Recycle Human Waste

For Health, Wealth and Energy

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MALAPRABHA BIOGAS PLANT

Developed By Dr. S. V. Mapuskar
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NEW DESIGN FOR RECOVERY OF BIOGAS FROM LATRINE

Published by Jyotsna Arogya Prabodhan, Dehu village, Tal. Haveli, Dist. Pune, Maharashtra 412 109 INDIA 1

Copy right Dr. S. V. Mapuskar, Dehu village, Tal. Haveli, Dist. Pune, Maharashtra 412 109 INDIA

Published June 1988 Updated: November 2011 For Private circulation only

Recycle Human Waste For Health, Wealth and Energy

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MALAPRABHA BIOGAS PLANT

Developed By Dr. S. V. Mapuskar
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NEW DESIGN FOR RECOVERY OF BIOGAS FROM LATRINE

CONTENTS Sr. No. 1. Particulars Development of Nightsoil Based Biogas Plants Introduction To Malaprabha Basis Of The Design Design Calculations Construction Work Field Implementation of the design Page No. 4

2. 3. 4. 5. 6.

12 14 18 24 32

ANNEXURES 1. 2. Material Estimates Labour Component Estimates 34 37

Chapter 1:- Development of Night Soil Based Biogas Plant

In India, biogas technology is in use very effectively for nearly five decades. Curiously, one of the first few biogas plants in the world which was constructed at Leprosy Home at Wadala in Bombay in about 1901, worked on sewage. Subsequently, in 1937, biogas generation was undertaken at Dadar Sewage works at Bombay, again, during the treatment of sewage sludge. Unfortunately, for the last several years, it is being presumed at various levels, that cattle dung is the only appropriate feed for the biogas plant. This presumption received a further boost, because the biogas plants in India were and are still known by people as Gobar Gas Plant. This name has been an unfortunate nomenclature in the development of biogas technology in this country, as it gave rise to the impression that gas is possible only from Gobar (cattle dung). We are aware that biogas is generated during the anaerobic digestion of any naturally produced dead organic matter. It is now high time that we start working more vigorously on the use of organic feeds (which are at present a wasted resource) other than cattle dung for biogas generation. The earlier we do it, the better it will be. The review of the cattle population in India gives some interesting findings. Only about 15% families in the country own 2 or more cattle heads. Therefore, it becomes obvious, that, 5

hardly about 10% population in the country (if all are ideally covered) can manage to run biogas plants. If biogas technology remains restricted to cattle dung feed, only the rich farmers will benefit from the biogas technology. The poor and weaker sections of the society will remain deprived from the benefits of biogas. We can take the benefits of biogas technology to these deprived people only if, we are able to use alternative feeds (other than cattle dung) for the production of biogas. Further, it is also necessary to think in terms of establishing community biogas production facilities. When we think in terms of use of alternative feeds, the existing technology has to be modified to suit the alternative feeds. Unfortunately, the technology in use for cattle dung feed was used in toto for other feeds also. This resulted in several problems. As a result, in many cases, the use of alternative feeds was abandoned. This is a negative approach. To take a more positive view, the parameters, the design criteria and characteristics of the feed will have to be considered as a package. Many such alternative feeds are available. At present, most of them are treated as an organic waste, a nuisance and hazard. The biogas programme could be easily extended to a wider section of population, if these alternative feeds are tapped imaginatively and adequately. Human nightsoil is one such alternative feed. At present, human nightsoil treatment is a major sanitation problem in the country. It is a major source of pollution, health hazard and social injustice. It has become a nuisance to rural and urban environment. Its effective treatment is becoming unmanageable. 6

If it is used imaginatively in biogas plant, it can become an asset instead of a nuisance. Realizing the importance of proper nightsoil disposal in rural India, Mahatma Gandhi included it in his gramsafai and village upliftment programme. Sanitary disposal of nightsoil was visualized to serve fold three purpose, viz. 1. emancipation of scavenger community (Bhangi Mukti), 2. clean villages (gram safai) and 3. production of manure (Khad nirmiti). Proper treatment of human waste (Nightsoil) is an essential requirement for better village sanitation and promotion of health, with the ultimate objective of Health for all. Recycled imaginatively, it can also partially meet the energy and fertilizer needs of the country. Thus, the waste can turn into wealth. On site nightsoil treatment methods are very satisfactory in developing countries as they obviate the process of manual lifting, carriage and occasional spilling of faeces. The aqua privy or septic tank latrines (an on site disposal method) which are essentially anaerobic digestion processes, are increasingly being constructed in the country. Human nightsoil, being a naturally occurring organic material, emits methane containing gas (i.e. biogas, which is an asset, not a nuisance) during anaerobic digestion in the septic tank. Unfortunately, no attention is given to this component, while promoting the construction of latrines. The gas emitted from these latrines is considered as a nuisance gas and is let off through as high a vent as possible, polluting the air and depleting ozone layer. Late Appasaheb Patwardhan took up human nightsoil treatment this activity as a mission for his life. He worked feverishly, since 1928, on the problem of nightsoil disposal, 7

