A live plant(Hissar, Gurgaon) based MBA summer internship project on converting Bio Waste to useful form of Energy. Identify the business opportunities for the Bio Gas & remove the bottlenecks of the plant to increase its efficiency.

1. Waste to Energy Management:
Resonance Energy Pvt. Limited
Submitted by:
Abhijit BISWAS

2. EXECUTIVE SUMMARY
• The aim of the project work is to study the energy scenario of the world as well as
of India. To analyze the existing and its future demand for energy, with respect to
India and the world, both. Moreover, what are the energy sources that India is using
to fulfill its ever growing energy demand. The gap analysis of the energy demand &
supply and probable ways by which India can bridge this energy gap.
• The focus of the project is primarily on Renewable sources of energy, including
Wind, Solar, Geo Thermal and BIO MASS energy, which are expected to play a
major role in bridging this energy gap, and thus reducing the dependence of import
of energy in the form of Oil & Gas from the Gulf Nations

3. Business Problem
• Study of Hansi biogas plant (OPTION ENERGY) in order to find the bottlenecks
of the plant.
Option energy has set up a bio gas plant in Hansi with a maximum capacity of
20tonnes of feedstock. Dr. B.S. Negi (Director of the company) told us that the
plant is not running well and the gas has very less sell at market hence the company
is incurring losses. We studied the plant and did market survey to find the
bottlenecks of the plant

4. HISSAR BIO GAS PLANT: HARYANA
• After studying the potential of waste to energy in India, a live survey of bio gas
plant, located in Hansi, district Hissar (Haryana), was conducted. Detailed analysis
of the working of the plant was carried out, plant’s bottlenecks were identified and
methods have been suggested to improve the efficiency of the plant.
• In the light of this knowledge, an initiative was launched by our mentor and guide,
Mr. B. S. Negi, in collaboration with Mr. H. P. Singh, to set up Bio gas plant which
could convert bio waste from cattle into useful Bio gas and bio manures. This plant
is only dedicated to process cow dung into usable Bio Gas and bio manures

5. Hansi Bio Gas Plant:
• Located just 4 kms away from the
famous GT road, the main market in
the Hansi, it is planted just beside a
goushala, for easy facilitation of the
raw materials (i.e. cow dung in this
case) to the main plant.

6. Plant Process
• Arrival of Cow Dung & Its Measurement:
• Primary Mixing of the Cow dung with water:
• Secondary mixer:
• Pumping Station:
• Heat exchanger:
• Anaerobic Digesters:
• Gas to boiler:
• Gas to balloon

7. • PSA Unit:
• Compression Unit:
• Filling Station:
• Separator Unit :

10. MARKET RESEARCH & ANALYSIS:
HANSI BIO GAS PLANT
• RESEARCH PROBLEM:
• The project is about ‘waste to energy management’- taking reference of a bio gas
plant, Hansi. The main concern is to identify the challenges and studying the way
ahead in Indian perspective. We wanted to identify the bottlenecks of the plant and
explore the market potential of Hansi.
• RESEARCH OBJECTIVE:
• Objective 1: Identify the bottlenecks of the plant.
• Objective 2: Explore the market potential

11. • DATA COLLECTION:
The entire data has been gathered by a survey from Experts, Questionnaire and various web
sites, research articles, reports etc. which are mentioned in the bibliography. For primary data
we used survey methodology and questioner. We chose the samples by judgmental sampling.
• LIMITATIONS:
The recourses for this research were limited to the end users of the fuel, since this bio gas
technology is still in the feasibility study process and haven’t been commercially implemented
yet in India, so we are still able to do the survey like consumer survey etc., whatever data has
been found related to the subject of the study is mentioned in this report. Hence the primary
data source is limited to consumer survey & sample size is limited to 15

12. • DATA ANALYSIS:
From both the Primary & Secondary data sources, information was gathered & then it
was analyzed with detailed research. Then conclusion was drawn. Then, based upon
available data, the detailed project report & presentation were prepared

