FUEL OR WINE FROM FOOD GRAINS…….. ???

In the last year there are some discussions on production of alcohol from food grains. Experts from different fields are giving their own opinions in backing or in oppose. I write this blog to offer a viable, eco-friendly, appropriate option in the interest of people of Maharashtra.
ALCHOHOL PRODUCTION – A VIEW
In Maharashtra around 16 industries have received licenses to produce alcohol from food grains, besides to this 210% subsidy has been offered. These industries will produce potable alcohol from food grains, which will be purchased from adjacent farmers & also offer them good rate. This activity will create a whooping quantity of 118 Core Liters alcohol for the 11 crore residents of Maharashtra, which has to be consumed in this state only.
ALCOHOL PRODUCTION – ECONOMICS
For production of 1ltr alcohol, we require 3 kg. of Maize at an average rate of 10/- kg. Average rate of potable alcohol is @ 35/-liter. If the cost of raw material is 30/- and we have to add cost of production & profit of the entrepreneur ,this will not be a viable option, hence a subsidy is required to make this viable, then how one can offer good rate to farmers?. As per available data @ 20% of the total yield of any farm is wasted due to handling, lack of storage facility, losses in transport etc. A single example of wastage of wet food grain in the state Haryana is @ 20 lakhs tons last year.
A SUSTAINABLE OPTION – BIO GAS
To produce ethanol from sweet sorghum or Maize and Molasses from sugar industry is not new to us but we are using ethanol in automotives@ 5 % only. While nations like Brazil are using ethanol 100 % & replaces existing fuel completely.
Since our research & development for last 10 years regarding biogas and its related fundamental parameters such as feeding material & its starch content & the bacterial count for degradation. Time required for degradation and so on. We have concluded the production of Biogas from waste food grain on a commercial scale will be economical, environment friendly and can be applied anywhere in India. Though it needs huge capital investment for infrastructure but we have proved the same can have high rate of returns.
Before going into details of the above mentioned project, we must understand what is biogas & how it can be produced , what are the affecting parameters on it etc.
A simple definition of Biogas is “A gas produced from any starchy biomass under anaerobic condition with the help of anaerobic bacteria.” The most known application is “GOBAR GAS” which produced with the same principle from Dung of Animals.
The affecting parameters are mentioned below.
1. Anaerobic Status of Digester Tank
2. Availability of Starch into biomass.
3. Time required for Biodegradation (Hydraulic Retention Time)
4. Total number of Anaerobic Bacteria
5. Temperature of Digester Tank @ 25C0 (Low Temperature Affects Bacteria’s)
The feed quantity of Biomass into Digester Tank of Biogas Plant is further degraded with the help of three type bacteria’s. Those are mentioned below.
(i) Hydrolytic Bacteria
(ii) Acidogenis Bacteria
(iii) Methanogensis Bacteria
Acetic Acid is formed by bacteria (CH3COOH) which is further degraded and two Gases (CH4) (Methane) & CO2 (Carbon dioxide) are produced in a combination of Biogas.
If we consider two different Feed Material for Biogas (a) Animal Dung (b) Food waste. (c) Food Grain. Let us compare the production of Biogas from the table mentioned below.

