H N Chanakya, CST, IISc, Bangalore

H N Chanakya,
CST, IISc, Bangalore
Biogas plants augment Agriculture by recycling agro-residues through cattle or
directly by new generation biogas plants – allows recycling and sustainability
Understanding history to predict future
Popularizing
Indian BGPs
Pull by
-Biogas
-Compost
Indian design
biogas plants
1960-70
-Low crop yield
-Efficient nutrient
management
-Basic needs of
lighting, pumping
-Popularizing
BGPs
- Acceptance
New - efficient
designs, IISc
1970-80
-Energy crises
-Alternative fuels
-(cooking fuel)
-Deenabandhu,
Janatha & local
designs of BGPs
-IISc design
-Cost reduction
-New designs
-Alt. feed stocks
-R&D initiated
-Better conv.
1980-90
-Energy crisis
consciousness
-NRE goals
MNES set up
-Multiple end-uses
-Commercial uses
and large plants
-Mixed feed,
-VAPs /uses
Cheaper rugged designs,
-Alt. Feeds, Big plants, Resource use efficiency, R&D contd. Demos, 19902000
-2nd -Energy crisis
- GEF /GHG etc.
- RE promo. policy
-Revitalized MNES
-Commercial plants
-USW /sewage BGPs
-Multi-use BGPs
-Remediation BGPs
-Pollution abatement
- USW, multi-feed, Waste water BGPs
-Pollution mgmt.
-Co-digest toxicant
2000-10
-Envi. friendly tech.
-Enviro. Clean-up
-Commercialization
-New laws, -CDM, Ctrade, -Profitability
Trajectory of AD/BG in India from 1950-2010, Chanakya & Sreesha, 2012
Biomethantion and Anaerobic Digestion
Goal: to develop designs using leaf biomass, agro-residues and
municipal solid waste: build livelihoods around BGP
Technologies: Optimized biogas plant designs-cost reduction
•
Solid-phase and plug flow reactors; leaf biomass and MSW
•
Coffee effluent treatment plants
Spread and Impact: Multi-feed and high rate bioreactors: 80 modules
•
MSW plant – 3, Canteen plants – 5, Community biogas plants: 17
Lifeline Energy
Drinking water lifting, Domestic
illumination,
Grain milling
Grid Power not used so no
Coal Burnt for Power
Pura ASTRA-IEI experiment
- 10 year operation (contd)
95% revenue collection, participatory
management.
Revenue enough only for O&M.
Dung borrowed, return as cake - equity.
Fermented dung premium manure
Better quality nursery material. No weeds
A 2m3 biogas balloon is easily
carried by a housewife or an
adolescent to the nearest gas
collection centre within the
village. Surplus gas is an
essential output providing daily
or weekly cash incomes to the
operator – usually the housewife.
When biogas is produced from
agro-wastes and other soft
biomass, it is possible to create
this output that will firstly reduce
pressure on trees being cut for
fuelwood, second could liberate
villages from fossil fuels.
These are also commercially
viable at the rural level
What can we dream?
The cup is half-full - Facilitate methane
collection system from grass-roots like milk
collection systems.
•It will encourage grass-root
level biomass use efficiency,
•HH fermentors
• methane collection without
transport of wood ash,
nutrients etc.
• HH level collection, Village
level purification and
compression, tanker based.
•Collection – vehicles also
run on methane!
• 50M HHÆ1m3/HH =4.2Bn Euro/yr upto 30Bn cap.
•
•
•
•
Recommend
1.Setting milk collection type infrastructure on trial basis and franchise.
2.Evolve policy cover
3.Gather technologies for above option franchise to local enterprises.
What biomass feed stocks
occur at
1.Village level?
2.Across India?
1.
2.
3.
4.
5.
Agro-residues in villages inadequately deployed today
Agro-industry residues (liquid and solid)
Urban solid wastes
Making biomass plants viable
Emerging and newer biomass feedstocks
EXISTING USE PATTERN
ACTIVITY
ALTERNATIVE Biomass Technologies
Fuel Source Annual
Annual biomass
Modern option and
power
requirement
requirement
total requirement
(Total)
tons, kWh, L
tons,
(tons, total)
================================================================================
Wood and 400
cooking
785 dung
BIOGAS
crop
137 green biomass
(210 m3/d)
residue
(dry basis) ----------------------------------------.
(609 t)
97
heating water
47 fuelwood
EFFICIENT WOOD
40
restaurants
23 fuelwood
BURNING DEVICES
44
jaggery making
33 residue
(113 t)
20
brick making
10 fuelwood ----------------------------------------.
.
5570
Agro20.8 fuelwood
PRODUCER GAS
Grid
Processing
(16,000 kWh)
ELECTRICITY .
Electri27079
Irrigation
190 fuelwood
(Total .
city
(146,160 kWh)
192,992 kWh).
