COMMUNICATIONS

IN
DEPENDABILITY AND
QUALITY
MANAGEMENT
CDQM, Volume 16, Number 2, 2013, pp. 28-37
An International Journal

UDC 662.767.2:614.8

Risk Analysis in A Biogas Production

Plant: Case Study
Sanja Stojanovic1 and Vesna Nikolic1
1
University of Nis, Faculty of Occupational Safety, Nis, Serbia
E-mail: tea.stasa@gmail.com, vesnik08@gmail.com
accepted May 22, 2013
Summary
In the contemporary human society, energy is an essential element of development that is woven into the complex
processes of social (political) - economic relations. Therefore, the sustainable energy is essential for sustainable
economic development and political stability of a country. Inability to dispose of energy sufficiently can cause severe
economic disruption and political sensitivity. In the conditions of global economy, instability spreads easily and is
therefore essential to provide reliable and sustainable access to energy resources and make efforts to reduce energy
poverty which affects most countries in transition and developing countries. The question of economic sustainability
can be solved by introducing alternative, i.e. renewable energy sources. In this way positive effects of the territorial
distribution of energy resources are achieved, as well as the effects of the incentives for local economic development
and the reduction of greenhouse gas emissions that contribute to global warming and climate change with
irreversible consequences for the survival of wildlife. In order to successfully find a solution, awareness of the
problem, the political will and ability to implement solutions are necessary. For this reason it is necessary to achieve
a consistent and sustainable energy policy at local and global levels, as well as the development of legislation in this
area. The share of renewable energy sources in the total energy of the Republic of Serbia is very small. The share
needs to be increased of the future if it is to reduce the adverse impact of non-renewable energy sources on human
health and the environment and provide sustainable energy in the future. Serbia, faced with major problems in
energy supply, as well as with its high price in the global market, still insufficiently uses the advantages provided in
the area of cattle breeding on farms. There is a small number of installed plants for production of biogas from
manure. The paper presents the results of a case study of a Serbian dairy farm where a biogas plant was installed as
one of a few examples of energy production from cattle manure and agricultural waste in Serbia. The specificity of
the biogas plant prompted the authors to identify and carry out a detailed risk analysis using the iNTeg-Risk tools for
risk identification.
Key words: Biogas plant, risk analysis, renewable energy.

1. THEORETICAL APPROACH TO THE RESEARCH

Combustion of fossil fuels degrades the environment, pollutes the air, water and land, but above all
it is a matter of the impact on human health of worrying proportions. The International Energy

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Agency, according to the research from 2008 came to the data that the energy sector emits 26
billion tons of carbon dioxide (CO2), where the production of electricity comprises 41% of emission
[7].
According to many studies of eminent experts, there is a strong likelihood that the world will face
the lack of these resources already in 2030, and that the level of emitted carbon dioxide (CO2) will
increase to more than 40 billion tons per year [7].
The use of large amount of energy is in direct contradiction to the achievement and maintenance of
energy efficiency at a high level. The very concept of energy efficiency has two meanings. The first
of the two meanings of the concept of energy efficiency states that energy efficiency implies a
series of measures taken to reduce energy consumption, which do not disturb the normal conditions
of life and work, and are not harmful to the environment and human health. The second meaning of
the concept of energy efficiency is related to technical devices, which are said to be energy efficient
if they have a high level of useful effect, i.e. low losses in the transformation of one form of energy
into another [4].
Due to the harmonization of national legislation with the legislation of EU, with the aim of joining
the EU, Serbia has adopted various legislative acts which have fueled the application of renewable
energy sources in order to achieve higher levels of energy efficiency. For this reason Law on
Efficient Use of Energy has been passed. This Law regulates the conditions and the way of efficient
use of energy in the sector of energy production, transmission, distribution and consumption; the
policy for efficient use of energy; the energy management system, labeling the level of energy
efficiency of products that affect energy consumption; financing, incentives and other measures to
this field [12].
The following objectives are achieved by the efficient use of energy:
increase of the security of energy supply and its efficient use;
increase of the competitiveness of the economy;
reduction of negative influence of the energy sector on the environment;
encouragement of responsible behavior towards energy, based on the implementation of energy
efficiency policies and measures for energy efficiency in energy production, transmission,
distribution and consumption [12].
By passing this law, as well as other legal regulations, Serbia is rapidly moving toward achieving
energy efficiency. Cost-effective energy efficiency, as well as the solutions related to the renewable
sources of energy are necessary for achieving the ambitious goals of the EU by 2020. In the
framework of the EU Strategy to 2020, the sustainable energy sources are in the very center,
because it is a wanted way to achieve a reduction in greenhouse gas emissions by at least 20%
below the level of that in 1990 within the EU, and to achieve a 20% reduction in primary energy
use through the improvement of energy efficiency. Directive 2009/28/EC obliges all EU member
states to secure at least 20% of total final energy consumption from renewable energy sources by
2020 [7].
This area was given primacy both in Serbia and other parts of the EU as energy efficiency and
renewable resources of energy are the key solutions to the main energy problems facing the EU
member states [1].
In the previous period and with the above mentioned objectives Serbia adopted a set of regulations
governing the area of energy efficiency. As one of the most important legal regulations, the Law on
Energy was set aside (Official Gazette no. 57/2011, 80/2011 - corr. 93/2012 and 124/2012), which

