Biomass based Biogas Plant

Construction details by RASTA

Kambalakkad Po, Wayanad Dist

Kerala- 673 121

Danesh Kumar

daneshkumar2@gmail.com

Lay out of Biogas Plant

After marking the layout for

the Bio rector, soil is

removed

Proper allowance is given for

the brickwork, so that back of

the laid bricks can be cleaned

of laid mortar

Laying of foundation of 40mm

of 10 cms thick, a

Cement Concrete using

20 mm in 1:2:4 mix for

7 Cms thick is applied on

top of this, It must be properly

tempered with weight,

so as to remove voids

Soaking of Bricks, at

least six hrs,

immersed in water

After laying of foundation, the first set of bricks are laid in cement mortar (1:5)

Bricks must be properly aligned, sufficient gap for mortar filling, mortar must be fresh

The mortar applied to the bricks

must be properly placed between

the gaps of the laid bricks,

at least 1 cm

At the end of the day, the mortar

Applied to the bricks must be

cleaned from the gaps of the laid

bricks, with a wire brush gently

Water level of the laid bricks must be checked for proper dimension

Laying of the inlet pipe, be in the middle, top must be above bio reactors height

Inlet pipe external side must be cleaned, cement grout applied for better joining to brick

IInlet pipe be tied with rope from inside to a post outside, use fresh cement concrete (1:2:4)

Where the inlet pipe is in contact with

laid brick, after applying cement concrete

on all sides, the brick lines must be

worked in fresh & rich cement mortar

Curing of the brick work is essential,

better to do in the morning before the

Start day’s work

Area around inlet pipe, concreted (1:2:4) 12 cms thick, for inlet box, slightly larger larger

Top height of Inlet box be higher than bio rector’s height,

Once the cement concrete is in place

Around inlet pipe, the form work of box

can start

After concreting, inlet box is built around it, the water in the box forms a perfect seal

Steel for reinforcement, must be worked\

To build the stirups and rings

Steel for reinforcement, for beam

After the concrete work is over building

The belt, the inside of the bio reactor be

chipped and clean of the remains of the

cement mortar, splashed with water ,

dusted with cement powder, then

Plastered with fresh cement mortar cm

(1:5) 12 mm thick

Next building top of reactor, called vault, use welded mesh for perfect shape

Use soaked bricks, fresh cement mix (1:3) complete each line of before starting next

Final brick of vault, keystone, locks all bricks of vault, quality bricks to be used

Next day, brush away all lose mortar

from the top with wire brush, a gap is left

For the outlet pipe from vault, plaster

with cm (1:3) of 12 mm thick, and on

Top a thin plaster of cm(1:6), start from

The bottom to top.

Clean edges of mortar, dust with cement powder, plaster cm (1:3) with minimum of water ,

proper curing of12 days, fill water to check leakages, gradually top it up

Gas storage tank, foundation 40 mm -12 cms thick, after wetting, properly pounded down

Top of 40 mm layer, add cement concrete (1:2:4) 7.5 cms thick,

Steel pipe as guide for storage tank with welded legs must be concreted in the gap

Steel pipe as guide for storage tank with welded legs must be concreted in the gap

On completion of plastering, water must

be introduced gradually into the tank for

full curing.

PVC tank must be pierced in centre, connect PVC pipe as a guide, ropes used for anchoring

Feeding the system with biomass, after

50 Kgs of Biogas slurry as starter

solution

Combustible gas was available from the

system after 3 weeks of incubation