Above table clearly illustrate that depending upon the quantity of Starch available in biomass, more quantity of Biogas can be produced. If we do not apply B.G. Technology even after same waste food grain gets degraded in the atmosphere and will produce CH4 and CO2 respectively but it is important that these gases are released directly in the atmosphere, this is a serious harm to environment. For example 1 kg of CH4 (Methane) is 21 times pollutant than 1 kg of CO2. But if we apply the Biogas technology, we can get good fuel besides to this pollution in the environment can be reduced sizably as we can also achieve Carbon Credit.
Earlier residents of rural area, who were using biogas, makes a complaint regarding burning of Biogas. This was true because biogas contains 60 % Methane (CH4) & 40 % Carbon dioxide (CO2) due to the non burning of Carbon dioxide an adverse impact on the flame of biogas resulting slow burning.
At “Shashwat Oorja” Pune with a continuous research and development in the same, we have separated both the gases successfully where the burning of Methane becomes complete & even the calorific value of biogas is increased. As both gases are separated we have successfully implemented their refilling into cylinders which will double the economics of the plant by selling CO2.
As Carbon dioxide has its own usage in different industries like forging, welding, Extraction solvency, Aerated drinks & dry ice, the rates for CO2 also different from 15 to 100 /kg depending upon application.
In these projects, it is not necessary to use good quality food grain, but wastage in grains, low quality food grain, wet waste of food grain can be used to produce biogas. This will become an additional income for farmers though which they will generate wealth from waste. This may be a small attempt to save pollution but will add same cash benefits like Carbon Credit Certificate. (C.C.C.)
Any farmer can install & use these plant. They are Eco friendly and Tech friendly. The farmers can cultivate some of the energy crops in their farm. Such as Tapioca, Maize, Sugar beet to produce highly starchy biomass. This will ensure the high rate for crop at the field / farmer itself. These energy crops produce high quantity of biogas as 900, 500 & 300 liter/kg respectively.
The slurry generated for biogas plant can be recycled in the farm to increase C: N ratio along with N.P.K. contents of the soil which will enhance the yield of crop.
As the 70% of our total L.P.G. (liquefied Petroleum Gas) is imported, we can offer a local & sustainable option of fuel to citizens of India. This will also save high expenditure on resources of our India.

Smokeless Village

Because of the increasing level of pollution, it has started to heat us the effects of Global Warming. Even after 50 years of Independence merely urban people are using clean fuel and rest of rural India is still dependant on wood and kerosene. Since in the villages the main stream of fuel is purely wood, which produces ample smoke, soot and ash. Besides to this it also produces Carbon Monoxides and Carbon dioxide. Because of Soot and smoke 52% female population in rural area is having deepest impact on breathing disease. There are efforts on international level to reduce the pollution level. On this background Central Ministry for New and Renewable Energy has decided to launch a special scheme by which the need of Rural India or villages can be met by producing their own clean and non pollutant fuel within the local area by using the available local Biomass and hence 100 pilot projects across India are proposed to demonstrate the available techniques with an integral effort.

Benefits of Project
Pilots projects in 100 cities across India.
1. Electricity of biogas is produced in the same village.
2. Efficient use of available biomass.
3. Total control on smoke and in house pollution.
4. Availability of Natural Manure.
5. Small scale industries in the village will enhance local employment.
6. Farmers or members of self help group (S.H.G.) so called Bachat Gat) can form an enterprise.

Aim of Project
By considering the available network of LPG distribution it is not possible to make available LPG on grass route level. And hence the available local biomass can be degraded in the biogas plant digester and appropriate quantity of biogas can be produced which can be distributed locally without effect on cost. The proposed option is the available local manure of cows and buffaloes, the agricultural residue and waste grains can produce biogas which can be supplied to number of households. The produced quantity of organic manure from the biogas plant will enhance the betterment of agricultural soil. The proposed quantity of biogas plant depending upon population may be 200, 400, 500 and 1000m3/day.

Application
These projects can be installed with the financial assistance from M.N.R.E. (Ministry of New and Renewable Energy) for which 57 proposals have been invited by the Ministry. One of the reciepnt is Pune based Private Organization “Shashwat Oorja Private Limited”. The director of the organization Shri Deepak Kanhere has illustrated the information regarding this scheme.

These Companies or Entrepreneur will select any village with consent of local resident will prepare “Detailed Feasibility Project Report” will send to MNRE. This proposal will be scrutinized by the expert panelist of MNRE. After receiving the pre sanctioned letter for the proposed project. It required funds for that project will be received by company or villagers 20 % and 80 %. The project cost can met by having loan facility from local lead bank to raise the remaining 80 % loan amount. The elected projects will run on B.O.O. principals. (i.e. Build, Operate and Own) The Nodal agency of State IREDA and B.G.F.P. based B.D.T.C. centre will help to improve the output.

Investment and Subsidy
There will be direct credit of 50 % cost of the project to the concern beneficiary after successful implementation of the project for a minimum period of 1 year. The fund raising can be alone by using C.S.R.F (Corporate Social Responsibility Fund) of any multinational company in the respective area.