devising in the process, several innovative designs for latrines such as Sopa Sandas (simple latrine), Gopuri latrine etc. and subsequently biogas plants. The technological design for a biogas plant to be used for nightsoil feed must be suitable for the characteristics of human nightsoil. In the initial stages, the design which was found to be suitable for cattle dung was used for human nightsoil without any change. Human nightsoil has physical, chemical and microbial characteristics which markedly differ from those of cattle dung. Therefore, the parameters, design criteria etc. fixed for cattle dung biogas plants are not valid for human nightsoil. Late Appasaheb Patwardhan a dedicated Gandhian worker, pioneered nightsoil based biogas plants in India, with the construction of the first nightsoil based biogas plant at Kankavli in Ratnagiri district of Maharashtra in 1953. It was based on Gramlaxmi design developed by Shri. Jasbhai Patel in 1951 (which was adopted for propagation by KVIC since 1962). Appasaheb Patwardhan worked further on Gram laxmi design and modified this design for the use of human nightsoil as a feed. The design which he devised, was a water jacketed digester with a floating dome gas holder. He termed it water jacket gas plant later called as Gramgaurav gas plant. This is the design which is now known as Floating Dome Water Jacketed Digester design. Subsequently he constructed many such plants throughout the country, creating a cadre of trained social workers in the process. The feasibility of on site treatment of nightsoil in a biogas plant was effectively demonstrated by him. He was a 8

visionary, quite ahead of his times. He constructed the first nightsoil based biogas plant in India, at a girls hostel in Kankavli. The plant receives nightsoil directly via pipes (no manual handling and exposure of nightsoil) from four adjacent latrines which are being used by the inmates of the hostel. The biogas is being used in the kitchen. The effluent slurry is being used as a fertilizer for plantation. The original plant at Kankavli still continues to function satisfactorily even after nearly 35 years. This fact speaks effectively for the suitability of the design and for the feasibility of biogas generation from nightsoil. Appasaheb Patwardhan, in his capacity as Chairman of Bhangi Mukti Samiti of Gandhi Smarak Nidhi, tried to popularize nightsoil fed biogas plants throughout the country and also arranged for the subsidy to be paid by Gandhi Smarak Nidhi headquarters in New Delhi. After the biogas programme was taken up by D N E S, it has given a positive boost for the propagation of nightsoil based biogas plants. In 1981, Dr. S. V. Mapuskar developed an innovative design MALAPRABHA BIOGAS PLANT for recovering biogas from anaerobically digested human nightsoil. While developing this design, he had taken into consideration the relevant hygiene factors along with the parameters for biomethanation of human nightsoil. The relevant social factors and convenient latrine use also were considered. These parameters could be enumerated as follows: There should not be any direct handling of nightsoil,

Undigested nightsoil should not get exposed to surroundings and should be inaccessible to insects and animals, Aesthetically there should be freedom from odour and unsightly conditions, There should not be any contamination of subsoil or surface water, Surface soil should not get contaminated, Maintenance of the treatment process should be easy and should not evoke any repulsive feelings, The recycling should give maximum possible advantages, The social and behavioural aspects need to be tackled by educational process.

Taking all the abovementioned parameters into consideration, it is felt that for human nightsoil biomethanation, only two designs are suitable:1. Floating dome water jacketed biogas plant developed by Shri S.P. alias Appasaheb Patwardhan in 1953. 2. Fixed dome Malaprabha Biogas Plant developed by Dr. S.V. Mapuskar in 1981. Malaprabha biogas plant has a cubical shape and hence can be installed even inside the house. Latrine seat can be installed above the biogas plant, minimizing the land requirement. It is very easy for operation and maintenance. As a result the design has been accepted widely. Since 1981, hundreds of Malaprabha biogas plants have been constructed. The results are very good. The plants have been designed from 1 CuM capacity to 30 CuM capacity. In Dehu village nearly 80 Malaprabha plants, working on human nightsoil are functioning satisfactorily. Dehu is probably 10

the only village in India which has such a large number of functioning nightsoil based biogas plants. In the following pages Malaprabha Biogas Plant design is described.

