Presentation

ANAEROBIC DIGESTERWaste Management - something out of nothing

Ekta ParaswaniProduct Design 2013

“ You may never know what results come of your action, but if you do nothing there will be no result.” - Mahatma Gandhi

Introduction

Diploma project briefHypothesis IntentClient

ProcessResearchSecondary research Primary researchInsights gatheredFocus area

IdeationIterationsIntial conceptsFinal concepts

DesignPrototype

Content

Introduction | 1

Introduction

LANDFILLSWaste Management infrastructure is woefully inadequate in Bangalore. All the waste is indiscriminately dumped in landfills in MANDUR and MAVALLIPURA.

On August 27, 2012, Bangalore city’s landfill at Mandur stopped receiving the mixed municipal waste due to a Public Interest Litigation filed in the Honourable High Court of Karnataka.Waste spilled over from every street corner of the city onto the roads and foothpaths.Bangalore is no longer identified as Garden City. It is now branded as Garbage City.

Mandur and Mavallipur landfills(Bangalore,Karntaka)

Mavallipur

Mandur

On October 1, 2012, Bangalore took a very big step through a directive of the Hon’ble High Court of Karnataka in terms of managing its waste by segregation at source into biodegradable and recyclables which was further strengthened by a notification from the comissioner of BBMP(Bruhat Bengaluru Mahanagara Palike), across the board to households and bulk generators of waste.

Managing Waste

Introduction | 1

WET(Organic)

DRY(Paper,plastic,metal)

GREEN(Leaf & litter)

SANITARY(toilet)

Waste categories

60 % Organic waste

10 %rejects

10 %toxic

20 %recycablewaste

NON - BIODEGRADABLEBIODEGRADABLE=GARDEN WASTE

(COMPOST) WET WASTE (COMPOST)

DRY WASTE (RECYCLE)

E-WASTE (RECYCLE)

BIO WASTE (DISPOSE)

. Dry/wet leaves

. Weeds

. Branches

. Lawn trimmings

. Vegetable, fruits, peels. Tea leaves, coffee powder. Flowers. Matchsticks. Hair. Kernels, seeds. Leftover food

NONCOMPOST. Citrus fruits

. PLASTICS Bags,toys, utensils, bottles.. PAPER Shredded, carton boxes, newspaper. METAL Cans, foils, Caps. OTHER Thermacole, Styrofoam

. Batteries

. Bulbs

. Tubelight

. Chokes

. Cds, DVDs

. Cartdridges

. Phones

. A/C adapters

. Audio/ Video cassettes

. Diapers

. Sanitary waste

. Shaving blades

. Condoms

. Ear buds

. Finger nails

. Band-aids

. Animal bones

Waste Categories

Understanding Waste

Research | 9

Source: http://www.slideshare.net/apnacomplex/wake-up-clean-up-how-to-process-wet-waste-hand-book352013

SI.NO.

1.

2.

3.

4.

5.

Size

XS

S

M

L

XL

Category

Household Level (houses)

Small sized establishments(apartments/ campuses)

Medium sized establishments

(complexes, apartments & office, parks)

Large sized establishments(choultries,restaurants,

hotels)

City wide (Centralised municipal waste

management)

Quantity of waste generated

1-10 kg/day

10-50 kg/day

50-150 kg/day

150-500 kg/day

500 kg/day and above

Area needed(sq.ft.)

<50

50-200

200-500

up to 1000

Above 1000

Daily waste generated by different organization/apartment

Assessment Metrics

Research | 10

Source: http://www.slideshare.net/apnacomplex/wake-up-clean-up-how-to-process-wet-waste-hand-book352013

Managing Wet Waste

Research | 9

COMPOSTING BIOGAS

Every waste generator must first assess the quantum and category of waste generated. Amount of wet waste depends on multiple factors such as nature of business and presence of food preparation units (Canteens,kitchens)

MANAGING WET WASTE

ELECTRICITY

BIOGASORGANIC WASTE

COOKING GAS

MOTOR VEHICAL

Fig 1.1 Different Application of biogas

Biogas is a gas produced by the breakdown of bio-degradable organic matter in the absence of oxygen. This process is also referred to as ‘anaerobic fermentation’ of bio-degradable materials.