(53,064) 10891
Grain milling
10.7 fuelwood
(251 t)
.
(kWh)
9524
lighting
(8,213 kWh) -----------------------------------------27.0 fuelwood
BASE-LOAD USES
Kerosene 6283L
lighting
(20,696 kWh)
biogas or producer
gas depending upon
Human
NA
Drinking
2.5 fuelwood
resource available
(1,923 kWh) ----------------------------------------.
Petrol/diesel
NA
mobile shaft power
NA Biodiesel
Mod. veg. Oils(MVO)
Total = 785t dung, 137t herbaceous biomass, 405t wood (all existing) (Bottled methane)
Bioenergy Fantasy – Low carbon path (>25 yrs)
Biomass supply potential exists
Endogenous energy security + Export
External technology dependency /inadequacy
Methane farming – sweet sorghum +
biomethanation = 500%>energy than ethanol
– closed cycle, high sustainability potential
Sweetsorghum
DOC
188
3
150 28125
600
1800
43500
3845
22617
7500
Total benefits
Rs/acre
Revenue from
CNG @20/m3
Revenue thru'
CDM
Biocompost
revenue @ 1500/t
Biogas Potential,
m3/acre/yr
Biogas potential,
m3/t
Yield, Ton per
acre
Feedstoks
Outputs from a typical methane farm (per acre basis): 4.6m3/hr, 27kWthermal, 10kWelec
power, steam, CNG, CDM, refrigeration, bio-compost, peripherals,
cooking gas, etc.
Sample potential projection by a Maharashtra biomethanation company for cane belt
56250 122367
1800 29345
2
1
3
PFR allows many soft biomass residues to be fermented to biogas
To ferment these soft biomass residues such as terrestrial weeds, agroresidues, aquatic residues, agro-processing wastes, food wastes, etc.
require different Fermenter designs
– because their properties differ and cannot become slurries
A three zone fermentation could be done in simple plug-flow
reactors with separate gas storage. These new biogas plant can
now reach every one in India, All rural families can build such
plants. Not a single tree has to be cut for fire-wood
3-zone, PFR for multi-feeds
A 4 m3/day biogas plant built for a farm to use
Various biomass residues requires only 12kg dry material per day = 1.2t DM/family/year
Gas to be used by two families.
USW /food waste plant in Sri Lanka
(CST-astra, IISc design, 2009)
How does the biology differ?
BMP and Decomposition properties
CST, IISc, Bengaluru, India
Centre for Sustainable Technologies, IISc, Bangalore
Complex
Organics
76%,NA, NA
20%, NA, NA
4%, NA, NA
Higher Organic Acids
52%, NA, NA
24%, NA, NA
Acetic Acid
Hydrogen
72%, 50%, 10%
28%, 50%, 90%
Methane
Cattle dung,
food wastes
and biomass
Complex
Organics
76%,NA, NA
20%, NA, NA
4%, NA, NA
Higher Organic Acids
52%, NA, NA
24%, NA, NA
Acetic Acid
Cow dung, thermophilic, CSTR
Pseudomonas pertucinogena,
Pseudomonas halodenitrificans
Hydrogen
Food waste, thermophilic, CSTR
72%, 50%, 10%
28%, 50%, 90%
Lactobacillus parabrevis,
Butyrivibrio sp.
Plant biomass, thermophilic, CSTR
Parabacteroides
distasonis ATCC 8503
Methane
Bacillus thermoterrestris
Clostridium sp. FCB90-3
Anaerobaculum mobile,
Lactobacillus hammesii
Sporanaerobacter acetigenes,
Syntrophococcus sucromutans,
Pseudoramibacter alactolyticus
Methanoculleus thermophilicus
Methanosarcina thermophila
Clostridium thermocellum
ATCC 27405
Syntrophomonas wolfei
Methanoculleus marisnigri JR1
Methanobrevibacter sp.,
Methanoculleus bourgensis
Municipal Solid Wastes
This resembles segregated MSW collection
“dry-waste” collection centres’ run for profit
Segregated for market within 24h after receipt
Stocking designed for minimum quantity for lifting
This resembles segregated MSW collection
“dry-waste” collection centres’ run for profit
Segregated for market within 24h after receipt
Stocking designed for minimum quantity for lifting
Compost odour is “offensive” to residents and needs
lots of leaves so change to “biomethanation”
Even this is economically viable - Evolution Î 2 next
page
Make it more “economically attractive Æ people
should fight for /over garbage rights!!
