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CLOSE THIS BOOKBiogas plants in Animal Husbandry (GTZ, 1989, 153 p.)
10. Appendix
VIEW THE DOCUMENT10.1 Design calculations and drawings
VIEW THE DOCUMENT10.2 Gas-law calculations
VIEW THE DOCUMENT10.3 Conversion tables
VIEW THE DOCUMENT10.4 Charts and tables for use in performing micro-economic
VIEW THE DOCUMENT10.5 List of pertinent suppliers and institutions
VIEW THE DOCUMENT10.6 Selected literature
VIEW THE DOCUMENT10.7 Lists and indexes

Biogas plants in Animal Husbandry (GTZ, 1989, 153 p.)

10. Appendix

10.1 Design calculations and drawings



10.1.1 Floating-drum plants

Design calculation

Sizing factors

Example

Daily substrate input, Sd

= 115 l/d

Retention time, RT

= 70 days

Daily gas production, G

= 2.5 m³/d

Storage capacity,Cs

= 60%

Digester volume, Vd

= 8 m³

Gasholder volume, Vg

= 1.5 m³

Calculating formulae after Sasse, 1984
1. Vg = Cs · G
2. ha = design-dependent
3. Vg= r · p · h
4. rg =
5. rd = r + 0.03
6. Vd1 = p · d2 · p · h
7. Vd2 = R3 · p · 2/3
8. R =
9. Vd3 = R2 · p · H/3
10. H = R/5
11. Vd3 = R3 · p · 1/15
12. Vd2 : Vd3 = 10 : 1
13. Vd(2+3) = 1.1 Vd2
14. Vd(2+3) = Vd - Vd1
15. hd = hg
16. hdk = hd + structurally dependent free board (0.1 . . . 0.2 m)


Fig. 10.1: Conceptual drawing of a floating-drum biogas plant

Vd = Vdl +Vd2 +Vd3
= digester volume
Vg = gasholder volume
Index g = gas holder
Index d = digester

Sample calculation

Results

1. Vg = 0.6 · 2.5

= 1.5 m³

hg = (specified)

= 0.7 m

4. r =

= 0.82 m

5. r = 0.85 (chosen)


6. Vdl = 0.852 ·3.14 · 0.7

= 1.58 m³

14. Vd (2+3) = 8.45 - 1.58

= 6.87 m³

8+ 14. R =

= 1.45 m



Fig. 10.2: Constructional drawing of a floating-drum plant. Vd = 6.4 m³, Vg = 1.8 m³. Material requirements: Excavation 16.0 m³, Foundation 1.6 m³, Masonry 1.1 m³, Rendered area 18.0 m², Sheet steel 5.7 m². (Source: OEKOTOP, Sasse)


Fig. 10.3: Constructional drawing of a water-jacket plant. Vd = 6.0 m³, Vg = 1.8 m³. Material requirements: Excavation 16.0 m³, Foundation 1.6 m³, Masonry 1.6 m³, Rendered area 21 m², Sheet steel 5.7 m². (Source: OEKOTOP, Sasse)


Fig. 10.4: Constructional drawing of a cylindrical floating-drum plant for quarrystone masonry. Vd = 9.4 m³, Vg = 2.5 m³. Material requirements: Excavation 21.0 m³, Foundation 1.0 m³, Masonry 5.4 m³, Rendered area 27.3 m², Sheet steel 6.4 m². (Source: OEKOTOP, KVIC)

10.1.2 Fixed dome plants

Design calculation

Sizing factors

Example

Sample calculation

Daily substrate input, Sd

= 115 l/d

R = (0.76 · 8)1/3= 1.85 m

Retention time,RT

= 70 days

r = 0.52 R= 0.96 m

Daily gas production, G

= 2.5 m³/d

h = 0.40 R= 0.72 m

Storage capacity, Cs

= 60%

p = 0.62 R= 1.14 m

Digester volume, Vd

= 8 m³


Gasholder volume, Vg=G·Cs

= 1.5 m³


Vd : Vg

= 5.3 : 1



Tab. 10.1: Calculating parameters for fixed-dome biogas plant (Source: Sasse 1984.OEKOTOP)

Vg : Vd

1:5

1:6

1:8

R

(0.76 · Vd)1/3

(0.74 · Vd)1/3

(0.72 · Vd)1/3

r

0.52 R

0.49 R

0.45 R

h

0.40 R

0.37 R

0.32 R

p

0.62 R

0.59 R

0.50 R



Fig. 10.5: Conceptual drawing of fixed-dome biogas plant. Vg gasholder volume, Vd digester volume. (Source: OEKOTOP, Sasse)


Fig. 10.6: Constructional drawing of a fixed-dome plant. Vd = 8 m³, V = 1.5 m³. Material requirements: Excavation 25 m³, Foundation 2.2 m³, Masonry 2.0 m³, Rendered area 22.0 m², Sealed area 7.0 m². (Source: OEKOTOP, Sasse, BEP Tanzania)

10.1.3 Earth pit with plastic-sheet gasholder


Fig. 10.7: Constructional drawing of an earth-pit biogas plant with plastic-sheet gasholder. Vd = 11 m³, Vg = 2.2 m³. Material requirements: Excavation 16 m, Rendered area 28 m², Sheeted area 10 m² (Source: OEKOTOP)

10.1.4 Estimating the earth-pressure and hydraulic forces


Fig. 10.8: Schematic diagram of earth-pressure and water-pressure forces

In-depth forces, h (e, w)

pW = wW · hw
pW = hydrostatic pressure at depth hw (m) wW = specific weight of water
= 1000 kp/m³ pW = 1000 · h (kp/m²)
pE = wE · ce · he
pE = active earth pressure, i.e. force of pressure of dry, previously loose but now compact column of earth on a solid vertical wall
wE = specific weight of dry backfill earth
= 1800 . . . 2 100 kp/m³
he = height of earth column (m)
ce = coefficient of earth pressure for the earth column in question
= 0.3 . . . 0.4 (-)
pE = (600 . . . 700) · h (kp/m² )

Force acting on a surface

P(E, W) = p · A (kp = (kp/m²) · m²)

Note: The above formulae are simplified and intended only for purposes of rough estimation.

