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A project of the National Center for Appropriate Technology                               1-800-346-9140 • www.attra.ncat.org


Micro-scale Biogas Production:
A beginner’s guide
By Rich Dana                                 Anaerobic digestion is a simple biochemical
NCAT Energy Specialist                       process by which waste products can be con-
© 2010 NCAT                                  verted to energy. Using manure, plant waste, crop
                                             residue, food scraps or other waste products,
                                             farmers can reduce their dependence on fossil
Contents
                                             fuels while saving money, reducing greenhouse
Introduction ......................1         gas emissions and solving odor problems (not
Using the Gas ....................1          to mention producing high-quality compost
                                             fertilizer as a by-product). This publication provides
Small is Beautiful .............2
                                             a beginner’s guide to using anaerobic digestion
Biogas Basics:                               to produce usable biogas on a small scale with a
The Chemistry of
Anaerobic Digestion ......2
                                             minimal investment.
Feeding Your                                 For more information on biogas and a discus-
Digester ..............................4     sion of larger-scale, manure-based digesters for
Micro-Digester                               livestock operations, please see the ATTRA
Designs ...............................5     publication Anaerobic Digestion of Animal Wastes:
Start-up, Operation                          Factors to Consider.
and Maintenance ............6
Side Streams......................8
Conclusion .........................9        Introduction

                                             A
References .........................9
                                                     naerobic digestion is one of the most
Further Resources
Online ..................................9
                                                     basic processes of life on earth. Anaer-
                                                                                                      Workshop participants building a micro-scale digester
                                                     obic means “in the absence of oxygen”            in Costa Rica. Photo by Ian Woofenden.
                                             and anaerobic digestion takes place when biode-
                                             gradable matter decomposes in a closed environ-          Although not widely used in the United States,
                                             ment. By managing the digestion process and              small-scale digesters are used successfully all
                                             capturing the biogas produced, we can power              over the world to turn small amounts of manure,
Funding for the development
of this publication was provided             boilers, burners and generators, and possibly            plant waste and food scraps into usable energy.
by the USDA Risk Management
Agency.
                                             even refrigerators.                                      For hundreds of years, biogas has been used in
                                                                                                      China and India (and more recently in Africa
                                             In the United States, there is a great deal of
                                                                                                      and Central America) to provide gas for cook-
                                             interest in using large-scale anaerobic digesters
                                                                                                      ing, heating and lighting—utilizing very simple,
                                             to control odor at livestock facilities and burning
                                                                                                      low-tech designs. Th is publication will exam-
                                             the biogas produced to run electrical generators.
The National Sustainable                                                                              ine several of the common designs for build-
Agriculture Information Service,             Commonly referred to as Methane Digesters,
ATTRA (www.attra.ncat.org),                                                                           ing micro-digesters that have been developed
was developed and is managed                 these large-scale units actually digest manure
                                                                                                      around the world, and discuss how sustainable
by the National Center for                   and produce biogas, which is made up of carbon
Appropriate Technology (NCAT).                                                                        farmers in American can take a lesson from their
The project is funded through                dioxide (CO2) and methane (CH4) with smaller
a cooperative agreement with                                                                          counterparts in the developing world.
the United States Department                 amounts of water vapor (H 2 O), hydrogen
of Agriculture’s Rural Business-             sulfide (H 2 S), and in some cases ammonia
Cooperative Service. Visit the
NCAT website (www.ncat.org/                  (NH3). Methane is flammable gas that can be              Using the Gas
sarc_current.php) for
more information on                          used to make power, and is the primary compo-            If you decide to build the digester, how will you
our other sustainable
agriculture and
                                             nent of the fossil fuel natural gas in common use        use the gas? Biogas can take the place of pro-
energy projects.                             to heat homes.                                           pane or natural gas in many instances. The most
common use is for cooking. It can, of course,             technology because of its low cost (and the abil-
                           be used as a heat source as well: to supplement           ity to adapt salvage materials or materials that are
                           home heating, for heating a poultry house, far-           commonly at hand), simplicity, and environmen-
                           rowing house incubator or other small livestock           tal and health benefits. In places where wood is
                           building, or for heating a greenhouse.                    used for cooking and heating, deforestation is a
                                                                                     major concern and burning wood can cause air
                           One unique use that has not been widely explored
                                                                                     quality issues and respiratory problems for resi-
                           in the U.S. (but has in China) is using the gas to
                                                                                     dents—especially small children. A household
                           power an absorption refrigerator. This is a type
                                                                                     digester can reduce the work of gathering wood
                           of refrigerator that uses a propane flame rather
                                                                                     and provide a cheap and plentiful fuel source
                           than an electric compressor to create the evapo-
                                                                                     where before there was none.
                           rative cooling cycle. These refrigerators are com-
                           monly found in RVs and in locations that have
                           no electricity or unreliable electricity supplies.        Biogas Basics: The chemistry
                           Though there is little research available on the use      of anaerobic digestion
                           of methane to power absorptive cooling, methane
                                                                                     Anaerobic bacteria and archaea predate most
                           has potential for use by farmers who may be look-
                                                                                     other forms of life on our planet, having devel-
                           ing for refrigeration options in remote areas.
                                                                                     oped in the period when the earth’s atmo-
Related ATTRA                                                                        sphere was mainly methane (CH4), carbon
publications               Small is Beautiful                                        dioxide (CO2) and water vapor (H2O). Anaero-
                           There are several major technical issues to over-         bic digestion takes place in environments with
Anaerobic Digestion        come in order to operate a large-scale digester           limited oxygen: underwater in a swamp or
of Animal Wastes:
                           successfully and use it to generate wholesale elec-       marsh, at the bottom of a compost heap, or in
Factors to Consider
                           tricity. Maintaining proper bacterial health in a         the gut of animals. Anaerobic digestion is used
Compost Heated             40,000- to multi-million-gallon digester tank             in septic systems and sewage treatment plants
Greenhouses                can be difficult—and mistakes are expensive.              to break down waste.
                           Large-scale digesters require hundreds—or thou-
                           sands—of head of livestock to provide adequate            The Stages of
                           manure, creating material handling issues. In
                           order to run large, sensitive electrical generat-         Anaerobic Digestion
                           ing equipment, the biogas must be “scrubbed” to           There are four stages to the digestion process—
                           remove most of the other gases, which can add             hydrolysis, acidogenesis, acetogenesis and meth-
                           work and expense. Large digesters often require a         anogenesis. These stages need to be managed
                           full-time manager. On the other hand, a micro-            early on in starting a digester, but if the pro-
                           digester can supply a family with cooking gas             cess is properly maintained, methane production
                           for two meals a day (or add heat to a greenhouse          should require a minimum of chemical testing
                           or workshop), from the manure of a few pigs,              and treatment. Bacteria must do their work in
                           cows or chickens, or food scraps and rotten or            the earlier stages to use up the oxygen in the
                           unusable vegetables and fruit. Because the cost of        material, and then break it down into volatile
                           construction is low, the feedstock is free, and the       fatty acids and fermented alcohols, before the
                           fuel is used at the source, economic risk can be          methanogenic bacteria can start to make methane.
                           minimized and sustainability maximized.                   The process is as follows:
                           In other parts of the world where energy resources              • Hydrolysis: Enzymes break down and
                           are not as readily available as they are in the                   liquefy the smaller molecules and break
                           United States, the micro-digester is an important                 down large polymers in the material.



  Disclaimer: This publication is meant as an introduction to micro-scale biogas production, and not a complete hands-on manual
  on how to construct and operate a digester. There is a list of references at the end of this publication, and we suggest doing con-
  siderable additional research before committing time and resources to a biogas project. Most importantly, remember that biogas,
  though relatively safe, can be dangerous, flammable, and potentially explosive if handled improperly. We suggest that you exercise
  all possible safety precautions and abide by all local, state and federal laws that might apply to a digester project in your location.



