entrepreneurship models on biogas for rural areas

8/6/2019 Entrepreneurship Models on Biogas for Rural Areas

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Village: BHITBUDRAKVillage: BHITBUDRAK Taluka: UCHHALTaluka: UCHHAL

District: SURATDistrict: SURAT

State: GUJARATState: GUJARAT Country: INDIACountry: INDIA


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Jilla /Taluka

Panchayat

Surat

Bhint

Budrak

Village


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Presently most of the Biogas plants installed traditionally are either

defunct or working unsatisfactorily and inefficiently.

The studies reveal following reasons for the above status:

1. The Digester loadings such as cattle dung and water are

not thoroughly mixed which results into either non-generation of gas or

lesser quantity gas production.

2. Due to the quality and pressure of the gas produced is being

insufficient, it cannot be transported to far of houses with required

pressure.


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The above constraints and defects were rectified and corrected

by Gram Vikas Trust.

The mixture of cattle dung and water are stirred in required

proportion uniformly and thoroughly by a mixing mechanism

with proper air circulation.

This results into maximum generation of the gas and utilization ofthe plant capacity.

As such, with the help of pressure regulating tank and

mechanism, the gas can be distributed to individual households

with uniform pressure as is done in case of CNG in major cities.


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Recently, Gram Vikas Trust, introduced GOBAR BANK concept and has

manufactured, installed and commissioned 2 Gobargas Plants in

Bhintbudrak village in Uchhal Taluka, Dist. Surat.

The plants are of 85 M3 capacity each totaling to 170 M3 of biogas

generation per day.

The gas is further purified and distributed satisfactorily to 121 houses

through pipeline. The design of the plant emphasizes the use of

minimum motive power as compared to plant total power output.

Apart from the above application, the purified biogas with maximumcontent of Methane can be used to generate electricity through gas

generators and also can be bottled and used to run the vehicles. The gas

purification systems are developed by Gram Vikas Trust.


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(1) Loading Platform

The Gobar Bank

members bring the dung

everyday to the

community biogas plant

which is weighed and

accounted for in their

pass books.


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(2) Slurry Preparation

The cattle dung taken fromdung loading platform areais delivered to feedpreparation tank section.

The fed dung is mixed withwater for maintaining ratioof 1:1 for fresh cattle dungand 1:1.25 for stale (hard)cattle dung.

The mixture is thenmechanically mixed to havehomogeneous slurry.


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(3) Anaerobic Digestion

Anaerobic digestion tank(biogas digester) creates ananaerobic condition togenerate methane gas bymethanogenic bacteria.

The digester employed hereis mostly KVIC model withfloating dome & water

jacket. The water jacket helps in

curbing the methaneleakage and wastage.


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(4) Common Collecting Tank

An intermediate gas

storage before Pressureregulating tank for

distribution to concerned

beneficiaries.


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(5) Pressure Regulating Tank

Gas is compressed by

blower and fed to the

pressure regulating tank

where gas is upgradeddue to the passage of

pressure


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ENVIRONMENTALNUISANCE SMOKE FROM WOOD BURNING

EARLIER


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An happy villager with her biogas connection and equipment

NOW


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The Slurry being transported to composting pits.


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The Compost.


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The slurry generated by these biogas

plants are being converted into Vermi-

Compost for Organic Farming.This Compost is very good fertilizer for the

agriculture having rich nutrient values.


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Vermi- Compost Unit


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Large Scale/ Community level Biogas Enterprises for Cooking needs- Pipeline supply and Rur al Sanitation and

bio manure production

I. Size of Biogas Plant- 85 m3/day No. of families Beneficiaries50

Cow dung required2 Tons/day- 250/Ton

A complex of 20 community toilets

Gas utilizationCooking

If for Cooking 2 hrs. morning & 2 hrs. evening(1.5 m3/familyper day)

Pipeline lengthup to 1km. distance Pipe qualityHDPE, pressurize system0.3 kg./cm2(Rs. 2.5

lacs cost)

Gas charge150/month-family


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II.R

awm

ateri

alCo

wdung+ Toi

let (community-20toilets costs 1.5lacs)

III. Slurry ManagementBiogas digested slurry

Four options-

1. Liquid slurry

2. Recycle water (upto 40 to 50% only)

3. Dry slurry

4. Semi dry

Local consumption of slurry is advised

Quality of slurry should be maintained


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Cost estimates

Non- recurring costRs. 8,20,000 ($ 20,500)

Recurring/ Variable costRs. 2,12,000 ($ 5300)

Manpower-- Rs.96,000 ($ 2400)

DepreciationRs.80,000 ($ 2000)

Sum of recurring cost- 3,88,000 ($ 9700)

Revenue generation- 5,90,000-3,88,000=

Rs.2,02,000 (& 5050)Note- In addition to this Carbon credit benefit to the

tune of Rs.71,000/yr. ($ 1775) will also be available.