10.2 Gas-law calculations



10.2.1 Calculating the pressure drop in a gas pipe

dp = FL + Ztot
dp = pressure drop (N/m²)
FL = friction losses in the gas pipe (N/m²)
Ztot = sum total of friction losses from valves, fittings, etc. (N/m²)
dp = cp l/D · D/2 v2
+ (cfl D/2 · v2 + . . . + cfn · D/2 · v2)
(approximation formula)
cp = coefficient of pipe friction (-)
l = length of pipe section (m)
D = pipe diameter(m)
g = density of biogas (1.2 kg/m³)
v = velocity of gas in the pipe (m/s)
cf = friction coefficients of valve, fittings, etc.
Q = v · A
Q = gas flow (m³/s)
v = velocity of gas in the pipe (m/s)
A = p r2 = cross-sectional area of pipe

The coefficient of pipe friction (cp = non. dimensional) is a function of:
- the pipe material and internal surface roughness
- pipe diameter
- flow parameter (Reynolds number)

For pipe diameters in the 1/2" . . . 1" range, the coefficients of friction read:
PVC tubes approx. 0.03
steel pipes approx. 0.04

Some individual friction-loss factors (cf; nondimensional)

elbow

0.5

valve 3.0

constriction

0.02-0.1

water trap 3 - 5

branch

0.8-2.0



10.2.2 Calculating gas parameters

Temperature-dependent change of volume and density

D = DN · P · TN / (PN · T)
V = VN · PN · T / (P · TN)

where:
D = density of biogas (g/l)
DN = density under s.t.p. conditions (0 °C, 1013 mbar)
V = volume of biogas (m³)
VN = volume of biogas under s.t.p. conditions
P = absolute pressure of biogas (mbar)
PN = pressure under s.t.p. conditions (1013 mbar)
T = absolute temperature of biogas (measured in ºKelvin = ºC + 273)
TN= temperature under s.t.p. conditions (0 0ºC = 273 °K)

Table 10.2: Atmospheric pressure as a function of elevation (Source: Recknagel/Sprenger, 1982)

Elevation (km)

0

0.5

1.0

2

3

4

6

8

Atm.pressure (mbar)

1013

955

899

795

701

616

472

365



Fig. 10.9: Nomogram for correcting gas pressures/temperatures (Source: OEKOTOP)

Determining the calorific value


Fig. 10.10: Nomogram for finding the net calorific value of biogas as a function of temperature, pressure and moisture content. T gas temperature (°C), F relative dampness of biogas (%), Hu, N net calorific value (n.c.v.) of biogas under s.t.p. conditions (0 °C, 1013 mbar), Hu, T net calorific value (n.c.v.) at gas temperature, P gas pressure (mbar), Hu, T, P net calorific value (n.c.v.) at gas temperature and pressure, PW partial pressure of water vapor, Hu, T, PF net calorific value (n.c.v.) of biogas at gas temperature, corrected to reflect the water-vapor fraction (Source: OEKOTOP)

Using the nomogram

1. Quadrant I: Determine the net calorific value under standard conditions as a function of the CH4-fraction of the biogas

2. Quadrant II: Determine the net calorific value for a given gas temperature

3. Quadrant III: Determine the net calorific value as a function of absolute gas pressure (P)

4. Quadrant IV: Interim calculation for determining the partial water-vapor pressure as a function of gas temperature and relative dampness. This yields the gas pressure (PF) = absolute pressure (P) - partial pressure of water vapor (PW); PF = P - PW. The expanded calorific value determination with account for the moisture content occurs via quadrant III.

Sample calculation

Given:


Biogas

55 vol. % CH4

Gas temperature

T = 40 °C

Gas dampness

F = 100%

Gas pressure

P = 1030 mbar

Results:



Hu, N

= f (CH4-vol. 70)

Quadrant I


= 5.5 kWh/m³


Hu,T

= f(T)

QuadrantII


= 4.8 kWh/m³


Hu,T,P

= f(T, P)

Quadrant III


= 4.6 kWh/m³


PF

= f(P, T)

Quadrant IV

- f(PW)

Quadrant III



Hu, T, PF = 4.3 kWh/m³



Table 10.3: Partial pressure of water vapor, PW, and absolute humidity, GM, at the saturation point (Source: Recknagel / Sprenger, 1982)

T (°C)

PW (mbar)

GM (g/m³)

.0

6.1

4.9

10

12.3

9.4

20

23.4

17.3

30

42.4

30.4

40

73.7

51.2

50

123.3

83.0

60

199.2

130.2

70

311.6

198.2

80

473.6

293.3

90

701.1

423.5

100

1013.3

597.7

10.3 Conversion tables



Table 10.4: SI units of calculation (selection) (Source: OEKOTOP, compiled from various sources)

Quantity

Symbol

Unit

Conversion

Length

1

m

1 m = 10 dm = 100 cm = 1000 mm

Area

A

1 m³ = 100 dm³ = 10000 cm³

Volume

V

1 m³ = 1000 dm³ = 1 mill. cm³

Mass

M

t; kg

1 t = 1000 kg

Density

D

t/m³

1 t/m³ = 1 kg/dm³

Force, load

F

kN

1 kN= 1000 N ~100 kp

Stress

d

MN/m²

1 MN/m² = 1 N/mm² ~10 kp/cm²

Pressure

p

MN/m²

1 MN/m² = 1 MPa ~10 kp/cm²

Energy

E

kWh

1 kWh = 3.6 · 106 Ws ~3.6 · 105 kpm

Work

W

kNm

1 J = 1 Ws = 1 Nm 1 kNm ~ 100 kpm

Quantity of heat

Q

kWh

1 kWh = 3.6 X 106 Ws; 1 kcal = 4187 Ws

Power

P

kW

1 kW ~100 kpm/s = 1.36 PS

Temperature

t

°C, K

0ºK = -273 °C; 0ºC = 273 °K

Velocity

v

m/s

1 m/s= 3.6 km/in

Acceleration

b

m/s

1 m/s², acceleration due to gravity: 9.81 m/s²

Table 10.5: Conversion of imperial measures (Source: Sasse, 1984)

Length

1 m = 1.094 yrd

1 yrd = 0.914 m


1 cm = 0.0328 ft

1 ft = 30.5 cm


1 cm = 0.394 inch

1 inch = 2.54 cm

Area

1 m² = 10.76 sqft

1 sqft = 0.092 m²


1 cm² = 0.155 sq.in

1 sq.in = 6.452 cm²


1 ha = 2.47 acre

1 acre = 0.405 ha

Volume

1 1 = 0.220 gall.

