BIOGAS
Biogas Magazine | Edition 37
EDITION 37
Bharat’s First
MAGAZINE
6 th BBB Expo & Summit | 06-08 May 2027 | Yashobhoomi (IICC), New Delhi, India
BIODIVERSITY
GOBARdhan GAS UPGRADING
ENERGY SECURITY
LNG
BIOREACTOR
CO₂ REMOVAL
AGRICULTURAL RESIDUE
ORGANIC WASTE
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FINANCING DISTRIBUTION
BIO INNOVATION AGRICULTURAL
ECO-FRIENDLY
RESIDUE
CNG STATIONS
INDUSTRY
ENERGY SECURITY
GREEN FUEL
DESULFURIZATION
BOTTLING
CBG PNG BIODIVERSITY
CLIMATE ACTION
WASTE
BIOGAS
DISPENSING
Segregation
VEGETABLE RESIDUES
GAS STORAGE
BIOENERGY
BIOMETHANE
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ANAEROBIC DIGESTION
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RENEWABLE ENERGY
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Biogas Magazine | Edition 37
WHAT GOES IN DEFINES WHAT COMES OUT An economical production with maximum gas yield always depends on the quality of the technology used and the individual impact of its components. In biogas production, every single element is crucial for the efficiency and economy of the plant as a whole. Whether pumping or shredding technology, solid matter feeders or disintegration systems – it is the interaction that determines the input and output ratio and energy performance.
Thanks to the highly functional and ever-improving biogas plant components from technology leader Vogelsang, the investment pays off. Based on the company‘s diverse experience and constant research, the developed biogas range ensures efficient gas production and trouble-free processes throughout the entire digestion system. After all: The more uniform the process sequences and the more homogeneous the biosuspension fed into the fermenter, the higher the gas yield!
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Gate Fold
Biogas Magazine | Edition 37
HiCone
XSplit
Adjustment instead of replacing wear parts: With the patent-pending system of the HiCone® Vogelsang offers a groundbreaking adjustment and readjustment system that 100% compensates for the effects of wear.
Clean and low-maintenance separation of solid and liquid with a dry matter outtake of up to 40% in order to avoid the formation of floating and sinking layers in the silo.
®
Conical progressive cavity pump
• Conical rotor and stator shape and unique
adjustment system for long service life and low operational costs
• Easy and rapid replacement of pumping elements
• Designed for heavy-duty use and suitable for pumping highly abrasive media/media with high foreign matter content
DisRuptor
Mechanical desintegrator Using the DisRuptor helps reduce the particle size and increase the surface area of substrates fed into a biogas tank thereby optimizing the biogas yield. • Increases the surface of
the biomass feed
• Homogenizes and reduces the viscosity
of the organic suspension
• Accelerates and increases gas production • Reduces the power consumption of mixers
and pumps
Vogelsang India Private Ltd. D 235, EPIP, UPSIDC, Kasna, Greater NOIDA, (UP) India Phone: +91 120 2341 701 - 2 | Fax: +91 120 2341 704 india@vogelsang.info | chitragupt.bhatnagar@vogelsang.info vogelsangindia.com
VOGELSANG – LEADING IN TECHNOLOGY
®
Separator
• Variation of the dry matter content due to
adjustable pressing area
• Easy access to sieve and screw for quick service • Reliable plug formation without auxiliary agents • Ideal separation results due to high-quality
elastomer sealing disc
RotaCut®
Wet cutter with heavy material separator The RotaCut is designed to ensure smooth operation of biogas plants by reliable heavy material separation and maceration of solid and disruptive matter in fluid media • Efficiently macerates fibers and foreign matter • Prevents blockages and clogging and protects
downstream system components from damage caused by heavy matter
• Reduces the viscosity and homogenizes liquids and
suspensions to prevent floating layers
Wholly owned subsidiary of Hugo Vogelsang Maschinenbau GmbH Holthoege 10 –14 | 49632 Essen (Oldenburg) | Germany Phone: +49 5434 83 - 0 | Fax: +49 5434 83 - 10 info@vogelsang.info vogelsang.info
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Gate Fold
Made in India Biogas Magazine | Edition 37
OIL INJECTED SCREW COMPRESSOR FOR BIOGAS UPGRADING
UVG 315 FLOW RATE: 0<890<1751 Nm³/h DELIVERY PRESSURE: 13.5 bar(g) WATER-COOLED, OUTOOR INSTALLATION LOCATION: ADELAIDE, AUSTRALIA
Screw compressor for biogas upgrading using membrane technology. Designed and manufactured in full compliance with Australian standards, ASME and IECEx. Suitable for outdoor installation, water-cooled and includes a complete gas treatment system, heat recovery unit, fine filtration and electro-pneumatic bypass system.
Visit us at booth D267 (A) from October 22 to 24 in Greater Noida Adicomp India Pvt Ltd
409, Centrum, Wagle Estate, Thane, PIN 400604 info@adicomp.com - adicomp.com
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Biogas Magazine | Edition 37
www.biogas-india.com |
Content Optimizing Hydraulic Retention Time, Organic Loading, and Preventing Acidification: Key Parameters to Improve Biogas Productivity from Food Waste
Biogas Magazine | Edition 37
16 12
In Conversation With
16
Mr. Aakash Kulshreshtha
Beyond Biogas: Process Optimization for Building India's Circular Bioeconomy
26 31
A Case Study on Upgrading Biogas to Biomethane Using Specialized Molecular Sieve
Innovative Waste-To-Energy Solutions: Transforming Palm Oil Mill Waste Into BioCNG
36 Automatic Digester Feeding Systems vs. Conventional Slurry Mixing Tanks in Biogas Plants
22
Choosing the Right Membrane Material for Biogas Gas HoldersPlants in India
41
Extending Performance Over Time: sustainability applied to the compressor life cycle
Disclaimer:
46
Indian Biogas Association does not endorse the content of advertisements printed in the magazine. All disputes are subject to the exclusive jurisdiction of competent courts and forums in Delhi/New Delhi only.
www.biogas-india.com | 4
“
Biogas Magazine | Edition 37
Dear Readers & Esteemed Members, A new ray of hope has emerged for the bioenergy sector with the continued momentum of the Gobardhan Scheme and the strong support from the Government towards achieving India’s bioenergy and CBG goals. As an industry, it is our collective responsibility to contribute to this journey and help turn these initiatives into meaningful outcomes. To further strengthen the bioenergy ecosystem, we are taking several initiatives. Through our webinar series, “Friday Carbon Vibes,” we have created awareness about the opportunities and benefits of carbon credits for CBG plants, and we are continuously providing knowledge sessions through our webinars. A valued platform, the Bio-Energy Pavilion at REI Expo, being held from 22nd to 24th October 2026 at India Expo Mart, will provide another opportunity for industry stakeholders to connect, collaborate, and explore new opportunities. We are also pleased to announce the 6th edition of BBB Expo & Summit, scheduled from 6th to 8th May 2027. It is equally encouraging to see industry professionals sharing their knowledge and experiences through the articles featured in the magazine. The biogas and biomethane sector continues to evolve with new technologies and innovative approaches aimed at improving efficiency, sustainability, and resource recovery. The articles bring together practical insights and case studies covering several important areas across the biogas value chain. The articles as well amalgamates valuable insights from across the biogas and biomethane sector, covering advancements in gas upgrading, renewable fuel production, and the conversion of industrial waste into useful energy. The contributions highlight how innovative technologies can improve resource recovery and support the growing demand for clean and sustainable fuels. They also focus on improving the efficiency and long-term performance of biogas plants. From process optimization and equipment sustainability to better management of hydraulic retention time, organic loading, and acidification, the articles provide practical perspectives on addressing key operational challenges and improving plant productivity. Further, a few of the articles explore important technology and equipment choices, including gas holder materials and digester feeding and mixing systems. Together, these contributions reflect the continuous innovation taking place across the sector and provide practical knowledge for developing more efficient, reliable, and sustainable biogas plants. We hope the articles provide valuable knowledge, practical insights, and new perspectives to our readers and contribute to the continued growth of India’s biogas and bioenergy sector.
Chief Editor: Dr. Savita Boral Editors: Abhijeet Mukherjee, Gaurav Kumar Kedia Copy Editor: Dr. K. Rohit Srivastava, Mansha Tejpal, Gautam Pandya Creative Director: Jyoti Narang Chintu Mishra Production: Arjun Gambhir, Payal Gupta, Shikhar Singh Tech Support: Sangram Rout Print Coordinator: Pawan Sahoo
Know us more The “Indian Biogas Association” (IBA) is the first nationwide and professional biogas association for operators, manufacturers and planners of biogas plants, and representatives from public policy, science and research in India. The association was established in 2011 and revamped in 2015 to promote a greener future through biogas. The motto of the association is “propagating biogas in a sustainable way”.
