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The Panchvati system: a loop with no waste
From the sugar mill to the fuel pump and back to the field: here is how one plant turns 180 tonnes of waste a day into clean fuel, fertiliser and pellets.
The Panchvati loop
Waste becomes fuel, and fuel feeds the farm
The left loop is our plant; the right loop is the farm it serves. Hover or tap any step, or switch to see our company goals.
Production process
Four stages from waste to fuel
Feedstock collection
Organic waste such as pressmud, agricultural residue and animal manure is collected from mills, farms and dairies around the plant.
Anaerobic digestion
The feedstock goes into airtight, oxygen-free tanks where microorganisms break it down into biogas: methane plus carbon dioxide.
Biogas purification
Hydrogen sulphide, CO₂ and moisture are removed, leaving nearly pure methane: bio-CNG.
Compression & storage
The bio-CNG is compressed into high-pressure cascades for distribution and use as transport fuel.
Process flow
Inside the plant
The engineering view: every stage from the pressmud yard to the CBG cascade, with the two by-product streams.
(bio-fertiliser)
(optional)
CBG purification system
Three-stage membrane purification
Polymer membranes let CO₂ and other acid gases pass through while holding methane back. Three stages in a row raise purity step by step to pipeline and vehicle grade, based on the patented SEPURAN® Green 3-stage process.
Upstream pre-treatment
- H₂S removalFerric chloride dosing in the digester plus activated carbon.
- Siloxane removalActivated carbon beds.
- DehydrationMolecular sieve or TEG drying to a dew point below −40 °C.
- Particulate filter1 µm nominal filter before the membranes.
- Oil knock-outCoalescing filters in case of compressor oil carry-over.
Membrane cascade
Plant sizing
A 6 TPD CBG plant, in numbers
The design basis for a standard Panchvati plant producing six tonnes of bio-CNG a day.
| Input | Per day |
|---|---|
| Pressmud | 160 t |
| Cow dung | 20 t |
| Fresh water | 89 t |
| Recycled slurry | 95 t |
| Total solids (TS) | 25–30% |
| Volatile solids (VS) | 75–85% |
| Output | Per day |
|---|---|
| Raw biogas | 17.48 t |
| CBG (bio-CNG) | 6.02 t |
| Fermented organic manure | 32 t |
| Liquid organic manure | 130 L |
| Utility | Per day |
|---|---|
| Power | 13,000–15,000 kWh |
| Compression | 250 bar |
| Methane in biogas | 55–60% |
Where it goes
One plant, many uses
Transport
Bio-CNG fuels cars, buses and trucks through CNG retail outlets.
Electricity
Biogas can drive generators for clean power on site or for the grid.
Heating & industry
Through city gas networks, CBG replaces fossil gas in kitchens and factories.
Back to the soil
Fermented organic manure restores the organic carbon in farmland.