Solid Wastes !! are a solid waste
Conventional methods becoming increasingly expensive, untenable and unsustainable
GenerationÆCollectionÆtransportÆprocessingÆDisposal
Economic Sustainability is itself poor as it stands today
Collection Costs Rs1500-3500/t,
Transport Rs550-1800/t,
Treatment Rs 300-500/t
Disposal Rs 300-600/t (assuming free landfill site)
Need to offset these costs Æ can we think of making this
profitable? extracting energy, by-products, recycling, reusing, infrastructural inputs
Sector-wise USW composition
Source
Domestic
Markets
Hotels and eatery
Trade and commercial
Slums
Street sweeping and parks
Quantity
(t/d)
780
210
290
85
20
40
Fraction %
(by weight)
55
15
20
6
1
3
Source: Chanakya and Sharatchandra, 2005
Although USW Generation today is about 3600t/d, the relative composition is still similar
waste
Data Source – KSPCB,2008; Chanakya and Sharatchandra, 2008
BITS-Goa Campus
Kitchen /Garden wastes
1tpd Æ gas for cooking
Small Apartment Biogas Plant
10kg/d, 600L/d, Rs.12-15,000 (2011)
.
FRP with internal reinforcements.
Balcony Biogas Plant (2kg/d,
Rs 12-15,000 (2012), 120L/d)
Mild Steel, Epoxy Coated
Rs.6-9000/- FRP versions
The Treatment and
Recycling system
Currently just about break
even costs or about
profitable at ideal
conditions. NEW AVENUES
FOR VALUE ADDITION
REQUIRED TO SHOW
SENSIBLE PROFITS
Treatment and Recycling potential (1tpd) system, 2014
INPUT
Capital cost/d (investment)
Quantity Recove Rate, Rs/kg
ry (%)
or gross
1200 Rs
O, M&D/d
Total input
OUTPUT
Rs/ton
1200
450 Rs
450
Biogas commercial
Paper
50kg/d
116 kg
100
75
50/kg
15
1650
2500
1305
Cloth, rubber, PVC, leather
Glass
10.1 kg
14.3 kg
50
75
12
3
60
32
Polythene /plastics
62.3 kg
75
12
561
10 kg
90
25
225
Metals
Total output
(net gain Rs @100% recovery)
Output
net gain Rs.@75% recovery)
3033
2487
4683
3033
The Treatment and
Recycling system
Currently just about break
even costs or marginally
profitable at ideal
conditions. NEW AVENUES
FOR VALUE ADDITION
REQUIRED TO SHOW
SENSIBLE PROFITS
Making Biogas economic
Value Added (by)Products
Mushroom,
Fibers (fabric, paper, ropes, etc)
Vermi-compost
Pest repellent, MA Storage
Fresh husk
(9t / ha)
30d SRT
CST-IISc Technology
Fiber (50%) =2.4t
(Rs40/kg=Rs96,000)
Areca yield =
6t fruit + 9t husk /ha/yr
Nuts value Rs.100,000 :
Compost
husk fibre value Rs.96,000
(0.93t/ha*3000=Rs2790)
(no process available today)
CST Areca Biogas Plants recover
40% as fibre, 40% fermentables as biogas
and 20% as compost
Process & Economics ARECA
30% fermentables for biogas
(1.4t/ha*400m3/t=640m3 =Rs5600)
CST-IISc Technology
Anaerobic digestion of
Banana leaf for fiber, biogas
and compost
•The pattern of banana leaf decomposition
was followed by staining the digesting leaf at
various intervals of fermentation and viewing
under microscope- suggesting only
cementing walls of vascular bundles being
broken down and getting vascular bundles as
intact fibers
Broken
channel
Cementing
channel
Vascular
bundles
(fibre)
a
•Decomposing banana leaf in CST biogas
plant , 20% of TS is recovered as fiber, 75% as
biogas and 5% as compost in 27days of
fermentation
b
c
CST-IISc Technology
Areca Husk
Banana leaf
CST-IISc Technology
Decomposition pattern with respect to fermentation time of banana leaf 5b. Areca husk
Problems, Challenges and New Tasks, etc.
Feasible on large scale and small scale, sustainable mode of operation
with zero energy input, Different agro-residues show different
fermentation pattern in the same reactor conditions and needs to be
standardized, Value added product like biogas and compost with zero
emissions and no pollution
Small scale fiber extraction - value addition at family level (Banana Leaf)
Fibre
4kg/day
120Rs/day
Biogas
Non fiber matter
Banana leaf
(100kg/day)
Plug flow type
biogas plant
Digested leaf
Raspador
Pest repellent
Compost
Profit and financial viability assessments
Cost of Biogas plant= 75,000
Cost of Rapador= 50,000
Annual Labor=5400
Annual power= 2160
Cost of fiber= 30 per Kg
Annual fiber production=1460 Kg
Total returns= 43800
Pay back period with interest: 4yrs
Total investment per year=132560
Separating Fibers-economics
Extent of Kill and
residual air in MA
storage of grains
• 1-2 fillings required and can
make and excellent
livelihood option with just a
small balloon and pipe.
