This presentation is about the BIO CNG Bottling plant design and technical detaials

1. Registered & Corporate Office:
Hall no: 1, First Floor, NICE Sankul,
ITI Signal, MIDC Satpur, Nashik- 422007,
Maharashtra, India
CIN NO. U74900MH2013PLC24315
E-Mail:info@mantrasresources.com
Web:www.mantrasresources.com
+91-253-2355665,8888824935
Fax: +91-253-2355665

2. Hello!
I am U.K. Sharma
Chairman
uksharma@mantrasresources.com
2

3. MANTRAS BIO-DIGESTER
Waste to Bio-CNG/CBG project for processing Municipal
Solid Waste (MSW)

4. “
”
Sustainability of the society
depends on non-
conventional energy sources
which have no recurring
expenses also to reduce the
scarcity of fuel and to solve
the problems of cleanliness.
4

5. What is Bio Gas
▰ Biogas comprises of 60-65% methane, 35-40 %
carbon dioxide, 0.5-1.0 % hydrogen sulphide
and rests of water vapour
▰ Biogas contains a large proportion (about 40 %
by volume) of carbon dioxide, a heavier and non-
combustible gas and some fraction of hydrogen
sulphide.
5

6. How Bio Gas produced
▰ Biomass contains ligno-cellulosic by anaerobic digestion
(biological process) decomposed in the absence of
oxygen to produce biogas which is a mixture of CH4 (55-
75 %), CO2 (25-45 %), H2 (0-3 %), N2 (1-5 %), CO (0-0.3
%), H2S (0.1-0.5 %), O2 and water vapours (traces).
▰ Biological process is the sequential action of hydrolytic,
acetogenic and methanogenic bacteria to produce biogas.
6

7. Waste to energy process
Agricultural waste or
lignocellulose consists of
cellulose, hemicellulose,
lignin, extractive, and
some inorganic
materials.
Cellulose, hemicellulose, and
lignin sources for producing
useful products, such as sugars
by fermentation process,
For instance : Rice husk is one
of agriculture waste containing
lignocellulose which consists of
58.852% cellulose, 18.03%
hemicellulose, lignin 20.9% and
ash 0.16% - 1%.
7
With a high amount of
lignocellulosic content, it
is difficult to be degraded
by microorganisms by
itself. special pre-
treatment before
fermentation in the
digester
Pre-treatment chamber consist
of a monitoring system where
PH and dosing system for
stabilising the PH.
There will be a provision for
adding urea which will be
stabilize C:N ratio and
provision for cow dung
feed

8. BIO DIGESTER
Bio gas converted to CNG
8

9. Process
flow
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10. 10
D
E
S
I
G
N

11. Technique
Pre-treatment
system will have a
continuous agitator
(mixing Mechanism)
which makes the
slurry homogenous
and ready feeding to
the digester.
slurry will be fed
through a screw
pump which is
usually a
positive
displacement
pump where the
feed will be fed
in constant feed
rate
▰ VPSA PROCESS -Twin tower PSA
module interconnected with
automatic Tuflin make
changeover valves provide with
Activated alumina for adsorbing
moisture from biogas. After
passing through this bed of
Activated Alumina air gets dried
with bed of Zeolite Molecular
Sieves (ZMS)
11

12. Bio digester for 12000 cum (300Mtons per day)
12

13. Salient features
13
Sl.
No.
Items Amount
1 Municipal Solid Waste + Cow
Dung
300 ton per day
2 Total biomass consumption per
annum
108000 MT
3 Biogas Plant Capacity (M3) 12000
4 Net actual exported Purified
Biogas (Methane) per annum in
kg
10000
5 Total generation of solid bio-
fertilizer per annum
30 ton per day
Waste type MSW and Cow Dung
Quantity of feed per day 300 MT/day MSW + cow
dung
Feeding Composition
Moisture 10%
Total Solids 90%
Volatile Solids 84%
Ash 16%
Lignin 5.6%
C: N Ratio 40% (Note: C& N Ratio
maintained by adding urea
at a rate of 18 – 20 g/kg as
preprocessing)

14. Waste to energy process
collection
The raw biogas is collected
from the landfill or the
digester plant, free water
is removed in a
conventional water
separator
Water Separation
biogas the gas needs to be
cooled to approx 20 deg C.
During cooling the available
water will condensate and is
separated in a water separator
Compression
The separation process for CO2
removal has it optimum at
approx 6 bar. A feed gas
compressor provides the biogas
at approx 7 bar
14
H2S Removal
chemisorption process with
activated carbon.
8H2S + 4O2 --> S8 + 8 H2O
Elemental Sulphur is adsorbed
on the activated Carbon.
Vacuum Pressure Swing
Adsorption Process (VPSA)
process for CO2 removal a
2 to 4 bed PSA process is
used. The CO2 is adsorbed
on a molecular sieve and
the Methane goes through
up to the CNG quality
Storing
Biomethane can be stored as CBM
to save space. The gas is
stored in steel cylinders such
as those typically used for
storage of other commercial
gases

