5 TPD & 10 TPD Biogas CNG CBG Plant Setup Cost in India

A 5 TPD plant costs approx. ₹25-30 crore and 10 TPD plant ranges ₹60–80 crore, depending on feedstock, technology, and infrastructure. Costs vary with SATAT subsidies, land, digester design, and compliance (PESO, MNRE) approvals.

What Is Biogas?

Biogas is a renewable gaseous fuel produced through the anaerobic digestion of organic matter. In this natural biological process, microorganisms break down organic materials in the absence of oxygen, generating a mixture of gases that is primarily composed of methane and carbon dioxide.

Common feedstocks used for biogas production include cattle dung, agricultural residues, food waste, municipal solid waste, sewage, and other biodegradable organic materials.

Typical Composition of Biogas –

The composition of biogas can vary depending on the type of feedstock and the digestion process. Typically, it contains:

• Methane (CH₄): Approximately 50–60%
• Carbon Dioxide (CO₂): Approximately 35–45%
• Trace Gases: Small quantities of hydrogen sulphide (H₂S), moisture, nitrogen, oxygen, and other gases.

How Biogas Is Converted into Bio-CNG (CBG)?

Biogas is converted into Bio-CNG/CBG through a series of purification and compression steps:

1. Anaerobic Digestion – Organic waste is decomposed in a digester to produce raw biogas.
2. H₂S Removal – Hydrogen sulphide is removed to protect equipment and improve gas quality.
3. Moisture Removal – Water vapour is removed to prevent corrosion and equipment damage.
4. CO₂ Removal – CO₂ and other impurities are separated using technologies such as PSA, membrane separation, water scrubbing, or chemical scrubbing, increasing methane concentration.
5. Compression – Purified biogas is compressed to high pressure, typically around 200–250 bar, for storage and transportation.
6. Quality Testing – The finished CBG is tested against applicable quality and safety requirements before storage, transportation, or dispensing.

Process: Organic Waste → Digestion → Raw Biogas → Purification → Upgrading → Compression → CBG

How CBG Is Produced: From Raw Biogas to Compressed Bio-Gas?

A Bio CNG manufacturing unit is also referred to as a Compressed Biogas (CBG) plant. The main purpose of the Bio-CNG unit is to convert organic wastes, such as agricultural waste, animal waste (partly including dairy waste), organic solid waste, and food waste, into compressed and purified renewable energy gas. This gas (CBG) has almost the same characteristics as conventional CNG gas by that can be employed instead of fossil fuel-based natural gas in transport, industrial, and other sectors of economy.

In India, CBG plants are constructed at low, medium, and high-scale level of production from about 1 tonne per day (TPD) for small plants to more than 30 TPD for large commercial, industrial, and municipal plants. The necessary level of production is defined by such factors as availability and quality of raw materials, land, demand, location of the project, infrastructure, etc. We’re top cbg plant manufacturers & supplier company in India.

1. Typical Plant Capacity and Investment

For a 5 TPD CBG biogas plant setup cost, CSE’s recent assessment puts investment around ₹30–35 crore for paddy straw and approximately ₹25–30 crore for animal dung, MSW or press mud, depending on technology.

Biogas Purification / Upgrading –

The raw biogas must be cleaned and upgraded before becoming CBG.

Common technologies include:

• PSA – Pressure Swing Adsorption
• Membrane separation
• Water scrubbing
• Amine scrubbing
• Hybrid systems

Raw biogas → upgraded biomethane → ~95–98%+ methane → compression → CBG

Indicative 5 TPD Compressed Biogas Plant Specification –

For preliminary project planning, a 5 TPD CBG plant setup could look approximately like this:

10 TPD Commercial Bio CNG Plant / Biogas CBG Plant Setup Cost in India –

A 10 TPD Bio CNG/CBG plant is a renewable energy facility that converts organic waste into purified and compressed biogas for use in automotive and industrial processes.