1 gall. = 4.55 1


1 m³ = 35.32 cbft

1 cbft = 28.31

Mass

1 kg = 2.205 lb

1 lb = 0.454 kg

Pressure

1 MN/m² = 2.05 lb/sqft

1 lb/sqft = 0.488 MN/m²


1 cm Ws = 205 lb/sqft

1 lb/sqft = 70.3 cm Ws

Quantity

1 kcal = 3.969 BTU

1 BTU = 0.252 kcal

of heat

1 kWh = 3413.3 BTU

1000 BTU = 0.293 kcal


1 kcal/kg = 1799 BTU/lb

1 BTU/lb = 0.556 kcal/kg

Power

1 PS = 0.986 HP

1 HP = 1.014 PS


1 kpm/s = 7.24 ft.lb/s

1 ft.lb/s = 0.138 kpm/s


Table 10.6: Conversion factors for work, energy and power (Source: Wendehorst, 1978)
Comparison of work units (work = power X time)


kpm

PSh*

Ws = J

kWh

kcal

1 kpm =

1

3.70 X 10-6

9.807

2.7 X 10-6

2.342 X 10-3

1 PSh*=

270 X 103

1

2.648 X 106

0.7355

632.4

1 Ws = J =

0.102

377.7 X 10-9

1

277.8 X 10-9

239 X 10-6

1 kWh =

367.1 X 103

1.36

3.6 X 106

1

860

1 kcal =

426.9

1.58 X 10-3

4186.8

1.163 X 10-3

1

* PS = 0.986 HP
UNDEFINED PAGEof_v">
Table 10.7: Energy content of various fuels (Source: Kaltwasser, 1980)

Fuel

Calorific value

Unit


MJ

kWh


Plants

16-19

4A- 5.3

kg TS

Cow dung

18-19

5.0 - 5.3

kg TS

Chicken droppings

14-16

3.9- 4.4

kg TS

Diesel, fuel oil, gasoline

41-45

11.4-12.5

kg = 1.1 1

Hard coal (anthracite)

30-33

8.3- 9.2

kg

Wood

14-19

3.9- 5.3

kg

Producer gas

5-7

1.4 - 1.9

Nm³

Pyrolysis gas

18-20

5.0- 5.6

Nm³

City gas

18-20

5.0- 5.6

Nm³

Propane

93

25.8

Nm³

Natural gas

33-38

9.2-10.6

Nm³

Methane

36

10.0

Nm³

Biogas

20-25

5.6- 6.9

Nm³


Table 10.8: Conversion factors for units of pressure (Source: Wendehorst, 1978)


kp/m²

N/m²

pa

cm WG

mbar

at

kp/m²

1

10

10

0.1

0.1

0.0001

N/m²

0.1

1

1

0.01

0.01

10-5

pa

0.1

1

1

0.01

0.01

10-5

cm WG

10

100

100

1

1

0.001

mbar

10

100

100

1

1

0.001

at

104

105

1000

1000

1000

1


Table 10.9: Table of powers and radicals

n

n2

n3

n

n2

n3

n

n2

n3

n

n2

n3

0.60

0.36

0.22

1.10

1.21

1.33

1.60

2.56

4.10

2.10

4.41

9.26

0.65

0.42

0.27

1.15

1.32

1.53

1.65

2.72

4.49

2.15

4.62

9.94

0.70

0.49

0.34

1.20

1.44

1.73

1.70

2.89

4.91

2.20

4.84

10.65

0.75

0.56

0.42

1.25

1.56

1.95

1.75

3.06

5.36

2.25

5.06

11.39

0.80

0.64

0.51

1.30

1.69

2.20

1.80

3.24

5.83

2.30

5.29

12.17

0.85

0.72

0.61

1.35

1.82

2.46

1.85

3.42

6.33

2.35

5.52

12.98

0.90

0.81

0.73

1.40

1.96

2.74

1.90

3.61

6.86

2.40

5.76

13.82

0.95

0.90

0.86

1.45

2.10

3.05

1.95

3.80

7.41

2.45

6.00

14.71

1.00

1.00

1.00

1.50

2.25

3.38

2.00

4.00

8.00

2.50

6.25

15.63

1.05

1.10

1.16

1.55

2.40

3.72

2.05

4.20

8.62

2.55

6.50

16.58

n

n1/3

n

n1/3

n

n1/3

n

n1/3

n

n1/3

n

n1/3

0.001

0.10

0.22

0.60

1.33

1.10

4.10

1.60

9.26

2.10

17.58

2.60

0.003

0.15

0.27

0.65

1.53

1.15

4.49

1.65

9.94

2.15

18.61

2.65

0.008

0.20

0.34

0.70

1.73

1.20

4.91

1.70

10.65

2.20

19.68

2.70

0.016

0.25

0.42

0.75

1.95

1.25

5.36

1.75

11.39

2.25

20.80

2.75

0.027

0.30

0.51

0.80

2.20

1.30

5.83

1.80

12.17

2.30

21.95

2.80

0.043

0.35

0.61

0.85

2.46

1.35

6.33

1.85

12.98

2.35

23.15

2.85

0.064

0.40

0.73

0.90

2.74

1.40

6.86

1.90

13.82

2.40

24.39

2.90

0.091

0.45

0.86

0.95

3.05

1.45

7.41

1.95

14.71

2.45

25.67

2.95

0.125

0.50

1.00

1.00

3.38

1.50

8.00

2.00

15.63

2.50

27.0

3.00

0.166

0.55

1.16

1.05

3.72

1.55

8.62

2.05

16.58

2.55

28.37

3.05



Fig. 10.11: Fundamental geometric formulae (Source: Sasse 1984)

10.4 Charts and tables for use in performing micro-economic

Notes on using the data sheet (table 10.10)

The data survey (data sheet, table 10.10) contains fictive, but nonetheless substantially realistic, data on a family-size biogas plant. Those data are reffered to for explaining and calculating the arithmetic models described in chapter 8. Such data must be ascertained separately for each project site.