Page 2        ATTRA                                                            Micro-scale Biogas Production: A beginner’s guide
• Acidogenesis: The products of the             Pure water is said to be neutral, with a pH level
       hydrolysis (soluble monomers) are fer-        of about 7. Acids have pH numbers below 7,
       mented to volatile fatty acids (or VFAs)      while bases have numbers above 7. A digester
       and alcohols.                                 operates best near the neutral point, up to
                                                     a pH of about 8.5. In the early stages of the
     • Acetogenesis: Acetogenic bacteria
                                                     anaerobic process, when the digester is making
       break down the VFAs and alcohols, ace-
                                                     acids, the pH can drop to 6 or below. When it
       tic acid, carbon dioxide and hydrogen.
                                                     reaches methanogenesis, it will operate in the
     • Methanogenesis: The methanogenic              7.5 to 8.5 range.
       bacteria convert acetic acid and hydrogen
       into CO2 and methane. (Note: The three        It is important to remember that the pH level
       earlier stages can take place at lower tem-   becomes less of an issue when the digester is
       peratures than Methanogenesis.)               well-buffered, as it can take a certain amount of
                                                     acid or base material being added to it without
                                                     upsetting the digestion.(Fry, 1973) Buffering is
Temperature and pH                                   the digester’s ability to resist pH change. Since
Two of the most important factors for proper         pH is a “lagging indicator”, proper buffering
anaerobic digestion and methane production are       is important to avoid problems with acidity.
temperature and pH. Failure to regulate these        (see Figure 1).
two factors is among the most common prob-
lems with a digester.                                In a large-scale digester, large variations in pH
                                                     can be catastrophic. In a micro-digester, how-
Most anaerobic bacteria perform best in warmer       ever, high or low pH conditions may be cor-
atmospheres. Th is is why micro-digesters are        rected relatively simply. A high-acid condition
most common in areas closer to the equator.          can be treated with small amounts of lime,
Th is does not mean a micro-digester will not        ammonia or even bicarbonates like baking soda.
function in more northerly climates, but it does
affect design decisions, as the digester may need    Carbon/Nitrogen Ratio (C:N)
to be insulated or even heated to make large
                                                     Carbon and nitrogen are the two components
amounts of methane. Anaerobic digestion does
                                                     that anaerobic bacteria require for survival. They
not stop completely at lower temperatures, but
                                                     need about 30 times more carbon than nitro-
methanogenesis is the stage most seriously hin-
                                                     gen, so the C:N ratio of your substrate should be
dered by low temperatures, and this will reduce
                                                     about 30:1. This is important when formulating
methane production. There is evidence, how-
                                                     your slurry. When determining the C:N ratio
ever, that plant-based feedstocks may perform
                                                     of feedstock like manure, the animal feed and
better at low temperatures than do manure-
based systems. (House, 2006)
Although micro-digesters in Central America or       Figure 1: Courtesy of David House.
India often operate completely without added
heat or even insulation at temperatures ranging
from 60ºF - 100+ºF, the micro-digester design
most popular in China is an underground
design, which utilizes the earth’s geothermal
properties to maintain a healthy temperature.
This publication discusses design considerations
below, in the section entitled Micro-digester
Designs: Global D.I.Y. technology.
Along with temperature, pH is vital to digester
health. The pH is a measure of the acidity or
alkalinity (baseness) of the contents of the
digester. Just as in the human digestive sys-
tem, too much acid creates “indigestion” in the
anaerobic system.


www.attra.ncat.org                                                                                        ATTRA   Page 3
amount of bedding material can heavily affect
                 the actual amounts of carbon and nitrogen—
                 you will need to adjust your feedstock accord-
                 ingly (see Table 1).

                 Table 1: Carbon Nitrogen Ratio
                    Substance                                                                             C:N
                    Cow Manure—Alfalfa                                                                    16:1
                    Cow Manure—Dairy (with bedding)                                                       21:1
                    Pig Manure                                                                            14:1
                    Sheep Manure                                                                          20:1
                    Chicken Manure                                                                        15:1
                    Oat Straw                                                                             48:1
                    Turnip Tops                                                                           19:1
                    Corn Stalks                                                                           53:1
                    Grass Clippings                                                                       19:1
                    Sunflower                                                                             30:1
                                             Source: House, David. 2006. Biogas Handbook. p.37-40


                 Feeding Your Digester:
                 Substrates
                 In the proper feeding and care of your digester,
                 you must remember the “Seven S’s” of anaerobic
                 digester design: (see Table 2)

                 Table 2: The Seven S’s of Digester Design
                   1. Substrate: The organic material that you will be feeding your digester. This can be manure,
                      plant waste, paper pulp, or other biodegradable material.
                   2. Slurry: The slurry is the homogeneous mush that you will be passing through the digester. In
                      order for efficient digestion to take place, the substrate material should be mashed or ground
                      and mixed with water to make a uniform substance with 15–40% solids, depending on your
                      digester design.
                   3. Stratification: As your slurry breaks down in the digester, it will separate into layers. These lay-
                      ers—or “strata”—are biogas, scum, supernatant, sludge and solids. Mixing of the slurry prevents
                      excessive stratification, but some stratification will always occur, especially in “batch” digesters
                      (see below, Micro-digester Designs: Global D.I.Y. Technology).
                   4. Scum: The scum layer floats on the top of the material in the digester, just below the gas level.
                      The scum level is formed by hard-to-digest material like coarse straw and grease.

                   5. Supernatant: The spent liquid of the slurry. The Supernatant has a high content of solids,
                      making it of high value as fertilizer, similar to “compost tea.”(Diver, 2002)

                   6. Sludge: Below the liquid supernatant is the sludge layer. The sludge is the digested and semi-
                      digested organic solids. This sludge can provide excellent composted fertilizer, but depend-
                      ing on the feedstock, it may need to be dried in the sun to kill any surviving pathogens. This is
                      more of an issue with manure-based systems.
                   7. (Inorganic) Solids or Sand: The bottom layer consists of those non-digestible solids that find
                      their way into the digester. These could include dirt, sand, small rocks, plastic or metal—any
                      inorganic solid that may inadvertently be introduced into the system.


Page 4   ATTRA                                                    Micro-scale Biogas Production: A beginner’s guide
Micro-Digester Designs:                               Figure 2: In-Ground Bag
Global D.I.Y. (do-it-yourself)
technology
There are two basic types of digester designs:
continuous-flow and batch processors. In a contin-
uous-flow digester, new substrate is regularly fed
into the digester. The slurry moves through the
digester, pushing out digested material (efflu-
ent). The material may also be moved mechani-
cally through the continuous-flow digester with
augers or pumps. Batch digesters are loaded once      The system consists of a long trench (approx.
and then the material is allowed to digest. When      20’), lined with a 48” diameter polyethylene
the digestion is complete, the effluent is removed    (poly) tube to form the “bag”. With an inlet at
and the process is repeated. By adding an inlet       one end, an outlet at the other and a gas out-
tube for feeding the digester and an outlet tube      let fitting on the top, it is an extremely simple
for the overflowing effluent, a batch processor       design (see Figure 2). The poly tubing is available
can be fed some extra material after the initial      by the roll, and is commonly used as packaging
start-up to extend the cycle, making the unit a       material. A double layer of 6-8 ml poly is sug-
semi-continuous batch processor. Each type has        gested to avoid punctures, and a pressure release
its advantages. Continuous digesters produce          allows excess gas to exit the system before over-
biogas without interruption. Batch digesters, on      inflation of the bag. This design will produce 4
the other hand, are simpler and less expensive to     hours of usable cooking gas per day and requires
build. Continuous-flow designs lend themselves        approximately 100 gallons of slurry to “charge”
better to manure-based systems, while batch           the digester, and an additional 10 gallons of
processors may be more appropriate for unpro-         slurry per day to maintain.(Brown, 2004)
cessed plant-based substrates.
The types of micro-digesters we will be cover-
ing in this publication fall into three categories,
with some variation. These are the in-ground
bag or tube style (continuous flow), the in-
ground dome style (semi-continuous batch) and
the floating top/tank design (batch or semi-con-
tinuous). Because much of the micro-scale bio-
gas technology has been developed by individu-
als and non-governmental organizations, these
designs are simple and “open source”—mean-
ing that the designs are non-proprietary and
much of the information on these designs is free
and readily available on the Internet. (See the
Resources section at the end of this publication
for a list of books and websites to visit for more
detailed information.)