/biogasindia
Happy Digesting! /indianBiogasAssociation
Dr. A. R. Shukla President Indian Biogas Association
/company/indian-biogasassociation/
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Biogas Magazine | Edition 37
BIO GAS COMPRESSORS
BIO GAS COMPRESSORS DESIGNED FOR LOW, MEDIUM AND HIGH CAPACITY REQUIREMENTS WITH VARIED SUCTION & DISCHARGE PRESSURES
Customized solutions Medium Pressure 100 Barg Oil-free compression High Pressure 250 Barg Low Pressure 20 Barg VFD option
Range includes Low Pressure Biogas SCREW COMPRESSORS also
Jyotech Engineering And Marketing Consultants Pvt. Ltd. G-141, Sector 63, Noida, Distt: Gautam Budh Nagar, Uttar Pradesh – 201301 www.biogas-india.com |
www.jyotech.com
info@jyotech.com
+91-120-4711300
Biogas Magazine | Edition 37
Maximise your biogas revenue. Clarke Energy specialises in converting waste to value through biogas to power and biogas upgrading systems. Proven biogas expertise
Why choose Clarke Energy?
Clarke Energy has over 30 years’ global
Established presence in India
biogas experience, delivering turnkey biogas
Dedicated local service engineers
and membrane based biogas upgrading
Proven, best-in-class biogas technology
systems for a wide range of applications.
Long-term service and upgrade support.
Get in touch... Tel. +91 9156141777 india@clarke-energy.com clarke-energy.com
Clarke Energy India Private Limited. Office No. 701-704, 7th Floor, Tower-15, Cybercity, www.biogas-india.com | Magarpatta City, Hadapsar, Pune, Maharashtra, India, 411013
Biogas Magazine | Edition 37
Advancing India’s Bioenergy Future Period: July ’26 – Sep ’26
GOBARdhan Scheme Comes into Effect to Strengthen India’s CBG Sector The GOBARdhan Central Sector Scheme came into effect on 1 September 2026, following its approval by the Union Cabinet on 6 August 2026. With a total outlay of ₹23,731 crore, the scheme will be implemented from FY 2026-27 to FY 2035-36 and aims to significantly scale up the production and use of Compressed Biogas (CBG) in India. The scheme brings together key support measures for the CBG sector, including assured offtake, stable pricing, capital assistance, pipeline infrastructure, credit support and technology development. It aims to increase domestic CBG production nearly ten-fold while encouraging private investment and creating a stronger ecosystem for CBG projects across the country. By converting agricultural residue, cattle dung, press mud, municipal organic waste and other biomass resources into clean fuel and organic manure, the scheme can also support better waste management and create additional opportunities
for farmers and rural communities. The initiative is expected to strengthen India’s energy security while supporting the growth of a circular bioeconomy.
GOBARdhan Scheme Can Help Reduce Gas Imports by $5 Billion, Says IBA The Indian Biogas Association has highlighted the potential of the recently approved GOBARdhan Scheme to reduce India’s dependence on imported natural gas. According to IBA, the ₹23,731 crore scheme should be seen as a strategic national investment, with benefits extending beyond the bioenergy sector to rural development, agriculture and the wider economy. IBA estimates that with around 1,500 fully operational Compressed Biogas (CBG) plants in the coming years, India could reduce its natural gas import bill by nearly one-third of its current level, translating to savings of around USD 5 billion. The Association also highlighted the potential to reduce fertiliser imports through the use of Fermented Organic Manure (FOM) and bio-slurry produced by CBG plants.
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Biogas Magazine | Edition 37 Beyond import reduction, the scheme can support rural employment, create additional income opportunities from agricultural residues and encourage better utilisation of organic waste. The growth of CBG plants can also help reduce open burning of biomass while supporting India’s clean energy and circular economy goals.
hosted the Curtain-Raiser Webinar for the 6th BBB International Expo & Summit 2027 on 31 August 2026. The webinar, centred around “Renewable Energy Transition: Net Zero 2070,” brought together experts and industry stakeholders to discuss India’s renewable energy journey and the opportunities ahead for the bioenergy sector.
IBA Hosts Curtain-Raiser Webinar for 6th BBB International Expo & Summit 2027
The discussion covered India’s growing renewable energy potential, with a special focus on the new GOBARdhan Scheme, policy opportunities, industry
The Indian Biogas Association
tors for knowledge sharing, collaboration and industry engagement.
IBA Visits Eco Sustain Expo 2026
three-day event brought together stakeholders from across waste management, bioenergy, recycling, effluent treatment and other sustainability-focused sectors.
The Indian Biogas Association visited the Eco Sustain Expo 2026, held from 30 July to 1 August 2026 at the HITEX Exhibition Centre, Hyderabad. The
During the visit, the IBA team interacted with industry stakeholders and explored technologies and solutions related to biogas, bioenergy and waste
collaboration and sustainable solutions. The session also highlighted the role of bioenergy, biofuels and biogas in supporting India’s clean energy transition. The webinar also unveiled the vision and roadmap for the 6th BBB International Expo & Summit 2027, scheduled to take place from 6 to 8 May 2027 at Yashobhoomi (IICC), New Delhi. The upcoming edition will once again bring together stakeholders from across the bioenergy, biofuels and biomaterials sec-
management. The expo provided an opportunity to connect with technology providers, innovators and businesses working across the sustainability ecosystem, while also gaining insights into emerging developments in the sector. The event also featured discussions around the future of bioenergy in India, including inno-
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Biogas Magazine | Edition 37 carbon monetization in the bioenergy sector. Titled “The Registry Blueprint: What Every CBG & Bioenergy Developer Must Know,” the session focused on helping project developers understand carbon registries and their role in developing successful carbon credit projects. The webinar covered important aspects of the carbon registry process, including project registration, documentation and the steps developers need to consider while preparing a project for carbon credits. The discussion aimed to simplify the registry process and provide practical guidance for CBG and bioenergy developers looking to participate in carbon markets.
vations, market opportunities and the role of bio-resources in supporting the country’s clean energy transition.
IBA Hosts Friday Carbon
Through the Friday Carbon Vibes series, IBA continues to bring discussions around carbon markets closer to the bioenergy industry, helping developers better understand carbon monetisation and the opportunities it can create for their projects.
Vibes Session on Carbon Registries The Indian Biogas Association hosted Session 03 of Friday Carbon Vibes on 31 July 2026, continuing its knowledge series on
Upcoming Events
Bio-Energy Pavilion 2026 22nd Oct to 24th Oct, 2026 India Expo Mart, Greater Noida, UP, India
Bio Energy Arena 2027 22nd April to 24th April, 2027 Chennai Trade Centre, Chennai, India
06th May to 08th May, 2027 06 07 08
7
Yashobhoomi (IICC), Dwarka, New Delhi, India
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Biogas Magazine | Edition 37
Agitator Technology from Germany – ‘Made in India’ AGITATOR TECHNOLOGY FOR THE BIOGAS INDUSTRY PRG Agitators Pvt. Ltd., located in Vadodara, is a 100% subsidiary of a German Multinational. We have successfully installed agitators for 700+ biogas plants worldwide and boast over 20 years of experience in the biogas industry. We provide a diverse range of sophisticated agitator types that can be perfectly adapted to the respective task and system size – for optimum yields and maximum operational reliability right from the start. Our product range includes: • • •
Central Agitators Paddle Mixers Lateral Agitators
Contact us to find the perfect mix for you. PRG Agitators Pvt. Ltd. 66 Alindra, Savli GIDC, Manjusar, Vadodara, 391 775 Gujarat, India Phone: +91 63549 16014 Email: info@prgagitators.com PRG Präzisions-Rührer GmbH Anton-Böhlen-Straße 13 34414 Warburg, Germany Phone +49 (0) 5641 9006-0 Email info@prg-gmbh.de
Visit us at: www.prg-agitators.com
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Biogas Magazine | Edition 37
Technology
Optimizing Hydraulic Retention Time, Organic Loading, and Preventing Acidification: Key Parameters to Improve Biogas Productivity from Food Waste
Biogas from Food Waste: A "waste" at all, but a rich source Major Opportunity That Is of material for generating valuable biogas. Landfilling, natural Hard to Ignore Across India, hotels and restaurants, religious institutions running free-meal programs, weddings and other events, large-scale canteens, and corporate or institutional kitchens generate tons of leftover and discarded food every day, along with biodegradable food plates such as banana leaves and food-utensil wash water. Most of this material is either sent to landfills or left to decompose naturally. From a scientific standpoint, however, it is not
decomposition, or even composting fails to capture its full energy potential; a significant amount of high-calorific-value energy is simply lost as heat. An anaerobic digester, by contrast, captures this energy as biogas that can power electrical equipment or serve as a source of clean cooking fuel. Compared with cow dung, food waste has a higher calorific value due to its content of refined sugars, oils, fats, proteins, and both digestible and indigestible fiber, along with micronutrients, all of which
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Biogas Magazine | Edition 37
Technology ultimately contribute to biogas output. That said, using food waste in an anaerobic digester is a different proposition altogether, and requires a deeper understanding of how to process it effectively for commercial biogas production compared with the more routine use of cow dung or agricultural waste. India is estimated to generate 70 million metric tons of food waste annually, nearly twice the amount of animal feed manufactured in the country each year, itself a primary energy source for meat and milk production. If we conservatively assume that leftover or discarded food accounts for just one-seventh of this total (around 10 million metric tons), the potential annual output could reach approximately 250–450 million cubic meters of biogas and 150–270 million cubic meters of methane (assuming a methane content of roughly 60%). Despite this potential, food waste has not been taken as seriously as cow dung as a biogas feedstock, largely because of its relative inconsistency and instability as an input. This article outlines several key parameters that can help address these challenges when using food waste as a biogas feedstock in anaerobic digesters.
the average number of days a liquid or soluble compound spends inside a reactor or treatment tank, calculated by dividing the reactor volume by the volumetric flow rate of the influent. For a food-waste digester, the ideal HRT is 15–33 days under mesophilic conditions (35°C–37°C) and 12–20 days under thermophilic conditions (50°C–55°C). Combining cow dung with food waste is also worth considering, as it naturally introduces a broader population of methanogenic microbes and tends to improve overall efficiency; for this combined influent, an HRT of 25–40 days under mesophilic conditions (35°C–37°C) is ideal. Avoiding both overloading and underloading is a key consideration, and operating within the recommended HRT range is essential. It is also worth noting that, in most cases, the volumetric flow rate reflects both the solids and the water they are mixed with, not the solids alone. A solution-based system using finely ground food waste creates the right environment for hydrolysis to proceed effectively, a prerequisite for the subsequent acidification, acetogenesis, and methanogenesis stages. In short, an optimally loaded substrate with the right HRT creates the ideal conditions for efficient methane generation downstream.
