CHAPTER IV
DESIGN, SIMULATION AND ANALYSIS OF RESULTS
This chapter composed of the simulation and test results from the procedures.
The analysis of each simulation was use to verify the performance of anaerobic
digestion system for the production of biogas. The data gathered from the results of test
and simulations validated if the design meets the requirements and specification.
4.1 Design Requirements
Design Requirements are an important input of a process, since tests should
trace back to specific requirements. Design requirements show what elements and
functions are necessary for the process which is the simulation of anaerobic digestion
system.
These are the design requirements that are determined in order to create the
control system for the anaerobic digestion system.
4.1.1 Data Analysis
[Link] Process Overview
Fig. [Link] Flow Chart of Anaerobic Digestion System
Fig. [Link] shows the process of existing anaerobic digestion system. The
existing process is compose of mixing tank, fermentation chamber and hydraulic
pressure tank where the inputs are manure and water. The mixing and inlet tank
are connected to each other. Wastes from pigpen canal transfer directly to the
mixing tank and eventually mixed with the other wastes while water is continuous
flowing during cleaning period. The fermentation chamber serves as the biogas
digester. It is a space where the organic wastes ferment and biogas isolates.
Under the absence of oxygen anaerobic bacteria are given birth. These bacteria
are responsible for producing the biogas by slowly digesting the sludge inside the
digester. The upper part of the chamber is the biogas tank. This place acts as
biogas collection and storage tank before distributing to service area. The
hydraulic pressure tank is for the regulation of the biogas pressure inside the
digester. This tank gives pressure to the biogas so that it can flow to the biogas
piping system. It also functions as the storage of the liquid waste coming out from
the fermentation chamber. The researcher used this flow chart to deepen their
knowledge for the design.
[Link] Review of Operating Parameters of Anaerobic Digester
A. Input Volume and Level
The digester maintains 1:1 ratio volume, pig manure to water. An
increase of volume increases the yield in gas. 1 cubic meter of manure
and water could produce up to 0.058 m3 of biogas.
The anaerobic digester of the current biogas system has inside
volume of 22.94 m3 hold up to 4.59 m3 of raw biogas when the anaerobic
digester is filled with the input volume to its maximum.
Level is also one of the main factors to consider while operating a
biogas plant. From the main chamber, when the manure and water reach
a certain level the incoming inflow will go to the hydraulic pressure tank.
Level is directly proportional to volume, where in if the level increase the
volume will be rise out
B. Temperature
Another factor was operating temperature of biogas system. The
operation temperature must not be too cold or too hot. It was stated in
PNS/PAES 413:2001 that operated temperature must be 20-55 celcius.
These conditions are known to be the Mesophilic Condition and
Thermophilic Condition where the microbes can live up to the specific
temperature and accumulate to produce biogas. Mesophilic is from range
20-35 degree celcius and the bacteria that can sustain that condition is
called mesophiles. Thermophilic has a range of 35-55 degree celcius
which the thermophiles exist.
C. pH
In the existing digester, pH was monitored because it affects the
activity of bacteria to destroy organic matter into biogas. Low pH can slow
the degradation of microbes and produce less biogas due to the effect in
the methanogen. The range 0f 6.2- 8.5 has the optimum value of biogas
produced.
4.1.2 Data Collection
[Link] Conservative Method for the Anaerobic Design
Conservative method was used by the researchers to choose what type of
digester was the best fit for the proposed design. Reading books and
undergraduate theses were the major sources of information in doing the
conservative method. The different types of criteria were chosen and how it
would affect the production of biogas. The four main digester types that were
being evaluated with their advantages and disadvantages were the following:
Fixed Dome, Floating Drum, Tubular, and Complete Mixed Digester. The types of
feeding systems were also considered like batch, continuous and mixed.
[Link].1 Technical Specifications of each Design
Table [Link].1.2 Types of Anaerobic Digester
In table [Link].1 shows the advantage and disadvantage of each digester
design. Each digester has unique characteristics and shows the strength and weakness
on each design.
Table [Link].2 Types of Feeding System
In table [Link].2 shows the types of feeding system. Digesters can be
designed for batch feeding or for continuous feeding. A full charge of raw material is
placed in the digester with batch digesters, which is then sealed off and left to ferment
as long as gas is produced. When gas production has stopped, a new batch of raw
materials empties and replenishes the digester. (Fry. J. l., 2009).
Table [Link].3 Shape of Digester
In table [Link].3 shows the advantages and disadvantages based from the
related studies of the considered shape of biogas digester, According to the DOST,
cylindrical shape is the best suited for the design of anaerobic digester because it has
better load bearing capacity and it can sustain the pressure inside while in operation
mode
Table [Link].4 Biogas Digester Structure
In table [Link].5 shows the different type of structure. The proponents choose
the Stainless steel as the structure of the design study. Stainless steel structure is best
suited in our design because our study is in thermophilic temperature and stainless
steel is ductile through all temperature ranges ([Link], 2013) and leak free. Using
black paint corrosion resistant, the massive corrosion cause by the presence of h2s in
the process can prevent.
Table [Link].5 Position of Digester
In table [Link].5 shows the two types of position. Ensuring that systems
are placed in fields of risk is another thing to consider. Digesters can be classified in
both horizontal and vertical models. Vertical tanks merely bring feedstock on one hand
in a pipe, whilst digestate overflows through a pipe on the other side.
Table [Link].6 Digester Exposure
In table [Link].6 shows the two types of exposure of digester. The
Digester shall not be placed in a flood plain unless the structure is protected from
flooding and flood harm. It must be located in a manner to meet separation
requirements noted in the appropriate local regulations and shall be located so the
potential impacts from breach of embankment, accidental release and or liner failure are
minimized.
Table [Link].7 Result of Conservative
[Link].1 Material Considerations
[Link].9 Calculations
Mixing tank
Inlet
Fermentation
Hydraulic Pressure tank
Level of manure in mixing tank
Level of manure in inlet tank
Level of manure in fermentation tank
Level of manure in Hydraulic Pressure tank
4.1.4 Program Software