In-ground bag                                         An in-ground bag digester in operation. Photo by Ian Woofenden.
The in-ground bag style digester is very popular
throughout Central America, and may be appro-
priate for use in the Southern U.S. It is a very      In-ground dome
simple continuous-flow design especially well         The in-ground dome design is used widely in
suited to a family farm with just a few pigs or       China, and may have considerable potential for
cows. It is a very inexpensive design, with parts     adaptation to northern climates in the United
that can be acquired for as little as $50.            States.(Koottatep et al., no date) Th is design

www.attra.ncat.org                                                                                           ATTRA      Page 5
Figure 3: In-Ground Dome
                                                                                    This design is used widely in India in particu-
                                                                                    lar, where ARTI (Appropriate Rural Technology
                                                                                    Institute) has developed a very functional fam-
                                                                                    ily-sized design utilizing a 1000-liter (264 U.S.
                                                                                    gallons) polyethylene base tank with a 750-liter
                                                                                    (198 U.S. gallons) tank as the inner floating gas
                                                                                    chamber.(Voegeli et al., 2009) Th is design can
                                                                                    be adapted to use any size of tanks, with a larger
                                                                                    diameter for the outer and smaller diameter
                                                                                    for the inner tank, and can be an excellent and
                                                                                    inexpensive design to experiment with. Many
                                                                                    sizes of drums are readily available for free, and
                                                                                    a very small test digester can be made with a
                                                                                    couple of barrels and just a few standard plumb-
                              is not unlike a western-style septic tank, and        ing parts (see Figure 4).
                              in fact, a conventional cast concrete or fiber-
                              glass septic tank could be modified to serve as
                              a digester (see Figure 3). In China, the latrine is   Other designs
                              often connected to the digester, so it serves as a    Several other designs have been developed that
                              septic system as well. In the U.S., zoning and        are variations on these three basic styles. One is a
                              public health laws in most areas would not allow      hybrid design that uses sealed 55-gallon drums as
                              “blackwater” from the home into the digester,
                              despite the obvious advantages to such a system.
                              This design involves a cast concrete, or concrete
                              block, or brick, tank and cap. While the expense
                              is much greater than that of a bag-style digester
                              (typical cost is $350 for 4-6 cu. meters), but by
                              using the earth’s natural insulation, the dome-
                              style digester can maintain a constant tempera-
                              ture, even in colder climates.(Nakagawa, 1981)

                              Floating top/tank
                              The floating top/tank design is one that adapts
                              itself particularly well to the materials at hand.
                              In this design, the slurry is contained in a bot-
                                                                                    A simple floating-top digester built from scrap materials.
                              tom tank, with another inverted tank or drum          Photo by Rich Dana.
                              serving as a cap, which is lifted by the biogas as
                              it is generated (see Figure 4).                       modular digesters that are connected to a separate
                                                                                    floating top/tank gas storage container. Another
                                                                                    style uses the 275-gallon totes commonly used
                                                                                    to transport farm and industrial chemicals. In
Figure 4: Floating Top/Tank                                                         general, plastic containers are preferable to steel
                                                                                    drums for the digester vessel and gas storage
                                                                                    tanks, because both the slurry and the biogas
                                                                                    itself can corrode steel drums fairly rapidly.

                                                                                    Start-up, Operation
                                                                                    and Maintenance
                                                                                    Start-up
                                                                                    The best way to get any anaerobic digester going
                                                                                    is by “seeding” or “inoculating” it with mate-
                                                                                    rial from another healthy, operating digester.

Page 6         ATTRA                                                          Micro-scale Biogas Production: A beginner’s guide
Introducing live anaerobic bacteria into the          scum layer can form and hinder the gas produc-
new digester will expedite start-up, and the          tion. Keeping substrate materials in suspension
higher the ratio of inoculant material used, the      will assist in the uniform breakdown of the mate-
more likely you will have a successful start-up.      rial, and will promote complete digestion.
If only a small amount of seed material can be
                                                      Loading the digester will be the most common
obtained, then new substrate should be added
                                                      operation, and this involves preparation of the
slowly over the course of several days, to pro-
                                                      slurry. Manure must be liquefied, food scraps
mote growth of the bacteria. If material from an
existing digester is not available, active sludge     must be mashed, cardboard or grasses must be
from a sewage treatment plant can be used.            shredded. Remember, the smaller the particles
Some DIY experimenters have used commercial           in your slurry, the happier your digester will
septic tank treatments to promote start-up, but       be. How much you need to feed your digester
only anecdotal evidence is available on the effec-    is called the loading rate. The loading rate is
tiveness of using septic starter. Of course, some     derived from the amount of organic matter
substrate material already contains anaerobic         fed daily, divided by the size (volume) of the
bacteria. Manure or material from the bottom of       digester. A healthier anaerobic environment can
a compost pile will contain some anaerobic bac-       handle a higher loading rate, but over-feeding
teria, and will begin the process more quickly        the digester can cause a rise in the acid content
than will fresh vegetable or plant matter. In the     and reduced gas production. Put more simply,
case of manure, the fresher the better. Anaerobic     more feedstock is not always better.
material exists in the gut, and as it is exposed to   Cleanout is necessary when gas production
air it begins to die. Dried dung will likely con-     drops below an acceptable level. Th is will be a
tain very little live bacteria.                       regular occurrence in a batch digester, but will
A batch digester will generally be easier to          be less necessary in a continuous-flow system,
start than a continuous flow unit, because for        since much of the material will be leaving the
the latter, the hydraulic retention time (HRT)        system as effluent. In both cases, at some point
is less than in a batch digester. HRT is the          during the operation, some digestate and inor-
time it takes for the slurry to move through          ganic solids will need to be removed.
the digester. In a continuous or semi-continu-        Depending on the climate, heating the digester
ous flow arrangement, the digester should not         may be another consideration. Obviously, using
be “fed” for several days after initial loading       any kind of fossil-fuel-based heating like pro-
to allow the growth of the anaerobic bacteria.        pane, oil or electricity doesn’t make economic or
During this start-up period, pH should be mon-        environmental sense, but it may be possible to
itored closely to make sure that the slurry is not    use compost or solar heating, or capture waste
slipping into an acid state. This can easily hap-     heat from another source, to keep a digester
pen by adding new material too quickly. If the        operating efficiently in the colder months.
pH number begins to drop, lime or other “ant-
acids” may be needed to keep the pH level in
anaerobic operating range.                            A word about safety
                                                      Remember, at all stages of construction, operation
Operation and maintenance                             and maintenance of a digester, you are exposing
                                                      yourself to potential hazards. Some feedstocks,
If a healthy environment is established for your      especially manures, contain pathogens or para-
anaerobic bacteria, very little effort is needed to   sites. You can be exposed to them not only in the
operate a micro-digester. In a continuous-feed        loading phase, but also in clean-out, depending
design, substrate should be added daily. A batch      on retention times. The digestion process may not
digester is loaded and then left alone (or agitated
                                                      kill them all. In a dung-based system, special care
occasionally) until gas production falls below
                                                      should be taken to keep yourself, your tools and
an acceptable level. In a small continuous-flow
                                                      your work area clean.
digester, agitation occurs as the material is added
and moves through the digester, although addi-        Methane and the other gases produced can be
tional mechanical agitation can be added. Agita-      deadly. If you are a rural resident, you have
tion of some kind is generally desirable, because     probably heard stories of individuals who have
without it, depending on the substrate, a thick       been overcome by “septic gases” when cleaning a