Key Specifications:

Production of CBG: Roughly between 500 and 600 Nm³ a day, depending on feedstock and plant design.
Methane Purity: Pure methane is normally at 96% to 97%
Compression: Compression is approximately equal to 200 bar before storage and cascading.
Operation: Plant operation can be automated using PLC-based systems.
Equipment Commissioning: Equipment can be commissioned in 45 to 70 days after installation depending on project conditions.
Land Requirement: The land needed for constructing the plant is between 6 to 12 acres depending on the type of installation and storage.

10 TPD Bio CBG Plant Project Cost in India –

10 tons per day (TPD) Compressed Biogas (CBG) / Bio-CNG plant in India typically requires a total project capital cost of ₹60 crore to ₹80 crore, depending on the feedstock choice, level of automation, and civil infrastructure.

Feedstock for 10 TPD Bio CNG CBG Plant –

A 10 TPD CBG plant typically requires 100-200 tonnes per day of organic feedstock, depending on the source material used:

• Cattle dung: Higher volume needed (lower biogas yield per tonne) — often toward the upper end of the range
• Agricultural residue (paddy straw, crop waste): Moderate volumes, but feedstock quality/moisture content affects yield significantly
• Food waste / poultry litter: Generally higher biogas yield per tonne, so can sit toward the lower end
• Napier grass (energy crop): Grown specifically as feedstock, offers more predictable yield consistency

The exact ratio depends on the feedstock’s Total Solids (TS) content, Volatile Solids (VS) content, and C:N ratio — richer, more digestible feedstock needs less tonnage to hit the same 10 TPD gas output, while low-yield feedstock (like plain cattle dung) pushes requirements toward 200 TPD.

10 TPD CBG Plant: Manpower & Electricity Requirements

A 10 Tonnes Per Day (TPD) Compressed Biogas (CBG) plant in India requires a total capital investment of ₹60 crore to ₹70 crore. Manpower requirement for a 10 TPD plant, typical staffing generally includes:

• Plant Operators/Technicians: 8-12 (rotational shifts for digester monitoring, gas upgrading, compression)
• Feedstock Handling/Loading Staff: 6-10 (unloading, shredding, mixing feedstock)
• Lab/Quality Control: 1-2 (testing gas purity, digestate quality)
• Maintenance/Electrical: 2-3
• Supervisors/Plant Manager: 1-2
• Admin/Security/Support: 3-5

Total workforce for a 10 TPD plant typically runs in the range of 25-35 people, though this varies based on automation level, feedstock type (MSW plants need more sorting/handling staff than dung-based plants), and whether it’s a single-shift or 24/7 operation.

Electricity Requirement –

This is a significant operating cost. Electricity consumption is influenced heavily by feedstock type and equipment (shredders, mixers, blowers, PSA compressors, chillers):

• Electricity typically accounts for ~20-48% of total operating expenses depending on feedstock and plant scale — with press mud/paddy straw plants around 28-34%, cow dung-based plants around 19%, and MSW-based plants running as high as 48% due to intensive shredding/sorting needs
• At industrial tariffs (~₹7/kWh), this becomes a major recurring cost — which is why sector bodies have been pushing for concessional/domestic tariff rates for CBG plants

For a 10 TPD plant, connected load commonly falls in the 500–1,000 kW range (varies significantly by technology vendor and feedstock type), so it’s worth getting a vendor-specific load calculation before finalizing electrical infrastructure/transformer sizing.

Government Financial Assistance –

This is important when calculating the actual project cost.

The MNRE Waste-to-Energy programme historically provided CFA for Bio CNG/CBG projects at:

• ₹4 crore per 4,800 kg/day of Bio CNG from a new biogas plant
• ₹3 crore per 4,800 kg/day when the CBG unit is attached to an existing biogas plant
• Maximum CFA: ₹10 crore/project

SATAT Support:

Guaranteed off-take pricing for the produced CBG via Oil Marketing Companies (OMCs) with floor price baselines around ₹2,110 per MMBTU to secure predictable cash flows.