Hydraulic Retention Time (HRT) and Biogas Output: A Loading vs. Organic Loading: Tightly Linked Pair An Important Distinction Hydraulic retention time (HRT) is
Organic Loading Rate (OLR),
commonly measured as kilograms of COD or volatile solids (*VS) per cubic meter of digester volume per day, should be considered alongside HRT before feeding material into the digester. Total Solids (TS) are an important parameter for characterizing the feedstock, but TS alone does not define the loading on the digester. Focusing on HRT alone, without accounting for OLR, can be misleading: a system operating at an optimal HRT may still be overloaded if the OLR is too high. Food waste, which is typically more than 70% water, can vary significantly in TS depending on the type of food involved. Cereal-based foods, foods high in refined sugar, and oily foods tend to carry a higher organic load than protein-rich or fibrous foods. For example, an operation using leftover banana leaves may be following the correct HRT, but given that banana leaves are roughly 70% cellulose, hemicellulose, and lignin combined, the system may in fact be significantly underloaded in terms of biodegradable organic matter. In such cases, blending this material with cow dung or another readily biodegradable organic waste can help. The ratio of digestible to indigestible fiber in the feedstock can also influence the process, although this becomes less critical when the fiber-to-soluble-sugar ratio is low, as with Napier grass. Compared with cow dung, food waste contains over 30% more TS (and volatile fatty acids, or VFAs), making it an excellent substrate for biogas production. However, unlike
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Biogas Magazine | Edition 37
Technology cow dung, which is a stable and predictable input, food waste requires upfront characterization and adjustment of both OLR and HRT to ensure healthy VFA production and maximize methane generation
Monitoring and Preventing Food Waste Acidification Food waste, particularly when rich in carbohydrates, is notorious for producing lactic acid and other volatile fatty acids (VFAs) rapidly, often faster than methanogens can convert them into methane. To manage this risk: 1. Install a real-time pH monitoring system on your reactors. A pH of 6.8 or above is ideal. 2. Maintain a reliable buffering system to correct any drop in pH or signs of acidification. 3. Recognize that acidification OLR and HRT are closely linked; avoid overloading the system with sugar-rich food waste, and maintain a healthy OLR and HRT to support stable methanogenesis and help prevent excessive VFA accumulation.
Conclusion Substantial energy cost savings in decentralized biogas units that process food waste can be achieved with a strong understanding of the basics of leftover food fermentation and digestion. In this article, we identify hydraulic retention time, organic loading, and acidity control as the key parameters for successful biogas production. In units where food waste is generated and loaded regularly, managing hydraulic retention time and organic loading in relation to the digester’s design and capacity is crucial for achieving the right balance of VFA production, allowing methanogenic bacteria to function in sync. Operationally, because leftover food can rapidly acidify the digester contents, maintaining pH is essential alongside well-managed hydraulic retention time and organic loading. By managing these three parameters, most of the major variables in food waste digestion can be effectively controlled.
4. Keep the VFA-to-alkalinity ratio at around 0.3 - 0.4 to support steady, controlled VFA production. 5. Watch for olfactory cues. A system fermenting faster than expected usually produces a foul odor, which typically points to excessive VFA accumulation rather than low production.
Meet the Author Dr. CB Gowda Rayapuram Founder & Director LEMMA BIOSOLUTIONS PVT LTD
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Biogas Magazine | Edition 37
www.biogas-india.com |
An Interview
Biogas Magazine | Edition 37
In conversation with
Mr. Aakash Kulshreshtha Aakash oversees Evonik's portfolio of membranes for gas separation and green hydrogen, as well as fibers for high-temperature applications. With more than 10 years of experience at EPC companies in India and in the USA, he has worked across Process Engineering, Process Safety, Construction Management, and Project Management roles in the Energy and Chemicals sector, apart from leading translational research on Catalytic Depolymerization of Lignin. He’s a Chemical Engineer from University School of Chemical Technology and holds MS in Chemical Engineering from Purdue University, USA.
Mr. Aakash Kulshreshtha Associate Director – Sales & Technical Services
Evonik India 1. With the new GOBARDhan scheme announcement, how do you expect the Biogas sector to further develop now? The new GOBARDhan scheme marks an important milestone for India's Compressed Biogas (CBG) sector and highlights the strategic role CBG can play in strengthening the country's energy security and sustainabili-
ty goals. With abundant and a variety of feedstock resources, growing demand for renewable energy, and strong government support, India has all the key ingredients for a vibrant and rapidly growing CBG industry. To sustain the momentum created by the GOBARDhan scheme, reliable, scalable, and efficient upgrading technologies will be essential to ensure long-term project success, attractive proj-
ect economics, and confidence among investors. With SEPURAN® Green membranes, Evonik offers a proven upgrading technology that is already used in more than 1,700 installations worldwide. Our membrane technology combines low energy consumption, compact footprint, high methane recovery, operational simplicity and attractive project
www.biogas-india.com | 16
Biogas Magazine | Edition 37
An Interview economics. Beyond the technology itself, we bring decades of membrane expertise and application know-how from projects around the world. We are excited about the opportunities in India and are ready to share our experience and work closely with project developers, OEM and EPC partners, technology providers, and plant operators to support the successful growth of the India’s CBG sector.
2. Membranes hold roughly 30–35% of the global upgrading mix; PSA, water and amine scrubbing still hold the rest. Where would you tell an Indian developer about the sweet spot for membrane? Historically, biogas upgrading has relied on a variety of technologies, including water scrubbing, PSA, amine scrubbing, and membranes. Over time, membrane technology has gained significant market share in many regions and today, it represents the preferred upgrading technology in many established upgrading markets as developers increasingly value solutions that combine low energy consumption, high methane recovery, operational simplicity, modular scalability, and low maintenance requirements. Rather than defining a specific sweet spot, we see membrane technology today as a highly versatile solution that can ad-
dress a broad spectrum of CBG projects. With SEPURAN® Green membrane technology, developers can successfully implement projects across a very wide capacity range, from smaller decentralized CBG plants to some of the largest renewable gas and landfill gas upgrading facilities worldwide. For Indian developers, key benefits include water- and chemical-free operation, a compact footprint, attractive project economics, and the flexibility to expand capacity stepwise as projects grow. This combination of flexibility, simplicity, and efficiency is particularly valuable in a market characterized by diverse feedstocks, varying project sizes, and ambitious growth targets.
and attractive energy efficiency can be maintained across a wide operating range. Maximizing methane recovery becomes particularly important when biomass resources are seasonal or limited, as every cubic meter of methane recovered contributes directly to project economics. In particular, the 3Stage process provides additional flexibility to handle seasonal variations while maintaining reliable operation and attractive project economics.
4. Evonik works across sectors far more demanding than biogas — semiconductors, chemicals, and energy storage. What's one standard from those industries that CBG plant operators in India haven't caught up to 3. Most of India's pipeline yet? sits in the 2–15 TPD band with seasonal loading. How One lesson from more mature much turndown can a mem- process industries is the combrane skid absorb before re- bination of standardization and covery and specific energy continuous improvement. Prodstart to slip? ucts and manufacturing processSeasonal fluctuations in feedstock availability are common for many Indian CBG projects and should already be considered during plant design. The key advantage of membrane technology is its modularity. Different membrane skids or modules can be operated as required, allowing the upgrading system to adapt efficiently to changing biogas flows. With a well-designed system, high methane recovery
es are continuously optimized to improve quality, consistency, and cost efficiency. At Evonik, we apply the same philosophy to membrane production and product development. Experience from more than 1,700 installations worldwide allows us to continuously improve product performance while maintaining consistent quality and reliable supply. We see a similar trend in matur-
www.biogas-india.com | 17
An Interview
Biogas Magazine | Edition 37
ing CBG markets. As the industry grows, developers increasingly rely on proven technologies with a strong track record rather than highly customized solutions. This reduces project risk, improves reliability, and creates confidence among investors. We believe the Indian market will follow a similar path as it continues to scale, and Evonik is well-positioned to support that growth with both the required expertise and the ability to supply large volumes of membranes with consistent quality.
many different vendors sell the same technology. What should a first-time developer ask that they usually don't — and what guarantee language actually holds up?