Introduction to Biogas

Research | 12

Introduction to Biogas

Research | 12

BOWEL MOVEMENT DIGESTION

FOOD WASTE

ANAEROBIC DIGESTION

GAS

FERTILISER

The process that takes place in biogas is quite similar to the digestive system in ours.

“ Its a very low tech product, you put food it decays and produces methane. The principle is very simple.” - Mr. Ramkumar (FOUNDER & MANAGING DIRECTOR, Our Native Resort)

Digestive system Anaerobic digester

DIPLOMA PROJECT BRIEF

HYPOTHESIS :To enhance the functionality of the existing biogas unit in order to make it more acceptable and user friendly.

INTENT :- To improve the overall aesthetics in order to make it more consumer friendly.- To study the user interface and make it more user friendly through design interventions in ergonomics and aesthetics.- Attempt to make it part of the space.- Exploring the complications invovled in scaling up the biogas plant from a low tech product to a commercial scale.

Diploma Project

Diploma project brief | 4

1. AESTHETICS3. CONSIDERING THE SPACE

4. IMPROVING THE EFFICIENCY BY ENHANCING THE ENGINEERING AND FUNCTIONALITY

2. USER FRIENDLY

Fig 1.4 Biogas at OPUS

Biogas

Research | 18

“ People invest in a digester for different objectives either to save LPG or for sustainability reason.” - Mr. Ramkumar (FOUNDER & MANAGING DIRECTOR, Our Native Resort)

Opus

Research | 18

Opus, in Latin means a piece of work of art or music. Located on Palace Cross road. Opus is essentially a huge bungalow that has been converted into a restaurant with the courtyard being the hub of action. The main courtyard is open and airy, with swaying palms and dim lighting to add to the Goan feel. The crowd is a mix of students, working professionals, couples, girl gangs and the who’s who!

No. of LPG(Liquified petroleum gas) used in a month: 32- 35 for restaurant and 9 for staff. Daily 1 cylinder and weekends 2 cylinders

Food cooked on daily basis in the resturant for around 80-100 people

Everyday menu for staff:

MONDAY: Dal and riceTUESDAY: ChickenWEDNESDAY: Egg curryTHURSDAY:Sambar and riceFRIDAY: Dal and riceSATURDAY: Vegetable, Dal and riceSUNDAY:Chicken

NOTE: Digester in opus is being used for staff cooking.

Opus Restaurant

Opus

Research | 18

Opus Space where the biogas is placed

Digester

Washing area Gas pipe Kitchen

Putting waste in the waste inlet Adding waste

“Delivering technological innovations that are sustainable, eco-friendly, cost-effective and simple.”

Based in Bangalore, India ‘Connect Infra’ is part of the Connect Ventures group of companies. Founded in 2009 with the objective of bringing new and innovative technologies and processes to the fields of road infrastructure, renewable energy and water treatment.

road infrastructure

renewable energy

water treatment

ConnectInfra

• Biogas plant• Solar photovoltaic systems

Client


Website: http://connect-infra.com/ http://connect-ventures.com/about

Process


Transform your choosen ideas into products that

can be industrialized and marketed successful.

Generate ideas, intervention and concepts which offer intelligentsolutions to the problems

Familiarize yourselfwith current product

Market researchUser researchBusiness research Design these products

to last atleast 10 years

Studying the people who use the product

Identify the problems

Insights

Secondary research Primary research Ideation Prototype

Create products that are beautiful, useful and

demonstrable.

RESEARCH

Questionnaire

Research | 13

Anaerobic Digester

LPG

BURNER

COSTGOVERNMENTSUBSIDIES

CLEANING

PROCESS

AESTHETICS

ALTERNATIVE METHODS OF COOKING

SECURITY

SPACE

STORAGE

WASTE INPUT

PRE DIGESTER

COMMERCIAL ASPECTS

WASTE INPUTHow much waste do you accumulate daily?What all can we put in the digester?How much of waste is sufficient?What if you put waste once a week?What waste products need to be avoided?How many times do we put the waste?