Notes on the individual data-sheet items

1. In order to keep the calculations uncomplicated, an unrealistically constant annual rate of inflation is assumed. It is possible to account for different inflation rates in the various analytical procedures. For explanatory details beyond those offered in this guide, please refer to Finck/Oelert, chapter C III.

2. Calculatory interest rate, i: assumed rate of interest for evaluating the cash flows (income and expenditure) generated by a biogas plant during its technical service plant. Proceeding on the assumption that the expenditures are all the more burdensome, the earlier they fall due, while income is all the more valuable, the earlier it is earned, all cash flows occuring in connection with the investment are compounded/discounted at an assumed rate for a fixed point in time. Please refer to chapter 8.4 for the calculation procedure.

3. Investment costs (incl. wages):
- planning
- land aquisition/leasing (as applicable)
- civil works
- building and structures/digester
- modification of animal housing
- gas appliances/aggregates
- slurry spreading implements
- assembly and commissioning
- customs, taxes, duties, fees
- transportation

4. Manpower costs for:
- feeding the plant
- spreading the digested slurry

5. Maintenance and repair:
- spare parts/materials
- wages for maintenance/repair work

6. Energy revenues
- market value of replaced energy
- energy supplied
- production induced with extra energy (market value)

7. Revenues from fertilizer:
- market value of replaced inorganic fertilizer
- revenues from sales of digested slurry
- higher cash-crop yields due to fertilizing with digested slurry

8. Time saved (real financial income only) for additional:
- wage work
- work on the farm (included additional incom)

9. Depreciation (annual for linear depreciation):
= investment costs / n (technical service life)

In this example, the technical service life of the plant is conservatively estimated at only 10 years.

10. Depreciation and capital-servicing costs (interest on loans): neither of these two factors is included as a cost factor in the dynamic models presented in chapter 8, because the cost of investment is equal to the sum of cash values from depreciation and interest (cf. Brandt, 1982, for details). In this example, it is assumed that no external capital is needed, i.e. that the biogas plant is fully financed with internal capital.

Table 10.10: Data sheet for economic analysis (Source OEKOTOP; Finck/Oelert, Table 1)

Project title:

Location:

Owner:

Type of plant/digester volume:

Technical service life:

years












Item Period


0

1

2

3

4

5

6

7

8

9

10

Year


19...

19...

19...

19...

19...

19...

19...

19...

19...

19...

19...

1.1 General inflation rate 1)

%

34

34

34

34

34

34

34

34

34

34

34

1.2 Market interest rate, p

%

48

48

48

48

48

48

48

48

48

48

48

1.3 Assumed interest rate, i 2)

%

10.4

10.4

10.4

10.4

10.4

10.4

10.4

10.4

10.4

10.4

10.4

2. Investment costs, I 3)

CU

1100











3.1 Manpower costs 4)

CU

-

-

-

-

-

-

-

-

-

-


3.2 Maintenance and repair 5)

CU

-

30

30

30

30

30

30

30

30

30

30

spare-parts requirement













4.1 Taxes and levies not linked to profit

CU

-

-

-

-

-

-

-

-

-

-

-

4.2 Other expenditures

CU

-

50

50

50

50

50

50

50

50

50

50

5. Total operating costs,

Co


35

35

35

35

35

35

35

35

35

35

6.1 Energy-related revenues 6)

CU

-

210

210

210

210

210

210

210

210

210

210

6.2 Revenues from fertilizer 7)

CU

-

250

250

250

250

250

250

250

250

250

250

6.3 Time saved 8)

CU

-

-

-

-

-

-

-

-

-

-

-

6.4 Other income

CU

-

-

-

-

-

-

-

-

-

-

-

6.5 Subsidies

CU

-

-

-

-

-

-

-

-

-

-

-

7. Total income

CU

-

235

235

235

235

235

235

235

235

235

235

8. Returns (item 7- item 5)

CU

200

200

200

200

200

200

200

200

200

200

200

9. Depreciation 9)

CU

110

110

110

110

110

110

110

110

110

110

110

10. Capital servicing costs 10)

CU

-

-

-

-

-

-

-

-

-

-

-

11. Profit

CU

-

90

90

90

90

90

90

90

90

90

90

CU = currency unit; in local currency or DM/US $ (conversion to DM/US $ rarely advisable due to fluctuating exchange rates)

Table 10.11: Discounting factors for interest rates of i = 1 -30% and periods of t = 1 - 30 years