5. You supply through integrators, so you see how
6. Two forks ahead: tightenThey should also look beyond ing gas specs as CBO rises to
Many first-time developers focus on CAPEX and product gas specifications but often underestimate the importance of understanding their raw biogas. Feedstock composition, impurities, and seasonal variations can significantly influence plant design and long-term operating performance.
headline specifications and understand how the upgrading concept balances investment cost, methane recovery and operational stability. Ultimately, methane recovery is not just a technical metric, it determines how efficiently the available biomass resource is converted into valuable biomethane. When it comes to guarantees, the most meaningful ones are linked to clearly defined feedgas conditions and measurable performance targets.
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An Interview
5%, or BioCO₂ and BioLNG as second revenue lines. Which moves an Indian plant's P&L more, and which is India less ready for?
Biogas Magazine | Edition 37
the ability to generate a valuable CO₂ stream will be well positioned as the market matures.
The stronger near-term impact on most project economics will likely come from tighter gas quality specifications, as they affect every CBG producer. BioCO₂ and BioLNG offer attractive additional value streams, but their growth depends on supporting infrastructure, logistics, offtake agreements and market demand. Both trends increase the importance of efficient upgrading and high methane recovery. At the same time, technologies that combine high biomethane quality, high methane recovery, and
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Biogas Magazine | Edition 37
Critical Biofuel Process Equipment
India's Leader in Membrane Based Biogas Upgrading CH4
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Biogas Magazine | Edition 37
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www.biogas-india.com |
Biogas Magazine | Edition 37
An Insight
Beyond Biogas: Process Optimization for Building India's Circular Bioeconomy
India's journey towards a circular bioeconomy depends on innovative technologies that convert organic waste into valuable resources. Biogas is not only a renewable source of energy but also an effective solution for managing biodegradable waste sustainably. However, the success of a biogas plant depends not only on its design but also on proper feedstock evaluation, process optimization, and continuous monitoring. At BEIL Infrastructure Limited, we focus on improving biogas plant performance through An-
aerobic Gas Lift Reactor (AGR) technology and scientific Biochemical Methane Potential (BMP) testing. This integrated approach helps industries maximize methane production while ensuring stable and efficient plant operation.
AGR Technology for Efficient Food Waste Management BEIL provides decentralized biogas plants based on Anaerobic Gas Lift Reactor (AGR) technology with capacities ranging from 50 to 500 kg/day. These plants are suitable for industries, ho-
www.biogas-india.com | 22
Biogas Magazine | Edition 37
An Insight tels, hospitals, educational institutions, commercial establishments, and industrial canteens generating food waste. AGR technology is a high-rate anaerobic digestion approach for converting biodegradable organic waste into biogas. The process includes pre-digestion, where waste is sized, soaked and hydrolyzed, followed by anaerobic digestion. The system maintains optimum solids and food-to-microorganism (F/M) ratio to facilitate efficient bio methanation. AGR technology is designed to improve the interaction between microorganisms and organic waste, resulting in efficient digestion and consistent gas production. Key advantages include: • Higher biogas yield • Faster digestion • Compact plant design • Lower maintenance requirements • Stable and reliable operation • Closed process, odorless, noiseless performance with little maintenance. The technology enhances microorganism–feedstock interaction by converting the waste into a homogeneous and partially hydrolyzed slurry before digestion. Shredding and pre-digestion increase the accessibility of organic matter to microorganisms. Within the digester, uniform slurry distribution and slurry/gas mixing ensure better contact be-
tween the feedstock and microbial culture, thereby promoting faster degradation and efficient biogas generation. By converting food waste into renewable biogas and nutrient-rich digestate, AGR technology helps reduce landfill disposal while supporting sustainable waste management practices.
NABL-Accredited BMP Laboratory: Scientific Foundation for Better Biogas Plants Every organic waste stream has unique characteristics and methane generation potential. Designing a biogas plant based solely on the quantity of waste may result in lower efficiency and operational challenges. To address this, BEIL conducts Biochemical Methane Potential (BMP) testing before plant design through its NABL-accredited BMP laboratory, demonstrating compliance with nationally recognized standards for testing quality, technical competence, and reliable analytical results.
The laboratory evaluates critical parameters, including: • Biochemical Methane Potential (BMP) • Total Solids (TS) • Volatile Solids (VS) • Cellulose • Hemicellulose • Lignin • CHNS Analysis • Volatile Fatty Acids (VFA) • Alkalinity These analyses help estimate methane yield, optimize reactor design, determine suitable operating conditions, and improve overall project performance. The NABL accreditation further strengthens confidence in the accuracy, consistency, and credibility of the laboratory's test results, enabling industries to make informed decisions for biogas project planning and optimization.
Process Optimization: The Key to Better Performance Efficient biogas production requires continuous monitoring
www.biogas-india.com | 23
Biogas Magazine | Edition 37 and optimization throughout plant operation. Important parameters such as feedstock quality, organic loading rate, solids concentration, pH, alkalinity, VFA levels, and temperature directly influence digester stability and methane production. Regular monitoring allows operators to identify process deviations early and take corrective actions before performance is affected. This results in: • Higher biogas generation • Better digester stability • Faster process stabilization • Reduced maintenance requirements • Improved resource utilization
ity of decentralized food waste biogas plants. This integrated approach enables industries to convert organic waste into clean energy while supporting India's vision of a sustainable and circular bioeconomy. As India continues to strengthen its bioenergy sector, the combination of technological innovation, accredited laboratory testing, and scientific process optimization will be instrumental in developing efficient, economically viable, and environmentally responsible biogas systems for the future.
Combining scientific BMP testing with continuous process optimization enables reliable, efficient, and long-term plant performance.
Building a Circular Bioeconomy Biogas technology plays a vital role in reducing landfill waste, lowering greenhouse gas emissions, and generating renewable energy from biodegradable resources. Scientific feedstock evaluation, innovative reactor design, and optimized plant operation are essential for maximizing these benefits. By integrating AGR technology with its NABL-accredited BMP laboratory, BEIL delivers scientifically validated solutions that improve the efficiency and reliabil-
Meet the Author Mr. Atul Agarwal Vice President BEIL Infrastructure Limited
Mr. Malaysinh Borasiya Manager – Projects BEIL Infrastructure Limited
Ms. Prachi Patel Executive – Projects BEIL Infrastructure Limited
www.biogas-india.com | 24
Biogas Magazine | Edition 37
www.biogas-india.com |
Biogas Magazine | Edition 37
Engineering
A Case Study on Upgrading Biogas to Biomethane Using Specialized Molecular Sieve
Abstract This case study focuses on the application of HON-IS adsorbent, specifically molecular sieves, for biogas purification and upgrading, often referred to as biogas-to-biomethane conversion. These high-performance adsorbents remove carbon dioxide from raw biogas to meet natural gas pipeline or compressed biogas standards.
Challenges in Biogas Purification Raw biogas contains corrosive hydrogen sulfide (H2S), along with large amounts of carbon dioxide (CO2) and water. Equipment Protection: H2S is highly corrosive, so it must be removed before combustion or, in many situations, before the biogas passes through a PSA system. Water Management: Moisture lowers the effectiveness of molecular sieves by reducing their ability to absorb other components such as CO2. Performance Requirements: The purified gas needs to meet strict standards for grid injec-
tion, including high methane content and low levels of CO2 and H2S.
Selection of Appropriate Biogas Purification Technology Selecting the right technology for biogas upgradation is essential. The choice typically depends on the plant's scale and specific needs. For large-scale Bio-CNG plants (5 TPD or higher), VPSA is often preferred because it offers high efficiency, excellent methane recovery, and scalability. This makes it suitable for producing Bio-CNG used in vehicles or industrial settings, with methane purity levels of >95%. For small to medium-sized plants (1–5 TPD), PSA provides a satisfactory balance between cost and performance, especially for those processing agricultural residues or organic waste. PSA can deliver methane purity of 90–95%, making it well-suited for Bio-CNG applications. Water scrubbers work best for small-scale or budget-friendly projects, including low-flow systems like landfills, compact anaerobic digesters, or wastewater treatment plants. They prioritize affordability and can
www.biogas-india.com | 26
Biogas Magazine | Edition 37
Engineering achieve methane purity rates of 80–90%. Both the pressure swing adsorption (PSA) and vacuum pressure swing (VPSA) technologies are widely utilized approaches for the removal of CO2 from biogas
, due to its energy efficiency, dry operation, and high efficacy in producing high purity biomethane. Both technologies employ solid adsorbents —such as zeolite or activated carbon— that selectively capture CO2 under elevated pressure and subse-
quently release it upon depressurization. Molecular sieves, including zeolites, are integral to both PSA and VPSA technologies for generating highly purified biogas. Below are the semantics (Figure 1) for 2-bed and 4-bed units.