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regulates the energy policy of Serbia in terms of achieving better financial and economic conditions
for the production of electricity from renewable energy sources [4].
This Law also defines the incentives for the construction of energy facilities used for the production
of energy from renewable energy sources. In addition to the Law on Energy, the following
ordinances were adopted:
The Ordinance on incentives for the privileged power producers (Official Gazette of RS, no.
8/2013),
The Ordinance on the conditions and procedure for acquiring the status of privileged power
producers (Official Gazette of RS, no.8/2013).
In addition to these legal acts, regulations that apply exclusively to the construction and production
of biogas were adopted, which is relevant for us in this study.
Regulations governing the activity of construction and biogas production in Serbia are divided into
two main groups:
The first group of rules stipulates the field of construction of the plant for energy production,
the method of determining the suitability of the facility for use, as well as a way of obtaining
building and occupancy permits for a given plant. According to these regulations, electricity and
thermal energy are simultaneously produced in the biogas production plant.
The second group of rules stipulates the rights in the field of electricity and/or thermal energy
production [1].

2. METHODOLOGICAL CHARACTERISTICS OF THE RESEARCH

We set out into this study with the aim of identifying and analyzing risks in the operation of the
biogas production plant. The realization of the specified objective meant the operationalization of a
series of tasks involving observation and description of the biogas plant, i.e. the specificity of its
setting, work process and risk management in the production of biogas. In the production of biogas
it is necessary to choose the same before the construction of the plant. The most commonly used
solutions for the construction of biogas production are:
self-outflow systems where a continuous collection of liquid manure is provided,
systems with barriers where a complete channel emptying is achieved [3].
The plant must be installed in order to achieve energy efficiency and reduce the cost of milk
production, but also with the aim to properly dispose of agricultural waste. There are certain risks in
the operation of every plant, including the scope of the biogas plant, so for that reason it is
necessary to implement an adequate facility management.
The dairy "Lazar" in Blace was determined as a research sample. The biogas production plant
within the dairy "Lazar" is one of two plants installed in the region of South Serbia. The plant was
installed as part of the dairy cows farm of the dairy "Lazar" in the village of Gornja Dragusa in the
vicinity of Blace municipality. The farm has 900 head of dairy cows, so that the starting raw
material for biogas production in this plant is the cattle manure. The plant itself was designed for a
daily intake of 40 tons of manure, 30 t of curd, 25 t of corn silage and 65 t of water.[11] The storage
(pool) with mixers for homogenization of raw material has dimensions of 7.5 m x 7.5 m, a digester
system consists of three overflow tanks, also with mixers, Figure 1 [11].
This plant started operating in May 2012, and was built by the support of the U.S. Department of
Agriculture. On this occasion, USA Technology, DVO GHD Co, Chilstone, was installed where the
capacity of the power plant is 1 MW/h or 24 MW/day, and the investment is 2.2 million worth.

