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TECHNICAL REPORT ON

PRODUCTION OF BIOGAS USING


WHEAT BRAN AND CAMEL DUNG

TEAM MEMBERS:
Ms. ARLENE ABUDA JOAQUIN
Dr. SIVAMANI SELVARAJU
Ms. ZAHRAH ABDULLAH KHALFAN AL-SHARJI
Ms. KHAIR ABDULHAKEEM MUSALLEM AL-RAWAS
Mr. MOHAMMED ABDULLAH ALI BAHJAJ
SUPPORTING AGENCIES:
SALALAH COLLEGE OF TECHNOLOGY
SALALAH MILLS CO. (SAOG)
SALALAH METHANOL COMPANY
ABSTRACT

Fossil fuel is a source of non-renewable energy that contributes to environmental


pollution. Carbon-di-oxide is the main product of fossil fuel which causes an enormous
damage to the ozone layer. However the numerous problems caused by fossil fuels make
researchers to think of solution to help saving our planet. Renewable energy can be a
perfect solution since they don't leave a huge impact on the environment and energy
security. Biogas is a source of renewable energy that is cheap to produce and an excellent
substitute for synthetic natural gas. In this project, wheat bran is the focus of attention for
biogas production because it contains significant amount of biological macromolecules.
This project focused on determination of C/N, COD/BOD and VSS/TSS ratios of bran,
yield of biogas at laboratory scale, quantity and calorific value of sludge using material
and energy balances, size of reactor for biogas production, total capital investment and
annual gross profit. Four different samples of wheat bran were collected from Salalah
Mills Co. (SAOG), and PCWB was found to be the best substrate because it produced
more biogas on laboratory scale. So, C/N ratio, BOD/COD ratio and VSS/TSS ratio
respectively are 18.94, 0.372, and 0.57. Biogas was yielded at 0.12 mL biogas/mL
wastewater. Material balance reveals the TBMP value of 0.3726 ml CH4/g VS, biogas
production of 0.10 ton per ton of bran on an industrial scale. From energy balance,
calorific value of sludge is 18552.982 kJ/kg. Design of anaerobic digester proved 644.43
m3/d of methane production, which can produce 1353.3 kWh of electricity. Cost analysis
shows that total capital investment required is 2130569.54 OMR and annual gross profit
4181681.42 OMR. The results reveal that this project could be feasible for Raysut
industrial area for commercialization and development of Oman economy.
Keywords: Anaerobic digestion, Biogas, Wastewater, Wheat bran
1. (a) IMAGES AND SUPPORTING DRAWINGS OF THE MODEL

