.2 Annual maintenance fee [ls] 0 20,000
Household Total
Subsidy 300,000
Plant Cost including subsidy
Agreed on: day month year
date:
Company: name:
signature
Household: name:

signature

34
Modified CAMARTEC domestic biogas installation 9m3
BoQ - Bill of Quantities and pricing

qty unit rate household TDBP

Subsidy
1 General bulk materials
1.1 Sand 4.00 [m3]
1.2 Gravel 3.00 [m3]
1.3 Stones 2.00 [m3]
1.4 Cement 20 [bags 50 kg]
1.5 Bricks 23x11x7 cm 1,150 [piece]
1.6 Lime 4 [bags 50 kg]
1.7 Cement waterproofing 5 [kg]
1.8 Chicken wire (1 mtr wide) 55 [mtr]
1.9 Welded / square mesh 1 [pcs]
1.10 Round bar 2 [length]
2 Fittings
2.1 Dome pipe 1 [pcs] 12,000 0 12,000
2.2 PVC pipe 4" 1 [length]
2.3 GS pipe 3/4" [length]
2.4 GS pipe 1/2" [length]
2.5 Main gas valve 1 [pcs]
2.6 Stove tap [pcs]
2.7 Lamp tap 1 [pcs]
2.8 Water trap 1 [pcs]
3 Appliances
3.1 Single biogas stove 1 [pcs] 40,000
3.2 Double biogas stove [pcs] 70,000
3.3 Biogas lamp 1 [pcs] 35,000
3.4 Pressure meter 1 [pcs] 5,000
3.5 Fitting material & sundry 1 [set price] 20,000 0 20,000
3.6 Repair & maintenace set 1 [set price] 8,000 0 8,000
4 Labour
4.1 Excavation, site preparation
5 Company services & fees
5.1 Construction fee [ls] 0 240,000
5.2 Annual maintenance fee [ls] 0 20,000
Household Total
Subsidy 300,000
Plant Cost including subsidy
Agreed on: day month year
date:
Company: name:
signature
Household: name:
signature

35
Modified CAMARTEC domestic biogas installation 13m3
BoQ - Bill of Quantities and pricing

qty unit rate household TDBP

Subsidy
1 General bulk materials
1.1 Sand 5.00 [m3]
1.2 Gravel 4.00 [m3]
1.3 Stones 3.00 [m3]
1.4 Cement 28 [bags 50 kg]
1.5 Bricks 23x11x7 cm 1,550 [piece]
1.6 Lime 5 [bags 50 kg]
1.7 Cement waterproofing 6 [kg]
1.8 Chicken wire (1 mtr wide) 75 [mtr]
1.9 Welded / square mesh 1 [pcs]
1.10 Round bar 2 [length]
2 Fittings
2.1 Dome pipe 1 [pcs] 12,000
2.2 PVC pipe 4" 1 [length]
2.3 GS pipe 3/4" [length]
2.4 GS pipe 1/2" [length]
2.5 Main gas valve 1 [pcs]
2.6 Stove tap [pcs]
2.7 Lamp tap 1 [pcs]
2.8 Water trap 1 [pcs]
3 Appliances
3.1 Single biogas stove 1 [pcs] 40,000
3.2 Double biogas stove [pcs] 70,000
3.3 Biogas lamp 1 [pcs] 35,000
3.4 Pressure meter 1 [pcs] 5,000
3.5 Fitting material & sundry 1 [set price] 20,000
3.6 Repair & maintenance set 1 [set price] 8,000
4 Labour
4.1 Excavation, site preparation
5 Company services & fees
5.1 Construction fee [ls] 0 280,000
5.2 Annual maintenance fee [ls] 0 20,000
Household Total
Subsidy 300,000
Plant Cost including subsidy
Agreed on: day month year
date:
Company: name:
signature
Household: name:
signature

36