LPGHow many LPG do you use in a month?How many cylinders are you saving after installing biogas?Would you want to get rid of LPG?How much do you spend on LPG?

ALTERNATIVEWhat are the other alternatives you use for cooking?How much did you invest in it?

PROCESSHow much time does it take to generate gas?Can we add any enzymes to increase the process?

Questionnaire

Research | 29

AESTHETICS + SPACE Are you happy with the aesthetics?Are you aware of the material?Are you happy with the material used?Does it occupy a lot of space?If you wanted to where else would you place your biogas?

SECURITYDo you find biogas safe?What precautionary measures do you take?Does it have any leakage problems?

CLEANINGHow do you clean it?How many times do you have to clean it?

COSTHow much did you pay?How much maintenance do you pay?

STORAGECan you store methane gaslike LPG?

Research | 30

Questionnaire

BIOGAS = METHANE + CARBON DIOXIDE + HYDROGEN SULPHIDE

70 % methane

30 %other gases

Fig 1.2 Biogas constituent

All methane flames are pure blue in color and are 30-40% low in calorific value compared to LPG and is low combustible.

Gas Composition

Research | 13

Fats and greases

Bakery waste

Food scraps

Corn silage

Grass silage Green Clippings

Brewery Waste

Chicken manure

Potato waste

Pig manure

Cow manure

Fig 1.3 Waste hierarchy

There is a waste pyramid, there are some waste which are very high in calorific value which means they give out a lot more methane in a shorter period of time and volume compared to other waste.

Raw Material

Research | 15

Once the gas is filled the dome rises up and floats, as the gas keeps getting over the dome comes down.

Floating Gas Holder

Research | 25

MATERIAL: FRP (Fiber reinforced plastic)MANUFACTURER: B-Sustain,ChennaiMANUFACTUING TECHNIQUE: Split moldingLAND REQUIREMENT: 3 feetVOLUME: 2 cubic meter

Anaerobic digester

Research |19

Waste Inlet

Gas holderSlurry outlet

Counter weight

Digester

Anaerobic digester

Research | 20

Waste inlet

Gas valveCounter weight

Floating gas drum

Slurry outlet

Partition

Section View

Research | 21

The first time you install biogas you need to fill up the digester completely with water and cowdung in 1:1 ratio.

Water and cowdung

Installation Of Biogas

Research | 22

1112"

1'-1

"

4'-112"

2'

2'-7

"

4'-512"

71 2"

101 2"

4'-6

1 2"

1'-1

"

2'-6

"

2"

3'-10"

11 2"

2'-5

"

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Fig 1.5 Front View

R512"

R1'-11

"

R2'

-1"

R2'-2 12"


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Fig 1.7 Top view

Dimensions

Research | 23

1112"

5"

R412"

R512"

11"

1'-1

1 2"

11 2"6"

3"

8"

112"

11"

10"

51 2"

1'-1

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712"

1'-7

1 2"

R2"

1'-4

"

812"


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Fig 1.6 Part drawing

Dimensions

Research | 24

1. Organic Waste

2. Crusher

3. Slurry4. Biogas plant

5. Gas stove

Process

Research | 27

Process

Research | 27

Segregate kitchen waste

This is the pre -digester

Chop the waste into small pieces,

especially meat products.

Wear Gloves

Process

Research | 27

Add the chopped pieces in the pre

digester along with water in the ratio of

1:1 (Waste:Water)

Once the waste is crushed, you get semi solid waste

called slurry.

Open the waste inlet lid.

Carry slurry to the anaerobic digester.

Process

Research | 27

Pour the slurry in the waste inlet.

Cover the waste inlet back.

While the gas is being used the

floating dome will come down.

Simultaneously the semi solid residue will exit from the pipe and can be

used as a fertiliser.

After 5-6 hours as the gas is generated

the floating dome will start rising.