Figure 1 Photographic image of anaerobic digester

Figure 2 Drawing of anaerobic digester


(b) THE PLAN IN WHICH THE MODEL WAS IMPLEMENTED
Literatures were collected on substrates and inoculum used to produce biogas,
production process, plant design and economic evaluation. Limited scientific
documents are available on biogas production from wheat bran and camel dung.
So, Salalah Mills Co. (SAOG) was approached with the project proposal. After
approval from company, the research was proceeded on biogas production from
wheat bran and camel dung. The research was planned and implemented with the
following objectives:
To collect wheat bran samples from Salalah Mills Co. (SAOG)
To analyse wheat bran for total solids (TS), total suspended solids (TSS), total
dissolved solids (TDS), volatile suspended solids (VSS), chemical oxygen
demand (COD), biochemical oxygen demand (BOD), dissolved oxygen (DO),
ash, sugars, starch, lipids, proteins and pH.
To execute material and energy balances for commercial biogas plant
To perform site selection and layout for industrial biogas production
To design anaerobic digester for large scale biogas plant
To estimate total capital investment and annual gross profit for implementation
of biogas plant in Raysut special economic zone (SEZ), Salalah
The research was implemented step by step in 7 months and successfully
completed with economic feasibility report.
(c) THE ESTIMATED FINANCIAL COSTS
Total capital investment Annual gross profit
Item Cost (OMR) Item Cost (OMR)
Cost of equipment 437488.75 Product sales 4867377
Purchased equipment- 437488.75 Raw materials cost
52330
deliver cost
Purchased equipment- 170620.61 Annual labor cost
109500
installation
Instrumentation and 56873.53 Operating supervision cost
16425
controls cost
Piping cost 135621.51 Maintains and repair cost 108409.67
Electrical cost 43748.875 Operating supplies cost 16261.45
Buildings cost 126871.73 Laboratory changes cost 16425
Yard improvements cost 43748.875 Variable cost 319351.12
Service facilities cost 240618.81 Property tax and insurance 54204.82
Land cost 26249.32 Fixed charges 54204.82
Total direct Plant cost 1281841.38 Plant overhead cost 140600.8
Engineering and 139996.4 Total manufacturing cost
514156.74
supervision cost
Construction expenses 148746.17 Administrative expenses 46866.93
Contractors fee 78747.97 Production cost 623359.63
Contingency 157495.95 Distribution and selling 31167.98
Total indirect cost 524986.49 Research and development 24934.38
Fixed-Capital investment 1806827.87 Royalties 6233.5963
Working-Capital cost 323741.67 Annual total production
685695.58
cost
Total Capital investment 2130569.54 Annual gross profit 4181681.42
(Detailed cost estimation in Annexure I)
(d) CLARIFICATION OF SOME OF THE DIFFICULTIES FACED BY
THE TEAM AND THE METHOD OF SOLUTION.

Difficulties faced Method of solution


Initially, there was problem in setting up The difficulty overcame by referring
laboratory scale high throughput biogas literatures.
digester.

2. PLAN TO DEVELOP THE MODEL AND CONVERT IT TO THE FINAL


PRODUCT
SCHEDULE: January to July 2017
PRACTICAL SKILLS: Biogas production
Analytical methods on characterization
Material and energy balances
Site selection and layout
Design calculations
Economic analysis
COMPUTER PROGRAMS: Not applicable
MATERIALS: Wheat bran
Camel dung
Process water
HARDWARE: Armfield Anaerobic digester setup
3. (a) THE FINAL COST OF THE FINAL PRODUCT
Cost of electricity = kwh of electricity produced no. of days work OMR
= 1353.3 kwh 300 d 5 BS /1000
=2029950 OMR
Cost of CO2 = total CO2 produce no .of days work ORM
m3 d OMR
= 322 300 1.8
d y m3
= 173880 OMR
Cost of sludge = total sludge produce no. of days work OMR
kg OMR
= 8878.49 300 d 1
day kg
= 2663547 OMR
Total product sales = 4867377 OMR

(b) ECONOMIC FEASIBILITY


Economic analysis shows that the biogas plant earns annual gross profit of 4181681.42
OMR. Hence, the proposal is economically feasible.

(c) MARKETING PLAN


Biogas produced with support from Salalah Mills Co. (SAOG) can be used by Salalah
Methanol Company for the production of methanol.

(d) COMPETITIVENESS WITH OTHER PRODUCTS IN THE MARKET


Since biogas plant is not yet implemented in Sultanate of Oman, the product will be
competitive with other products in the market.

(e) WHAT ARE EXPECTED TO SUPPORT


Gas chromatography in Salalah Methanol Company was used to analyse the quality of
biogas. If the facility is supported in Salalah College of Technology, it would be
convenient for future research.

(f) CONTRIBUTE TO THE DEVELOPMENT OF THE PRODUCT, IF


ANY: Not applicable
CONCLUSION

Biogas is a source of renewable energy that is cheap to produce and excellent substitute
for natural gas.
The selection site must be suitable for the construction, design, transport, guarantee
plant safety etc. The site layout we have compiled includes feeding tank, phase
digester 1 and phase digester 2 and premises for generators etc.
Design of anaerobic digester we find is theoretically, 644.43 m3/d of methane, which
can produce 1353.3 kWh of electricity.
Total capital investment 2130569.54 OMR and annual gross profit 4181681.42 OMR.
This build calculation for large scale plant which do it to have knowledge about how
and when and the result from start this project as plant (Tables 4.6 and 4.7).
ANNEXURE I