13. Bottelnecks Identified Solution offered
Quality of gobar supplied is below standard and high
amount of impurities like abrasives and undigestable “to-di”
increases the chances of wear and tear of the machine
To have proper conversation with the goushala owner to
provide better standard of gobar so that better quality of
gas could be produced instead of lower quality of gobar.
The blades of the primary bend as frequently as in a month
period, which takes a day or two get repaired
The best possible solution for this is to replace the mixer
blade with a better quality of the blade with better
endurance, if the frequency of the mixer blade failure is too
high. Moreover, it should be made clear to the plant workers
how much quantity of substrate (mixed water and gobar)
should the mixer be loaded with so as to avoid wear and tear
or bending of the blade. Proper guidance and awareness
about the quantity to be loaded may avoid this kind of failure

14. The secondary mixer malfunctions as gear rupture
occurs once every 4 or 6 months, which hinders the
plant operations. Not only this, to solve this major
issue, the part of the machine equipment is taken to
delhi where the repairmen of the machine takes about
a week or sometimes even two weeks. Thus, for the
time being the entire process is halted, thereby
hampering the bio gas production
Even though, the frequency of the failure is not very
high, still the production does get affected due to this.
The best solution for this could be proper maintenance
of the pump, when it is NOT in use, regular checkups
and proper greasing (LUBRICATING) is prescribed,
and prescribed quantity of substrate should only be
processed
The principle problem of the pump is the corrosion of the
“bushes”- part of a motor and the leakage of the substrate
in the pumping motor. The frequency of the failure is about
once in two months
Possible reasons for the failure of the motor pump can be
inappropriate pump used in this kind pumping system. The
best prescribed pump for pumping the substrate could be
semi closed impellers
The boiler station where the water is boiled using raw gas is
used as a fuel, is not very efficient. The burner is not
appropriate, improper air and fuel mixing due to which black
spots all around the burner and the burner is developed
The major reason for the inappropriate working of the
burner is clearly the wrong selection of the burner. Different
fuels(in this case raw bio gas) require different kinds of
burner. The efficiency of the burners varies with an air fuel
mixture required. Thus, proper mixing of the air fuel is
required for proper burning. Hence the change of burners is
required.

15. Chocking of pipeline and rusting Anti choking chemicals should be in place. Some of the
metal pipes are rusted, these kinds of problems
unavoidable, with time depreciation of equipments
occurs. This can be solved using anti rust paints
The life of the balloon is said to almost over, frequent
leakage and timely depreciation has made this gas container
unsafe for the gas keeping purpose. Another reason for this
fast depreciation is that, te gas balloon has no shade and
cover. During windy days, the balloon which has no anchor
loses its places Most of the time the bio gas produced and
stored in the balloon has to be flared which is a big loss to
the parent company of this bio gas plant.
Shelter has to be created for the balloon as of now, Not only
shelter is needed, it has to be properly anchored so that it
does not leave its actual position.
The pressure swing adsorption system which is responsible
for the purification of the raw gas was out of service, due to
which the production of the bio gas (pure form) was not
happening.
The primary unit of the PSA unit is out of phase but the
plant is equipped with the spare PSA unit cum compression
unit. During the inspection period, the primary unit was out
of service. The reason was told machine has some problem;
the problem was unknown to the plant operators. Thus, only
suggestion that can be offered is to proper check up of the
machine by the expert, so that the actual problem could be
determined and solved..

