AGRO CNG

Chapter: 1

INTRODUCTION

Agricultural residues generally considered as agro-wastes which are produced in huge

quantities every year in Indian farm fields. To an approximation, the amount of crop residues
produced every year exceeds 620 million tons in India [1] of which, almost 50% finds
applications in various agricultural and industrial purposes like animal feedstock, paper industry,
roofing material and energy generation. However, major quantities of the on-farm agricultural
residues, to which farmers generally treat as wastes, are burnt in the field itself. Although this is
a very cheap, non-labor intensive and easy mean of agro-waste disposal, but in return this has
great negative impact on the agro-ecosystem as it generates a lot of particulate matter in
environment to form smog, smoke that cause air pollution, and disturbs soil physical, chemical
and biological structure including microbial population and micro-flora and micro-fauna life
forms [2]. It is therefore, imperative to make use of crop-residues in the agriculture production
system to help improve soil conditions, crop productivity and environmental sustainability.
Experimental observations suggest that direct application of crop residues in the fields has its
own negative implications as it may improve soil health significantly [3] but may decrease crop
yields subsequently due to microbial infestation, production of phytotoxins, allelochemicals and
immobilization of nutrients like nitrogen [1].

Direct incorporation of paddy straw increases CH4 emission from the irrigated fields and impact
global warming [4]. It is also estimated that almost 50% of the total agricultural residues are
produced majorly by rice, wheat and oilseed crops. The residues from these crops are estimated
to contain almost 0.5% N, 0.2% P2O5 and 1.5% K2O [1]. Overall, this could turn out to a big
amount of mineral content, approximately 6.5 million tons equating to almost 30% of the total
NPK mineral consumption in India, being contained in the form of these farm residues even after
assuming that almost 50% of all the overall content per year is being utilized in different ways.
Therefore, recycling of the agricultural farm residues (agro-wastes) from major crops, especially
rice and wheat becomes a subject of not only major agro-ecological concern but is also well
connected with the improved soil and plant health.

The recycled waste products could be bio-

composts, which may be fortified with microbial consortia
and organic material (like amino acids, humic acid,
phytostimulants and minerals etc.) to produce bio-organic
farm inputs at commercial scale which could ultimately
generate economic livelihood to the rural society also. Bio
composting process taking agro-wastes of rice, wheat and
plant leaves and litter and value addition of the bio-
organic farm-input produced using microbes and minerals.
The impact of the bio-organic farm-input thus produced was assessed on field crops.

Bio CNG is the purified form of biogas where all the unwanted gases are removed to
produce >95% pure methane gas. Bio CNG is exactly similar to the commercially available
DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 1
 AGRO CNG

natural gas (CV: ~52,000 kJ/kg) in its composition and energy potential. As it is generated from
biomass, it is considered a renewable source of energy and thus, attracts all the commercial
benefits applicable to other renewable sources of energy. Bio CNG can directly replace every
utility of LPG and CNG in India. It has the potential to be the future of renewable fuel because of
the abundance of biomass in India.

The Indian economy has been growing steadily over the last few years leading to a rise in
demand for petroleum products. With limited availability of petroleum products domestically,
India is compelled to import over 75 per cent of petroleum products every year. India has total
reserves of 849.44 MMT of crude oil and 1399.57 BCM of natural gas, according to a research
study conducted by the Ministry of Petroleum and Natural Gas, India, in FY 2017–18. The CGD
(City Gas Distribution) Infrastructure consists of two components—Compressed Natural Gas
(CNG) and Piped Natural Gas (PNG). How are they different? CNG caters to public and private
transport whereas PNG caters to domestic and industrial consumers.

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Chapter: 2

LITERATURE REVIEW

Every Year 600 million tonnes of agriculture waste is generated in India. There exist
several options for managing this wastes (crop residues). These include being removed from the
field, left on the soil surface, incorporated into the soil, composted, or used as mulch for
succeeding crops, animal feed. Only 15- 20% of the waste is used for it and rest of the waste is
burnt in fields. In many parts of the tropics, crop residues are burned in the field due to the
ignorance of farmers about their value and lack of proper technology. In the intensive rice–wheat
cropping system in the North India, crop residues, particularly rice straw, are not used as animal
feed and are disposed of by burning. This is a cost-eVective method of straw disposal and helps
to reduce pest and disease populations resident in the straw biomass, but it also causes pollution
by releasing CO2, N2O, NH3, SOx, NOx and particulate, leading to global warming and health
concerns.[3]

It also reduces the number and activity of soil microbes. The magnitude of farm friendly
organism and nutrient loss during burning is influenced by the quantity of residue burned and the
intensity of the fire [3].The heat generated during the combustion kill the organism present in the
field soil. This reduces the fertility and yield of the soil. Moreover, if this waste is dumped or
land filled this releases methane gas in atmosphere which is hazardous.