www.attra.ncat.org                                                                                          ATTRA   Page 7
septic tank. The same can hold true for an              tech method of adding weight to the top of the
                             anaerobic digester. Remember, the digester is           gas storage unit, using bricks or other heavy
                             designed to be an oxygen-free environment—              objects. This can be tricky with a bag digester,
                             good for anaerobic bacteria, bad for humans!            and care must be taken not to snag or puncture
                                                                                     the plastic. Some trial and error is necessary, but
                             Finally, of course, biogas is explosive. Never
                                                                                     in combination with a regulator valve and a car-
                             smoke or use a torch or lantern in the pres-
                                                                                     buretor orifice to adjust the gas/air mixture, a
                             ence of biogas, and use soapy water—NOT a
                             flame—to test for the presence of biogas, unless        good, efficient flame can easily be achieved.
                             it is fed to a properly regulated burner.
                                                                                     Environmental benefits
                             Gas quality                                             of using biogas
                             Because biogas is coming fresh out of a warm            When biogas is burned, it does produce CO2,
                             biological environment, a fair amount of water          which is a greenhouse gas. However, using bio-
                             vapor is present in the gas. Systems for removing       gas is still environmentally beneficial. Along
                             moisture will need to be implemented for good           with CO2 , methane is one of the greenhouse
                             combustion. These can be as simple as pitching          gases that concern scientists most in their study
                             the gas pipe to cause the moisture to run back          of global climate change. According to the
                             into the digester, or fashioning a moisture trap        U.S. Environmental Protection Agency (EPA),
                             made out of a glass jar or bottle.                      although there is less methane in the environ-
                                                                                     ment than CO2 , methane is about 21 times
                             Another potentially more serious issue is fi l-
                                                                                     more powerful at warming the atmosphere than
                             tering or “scrubbing” the gas. Because of the
                                                                                     CO2 (by weight). Methane’s chemical lifetime
                             corrosive nature of the hydrogen sulfide and
                                                                                     in the atmosphere is approximately 12 years.
                             ammonia in the raw biogas, pipes, burners, and
                             especially generator engines can be damaged             (U.S. EPA, 2010) Burning the methane (rather
                             over time. A number of designs for scrubbers are        than allowing it to escape into the atmosphere),
                             available on the Internet, most using beakers or        using the energy and turning the emissions into
                             vessels packed with steel wool, or bubbling the         CO2 reduces the potency of the greenhouse
                             gas through a solution of sodium carbonate.             gases being released, but more importantly, dis-
                                                                                     places fossil fuel use and prevents the release of
                                                                                     additional CO2.
                             Pressure
                             Achieving the proper pressure for combustion            The EPA estimates that in large-scale dairy
                             of the biogas can be done in several very simple        digesters, for each 10 cows from which the
                             ways. Rather than using a high-tech mechani-            manure is anaerobically digested and the biogas
                             cal compressor, most people use the very low-           captured and used, greenhouse gas emissions are
                                                                                     reduced an amount equivalent to taking 4.3 pas-
                                                                                     senger cars off the road. Of course, this statistic
                                                                                     does not address the overall lack of sustainabil-
                                                                                     ity of large-scale confined animal feeding opera-
                                                                                     tions. Other sources estimate that small digest-
                                                                                     ers can reduce greenhouse gas emissions by the
                                                                                     equivalent of 5-7 metric tons of CO2 in house-
                                                                                     holds that currently burn wood.(BMU, 2009)

                                                                                     Side Streams:
                                                                                     Fertilizer and compost tea
                                                                                     Aside from biogas production, the other impor-
                                                                                     tant benefit of operating an anaerobic digester
                                                                                     is the high-quality fertilizer and compost that
                                                                                     it produces. This side stream of the digester can
A farmer in Costa Rica exhibits the amount of gas available from his digester.       provide your operation with a great deal of high
Photo by Ian Woofenden.                                                              valuable soil amendments that can be used at

Page 8         ATTRA                                                             Micro-scale Biogas Production: A beginner’s guide
the farm, or possibly sold for additional income.    composted before application to eliminate any pos-
Certified organic producers should check with        sible surviving pathogens or parasites.
their certifiers for any restrictions.
The effluent and spent substrate that remain         Conclusion
after anaerobic digestion contain higher concen-     Building and operating a micro-scale biogas pro-
trations of potassium, phosphorous and nitrogen      duction system is not right for everyone. It can
than the raw manure or plant waste that went         be messy and labor intensive. Your regional cli-
into the digester. Unlike the raw feedstock,         mate, available feedstock and ability to use the
the nitrogen is more readily available to plants,    gas at your site will determine if a project is even
because it is now in a mineralized form, rather      viable. If you are looking for a good return on
than an organic form.                                investment (ROI) in a conventional farm busi-
In addition, weed seeds, parasites and pathogens     ness model, it may be a hard case to make.
are much less of an issue than with raw manure.
The temperature and lack of oxygen in the anaero-    On the other hand, if you are a small-scale farmer
bic environment is sufficient to destroy many weed   looking to increase the sustainability of your
seeds and pathogens. Nonetheless, particularly in    operation by utilizing the resources at hand with
the case of manure-based digesters, it is strongly   an investment of “sweat equity” rather than cash,
advised that the spent substrate be sun-dried or     micro-scale biogas may be worth exploring.


References
Bates, L. 2007. Biogas Technical Brief. Practical Action. 7 p.    Voca, N. et al. 2005. Digester residue as fertilizer after
http://practicalaction.org/practicalanswers                       mesophilic process of anaerobic digestion. Faculty of
                                                                  Agriculture, University of Zagreb, Croatia. 265 p.
BMU—German Federal Ministry for the Environment,
Nature Conservation & Nuclear Safety. 2009. Mini Biogas           Voegeli, Y., C. Lohri, G. Kassenga, U. Baier and C.
Plants for Households. Project number:                            Zurbrugg. 2009. Technical and Biological performance of
08_I_036_VNM_A_Biogas, 54 p.                                      the ARTI compact biogas plant for kitchen waste. CISA
                                                                  Publisher, Italy. 9 p.
Brown, Laura. 2004. Gas Bio-digester Information and
Construction Manual for Rural Families. Sustainable               Woofenden, Ian. 2009. Appropriate Technology for the
Harvest International. 16 p.                                      Developing World. Home Power Magazine. Oct./Nov.
www.wcasfmra.org/biogas_docs/6%20Biodigester%20manual.pdf         80 p. www.homepower.com