WASTE MANAGEMENT

Something from nothing

USERS

PROCESS

WASTE

SPACE

RestaurantBIOGAS

ERGONOMICS

Where

Material Transporatation Dome

movement

External clamps

Types of biogas

Cost reduction

Motivation to use the product

Portable Ugly looking

Minimalistic

Dismantable

FunInnovative

Planters

Pre-digester

space around the digester

Lamp

Playful

Universal

IDENTIFYING THE PROBLEM

What Why How

IMPROVING USER EXPERIENCEAdding utility

LPG

System design

Testing

Simplying the process

Opus

UndergroundMiddle Above

Types of waste

Nobody wants to touch it

Dealing with waste

AESTHETICS

Brainstorming

Research | 8

Usability testing

Research | 10

WHAT: We tracked the digester for a month on a daily basis.

WHY: To evaluate the user friendliness of the existing biogas unit witht the representative user.

Comparing it to LPG in terms of time.

WHERE: The digester is used at OPUS, located on palace cross road essentially a bungalow that has been converted in a restaurant . The crowd is a mix of students, working professionals, couples and girls gangs.

WHEN: The waste input (15 kilo minimum) was added once in a day which generated gas for 2 hours in the morning and 2 hours in the evening.

HOW: User attempted to complete the typical tasks while performance and subjective metrics were measured.Performance metrics: Success,time taken for completion of tasks and errors.Subjective metrics: User’s self reported satisfaction and comfort ratings in relation with the tasks performed.

Usability testing

Research | 10

Different waste input

Noodles

Chicken

Rice

Bread

Sambar

Vegetable waste

Usability testing

Research | 10

Different food cooked on biogas

Rice

Chicken curry Boiling vegetables Boiling potato

Boiling Tomato Omellette

Benefits

Simple, user-friendy, and needs no recurring expenses.

Can be converted to electricity and heat in anaerobic digesters.

The climate change and green house gas emission can be controlled/reduced by the capturing of methane through biomethanisation.

The treated biowaste materials coming out from the digester is in the form liquid or semi liquid. This is a very good fertilizer for all types of plants. This can be mixed with equal or more quantity of water and directly be applied to plants.

It is a renewable source of energy, can be effectively used to tackle the energy crisis.

Since it is generated from organic waste it facilitates the process of decentralised waste management - the collection, transportation, and segregation of waste can be totally avoided as the wastes are treated at source itself.

Benefits Of Biogas

Research | 16

SECONDARY STAKEHOLDERS

bbmp

restaurant customers

lpg companies

college

other biogas companies

restaurant staff

restaurant chef

marketing team

Connect Infra team

Restaurant owners

Household

Schools

B.sustain

Hospitals

Roto mouldingmanufacturers

PRIMARY STAKEHOLDERS

Stakeholders Map

Research | 17

3 inches gap above the water jacket.

Inlet pipe needs to be lower than the outlet pipe.

Both the pipes need to be till the water jacket level.

Floating domes height depends on the water jacket.

Design Consideration

Research | 26

No human contact as nobody wants to touch it.

Bigger pieces its difficult to grind.

Have to break them into small pieces and then grind it.

Pipe is used to push the food inside.

Its a tedious task to add water and the food together.

The container in which the slurry is collected need to come with the product.

storage od methane.

Hybrid of LPG and biogas.

Improving the effeciency.

Kitchen waste Pre digester Slurry Waste inlet

Methane

Shadowing

Research | 28

WASTE: Waste should be considered as raw material.

PRODUCT: Should be part of kitchen. Should have qualities of a household product. Should be plug and play. Crusher should be incorporated in the unit itself. Blend in the environment. Space constraint. Movability.

PROCESS: Should become part of your routine. One person should be able to operate it. Everyone cannot carry slurry. Touching of watse. Wearing gloves.

Insights

Research 31

WASTE INLET ACCESSIBILITY

SLURRY

PRESSURE

HEAVY

BULKY

MOVABILITY

INDUSTRIALLOOKING

Problems Identified

Research | 32

WASTESegregation

of waste

CRUSHERManual

Adding waterCollecting slurryCarrying slurryTouching waste

BIOGASWaste inlet

accessibilityCarrying the

slurry

COOKING GASStoraging methane.