15. PLANT FACILITIES
Biogas plant
Anaerobic Digester. 12000cum
MUASB , Gas holder -
Balloon based storage,
Slurry mixing, Outlet tank
and slurry pit
Biogas Purification System
VPSA technology Methane
recovery figures can be reached
up to 98%.
Biogas compression Unit
compressed up to 200 bar
pressure using a four-stage gas
compressor. Compressed gas is
stored in high-pressure steel
cylinders as used for CNG. CBG
Cylinders can be sold as cooking
gas or Vehicle fuel
15
Control Monitoring Panel BSI
Standard control /
monitoring panel would be
supported to operate the
plant smoothly.
Machine Room
A proper machine room with
shed would be planned as
per standard practices.
Manure management system
protocol
Manure management is an integral
part of a compressed biogas
generation system for arriving
at an economically feasible
operation level

16. PLANT FACILITIES cont…
QUALITY CONTROL
FACILITIES
Wet chemical analysis section
▰ Analysis of raw materials
▰ *Testing of gas samples
FIRE PROTECTION
FACILITIES
▰ Early Detection
▰ Alarm
▰ Suppression of Fire
POLLUTION CONTROL FACI LITIES
Measures to be taken to contain all pollutants to strictly acceptable safety norms
16
Man Power
2 Supervisor
4 skilled
6 unskilled

17. 300 metric tones = 7500m3
One Metric ton watse can
produce 60% methane
10 kg 1.5 m3
Bio gas
17

18. Technical Details
▰ FEED CONVEYOR
╺ Capacity 6 TPH
╺ Power 5 HP
▰ PRESS MUD CRUSHER MACHINE
╺ Capacity 8-10 t/h (1-
15mm)
╺ Power 25hp
▰ PRE-TREATMENT CHAMBER
╺ No’s 2
╺ Capacity each 1600 cum
▰ FAN SEPERATOR
╺ Capacity 20 m3/hr
╺ Power 7.5 HP
▰ SLUDGE HOPPER WITH CONVEYOR
╺ Power 5.0 HP
╺ Hopper Volume 1. 5 M3
▰ MIXER
╺ Capacity 20 Hp( 2 No’s)
▰ DOSING SYSTEM
╺ Dosing Pump : e-
dose/UKL/Blackstone/Eqv
t.
╺ Tank: HDPE
▰ PH SENSOR
▰ BLOWER FOR AERATION
╺ Capacity 45 m3/hr
╺ Power 15 KW
▰ SLURRY FEED PUMP SPECS
╺ No’s 4 Nos (2W + 2 S)
╺ Hp 5 hp X 2 nos
▰ DIGESTER WITH BIOGAS
BALLOON ON TOP
╺ Capacity 12000 cum
╺ Gas holder Double
membrane type
▰ AGITATORS FOR DIGESTER
╺ Power 15 KW
▰ MOISTURE SEPARATORS
╺ Plate Baffle plate
▰ PRESSURE CUM VACCUM
REDUCING VALVE
╺ Range Pressure/Vacuum 50
to 500 mm
╺ WC / 25 to 40 mm WC
18

19. Technical details cont…
▰ FLAME ARRESTOR
╺ No’s Two (Working)
▰ GAS FLARING SYSTEM
╺ Capacity 650 m3/hr
╺ Power 0.12 HP
▰ GAS FLOW METER FOR GAS
FLARING LINE
╺ Capacity 650 m3/hr
╺ Power 0.06 HP
▰ SLURRY PUMP SPECS
╺ Motor type Submersible
slurry pump
╺ Hp 2hp
▰ BIOGAS CASCADE CYLINDERS
╺ Each cylinder capacity 75
Ltrs
▰ VACUUM PUMP
╺ Vacuum Level 700 mm of Hg
▰ PRE COOLER
╺ Type Shell & Tube
▰ SURGE VESSELS
╺ MOC shell C.S.
▰ FINE FILTER
╺ Type Shell & Tube
▰ H2S SCRUBBER
╺ Flow 650 M3/hr
▰ METHANE ENRICHMENT PLANT
╺ Capacity 650 M3/hr
╺ Type VPSA Based
╺ Power 25 HP
▰ FILLING STATION
╺ 1 set. Of filling station SS material of 4 nos.
Cylinders each.
▰ HIGH PRESSURE COMPRESSOR
╺ Capacity 400 – 450 M3/hr
╺ Electric Motor 60 + 180 HP
▰ CO2 LIQUIFICATION SYSTEM
╺ Liquification capacity 500 Kg/hr
Food grade Co2
╺ Motor Spec 41 HP DOL
▰ OVER / UNDER PRESSSURE PROTECTOR
╺ Over pressure 1000 pa
╺ Under pressure 200 pa
▰ INSPECTION WINDOW
╺ Glass Thickness 10 mm
▰ OTHER ACCESSORIES
╺ Individual feeder type incomer,
switch Gear component and cable
alley
╺ Base frame
19