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Chapter 2: Introduction to Malaprabha

Any naturally grown dead organic matter generates biogas after anaerobic digestion. However, so far, the stress has been on using cattle dung as main feed material for the biogas plant. During the past few years, there has been a distinct change in this attitude. The presently available designs were designed mainly for the cattle dung feed. These designs may not be the optimized designs for other feeds. Hence, the designs need to be evolved so that the optimum conditions are created for the utilization of these feeds within the right parameters. Now the efforts are being made to decide on the parameters which would be suitable for the use of feed materials other than cattle dung. Human nightsoil is one of the important and readily available feed materials for biogas generation. The biogas programme could be given an additional boost if the human faeces are utilized for the biogas generation. However, for the use of human night soil feed and for the efficient functioning of human night soil based biogas plant, the parameters and the design criteria as regards the procedures for the feeding and handling the feed, the physical and chemical characteristics of the feed, the movement of slurry, odour, aesthetics, etc. need to be considered so as to create optimum conditions for the use of human nightsoil. Further, from health point of view, it will be necessary to see that the raw human nightsoil is not exposed to environment, insects, animals etc. and is not manually handled. During the digestion process, it should not be exposed to environment. Further, the most important parameter from health point of view will be the extent 12

of pathogen kill or pathogen inactivation achieved, during the process so that the effluent is not pathogenic. It may be necessary to accommodate such a biogas plant in close proximity of the residence, perhaps in the house itself. Thus, it may be desirably suitable for the space constraints and the conventional cubical format of house construction. Further, the cost of the unit and the space requirement could be minimized if the biogas plant and the toilet seat are made into an integrated unit where the toilet seat is superimposed on the biogas plant, although offset toilet seat may be a requirement in some situations. Keeping these factors in mind, a new design specially suitable for the human nightsoil has been evolved, by Dr. S. V. Mapuskar, in 1980. After watching the performance for five years, the design was presented at national conference on Biogas from Human Waste organized by CORT at New Delhi from 22nd Aug. 1985 to 23rd Aug. 1985. It is named as MALAPRABHA BIOGAS PLANT. It could be classified as a fixed dome biogas plant. With a little modification, it can also be used for other feeds.

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Chapter 3: BASIS OF THE DESIGN

As stated earlier, the basis for the biogas plant functioning on human nightsoil will necessarily differ from that for the cattle dung based biogas plant. Number of studies has already been done throughout the world on the anaerobic digestion of human nightsoil. These studies have been in the context of a human nightsoil disposal system and not as a biogas generation system. However, since these studies are for anaerobic digestion, such available data was taken into consideration while developing this design. 1. Pathogenicity - The destruction or inactivation of the pathogens will be a very important criterion for the biogas system working on human nightsoil. The human faeces contain various species of viruses, bacteria, protozoa as well as the vegetative forms and ova of helminthes. It has been reported that, for the inactivation and/or destruction of viruses, bacteria and protozoa, a maximum period of about 45 days of anaerobic digestion is necessary. Helminthes ova are not destructed in anaerobic condition. However, they either float at the top or sink to the bottom (depending on the species) in the digester. Hence, in Malaprabha design, the care has been taken to see that the top and the bottom layers of the slurry do not flow onwards and do not get in to the effluent. Thus, these ova are retained in the plant and end in a natural death or inactivation over a period of about two years. Thus, the effluent coming out from the biogas plant of this design will be free from active viable pathogens. 2. Direction of slurry flow - In biogas generation systems, because of the buoyancy due to gas bubbles attached to slurry particles and some other factors, there is a vertical up and down 14

movement in the slurry. However, the slurry getting in from the inlet tends to push the digesting slurry in the digester towards the outlet. It would be desirable not to have these two movements in the same direction. It would be better if inlet to outlet movement is horizontally directed. This sort of a movement would be more akin to horizontal plug flow type of movement. In this design, it has been arranged that the movement of the slurry from inlet to outlet is in horizontal direction. The consistency and the physical characteristics of human night soil are such that the diluted digesting slurry gets stratified into three layers. The lighter material floats as a suspension in upper rd portion. The heavier component settles down in the lower rd portion. During the digestion process, these materials tend to move up and down in vertical direction, depending upon the attached gas bubbles, specific gravity etc. However, the middle rd portion is found to be relatively free from solids. Hence, in this design, care has been taken to see that the horizontally forward movement of the digesting slurry is from the middle rd portion. This more or less simulates the plug flow pattern in horizontal direction, mainly from the middle rd portion. The plant is designed to have three horizontally interconnected chambers. This mode of movement ensures that there is no short circuiting of incoming raw slurry. Incidentally, slurry inlet and outlet pipes also serve as small additional chambers regulating the flow.

