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Village: BHITBUDRAK

Taluka: UCHHAL
District: SURAT
State: GUJARAT
Country: INDIA
Bhint Jilla/Taluka
Budrak Panchayat
Village Surat
PresentlymostoftheBiogasplantsinstalledtraditionallyareeither
defunctorworkingunsatisfactorilyandinefficiently.

Thestudiesrevealfollowingreasonsfortheabovestatus:

1. TheDigesterloadingssuchascattledungandwaterare
notthoroughlymixedwhichresultsintoeithernongenerationofgasor
lesserquantitygasproduction.

2. Duetothequalityandpressureofthegasproducedisbeing
insufficient,itcannotbetransportedtofarofhouseswithrequired
pressure.
Theaboveconstraintsanddefectswererectifiedandcorrected
byGramVikasTrust.
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 of
the 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.
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 maximum
content 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.
(1)LoadingPlatform

TheGobarBank
membersbringthedung
everydaytothe
communitybiogasplant
whichisweighedand
accountedforintheir
passbooks.
(2)SlurryPreparation
Thecattledungtakenfrom
dungloadingplatformarea
isdeliveredtofeed
preparationtanksection.
Thefeddungismixedwith
waterformaintainingratio
of1:1forfreshcattledung
and1:1.25forstale(hard)
cattledung.
Themixtureisthen
mechanicallymixedtohave
homogeneousslurry.
(3)AnaerobicDigestion

Anaerobicdigestiontank
(biogasdigester)createsan
anaerobicconditionto
generatemethanegasby
methanogenicbacteria.
Thedigesteremployedhere
ismostlyKVICmodelwith
floatingdome&water
jacket.
Thewaterjackethelpsin
curbingthemethane
leakageandwastage.
(4)CommonCollectingTank

Anintermediategas
storagebeforePressure
regulatingtankfor
distributiontoconcerned
beneficiaries.
(5)PressureRegulatingTank

Gasiscompressedby
blowerandfedtothe
pressureregulatingtank
wheregasisupgraded
duetothepassageof
pressure
EARLIER

ENVIRONMENTALNUISANCE SMOKEFROMWOODBURNING
NOW

Anhappyvillagerwithherbiogasconnectionandequipment
TheSlurrybeingtransportedtocompostingpits.
TheCompost.
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.
Vermi- Compost Unit
Entrepreneurship Models on Biogas for Rural Areas
Large Scale/ Community level Biogas Enterprises for
Cooking needs- Pipeline supply and Rural 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/family
per day)
Pipeline lengthup to 1km. distance
Pipe qualityHDPE, pressurize system0.3 kg./cm2(Rs. 2.5
lacs cost)
Gas charge150/monthfamily
II. Raw materialCow dung+ Toilet (community-20
toilets 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
Quality of slurry should be maintained
Cost
PlantCost Rs4,50,000/
PipeLineCost Rs1,50,000
Appliances50*400 Rs20,000
PressurizingSystem Rs2,00,000
Manpower(Mechanic 5000,Helper3000) 96,000
Income
Gas 150*50 Rs7500/month=Rs90,000/yr
Slurry Rs1500/day=Rs5,00,000/yr
CDMBenefits Rs71,000/yr
Costestimates
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 5,90,0003,88,000=
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.
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.
Cost

A. Nonrecurring
PlantCost Rs4,50,000
Electricitydistributioncost Rs2,00,000/
GensetCost 15kW Rs1,00,000
GensetRoomCost Rs1,00,000
Sum Rs8,50,000
B.Recurring
Manpower(mechanic 5000,helper 3000) Rs90,000
RawMaterial 1,62,000
Miscellaneous 50,000
Depreciation 85,000
Sum=3,87,000
Costestimates
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.7,84,0003,87,000=Rs.3,97,000($9925)
Cylindering of methane available from biogas plant for
tractors and rural vehicles and production of bio manure

Feasibilityanalysisforacommunitybiogasplantof300M3 perdaycapacitywithbiogas
enrichmentandbottlingplanthasbeenshownbelow.

Dungrequirement
For300cum.BiogasPlant=6000Kgs.
AssumingcostofDung=0.20Rs/kg.
CostofDungforBiogasplant=1200Rs.perday.
CAPITALCOST
1. BioGasPlant(Digester) ProvidedbyBuyer(@Rs.
3000/ percubicmetercapacity,for300cubicmetercapacityRs.900000/)
2. CostofScrubbingunit Rs.6,00,000.00
3. CostofCompressor Rs.6,00,000.00
4. C.N.G.cylinders Rs.2,00,000.00
5. Storagetank Rs.1,00,000.00
6. InstallationExp. Rs.2,00,000.00
Total Rs. 17,00,000.00
OPERATIONCOST
A. Fixedoperationalcost
1. Interestoncapital@10%perannum=0.1x14,00,000=Rs.1,40,000per
annum
2. Depreciation@5%perannum=0.05x42,50,000=Rs.70,000per
annum.
Totalcost=2,10,000 perannum

B. AnnualRunning(Operational)Cost:
1. Dungcost1200x350=Rs.4,20,000P.A.
2. LaborsCost(1skilledand2unskilledlabors)300x350=Rs.1,05,000P.A.
3. Electricitycost(10kWhx12hr)360x350@3/ unit=Rs.1,26,000P.A.
4. RepairandMaintenance@2%capitalcoston14,00000=Rs.28,000
P.A.

Totalcost=6,79,000 perannum

SumofFixedOperationcostandannualrunningcost:
=6,79,000+2,10,000=8,89,000.00
Cylindering of methane available from biogas plant for
tractors and rural vehicles and production of bio manure

Biogasplantof300M3 perdaycapacitywithenrichmentandbottling
CAPITAL COST Rs. 28,00,000.00 ($ 70,000)
OPERATION COST
A. Fixed operational cost3,00,000 per annum ($ 7500)
B. Annual Running (Operational) Cost: 12,00,000 per annum
Total cost of Operation = Rs. 15,00,000 / ($ 37,500)
Income:
income generate by selling CBG and slurry = Rs. 22,00,000/ ($ 55,000)
Profit = Rs. 7,00,000/ ($ 17,500)
Payback Period = 4 years