CALCULATION OF INVESTMENT AND PROFIT FOR BIOGAS PLANT


A cost estimate is the approximation of the cost of a program, project, or operation. The
cost estimate is the product of the cost estimating process
Equipment cost C= FMexp( 11.662 0.6104 (ln ) + 0.04536( )2
C= 2.75 exp( 11.662 0.6104 (ln 1408978) + 0.04536(1408978)2
C= 2.75 exp (12.122)
C= 505650.45$
C=197203.67 OMR
The regression equation relating cost index and year is
Cost index = 12.554 x Year - 24600
= 12.554 (2017) 24600 = 721
Direct plant costs

Present cost =

721
Present cost = 197203.67
325

= 437488.75 OMR
Purchased equipment installation =437488.75 OMR
39
Instrumentation and controls (installation) = 437488.75
100

= 170620.61 OMR
13
Instrumentation and controls (installation) = 437488.75
100

= 56873.53 OMR
31
Piping (installation) = 437488.75
100
= 135621.51
10
Electricity (installation) = 437488.75
100

= 43748.875
29
Buildings (including services) = 437488.75
100

= 126871.73
10
Yard improvements = 437488.75
100

= 43748.875
55
Service facilities (installed) = 437488.75
100

= 240618.81
6
Land = 437488.75
100

= 26249.32
Total direct plant costs = 1281841.38 OMR

Indirect plant costs


32
Engineering and supervision= 437488.75
100

= 139996.4
34
Construction expenses= 437488.75
100

= 148746.17
18
Contractors free(about 5% of D and ID cost) = 437488.75
100

= 78747.97 0
36
Contingency (about 10% of D and ID cost) = 437488.75
100

= 157495.95
Total indirect plant cost = 524986.49 OMR
Fixed capital investment = 1281841.38 OMR +524986.49 OMR
= 1806827.87 OMR
Working capital investment = 74% 437488.75 OMR
= 323741.67
Total capital investment=1806827.87 OMR + 323741.67
= 2130569.54

Total product sales


Cost of electricity = kwh of electricity produce no. of days work OMR
= 1353.3 kwh 300 d 5 BS /1000
=2029950 OMR
Cost of CO2 = total CO2 produce no .of days work ORM
m3 d OMR
= 322 300 1.8
d y m3
= 173880 OMR
Cost of sludge = total sludge produce no. of days work OMR
kg OMR
= 8878.49 300 d 1
day kg
= 2663547 OMR

Annual operating labor cost


persons shift day
Annual operating labor cost = 2 3 365
shift day year

= 109500 OMR
Operating supervision cost = 15% of annual operating labor cost
15
= 109500
100
= 16425 OMR
Maintains and repair cost = 6% of fixed capital investment
6
= 1806827.87
100
= 108409.67 OMR
Operating supplies cost = 15% of maintains and repair cost
15
= 108409.67
100
= 16261.45 OMR
Laboratory changes cost = 15% of annual operating labor cost
15
= 109500
100
= 16425 OMR
Total raw material cost
days Bz
Wheat bran cost= production of wheat bran 300 0.0833
year kg

kg days OMR
= 333333.3 300 8.33 105
day year kg
= 8329.9 OMR
days Bz
Water cost = production of water 300 440
year m3

L days OMR
= 333333.3 300 0.44
day year m3
m3 days OMR
= 333.3333 300 0.44
day year m3
=43999.9 OMR
Camel dung = 0
Variable cost = total raw material cost + annual operating labor cost + operating
supervision cost + maintains and repair cost + operating supplies cost + laboratory
changes cost
o Variable cost= 52329.8 + 109500 + 16425 + 108409.87 + 16261.45 + 16425
= 319351.12 OMR