16. The failure of the gearbox, bearing and other small
equipments keeps separating machine mostly out of
work.
Keeping the spare part to change the gearbox as soon
as possible.
During the rainy season the entire plant is prone to severe
water logging thereby halting process of the entire bio gas
production. Sometimes even during heavy rains, the office
room and the control rooms are flooded with water during
which controlling the plant and production extremely
difficult.
Water logging in the plant can be attributed to only design
defect of the plant only. The office and entire area is flooded
with the water during rainy season, severely hampering the
work of production. The office should have been built on a
slightly above the grounfd level and the working area of the
plant should have been well equipped with a proper drainage
system. The design of the plant can not be changed it can
only be modified. Proper channels and water collecting well
be set up. Channels would ensure that easy flow of water be
allowed leading to the water collecting well, thus avoiding
water logging
The manures and leftovers from the digesters don’t have
enough space so that it could be properly disposed. The
plant is equipped with 4 pits (30*20*4 feet)and all the pits are
full upto its edge.
Proper marketing strategy has to be employed to attract
farmers to buy the bio manures and bio liquid. Proper
awareness about the bio fertilizers should be spread out so
that not only waste is disposed but commercially also the
plant is profited by this.

17. Research analysis
• The response to the questionnaire is taken into consideration to come to a conclusion of the market of the
bio gas, its potential to be analyzed.
• Question 1: Fuel used
• (a) LPG: 66% 20% respondents use both LPG and diesel
• (b) Diesel: 40% 6.5% respondents use both LPG and wood
• (c) Wood: 13%s
• Null Hypothesis (Ho): 60% use LPG and rest Diesel
• Using proportion test: z= (P-p)/(p.q/n)^0.5
• P= .66 , p= .60, n=15
• Z= 0.5
• Since, z is less than 1.80 ( at 5% level of significance), null hypothesis is accepted.
• Conclusion: Diesel and LPG have a lion’s share when it comes to commercial use of the energy in the
food sector.

18. • Question 2: Area of usage of fuel
• (a) Heating 100%
• Hypothesis(Ho): 80% of the population use fuel for heating purpose only.
• Using proportion test: z= (P-p)/(p.q/n)^0.5
• P= 1.0, p= 0.80, n= 15
• Z= 0.2, which is less than 1.8 ( Z test value at 5% level of significance)
• Thus, null hypothesis is accepted.
• Conclusion: It is inevitable that the food industry (which has been specifically targeted)
utilize its energy in heating only

19. • Question 3: Application of fuel
• (a) Cooking: 100%
• (b) Feed: 0%
• (c) Power generation: 0%
• Hypothesis(Ho): 80%Fuel is used for cooking purpose only
• Using proportion test: z= (P-p)/(p.q/n)^0.5
• P=1.0, p=0.80, q=0.20
• Z=0.2 , thus the null hypothesis is accepted as the calculated value is less than the
tabulated value at 5% level of significance.
• Conclusion: food industry is expected to utilize its energy in the cooking only, so
no surprises, none of the respondents used their fuel anywhere else other than
cooking

20. • Question 4: Unit price of the fuel:
• (a) LPG (19 kg): Rs. 1100 to 1300 Black market price: 1500 to 1800
• (b) LPG (14.2 Kg): Rs. 650 to 750 Black market price: 800 to 1100
• (c) Diesel: Rs. 52/Lt.
• (d) Kikkar wood: Price not Quoted but highest of all.
• Conclusion: Price fluctuation is huge which suggest that improper distribution of
price of LPG fuel within the same market

21. • Question 5: Daily/ weekly/ monthly consumption of fuel
• Different respondents gave different quantities which are mentioned below:
• (a) LPG cylinders (Taking equivalent of 14.2 Kg)
• (i) Less than 5 cylinders/ month: 30%
• (ii) 5 to 15 cylinders/ month: 40%
• (iii) 15 to 30 cylinders/ month: 20%
• (iv) More than 30 cylinders/ month: 10%
• (b) Diesel consumption: (i) 0 to 30 Lt/month: 16.5%
• (ii) 30 to 90 Lt/month: 34.5%
• (iii) 90 Lt/month: 50%
• Hypothesis(Ho): It is expected that 50% of the respondent use 5 to 15 cylinders in the month.
• Using proportion test: z= (P-p)/(p.q/n)^0.5
• P=0.4, p=0.5, q=0.5
• Z=0.83, z calculated value is less than z tabulated value(1.8 at 5 % level of significance)
• Conclusion: Medium size firm using substantial fuel in the form of LPG and Diesel are very much into existence
which are dominating the market

