1.
Biomass based Biogas Plant
Construction details by RASTA
Kambalakkad Po, Wayanad Dist
Kerala- 673 121
Danesh Kumar
daneshkumar2@gmail.com

2.
Lay out of Biogas Plant

3.
After marking the layout for
the Bio rector, soil is
removed
Proper allowance is given for
the brickwork, so that back of
the laid bricks can be cleaned
of laid mortar

4.
Laying of foundation of 40mm
of 10 cms thick, a
Cement Concrete using
20 mm in 1:2:4 mix for
7 Cms thick is applied on
top of this, It must be properly
tempered with weight,
so as to remove voids

5.
Soaking of Bricks, at
least six hrs,
immersed in water

6.
After laying of foundation, the first set of bricks are laid in cement mortar (1:5)

7.
Bricks must be properly aligned, sufficient gap for mortar filling, mortar must be fresh

8.
The mortar applied to the bricks
must be properly placed between
the gaps of the laid bricks,
at least 1 cm

9.
At the end of the day, the mortar
Applied to the bricks must be
cleaned from the gaps of the laid
bricks, with a wire brush gently

10.
Water level of the laid bricks must be checked for proper dimension

11.
Laying of the inlet pipe, be in the middle, top must be above bio reactors height

12.
Inlet pipe external side must be cleaned, cement grout applied for better joining to brick

13.
IInlet pipe be tied with rope from inside to a post outside, use fresh cement concrete (1:2:4)

14.
Where the inlet pipe is in contact with
laid brick, after applying cement concrete
on all sides, the brick lines must be
worked in fresh & rich cement mortar

15.
Curing of the brick work is essential,
better to do in the morning before the
Start day’s work

16.
Area around inlet pipe, concreted (1:2:4) 12 cms thick, for inlet box, slightly larger larger

17.
Top height of Inlet box be higher than bio rector’s height,

18.
Once the cement concrete is in place
Around inlet pipe, the form work of box
can start

19.
After concreting, inlet box is built around it, the water in the box forms a perfect seal

20.
Steel for reinforcement, must be worked
To build the stirups and rings

21.
Steel for reinforcement, for beam

22.
After the concrete work is over building
The belt, the inside of the bio reactor be
chipped and clean of the remains of the
cement mortar, splashed with water ,
dusted with cement powder, then
Plastered with fresh cement mortar cm
(1:5) 12 mm thick

23.
Next building top of reactor, called vault, use welded mesh for perfect shape

24.
Use soaked bricks, fresh cement mix (1:3) complete each line of before starting next

25.
Final brick of vault, keystone, locks all bricks of vault, quality bricks to be used

26.
Next day, brush away all lose mortar
from the top with wire brush, a gap is left
For the outlet pipe from vault, plaster
with cm (1:3) of 12 mm thick, and on
Top a thin plaster of cm(1:6), start from
The bottom to top.

27.
Clean edges of mortar, dust with cement powder, plaster cm (1:3) with minimum of water ,

28.
proper curing of12 days, fill water to check leakages, gradually top it up

29.
Gas storage tank, foundation 40 mm -12 cms thick, after wetting, properly pounded down

30.
Top of 40 mm layer, add cement concrete (1:2:4) 7.5 cms thick,

31.
Steel pipe as guide for storage tank with welded legs must be concreted in the gap

32.
Steel pipe as guide for storage tank with welded legs must be concreted in the gap

33.
On completion of plastering, water must
be introduced gradually into the tank for
full curing.

34.
PVC tank must be pierced in centre, connect PVC pipe as a guide, ropes used for anchoring

35.
Feeding the system with biomass, after
50 Kgs of Biogas slurry as starter
solution

36.
Combustible gas was available from the
system after 3 weeks of incubation