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Within the descriptive research method, the primary and secondary sources analysis and
unstandardized interview were used for obtaining the relevant data. The integ-risk method and tools
were implemented for successful monitoring and risk management in the biogas plant, with which
full results of the monitoring of risks in the plant are obtained.

Figure 1. Scheme of the biogas plant "Lazar" Blace,

technology DVO GHD Co [3]
Integ-risk represents a new methodology that involves early recognition, monitoring and integrated
risk management. This methodology is implemented in new production technologies (technology of
biogas production), nano-sciences and nano - technologies. The use of this methodology
coordinates the research and development activities related to the use of new materials and
technologies, with the aim of establishing a common EU approach to face the challenges of the
emergence of risk for the next 15 years [10].

3. RESULTS AND DISCUSSION

In cases where livestock manure is used as a raw material for biogas production, the data presented
in Table 1 (see Appendices) are used as reference values for biomass energy potential in the farms,
which is presented within the Annex, and the reference values is determined by the number of
livestock (UG) [8].
By anaerobic digestion, i.e. decomposition of organic substances under anaerobic conditions, biogas
is obtained, which is a mixture of methane (CH4) and carbon dioxide (CO2), in following
proportions, methane 60-70%, and carbon dioxide 30-40%. Calorific value of biogas is about
6.5kWh/Nm3 [8].
Due to the anaerobic digestion by bacteria that cause the breakdown of organic substances, a
metabolic product biogas, is produced. Anaerobic digestion is carried out in the absence of
oxygen, where it is also necessary to achieve other conditions in terms of maintaining a constant
temperature and pH values in the range of 6.5 to 7.5. The most effective degradation of organic
substances is achieved by the so-called mesophilic temperature range, where the achieved
temperature is 35 C. In addition to the mesophilic stage production of biogas, the psychrophilic
phase is also used in the plant where psychrophilic bacteria carry out decomposition of organic
substances at the temperature of 15C, as well as the thermophilic phase, which is carried out at the
temperature of 55C in the presence of thermophilic bacteria [9].

31
The process of anaerobic digestion is extremely favorable for the treatment of organic waste,
because it is in this case the most environment friendly, but it also provides the best way of
conversion of organic substances from the waste into electricity. This process reduces the amount of
agricultural waste, reduces the number of pathogenic substances in the waste, and increases energy
efficiency. Biogas is a fuel of good quality, which can replace fossil fuels in higher percentage with
minimal emissions or even without any carbon dioxide emissions (CO2). Biogas production from
biomass is one of the most important renewable energy sources, it offers many benefits for both the
local community and for the country as a whole. Within these plants gases are produced which may
be described as hazardous, toxic and flammable, so that certain risks occur in biogas production
plants [9].
The process of anaerobic digestion of organic substances is an alternative energy source. All
operations that are executed within the framework of the process bear certain risks (individual,
technical and environmental risk), and may cause potential hazards (explosions, fires, toxicity ...)
For this reason, risk analysis and responsible management of the plant are necessary. Within the
plant itself, the most attention is given to the detection and analysis of technical risk, which
certainly does not mean that the other risk groups are neglected.
For the reason that in every plant present a number of risks, it is necessary to perform an analysis
thereof, but depending on the composition of the product and the specifics of the facility. Results of
the investigation of accidents, whose causes and consequences are similar to the parameters of the
plant, are very often used for analysis. Therefore, special attention is paid to the information from
past experiences, as well as the communication about potential risks in biogas plants globally.
Despite the fact that each plant is specific, it is possible define a global security access and common
risk analysis for all biogas plants, based on global communication. Namely, in order to conduct a
quality risk monitoring in every biogas plant, the employees and the responsible ones at that plant
must adopt a strategy for risk management.
The strategy for risk management in a biogas plant is intended to:
1) explain and describe the regulations that apply to biogas production (safety measures,
specification of biogas),
2) develop a technical department organized so that includes all the recognized technical regulations
in the field,
3) improve knowledge of operators in the field of monitoring and risk analysis within a biogas
plant, which gives an overview and description of the risks in the production of biogas using the
methods and tools of integ-risk,
4) develop informational guidelines to raise awareness among stakeholders,
5) develop appropriate communication activities at the European level, related to the risks in this
field [11].
Monitoring and risk analysis in a biogas plant is carried out in accordance with EU Directives, in
particular in accordance with the Directive 99/92/EC, known as ATEX 137 [6]. Processes in a
biogas plants are accompanied by the creation of explosive atmosphere (the formation of methane
CH4 during anaerobic digestion), and it is therefore necessary to work on prevention of the risk of
explosion, which is achieved by an appropriate application of the ATEX Directive, includes two
sub-directives. The first sub-directive refers to prevention of separation of explosive gases and their
getting in touch with a source of ignition. The second sub-directive refers to the exercise of
requirements for the improvement of health and safety of workers in a biogas plant. Risk
assessment is a process of identifying hazards, which includes the analysis and correlation of risk
with a given hazard, but it is also a process of determining the type, severity and probability of