22. • Question 6: Mode of transportation
• (a) LPG cylinders via roadways (Hanuman gas agency and sajjan gas agency)
• (b) Diesel: Retail outlets
• Question 7: Availability of fuel
• Fuel is readily available to all the consumers

23. • Question 8: Availability of any back up fuel
• People don’t have any back up fuel as such. Many end users have the policy of using dual fuel ie
LPG and Diesel both or even wood. The regular supply of cylinders ensures that no shortage is
present. Even during shortage, fuel is available in the black market with slightly higher price.
• Question 9: Readiness for switching to bio gas.
• (a) Yes: 86%
• (b) No: 7%
• (c) Can’t say: 7%
• Hypothesis(Ho): It is expected that 60% of the respondents are willing to switch to bio gas
• Using proportion test: z= (P-p)/(p.q/n)^0.5
• P= 0.86, p=0.60, q=04.
• Z=2.1, which is greater than tabulated value of 1.86, thus we reject our null hypothesis.
• Conclusion: It is extremely good news that people are ready to switch to bio gas if it is readily
available at a cheaper price

24. • Question 10: Price differential expected
• (a) Less than 10%: 14%
• (b) 10 % to 20%: 14%
• (c)More than 20%: 62%
• End user suggestions:
• (a) People are ready to use if the bio gas is readily available, cheap and not higher
cost.
• (b) People expect that efficiency of the burning of this bio gas should be similar to
that of LPG.
• (c) People also expect, there won’t be too much cost involved in changing the setup
for bio gas
• (d) Initially, the bio as should be delivered to the end user free of cost so that the
users can test the efficiency of the bio gas before switching to it permanently

25. End user problems discussed and solution
offered
• Problem 1:
The foremost problem which has been described here is the weight of the bio gas
cylinders. The bio gas cylinders are as high as 6 feet and weighing up to 100kgs which
makes handling of these cylinder very difficult.
• Solution offered:
Movement of 100 kg cylinder is not any mean task. At least two people are always
required for the proper movement of the cylinder from one place to another, thus,
making handling of the cylinder very difficult at a ground. Best alternative at a ground
level would be the pipeline supply of the gas to the end user

26. • Another alternative solution could be the concept of semi pipeline. The
cylinders would be transferred to the end users via roadways transport and
cylinders would be installed in a predefined position. From that position
small pipelines could be laid off to the main kitchen of the household or
shop, thus reducing the handling issue to a great extent

27. • Problem 2: The problem of formation of ice in the pipe. The bio gas cylinders
have the pressure of 150 bar at the time of filling but the required pressure for the
burning of fuel is 21 milli bar, thus such a drastic downfall of temperature (joule
Thompson effect), ice us formed due to which irregular supply of the fuel occurs.
• Solution offered:
• This problem was inevitable to come. The engineering solution to this problem
could be installment of multi stage pressure controller in order to avoid formation
ice. Still this method is not full proof. The distribution of bio gas remains the best
alternative to this solution as well as controlling and reducing the pressure would be
lot more easy

28. SUMMARY:
• The entire focus of the internship was to analyze the market aspect of this bio gas
plant & identify the bottlenecks of the Bio gas plant in Hansi. The current
consumption of fuel in the market has been identified which clearly depicts that the
potential of the bio gas its huge. The rated capacity of the plant is 20 tones, but the
required fuel by the market much more than the 20 tone. All the plant needs is to
have a proper marketing strategy so that the produced bio gas as well as bio
manures could be continuously sold off.
• Some of the concerns of the end consumer have also been discussed here, and
possible solutions have also been identified

29. Thank you…