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3. Solid Content & Digester Volume - Available data shows that for anaerobic digestion of human nightsoil, the optimum solid contents need to be around 3% to 4 %, the variation being between 2% to 5%. The fresh night soil has a solid content of about 25%, varying between 20% to 30%. In Indians, the average weight of fresh night soil per person/day is around 300 gm. It has been shown that the use of about 217 liters of water per person/day would give an optimum solid content required for the anaerobic digestion of slurry. Hence, this volume has been taken as a basis for calculating the digester volume. It has been noted that human nightsoil yields about 35 to 40 litres of biogas per person/day. Therefore, for getting 1 CuM of biogas per day, it would be necessary to feed the night soil of about 25 persons/day. Thus, for a biogas plant having a capacity of producing one CuM. Biogas per day, the digester volume should be sufficient to accommodate the night soil of 25 persons per day with input volume of 217 litres per person per day. Further, the expected retention period required for the pathogen kill has been taken as 45 days. This basis has been used for the calculation of digester volume. 4. Scum Breaking & Allowance for Sedimentation During the digestion of slurry, the lighter solids will tend to form a scum which will hamper the gas accumulation at the top. In order to avoid this, a scum breaking arrangement has been incorporated. This device consists of horizontally fixed PVC pipe grid attached to the inlet pipe at a distance of 300mm from the top. Every time the slurry moves up and down, this device automatically breaks the scum accumulating on the top of the slurry.

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In order to prevent the helminth ova from escaping to the second chamber, a very simple arrangement has been made at the bottom. The displacement window between the first and second chamber is partially closed at the bottom by placing loose bricks up to height of 225 mm from the bottom. While desludging the plant, these bricks can be removed so as to facilitate the removal of the settled nondigestible sludge from the first chamber. 5. Slurry Inlet Pipe A 100 mm Dia. PVC pipe is embedded in the R.C.C roof of the first chamber, with the help of M. S. flanges and anchoring bolts, the pipe projecting in the chamber to a depth of 700 mm from the roof. This ensures that the gas does not escape through the inlet. 6. Gas Storage & Gas Outlet The roof of the digester chamber and the sides of the digester chamber are rendered gas proof by cement plastering and by gas proofing treatment. Thus the upper portion of the digestion chamber serves as a gas storage space. Gas outlet is fixed in the roof of the digester by embedding it in R.C.C. roof with the help of flanges and anchoring bolts. In order to avoid the blockage by the scum, the diameter of gas outlet pipe is kept at 75 mm. The continuously generating biogas will keep on accumulating in the upper portion of the digestion chamber by pushing the corresponding amount of slurry towards the second chamber (Displacement chamber). As the slurry outlet level in the third chamber is at the level of the top of the digestion chamber, the accumulating gas in the digestion chamber will be stored at a pressure exerted by the slurry column in the second and third chambers which will be at a higher level than the 18

slurry level in the digestion chamber. (This action is similar to the action in the other fixed dome designs.) The pressure on the gas will vary between 0 to 30 cm water column. 7. Slurry Outlet Position Slurry outlet pipe is placed in the third chamber at the level of the roof of the digestion chamber. Thus, when there is no gas in the gas storage space, the slurry levels in all the three chambers will be at the outlet level. 8. Structural Provisions to Prevent Gas Leakage As stated earlier, the roof of the first chamber is cast in R.C.C., in which the slurry inlet pipe and gas outlet pipe are embedded with the help of M. S. flanges and anchoring bolts. PVC pipes are used. In order to avoid the lifting of the edges of the slab, a brickwork load is given on the edges of the slab. Also, anchoring for the slab is provided in the top layer of the brickwork supporting the slab. In order to minimize the stresses at the corners and joints, the corners are rounded off with cement mortar plaster, thus diverting the stresses. The joints between the brickwork and the slab as well as slab and pipes are also rounded off in a similar way. 9. Toilet Seats As stated earlier, the toilet seat is placed on top of the digestion chamber using load brickwork as a plinth. The latrine pan is connected to the inlet pipe through the water seal trap via inspection chamber. If desired toilet seat may be placed off site. However, it will increase the construction cost to that extent. As it is necessary to restrict the use of water to about 217 litres per person, the water seal trap with only 20 mm water seal is used. With this type of water seal, only 15 liters of water is sufficient for flushing. Automatic flushing cistern is not 19

