Information About Biogas Achievements at Zorays Solar Pakistan. Zorays Biogas 5 Cubic Metre Plant Solution: https://www.zorays.com/product/biogas/ Zorays Biogas Plant Design Patent Detailed Article: https://www.zorays.com/biogas/

1. Bio-Gas Technology in Pakistan

2. Biogas Technology
• Biogas Production is basically a
process of in which methane gas is
produced anaerobically from organic
matters (like animal waste, crop
residue etc).

3. This process proceeds in three steps:
1. Hydrolytical Breakdown of complex
organic matters in the simpler
compounds
2. Formation of organic acid from simpler
compounds
3. Conversion of organic acids into
methane gas

4. R&D Work Conducted on
Various Designs of
Biogas Plants in Pakistan

5. Modified Indian-Type Vertical Biogas Plant
1 Mixing tank, 2 inlet pipe, 3 digester, 4 movable gas holder, 5 gas
line, 6 water tap, 7 iron guide to movement of gas holder, 8 outlet pipe,
9 stove, 10 ground level
1.

6. Modified Indian-Type Vertical
Biogas Plant
• 2.8 m3
/ day biogas produced in summers
• 1.6 m3
/ daybiogas produced in Winters (temp 8o
C to
10o
C)
• Suitable for areas where temperature > 20o
C
• Corrosion Resistant Paint such as polyvinyl solution
required to be coated on the steel drum used for biogas
storage.
• 2m3
plant produced enough gas to meet the heating &
cooking requirements for 8 hours daily of a medium size
family.
• 30 kg cow dung is required daily.
• Total Cost of the 2m3
biogas plant is approx. Rs.80000

7. Horizontal Biogas Plant for High Water Table Areas
1 mixing tank, 2 inlet pipe, 3 primary chamber, 4 secondary chamber,
5 main hole, 6 digester portion above ground level, 7 gas holder, 8 water
with oil seal, 9 gas line, 10 outlet, 11 water trap, 12 stove, 13 ground
level
2.

8. Horizontal Biogas Plant for High
Water Table Areas
• 2.4 m3
/daybiogas produced in summers
• 20% reduction in biogas produced in Winters
• Suitable for areas where water table is high or
soil is too sandy to prevent deep excavation.
• More efficient Methanogenesis than in vertical
type biogas plants.
• Mixture of oil and water protected the corrosion
of gas holder as well as prevented leakage of
gas that was noticed in vertical biogas plants.

9. Community-size Biogas Plant
1 mixing tank, 2 primary digester, 3 secondary digester, 4 movable gas
holder, 5 water with oil seal, 6 gas line, 7 gas measuring gauge, 8 water
trap, 9 dsicharge pipe, 10 support for movement of drum, 11 colony
3.

10. Community-size Biogas Plant
• 10.3 m3
/daybiogas produced in summers
• Sufficient biogas produced to meet the daily heating /
cooking requirements of five normal sized families.
• 15% reduction in biogas produced in Winters
• The plant could also operate a 1 hp electric generator for
21 hr a day.
• Painting the drum black, charging the biogas plant in the
evening, diluting the dung with solar-heated water and
reflecting sunlight on gas holder reduced heat losses in
winter.
• Mixture of oil and water protected the corrosion of gas
holder and prevented excessive dilution of slurry by rain
water as well as prevented leakage of gas that was
noticed in vertical biogas plants.

11. Modified Chinese type Fixed Dome Biogas Plant
1 fixed dome gas holder, 2 digester, 3 mixing tank, 4 auxiliary chamber,
5 gas line, 6 water trap, 7 outlet, 8 stove
4.

12. Modified Chinese type Fixed
Dome Biogas Plant
• 1.2 m3
/ day biogas produced in summers
• Wide inlet & outlet and less depth of the plant
was suitable for using biomass containing high
fibrous materials like rice barn, wheat straw, fruit
& vegetable wastes.
• The plant has low gas pressure and minor
leakages in the dome.
• Many cracks appeared in the dome as a result
of atmospheric temperature variation from 10o
C
to 44o
C in Pakistan.

13. French type Biogas Plant for cold climate
1 inlet pipe, 2 stainless steel digester, 3 outlet pipe, 4 biomass covering
steel drum, 5 gas line, 6 water trap, 7 truck tyre tubes, 8 gas tap, 9
stove, 10 ground level
5.

14. French type Biogas Plant for
cold climate
• Produced 1.13 m3
/ day biogas
• Suitable for regions with low atmospheric
temperatures.
• Most suitable for biomass with high percentage
of fibre.
• Municipal waste covering of digester ensured
internal temperature of 56o
C even in winters.
• Also recommended for areas where only
available biomass is plant roots, shoots and
bushes.

15. Low Cost Rubber Tubes Biogas Plant
1 mixing tank, 2 rubber tube digester, 3 gas vent, 4 outlet, 5 rubber tube
gas holder, 6 gas line, 7 stove
6.