20. Equipment Coast
Place your screenshot here
20
Sr.
No
Equipment Units (kWh) No of
hrs.
Total
(kW)
1 Feed conveyor 3.73 10 37.3
2 Grinding shedder unit 18.65 10 186.5
3 Mixer 29.84 12 358.08
4 blower 30 12 360
5 Slurry feed pump 7.46 2 14.92
6 Agitator 60 12 720
7 Flaring unit 0.08952 12 1.07424
8 Gas flow meter 0.08952 12 1.07424
9 Slurry pump 1.2 2 2.984
10 Vacuum pump 22 2 44
11 Methane enrichment
plant
37.3 12 447.6
12 High pressure
compressor
358.08 12 4296.96
13 Methane enrichment
plant
37.3 12 447.6
14 CO2 Liquification 30.586 12 367.032
15 Fan separator 11.19 12 134.28
16 Sludge hopper with
conveyor
7.46 12 89.52
TOTAL 7061.324

21. May-19Dec-19Jun-20 Jan-21 Jul-21 Feb-22Aug-22
Tentative Macroschedule for 200-300 TPD MSW processing facility Based on…
BASIC PROJECT ENGINEERING SCHEDULE
Signing of Concession Agreement
Kickoff meeting with Project Charter with Project Budget
Preliminary Activities
Finalization of WO for site surveys and investigations
Finalization of EPC Contractor
Site demarcation and handing over
Statutory approvals, clearances & permissions from respective authorities
Site surveys and investigation report
Boundary, area and contour surveys with report
Soil, Ground water and resistivity surveys with report
Basic Engineering
Process Engineering (Finalization of process, mass balance, basic sizing &…
Basic Engineering (mechanical equipment, power island, eletcrical, instrumentation…
Detailed Engineering (With Technical approval) - DS, Drawings, Specs., QAP, QA,…
n-house
Mechanical - Inhouse
Instrumentation
Automation
Out-Sourced (EPC Contractor / Vendor/Consultant)
Piping
Utilities and Services
Civil
Execution
Water & power supply arrangement
contractor Mobalization
Civil
Mech eq. procurement, erection & interconnection
Ele procurement, erection & interconnection
Piping procurement & interconnection
Inst procurement, erection & interconnection
Utility services procurement , erection & interconnection
Automation procurement & installation
Testing & trials
Commissioning
Start Duration
TIME
FRAME

22. Total and Annual Project Cost
22
Sl.
No.
Descriptions Amount in Rs.
1 Cost of Manpower (40 employees) 12,50,000.00
2 Cost of Electricity and utilities 16,94,717.76
3 Cost for raw material@ 500 Rs/ton 12,00,000.00
4 Cost of sales, selling overheads, administrative overheads 4,50,000.00
5 Total Expenditures per Month 45,94,717.76
6 Sales Realization of 5000 kg of methane (CBG)
@Rs.46.5/kg
69,75,000.00
Sales Realization of Bio compost 8 tons @ 1.5 /- per kg 3,60,000.00
Total Revenue per Month 73,35,000.00 Profit per Month 27,40,282.24
Sr.
No.
Particulars Cost in
Rs.
1 Plant & Machinery for purification 2,40,00,000
2 Plant & Machinery for Compression 1,87,00,000
3 Biogas Plant and accessories (including
segregator)
5,50,00,000
4 Slurry management system 50,00,000
5 Civil work of digester/enamel metal glass 4,58,00,000
6 Prelim. & Preoperative Expenses 2,00,000
7 Know-how and Engineering Fees 1,78,00,000
Total 16,65,00,000

23. Benefits of Bio Gas
▰ 7500 Cu. M. biogas bottling
plant, enriched biogas filled
cylinders able to replace
Rs.128 lakh fuel annually in
the country. The whole cost
can be recovered within two-
three years from the
installation of the plant.
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24. 24Any questions?
You can find me at:
▰ https://www.mantrasresources.com/
▰ uksharma@mantrasresources.com
Thanks!