•
•
•
•
Pests Tried
Sitophilus oryzae
Tribolium castaneum
Rhyzopertha dominica
Offset high costs
Pest repellant uses
Æ outcomes
Liquid in the digester has pest
repellant properties that needs
to be tested locally. Best way
to use needs to bd determined
locally
Mushroom cultivation on
digested biomass
Mushroom cultivation is best done when there is a large content
of leaf litter and agro wastes. Digested residue (top left) is
mixed with a bulking agent like rice straw (bottom left) and kept
for mushroom production – typically oyster mushroom
(Pleurotes spp). Within 20-45d about 2-3kg mushroom /kg of dry
mixture is produced whose value is about Rs.120.
Other Pleurotes varieties to be tested, other mushrooms to be
tested, household technology /device to evolved.
R
CST, IISc, Bengaluru, India
Spawning
Fruiting body
Centre for Sustainable Technologies, IISc, Bangalore
1st flush
Biogas
Digester liquid spraying
Astra-CST PFR
Digester residue
-- CURRENT PROCESS -With only biogas and compostLOW ECONOMIC SUSTAINABILITY
Pre-packed mushroom bags purchased from
IIHR-Bangalore
Leachate
Mushroom
Spraying digester liquid to mushroom
increases economic sustainability
Multi-Feed Biogas Plants
Agro-processing wastewater
coffee Industry Wastewater
Seasonal outputs
Multi-feed capability needed
Solid to liquid switching in 10d!!
Independent operation
Biogas plants for mixed
Agro-processing waste-water
and soft biomass
Mixed solid–liquid feed,
no gas drum
A 4X60m3 plug-flow based coffee bioreactor
/biomass based biogas plant at Mallandur (below)
and a 6X60m3 coffee bioreactor near Balehonnur,
Chikkamagalur, Karnataka. Gas production is large
and collected in gas bags (right)
Each module Rs.4 Lakhs = 30m3 gas /d
Î40RsX15LX350d=210,000/yr
Gas given to Labour Lines = Trees saved
Fossil fuel substituted
Pollution prevented
Biogas from
Emerging Biomass
by-products
Micro-algal production
Biodiesel rejects – non-edibledeoiled cake, /
glycerol+methanol
Sustainable Cultivation of Algae for Biofuel is possible at four locations in India
• Paddy fields as a multi‐tier crop (16.49Mha) • Saline brackish region of Kachch (Gujarat; 3.0Mha)
• Urban domestic wastewater (40billion L/d)
• Fishery deficient seashores (3Mha).
(Chanakya et al., 2012b)
(Chanakya et al., 2012b)
Mixed Consortia and Wastewater
Kill three birds with one stone
Algal-biofuel, COD/ BOD removal and Nutrient recycling
Bellandur tank can provide 30,000L biofuel + 30,000m3 biogas daily
150 Million BGPs potential exists
How to make the program ‘profitable’?
Rapidity /critical mass
Biomethanation Technologies /byproducts
Agro-residues,
Weeds, Straws
Leaf Litter, MSW
(no dung needed)
Grain Disinfestation, Auto-Fuel,
Pico-power, CO2, Direct Fuel Cell
Biogas
Pest Repellant, AlgaePisciculture, Fertigation
Digester
liquid
Digested
Residue
Mushroom, Fiber (fabricpaper), Rooting Medium,
Inoculant Carrier, BioFilm
Support, Vermi-compost
(derivatives),
Rural Enterprises will market these for local and
urban markets Æ Rapid pay back.
ADD CDM BENEFITS, Highly “Enterprisable”!!!!
Mushrooms
Pico-power (0.2-2kW)
Vermi-compost
Direct Fuel Cells, 10-200W
AutoGas (clean /compress)
Biogas Plants
CA storage /Fumigation
Mushroom growth promoter
Aqua-culture
Algal culture /N harvest
Pest repellant
Fiber for cloth
(keystone technology
approach)
Compost
Rooting medium
Microbial Inoculant Carrier
Lignin formaldehyde
Biofilm Support
Fiber ÆPaper, upholstery, etc.
Compost is “offensive” to residents
and needs lots of leaves so change
to “biomethanation”
Even this is economically viable Evolution Î 2 next page
Make it more “economically
attractive Æ people should fight
for /over garbage rights!!
The cup is half-full - Facilitate methane
collection system from grass-roots like milk
collection systems.
•It will encourage grass-root
level biomass use efficiency,
•HH fermentors
• methane collection without
transport of wood ash,
nutrients etc.
• HH level collection, Village
level purification and
compression, tanker based.
•Collection – vehicles also
run on methane!
• 50M HHÆ1m3/HH =4.2Bn Euro/yr upto 30Bn cap.
•
•
•
•
Recommend
1.Setting milk collection type infrastructure on trial basis and franchise.
2.Evolve policy cover
3.Gather technologies for above option franchise to local enterprises.