Figure 1: Semantics of 2-bed and 4-bed units Zeolites are effective for this purpose due to their crystalline, nanoporous structure and selective adsorption properties. Zeolite characteristics such as pore size (3–12 Å), metal-phase content, Brønsted acid sites, and Si/Al ratio influence their activity and selectivity. Advances in adsorbent materials, process optimization, and integrated systems are needed for cost-effective and sustainable biogas upgrading. Thus, the core component of the PSA/VPSA system is the adsorbent material. To address the challenges associated with this
technology, there is a significant need for advanced, high-capacity adsorbents such as molecular sieves and zeolites. Honeywell Industrial Solutions is a market leader in the production of molecular sieves like LTA, FAU, MFI, mordenite etc. for different applications which recently supplied FAU-type zeolite to one of the biogas producers in Ludhiana, Punjab, a part of northern India, for removing CO2 from methane. It performed better and gave superior results as compared to the adsorbent material from other sources. In the following section, the details are captured.
Adsorbent Efficiency Comparison One notable example of the Govt. of India’s green energy initiative is PEDA, Punjab Energy Development Authority, being maintained/managed/run by TR Mega Food CBG plant located in Ludhiana, which has been in operation since 2016. This facility, with a capacity of 3 tons per day, underwent material reloading in 2021. The typical composition of raw biogas produced in this plant is 54-56% methane and 42- 45% CO2, <1% oxygen and water saturated. The plant runs on the advanced Vacuum Pres-
www.biogas-india.com | 27
Biogas Magazine | Edition 37
Engineering
sure Swing Adsorption (VPSA) technology, which is patented by IIP-CSIR, Dehradun, with GASKON Engineering, Delhi, being their manufacturing partner.
Figure 2: General overview of TR Mega Food CBG plant Ludhiana-India. The Ludhiana CBG unit is equipped with two VPSA trains, each consisting of a pair of adsorbers labeled as VPSA tower-A and VPSA tower-B. During operation, VPSA tower-A processes the feed gas while VPSA tower-B undergoes vacuum regeneration. Upon completion of the adsorption cycle, VPSA tower-B assumes the processing function, allowing VPSA tower-A to be regenerated in turn.
in methane production. The adsorbent has contributed to a production increase of 50–60%, the current production level of the plant is approximately 2,897 normal cubic meters per day (Nm³/day), which is ~50% higher than the production achieved with previous adsorbents, a substantial improvement in yield. Additionally, the cycle time for processing has
been extended from 8 minutes to 12 minutes which contributes to the life of the valve with less movements.
HON-IS adsorbent was installed in one of the trains in 2025 and in terms of results, with use of these adsorbents the plant has achieved remarkable performance, reaching 99% purity
www.biogas-india.com | 28
Biogas Magazine | Edition 37
Engineering
olite achieved 99% methane purity, increased production by 50–60% to about 2,897 Nm³/ day, and extended cycle time from 8 to 12 minutes, improving operational efficiency and adsorbent life.
Conclusions This case study examines the use of Honeywell’s molecular sieve adsorbents, specifically zeolites, for upgrading biogas to biomethane by removing carbon dioxide to meet natural gas standards. It highlights the challenges in biogas purification, technology selection, and a practical example demonstrating improved performance in an Indian biogas plant. Raw biogas typically contains hydrogen sulfide, carbon dioxide, and water vapors, all of which must be effectively managed to safeguard equipment and ensure compliance with methane purity standards. The selection of suitable biogas purification technology is a critical step in establishing an effective Bio-CNG plant. The decision among VPSA, PSA, or Water Scrubber technologies for CO2 removal is mainly done based on factors such as plant capacity, type of feedstock, desired methane purity, and available budget. Both PSA and VPSA
use solid adsorbents like zeolites for CO2 removal. Zeolites’ nanoporous crystalline structure and selective adsorption make them ideal for CO2 removal. The supplied FAU-type zeolite to a biogas plant in Ludhiana, India performed better than other adsorbents in CO2 removal. The TR Mega Food CBG plant using VPSA technology with this high-performance FAU-type ze-
Meet the Author Mr. Satish Kumar Adsorbent Development Group Honeywell Industrial Solutions, India
Mr. Pourang Shamsi Business Development Honeywell Industrial Solutions, USA
Mr. Dheeraj Dixit Adsorbent Sales Honeywell Industrial Solutions, India
www.biogas-india.com | 29
Biogas Magazine | Edition 37
Membrane Solutions
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Biogas Magazine | Edition 37
Case Study
Innovative Waste-To-Energy Solutions: Transforming Palm Oil Mill Waste Into Bio-CNG
Introduction The palm oil business is an important economic sector, but waste management issues raise serious environmental problems. A pioneering idea is to convert palm oil mill waste— including palm oil mill effluent (POME), empty fruit bunches (EFB), and fresh fruit bunches (FFB) into BioCNG, a greener and cleaner fuel alternative to fossil fuels. This ground-breaking technology not only lowers greenhouse gas (GHG) emissions, but it also improves indus-
trial sustainability and energy efficiency.
Technological Breakthrough: Converting Palm Oil Waste to BioCNG Palm oil mills produce large amounts of organic waste, traditionally disposed of through landfilling or incineration, leading to methane emissions and air pollution. The waste-to-energy process harnesses anaerobic digestion and biogas upgrading to transform this waste into high-purity BioCNG.
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Biogas Magazine | Edition 37
Case Study A biogas plant utilizing Palm Oil Mill Effluent (POME) employs anaerobic digestion (AD) technology to convert organic waste into biogas. POME, a wastewater rich in organic content from palm oil processing, is an ideal feedstock for biogas production.
• Feedstock Preparation: POME is a wastewater by-product generated during the palm oil milling process. This POME has high levels of COD, BOD and TSS along with oils. These high levels of COD and BOD can be treated in the anaerobic process where there are 80-85% COD reductions along with generation of Biogas. This anaerobic process has 2 advantages 1. Effluent COD and BOD are reduced, thus meeting the environmental discharge standards with less cost. 2. The biogas is generated in the process which can be used to generate power or BioCNG; which can be further used for energy requirements replacing fossil fuels. The digestate from the anaerobic process will be further treated in aerobic condition and discharged into the environment. This anaerobic and aerobic process meets the compliance requirements. Both the environment regulations and the replacement of fossil fuels with Bioenergy – Net ZERO for
Industries drives the POME as feedstock. Other than the above there is no further alternate use of POME.
ed.
POME is well suited for anaerobic digestion because it contains a high amount of biodegradable organic matter, with a typical COD ranging from 50,000 to 100,000 mg/L. This makes it an ideal feedstock for biogas production, as the organic matter can be efficiently converted into methane. Its high moisture content and continuous generation at the palm oil mill also make it a reliable and sustainable feedstock for renewable energy production.
The prepared POME is fed into a sealed digester. Microorganisms break down organic matter in an oxygen-free environment, producing biogas (60-70% methane, CH₄, and CO₂).
Palm oil mill effluent (POME) is an organic wastewater generated during the processing of palm fruits to produce palm oil. The palm oil mill (PT UKINDO) of 45 TPH processes fresh fruit bunches (FFB) with a capacity of 240,000 tons FFB/year to produce palm oil. During this process, wastewater effluent of around 520 m3/day is generat-
• Anaerobic Process:
Digestion
(AD)
• Gas Collection, Purification and Utilization The produced biogas is transferred to a gas holder. Reactor sludge goes to the ZPHB® Clarifier, separating solids and liquids. Clarified water is reused for land applications. Biogas in the gas holder is also used as a fuel at boiler or Biogas Engine for Power generation. Biogas from the gas holder goes to the PSA system for gas upgradation system after removal of H2S. The purified methane is compressed in the compressor system and filled into Gas Transport Module (GTM). Filled cascades (GTM) are transported by trucks to re-
www.biogas-india.com | 32
Biogas Magazine | Edition 37
Case Study
gestate reduces reliance on chemical fertilizers. Economic & Energy Security Benefits: Provides cost-effective energy for industries and local communities. Reduces fuel import dependency and stabilizes energy supply. Figure 1: Purification PSA and Membrane system
Figure 2: Filling gas into cascade place the fossil fuel uses at the atmosphere, significantly reducContracted factory. ing GHG emissions. Offsets CO₂ emissions by replacing fossil fuel • By Product Management usage. Digestate, the solid and liquid residue from POME digestion, is rich in nutrients and can be used as an organic fertilizer or soil conditioner. It enhances soil fertility, reduces the need for chemical fertilizers, and supports sustainable agricultural practices.
