Construction manual of a biogas digester by T.H. Culhane Here is the description of the system, the basic principles are very simple, use the things you
find in your surroundings.
1. Cut the top off at a 2.500 liter water tank.You have now made the stomach of your “sacred cow”.
2. Drill 2” hole at bottom of tank and 1” hole at top of tank.
Construction and use of a biogas digester Biogas systems can be built on any scale: small and simple for a single household, or large and industrial for a whole municipality. In Tamera we are interested in biogas digesters appropriate for a village or community
kitchen; we strive to make these with inexpensive, widely accessible materials and technology.As previously stated, biogas consists of about two third methane and one third CO2, with some water vapor and trace gasses (principally H2 S) and as such, without any alteration or purification, it can be used in all appliances made for natural gas for example cookers and water and space heaters and electric gensets with minimal modifications.
A basic biogas digester consists of a tank in which the organic material is digested, combined with a system to collect and store the biogas produced. The digesters can be quite simple, and the details vary depending on available materials and the needs of the community. Our biogas digester, built in cooperation with T.H. Culhane from Solar C³ITIES e.V., consists of a cylindrical 3000 liter tank, open on top, in which the organic material is digested. A second, slightly smaller tank is placed in the larger tank, upside-down. As biogas is produced, the inner tank fills with gas and rises, telescoping out of the outer tank. As biogas is removed for use, the inner gas storage tank sinks back into the larger, outer tank. In this system, the inner tank acts as both storage, and as a lid for the digester tank. The gap between the tank walls is narrow enough to prevent significant quantities of oxygen from entering the digester, which would kill the anaerobic bacteria that produce the methane.
The amount of biogas lost though the gap is negligible. 3000 liter digester is typically “fed” around 40-60 liters of biomass daily a few full buckets of ground up organic waste mixed with water and produces enough gas for several hours of cooking per day. The main sources of biomass are food scraps and kitchen waste. Non-woody garden waste is also appropriate.Before being fed into the digester tank, the biomass is mechanically macerated — chewed up — with an
“Insinkerator” garbage disposal.Nowadays these “waste disposal” machines are being rebranded as “feedstock preparation devices”and we call them “compost companions” because they can be used to prepare organic garbage for use in both anaerobic and aerobic decomposition processes.Grinding allows the bacteria to access and digest the organic material more easily; in an anaerobics ystem the transformation into gas and fertilizer can take as little as 24 hours while in an aerobic compost pile the transformation into soil can take as little as three to six days instead of months.For our biogas digestor a slurry of ground biomass and warm (40°C) water is poured into the tank inlet funnel. The inlet for the digester leads down to the bottom center of the digester tank. The digested organic material leaves as a high-quality liquid fertilizer, through an outlet near the top of the outer digester tank. At the top of the inverted, inner tank, there is an outlet for the biogas. Before normal operation, the biogas digester must be “started.” This is done by preparing a 1:1 mixture of fresh animal manure and water, and allowing this to ferment anaerobically for several weeks. The volume of this mixture should be around 200 liters for a 3000 liter digester or roughly 30-40 kg of animal manures per cubic meter of digestor tank space. Less can be used but it would simply take longer to establish the colonies of bacteria to enable feeding (feeding only starts once first flammable gas is produced).The slurry can be prepared in a seperate container or in the digester tank. The manure contains the naturally-occurring bacteria that digest organic matter and produce methane. Note that unlike in cheesemaking or yoghurt making biogas digestors do not rely on one strain of bacteria but depend on a balanced ecology of many different types of microbes – hydrolytic, acidogenic, acetogenic and methanogenic.
Fortunately these are all found in animal manure and even lake mud. Essentially any animal wastes can be used cow, horse, pig, and others; alone or mixed.Human excreta can be used as well, although in this case the fertilizer output of the digester should only be used on trees, or in other appropriate applications. Once the manure-mixture is producing flammable gas, feeding of the digester with biomass can begin. It is best to begin gradually, for example with 1/3 of the expected feeding for the first week, 2/3 for the second, and then onto a normal feeding regime. The maximum ratio is about 25 liters of feedstock slurry for every 1000 liters of digestor space.During normal operation, manures can still be included in the feed stock. Most energy has already been extracted from manure, but it can help maintain or replenish bacteria populations in the digester and help balance the pH. The pH and temperature of the digester will affect its performance. Biogas digesters prefer to be at a neutral pH; overfeeding with fats and carbohydrates and certain acidic feedstocks can lower the pH and damage bacterial populations while overfeeding with proteins (animal or vegetable) or nitrogen-rich materials (for example chicken droppings, feathers, skin, hair or slaughterhouse waste) can raise the pH and also damage the bacterial consortia. If one thinks of the digester simply as a stomach (for this is where the bacteria originated) and gives it a balanced nutrition, or if one thinks of it as a liquid compost pile and observes the usual C:N ratio of about 25 to 1, the system should last indefinitely. But if the bacterial ecology does get out of balance, one can simply restore the pH to neutral, add more manures, and start over, so it isn’t difficult to recover from improper feeding and one shouldn’t fret too much about “damaging” the system. Fortunately every one of us carries in our own guts all the materials we need to get things working again, and for this reason biogas systems are truly the easiest and most democratic of all forms of renewable energy. High temperatures can kill bacteria; low temperatures may cause them to become dormant. Different methane-producing bacteria respond to temperature differently; some prefer cooler temperatures as low as 17°C-20°C (psychrophilic). Others thrive at higher temperatures around 57°C (thermophilic). On the whole, however, biogas digesters well-suited to temperate climates work best at temperatures around 37°C (mesophilic). In most non-tropical climates, it may be worthwhile to insulate and heat the digester tank, for example with a solar hot water system. It can be helpful to put lake mud in the digester to populate the colder bottom regions with psychrophilic (cold-adapted) microbes.
