Delhi Jal Board: Integrated Biogas Processing & Utilization Package
The project aimed to transform digester gas, a byproduct of anaerobic sludge digestion, into a clean, safe, and usable fuel source — while providing an environmentally compliant route for excess gas disposal. CRA engineered a fully integrated system comprising an H₂S Scrubber, Dehumidifier, Gas Booster, and Open Flare, ensuring reliable gas quality management and operational safety for continuous plant operation. Commissioned in August 2014, this turnkey package became a key milestone in Delhi Jal Board’s sustainability roadmap, supporting renewable energy generation and efficient biogas handling at one of the city’s major wastewater treatment facilities.
The Delhi Jal Board facility faced several technical and operational challenges in handling its biogas stream
- High H₂S Content: Raw digester gas contained elevated levels of hydrogen sulfide, posing risks of corrosion, odor, and safety hazards.
- Moisture-Rich Gas: The saturated biogas led to condensation in pipelines and downstream equipment, reducing efficiency and damaging components.
- Variable Gas Flow and Pressure: Fluctuations in digester gas generation required a system capable of stable operation under changing flow and pressure conditions.
- Environmental Compliance: Meeting emission norms demanded smokeless and complete combustion during biogas flaring.
- Integration with Existing Infrastructure: The new system had to integrate seamlessly with Veolia’s process layout, control architecture, and operating schedule.
Comprehensive biogas treatment and control system
CRA engineered and delivered a comprehensivebiogas treatment and control system, built for reliability, efficiency, andminimal maintenance in demanding wastewater plant environments.
Biogas Scrubbing System
- Capacity: 1200 Nm³/hr
- Purpose: Removal of H₂S and trace impurities using a packed-bed chemical scrubbing process.
- Design Features:
- Multi-stage scrubbing tower for enhanced gas-liquid contact efficiency.
- Corrosion-resistant FRP construction for long service life.
- Automatic dosing and pH control to maintain consistent scrubbing performance.
- Outcome: Achieved outlet H₂S levels of <100 ppm, protecting downstream components and ensuring safe combustion.
Biogas Dehumidifier (Drier)
- Capacity: 1200 Nm³/hr
- Purpose: Moisture removal from scrubbed gas prior to compression and utilization.
- Design Features:
- Refrigeration-based cooling to achieve dew point reduction up to 5–8°C.
- Automatic condensate drainage and real-time temperature control.
- Integrated skid with corrosion-resistant piping and sensors.
- Outcome: Delivered consistently dry biogas, preventing corrosion, enhancing burner efficiency, and ensuring stable flare operation.
Gas Booster System
- Capacity: 100 mbar
- Purpose: Pressure boosting for biogas transfer to flare and optional energy recovery units.
- Design Features:
- Positive displacement blower driven by flameproof motor.
- Safety interlocks for overpressure and reverse flow protection.
- Flexible coupling and vibration isolation for silent operation.
- Outcome: Maintained steady gas delivery pressure for consistent combustion and safe gas management.
Open Flare System
- Capacity: 450 Nm³/hr
- Purpose: Safe and complete combustion of surplus or unutilized biogas.
- Design Features:
- Pilot-assisted ignition with flame arrestors and flame detection sensors.
- Optimized air-fuel mixing for smokeless, high-efficiency flaring.
- Heavy-duty construction suitable for outdoor, continuous operation.
- Outcome: Achieved stable, smokeless flaring of excess gas, ensuring environmental compliance and operational safety.
Engineering, fabrication, and assembly
CRA executed the engineering, fabrication, andassembly entirely in-house, ensuring full control over quality andperformance. The modular skid-mounted systems allowed quick installation andseamless integration into Veolia’s existing gas handling network.
Comprehensive commissioning and performancevalidation were carried out on-site, including flare ignition tests, gasquality verification, and automation checks. Operator training sessions ensuredsmooth handover and reliable long-term operation.
Enhanced Biogas Quality, Reliability, Sustainability
- Enhanced Biogas Quality: Effective H₂S and moisture removal enabled reliable utilization and safe flaring.
- Improved Safety and Compliance: Automated ignition, pressure control, and emissions management ensured safe operation aligned with CPCB and Oil & Gas industry standards.
- Operational Reliability: Modular design with automated monitoring reduced manual intervention and downtime.
- Sustainability Boost: Enabled energy-efficient gas management at Delhi Jal Board’s wastewater treatment facility, supporting its renewable energy goals.
- Scalable Solution: The success of this system established a replicable model for biogas recovery and processing in municipal utilities across India.
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