Zone 1: Pre-Processing & Feeding (10 TPD Capacity) - Capacity, specification & price ranges
Seven pre-processing and feeding equipment items for a 10 TPD CBG plant — with throughput specifications and indicative procurement price ranges — covering shredders, hydro-pulpers, conveyors, mixing tanks, and feeding pumps.
| Equipment | Capacity / Throughput | Key Specifications | Price Range (Approx. INR) |
| Hammer Mill / Shredder | 2 - 3 Tons per hour | Motor: 25-40 HP; Stainless Steel (SS 304) contact parts. | ₹4,00,000 – ₹7,50,000 |
| Hydro-Pulper (For MSW) | 5 - 10 m^3 per batch | SS 304 Body; Heavy-duty centrifugal rotor. | ₹8,00,000 – ₹12,00,000 |
| Screw Conveyor (Solid) | 5 Tons per hour | Length: 5-8 meters; U-Trough design; Carbon Steel/SS. | ₹2,50,000 – ₹4,50,000 |
| Pre-Mix Tank (Mixer) | 15 - 20 m^3 volume | RCC or MS with Epoxy; High-torque geared agitator (10 HP). | ₹5,00,000 – ₹9,00,000 |
| Magnetic Separator | Fits on 500mm belt | Over-belt suspension type; Permanent Magnet. | ₹1,50,000 – ₹2,50,000 |
| Feeding Pump (PCP) | 5 - 10 m^3 per hour | Progressive Cavity type; 5-7.5 HP; Tool steel rotor. | ₹3,00,000 – ₹5,00,000 |
| Bio-Extruder (Optional) | 1 - 2 Tons per hour | High-pressure screw; 50-75 HP motor (High energy). | ₹15,00,000 – ₹25,00,000 |
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How to read this table
- Equipment is listed in the order it appears in the processing line — shredder first, feeding pump last.
- Price ranges are indicative procurement costs from Indian suppliers for equipment sized to a 10 TPD plant. Actual quotes will vary by manufacturer, delivery location, and scope of supply (civil works not included).
- The Bio-Extruder row is marked Optional — it is needed only for lignocellulosic (high-fibre) feedstocks such as agricultural straw and Napier grass, not for food waste or slurry-based plants.
- m^3 = cubic metres; HP = horsepower; SS 304 = food-grade stainless steel; RCC = reinforced cement concrete.
About this table
Zone 1 of a Compressed Biogas (CBG) plant covers everything that happens before the feedstock enters the Anaerobic Digestion (AD) reactor: size reduction, mixing with water to achieve the target Total Solids (TS) percentage, contaminant removal, and pumped delivery into the digester. This table shows the seven core equipment items for a 10-tonne per day (TPD) plant capacity, with throughput specifications and indicative procurement price ranges from Indian suppliers as of 2024.
The Hammer Mill or Shredder is the first-contact equipment for solid feedstocks like agricultural straw and pressed waste. Running at 25–40 HP with SS 304 contact parts, it reduces particle size to below 50mm — the typical upper limit for efficient anaerobic digestion. For MSW-heavy plants, the Hydro-Pulper replaces the shredder: it breaks open food waste and organic material in a water medium while rejecting plastics and inorganics, making it the correct choice when the feedstock mix includes urban food waste or vegetable market waste with contamination.
After size reduction, the Pre-Mix Tank (15–20 m³, 10 HP agitator) is where water is added to dilute solid feedstock to the 8–12% Total Solids (TS) concentration required for a Continuously Stirred Tank Reactor (CSTR) digester, or 15–40% TS for a Plug Flow Reactor. The tank's RCC or epoxy-lined mild steel construction handles the corrosive pH environment of partially degraded organic matter. The Magnetic Separator, though small and relatively inexpensive, is critical for MSW plants where metallic contaminants in the feedstock can damage downstream pumps and agitators. The Feeding Pump — a Progressive Cavity (PCP) type — then delivers the prepared slurry to the digester at controlled flow rates; tool steel rotors are specified to handle the abrasive fine particles in the slurry. The optional Bio-Extruder is relevant only for high-fibre lignocellulosic feedstocks like Napier grass or paddy straw — its high-pressure screw mechanically ruptures cell walls to improve biodegradability, but the significant motor power (50–75 HP) adds to daily electricity consumption.
Key insights
- The choice between Hammer Mill and Hydro-Pulper is determined by feedstock type: Hammer Mill for dry agricultural waste, Hydro-Pulper for MSW or wet food waste — using the wrong equipment for the feedstock causes operational problems.
- The Magnetic Separator is a low-cost item but protects all downstream equipment from metal damage — it is not optional for MSW feedstock plants regardless of budget.
- The Bio-Extruder is the highest-cost optional item in Zone 1, at 50–75 HP power draw, significantly increasing daily electricity consumption — its inclusion must be justified by a measurable increase in biogas yield from the specific lignocellulosic feedstock used.
- Progressive Cavity Pumps are specified for the feeding role over centrifugal pumps because they handle high-viscosity, particle-laden slurry without the cavitation and blockage problems that centrifugal pumps face at TS percentages above 8%.
Methodology & sources
Equipment specifications are typical for Indian-manufactured equipment sold for 10 TPD CBG plants as of 2024. Price ranges are indicative ex-works quotes and exclude installation, civil works, and GST. Actual procurement prices depend on vendor selection, quantity ordering, and delivery location. HP ratings are nominal motor sizes; actual installed power may include a 10–15% safety margin.
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