Regarding the above mentioned scheme Shri Deepak Kanhere said in early times banks were not ready to fund B.G. plants. But after the successful implementation of some projects even Co-operative banks are also ready to finance. Refilling the B.G. into cylinders which has technical constraint earlier, but after the successful research and development made by “Shashwat Oorja Private Limited” the department of explosives has permitted to do the same. Simultaneously SOPL has also developed an indigenous technology for separation of Methane and Carbon dioxide from Biogas.
Now this company is ready to guide the required the guidance for technology to interested persons in this field.

Application of bBiogas

A) Heating/cooking:
1 kg of food waste can generate 80 liters of biogas equivalent to 32 grams of LPG, sufficient for 10 minutes of heating/cooking.
B) Electricity generation:
500 liters of biogas is required to run 1 Hp engine for 1 hour. So appropriate engine can be used for running water pumps and other electrical equipments.

Benefits of using biogas:
· Generation of fuel for cooking from waste.
· Savings in LPG usage.
· Savings in foreign exchange as LPG is mostly imported.
· Concession in municipality taxation for some cities.
· Generation of electricity.
· Direct participation in waste management of city.

Biogas : Sustainable fuel from food waste

Treatment and proper disposal of municipal solid waste (MSW) is a tough task for civic bodies all over India. In a city like Pune, around 1400 Tons of MSW is generated per day. Presently, the waste generated in Pune is just dumped at a dumping ground near ‘Devachi Urali’ at Phursungi, Pune. As a responsible civilian, it is our duty to reduce waste generation and dispose our waste generated at our own level. It is possible to do so using simple cost effective methods.

MSW mainly consists of roughly 50% non biodegradable and 50% biodegradable waste. Non- biodegradable waste like plastic, metal and glass is reused/ recycled in various ways. Biodegradable waste treatment can be efficient if done in a decentralized manner. Biomethanation (biogas production), vermicomposting and aerobic degradation are some routinely used methods, used for treatment of biodegradable waste.

Biogas Generation
Biogas is generated by bacteria in the process of biodegradation of organic material under anaerobic conditions. This process creates methane that can be captured and used to either run thermal appliances (cooking) or to create electricity by feeding the methane to generators.
Biogas can be created from a wide variety of biomass (starch and sugar based). These can range from energy crops, crop refuse and waste. The use of waste such as manure and kitchen waste to create energy is an aspect that makes biogas especially relevant in the context of rural India.

A new perspective in biogas technology
(Pune based scientist’s modern experiment)

Preface:
To produce biogas from waste or stale food, waste flour, wet waste in house, edible and non-edible seeds is now not new to us. But to separate the gases like methane (CH4) and carbon dioxide (CO2) from biogas and to fill it in separate cylinders is certainly a modern technology. The above mentioned procedure is done successfully in Pune’s suburb, Hadapsar by Mr. Deepak Kanhere, Director, Shashwat Oorja Pvt. Ltd. Both gases have separate application in industrial field. This is the only experiment in India what they have claimed.
Pune based NGO ‘ARTI’ (Appropriate Rural Technology Institute) headed by senior scientist Dr. A. D. Karve, used food waste to produce biogas and also won the prestigious Ashden awards for sustainable development in 2006. But scientist Mr. Deepak Kanhere has gone further and separated Methane and Carbon dioxide successfully and enhanced the biogas usage. Prior to this he was associated with ARTI, Pune. And since last 7-8 years was in research for various type of material to be used as feeding material. In the last year, he has founded Shashwat Oorja Pvt. Ltd. and kept the biogas research further in the interest of society. They have installed a prototype demonstration plant at Hadapsar, Pune, where vegetable waste and waste food is the primary feed for which the near by 2-3 restaurants is the point of supply for same.