16. Low Cost Polyethylene Bag Biogas Plant
1 mixing tank, 2 PVC inlet pipe, 3 circular bag digester above ground,
4 circular bag digester portion under ground, 5 outlet with auxiliary chamber,
6 gas line, 7 water trap, 8 stove, 9 ground level.
7.

17. Low Cost Plastic & Rubber
Tubes Biogas Plant
• Plastic and rubber-tubes biogas plants deteriorated
rapidly due to seasonal changes and sunlight.
• Both type of plants despite of great care during
fabrication and installation, did not give reliable results
because of leakage of biogas produced.

18. Composition of Biogas
• Methane = 60 – 70 %
• Carbon dioxide = 30 – 40 %
• Hydrogen = 0.1%
• Oxygen = 0.1%
• Hydrogen Sulphide = Traces

19. Photographs of Vertical Biogas Plant
Installed in Lahore

22. Vertical Type Biogas Plant being used
for generation of electricity and
to operate water lifting pump

23. Use of Biogas Effluent for
Fish Farming in Pakistan

24. Live Stock population in the country to
produce substrate for Biogas Generation
(2006 -07)
Animals (No. in Millions)
Buffaloes 27.3
Cattle 29.6
Goats 53.8
Sheep 26.5
Poultry 401
Camels 0.9
Asses 4.3
Horses 0.3

25. Potential of Biogas Production
for Animal Waste in the Country
• Availability of Dung @ 15 kg per animal per day
for 56900000 (cows & buffaloes)
= 426750000 kg on the basis of 50% collectivity
• Biogas produced per kg = 0.05 m3
• Biogas production capacity for 4.3 x 108
kg dung
per day = 21337500 m3
or 2.1 x 107
m3
• 1 m3
Biogas = 0.67 Litre Kerosene Oil
• 1 m3
Biogas = 8260 kCal of Heat Energy

26. Quantity of Important Crops
Produced in Pakistan
(2006 -07)
Crops (No. in 1000 Tonnes)
Wheat 23520
Rice 5438
Bajra 238
Jowar 180
Maize 2968
Barley 83
Gram 842
Sugar Cane 54752

27. Facts and Figures of a
Working Biogas Plant
• Methane Gas Generation Capacity = 10m3
• No of animals required = 15 (animals)
• Quantity of dung available from 15 animals @ 15kg
per animal = 225kg
• Water required for dilution = 225 kg
• Biogas produced = 10 m3
Approx.
• 1 hp Engine can run for 20 hrs.
• Additional fertilizer with added nitrogen
contents will be available (225 x0.72) = 162kg

28. Benefits of Biogas Production
1. Self reliance in Energy Production
2. Production of Organic Fertilizer with higher
nitrogen contents that can improve crop yield by
10 - 15%
3. Smokeless flame of burner
4. Pathogen free and odourless effluent
5. Provide fuel energy
6. Import substitute of oil
7. Substitute of natural gas
8. 1 m3 of Biogas = 19085 – 24737 BTU
9. 1 m3 of Biogas = 0.6 Litre Kerosene oil
10. 1 m3 of Biogas can run 1hp engine for 2 hr.

29. Additional Work
by Zorays Solar
1. Consultancy provided to different private
parties regarding Biogas Plant Setup
2. Training of Manpower
3. Provision of Research Facilities for M.Sc
and B.E Students from various institutes
regarding Biogas Production.

30. Chemical Analysis of
Various Substrates used for
Biogas Generation

31. Substrate Dry
Matter
%
Ash
%
Lipids
%
Fiber
%
Crude
Protein
%
N.F.E.
%
Buffalo
dung
20.0 18.8 1.4 26.9 9.0 43.9
Chicken
droppings
42.0 31.8 2.6 22.7 21.0 21.9
Municipal
waste
73.4 36.8 1.6 47.0 4.9 9.8
N.F.E. = Nitrogen Free Extract

32. Waste Wheat Straw
• Crude protein = 0.56 x 6.0 = 3.36 %
• Lipids = 1.2%
• Crude Fibre = 37.16%
• Ash = 15.2%
• Dry Matter = 19.9%
• Nitrogen Free = 43.09%
extract

33. Chemical Analysis of
Effluent of Biogas Plant
Dry matter = 18.90 %
Ash = 19.10%
Lipids = 1.25%
Fibre = 22.16%
Nitrogen = 3.51%
Crude Protein = 21.94%

34. Effect of Effluent on the
Yield of Barseem
Production
(Tonnes / Hactare)
Protein content
(%)
Without fertilizer 10.14 21.50
With Effluent 11.25 26.00

35. Future R&D Work
• To improve Biogas Production per kg cow /
buffalo dung and other organic matter
• Purification of Biogas from impurities as required
• Utilization of Biogas in the generation of
electricity and mechanical energy
• Establishment of Biogas Research Institute for
R&D and HR development at Zorays Solar
• Training of Manpower from foreign countries
having advanced Biogas Generation Systems
Contd..

36. • Rectification of biogas plants not working
in rural areas
• Provision of technical know how to
consumer
• Elimination of difficulties in Biogas
generation.

37. Thank You