ti

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

1

.990

.980

.971

.962

.952

.943

.935

.926

.917

.909

.901

.893

.885

.877

.870

2

.980

.961

.943

.925

.907

.890

.873

.857

.842

.826

.812

.797

.783

.769

.756

3

.971

.942

.915

,889

.864

.840

.816

.794

.772

.751

.731

.712

.693

.675

.658

4

.961

.924

.888

.855

.823

.792

.763

.735

.708

.683

.659

.636

.613

.592

.572

5

.951

.906

.863

.822

.784

.747

.713

.681

.650

.621

.593

.567

.543

.519

.497

6

.942

.888

.837

.790

.746

.705

.666

.630

.596

.564

.535

.507

.480

.456

.432

7

.933

.871

.813

.760

.711

.665

.623

.583

.547

.513

.482

.452

.425

.400

.376

8

.923

.853

.789

.731

.677

.627

.582

.540

.502

.467

.434

.404

.376

.351

.327

9

.914

.837

.766

.703

.645

.592

.544

.500

.460

.424

.391

.361

.333

.308

.284

10

.905

.820

.744

.676

.614

.558

.508

.463

.422

.386

.352

.322

.295

.270

.247

11

.896

.804

.722

.650

.585

.527

.475

.429

.388

.350

.317

.287

.261

.237

.215

12

.887

.788

.701

.625

.557

.497

.444

.397

.356

.319

.286

.257

.231

.208

.187

13

.879

.773

.681

.601

.530

.469

.415

.368

.326

.290

.258

.229

.204

.182

.163

14

.870

.758

.661

.577

.505

.442

.388

.340

.299

.263

.232

.205

.181

.160

.141

15

.861

.743

.642

.555

.481

.417

.362

.315

.275

.239

.209

.183

.160

.140

.123

16

.853

.728

.623

.534

.458

.394

.339

.292

.252

.218

.188

.163

.141

.123

.107

17

.844

.714

.605

.513

.436

.371

.317

.270

.231

.198

.170

.146

.125

.108

.093

18

.836

.700

.587

.494

.416

.350

.296

.250

.212

.180

.153

.130

.111

.095

.081

19

.828

.686

.570

.475

.396

.331

.277

.232

.194

.164

.138

.116

.098

.083

.070

20

.820

.673

.554

.456

.377

.312

.258

.215

.178

.149

.124

.104

.087

.073

.061

21

.811

.660

.538

.439

.359

.294

.242

.199

.164

.135

.112

.093

.077

.064

.053

22

.803

.647

.522

.422

.342

.278

.226

.184

.150

.123

.101

.083

.068

.056

.046

23

.795

.634

.507

.406

.326

.262

.211

.170

.138

.112

.091

.074

.060

.049

.040

24

.788

.622

.492

.390

.310

.247

.197

.158

.126

.102

.082

.066

.053

.043

.035

25

.780

.610

.478

.375

.295

.233

.184

.146

.116

.092

.074

.059

.047

.038

.030

26

.772

.598

.464

.361

.281

.220

.172

.135

.106

.084

.066

.053

.042

.033

.026

27

.764

.586

.450

.347

.268

.207

.161

.125

.098

.076

.060

.047

.037

.029

.023

28

.757

.574

.437

.333

.255

.196

.150

.116

.090

.069

.054

.042

.033

.026

.020

29

.749

.563

.424

.321

.243

.185

.141

.107

.082

.063

.048

.037

.029

.022

.017

30

.742

.552

.412

.308

.231

.174

.131

.099

.075

.057

.044

.033

.026

.020

.015

ti

16

17

18

19

20

21

22

23

24

25

26

27

28

229

30

1

.862

.855

.847

.840

.833

.826

.820

.813

.806

.800

.794

.787

.781

.775

.769

2

.743

.731

.718

.706

.694

.683

.672

.661

.650

.640

.630

.620

.610

.601

.592

3

.641

.624

.609

.593

.579

.564

.551

.537

.524

.512

.500

.488

.477

.466

.455

4

.552

.534

.516

.499

.482

.467

.451

.437

.423

.410

.397

.384

.373

.361

.350

5

.476

.456

.437

.419

.402

.386

.370

.355

.341

.328

.315

.303

.291

.280

.269

6

.410

.390

.370

.352

.335

.319

.303

.289

.275

.262

.250

.238

.227

.217

.207

7

.354

.333

.314

.296

.279

.263

.249

.235

.222

.210

.198

.188

.178

.168

.159

8

.305

.285

.266

.249

.233

.218

.204

.191

.179

.168

.157

.148

.139

.130

.123

9

.263

.243

.225

.209

.194

.180

.167

.155

.144

.134

.125

.116

.108

.101

.094

10

.227

.208

.191

.176

.162

.149

.137

.126

.116

.107

.099

.092

.085

.078

.073

11

.195

.178

.162

.148

.135

.123

.112

.103

.094

.086

.079

.072

.066

.061

.056

12

.168

.152

.137

.124

.112

.102

.092

.083

.076

.069

.062

.057

.052

.047

.043

13

.145

.130

.116

.104

.093

.084

.075

.068

.061

.055

.050

.045

.040

.037

.033

14

.125

.111

.099

.088

.078

.069

.062

.055

.049

.044

.039

.035

.032

.028

.025

15

.108

.095

.084

.074

.065

.057

.051

.045

.040

.035

.031

.028

.025

.022

.020

16

.093

.081

.071

.062

.054

.047

.042

.036

.032

.028

.025

.022

.019

.017

.015

17

.080

.069

.060

.052

.045

.039

.034

.030

.026

.023

.020

.017

.015

.013

.012

18

.069

.059

.051

.044

.038

.032

.028

.024

.021

.018

.016

.014

.012

.010

.009

19

.060

.051

.043

.037

.031

.027

.023

.020

.017

.014

.012

.011

.009

.008

.007

20

.051

.043

.037

.031

.026

.022

.019

.016

.014

.012

.010

.008

.007

.006

.005

21

.044

.037

.031

.026

.022

.018

.015

.013

.011

.009

.008

.007

.006

.005

.004

22

.038

.032

.026

.022

.018

.015

.013

.011

.009

.007

.006

.005

.004

.004

.003

23

.033

.027

.022

.018

.015

.012

.010

.009

.007

.006

.005

.004

.003

.003

.002

24

.028

.023

.019

.015

.013

.010

.008

.007

.006

.005

.004

.003

.003

.002

.002

25

.024

.020

.016

.013

.010

.009

.007

.006

.005

.004

.003

.003

.002

.002

.001

26

.021

.017

.014

.011

.009

.007

.006

.005

.004

.003

.002

.002

.002

.001

.001

27

.018

.014

.011

.009

.007

.006

.005

.004

.003

.002

.002

.002

.001

.001

.001

28

.016

.012

.010

.008

.006

.005

.004

.003

.002

.002

.002

.001

.001

.001

.001

29

.014

.011

.008

.006

.005

.004

.003

.002

.002

.002

.001

.001

.001

.001

.000

30

.012

.009

.007

.005

.004

.003

.003

.002

.002

.001

.001

.001

.001

.000

.000

10.5 List of pertinent suppliers and institutions

Plant engineering, construction and consultancy services in developing countries

AIT Asian Institute of Technology - Division for Energy Technology, P.O. Box 2754, Bangkok 10501, Thailand

AVARD Association of Voluntary Agencies for Rural Development, c/o Safdarjung Development Area, New Delhi, India

BORDA Bremen Overseas Research and Development Association, Bahnhofsplatz 13, 2800 Bremen, Federal Republic of Germany

Biogas projects: BORDA/UNDARP Poona, India

CEMAT Centro Mesamericano de Estudios sobre Tecnologia Apropiada, A.P.1160, Guatemala-City, Guatemala

GATE/GTZ German Appropriate Technology Exchange/Deutsche Gesellschaft fur Technische Zusammenarbeit (GTZ) GmbH, Postfach 5180, 6236 Eschborn, Federal Republic of Germany