provided. If the situation demands, automatic flushing system with low volume controlled flushing, can be used. Because of the provision of water seal, there is no smell or odour from inlet pipe. Further, the insects do not find an access to the system. Some gases are likely to emanate from the inlet pipe. A vent is provided for these gases. This vent also ensures that the water seal is not disturbed by the negative pressure. An inspection chamber provided between inlet pipe and the water seal trap allows for the cleaning and maintenance of water seal trap and inlet pipe whenever necessary. The second and third chambers are completely covered. Some gases are likely to accumulate in second and third chambers. For these gases also a vent is provided. This vent is combined with the vent from inlet chamber and a common vent is taken above the roof of the latrine. Thus the system becomes totally odourless. 10. Maintenance The required routine maintenance is minimal. Inspection chambers at inlet and outlet provide an easy access for occasional cleaning. In this system it is not necessary to manually handle the night soil. Once the night soil gets past the water seal trap under the seat, it is not exposed to environment anywhere in the system. After total digestion, the end product in the form of harmless digested slurry comes out from the slurry outlet. Thus, in this design all the important requirements for the biogas generation and hygienic requirements for human night soil management are taken care of. 11. Safety In comparison to LPG, biogas contains a mixture of mainly methane and carbon-dioxide which is under very low 20

pressure ranging between 0 to 40cms water column. Further, methane is not explosive, unless it is mixed with air and is under very high pressure. Therefore, the biogas plant is very safe. Further, in case, because of non use, more gas is stored in the gas storage space, the pressure will never exceed 40 cms of water column. It is because after the maximum storage space is occupied, the excess gas escapes through inlet pipe and further through the vent provided for inlet chamber and second and third compartments. Therefore, this plant can be installed even inside homes.

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Chapter 4: Design Calculations

1. Basic Data i. Average weight of fresh human night soil 300gm/person/day. ii. Solid content -25% (varying between 20% to 30%). iii. Quantity of biogas generated -35 to 40 litres/day/person. iv. Optimum water use -217 litres/ person/day. v. Desirable solid content of slurry 3% to 5%.

2. Calculations for 1 CuM biogas/day Daily feed for 1 CuM biogas/dayNight soil from 25 persons/day. Therefore, daily input 25x217 5425 litres/day. Therefore, for 45 days HRT Required digester volume= 5425 x 45 = 244125 litrers. Now, Total volume= vol. of I chamber + (vol. of II+III chamber) Therefore, The proposed dimensions of I chamber (digestion chamber) are, Length = 1125 M, Breadth = 105 M, Depth = 15 M. Thus, Volume of I chamber (digestion chamber) = 17718 CuM Volume of II chamber (displacement chamber) = 04061 CuM Volume of III chamber (outlet chamber) = 04061 CuM Total vol. of I+II+III chambers = 2584 CuM 3. Calculations for 2 CuM biogas/day Daily feed for 2 CuM biogas/day Night soil from 50 persons/day. Therefore, daily input50x217=1085 litres/day Therefore, for 45 days HRT Required digester volume = 1085x45=48825 litres Therefore, The proposed dimensions for I chamber (digestion chamber) are, 22

Length=203 M, Breadth=105M, Depth=15 M. Thus, Volume of I chamber Volume of II chamber Volume of III chamber Total Volume of I+II+III

= 31985 CuM = 0780 CuM = 0780 CuM = 4758 CuM

4. Calculations for 3 CuM biogas/day Daily feed for 3 CuM biogas /day Night soil from 75 persons/day. Therefore, daily input 75x217=16275 litres/day Therefore, for 45 days HRT Required digester volume = 16275x45=732375 litres. Therefore, The proposed dimensions for I chamber (digestion chamber) are, Length = 315 M, Breadth = 105 M, Depth = 15 M. Thus, Volume of I chamber = 497 CuM Volume of II chamber = 111 CuM Volume of III chamber = 111 CuM Total volume of I+II+III = 719 CuM

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Chapter 5 Construction Work

1. Rectangular lineout is given for excavation. In lineout 150 mm more on each side than the actual construction measurements are given to make an allowance for a regular excavation. 2. Soling is laid and P.C.C. as per drawing is laid.