The methane-producing bacteria are not adapted to floating free in a tank; they evolved to live in an
animal’s stomach, where they attach to surfaces while being exposed to flows of digestible material.
These conditions can be recreated by covering the bottom of the tank with porous stones or gravel and by
building high-surface-area “hi-rise” structures inside the digester tank (we call these “microbial motels”!).
Vertical structures which permit bacteria to inhabit all the temperature zones of the tank increase
efficiency – water separates into thermal layers with the coldest water accumulating at the bottom of the tank
and the warmest water at the top. Unfortunately, most biodigestors rely on bacteria living in sludge granules
on the cold tank floor to do most of the work.
By providing bacterial “elevators” or vertical “fuel rods” we give our “pet microbes” a chance to find the
zone within the thermocline most suited to their needs. We often build our “microbe motels” with recycled plastic tubing, striving for minimum impact on the flow of gasses and slurry in the tank. We find verticle plastic pipes with holes cut in them to let food in and bubbles out to work well (think of a pipe organ) but vertically strung nets also work as does filling the tank with “bio-blocks” or “bio-balls” or other typical pond filtration media used to encourage bacterial growth. One doesn’t need to buy them – we make them by chopping up old corrugated plastic electrical conduit; in Palestine our colleagues throw in the husks of almonds and pistachios; the idea is simply to have floating media upon which bacteria can form their active biofilms. The more surface area in the tank the larger your bacterial population and theoretically the more you
can feed them; the more biofilms there are the more efficient the bacteria making them up can work and
produce more gas and fertilizer (bacteria form what have been likened to “microbial cities” in their biofilms
where different regions engage in specialized functions). As Dr. Anand Karve, inventor of the ARTI India Telescoping biogas system we have adapted, said: “after all, we are talking about bacteria for heaven’s sake - bacteria that can be found anywhere and everywhere, even in our own stomachs!”
Construction manual of a biogas digester by T.H. Culhane
You can make biogas energy with a DIY methane generator.
Producing methane from manure using your own small scale waste to energy biogas digester is feasible for many small farms. What is Biogas Energy?Biogas energy is fueled by burning methane produced by the decomposition of organic wastes.
Small scale biogas generator
Methane is a gas – chemically CH4. It is colourless, odourless and, of course, flammable. Methane is widely used as the main constituent of mains natural gas.
Whenever organic materials are decomposed by bacteria anaerobically (i.e. in the absence of oxygen) methane and carbon dioxide are produced.
Small scale manure-to-energy methane generator plans are available here. Sources of Biogas Energy
Just about any organic waste can be decomposed as a methane generator - plant (soft material is better than woody material) and animal wastes, and even human waste.
On a municipal level, rubbish tips act as biogas digesters and are prodigious methane generators. Even in Perth, Australia, companies are actively harvesting this methane to produce climate friendly biogas electricity.
In fact, because un-burnt methane released into the atmosphere is a powerful greenhouse gas, 10% of our personal impact on the climate comes from the food refuse we put in our garbage bins that ends up decomposing under landfill.
In a small scale waste to energy situation it is possible to generate methane from manure or even sewerage. And biogas energy is constantly being manufactured in digestive systems like yours and your cow’s… yes, farts are methane too! Check out this video to see how to make a simple home digester:
Pros and Cons of Methane Generator Systems Advantages
• Makes good use of organic wastes. You can obtain fuel from sewage sludge and animal slurries first, and prevent runoff and methane emissions at the same time – and you still get fertiliser at the end of the process.
• Is a clean, easily controlled source of renewable energy.
• Uses up methane, a powerful greenhouse gas.
• Reduces pathogen (disease agent) levels in the waste.
• Residue provides valuable organic fertilizer.
• Simple to build and operate.
• Low maintenance requirements.
• Can be efficiently used to run cooking, heating, gas lighting, absorption refrigerators and gas powered engines.
• No smell (unless there’s a leak, which you’d want to know about and fix immediately anyway!). Disadvantages
• Most practical to be generated and used at the source of the waste. This is because the energy needed to compress the gas for transport, or convert it into electricity is excessive, reducing the efficiency of biogas energy production.