Diver, Steve. 2002. Notes on Compost Teas. ATTRA
Publication. National Center for Appropriate Technology.          Further Resources Online
19 p. www.attra.ncat.org/attra-pub/compost-tea-notes.html         ARTI Biogas Plant: A compact digester for producing
                                                                  biogas from food waste. ARTI,
Fry, L. John. 1973. Methane Digesters For Fuel Gas and            www.arti-india.org/content/view/45/52
Fertilizer, With Complete Instructions For Two Working
                                                                  Articles and videos by Al Rutan “The Methane Man”
Models. The New Alchemy Institute. 58 p.Available online
                                                                  www.rebelwolf.com/essn.html
at: http://journeytoforever.org/biofuel_library/Methane
                                                                  www.green-trust.org/wordpress/2009/08/12/
Digesters/MD1.html
                                                                  free-bio-methane-articles
Fulford, David. 1988. Running a Biogas Program. Practical         An introduction to biogas
Action, Bourton on Dunsmore, UK. 200 p.                           Harris, P. University of Adelaide
House, David. 2006. The Complete Biogas Handbook                  www.adelaide.edu.au/biogas
(3rd Edition). House Press. 288 p.                                A biogas plant for the digestion of fresh undiluted cattle
                                                                  dung. Shyam, M.
Koottatep, Suporn, Manit Ompont and Tay Joo Hwa. No
                                                                  http://practicalaction.org/docs/energy/docs47/BP47Shyam.pdf
date. Biogas: A GP Option For Community Development.
www.apo-tokyo.org/00e-books/GP-07_Biogas.htm                      Methane Digesters
                                                                  www.green-trust.org/methane.htm
Nakagawa, Charles H. 1981. Chinese Biogas Digester. U.S.
                                                                  What is Biogas?
Peace Corps Information Collection and Exchange. 92 p.
                                                                  U.S. Department of Energy
U.S. EPA. 2010. Methane. www.epa.gov/methane                      www.afdc.energy.gov/afdc/fuels/emerging_biogas_what_is.html

www.attra.ncat.org                                                                                          ATTRA        Page 9
Notes




Page 10   ATTRA   Micro-scale Biogas Production: A beginner’s guide
Notes




www.attra.ncat.org   ATTRA   Page 11
Micro-scale Biogas Production: A beginner’s guide
                  By Rich Dana
                  NCAT Energy Specialist
                  © 2010 NCAT
                  Tracy Mumma, Editor
                  Amy Smith, Production
                  This publication is available on the Web at:
                  www.attra.ncat.org/attra-pub/biogas.html
                  or
                  www.attra.ncat.org/attra-pub/PDF/biogas.pdf
                  IP370
                  Slot 369
                  Version 082910


Page 12   ATTRA

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Micro-scale Biogas Production: A Beginner's Guide