3. Bricks of good quality are used for brick work. Improperly burnt or excessively burnt bricks are not used. Bricks are soaked fully in water. Care is taken to see that mud does not get attached to the bricks. 4. Bricks are laid in alternate layers of headers and stretchers. While laying the bricks, each layer is laid continuously for all the walls including partition walls. So that the bonding at the corners is not weak. (A practice of raising each wall separately is not followed.) 5. During this process, the partition wall is also simultaneously laid leaving appropriate gap for the displacement window. Brick work is raised up to 525 mm. 6. While laying the next layer, an arch is constructed over the window. For the arch, dry bricks are stacked to serve as a shuttering for the arch. The height of the arch at the centre is 600 mm and at both corners it is 525mm. 7. Brick work is then continued up to a total height of 1.4 meters, taking care that top most layer is a header layer. 8. On top of this a stretcher layer is laid with bricks laid on edges so that a groove of 50 mm is formed in the middle. 24

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9. The dry bricks which were stacked to serve as a shuttering for the arch are removed, so that a passage is established between first and second chamber. 10. A shuttering is fixed for the first chamber. A slope of about 25 mm is given at the far end. 11. A hole is provided in the shuttering at an appropriate place for the inlet pipe. 12. Reinforcement steel is laid as per specifications in the drawing. A two way slab is planned. 13. The slurry inlet assembly is placed in the hole provided in the shuttering. Care is taken to see that this assembly is placed over the reinforcement so that it would get properly embedded in the R.C.C. slab. 14. The Biogas outlet assembly is placed at the far end of the slab, which is raised by 25 mm while providing shuttering, care is taken to see that flanges of gas outlet assembly are placed below the reinforcement grill. 15. The R.C.C slab is then laid in 1:2:4 proportion of cement concrete. While laying the cement concrete, care is taken to see that the flanges of slurry inlet assembly and biogas outlet assembly are properly embedded in cement concrete. Further, care is taken to see that a slab is laid in shortest possible time and in one sitting. 16. Care is taken to see that the cement concrete is laid properly in the groove provided in the top layer of brick work. Also, short lengths of steel are inserted in the groove at the four corners. 26

17. The slab is then kept wet for curing. A curing period of minimum 21 days is given. Shuttering is removed after two weeks. 18. After laying the slab, on the next day the brick work on top of the slab and the second and third chambers is completed, to the height of 300 mm. (During the construction of the superstructure the weight of the partition walls is likely to come on the slab. In order to laterally distribute it, the placing of an arch under the partition wall is suggested.) 19. Simultaneously, tee pipe is fixed for slurry outlet from third chamber. The bottom of horizontal arm of tee is kept at the level of top of the slab in first chamber. 20. After about 15 days after casting the slab, the shuttering of the digestion chamber is removed through the displacement window. 21. Lime cement mortar is then used for rendering the plaster coating for all the chamber walls and the roof from underneath. Addition of lime helps in reducing the chances of development of hairline cracks in the plaster layer. Further, it will have to be seen meticulously that excess water is not added during preparation of cement mortar. Proportion of water quantity of approximately 30 to 35 litres per 50 kg bag of cement is observed. Freshly prepared cement mortar must be used. Polymer additives for water proofing should be used. Plastering the chambers should be preferably completed in a single day so as to avoid joints in the CM plaster layer. These precautions will help in rendering gas tight plastering avoiding any possibilities of biogas leakage.

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22. Plaster coating is done in two layers, each of 12 mm thickness. 23. For the first coat, 1:3 cement mortar with 10% lime powder (Percentage in relation to quantity of cement) is used. 24. For the second coat, 1:2 cement mortar with 10% lime powder is used. 25. Neat finish is provided with cement to which lime powder is added. (10% lime). 26. All the corners and the joints are rounded off during the process of plastering. This is done followed at the joints for slurry inlet assembly and biogas outlet assembly also. 27. All renderings of cement mortar plaster coating are completed in one day, so that there is no chance left for the gas leakages at the joints of the rendering. 28. A groove for the partition wall between second and third chamber is prepared by laying additional cement mortar without disturbing the initial plaster coating. 29. On the next day, partition wall between second and third chamber is raised. An opening of 100 mm dia. is provided in this wall as a connection between the second and third chamber at 700 mm from the bottom of the plant. An opening of 50 mm dia. is provided in the same wall above the level of the slurry outlet, so as to serve as the vent. 30. The partition wall is then coated with cement mortar plaster rendering.

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31. Bottom of the chambers is also finished with cement mortar. 32. On top of the R.C.C. slab of first chamber, an inlet chamber is constructed. An inspection window opening through the wall, to the outside is provided. Further a vent pipe is laid horizontally from third chamber to the inspection chamber. 33. A vertical vent pipe is provided from the inspection chamber. This vent pipe will be later carried above the roof of the latrine super structure. It will be fixed along the wall of latrines super structure. 34. Sufficient time of 21 days for curing of the plaster is allowed, taking care to see that the plaster coating is kept wet continuously. 35. After curing, the plaster is allowed to dry completely.