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Large Scale/ Community level Biogas Enterprises for Electricity

Generation and supply for domestic consumption, water supply and

community consumption and Rural sanitation

15 KVA Power Generating System from - 85 m3/day Biogas Plant

No. of families Beneficiaries50

No. of Animals200

Cow dung required2 Tons/day- 250/Ton

Gas utilization Electricity

Domestic connection2CFL, 1 Fan= 100 Wt.*50=5000Wt.

Water supply connection4000 Wt. Community Hall2 CFL, 2 Fan & 1 TV.= 500 Wt.


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Cost estimates

A. Non recurring

Sum =8,50,000 ($ 21,250)

B. Recurring

Sum=3,87,000 ($ 9675)

Income

Electricity supply 130 unit @ Rs.6 per unit *365 = Rs.2,84,700/yr. ($7117)

SlurryRs.1500/day= Rs.5,00,000/yr. ($ 12,500)

CDM benefits Rs.71,000/yr. ($ 1775)Sum= Rs.7,84,000 ($ 19,600)

Surplus

Rs. 7,84,000-3,87,000= Rs. 3,97,000 ($ 9925)


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Cylindering of methane available from biogas plant for

tractors and rural vehicles and production of bio manure

Biogas plant of 300 M3 per day capacity with enrichment and bottling

CAPITAL COST Rs. 28,00,000.00 ($ 70,000)

OPERATIONCOST

A. Fixed operational cost-3,00,000 per annum ($ 7500) B. Annual Running (Operational) Cost: -12,00,000 per annum

Total cost of Operation = Rs. 15,00,000 /- ($ 37,500)

Income:-

incomegenerate by selling CBG and slurry = Rs. 22,00,000/- ($ 55,000)

Profit = Rs. 7,00,000/- ($ 17,500)

Payback Period = 4 years


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Further R&D Work Required for Biogas Development

Biogas production using easily available local wastematerial preferably agricultural wastes.

Development of new and low cost improved designs ofbiogas plants for large sizes.

Development of low cost technology for separation of

methane, CO2 and sulfur compounds from biogas for easybottling of pure methane and to reduce the damagescaused by S-compounds on machines using the biogas.


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The effect of bio-wash (liquid from digested slurry) onvegetables and crops.

Design of kitchen waste biogas plant for restaurants

Testing of oil seed cake based biogas plant slurry fornutrient value and its effect on crop production


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Entrepreneurship Models on Biogas for Rur al AreasLarge Scale/ Community level Biogas Enterprises for Cooking needs- Pipeline supply and Rur al Sanitation and

bio manure production

I. Size of Biogas Plant- 85 m3/day No. of families Beneficiaries50

Cow dung required2 Tons/day- Rs 250/Ton

A complex of 20 community toilets

Gas utilizationCooking

If for Cooking 2 hrs. morning & 2 hrs. evening(1.5 m3/familyper day)

Pipeline lengthup to 1km. distance Pipe qualityHDPE, pressurize system0.3 kg./cm2(Rs. 2.5

lacs cost)

Gas charge150/month-family


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II.R

awm

ateri

alCo

wdung+ Toi

let (community-20toilets costs 1.5lacs)

III. Slurry ManagementBiogas digested slurry

Four options-

1. Liquid slurry

2. Recycle water (upto 40 to 50% only)

3. Dry slurry

4. Semi dry

750 kg semi dry slurry @ Rs 2/- per kg costs Rs 1500/day

Local consumption of slurry is advised

Qual

ity of slurry shou

ld be m

aint

ained


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Cost

Plant Cost Rs 4,50,000/-

Pipe Line Cost Rs 1,50,000

Appliances 50*400 Rs 20,000

Pressurizing System Rs 2,00,000 Manpower ( Mechanic 5000, Helper -3000 ) 96,000

Income-

Gas 150*50 Rs 7500/ month = Rs 90,000/yr

Slurry Rs 1500/day = Rs 5,00,000/yr

CDM Benefits Rs 71,000/yr


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Cost estimates

Non- recurring costRs. 8,20,000 ($ 20,500)

Recurring/ Variable costRs. 2,12,000 ($ 5300)

Manpower-- Rs.96,000 ($ 2400)

DepreciationRs.80,000 ($ 2000)

Sum of recurring cost- 3,88,000 ($ 9700)

Revenue generation- 5,90,000-3,88,000=

Rs.2,02,000 (& 5050)Note- In addition to this Carbon credit benefit to the

tune of Rs.71,000/yr. ($ 1775) will also be available.