Key Advantages and Environmental Impact Waste-To-Energy Utilization: Converts organic waste into a valuable energy resource. Reduces landfill waste and wastewater pollution. Reduction In Greenhouse Gas Emissions: Methane capture prevents direct release into the
Climate Action: contributes to climate action by capturing methane. It stands out as an excellent climate action initiative compared to other renewable projects. Life Below Water: Our Projects prevent water pollution by not releasing polluted water into the river, protecting marine life from any harmful effects. Life on Land: Our project prevents pollution and promotes a healthy environment for people working in the area. Water & Resource Efficiency: Biogas plants with Zero Liquid Discharge (ZLD) help in water conservation. Nutrient-rich di-
Successful Implementation and Case Study A landmark achievement in sustainable waste management is the successful implementation of Asia's First Palm Oil Mill Waste-to-BioCNG Plant, demonstrating the commercial viability of converting palm oil mill residues into clean and renewable energy. The project showcases how innovative engineering can transform Palm Oil Mill Effluent (POME), Empty Fruit Bunches (EFB), and Fresh Fruit Bunch (FFB) residues into a valuable source of BioCNG while significantly reducing the environmental footprint of the palm oil industry. The facility processes 50,000 tonnes of POME, EFB, and FFB annually, utilizing advanced anaerobic digestion and biogas upgrading technologies to produce approximately 20,000 m³ of BioCNG per day. The upgraded BioCNG is compressed and supplied to industrial consumers, where it serves as a clean alternative to conventional fossil fuels for boiler operations and transportation applications. The project has delivered sub-
www.biogas-india.com | 33
Biogas Magazine | Edition 37
Case Study stantial environmental and economic benefits by replacing approximately 10,000 metric tons of fossil fuels annually and avoiding nearly 30,000 tons of CO₂-equivalent emissions each year. In addition to mitigating greenhouse gas emissions through effective methane capture, the project contributes to improved waste management practices, enhanced energy efficiency, and the production of renewable fuel from agricultural residues that would otherwise pose environmental challenges. Beyond renewable energy generation, the facility follows a circular economy approach by recovering valuable resources from palm oil mill waste. The treated effluent is safely reused for land application, while the nutrient-rich digestate is utilized as an organic fertilizer, reducing dependence on chemical fertilizers and promoting sustainable agricultural practices. This successful implementation demonstrates that palm oil mill waste can be transformed from an environmental liability into a valuable renewable energy resource. The project serves as a scalable and replicable model for the palm oil industry, illustrating how advanced waste-to-energy technologies can simultaneously support industrial sustainability, energy security, greenhouse gas mitigation, and the transition toward a low-carbon economy.
As global companies move toward decarbonization, waste-toBioCNG technology provides an effective approach to reduce carbon footprints. Future advancements in biogas efficiency, feedstock diversification, and carbon capture integration will increase BioCNG usage in a variety of sectors. Stronger government incentives, policy frameworks, and industrial cooperation will accelerate large-scale adoption, assuring the palm oil sector's long-term viability.
Conclusion Transforming palm oil mill waste into BioCNG is a game-changing invention for sustainable waste management and renewable energy production. This technology offers a viable solution for cutting industrial emissions, fuel costs, and achieving a carbon-neutral future. Embracing such breakthroughs is crucial for firms seeking energy security, environmental responsibility, and long-term profits.
Meet the Author Mr. Raghunath K. R. KIS Group Sustainability² Founder & CEO
Dr. Jyothi Hadli KIS Group Sustainability² Director
Future Scope and Industrial Relevance www.biogas-india.com | 34
TECHMARK
Biogas Magazine | Edition 37
PRECISE BIOGAS ANALYSIS CH4, CO2, H2S, O2, N2, GCV, NCV, DENSITY, MMBTU
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Biogas Magazine | Edition 37
Science
Choosing the Right Membrane Material for Biogas Gas Holders
Introduction As the biogas industry matures, plant owners and EPC contractors increasingly prioritize enhancing operational reliability, efficiency, and lifecycle performance. While considerable attention is often given to digesters, gas upgrading equipment, and process automation, one critical component is frequently underestimated—the membrane system used for biogas storage. A gas holder is not merely a storage enclosure; it is the heart of a biogas plant. Its performance directly influences gas retention, plant uptime, operational safety, and maintenance requirements. Selecting the right membrane therefore becomes an engineering decision rather than simply a material procurement exercise. Modern membrane systems operate under demanding conditions. They are continuously exposed to ultraviolet radiation, fluctuating temperatures, wind loads, internal gas pressure, moisture, and the chemical characteristics of biogas. Long-term performance depends not only on the membrane material itself but also on how the complete system is engineered, fabricated, installed, and maintained.
pertinent to the selection of membrane systems for biogas storage.
The Membrane: More Than Just a Cover A gas holder membrane performs several critical functions simultaneously. It must: • Safely contain biogas under operating pressure
liability of the entire plant.
Why PVC-Coated Technical Fabrics Are Widely Used Among flexible gas storage materials, engineered PVC-coated technical fabrics have become one of the most widely adopted solutions due to their balance of strength, flexibility, weldability, and durability.
• Minimise methane leakage
A typical engineered membrane consists of:
• Withstand continuous mechanical loading
• High-strength polyester reinforcement
• Resist weathering and environmental exposure
• PVC coating on both sides
• Maintain dimensional stability throughout its service life Unlike conventional covers, gas holder membranes function as structural components operating under constant stress. Their reliability directly affects the re-
• Protective surface lacquer such as PVDF or acrylic Each layer contributes to the membrane's overall structural and environmental performance.
Key Factors to Consider
This article emphasizes the principal engineering factors
www.biogas-india.com | 36
Biogas Magazine | Edition 37
Science When Selecting Membrane Material 1. PVC-Coated Fabric Quality Not all PVC-coated fabrics are manufactured to the same standard. Performance depends on factors such as the quality of the reinforcement fabric, coating uniformity, dimensional stability, surface protection, and consistent weldability Selecting materials based only on appearance or price can result in reduced durability and increased maintenance over time.
2. UV Resistance Biogas gas holders installed outdoors are exposed to sunlight year-round. UV radiation gradually degrades many polymer materials, causing surface cracking, loss of flexibility, colour fading, reduced mechanical strength premature ageing High-quality membranes incorporate UV stabilisers and protective surface coatings to minimise these effects. Good UV resistance matters most in regions with high solar radiation, where prolonged exposure can significantly shorten the service life of untreated materials.
3. Gas Permeability Gas retention is fundamental to plant efficiency. Since biogas primarily contains methane and
carbon dioxide, membrane permeability directly affects methane losses, energy recovery, greenhouse gas emissions, overall storage efficiency. Low-permeability membrane systems help maximize usable energy while supporting environmental performance.
4. Tensile Strength Gas holder membranes carry continuous mechanical loading from internal gas pressure, wind loads, snow loads (in colder climates), thermal expansion, and installation tension. A membrane with insufficient tensile strength may deform excessively or fail structurally under sustained loading. Key mechanical properties to evaluate include Tensile strength, Tear resistance, Seam strength, Burst resistance, Elongation characteristics. Rather than focusing on a single strength value, engineers should assess the overall mechanical performance of the membrane
system—including welded joints and connection details.
5. Fire-Retardant Properties Although biogas storage systems are designed to minimise ignition risk, fire safety remains an important design consideration. Depending on local regulations and project requirements, membranes may need certified fire-retardant properties, which help Slow flame propagation, improve overall plant safety, meet regulatory compliance, reduce risk during accidental ignition. Many industrial projects specify membranes that comply with recognised international fire classifications, particularly where gas storage sits near process equipment or occupied facilities.
Maintenance Considerations Compared with many rigid gas storage systems, PVC Fabric membrane gas holders generally require simpler maintenance. Recommended practices in-
www.biogas-india.com | 37
Biogas Magazine | Edition 37
Science clude regular visual inspections, checking inflation pressure, Inspecting welded seams, cleaning accumulated dirt where necessary, monitoring tension and anchoring systems, verifying blower and pressure control equipment. Preventive maintenance increases reliability and reduces the likelihood of unexpected downtime. Maintenance schedules should follow manufacturer recommendations while accounting for local environmental conditions.
Engineered Membrane Systems vs. Conventional Materials Gas holder performance depends not only on the membrane fabric itself but also on how the complete membrane system is engineered. Modern engineered membrane systems are typically designed using specialised structural analysis software that accounts for wind loading, internal pressure, snow loading, stress distribution, material behaviour, Safety factors[SB1.1] This engineering approach allows membrane geometry, reinforcement, and fabrication details to be optimised for the intended operating conditions. Conventional or generic flexible covers, by contrast, are often selected primarily based on material thickness or cost, without comprehensive structural analy-
sis. Such solutions may suit temporary or low-demand applications but typically don't match the long-term performance of engineered systems under continuous operation. Engineered systems generally offer more uniform stress distribution, better dimensional stability, improved fatigue resistance, enhanced pressure control, longer operational life, lower lifecycle maintenance requirements. These advantages matter most for industrial-scale biogas plants, where reliability and operational continuity are critical.
Procurement Considerations For procurement teams, selecting membrane material should involve more than comparing price quotations. Key technical parameters to evaluate include Fabric weight (GSM), tensile strength, tear resistance, gas permeability, UV resistance, fire-retardant certification, surface coating technology, Weldability, expected service life, availability of technical documentation and quality certifications A structured technical evaluation helps ensure the selected
material meets both project requirements and long-term operational expectations.
Conclusion The membrane material used in a biogas gas holder plays a fundamental role in determining the efficiency, safety, and longevity of the storage system. PVC-coated fabric quality, UV resistance, gas permeability, tensile strength, fire-retardant properties, and maintenance requirements all shape overall performance. Rather than focusing solely on upfront procurement cost, project stakeholders should weigh the membrane's lifecycle performance and suitability for its operating environment. Engineered membrane systems, backed by sound design and quality materials, deliver greater reliability, improved gas retention, and reduced maintenance compared with conventional alternatives. As biogas plants continue to grow in size and complexity, careful membrane selection remains a key engineering decision—one that supports efficient, sustainable plant operation over the long term.