GATE/GTZ Biogas Extension Program Projects:
Projecto de Biogas c/o ENPRA, km 11.5 vieja a Leon, A.P.4772 Managua, Nicaragua
Biogas Extension Service c/o CAMARTEC, P.O. Box 764, Arusha, Tanzania Projet Biogaz Cankuzo, D/S 148, Bujumbura, Burundi

CDB/GATE Biogas Team c/o CDB, P.O. Box 407, Wildey St. Michael, Barbados
Proyeto Biogas PAAC-UMMS-GATE, Casilla 4740, Cochabamba Bolivia

Special Energy Program biogas projects (GTZ-Div.34) GTZ Special Energy Program, P.O. Box 41607, Nairobi, Kenya Projet Special de l'Energie, c/o I.V.E., B.P. 5321 Ouagadougou, Burkina Faso

KVIC Khadi and Village Industries Commission, Gobar Gas Scheme, Ivla Rees, Vila Parle, Bombay 400 056, India

Maya Farms Angona, Rizal, Philippines

OEKOTOP Gesellschaft fur Angepaßte Technologien in Entwicklungsgebieten, Bingerstr. 25a, 1000 Berlin 33, Federal Republic of Germany

Biogas projects (by order of GTZ): Projet Biogaz c/o SODEPRA Ferkessedougou, Cote d'Ivoire Proyecto Biogas Colombo-Aleman c/o CVC, Apto. A2366, Cali, Colombia

RED-Latino Americana de Biogas, Emprater, W3 Norte Q515, Brazilia, Brazil

Equipment producers / suppliers

Elster AG, Postfach 129,6500 Mainz, Federal Republic of Germany
Products: gasmeters

Kromschroder AG, Postfach 2809,4500 Osnabruck, Federal Republic of Germany
Products: full range of gas valves

Metallurgica Jackwal Ltd., Rua Braz Cardoso 674, Vila Nova Canceicao, Sao Paulo, Brazil
Products: lamps, burners, reducing valves

OEKOTOP GmbH, Berlin
Product: portable biogas measuring set

Patel Gas Crafters Ltd., Shree Sai Bazar, Mahatma Gandhi Road, Bombay 400 054, India
Products: lamps, burners

Saron Vdyog, Shanghai, PR China
Products: gasmeters, lamps, burners

Service Centre for Development on New Energy, NO. 33 Fugiun Skeet, Shijiazkuang, PR
China
Products: burners, motors

Shanghai Bioenergy, Shanghai, PR China
Products: gasmeters, lamps, burners, motors

T.A. Schiller, Postfach 1224, 2072 Bargteheide, Federal Republic of Germany
Products: lamps, burners, motors

Producers of biogas-fueled engines

Ford AG, Edsel-Ford-Str., 5000 Cologne 71, Federal Republic of Germany
- Type 2274 E, 15-25 kW, 1500 - 3000 min-1, 4-cylinder, water-cooled, spark ignition

Henkelhausen, Postfach 9149, 4150 Krefeld 12, Federal Republic of Germany
- Series GFL 912, 19~0 kW, 1500-2300 min-1, 3-, 4-, 5-, 6-cylinder, air-cooled, spark ignition
- Series GFL 413, 55 - 140 kW, 1500 - 2300 min-1, 5-, 6-, 8-, 10-, 12-cylinder, air-cooled, spark ignition

Kirloska, India, German representative: Schule Co., Postfach 260620, 2000 Hamburg 26,
Federal Republic of Germany
- Series AVG, TVG, CAG, TAG, 5 - 12 kW, 1200 - 2000 min-1, 1-, 2-cylinder, air-cooled or water-cooled, dual-fuel

MWM AG, Carl-Benz-Str., 6800 Mannheim, Federal Republic of Germany
- Series G 227, 18 - 40 kW, 1500 - 2200 min-1, 3-, 4-, 6-cylinder, water-cooled, spark ignition

10.6 Selected literature

Biotechnical fundamentals and plant engineering

Anaerobic Digestion, Proceedings of the Fourth International Symposium on Aerobic Digestion, held in Guangzkou, China on 11 -15 November 1985
Baader et al., Biogas in Theorie and Praxis. KTBL Darmstadt 1980
Biogas Technology Resource Index, Tata Energy Documentation and Information Cenke, Bombay 1985
BORDA, Biogas Workshop on Community Plants - Input Papers, Bremen 1984
Braun, R, Biogas - Methangarung organischer Abfalle, Vienna/New York 1982
Guidebook on Biogas Development, Energy Resources Development Series, ESCAP, Bangkok 1980
Hohlfeld, J. et al., Production and Utilization of Biogas in Rural Areas of Industrialized and Developing countries, GTZ Eschborn 1986
Eggeling, G. et al., Biogas Manual for the Realisation of Biogas Programmes, BORDA, Bremen 1980
Biogasanlagen in Europa, Neue Energien, Resultate der Energieforschung der Europaischen Gemeinschaft, TUV Rheinland, Cologne 1985
Sasse, L., The Biogas Plant, GTZ/GATE, Eschborn 1984
Wellinger et al., Biogas-Handbuch, Grundlagen, Planung, Betrieb landwrrtschaftlicher Anlagen, Aarau 1984

Agriculture

Comberg, G. (Ed.), Tierzuchtungslehre, Stuttga~t 1980
Demant, D., GATE/GTZ, Arbeitspapier zur einheitlichen Versuchsmethodik fur Faulachlammdungeversuche Eschborn 1987
Memento de l'agronome, Republique Francaise, Ministere de la Cooperation, 1984
Rehm/Espig, Die Kulturpflanzen der Tropen und Subtropen, Stuttgart 1976
Williamson, G./Payne, W.J.A., An Introduction to Animal Husbandry in the Tropics, London/New York 1977

Economic aspects and dissemination/diffusion

Brandt, H., Projektplanung in der kleinbauerlichen Produktion, Berlin 1982
Finck, H./Oelert, G., A Guide to the Financial Evaluation of Investment Projects in Energy Supply, GTZ Eschborn 1982
Oelert et al., Economic Issues of Renewable Energy Systems - A Guide to Project Planning, Eschborn 1985

