Biogas Fired Boiler
100% Green Steam | High-Efficiency Clean Energy Solutions
At IndianBoilers.com, we empower industries to harness the power of waste. Our Biogas Fired Boilers are precision-engineered to utilize methane-rich biogas generated from industrial effluents, food waste, or agricultural residue. By converting “waste gas” into high-pressure steam, our boilers eliminate fuel costs while drastically reducing your facility’s carbon footprint.
Manufactured in Ahmedabad, our systems feature specialized gas burner technology designed to handle the specific characteristics of biogas—including varying methane concentrations and moisture content—ensuring stable, safe, and efficient combustion.
Key Features & Performance
- Specialized Biogas Burners: Equipped with high-performance burners featuring stainless steel components to resist the mildly corrosive nature of Hâ‚‚S (Hydrogen Sulfide) often found in biogas.
- Dual-Fuel Versatility: Our boilers can be configured as Multi-Fuel units, allowing you to switch between Biogas and Natural Gas, LPG, or Diesel seamlessly, ensuring 24/7 steam availability even if biogas production fluctuates.
- High Thermal Efficiency: Featuring a sophisticated 3-pass wet-back design that captures maximum heat, achieving efficiencies of 90% to 94% when equipped with our heat recovery units.
- Low Emission Profile: Biogas is a clean-burning fuel. Our boilers produce near-zero SOx and significantly lower NOx compared to coal or oil-fired systems, making them ideal for environmentally sensitive zones.
- Fully Automated Controls: Integrated with advanced Flame Safeguard Systems, gas leak detectors, and PLC-based modulation to maintain precise steam pressure with minimal human intervention.
- Corrosion Protection: Critical internal components are treated or constructed from specialized alloys to withstand the moisture and trace acidic elements typical of unrefined biogas.
Core Industry Applications
The Biogas Fired Boiler is the ultimate choice for:
- Distilleries & Breweries: Utilizing spent wash and process waste to generate the steam required for distillation.
- Dairy & Food Processing: Converting organic wash-water and food scraps into clean steam for pasteurization.
- Paper & Pulp Mills: Harnessing energy from wastewater treatment plant (ETP) sludge digestion.
- Starch & Sugar Industries: Utilizing pressurized biogas from anaerobic reactors for process heating.
- Pharmaceuticals: Providing sustainable heat for reactors and sterilization using treated effluent gas.
Advantages
- Gas Train Engineering: We provide a complete, IBR-approved gas train including filters, regulators, and safety shut-off valves tailored to your specific biogas pressure.
- Custom Gas Mixing: If your biogas quality varies, our burners can be tuned to maintain a stable flame even at lower methane percentages.
- Local Manufacturing: Based in Ahmedabad, we offer specialized technical support for gas-fired systems, ensuring rapid commissioning and periodic safety audits.
Operating Range
- Capacity – 0.5 TPH to 15.0 TPH
- Fuel- Oil (FO, Diesel, LDO), Gas (Natural Gas, LPG), and various waste gases
- Pressure- 10.54 Kg/cm² to 21 Kg/cm²
Technical Specifications
| Specification | Unit | SJ-05 | SJ-10 | SJ-15 | SJ-20 | SJ-30 | SJ-40 | SJ-50 | SJ-60 | SJ-80 | SJ-100 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| General | |||||||||||
| Steam Output From & at 100°C | Kg/hr | 500 | 1000 | 1500 | 2000 | 3000 | 4000 | 5000 | 6000 | 8000 | 10000 |
| Working Pressure | Kg/CM² | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 |
| Steam Temprature | °C | 183 | 183 | 183 | 183 | 183 | 183 | 183 | 183 | 184 | 185 |
| No’s Passes | No’s | Three | Three | Three | Three | Three | Three | Three | Three | Three | Three |
| No’s of Furnace | No’s | 1 | 1 | 1 | 1 | 1 | 1 | 1 | 1 | 1 | 1 |
| Steam Outlet | MM | 40 | 50 | 80 | 80 | 100 | 100 | 125 | 150 | 150 | 200 |
| HTA | M² | 15 | 30 | 45 | 60 | 90 | 120 | 150 | 180 | 240 | 300 |
| Burner: Pressure jet Monoblock Burner | |||||||||||
| Type of Fuel: Diesel, LPG, NG, PNG, FO, LDO | |||||||||||
| Boilers Efficiency | |||||||||||
| On Gas | % | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 | 90 +/-2 |
| On Oil | % | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 | 88 +/-2 |
| Fuel Consumption | |||||||||||
| Diesel (10500) | Kg/hr | 29 | 58 | 88 | 117 | 175 | 234 | 292 | 351 | 468 | 584 |
| Furnace Oil (9600) | Kg/hr | 32 | 64 | 96 | 128 | 192 | 256 | 320 | 384 | 511 | 639 |
| LDO (10200) | Kg/hr | 30 | 60 | 90 | 120 | 180 | 241 | 301 | 361 | 481 | 602 |
| LPG (11000) | Kg/hr | 30 | 60 | 90 | 120 | 180 | 241 | 301 | 361 | 481 | 602 |
| Natural gas(8900) | M³/hr | 34 | 67 | 101 | 135 | 202 | 270 | 337 | 404 | 539 | 674 |
| Electrical Load | |||||||||||
| Feed Water Pump | H.P. | 2.00 | 2.00 | 3.00 | 3.00 | 4.00 | 4.00 | 6.00 | 7.50 | 10.00 | 15.00 |
| Burner Blower (oil) | H.P. | 0.37 | 1.10 | 3.00 | 3.00 | 5.50 | 7.50 | 7.50 | 11.00 | 18.5 | 18.5 |
| Fuel Pump | H.P. | * | * | * | * | 1.10 | 1.10 | 1.10 | 1.50 | 3.0 | 3.0 |
| Total Electric Load | H.P. | 2.37 | 3.10 | 6.00 | 6.00 | 10.60 | 12.60 | 14.60 | 20.00 | 31.50 | 36.50 |
| NOTE: In view of constant endeavors to improve our products, we reserve the right to alter or change above specifications without prior notice. | |||||||||||
Frequently Asked Questions
Can any boiler run on Biogas?