32
injury or damage. Then it includes the provision of appropriate equipment for the first aid and the
first aid training. Finally it includes determination of appropriate ways to eliminate and control
hazards [6].

4. EXPLOSION RISK

In a plant for biogas production, there are many workplaces within which there can occur explosive
or potentially explosive atmospheres. During anaerobic digestion there comes to the formation of
methane (CH4), the gas which makes 50 to 75% of biogas. Methane is a gas which in certain
relations may form explosive mixtures in the air. The lower explosion limit of methane is 4.4 vol %,
while the upper limit is 16 vol % [2].
In cases where environmental conditions are maintained, an explosion cannot occur. Premises with
an increased likelihood of an explosive atmosphere are classified into particular zones.
The most explosive zones are areas of bioreactors, gas storage facilities, the air intake part, the
biogas combustion engine and the gas torch [2].
Zones are defined on the basis of the standard EN 60079-10-1 which refers to gases. Depending on
the results of the risk assessment, the definition of explosive areas must be described in the
document for protection against explosions. To reduce the risk of explosion, the responsible persons
in a biogas plant must ensure that the air does not enter the digesters or the bioreactor. All pipes and
fittings shall be sealed in accordance with regulations in order to prevent the methane from reaching
into the environment. Also, a warning against smoking and making any sparks must be prominently
displayed in these places, because a slightest spark can ignite methane and lead to explosion [2].

5. FIRE RISK

In a biogas plant the whole space is divided into sectors of fire protection. The sectors are divided
into: the bioreactor and gas tanks sector, the gas compressors sector and the sector of equipment for
gas combustion. In order to adequately prevent the occurrence of this risk, the prescribed distance
between objects within the facility must be maintained, which is determined for each plant
individually, depending on how much space is available. For prevention of this risk it is important
to appropriately choose the material of the outer walls of the buildings.[2]
5.1 Health Risk
Each component of biogas can cause a variety of problems. The most important components are
methane (CH4 ), carbon dioxide (CO2) and hydrogen sulphide (H2S).
Methane ( CH4) is an inert gas, colorless and odorless, lighter than the air, and for this reason it
collects in spaces under the roof. In cases when it is present in low concentrations it causes narcosis,
while a higher concentrations it can lead to suffocation. The victim is not even aware of the
presence of methane nor the suffocation itself. Higher concentrations lead to an explosion [2].
Carbon dioxide (CO2) is also inert, odorless and colorless, and it is heavier than the air. In cases
when CO2 is present in concentrations up to 3%, the toxic effects do not occur if the space is filled
with a sufficient amount of oxygen. If there is an increase in CO2 concentration above 5%, there
comes to irritation of the respiratory tract and breathing disorder [2].
Hydrogen sulfide( H2S) is a flammable gas, identified by its characteristic smell that resembles a
rotten egg smell; inhalation of large concentrations of this gas causes the degradation of lung tissue
[2].