  • 1. A project of the National Center for Appropriate Technology 1-800-346-9140 • www.attra.ncat.org Micro-scale Biogas Production: A beginner’s guide By Rich Dana Anaerobic digestion is a simple biochemical NCAT Energy Specialist process by which waste products can be con- © 2010 NCAT verted to energy. Using manure, plant waste, crop residue, food scraps or other waste products, farmers can reduce their dependence on fossil Contents fuels while saving money, reducing greenhouse Introduction ......................1 gas emissions and solving odor problems (not Using the Gas ....................1 to mention producing high-quality compost fertilizer as a by-product). This publication provides Small is Beautiful .............2 a beginner’s guide to using anaerobic digestion Biogas Basics: to produce usable biogas on a small scale with a The Chemistry of Anaerobic Digestion ......2 minimal investment. Feeding Your For more information on biogas and a discus- Digester ..............................4 sion of larger-scale, manure-based digesters for Micro-Digester livestock operations, please see the ATTRA Designs ...............................5 publication Anaerobic Digestion of Animal Wastes: Start-up, Operation Factors to Consider. and Maintenance ............6 Side Streams......................8 Conclusion .........................9 Introduction A References .........................9 naerobic digestion is one of the most Further Resources Online ..................................9 basic processes of life on earth. Anaer- Workshop participants building a micro-scale digester obic means “in the absence of oxygen” in Costa Rica. Photo by Ian Woofenden. and anaerobic digestion takes place when biode- gradable matter decomposes in a closed environ- Although not widely used in the United States, ment. By managing the digestion process and small-scale digesters are used successfully all capturing the biogas produced, we can power over the world to turn small amounts of manure, Funding for the development of this publication was provided boilers, burners and generators, and possibly plant waste and food scraps into usable energy. by the USDA Risk Management Agency. even refrigerators. For hundreds of years, biogas has been used in China and India (and more recently in Africa In the United States, there is a great deal of and Central America) to provide gas for cook- interest in using large-scale anaerobic digesters ing, heating and lighting—utilizing very simple, to control odor at livestock facilities and burning low-tech designs. Th is publication will exam- the biogas produced to run electrical generators. The National Sustainable ine several of the common designs for build- Agriculture Information Service, Commonly referred to as Methane Digesters, ATTRA (www.attra.ncat.org), ing micro-digesters that have been developed was developed and is managed these large-scale units actually digest manure around the world, and discuss how sustainable by the National Center for and produce biogas, which is made up of carbon Appropriate Technology (NCAT). farmers in American can take a lesson from their The project is funded through dioxide (CO2) and methane (CH4) with smaller a cooperative agreement with counterparts in the developing world. the United States Department amounts of water vapor (H 2 O), hydrogen of Agriculture’s Rural Business- sulfide (H 2 S), and in some cases ammonia Cooperative Service. Visit the NCAT website (www.ncat.org/ (NH3). Methane is flammable gas that can be Using the Gas sarc_current.php) for more information on used to make power, and is the primary compo- If you decide to build the digester, how will you our other sustainable agriculture and nent of the fossil fuel natural gas in common use use the gas? Biogas can take the place of pro- energy projects. to heat homes. pane or natural gas in many instances. The most
  • 2. common use is for cooking. It can, of course, technology because of its low cost (and the abil- be used as a heat source as well: to supplement ity to adapt salvage materials or materials that are home heating, for heating a poultry house, far- commonly at hand), simplicity, and environmen- rowing house incubator or other small livestock tal and health benefits. In places where wood is building, or for heating a greenhouse. used for cooking and heating, deforestation is a major concern and burning wood can cause air One unique use that has not been widely explored quality issues and respiratory problems for resi- in the U.S. (but has in China) is using the gas to dents—especially small children. A household power an absorption refrigerator. This is a type digester can reduce the work of gathering wood of refrigerator that uses a propane flame rather and provide a cheap and plentiful fuel source than an electric compressor to create the evapo- where before there was none. rative cooling cycle. These refrigerators are com- monly found in RVs and in locations that have no electricity or unreliable electricity supplies. Biogas Basics: The chemistry Though there is little research available on the use of anaerobic digestion of methane to power absorptive cooling, methane Anaerobic bacteria and archaea predate most has potential for use by farmers who may be look- other forms of life on our planet, having devel- ing for refrigeration options in remote areas. oped in the period when the earth’s atmo- Related ATTRA sphere was mainly methane (CH4), carbon publications Small is Beautiful dioxide (CO2) and water vapor (H2O). Anaero- There are several major technical issues to over- bic digestion takes place in environments with Anaerobic Digestion come in order to operate a large-scale digester limited oxygen: underwater in a swamp or of Animal Wastes: successfully and use it to generate wholesale elec- marsh, at the bottom of a compost heap, or in Factors to Consider tricity. Maintaining proper bacterial health in a the gut of animals. Anaerobic digestion is used Compost Heated 40,000- to multi-million-gallon digester tank in septic systems and sewage treatment plants Greenhouses can be difficult—and mistakes are expensive. to break down waste. Large-scale digesters require hundreds—or thou- sands—of head of livestock to provide adequate The Stages of manure, creating material handling issues. In order to run large, sensitive electrical generat- Anaerobic Digestion ing equipment, the biogas must be “scrubbed” to There are four stages to the digestion process— remove most of the other gases, which can add hydrolysis, acidogenesis, acetogenesis and meth- work and expense. Large digesters often require a anogenesis. These stages need to be managed full-time manager. On the other hand, a micro- early on in starting a digester, but if the pro- digester can supply a family with cooking gas cess is properly maintained, methane production for two meals a day (or add heat to a greenhouse should require a minimum of chemical testing or workshop), from the manure of a few pigs, and treatment. Bacteria must do their work in cows or chickens, or food scraps and rotten or the earlier stages to use up the oxygen in the unusable vegetables and fruit. Because the cost of material, and then break it down into volatile construction is low, the feedstock is free, and the fatty acids and fermented alcohols, before the fuel is used at the source, economic risk can be methanogenic bacteria can start to make methane. minimized and sustainability maximized. The process is as follows: In other parts of the world where energy resources • Hydrolysis: Enzymes break down and are not as readily available as they are in the liquefy the smaller molecules and break United States, the micro-digester is an important down large polymers in the material. Disclaimer: This publication is meant as an introduction to micro-scale biogas production, and not a complete hands-on manual on how to construct and operate a digester. There is a list of references at the end of this publication, and we suggest doing con- siderable additional research before committing time and resources to a biogas project. Most importantly, remember that biogas, though relatively safe, can be dangerous, flammable, and potentially explosive if handled improperly. We suggest that you exercise all possible safety precautions and abide by all local, state and federal laws that might apply to a digester project in your location. Page 2 ATTRA Micro-scale Biogas Production: A beginner’s guide
  • 3. • Acidogenesis: The products of the Pure water is said to be neutral, with a pH level hydrolysis (soluble monomers) are fer- of about 7. Acids have pH numbers below 7, mented to volatile fatty acids (or VFAs) while bases have numbers above 7. A digester and alcohols. operates best near the neutral point, up to a pH of about 8.5. In the early stages of the • Acetogenesis: Acetogenic bacteria anaerobic process, when the digester is making break down the VFAs and alcohols, ace- acids, the pH can drop to 6 or below. When it tic acid, carbon dioxide and hydrogen. reaches methanogenesis, it will operate in the • Methanogenesis: The methanogenic 7.5 to 8.5 range. bacteria convert acetic acid and hydrogen into CO2 and methane. (Note: The three It is important to remember that the pH level earlier stages can take place at lower tem- becomes less of an issue when the digester is peratures than Methanogenesis.) well-buffered, as it can take a certain amount of acid or base material being added to it without upsetting the digestion.(Fry, 1973) Buffering is Temperature and pH the digester’s ability to resist pH change. Since Two of the most important factors for proper pH is a “lagging indicator”, proper buffering anaerobic digestion and methane production are is important to avoid problems with acidity. temperature and pH. Failure to regulate these (see Figure 1). two factors is among the most common prob- lems with a digester. In a large-scale digester, large variations in pH can be catastrophic. In a micro-digester, how- Most anaerobic bacteria perform best in warmer ever, high or low pH conditions may be cor- atmospheres. Th is is why micro-digesters are rected relatively simply. A high-acid condition most common in areas closer to the equator. can be treated with small amounts of lime, Th is does not mean a micro-digester will not ammonia or even bicarbonates like baking soda. function in more northerly climates, but it does affect design decisions, as the digester may need Carbon/Nitrogen Ratio (C:N) to be insulated or even heated to make large Carbon and nitrogen are the two components amounts of methane. Anaerobic digestion does that anaerobic bacteria require for survival. They not stop completely at lower temperatures, but need about 30 times more carbon than nitro- methanogenesis is the stage most seriously hin- gen, so the C:N ratio of your substrate should be dered by low temperatures, and this will reduce about 30:1. This is important when formulating methane production. There is evidence, how- your slurry. When determining the C:N ratio ever, that plant-based feedstocks may perform of feedstock like manure, the animal feed and better at low temperatures than do manure- based systems. (House, 2006) Although micro-digesters in Central America or Figure 1: Courtesy of David House. India often operate completely without added heat or even insulation at temperatures ranging from 60ºF - 100+ºF, the micro-digester design most popular in China is an underground design, which utilizes the earth’s geothermal properties to maintain a healthy temperature. This publication discusses design considerations below, in the section entitled Micro-digester Designs: Global D.I.Y. technology. Along with temperature, pH is vital to digester health. The pH is a measure of the acidity or alkalinity (baseness) of the contents of the digester. Just as in the human digestive sys- tem, too much acid creates “indigestion” in the anaerobic system. www.attra.ncat.org ATTRA Page 3