No. Biogas has different combustion properties than Natural Gas or LPG. It requires a specific gas train and a biogas-rated burner to handle the lower pressure and potential impurities like H2S.
What is the minimum methane (CH4) percentage required?
For stable and efficient combustion, we recommend a methane content of at least 55%. However, our custom burners can be tuned to handle leaner gas if required.
How much steam can 1 cubic meter of biogas produce?
On average, 1 m³ of biogas (with 60% methane) can produce approximately 1.3 to 1.5 kg of steam, depending on the boiler's efficiency.
Is the Biogas Fired Boiler IBR certified?
Yes. IndianBoilers.com manufactures units that are fully compliant with Indian Boiler Regulations (IBR), as well as Non-IBR models for low-pressure applications.
Does the biogas need to be purified before entering the boiler?
While the boiler can fire raw biogas, we strongly recommend removing moisture (using a moisture separator) and reducing H2S levels to prevent long-term corrosion of the boiler tubes.
What is the thermal efficiency of these boilers?
Our biogas boilers typically achieve 88% to 92% efficiency. By adding a heat recovery unit like an Economizer, efficiency can be boosted up to 95%.
Can I use Biogas and Diesel in the same boiler?
Yes. we offer Dual-Fuel Burners that allow you to switch between Biogas and Diesel (or LPG/Natural Gas) seamlessly. This is crucial if your biogas production fluctuates.
How does moisture in the gas affect the boiler?
High moisture reduces the flame temperature and can cause "sputtering." Our integrated gas trains include filters and traps to ensure only dry gas reaches the burner.
Is biogas a "Green" fuel?
Absolutely. Biogas is carbon-neutral. Using it prevents methane (a potent greenhouse gas) from escaping into the atmosphere and replaces the need for fossil fuels.
What safety features are included for gas handling?
We provide a Double Block & Bleed valve system, gas pressure switches (high/low), and a sophisticated flame safeguard system that shuts off gas instantly if the flame is not detected.
How do you handle the corrosive nature of H2S?
For gases with high sulfur content, we use Stainless Steel (SS 316) for the burner head and specialized coatings for the chimney and flue gas paths to prevent acidic corrosion.
Does the boiler produce any smell?
No. The high-temperature combustion (above 800°C) completely destroys the odorous compounds (like H2S and Mercaptans) present in raw biogas.
What maintenance is required for the burner?
Routine maintenance involves cleaning the gas filters, checking the spark electrodes, and ensuring the UV flame sensor is clear of soot or dust.
Is there a risk of "Flashback"?
Our burners are engineered with specific nozzle velocities and Flame Arrestors to ensure the gas only burns at the burner head, preventing any flame from traveling back into the gas line.
How much can I save by switching to Biogas?
If you generate biogas onsite (e.g., from an ETP or Distillery), your fuel cost is virtually zero. Most industrial units recover the cost of the boiler in less than 12 months.
Do you provide a "Plug & Play" system?
Yes. We offer skid-mounted biogas boilers where the boiler, burner, feed pumps, and control panel are pre-installed on a single base for rapid site commissioning.
Can the boiler be monitored via mobile or PC?
Yes. Our PLC panels support Industry 4.0 features, including remote monitoring, data logging of gas consumption, and SMS alerts for any safety trips.
What capacity range do you offer?
IndianBoilers.com offers biogas boilers from 500 kg/hr to 20,000 kg/hr (20 TPH).
Why choose IndianBoilers.com for Biogas projects?
Based in Ahmedabad, we are experts in handling "unconventional" fuels. We provide end-to-end support—from gas train engineering to IBR documentation—ensuring a hassle-free transition to green energy.
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