• For safety, basic precautions (see below) must be adhered to. Small Scale Waste to Energy Methane Generator Systems Biogas Energy
Each kilogram of biodegradable material yields around 0.4 m³ (400l) of gas.
So in practice, in small scale waste to energy systems, if you have some livestock, plus kitchen and human waste you can meet your cooking and lighting needs easily:
• 2 gas rings for a couple of hours a day will use between 1-2 m³
• Gas lights need around 0.1 m3 (100l) per hour.
Driving any kind of engine (eg a generator or a pump) is, however, way beyond the domestic-scale. (Better to go for algal biodiesel!)
What Size Methane Generator is Needed?
If generating methane from manure, collect dung for several days to determine average daily dung production. On this basis, the appropriate size biogas digester plant can be calculated.
For example, where 55 kg of dung a day is available a 8 m3 plant is warranted; where it’s only 6 kg of dung a day, a 1 m3 plant will suffice.
For a family of 8 with a few animals (say 8-10 cows), a 10m³ digester is a commonly used size in India, with 2 m³ gas storage. Ideal Temperatures for Producing Methane from Manure
How long you leave the material in a batch digester depends on temperature (2 weeks at 50°C up to 2 months at 15°C). The average is around 1 month – so gauge how much material you will add each day, and multiply it by 30 to calculate the size of the digester.
While anaerobic digestion occurs between 32° F (0°C) and 150° F (65°C), the optimum temperature range for methane generating microbial activity is 85°F (29°C) to 95° F (35°C).
Little gas production occurs below 60°F (16°C). In colder climates placing the digester in a greenhouse, and perhaps using some of the methane to warm the system, are possible strategies. Methane Generator Systems
• The biogas digester is the system component where the animal, human and other organic wastes are introduced, usually as a slurry with water, to break down anaerobically.
• A storage container is used to hold the gas produced, from which it is piped for burning as a fuel. Variable volume storage (i.e. flexible bag or floating drum) is easier, cheaper and more energy efficient than high pressure cylinders, regulators or compressors.
• When the digester is emptied, the spent effluent is dried for later reuse as a fertilizer. Types of Biogas Digesters
The two main digester types of digesters are the continuous and the batch. Continuous digesters have a constant throughput of material, and batch digesters extract the gas from a contained batch of material, which is then emptied and a new batch added.
As firewood for cooking has become scarce, millions of small scale continuous digesters are in use in developing countries, especially India and China. Digesters tend to be larger-scale in developed countries, taking animal slurries and human sewage. Methane Generator Design
The Indian cylindrical pit design has become a popular choice around the world due to its reliability and simplicity. It comprises two basic parts: a slurry tank and a covered by a gas cap or drum to capture the gas released from the slurry. Domestic Scale Batch Biogas Digestor
Small experimental biogas digester at Redfield. Waste material is put into the oil drum, neoprene cover rises when full of gas, gas is tapped into container (upside-down plastic drum with water seal) which rises as more gas enters. When full, gas can be tapped off and used with the little gas ring.
Batch digesters based on a container (see photo, above) are feasible on the domestic scale. Mini Methane Generator Project
Instructions to make a mini methane generator (suit education project) are in the "Methane-Biogas Production Guide" which, along with heaps of other free eBooks on sustainable living, can be accessed free here.
Methane Safety
Like electricity and other energy systems, safety is usually assured so long as the risks are understood and sensible precautions are followed. Fire or Explosion Risk
Methane is obviously flammable, and can even be explosive. With this in mind...
• The methane generator digester area must be well ventilated to prevent the accumulation of trapped gases.
• In the vicinity of a digester no naked flames are permitted, electrical equipment must be of suitable quality, normally "explosion proof", and other sources of sparks are any iron or steel tools or other items, power tools, normal electrical switches, mobile phones and static electricity kept a safe distance away.
A flame trap should be incorporated in the supply line, which must be of a minimum of 20 m long. Instructions on building a flame trap can be found here.
Asphyxiation Risk
Biogas displaces air, reducing the oxygen level so any digester area needs to be well ventilated. Disease
While the spent slurry has lost a lot of its pathogens, there’s a lot of microbial activity at work in producing biogas energy!
So avoid contact with the digester contents and wash up thoroughly after working around the methane generator (especially before eating or drinking).
A PILOT PROJECT TO GENERATE BIOGAS USING HUMAN WASTE
The main objective of this project was to use the prisoners' waste to produce biogas that could be used as cooking fuel and cut down the cost incurred in buying of firewood initially used as fuel to cook for the prisoners.
However after completion, the project brought forth multiple benefits namely, treatment of the sewage waste in order to prevent waterborne diseases within the community, production of organic food for fish in the fish ponds, a cleaner environment realised through better sanitation practices thus ensuring that the prisoners do not fall sick as often as before.
The prison has 1,200 inmates and about 300 saffs and it's in the Eastern provinnce of our country Kenya.
What is Biogas Energy?Biogas energy is fueled by burning methane produced by the decomposition of organic wastes. 