10.7 Lists and indexes



10.7.1 Illustrations

Fig. 1.1: A typical biogas-system configuration
Fig. 2.1: Biogasplanningmodules
Fig. 3.1: Global 15 °C isotherms for January and July, indicating the biogas-conducive temperature zone
Fig. 3.2: Integration of a biogas plant into the agricultural production cycle
Fig. 3.3: Pen with concrete floor and collecting channel for dung and urine
Fig. 3.4: Stanchion barn with floating gutter
Fig. 3.5: Cow-cubicle barn with floating gutter
Fig. 3.6: Piggery with group bays (no litter)
Fig. 3.7: Slurry storage and composting
Fig. 3.8: Flow diagram for integral farming with a biogas plant
Fig. 3.9: Site plan of the Bouake Ecofarm in Cote d'Ivoire
Fig. 4.1: Balancing the-energy demand with the biogas production
Fig. 5.1: Three-stage anaerobic fermentation
Fig. 5.2: Gas yield as a function of temperature and retention time (fT,RT-curves)
Fig. 5.3: The batch-feed principle vs the continuous-feed principle
Fig. 5.4: The fermentation channel vs the complete-mixed digester
Fig. 5.5: Slurry flow for various configurations of feed, discharge and stirring
Fig. 5.6: Floating-drum plant with internal guide frame
Fig. 5.7: Water-jacket plant with external guide frame
Fig. 5.8: Cylindrical plant design for quarrystone masonry construction
Fig. 5.9: Basic function of a fixed-dome biogas plant
Fig. 5.10: Fixed-dome plant with cenkal entry hatch
Fig. 5.11: Fixed-dome plant with suspended dome
Fig. 5.12: Horizontal balloon-type biogas plant
Fig. 5.13: Earth-pit plant with plastic-sheet gasholder
Fig. 5.14: Ferrocement biogas plant
Fig. 5.15: Horizontal biogas plant (KVIC shallow design)
Fig. 5.16: Mixing pit
Fig. 5.17: Mixing pit, gutter and toilet drain pipe
Fig. 5.18: Inlet and outlet for fixed-dome and floating-drum plants
Fig. 5.19: Forces acting on a spherical-dome digester
Fig. 5.20: Level line, excavation and foundation
Fig. 5.21: Construction of a spherical dome from masonry
Fig. 5.22: Construction of a metal gasholder with internal guide frame
Fig. 5.23: Construction of a fixed-dome gasholder
Fig. 5.24: Entry hatch of a fixed-dome biogas plant
Fig. 5.25: Sealing the masonry with paraffin
Fig. 5.26: Separate, mobile, plastic-sheet gasholder
Fig. 5.27: Gas pipe, valves and fittings of a biogas plant
Fig. 5.28: Gas valves and fittings: U-tube pressure gauge, water trap with drain valve, U-tube water separator, "gravel pot" flashback arrestor
Fig. 5.29: Ferric-hydrate gas purifier
Fig. 5.30: Schematic drawing of a biogas burner and its parts
Fig. 5.31: Various types of biogas burners
Fig. 5.32: Schematic drawing of a biogas lamp
Fig. 5.33: Schematic drawing of a radiant heater
Fig. 5.34: Schematic drawing of an incubator
Fig. 5.35: Various gas mixers for spark-ignition and diesel engines
Fig. 5.36: Consumption of diesel and biogas by a 10-kW engine
Fig. 5.37: Energy shares of an internal-combustion engine
Fig. 5.38: Measuringinstruments for biogas field tests
Fig. 6.1: Basic principle of organic wastewater treatment
Fig. 6.2: Biogas plant in Ferkessedougou - system OEKOTOP
Fig. 7.1: Water-seal testing of a digester
Fig. 7.2: Seal testing (water and gas) of a fixed-dome plant
Fig. 7.3: Gas-seal testing of a metal-gasholder
Fig. 7.4: Pressure testing a gas pipe
Fig. 8.1: Basic elements of an economic analysis
Fig. 8.2: Costs and benefits of a fixed-dome biogas plant
Fig. 10.1: Conceptual drawing of a floating-drum biogas plant
Fig. 10.2: Constructional drawing of a floating-drum plant
Fig. 10.3: Constructional drawing of a waterjacket plant
Fig. 10.4: Constructional drawing of a cylindrical floating-drum plant for quarrystone masonry
Fig. 10.5: Conceptual drawing of a fixed-dome biogas plant
Fig. 10.6: Constructional drawing of a fixed-dome plant
Fig. 10.7: Constructional drawing of an earth-pit biogas plant with plastic-sheet gasholder
Fig. 10.8: Schematic diagram of earth-pressure and water-pressure forces
Fig. 10.9: Nomogram for correcting gas pressures/temperatures
Fig. 10.10: Nomogram for finding the net calorific value of biogas as a function oftemperature pressure and moisture content
Fig. 10.11: Fundamental geometric formulae