Meet the Author Mr. Punit Jhaveri Director – Strategic GrowthHead LUCKY-TECH Membranes Pvt. Ltd.
www.biogas-india.com | 38
B&V TEX
ENGINEERING FROM EUROPE Biogas MagazinePRODUCTION | Edition 37 IN INDIA
Biogas Versatility in TEXtile Solutions
TEXTILE BIOGAS GASHOLDER SYSTEMS
Engineered storage solutions for CBG, MSW, agriculture and industrial biogas projects
PROJECT-SPECIFIC GAS STORAGE B&V TEX designs, produces and installs highquality textile biogas covering and storage solutions. Through collaboration with CTEX Solutions GmbH, Austria, the systems combine European application engineering with local manufacturing in India.
Designed for: • New biogas plants and CBG facilities • MSW and agricultural applications
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www.bvtex.in
Biogas Magazine | Edition 37
The GOBARdhan Scheme is a landmark initiative that strengthens the entire CBG value chain through assured offtake, stable pricing, capital support, and ecosystem development, paving the way for a robust circular economy and a cleaner energy future for India.
GOBARdhan scheme has the potential to catalyse the CBG sector nationwide by addressing key challenges of market certainty, project financing and supporting infrastructure, thereby unlocking greater private investment and advancing India’s circular bioeconomy.
O P I N I O N For India, biogas is not merely an alternative fuel; it is an opportunity to integrate the Gobardhan initiative, waste management, agriculture, renewable energy, and the circular economy into one sustainable ecosystem.
The GOBARdhan scheme is a timely and comprehensive initiative that can improve CBG project viability, strengthen energy security, and support the achievement of India's circular-economy objectives.The scheme creates a more predictable environment for sustained investment and technology cooperation in India’s dynamic biogas sector.
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Biogas Magazine | Edition 37
An Overview
Automatic Digester Feeding Systems vs. Conventional Slurry Mixing Tanks in Biogas Plants
A more scientific and technology-focussed approach to reliable and efficient digester feeding
mixed with recycled digestate or water, homogenized using agitators, and subsequently pumped into the digester.
Efficient feeding of a biogas digester is one of the most critical factors influencing plant performance, gas yield, process stability, and operating cost. Unfortunately, it is generally ignored, and undervalued while designing the plant.
While this approach is simple and familiar, most modern biogas plants globally have already adopted and implemented the idea of automatic digester feeding systems that integrate controlled feeding, solids handling, mixing, pumping, and process automation.
Traditionally, many biogas plants use a conventional slurry mixing tank where feedstock is
The shift from a conventional mixing tank to an automatic
Scraper Floor Feeder
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Biogas Magazine | Edition 37
An Overview feeding system can provide significant advantages, particularly in medium and large-scale plants handling variable feedstocks such as agricultural residues, food waste, manure, industrial organic waste, and energy crops as well as a mix of multiple feedstocks.
require operators to manually control valves, pumps, and agitators and coordinate the feeding process. An automatic system can perform these operations according to a predefined feeding program.
We try to explore a few benefits in detail:
Receive → Mix → Homogenize → Pump → Feed → Repeat
The system can automatically
1. Controlled and Consistent with minimal operator intervention. Feeding
ever prominent, depend on feedstock characteristics, tank volume, agitator design, dry matter content, and operating philosophy. An optimally designed feeding system is capable of reducing the installed power required in the digester and may reduce the number of agitators in the digester.
4. Better Handling High-Solids Feedstock
of
A conventional mixing tank generally depends on operator intervention to maintain the correct slurry level, mixing conditions, and feeding frequency. An automatic feeding system can continuously monitor and control:
This is particularly valuable for plants operating 24/7, where feeding cannot depend entirely on the availability and experience of an operator.
Modern biogas plants increasingly process feedstocks with higher total solids (TS), fibrous material, and varying particle sizes.
3. Lower Energy Consumption
• Feedstock quantity • Feeding frequency • Slurry level • Pump operation • Mixing requirements • Feeding rate • Recirculation
One of the major disadvantages of a conventional mixing tank is the requirement for continuous or frequent agitation of a relatively large volume of slurry. Large agitators operating for long periods can consume substantial electrical energy. An optimized automatic feeding system can reduce this requirement by:
Conventional slurry mixing tanks can experience problems such as floating layers, sedimentation, fibrous accumulation, rope formation, pump blockage & uneven mixing.
This enables the digester to receive a more consistent Organic Loading Rate (OLR).
2. Reduced Dependence on Operators
• Mixing only when required • Controlling mixing duration automatically • Using targeted feedstock homogenization • Avoiding unnecessary circulation • Optimizing pump operation
Conventional slurry tanks often
The actual power savings, how-
Consistent feeding is important because sudden variations in loading can disturb the biological process and negatively affect methane production.
A properly engineered automatic feeding system can incorporate appropriate: • Macerators • Solid feeders • Screw conveyors • Progressive cavity pumps • Recirculation systems • Foreign-material removal systems This allows the flexibility of designing the feed system specifically around the characteristics of the feedstock.
5. Improved Digester Process www.biogas-india.com | 42
Biogas Magazine | Edition 37
An Overview Stability The biology inside a digester performs best under relatively stable operating conditions. Automatic feeding allows the plant operator to establish a controlled feeding profile instead of introducing large quantities of substrate at irregular intervals. For example, instead of feeding a large batch several times per day, the same daily quantity can be distributed into smaller and more frequent feeding cycles. This can help maintain: • Stable organic loading • More uniform substrate availability • Better pH stability • More consistent microbial activity • Stable gas production Stable feeding ultimately supports stable digestion.
6. Prevention of Overfeeding Overfeeding a digester can result in excessive organic loading and may contribute to process instability, including accumulation of volatile fatty acids (VFAs). An automatic system can incorporate programmed limits and process interlocks to prevent feeding beyond the designed capacity. For example: Daily Feed Quantity → Maxi-
Moving Floor Feeder mum Feeding Rate → Feeding Schedule → Automatic Interlock If an abnormal operating condition occurs, the system can automatically stop or reduce feeding. This provides an additional layer of process protection.
Historical data can also be recorded for performance analysis of the entire plant process through the PLC/SCADA. This creates a data-driven feeding process rather than relying primarily on manual observation.
8. Reduced Wear and Maintenance
7. Better Integration with Plant Automation In a conventional mixing tank, Automatic feeding systems can easily be integrated with the plant's PLC and SCADA system. They are able to accurately provide the substrate feed rate feedback from the solid feeding system and the liquid flow rate from the pump, if the liquid feeding system is used. This enables better control of the TS% while feeding the digester. The operator can monitor parameters like feed quantity through the feeding system, tank level , currents, operating hours , pump status, number of feeding cycles etc from the PLC.
agitators and pumps can be subjected to continuous operation and harsh conditions. High levels of sand, stones, fibres and foreign materials can significantly increase wear resulting in frequent breakdowns and maintenance/replacement activity thereby increasing the OPEX. An automated feed system extends equipment life and reduces unplanned downtime.
9. Improved Safety Automation also reduces the re-
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Biogas Magazine | Edition 37
An Overview
where skilled manpower is difficult to retain.
12. More Predictable and Efficient Biogas Production
Liquid Feeding System quirement for operators to work around slurry tanks, pumps, mixers and valves.
• Industrial organic waste • Other biodegradable substrates
Fewer manual interventions mean reduced exposure to:
An automatic feeding system can be configured for multiple feedstock streams and controlled dosing.
• Biogas • Hydrogen sulphide (H₂S) • Moving machinery • Slurry splashing • Confined or hazardous areas Remote monitoring and automatic shutdown functions can further improve operational safety.
10. Better Feedstock Flexibility A modern biogas plant may not always use a single feedstock. Feedstock availability and economics can change, requiring the plant to process combinations of: • Cattle manure • Food waste • Vegetable waste • Agricultural residues • Energy crops
This gives the plant greater flexibility to optimize its feedstock mix according to availability, cost and biogas potential.
Biogas production is directly influenced by the quantity and characteristics of substrate entering the digester. A controlled feeding system allows the plant to maintain a more predictable substrate input. This can be particularly important for applications, where stable gas production improves downstream equipment utilization. For CBG plants, stable feeding can ultimately contribute to more consistent operation of the gas upgrading and compression systems.
Conclusion
11. Lower Operating Labour Requirement The conventional slurry mixing A conventional slurry preparation system can require operators for loading, mixing, pump operation, level monitoring, feeding control and troubleshooting etc. Automation can substantially reduce routine manual activities. The operator's role shifts from continuous manual operation to supervision and process management. This is particularly beneficial for plants located in remote areas
tank has played an important role in the development of biogas technology and remains suitable for many small and relatively simple installations. However, as biogas plants become larger, more automated and increasingly focused on CBG, biomethane and high-efficiency operation, automatic digester feeding systems offer a significant technological advantage for modern biogas plants. An automatic feeding system can therefore be an important step toward achieving higher reliability, improved operational efficiency and more predictable
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Biogas Magazine | Edition 37
An Overview plant performance, thereby resulting in higher biogas yield and improving the ROI substantially.