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Water pollution which comes from a biogas production plant is a major threat to human health and
the environment as a whole.
Water pollution arises in the vicinity of a biogas plant, when contaminated water under the pressure
of rainfall reaches the subterranean waters or soil. High permeability of the terrains on which a
biogas plant was built, then cracks on the channels that transport livestock manure to the digester
and corrosion in the are listed as the main causes of water pollution [2].
Noise is mentioned as one of the important aspects of the health risk within a plant. In biogas
production plants, there is a disturbing sound that exceeds the limit of 80 dB. The noise is
transmitted through exhaust pipes and through ventilation openings, and in most cases it comes
from the generator [2].
For this reason, it is required to install the latest noise protection consistent with local regulations.
In a biogas plant successful monitoring and risk management is done by implementation of methods
and tools integ-risk, by means of which we get full results of the risk monitoring in the plant.
Integ-risk presents a new methodology that involves early recognition, monitoring and integrated
risk management. This methodology is implemented in new production technologies (technology of
biogas production), nano-sciences and nano - technologies.
The use of this methodology coordinates the research and development activities related to the use
of new materials and technologies, with the aim of establishing a common EU approach to face the
challenges of the emergence of risk for the next 15 years [10].
The model of risk development management consists of the four dimensions, shown in Figure 2.
The management framework includes a technological and technical dimension, a dimension of
regulatory policy and standardization, a dimension of health management and a dimension of the
government and communications. Namely, the use of integ-risk tools is based on four steps: pre-
assessment (risk identification and timely warning), risk assessment, tolerance/adaptation and risk
management [10].

Figure 2. The four dimensions of the risk development management [10]

Figure 3. shows a model of risk management, consisting of two spheres. Communication is in the
very center and it is connected with all the other parts including the sphere of management, but also
the sphere of risk assessment.

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 Figure 3. The risk management model [10]

The matrix of risk development management is the matrix 4x4, as shown in the appendices. This
matrix represents risks in a biogas plant. The matrix consists of four dimensions of risk
development management (technical and technological, medical, communicative and regulatory
dimension), and the four-part model for risk development management (pre-estimate, risk
assessment, tolerance and adaptation and risk management) [10].

6. CONCLUSION

Using renewable energy can be regarded as a significant indicator of social and economic development
of the society in the future. However, the use of these energy sources brings new risks that must be
investigated, identified and analyzed.
On the basis of the analysis and the results presented in the paper the following conclusions can be
made. Biogas production has taken precedence both in the EU and other parts of the world. Serbia
today, in the 21st century is still lagging behind in this field. Although biogas imposes itself as a
cheaper energy source, its intensive production has still not been realized in Serbia, especially
when cattle manure from cattle farms is a starting raw material used. In the already installed plants,
such as the plant on the dairy farm "Lazar", the production of biogas leads to the formation of
specific risks. To protect primarily the human health and life, and then the environment, it is
necessary to properly identify the risks in the plant and perform responsible management of the
same, with respect to the adopted legal regulations and standards. For successful monitoring of risk
development education is necessary in various fields related to innovation, such as the application
of integ-risk matrix. Only in this way can we help prevent the emergence and development of risk
both in a biogas plant and other types of plants. The obtained results suggest the need for greater
accountability in the treatment of energy issues, particularly through education and vocational

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training in biogas plants. In addition, raising awareness about renewable energy raw materials
promises responsible energy consumers in the future. Education can play a major role in the
acceptance of energy frugality, the development of energy-efficient behavior and attitudes towards
sustainable energy development in a society.
Serbia's energy policy needs to be further upgraded with respect to the process of gradual
integration into the European legislation and the power grid. Cooperation could be targeted to the
design and planning of energy policy, modernization of infrastructure, improvement and diversity
of energy resources, their development and the introduction of renewable energy sources and
promotion of efficient energy use.

AKNOWLEDGEMENTS

Research reported here is part of the project titled "Research and Development of Energy Efficient
and Environment Friendly Polygeneration Systems based on Renewable Energy Sources
Utilization" III 42006, funded by Serbian Ministry of Education and Science.