10.7.2 Tables

Tab. 2.1: Detailed planning guide for biogas plants
Tab. 3.1: Climate zones and their suitability for biogas plants
Tab. 3.2: Standard liveweight values of animal husbandry and average manure yields (dung + urine) as percentages of liveweight
Tab. 3.3: TS- and VS-contents of green plants
Tab. 3.4: Digestion characteristics of animal-husbandry residues
Tab. 3.5: Mean gas yields from various types of agricultural biomass
Tab. 3.6: C/N-ratios of various substrates
Tab. 3.7: Biogas compatibility of farm types
Tab. 3.8: Survival time of pathogens in biogas plants
Tab. 3.9: Concentration of nutrients in the digested slurry of various substrates
Tab. 3.10: Effects of digested slurry on crop yields
Tab. 4.1: Outline for determining biogas demand
Tab. 4.2: Outline for determining biomass incidence
Tab. 4.3: Simplified gas-yield values for substrate from cattle and pigs
Tab. 5.1: Basic criteria for acetobacters (acid forming bacteria) and methanobacters (methaneforming bacteria)
Tab. 5.2: Energy potential of organic compounds
Tab. 5.3: Energetical comparison of aerobic and anaerobic fermentation
Tab. 5.4: Temperature ranges for anaerobic fermentation
Tab. 5.5: pH ranges for biomethanation
Tab. 5.6: Substances with an inhibiting effect on biomethanation
Tab. 5.7: Comparison of various plant designs
Tab. 5.8: Common substrate mixing ratios
Tab. 5.9: Mortar mixing ratios
Tab. 5.10: Suitability tests for rendering/mortar sands
Tab. 5.11: Quality ratings for various dome-sealing materials
Tab. 5.12: Properties of plastic sheeting - gasholder suitability ratings
Tab. 5.13: Gas-pipe pressure losses
Tab. 5.14: Composition and properties of biogas and its constituents under s.t.p. conditions (0 °C, 1013 mbar)
Tab. 5.15: Pointers on flame adjustment
Tab. 5.16: Comparison of various internationally marketed biogas burners
Tab. 5.17: Biogas consumption for cooking
Tab. 5.18: Tests for biogas cookers/stoves
Tab. 5.19: Standard lighting terms and units of measure
Tab. 5.20: Comparison of various biogas lamps
Tab. 5.21: Artificial brooding requirements, exemplified for a chick incubator
Tab. 5.22: Technical data of absorption refrigerators
Tab. 5.23: Engine-conversion requirements for various duty and control modes
Tab. 6.1: Some examples of biogas production from agro-industrial residues and wastewater
Tab. 6.2: Technical data of the Ferkessedougou biogas plant
Tab. 6.3: Slaughterhouse waste quantities
Tab. 7.1: Checklist for the inspection and acceptance of biogas plants
Tab. 7.2: Checklist for the daily operation and regular maintenance of biogas plants
Tab. 7.3: Checklist for troubleshooting in case of insufficient gas production
Tab. 7.4: Simple-plant malfunctions and remedial measures
Tab. 7.5: Potential repair situations for simple biogas plants
Tab. 8.1: Comparison of working time with and without biogas utilization
Tab. 8.2: Investment-cost comparison for various biogas plants
Tab. 8.3: Schedule of data for calculating the plant payback period
Tab. 8.4: Schedule of data for net-present-value calculation
Tab. 8.5: Socioeconomic benefits and drawbacks of biogas production and utilization
Tab. 9.1: Biogas dissemination strategies
Tab. 9.2: Innovation cycle of biogas dissemination
Tab. 9.3: Catalogue of attributes for partners in biogas dissemination projects
Tab. 9.4: Institutional breakdown of biogas-dissemination tasks and activities
Tab. 9.5: Target-group-oriented biogas training measures
Tab. 10.1: Calculating parameters for fixed-dome biogas plants
Tab. 10.2: Atmospheric pressure as a function of elevation
Tab. 10.3: Partial pressure of water vapor and absolute humidity at the saturation point
Tab. 10.4: SI units of calculation (selection)
Tab. 10.5: Conversion of imperial measures
Tab. 10.6: Conversion factors for work, energy and power
Tab. 10.7: Energy content of various fuels
Tab. 10.8: Conversion factors for units of pressure
Tab. 10.9: Table of powers and radicals
Tab. 10.10: Data sheet for economic analysis
Tab. 10.11 : Discounting factors for interest rates of i = 1 - 30% and periods of t = 1- 30 years

10.7.3 Abbreviations

A

area

a

inflation rate

a

year (per annum)

at

atmosphere

B

biomass

B.D.C.

bottom dead center

BEP

GATE/GTZ Biogas Extension Program

BOD

biochemical oxygen demand

C

carbon

C

circumference

CaO

calcium oxide

cd

candela (candle power)

ce

coefficient of earth pressure

cf

coefficient of friction

CH4

methane

cmWG

cm water gage

C/N

carbon/nitrogen ratio

CO2

carbon dioxide

COD

chemical oxygen demand

cp

coefficient of pipe friction

cP

heat capacity

CS

crankshaft

Cs

storage capacity

D

density of biogas

D

energy demand

D, d

pipe diameters

d

day

d

stoichiometric air ratio

DN

density of biogas under normal (s.t.p.) conditions

dp

pressure drop

Dr

digestion rate

E

illuminance

E

compression ratio

E

energy

Ee

energy input

Es

specific illuminance

F

luminous flux

F

relative dampness of biogas

Fe(OH)3

ferric hydrate

FL

friction losses

G

gas production

gc, max

max. gas consumption per hour

GM

moisture content of gas

Gp

specific gas production

GRP

glass-reinforced plastic

Gy

gas yield

H, h

height

H2

hydrogen

he

height of earth column

hp

horsepower

hph

horsepower-hour

H2S

hydrogen sulfide

I

luminous intensity

i

discounting factors/calculatory (assumed) interest rate

Io

initial investment

J

joule

K

potassium

KA

average capital invested (per time interval)

kcal

kilocalorie

K2O

potassium oxide

kWh

kilowatt hour

L

latent heat of evaporation

I

length of pipe

Ld

digester loading

lrn

lumen

mbar

millibar

MgO

magnesium oxide (magnesia)

mWG

meter water gage

N

nitrogen

N

burner efficiency

N

Newton

n.c.v.

net calorific value (in diagrams: n.c.v. = Hu)

NP

net profit

P

pressure/gas pressure

P

phosphorus

p

market rate of interest

p

biogas/energy production

pa

Pascal

PE

polyethylene

pE

active earth pressure

PN

normal pressure

P2O5

phosphorus pentoxide

PVC

polyvinyl chloride

PW

partial pressure of water vapor

pw

hydrostatic pressure

Q

gas flow

QW

quantity of heated water

R, r

radius

Re

luminous efficiency

ROI

return on investment (profitability)

RT

retention time

Sd

daily substrate input

T, t

temperature

tc, max

maximum consumption time

T,D.C.

top dead center

tz, max

maximum period of zero consumption

TN

temperature under normal (s.t.p.) conditions

TS

total solids content

V

volume

v

velocity/speed

vc

maximum gas consumption

Vd

digester volume

Vg

gasholder volume

Vh

compression volume

VN

volume of biogas under normal (s.t.p.) conditions

Vn

swept volume

VS

volatile solids content

Vtot

total volume of a cylinder

W

water

W

watt

Wd

daily water input

wE

weight of dry earth

Wl

water loss (leak testing)

wW

weight of water

Ztot

sum total of friction losses

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