Importance of Selecting the Best Feeding System Automation Is not simply replacing a tank. The objective should not be to replace a conventional mixing tank with an automatic system merely for the sake of automation. The feeding system should be engineered around the feedstock and the biological process. The correct combination of solid handling, mixing, pumping, dosing and automation is what delivers the real benefit. It is most important to involve a feed system designer and supplier who brings vast experience and has installed numerous high-quality systems globally under different geographical and substrate conditions. With the establishment of Maschinen Schmidberger India Pvt. Ltd. a subsidiary of Maschinen Schmidberger GmbH, the group is sending a clear signal that the Indian biogas and CBG market will not only be supplied from Europe, but will also be developed locally, supported directly on site, and gradually served through local production in the long term. For a company that has built a strong reputation over the years
in robust machinery and system solutions for biogas plants, this step is more than geographical expansion. It is a commitment to a market that will play a key role in the global development of biogas and biomethane in the years ahead. The new venture has been founded not only to serve the Indian market commercially, but also to establish a structural presence. The goal is to be much closer to customers, partners, and project developers in India in the future – with faster response times, local project support, improved technical exchange, and a growing service and production network. In the biogas sector in particular, success is not determined solely by the theoretical performance of a plant, but by the day-to-day reliability of every individual component making a local presence the most crucial factor for llongterm success.
Meet the Author 36
Mr. Yatin Wadile Managing Director Maschinen Schmidberger India Pvt. Ltd.
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Biogas Magazine | Edition 37
Utility
Extending Performance Over Time: The biogas plant, a model of a sustainable process
The Biogas Plant, a Model of als are instead transformed into a renewable energy resource. a Sustainable Process The biogas plant represents an intrinsically sustainable energy supply chain, based on the principles of resource valorization and circular economy. Biogas production, in fact, largely derives from feedstocks such as agricultural by-products, livestock manure, agri-food waste, wastewater treatment sludge, and landfill waste – materials that, in the absence of recovery, would constitute an environmental and management cost. Through anaerobic digestion, these materi-
Within this supply chain, biogas represents not only an energy source – for both electricity generation and biomethane production to be injected into the grid – but also a means of closing the production cycle, since the residual digestate can be reused as an agricultural soil fertilizer, reducing the need for synthetic ones. The sustainability of biogas, therefore, is not limited to the production of renewable energy; it extends to the responsible management
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Biogas Magazine | Edition 37
Utility of organic waste, the reduction of greenhouse gas emissions, and the enhancement of local agri-industrial supply chains. The Indian renewable energy
Application
Technology
market, although relatively recent, has quickly recognized the potential of this process, especially with the aim of producing biomethane using waste materials. A practical example is pro-
Location
Model
vided by the list below showing Adicomp compressors installed in biogas upgrading plants, where biogas from various biomass sources is used to produce biomethane.
Biogas flow rate
Delivery pressure
Nm³/h
bar(g)
Source of biomass
Biogas upgrading
Water scrubbing
Badaun
2xUVG90
0<435<870
8.5
Rice Straw
Biogas upgrading
Membrane
Baheri
UVG250
0<720<1439
14
Press Mud
Biogas upgrading
Membrane
Balrampur
UVG250
0<720<1439
14
Press Mud
Biogas upgrading
Membrane
Kumbhi
UVG250
0<720<1439
14
Press Mud
Biogas upgrading
Membrane
Nagothane
2x UVG250
0<840<1680
14
Press Mud
Biogas upgrading
Membrane
Prayagraj
2x UVG250
0<840<1680
14
Paddy Straw
Biogas upgrading
Membrane
Chennai
UVG200
0<517<1033
15
Municipal waste
Biogas upgrading
Membrane
Hyderabad
UVG250
0<760<1520
14
Press Mud & other
Biogas upgrading
Membrane
Nagpur
2x UVG355
0<1125<2250
15
Municipal waste
Biogas upgrading
Membrane
Adelaide, Australia
UVG315
0<880<1751
13.4
Agricultural waste
Biogas upgrading
Membrane
Palakkad
UVG315
0<818<1635
15
Municipal waste
Biogas upgrading
Membrane
Bikaner
UVG250
0<840<1620
15
Press Mud
Biogas upgrading
Membrane
Kharkhoda
2x UVG200
0<600<1200
16
Agricultural waste
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Biogas Magazine | Edition 37
Utility
The Biogas Compressor in print of the plant. An inefficient tured approach to compressor compressor, subject to frequent life cycle management. The susthe Upgrading Plant Within a biogas upgrading plant, the compressor plays a central role, and its efficiency and performance directly affect the biomethane production: a compressor failure can compromise the output, as operating costs continue while no revenue is generated. Biogas production can vary depending on the feedstock’s composition, process conditions and plant management strategies; consequently, the machines operating in this context must ensure operational continuity, stable performance, and long-term adaptability.
downtime or characterized by high energy losses, can compromise a large part of the benefits associated with renewable energy production.
Therefore, it becomes essential not only to keep the machine in operation, but also to preserve its energy efficiency throughout its entire life cycle. This approach directly contributes to the sustainability of biogas by reducing specific energy demand, limiting corrective interventions, and maximizing the environmental and economic return on investment.
From the Supply Chain Context to Operational Levers They do not merely support the along the Life Cycle process but have a direct impact on energy efficiency and the overall environmental foot-
Translating these principles into concrete results requires a struc-
tainability of the biogas supply chain, in fact, depends not only on the energy source itself, but also on how machines are maintained, upgraded, and managed over time. It is at this level that targeted interventions such as overhauling, upgrading, energy saving solutions, heat recovery, and spare parts reliability come into play, making it possible to align operational performance, energy efficiency, and asset lifespan with the sustainability objectives of the overall system.
Sustainability and Life Cycle in the Industrial Context In today’s industrial landscape, sustainability is no longer an abstract concept, but a measurable parameter directly linked to energy efficiency, system reliability, and optimized lifecycle
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Biogas Magazine | Edition 37
Utility management of machinery. A large installed base of compressors worldwide provides a broad operational dataset, enabling the development of a systematic approach focused on extending performance over time. This approach aims to ensure consistent reliability and efficiency for both newly installed units and equipment that has been in operation for extended periods. It is based on the integration of targeted technical interventions, performance monitoring and analysis, and advanced asset management strategies. - Energy Saving and Dynamic Load Adaptation A key element of energy sustainability is the compressor’s ability to adapt to non-constant gas flows, a typical condition of biogas plants. Thanks to the presence of inverters and an integrated bypass circuit, it is possible to achieve accurate flow modulation according to actual process demand, avoiding operation under non-optimal load conditions and with greater efficiency than other technologies such as slide valve. This approach reduces energy consumption as a function of flow rate, limiting waste and containing mechanical stress on the main components. The result is improved machine du-
rability, greater long term operational stability, and a consequent reduction in indirect emissions associated with energy consumption. - Heat Recovery: System-Level Energy Efficiency In screw compressors, a significant part of the absorbed power – about 80% – is transferred to the oil. Using oil/water heat exchangers, this energy can be efficiently recovered and made available to the customer for process uses or auxiliary services. Heat recovery represents a key element of system-level energy efficiency, particularly in biogas plants, which are already embedded in a resource valorization logic. The ability to reuse energy that would otherwise be dissipated enables a significant reduction in overall energy costs and a measurable improvement in plant efficiency. - Overhauling: Restoring Performance and Extending Asset Life The gas end (screw block) is the heart of the compression package, and it is therefore essential that its performance does not degrade over time. Through overhauling, functionality can be restored to original levels even after years of continuous operation, avoiding failures that can even lead to scrapping the part. This operation is carried out by
certified technicians who ensure compliance with design specifications, following standardized procedures that include dimensional checks, and performance test of the screw block. The result is the restoration of nominal performance, increased operational reliability, and component warranty extension. - Upgrade: Technological Evolution Alongside asset preservation, Upgrade is a fundamental tool for updating existing compressors to the needs of an evolving industrial context. The possibility of integration of technologies not required at the time of the original design allows the system to be updated without replacing the machine. Upgrade solutions include the replacement of obsolete electronics, flow rate increase and/ or operating pressure modification, and installation of LM (Long Maintenance) solutions. From a sustainability perspective, these interventions reduce Life Cycle Cost and overall environmental impact, while maintaining high operational performance. - Spare Parts: Operational Sustainability Operational sustainability is also closely linked to component reliability. The use of original spare parts, designed to high-quality standards and proven performance over time, helps preserve
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Biogas Magazine | Edition 37
Utility performance and compressor uptime.
maximize
All major compressor components can be replaced in the event of failure or excessive wear, ensuring a service life aligned with that of the plant. Fewer failures and greater operational continuity result in reduced resource waste, lower indirect consumption, and a more controlled environmental impact throughout the compressor’s life cycle.
Conclusions Within a supply chain such as biogas – intrinsically sustainable and based on the valorization of waste materials – compressors play a decisive role not only functionally, but also environmentally. Adopting an “Extending performance over time” approach makes it possible to integrate reliability, energy efficiency, and advanced component management into a unified life cycle vision. Dynamic adaptation to flow rate variations, heat recovery, overhauling, upgrade, and component reliability are not isolated solutions, but complementary levers that together reduce overall environmental impact. In this sense, the ability to maintain high performance over time becomes an essential condition for preserving the environmental value of the biogas supply chain and sustainable energy systems.
Meet the Author Ms. Mariangela Riggi Marketing Manager Adicomp
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Biogas Magazine | Edition 37
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Biogas Magazine | Edition 37
Clients in India
CBG Projects in India 18 TPD 11 TPD 11 TPD 11 TPD 01 TPD 08 TPD 10 TPD
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