36. After the plaster has dried, the roof and side walls of the digestion chamber are painted in two coats by bituminous paint or epoxy resin paint. (Two component water miscible epoxy paint is preferable). 37. After the paint has dried, the scum breaker fittings are fitted along the slurry inlet pipe in the digestion chamber. 38. The slurry outlet pipes are fitted to the tee embedded in brick work at slurry outlet level. Upward arm of the tee is brought above the level of cover over second and third chamber. This opening is closed with removable end cap. The opening serves as an inspection cum maintenance window.

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39. Dry bricks are stacked in displacement window up to a height of 275 mm. The second and third chambers are then covered with flagstone or R.C.C slab fitted with chamber covers. The vent pipe will emerge from under the cover. 40. The joints are properly sealed with cement mortar so that the gases do not escape from the joints. 41. pits. A channel is provided from the slurry outlet to manure

42. Gas supply line fitting along with condensate removal arrangement is carried out as per requirements. 43. Water seal trap for the latrine seat is fixed on top of the digestion chamber, the opening of the trap leading to inlet chamber on top of the slurry inlet pipe. 44. The latrine superstructure is constructed on top of the digestion chamber and toilet seat is fitted over the water seal trap. 45. While fixing the seat, the inlet chamber is covered from the top so that inlet chamber has an access only from out side through the window in the wall. 46. As stated earlier, vent pipe assembly is led above the roof of the latrine superstructure. 47. The gas plant is then completely filled with water. If possible the slurry from the other biogas plant could be put in the digestion chamber via latrine seat. This slurry will act as seeding for the digestion process.

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48. use.

The latrine and the biogas plant will then be ready for

49. If required toilet seats can be placed at distance from biogas plant. In that case, the inlet chamber will have to be provided a separate chamber cover.

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Chapter 6: Field implementation of the design Field Performance

The plants of this design are functioning at a number of homes in Dehu village of Pune district, as also in Madhya Pradesh, Tamil Nadu and Hyderabad with very satisfactory performance since 1980. The beneficiaries appreciate the design as it occupies minimum space, can be installed inside homes, and the top of the biogas plant can be used as an empty floor space. These plants have been constructed in places like hostels, institutions etc. In these cases, the plant capacities reach upto 20 cu.m. gas capacity per day.

Need for Training

The construction demands meticulous work and skilled masons. Cement plaster coating in gas storage area is crucial. Hence, it demands skills on the part of the masons. Therefore adequate training of the masons is essential. This is being carried out by Appa Patwardhan Safai wa Paryawaran Tantraniketan, Dehu village, District:Pune, Maharashtra, India. The need for adequate supervision during construction is also very crucial. Further the guidance for operation and maintenance of the plant as well as for the gas utilization system is very essential.

Suggestions for Promotion And Wider Application

1. This design is very useful in urban housing complexes.

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2. It can be accommodated in a limited space and can be incorporated during the construction of the house. 3. In rural area it can be used as a shared latrine facility.

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Annexures: Table I A: Estimates of quantities of Materials Required for 1CuM (One CuM) capacity Malaprabha Biogas Plant Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Bricks Cement Sand Soling Stone Chips Lime P.V.C. Assembly Set for Inlet and gas outlet A.C. Pipe 75 mm dia. A.C. Bend 75 mm A.C. Cowl & Net cover Chamber Cover 10 mm Steel Bar Quantity 1621 720.009 ie 14.40 1.71665 0.612 0.5669 13.543 One 4.0 One One One 40.575 ie 16.027 0.25 1.2375 1.78104 Unit Nos. Kg. Bag m m m Kg. No. Meter No. No. No. Meter Kg. Kg. m Litre Amt in Rs.

Binding Wire Rough Shahabad Stone Paint Total N.B. Cost will change depending on Market rates.

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Table II A: Estimates of quantities of Materials Required for 2 CuM (Two CuM) capacity Malaprabha Biogas Plant Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Bricks Cement Sand Soling Stone Chips Lime P.V.C. Assembly Set for Inlet and gas outlet A.C. Pipe 75 mm dia. A.C. Bend 75 mm A.C. Cowl & Net cover Chamber Cover 10 mm Steel Bar Quantity 2246 1058.300 ie 21.166 2.47198 0.9664 0.89436 20.2328 One 4.5 One One One 62.84 ie 24.821 0.25 2.075 2.1492 Unit Nos. Kg. Bag m m m Kg. No. Meter No. No. No. Meter Kg. Kg. m Litre Amount in Rs.