Fig. 1: Crop Residue Burning

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 3

 AGRO CNG

Fig. 2: Consequences of crop residue burning

Many developed countries like US, UK use this agro waste as raw material to generate
bio gas. Huge bio gas plants are setup to generate this recycle fuel.The bio gas obtained from
agro waste is similar to the Coal Bed Methane (CBM). We can obtain 97% pure methane from
bio digester.
Under the scheme “ENERGY FROM URBAN, INDUSTRIAL AND
AGRICULTURAL WASTES/RESIDUES for PLAN PERIOD (2017-18, 2018-19 & 2019-20)”
Government of India has initiated various project to promote installation of bio gas plants to
obtain renewable energy. It is also conducting Promotional activities including R&D, Resources
assessment, technology up gradation and performance evaluation, etc. [4]

Hindustan Waste Treatment plant Goa has made an impact in the field of renewable
energy from waste. It handle 100 tonne waste every day. The plant generates 4000 units of
electricity daily out of the biogas obtained from waste. [5]

Primove Engineering Pvt. Ltd. Pune who has been another example who has successfully
developed a plant which produce 97% pure methane from agro waste. [6]

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 4

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Chapter: 3

METHODOLOGY

The raw material to produce high quality CNG is actually agricultural waste comprising
of straws, chaffs, husks, shells etc. The heart of Agro CNG is a bio-gas reactor, commonly called
a digester. It is filled up to 80% capacity with microbial culture. The raw material is fed into a
reactor through a feed mixing tank. The temperature inside is steadily maintained at about 37℃
to allow bacteria grow and multiply. And this conditions inside the digester and the slurry should
be monitored. The total solids (TS) of the slurry, bacterial count, and microbial balance should
be constantly maintained.

The overflow from the digester is carried into a storage tank through pipes. From here it
is diverted into a solid-liquid separator. The solid waste that is churned out is carried through a
shoot into another plant. This dry waste is transformed into green coal, can be reused for lighting
the furnaces for cooking, or used into other fire heated systems Also it can be a good bio-
fertilizer.

The generated gaseous composition commonly known as Bio-Gas, comprises of

Methane, Carbon Dioxide, traces of Hydrogen Sulphide and moisture. It is first stored in
specially created rubber balloons. Then it undergoes a process of purification. It is very critical
that the purified methane is free from all impurities to make it safe to store and use at high
pressure. The resulting high quality specification CNG of 96% purity or more is ready to now
dispense into vehicles. The purified gas is then compressed to a desired pressure in a four stage
compression process and is transferred to a cascade of high pressure cylinders.

Fig. 3: Schematic of Agro CNG process

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 5

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Chapter: 4

EQUIPMENTS REQUIRED FOR AGRO CNG PLANT

4.1. Macerator

4.2. Digester

4.3. Solid Liquid separator

4.4. Methane Filter

4.5. Compressor

4.6. Storage and Dispenser

4.1. MACERATOR :

Macerator is a machine which crushes the large biomass into minute particle which can
be easily consumed by the bacteria. It contain set of blades which rotate at high speed
(2900RPM). The rotation of the blade cause size reduction of agro waste like rice stalk, wheat
stalk, soya bean plant etc. it used for both wet and dry waste. The feed size effect the efficiency
of the production of methane gas.

Fig. 4: Macerator

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 6

 AGRO CNG

4.2 DIGESTER :

This is heart of the biogas plant. It is large cylindrical tank in which the shredded feed is given.
Anaerobic digestion is a collection of processes by which microorganisms break
down biodegradable material in the absence of oxygen.[2] The process is used for industrial or
domestic purposes to manage waste or to produce fuels. Much of the fermentation used
industrially to produce food and drink products, as well as home fermentation, uses anaerobic
digestion.

Fig. 5: Digester

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 7

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4.2.1 DIGESTER PROCESS STAGES

The overall process can be described by the chemical reaction, where organic material
such as glucose is biochemically digested into carbon dioxide (CO2) and methane (CH4) by the
anaerobic microorganisms.
C6H12O6 → 3CO2 + 3CH4

 Hydrolysis

 Acidogenesis

 Acetogenesis

 Methanogenesis

4.3 SOLID – LIQUID SEPARATOR

Agro CNG plant must consist of Solid – Liquid separator which is essential part in
production of CNG. The liquids are further passed into a Methane Filter whereas the solids are
used as fertilizers.

4.4 METHANE FILTER

When it comes to extracting natural gas or producing biogas, it's all about the methane. But
methane is never found in its pure form. Natural gas, for instance, always contains quite a bit of
carbon dioxide (the greenhouse gas CO2), sometimes up to 50 percent. To purify the methane --
or, in other words, remove the CO2 -- the industry often uses membranes. These membranes
function as molecular sieves that separate the methane and the CO2. The methane can then be
used as a source of energy for heating, for the production of chemicals, or as fuel, while the
CO2 can be reused as a building block for renewable fuels and chemicals.