  • 4. amount of bedding material can heavily affect the actual amounts of carbon and nitrogen— you will need to adjust your feedstock accord- ingly (see Table 1). Table 1: Carbon Nitrogen Ratio Substance C:N Cow Manure—Alfalfa 16:1 Cow Manure—Dairy (with bedding) 21:1 Pig Manure 14:1 Sheep Manure 20:1 Chicken Manure 15:1 Oat Straw 48:1 Turnip Tops 19:1 Corn Stalks 53:1 Grass Clippings 19:1 Sunflower 30:1 Source: House, David. 2006. Biogas Handbook. p.37-40 Feeding Your Digester: Substrates In the proper feeding and care of your digester, you must remember the “Seven S’s” of anaerobic digester design: (see Table 2) Table 2: The Seven S’s of Digester Design 1. Substrate: The organic material that you will be feeding your digester. This can be manure, plant waste, paper pulp, or other biodegradable material. 2. Slurry: The slurry is the homogeneous mush that you will be passing through the digester. In order for efficient digestion to take place, the substrate material should be mashed or ground and mixed with water to make a uniform substance with 15–40% solids, depending on your digester design. 3. Stratification: As your slurry breaks down in the digester, it will separate into layers. These lay- ers—or “strata”—are biogas, scum, supernatant, sludge and solids. Mixing of the slurry prevents excessive stratification, but some stratification will always occur, especially in “batch” digesters (see below, Micro-digester Designs: Global D.I.Y. Technology). 4. Scum: The scum layer floats on the top of the material in the digester, just below the gas level. The scum level is formed by hard-to-digest material like coarse straw and grease. 5. Supernatant: The spent liquid of the slurry. The Supernatant has a high content of solids, making it of high value as fertilizer, similar to “compost tea.”(Diver, 2002) 6. Sludge: Below the liquid supernatant is the sludge layer. The sludge is the digested and semi- digested organic solids. This sludge can provide excellent composted fertilizer, but depend- ing on the feedstock, it may need to be dried in the sun to kill any surviving pathogens. This is more of an issue with manure-based systems. 7. (Inorganic) Solids or Sand: The bottom layer consists of those non-digestible solids that find their way into the digester. These could include dirt, sand, small rocks, plastic or metal—any inorganic solid that may inadvertently be introduced into the system. Page 4 ATTRA Micro-scale Biogas Production: A beginner’s guide
  • 5. Micro-Digester Designs: Figure 2: In-Ground Bag Global D.I.Y. (do-it-yourself) technology There are two basic types of digester designs: continuous-flow and batch processors. In a contin- uous-flow digester, new substrate is regularly fed into the digester. The slurry moves through the digester, pushing out digested material (efflu- ent). The material may also be moved mechani- cally through the continuous-flow digester with augers or pumps. Batch digesters are loaded once The system consists of a long trench (approx. and then the material is allowed to digest. When 20’), lined with a 48” diameter polyethylene the digestion is complete, the effluent is removed (poly) tube to form the “bag”. With an inlet at and the process is repeated. By adding an inlet one end, an outlet at the other and a gas out- tube for feeding the digester and an outlet tube let fitting on the top, it is an extremely simple for the overflowing effluent, a batch processor design (see Figure 2). The poly tubing is available can be fed some extra material after the initial by the roll, and is commonly used as packaging start-up to extend the cycle, making the unit a material. A double layer of 6-8 ml poly is sug- semi-continuous batch processor. Each type has gested to avoid punctures, and a pressure release its advantages. Continuous digesters produce allows excess gas to exit the system before over- biogas without interruption. Batch digesters, on inflation of the bag. This design will produce 4 the other hand, are simpler and less expensive to hours of usable cooking gas per day and requires build. Continuous-flow designs lend themselves approximately 100 gallons of slurry to “charge” better to manure-based systems, while batch the digester, and an additional 10 gallons of processors may be more appropriate for unpro- slurry per day to maintain.(Brown, 2004) cessed plant-based substrates. The types of micro-digesters we will be cover- ing in this publication fall into three categories, with some variation. These are the in-ground bag or tube style (continuous flow), the in- ground dome style (semi-continuous batch) and the floating top/tank design (batch or semi-con- tinuous). Because much of the micro-scale bio- gas technology has been developed by individu- als and non-governmental organizations, these designs are simple and “open source”—mean- ing that the designs are non-proprietary and much of the information on these designs is free and readily available on the Internet. (See the Resources section at the end of this publication for a list of books and websites to visit for more detailed information.) In-ground bag An in-ground bag digester in operation. Photo by Ian Woofenden. The in-ground bag style digester is very popular throughout Central America, and may be appro- priate for use in the Southern U.S. It is a very In-ground dome simple continuous-flow design especially well The in-ground dome design is used widely in suited to a family farm with just a few pigs or China, and may have considerable potential for cows. It is a very inexpensive design, with parts adaptation to northern climates in the United that can be acquired for as little as $50. States.(Koottatep et al., no date) Th is design www.attra.ncat.org ATTRA Page 5
  • 6. Figure 3: In-Ground Dome This design is used widely in India in particu- lar, where ARTI (Appropriate Rural Technology Institute) has developed a very functional fam- ily-sized design utilizing a 1000-liter (264 U.S. gallons) polyethylene base tank with a 750-liter (198 U.S. gallons) tank as the inner floating gas chamber.(Voegeli et al., 2009) Th is design can be adapted to use any size of tanks, with a larger diameter for the outer and smaller diameter for the inner tank, and can be an excellent and inexpensive design to experiment with. Many sizes of drums are readily available for free, and a very small test digester can be made with a couple of barrels and just a few standard plumb- is not unlike a western-style septic tank, and ing parts (see Figure 4). in fact, a conventional cast concrete or fiber- glass septic tank could be modified to serve as a digester (see Figure 3). In China, the latrine is Other designs often connected to the digester, so it serves as a Several other designs have been developed that septic system as well. In the U.S., zoning and are variations on these three basic styles. One is a public health laws in most areas would not allow hybrid design that uses sealed 55-gallon drums as “blackwater” from the home into the digester, despite the obvious advantages to such a system. This design involves a cast concrete, or concrete block, or brick, tank and cap. While the expense is much greater than that of a bag-style digester (typical cost is $350 for 4-6 cu. meters), but by using the earth’s natural insulation, the dome- style digester can maintain a constant tempera- ture, even in colder climates.(Nakagawa, 1981) Floating top/tank The floating top/tank design is one that adapts itself particularly well to the materials at hand. In this design, the slurry is contained in a bot- A simple floating-top digester built from scrap materials. tom tank, with another inverted tank or drum Photo by Rich Dana. serving as a cap, which is lifted by the biogas as it is generated (see Figure 4). modular digesters that are connected to a separate floating top/tank gas storage container. Another style uses the 275-gallon totes commonly used to transport farm and industrial chemicals. In Figure 4: Floating Top/Tank general, plastic containers are preferable to steel drums for the digester vessel and gas storage tanks, because both the slurry and the biogas itself can corrode steel drums fairly rapidly. Start-up, Operation and Maintenance Start-up The best way to get any anaerobic digester going is by “seeding” or “inoculating” it with mate- rial from another healthy, operating digester. Page 6 ATTRA Micro-scale Biogas Production: A beginner’s guide
  • 7. Introducing live anaerobic bacteria into the scum layer can form and hinder the gas produc- new digester will expedite start-up, and the tion. Keeping substrate materials in suspension higher the ratio of inoculant material used, the will assist in the uniform breakdown of the mate- more likely you will have a successful start-up. rial, and will promote complete digestion. If only a small amount of seed material can be Loading the digester will be the most common obtained, then new substrate should be added operation, and this involves preparation of the slowly over the course of several days, to pro- slurry. Manure must be liquefied, food scraps mote growth of the bacteria. If material from an existing digester is not available, active sludge must be mashed, cardboard or grasses must be from a sewage treatment plant can be used. shredded. Remember, the smaller the particles Some DIY experimenters have used commercial in your slurry, the happier your digester will septic tank treatments to promote start-up, but be. How much you need to feed your digester only anecdotal evidence is available on the effec- is called the loading rate. The loading rate is tiveness of using septic starter. Of course, some derived from the amount of organic matter substrate material already contains anaerobic fed daily, divided by the size (volume) of the bacteria. Manure or material from the bottom of digester. A healthier anaerobic environment can a compost pile will contain some anaerobic bac- handle a higher loading rate, but over-feeding teria, and will begin the process more quickly the digester can cause a rise in the acid content than will fresh vegetable or plant matter. In the and reduced gas production. Put more simply, case of manure, the fresher the better. Anaerobic more feedstock is not always better. material exists in the gut, and as it