Research | 33

Problems Identified

biogas

Kitchen Washing area

Open area

wastebin

cooking gas

Research | 34

Problems Identified

1 2 3

KITCHEN TO BINSegregartion of waste.

BIN TO CRUSHERCarry the waste near the crusher.

SLURRY TO BIOGASCarry the slurry to the biogas

Research | 35

Problems Identified

System Flow 1

Biogas unit + grinder

SlurryBiogas for cooking

Waste

garden

kitchen

The waste is produced in the kitchen, from where it is transported into the biogas unit in the garden. Once biogas has been created the slurry is released in the garden, and the biogas has to be transported into the kitchen.

Cons:• The waste has to be carried outside = inconvenient

Pros:• If there is any smell, it will not be in the house• The slurry can be used where it is produced

System Flow 1

Research | 36

System Flow 2

Biogas unit

SlurryBiogas for cooking

Waste

Biogas unit + grinder

The waste is produced in the kitchen, where it is also deposited into the biogas unit. Once biogas has been created the slurry is taken into the garden, and the biogas can be used directly in the kitchen.

garden

kitchen

Cons:• If there is any smell coming from the unit, it will be released in the house• The slurry will have to be taken outside from the kitchen

Pros:• The biogas can be used where it is produced

Could it be placed next to the normal bin in most households? Is there space?

System Flow 2

Research | 37

Aesthetics :> Material> Color> Form> Pipes

Waste inlet :> Movable> Adjustable

Crusher :> Insink motor> Peddle

Adding utility :> Seating> Lamp

Ergonomics :> Above the gorund> Under the ground> Mid-level

Space design :

Slurry :

Movability :> Wheel>Stand

Transportability

Problems Identified

Research | 38

IDEATION

Moodboard

Ideation | 40

ORGANIC | PLAYFUL | COLORFUL | GREEN | INNOVATIVE

Ideation | 41

Moodboard

ORGANIC | PLAYFUL | COLORFUL | HOUSEHOLD

Lamp (using methane gas produced inside)

Led lights

stand

Gas markings

two different colors

different shapes of dome

different finishes in plastic

cutouts for aesthetics

Elastic thread going around for pressure

Led lights

Form Exploration

Ideation | 42

geo membrane biogas balloon

concelling the pipes

Ideation | 43

Form Exploration

different shapes of dome

different shape from outside but cylindrical from inside

Ideation | 44

Form Exploration

Stackable

translucent plastic

Ideation | 45

Form Exploration

churner that increases the process inside

translucent to see inside

Ideation | 46

Form Exploration

Concept Development

Ideation | 47

PROTOTYPE

1. Figuring out size 2. stackable digesters 3. Size of the prototype

4. Scaled down model 5. Form exploration 6. Pipe fittings

Quick Mock-up

Prototype | 49

10. Pipe fittings 11. size of the waste inlet 12. Figuring out shape

7. Two digesters 8. Waste inlet 9. Waste inlet fitting

Quick Mock-up

Prototype | 50

Introduction 4

front view

Anaerobic Digester

Prototype | 51

Waste inlet

Prototype | 52

Anaerobic Digester

DIGESTER 2

DIGESTER 1

WASTE INLET

SLURRY OUTLET

PRESSURE

PARTITION

Exploded view

Prototype | 53

Anaerobic Digester

SLURRY OUTLET

WATER JACKET

FLOATING DRUM

COUNTER WEIGHT

WASTE INLET

DIGESTER 1

DIGESTER 2

PARTITION

Section view

Prototype | 54

Anaerobic Digester

Anaerobic digester

Digester 2

Digester 1 Floating gas drum

PARTITION

WATER JACKET

PRESSURE

Exploded view

Prototype | 55

Anaerobic Digester

Exploded view

Prototype | 56

Anaerobic Digester

Color exploration

Prototype | 57

Anaerobic Digester

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FRONT VIEW SIDE VIEW

Dimension Drawing

Prototype | 58

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SIDE VIEW TOP VIEW

Prototype | 58

Dimension Drawing


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SECTION VIEW DETAILING


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Prototype | 59

Dimension Drawing


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DIGESTER 1 DIGESTER 2

Digesters

Prototype | 60

PVC pipe

Connectors

Elbow joint

Pipe Detailing

Prototype | 61

1 2

34

1

1 2

2

34

Pattern

Prototype | 62

FRONT VIEW TOP VIEW SIDE VIEW RIB DETAIL

A B

Stacked MDF boards

CNC (computer numerical control)