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 8

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4.5 COMPRESSOR

CNG is made by compressing natural gas, (which is mainly composed of methane, CH4), to
less than 1 percent of the volume it occupies at standard atmospheric pressure. It is stored and
distributed in hard containers at a pressure of 20–25 MPa (2,900–3,600 psi), usually
in cylindrical or spherical shapes.

4.5 STORAGE AND DISPENSOR

Generated bio gas comprises of Methane, Carbon Dioxide, traces of Hydrogen Sulphide and
moisture. It is first stored in specially created rubber balloons. The methane is then purified and
compressed to a desired pressure in a four stage compression process and is transferred to a
cascade of high pressure cylinders. The resulting high quality specification CNG of 96% purity
or more is ready to now dispense into vehicles.

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 9

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Chapter: 5

PLANT LAYOUT

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 10

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Chapter: 6

ADVANTAGES OF AGRO CNG PLANT

1. Biogas is eco-friendly fuel. Provides a non-Polluting and renewable source of energy.

2. Has a calorific value of around 6kWh/m3—this is equivalent to half a liter of diesel.
3. Larger biogas plants generate and feed electricity into mainstream power grids.
4. Efficient way of energy conversion.
5. Saves women and children from drudgery of collection and carrying of firewood, exposure to
smoke in the kitchen, and time consumed for cooking and cleaning of utensils.
6. The digested sludge is high quality organic manure, completely natural and free from harmful
synthetic chemicals. It can supplement or even replace chemical fertilizers.
7. Leads to improvement in the environment, sanitation and hygiene.
8. Provides a source for decentralized power generation.
9. Leads to employment generation in the rural areas.
10. Household wastes and bio-wastes can be disposed of usefully and in a healthy manner.
11. The technology is cheaper and much simpler than those for other bio-fuels.
12. Dilute organic waste materials (2-10% solids) can be used as feed materials.
13. Any biodegradable matter can be used as substrate.
14. Anaerobic digestion inactivates pathogens and parasites, and is quite effective in reducing the
incidence of water borne diseases.
15. Environmental benefits on a global scale: Biogas plant significantly lowers the Greenhouse
effects on the earth’s atmosphere. The plant lowers methane emissions by entrapping and using it
as fuel.

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 11

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Chapter: 8

LIMITATIONS OF MAGNETO-RHEOLOGICAL DAMPER

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 12

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Chapter: 9

CONCLUSION

The enormous rise in the number of automobiles in India and the mountain imports of fossil fuels
is a cause for alarm. India currently imports 79% of its oil needs. The countries need will keep on
increasing. In the first generation Bio-Fuel technology, bio-gas is produced from sugars, starch,
proteins, and fats. But there is always been a conflict between food and fuel. So, to remove this
conflict, this method being second generation Bio-fuel technology, where the use of specifically
different kind of agricultural residues will be economically viable in terms of fuel, beneficial for
farmers and ecofriendly. Every year 600 million tonnes of agricultural waste is produced, now if
this is put to productive use. It could produce about 25 times the capacity of CNG that we
consume today. And also it can replace about 54% of the total fuel imports. In terms of making
India self-sufficient, reducing fuel imports, helping farmers, reducing the pollution levels this
can go a long way.

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 13

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REFERENCES

1. Dhananjaya Pratap Singh, Ratna Prabha , Bioconversion of Agricultural Wastes into

High Value Biocompost: A Route to Livelihood Generation for Farmers, ICAR-National
Bureau of Agriculturally Important Microorganisms, Kushmaur, Maunath Bhanjan, Uttar
Pradesh, India.

2. Muhammad Baqer Mollah, Design and cost analysis of biogas based power plant for
commercial usage, INSPEC Accession Number: 12556925, 2nd International Conference
on the Developments in Renewable Energy Technology (ICDRET 2012).

3. Yadvinder-Singh, Bijay-Singh and J. Timsina , Crop Residue Management for Nutrient

Cycling and Improving Soil Productivity in Rice-Based CroppingSystems in the Tropics,
Department of Soils, Punjab Agricultural University, Ludhiana 141 004, India ;CSIRO
Land and Water, Griffith NSW 2680, Australia.

4. Government of India Ministry of New and Renewable Energy (Waste to Energy

Division) PROGRAMME GUIDELINES on ENERGY FROM URBAN, INDUSTRIAL
AND AGRICULTURAL WASTES/RESIDUES for PLAN PERIOD (2017-18, 2018-19
& 2019-20)

5. HINDUSTAN WASTE TREATMENT PRIVATE LIMITED, Saligoan, Goa, CIN-

U90002MH2014PTC255728.

6. Primove Engineering Pvt. Ltd. Pune, Fuel for the future,

https://www.youtube.com/watch?v=gaFlLDRVtIw&feature=youtu.be,
http://mnre.gov.in/file-manager/akshay-urja/december-2016/Images/31-33.pdf

DEPARTMENT OF MECHANICAL ENGINEERING, K.L.S. GOGTE INSTITUTE OF TECHNOLOGY. 14