Binding Wire Rough Shahabad Stone Paint Total N.B. Cost will change depending on Market rates.

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Table III A: Estimates of quantities of Materials Required for 3 CuM (Three CuM) capacity Malaprabha Gas Plant Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Bricks Cement Sand Soling Stone Chips Lime P.V.C. Assembly Set for Inlet and gas outlet A.C. Pipe 75 mm dia. A.C. Bend 75 mm A.C. Cowl & Net cover Chamber Cover 10 mm Steel Bar Item Quantity Unit Amou nt in Rs.

3844 1380.943 ie 31.618 3.8236 2.2581 1.2702 28.511 One 5.0 One One One 90.30 ie 35.668 0.50 2.70 3.750

Nos. Kg. Bag m m m Kg. No. Meter No. No. No. Meter Kg. Kg. m Litre

Binding Wire Rough Shahabad Stone Paint Total N.B. Cost will change depending on Market rates.

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Table I B: Estimates of Labour Component for 1 CuM (One CuM) Capacity Malaprabha Biogas Plant

Sr. No. 1. 2. 3. 4. 5.

Item Mason Carpenter Painter Labour Excavation Total

Period 7 Work Days 1 Work Day 1 Work Day 16 Work Days Lump sum

Cost in Rs.

N. B. Cost will change depending on prevalent daily wages rates.

Table II B: Estimates of Labour Component for 2 CuM (Two CuM) Capacity Malaprabha Gas Plant

Sr. No. 1. 2. 3. 4. 5.

Item Mason Carpenter Painter Labour Excavation Total

Period 10 Work Days 1 Work Day 1 Work Day 22 Work Days Lump sum

Cost in Rs.

N. B. Cost will change depending on prevalent daily wages rates.

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Table III B: Estimates of Labour Component for 3 CuM (Three CuM) capacity Malaprabha Gas Plant

Sr. No. 1. 2. 3. 4. 5.

Item Mason Carpenter Painter Labour Excavation Total

Period 13Work Days 1 Work Day 1 Work Day 28 Work Days Lump sum

Cost in Rs.

N. B. Cost will change depending on prevalent daily wages rates. On a similar basis, the configuration of compartments can be adjusted to suit the available space and necessity.

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Appa Patwardhan Safai Va Paryawaran Tantraniketan Dehu, Tal. Haveli, Dist. Pune, Maharashtra, Pin. 412 109, INDIA.
It has been observed that in developing countries, about 80% ailments occur because of improper sanitation and unsafe water supply, 80% aliments could possibly be prevented at causative end, rather than at an attempt to treat these aliments. Under these circumstances, there is a need for positive sanitation promotion efforts if health promotion in developing countries is to be achieved. Therefore, it is necessary to promote these ideas and to suggest appropriate low cost technologies for sanitation promotion. In light of these considerations, Appa Patwardhan Safai W Paryawaran Tantraniketan was established in 1988.

Activities of Tantraniketan
A: Training : Technical and practical training imparted at this institution is useful for creating awareness and developing manpower for sanitation, non conventional energy sources and environment programmes. B: Research and Development : Sanitation is a discipline which has so far been neglected for multiple reasons. Therefore, there is a need to undertake research and development work as regards various aspects of sanitation. This institution is trying to do its own bit in the field in its own laboratory. Research as regards biomethanation is also undertaken. C: Project consultancies : With available knowledge resource, the institution offers consultancy services so as to come up with field level solutions for sanitation problems and bioenergy projects. D: Project Implementation : Wherever necessary, the institution also undertakes project implementation work especially if the work is of pioneering nature. 39

JYOTSNA AROGYA PRABODHAN

Dehu, Tal. Haveli, Dist. Pune, Maharashtra, Pin 412 109, INDIA, In a developing country like India, attainment of health for its population is an important means towards bright future. Jyotsna Arogya Prabodhan Proposes to contribute in a small way in tackling this gigantic task. This institution is engaged in health education activities predominantly amongst the rural population of India. With the highest possible standard of health for the population in view, it is under taking various educational and field research activities for creating awareness, imparting information, fostering attitudes and inspiring ideals as far as health is concerned. Some of its activities are as follows: Preparing and using various audio-visual aids, Organizing discussions, seminars etc. about the various aspects of health, Publishing health information hand outs, periodicals etc., Organizing exhibitions etc., Establishing health library for public use, Undertaking research activities in the field, Running experimental workshop for sanitary conveniences.

JYOTSNA AROGYA PRABODHAN, AN INSTITUTION BASED IN RURAL AREA & DEDICATED TO THE CAUSE OF RURAL HEALTH

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