is exposed to Cleanout is necessary when gas production air it begins to die. Dried dung will likely con- drops below an acceptable level. Th is will be a tain very little live bacteria. regular occurrence in a batch digester, but will A batch digester will generally be easier to be less necessary in a continuous-flow system, start than a continuous flow unit, because for since much of the material will be leaving the the latter, the hydraulic retention time (HRT) system as effluent. In both cases, at some point is less than in a batch digester. HRT is the during the operation, some digestate and inor- time it takes for the slurry to move through ganic solids will need to be removed. the digester. In a continuous or semi-continu- Depending on the climate, heating the digester ous flow arrangement, the digester should not may be another consideration. Obviously, using be “fed” for several days after initial loading any kind of fossil-fuel-based heating like pro- to allow the growth of the anaerobic bacteria. pane, oil or electricity doesn’t make economic or During this start-up period, pH should be mon- environmental sense, but it may be possible to itored closely to make sure that the slurry is not use compost or solar heating, or capture waste slipping into an acid state. This can easily hap- heat from another source, to keep a digester pen by adding new material too quickly. If the operating efficiently in the colder months. pH number begins to drop, lime or other “ant- acids” may be needed to keep the pH level in anaerobic operating range. A word about safety Remember, at all stages of construction, operation Operation and maintenance and maintenance of a digester, you are exposing yourself to potential hazards. Some feedstocks, If a healthy environment is established for your especially manures, contain pathogens or para- anaerobic bacteria, very little effort is needed to sites. You can be exposed to them not only in the operate a micro-digester. In a continuous-feed loading phase, but also in clean-out, depending design, substrate should be added daily. A batch on retention times. The digestion process may not digester is loaded and then left alone (or agitated kill them all. In a dung-based system, special care occasionally) until gas production falls below should be taken to keep yourself, your tools and an acceptable level. In a small continuous-flow your work area clean. digester, agitation occurs as the material is added and moves through the digester, although addi- Methane and the other gases produced can be tional mechanical agitation can be added. Agita- deadly. If you are a rural resident, you have tion of some kind is generally desirable, because probably heard stories of individuals who have without it, depending on the substrate, a thick been overcome by “septic gases” when cleaning a www.attra.ncat.org ATTRA Page 7
  • 8. septic tank. The same can hold true for an tech method of adding weight to the top of the anaerobic digester. Remember, the digester is gas storage unit, using bricks or other heavy designed to be an oxygen-free environment— objects. This can be tricky with a bag digester, good for anaerobic bacteria, bad for humans! and care must be taken not to snag or puncture the plastic. Some trial and error is necessary, but Finally, of course, biogas is explosive. Never in combination with a regulator valve and a car- smoke or use a torch or lantern in the pres- buretor orifice to adjust the gas/air mixture, a ence of biogas, and use soapy water—NOT a flame—to test for the presence of biogas, unless good, efficient flame can easily be achieved. it is fed to a properly regulated burner. Environmental benefits Gas quality of using biogas Because biogas is coming fresh out of a warm When biogas is burned, it does produce CO2, biological environment, a fair amount of water which is a greenhouse gas. However, using bio- vapor is present in the gas. Systems for removing gas is still environmentally beneficial. Along moisture will need to be implemented for good with CO2 , methane is one of the greenhouse combustion. These can be as simple as pitching gases that concern scientists most in their study the gas pipe to cause the moisture to run back of global climate change. According to the into the digester, or fashioning a moisture trap U.S. Environmental Protection Agency (EPA), made out of a glass jar or bottle. although there is less methane in the environ- ment than CO2 , methane is about 21 times Another potentially more serious issue is fi l- more powerful at warming the atmosphere than tering or “scrubbing” the gas. Because of the CO2 (by weight). Methane’s chemical lifetime corrosive nature of the hydrogen sulfide and in the atmosphere is approximately 12 years. ammonia in the raw biogas, pipes, burners, and especially generator engines can be damaged (U.S. EPA, 2010) Burning the methane (rather over time. A number of designs for scrubbers are than allowing it to escape into the atmosphere), available on the Internet, most using beakers or using the energy and turning the emissions into vessels packed with steel wool, or bubbling the CO2 reduces the potency of the greenhouse gas through a solution of sodium carbonate. gases being released, but more importantly, dis- places fossil fuel use and prevents the release of additional CO2. Pressure Achieving the proper pressure for combustion The EPA estimates that in large-scale dairy of the biogas can be done in several very simple digesters, for each 10 cows from which the ways. Rather than using a high-tech mechani- manure is anaerobically digested and the biogas cal compressor, most people use the very low- captured and used, greenhouse gas emissions are reduced an amount equivalent to taking 4.3 pas- senger cars off the road. Of course, this statistic does not address the overall lack of sustainabil- ity of large-scale confined animal feeding opera- tions. Other sources estimate that small digest- ers can reduce greenhouse gas emissions by the equivalent of 5-7 metric tons of CO2 in house- holds that currently burn wood.(BMU, 2009) Side Streams: Fertilizer and compost tea Aside from biogas production, the other impor- tant benefit of operating an anaerobic digester is the high-quality fertilizer and compost that it produces. This side stream of the digester can A farmer in Costa Rica exhibits the amount of gas available from his digester. provide your operation with a great deal of high Photo by Ian Woofenden. valuable soil amendments that can be used at Page 8 ATTRA Micro-scale Biogas Production: A beginner’s guide
  • 9. the farm, or possibly sold for additional income. composted before application to eliminate any pos- Certified organic producers should check with sible surviving pathogens or parasites. their certifiers for any restrictions. The effluent and spent substrate that remain Conclusion after anaerobic digestion contain higher concen- Building and operating a micro-scale biogas pro- trations of potassium, phosphorous and nitrogen duction system is not right for everyone. It can than the raw manure or plant waste that went be messy and labor intensive. Your regional cli- into the digester. Unlike the raw feedstock, mate, available feedstock and ability to use the the nitrogen is more readily available to plants, gas at your site will determine if a project is even because it is now in a mineralized form, rather viable. If you are looking for a good return on than an organic form. investment (ROI) in a conventional farm busi- In addition, weed seeds, parasites and pathogens ness model, it may be a hard case to make. are much less of an issue than with raw manure. The temperature and lack of oxygen in the anaero- On the other hand, if you are a small-scale farmer bic environment is sufficient to destroy many weed looking to increase the sustainability of your seeds and pathogens. Nonetheless, particularly in operation by utilizing the resources at hand with the case of manure-based digesters, it is strongly an investment of “sweat equity” rather than cash, advised that the spent substrate be sun-dried or micro-scale biogas may be worth exploring. References Bates, L. 2007. Biogas Technical Brief. Practical Action. 7 p. Voca, N. et al. 2005. Digester residue as fertilizer after http://practicalaction.org/practicalanswers mesophilic process of anaerobic digestion. Faculty of Agriculture, University of Zagreb, Croatia. 265 p. BMU—German Federal Ministry for the Environment, Nature Conservation & Nuclear Safety. 2009. Mini Biogas Voegeli, Y., C. Lohri, G. Kassenga, U. Baier and C. Plants for Households. Project number: Zurbrugg. 2009. Technical and Biological performance of 08_I_036_VNM_A_Biogas, 54 p. the ARTI compact biogas plant for kitchen waste. CISA Publisher, Italy. 9 p. Brown, Laura. 2004. Gas Bio-digester Information and Construction Manual for Rural Families. Sustainable Woofenden, Ian. 2009. Appropriate Technology for the Harvest International. 16 p. Developing World. Home Power Magazine. Oct./Nov. www.wcasfmra.org/biogas_docs/6%20Biodigester%20manual.pdf 80 p. www.homepower.com Diver, Steve. 2002. Notes on Compost Teas. ATTRA Publication. National Center for Appropriate Technology. Further Resources Online 19 p. www.attra.ncat.org/attra-pub/compost-tea-notes.html ARTI Biogas Plant: A compact digester for producing biogas from food waste. ARTI, Fry, L. John. 1973. Methane Digesters For Fuel Gas and www.arti-india.org/content/view/45/52 Fertilizer, With Complete Instructions For Two Working Articles and videos by Al Rutan “The Methane Man” Models. The New Alchemy Institute. 58 p.Available online www.rebelwolf.com/essn.html at: http://journeytoforever.org/biofuel_library/Methane www.green-trust.org/wordpress/2009/08/12/ Digesters/MD1.html free-bio-methane-articles Fulford, David. 1988. Running a Biogas Program. Practical An introduction to biogas Action, Bourton on Dunsmore, UK. 200 p. Harris, P. University of Adelaide House, David. 2006. The Complete Biogas Handbook www.adelaide.edu.au/biogas (3rd Edition). House Press. 288 p. A biogas plant for the digestion of fresh undiluted cattle dung. Shyam, M. Koottatep, Suporn, Manit Ompont and Tay Joo Hwa. No http://practicalaction.org/docs/energy/docs47/BP47Shyam.pdf date. Biogas: A GP Option For Community Development. www.apo-tokyo.org/00e-books/GP-07_Biogas.htm Methane Digesters www.green-trust.org/methane.htm Nakagawa, Charles H. 1981. Chinese Biogas Digester. U.S. What is Biogas? Peace Corps Information Collection and Exchange. 92 p. U.S. Department of Energy U.S. EPA. 2010. Methane. www.epa.gov/methane www.afdc.energy.gov/afdc/fuels/emerging_biogas_what_is.html www.attra.ncat.org ATTRA Page 9
  • 10. Notes Page 10 ATTRA Micro-scale Biogas Production: A beginner’s guide
  • 11. Notes www.attra.ncat.org ATTRA Page 11
  • 12. Micro-scale Biogas Production: A beginner’s guide By Rich Dana NCAT Energy Specialist © 2010 NCAT Tracy Mumma, Editor Amy Smith, Production This publication is available on the Web at: www.attra.ncat.org/attra-pub/biogas.html or www.attra.ncat.org/attra-pub/PDF/biogas.pdf IP370 Slot 369 Version 082910 Page 12 ATTRA