About the plant :

Daily around 100 kg waste is treated in plant to produce around 8000 liters of biogas. This has the budgetary expenditure of 6.36 Lac. This plant has consumed around 1200 sq. ft space for erection. Initially all the waste is physically inspected to sort out non degradable material such as plastic bags. By using pulveriser all material is crushed to form a paste. Water is added to form slurry and all the material is pumped up to digester tank. This digester tank contains slurry of dung to avail a colony of anaerobic bacteria for degradation process. This mixture goes further into two tanks to form acidogenesis and methanogenesis. All the tanks are airtight to keep anaerobic status for bacteria’s survival. At the last two tanks biogas is produced and is catched in gas holder tank, which is inverted into digester tank. At the time of biogas production the waste water coming out in the form of slurry is reused for next day’s feeding material. And hence no additional water is required daily which saves the cost and efforts. Produced quantity of biogas is further compressed by a compressor in MS capsule. Update this is normal process to form CBG (Compressed Biogas).

An innovative option:
Biogas contains methane (CH4), carbon dioxide (CO2), hydrogen sulfide (H2S) but methane is the only gas which is flammable. One can roughly estimate the percentage of methane and carbon dioxide is 60% and 40% respectively. To separate these gases, a “scrubbing system” is used. This is seamless MS pipe containing ceramic reching as the scrubber material which is porous in state and hence enhances the process of scrubbing.

Biogas with a pressure of 10 kg/cm2 is forced in from lower side while water at the rate of 40 ltr/min through the scrubber. Carbon dioxide is easily soluble in water, hence get dissolved and purified methane comes out, which is again passed trhough a second scrubber to remove moisture. The CO2 dissoloved water is again passed through third scrubber where CO2 is released and collected in a capsule. Plain water is recycled in the process again and again. The produced quantity of CO2 is raw in nature and needs further purification.

Cost of production:
By the scrubbing of biogas 1 kg CH4 and 1 kg CO2 is separated and roughly costs 17-19 Rs/kg. Purified CH4 can be sold at rate of Rs. 35/kg while CO2 at the rate of Rs. 25/kg. but if the CO2 is purified further then can be sold at Rs. 40/kg. All the required material to erect this type of p lant is available easily across India.

CO2 usage:
1. Foundry: to keep the molding porous in nature.
2. In extraction solvent system – distillation
3. In aerated soft drinks (food grade)
4. For photo synthesis of crops in farm.
5. As pesticide for aerobic pests can be possible.
Slurry is rich in nutrients and can be used as liquid fertilizer.

Fuel farming:
If we cultivate Sugar-beet as energy crop in the farm, which yields around 30 Tons /acre. In addition to this around 10-12 tons vegetative waste is available as fodder to animals. This crop is of 5 months and won’t require specific soil conditions or integrated crop management. It enhances the soil condition for nitrogen fixation. This adds good amount of income to farmer, besides saline land management.
Maize, sugar-beet and tapioca are few examples of energy crop yielding 500/ 300/900 lit/kg respectively.

Carbon credit:
Due to high penetration of CFC gases, the problem of global warming and pollution arises. To reduce the emission of these gases is awarded by carbon credit certificate (CCC). If we reduce the amount of CO2/ CH4 by installing a biogas plant we can claim carbon credit. For which plant size of biogas should be bigger.
By filling one ton of CO2 in cylinder, we can avoid its release in atmosphere, then 12 euro (INR 720) is offered by CCC. As methane is 21 times more polluting than CO2, we can claim 252 Euros (INR 15000) for one ton. By this we can save pollution, but also add income source to project.

Very easy installation:
We can install these type of projects in hotels, educational institutes and even in hostels, because they produce large amount of food waste and biomass.
Methane cylinders can be sold in comparison with LPG at an estimated price of Rs. 35/kg. this plant becomes economically viable when it has a capacity of 4 tons waste /day and costs approximately 85 Lacs with a payback period of 6.5 years. All these projects are eligible for bank finance with 10-12% rate of interest.

Some international organizations such as Shell Foundations offer funding for these type of project in the form of subsidy. If in any town of village a group of entrepreneurs come together, can erect this type of project to achieve a good opportunity for income source as well as local employment.

Methane usage:
This gas can be used as fuel in kitchen, automotive in compressed form. This gas generates electricity by means of a generator. Since the gas is purified, it adds more calorific value in comparison with biogas.