REFERENCES

[1] EU Sustainable Energy Week, The Delegation of the European Union to the Republic of Serbia,
2013. http://www.eusew.eu/ ( 25.12.2013).
[2] Deublein, D., Steinhauser, A. (2008) Biogas from Waste and Renewable Resources, 2nd
Edition, Weinheim, WILEYVCH, Verlag.
[3] DVO Anaerobic Digester Systems http://www.dvoinc.net/https (25.12.2013).
[4] Energy efficiency, the definition, http://www.eenergetika.proboards.com/index.cgi?board.
(28.12.2013).
[5] Faoro, L. (2010) USAID Serbia Agribusiness Project Quarterly Report Year Three Quarter
Contract no.: EDH-I-00-05-00004-00/09 USAID Agribusiness Project RFTOP No.: 169-07-016
under the RAISE Plus IQC Contractor: Development Alternatives (22.12.2013).
[6] Health and Safety Executive, ATEX and explosive atmospheres, (2013) http://www.hse.gov.uk
Guidance Topics Fire and explosion (22.12.2013).
[7] Kjaer, C., Zervos, A. (2008) Pure PowerWind Energy Scenarios up to 2030, EWEA
(European Wind Energy Association).
[8] Mitic, D. (2008) Energija (Energy), Ni: Fakultet zatite na radu u Niu, str. 396-400.
[9] Russell M., (2007) Anaerobic Digestion Gas Production, Liepgartner, Biogas West.
[10] Salvi,O., Chaubet, C. (2012) Biogas: Opportunities to Improve Safety and Safety Regulation
Safety Engineering 2012 Ostrava October 17, 2012 - EU-Vri Sbastien Evanno, INERIS,
http://www.integrisk.eu-vri.eu (24.12.2013.)
[11] Studija o resursima biomase u Niavskom, Zajearskom i Jablanikom okrugu (Study over
biomass resources for Nis, Zajecar and Jablanica regions) u okviru projekta: ''Jaanje
prekogranine teritorijalne konkurentnosti i ekonomskog razvoja Niavskog i Jablanikog
(Srbija) i Sofijskog (Bugarska) regiona efikasnim korienjem regionalnih obnovljivih izvora
energije sa naglaskom na korienje biomase'' Project ref: 2007CB16IPO006-2011-2-19 The
project is co-funded by EU through the Bulgaria-Serbia IPA Cross-border Programme
[12] Zakon o efikasnom korienju energije Republike Srbije, Sl. Glasnik
RShttp://www.parlament.gov.rs/.../files/.../zakoni/.../424-13Lat (25.12.2013.)

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APPENDICES

Table 1. Referent values for the energy potential of UG livestock [10]

1UG = 0.6 1.2 dairy cows
Cattle - - approximately 1.3m3 of biogas daily per UG
- calorific value: 6 kwh/Nm3
1UG = 2 6 pigs
Pigs - approximately 1.5m3 of biogas daily per UG
- calorific value: 6 kwh/Nm3
1UG = 250 320 laying hens
Hens - approximately 2m3 of biogas daily per UG
- calorific value: 6.5 kwh/Nm3

The risk management matrix [10]

Pre-assessment Risk Appraisal Tolerability and Risk

Acceptability Management
Judg
Pretty good No enough data Lack of monitoring Lack of technical
knowledge on the available on the / indicators about guidance
T hazards of biogas various situations incidents and documents
for biogas accidents for safety
production

Lack of education Lack of risk No criteria Lack of channels

and safety culture perception available of risk to
H studies tolerability share experience
on
incidents and
accidents

Lack of Lack of concern No discussion on Lack of

awareness is assessment risk acceptability communication
C observed has taken place. on the
hazards and
residual
risks

The problem is No cost-benefit Lack of Lack of

not yet clearly analysis and acceptability harmonized
R framed socio-economic criteria regulation with a
impact clear
doctrine
on going
initiatives in
some countries
to set
up a safety
regulatory
framework

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