MATERIAL: MDF(Medium density fibeboard)SIZE OF THE BOARD: 8’x4’NO. OF BOARDS:THICKNESS: 1”

800 dia - 13825 dia - 5724 dia - 2

724 dia 800 dia 825 dia

8’ X 4’

Digesters

MDF Pattern

Prototype | 63

MATERIAL: MDF(Medium density fibeboard)SIZE OF THE BOARD: 8’x4’NO. OF BOARDS:THICKNESS: 1”

SIDE VIEWTOP VIEW 2

296.73 284.23

TOP VIEW 1BASE

A B

RIB DETAIL

Stacked MDF boards

800 dia - 13825 dia - 5724 dia - 2

CNC (computer numerical control)

8’ X 4’

Side covers

Prototype | 64

MDF Pattern

8’ X 4’

1”

762762

1. MDF board

FRONT VIEW TOP VIEW SIDE VIEW

2. CNC machine 3. MDF cut-outs 4. Pattern

Floating drum

Prototype | 65

MDF Pattern

8’ X 4’

0.5”

1. MDF board 2. CNC machine 2. CNC machine 2. CNC machine

Funnel

Prototype | 66

MDF Pattern

1. CNC Machine 2. Cutting of MDF 3. Stacking of MDF Pattern

4. MDF Pattern-Floating drum 5. Waste inlet 6. Sanding-Rib

MDF Pattern Prototype

Prototype | 67

7. Putty work on MDF pattern 8. Spray paint on MDF Pattern 9. Resin

10. Fiber glass 11. FRP Mold drying 12. FRP Mold

FRP Mold

Prototype | 68

Prototype

13. Mold layering 14. Spilt molding 15. Joining of parts

16. Partition 17. Assembling of parts 18. Water Jacket

Prototype | 69

Prototype

NEXT STEP

Resources

Resources | 71

Over a period of three months, several concepts were developed upon, most in theory and some selected practically. Working around technical constraints was the hardest challenge, one not so easy to overcome, and alternative remained few. The final developed products need another stage of refinement, where the pre-digester needs to be a part of biogas.

Aesthetically could be more appealing, but couldn’t due to time contraint.Biogas is a easy process, there is need to make people aware of the technology.

My aim next, is to work on the pre-digester being a part of the digester which will make the product very user friendly and encourage people to invest in it as it will be plug and play.

ResourcesBOOKSHow to manage your wet bio degradable wasteWEBhttp://www.biotech-india.org/ http://www.indiamart.com/bsustain/http://en.wikipedia.org/wiki/BiogasPEOPLE Mr. Ramakrishna,Our native village, BangaloreMr. Ramakanth ,Member of solid waste mangement round table, BangaloreSheetal singh,City managers association, KarnatakaAnita PG, userMr. Kumar, UserMr. Parthasarathy,Owner of B-sustainChitravishwanath, ArchitectJacksonDOVETAILJohn Matthew, Director, DovetailShivannaUNIQUE FIBRESK. Chandran, Proptietor, unique fibres

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ADVISORSJanak Mistry, Teacher, Product Design dept, Srishti School of Art, Design and TechnologyCarl Lindquis, Teacher, Srishti School of Art, Design and Technology Abhiyan, Teacher, Srishti School of Art, Design and TechnologyManas, Teacher, Product Design dept, Srishti School of Art, Design and TechnologyJohn Matthew, Teacher,Furniture design dept, Srishti School of Art, Design and TechnologyCONNECT VENTURES Mr. Karn MalhotraMr. Shiva SPECIAL MENTIONAnees MehkriPradeep James

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Resources

UNIQUE FIBERS

THANK YOU