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2. Large Scale/ Community level Biogas Enterprises for Electricity

Generation and supply for domestic consumption, water supply and

community consumption and Rural sanitation

15 KVA Power Generating System from - 85 m3/day Biogas Plant

No. of families Beneficiaries50

No. of Animals200

Cow dung required2 Tons/day- Rs 250/Ton

Gas utilization Electricity

Domestic connection2CFL, 1 Fan= 100 Wt.*50=5000Wt.

Water supply connection4000 Wt. Community Hall2 CFL, 2 Fan & 1 TV.= 500 Wt.


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Cost

A. Non recurringPlant Cost Rs 4,50,000

Electricity distribution cost Rs 2,00,000/-

Genset Cost 15 kW Rs 1,00,000

Genset Room Cost Rs 1,00,000Sum - Rs 8,50,000

B. Recurring

Manpower ( mechanic 5000, helper 3000) Rs 90,000

Raw Material 1,62,000

Miscellaneous 50,000

Depreciation 85,000Sum = 3,87,000


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Cost estimates

A. Non recurring

Sum =8,50,000 ($ 21,250)

B. Recurring

Sum=3,87,000 ($ 9675)

IncomeElectricity supply 130 unit @ Rs.6 per unit *365 = Rs.2,84,700/yr. ($

7117)

SlurryRs.1500/day= Rs.5,00,000/yr. ($ 12,500)

CDM benefits Rs.71,000/yr. ($ 1775)

Sum= Rs.7,84,000 ($ 19,600)

Surplus

Rs. 7,84,000-3,87,000= Rs. 3,97,000 ($ 9925)


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Feasibility analysis for a community biogas plant of 300 M3 per day capacity with biogas

enrichment and bottling plant has been shown below.

Dung requirement -

For 300 cum. Biogas Plant = 6000 Kgs.

Assuming cost of Dung = 0.20 Rs/kg.

Cost of Dung for Biogas plant = 1200 Rs. per day.

CAPITAL COST

1. BioGas Plant (Digester) Provided by Buyer (@Rs.

3000/- per cubic meter capacity, for 300 cubic meter capacity Rs. 900000/-)

2. Cost of Scrubbing unit Rs. 6,00,000.00

3. Cost of Compressor Rs. 6,00,000.00

4. C.N.G. cylinders Rs. 2,00,000.00

5. Storage tank Rs. 1,00,000.00

6. Installation Exp. Rs. 2,00,000.00

Total Rs. 17,00,000.00


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OPERATION COST -

A. Fixed operational cost-

1. Interest on capital @ 10% per annum= 0.1x 14,00,000 = Rs. 1,40,000 per

annum2. Depreciation @ 5% per annum = 0.05x 42,50,000= Rs.70,000 per

annum.

Total cost = 2,10,000 per annum

B. Annual Running (Operational) Cost: -

1. Dung cost 1200x350 = Rs. 4,20,000 P.A.

2. Labors Cost (1 skilled and 2 unskilled labors) 300x 350 = Rs. 1,05,000 P.A.

3. Electricity cost (10 kWh x12 hr) 360x350 @3/- unit = Rs. 1,26,000 P.A.

4. Repair and Maintenance@ 2% capital cost on 14,00000 = Rs. 28,000

P.A.

Total cost = 6,79,000 per annum

Sum of Fixed Operation cost and annual running cost:

=6,79,000+2,10,000 = 8,89,000.00


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Biogas plant of 300 M3 per day capacity with enrichment and bottling

CAPITAL COST Rs. 28,00,000.00 ($ 70,000)

OPERATIONCOST

A. Fixed operational cost-3,00,000 per annum ($ 7500) B. Annual Running (Operational) Cost: -12,00,000 per annum

Total cost of Operation = Rs. 15,00,000 /- ($ 37,500)

Income:-

incomegenerate by selling CBG and slurry = Rs. 22,00,000/- ($ 55,000)

Profit = Rs. 7,00,000/- ($ 17,500) Payback Period = 4 years


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entrepreneurship models on biogas for rural areas

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