Property tax =2% of fixed capital investment


2
= 1806827.87
100
= 36136.55 OMR
Insurance = 1% of fixed capital investment
1
= 1806827.87
100
= 18068.27 OMR
Fixed changes = property tax + insurance
= 36136.55 + 18068.27
= 54204.82 OMR
Plant overhead cost = 60 % of (annual operating labor cost+ operating supervision cost
+ maintenance and repair cost )
60
Plant overhead cost = ( 109500 + 16425 + 108409.67)
100

= 140600.8 OMR
Total manufacturing cost = variable cost + fixed changes + plant overhead cost
= (319351.12 + 54204.82 + 140600.8)
= 514156.74 OMR
plant over head cost
Administrative expenses =
3

140600.8
=
3
= 46866.93 OMR
total manufacturing + administrative expenses
Production cost =
0.9

514156.74 + 46866.93
=
0.9
= 623359.63 OMR
Distribution and selling = 5% of production cost
5
= 623359.63
100
= 31167.98 OMR
Research and development = 4% of production cost
4
= 623359.63
100
= 24934.38 OMR

Royalties = 1% of production cost


1
= 623359.63
100
= 6233.5963 OMR
Annual total production cost = production cost + Distribution and selling + Research
and development + Royalties
Annual total production cost= 623359.63 + 31167.98 + 24934.38 + 6233.5963
= 685695.58 OMR
Annual gross profit = total product sales annual total production cost
= 4867377 685695.58 = 4181681.42 OMR
DESIGN OF ANAEROBIC DIGESTER FOR BIOGAS PRODUCTION
Production of wheat bran (PCWB) from Salalah Mills company per day =
kg
100000 = 3333333.33
day

Volume of water required to prepare (PCWB) based waste water = 100000 =

kg L
3333333.33 = 3333333.33
day day
kg
Average flow rate wastewater into anaerobic digester = 666666.66
day

Digester BOD removal efficiency =75%


Yield coefficient Yx/s = 0.1 (constant)
Yx
NVSS produced in BOD removed= BOD
s

= 0.1 1570 0.75


= 117.75
Non-biodegradable residue = (1 0.4)
= 12000 0.6
= 7200
Non-biodegradable residue of VSS coming with effluent is assumed for 40%
degradable and 60% residue
Ash in influent = TSS VSS
= 18000 12000
= 6000
Total sludge produced = ( + +
)

= (7200 + 6000 + 117.75 ) 666666.66 / = 8878.49


Area of anaerobic digester =

666666.66 /
=
1 (24)

= 27.7 m2
Volume of reactor = average flow rate hydraulic retention

= 666666.66 8

= 5333.3 m3
COD loading rate = COD in wastewater Average flow rate

= 4218.18 666666.66


= 2812.12


Volumetric loading rate =

2812.12 /
=
5333.3 3
= 0.53 kg COD /m3

Average concentration of sludge in the blanket =

887.49 /
=
666666.66 /

= 0.013


COD removal efficiency () = 100

4218.18 900
=
4218.18
= 78.6%
Total COD removed = COD removal efficiency COD in influent average flow rate

= 0.786 4218.18 666666.66


= 2210.3

COD available for methane gas production = Total COD removal

Theoretically methane gas production = 300

Methane gas production rate = methane gas produce total COD removed
= 300/ 2210.3/
3
= 663.09
day
0.028 3
Methane gas loss = 3

3
= (666666.66 ) /1000 0.028

3
= 18.66
day
Methane gas produce by digester = methane gas production rate Total methane gas
loss

3
3
= 663.09 18.66
day
3
= 644.43
day
Theoretically, 1m3 of biogas contains 2/3 m3 of methane which can produce 1.4 kWh
of electricity (constant)
2
So kWh 0f electricity = 1.4 644.43 /( )
3

= 1353.3 kWh electricity


volume of reactor
Height of reactor =
area of reactor
5333.3 m3
=
13.8 m2
= 386.47
4
(Diameter) 2=

4 5333.3 3
=
3.14 386.47
2
Diameter= 17.5
= 4.2 m

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