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Home » Special Report » EverEnviro compressed biogas plant sets a global standard in sustainable innovation

EverEnviro compressed biogas plant sets a global standard in sustainable innovation

June 3, 2024 2:04 pm

EverEnviro compressed biogas plant sets a global standard in sustainable innovation
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Revolutionise waste into renewable power, paving the way for sustainable futures by transforming environmental burdens into energy solutions and innovating for a cleaner planet.

Nestled in the heart of Madhya Pradesh, Indore stands as a beacon of innovation and sustainability. Amidst its bustling streets and rich cultural tapestry lies a testament to environmental stewardship: the Indore Clean Energy Pvt. Ltd. plant, spearheaded by EverEnviro Resource Management Pvt. Ltd. This facility, the largest MSW-based CBG facility in India, has transformed the city’s waste management landscape, setting a new standard for cleanliness and eco-friendly practices.

Indore, a beautiful city in Madhya Pradesh, is a vibrant hub for industry, education, culture, and innovation. It is recognised as the cleanest Urban Local Body (ULB) in India, with over 95 percent waste segregation despite its status as the most populous city in the state. It is also home to Indore Clean Energy Pvt. Ltd., India’s largest MSW-based CBG facility, set up by EverEnviro Resource Management Pvt. Ltd. From once being a landfill burdened with 2 Lacs MT of waste, the facility today handles 550 MT of organic waste daily. It can produce 17 tonnes of BioCNG and 40 MT of organic fertiliser daily, preventing the potential accumulation of over 4 million tonnes of waste in the next 20 years. The plant has been frequently visited by national and international delegates, including British High Commissioner Alex Ellis, Chiri Babu Maharjan, Mayor of Lalitpur Metropolitan City, Nepal, and delegates representing PAN India ULBS, amongst others.

EverEnviro’s initiative in Indore highlights the remarkable impact of compressed biogas (CBG) on the environment and community. This case study examines the plant’s journey, illustrating its substantial effect on the city’s cleanliness initiatives and its alignment with India’s Swachh Bharat Mission to establish ‘Garbage Free Cities.’

The Indore Plant: A Beacon of Hope for Environmental Sustainability

Largest Cleanliness Drive: EverEnviro’s Indore plant is at the forefront of the city’s largest cleanliness drive. Through meticulous waste segregation, the workers of Indore Municipal Corporation are trained by Enviro to distinguish between wet and dry waste for better source segregation.

Waste Collection and Processing: The collection process involves gathering wet and dry waste at collection points. Enviro’s skilled workforce identifies and removes plastic and metal parts, ensuring the plant receives only green waste.

Processing and Digestion: The collected waste, transported by 45–55 trucks daily, undergoes a comprehensive processing journey. It moves through a deep bunker, a hammer mill, and a digester, ensuring that only green waste reaches the anaerobic digestion stage.

Biogas Production: After 30–40 days of digestion, microbes facilitate hydrogenesis, producing high-quality biogas with a methane content of 96 percent. This biogas is then compressed to 250 bars, contributing to the plant’s success story.

Success Amid Challenges

Commencing this first-of-its-kind and magnanimous facility in India posed an initial testing phase for the entire project team that experienced difficulties operating the plant, contributing to fluctuating production levels. Overcoming these challenges required strategic planning and adaptation to ensure the project’s financial sustainability in the long run. During this experimental period, substantial investments were made to incorporate cutting-edge global technologies, machinery, and manpower to effectively manage source-segregated organic waste, which is the most suitable input for the plant.

The facility has reached a significant milestone by becoming the first CBG project in India to reach total operational capacity. With the support of a public-private partnership with the Indore Municipal Corporation, the facility has achieved a consistent production rate of nearly 15 tonnes per day (TPD) of compressed biogas (CBG), reaching a milestone with its highest single-day CBG production of 18 tonnes in March 2024. Previously laden with 200,000 metric tonnes (MT) of waste, the site now efficiently processes 550 MT of organic waste daily.

This daily treatment of segregated organic material has significantly reduced greenhouse gas emissions, cutting up to 70,000 metric tonnes of CO2 equivalent (tCO2eq), and enhancing the environmental quality of the region’s 4.3 million inhabitants. Integrating CBG into Indore’s Avantika Gas Limited (AGL) network has facilitated a shift to eco-friendly fuel for roughly 15,000 households. The plant can generate 17 tonnes of biofuel and 40 MT of organic fertiliser daily.

KA Chowdary, Chief Project and Operations Head at EverEnviro Resource Management Pvt. Ltd. said, “Stabilising this pioneering facility in India was initially challenging for our team. During the initial testing phase, significant investments were made in technologies and machinery to effectively manage source-segregated waste, the most suitable input for the plant. We are proud to announce that we have successfully reached nearly 100 percent operational capacity through continuous learning and effort.”

“H.D. Wire was utilising natural gas at its manufacturing facility for heating needs. However,  after thorough discussions and addressing all concerns, we have successfully implemented CBG as our primary heating fuel for our processes. We have noticed no difference in calorific value compared to natural gas, and EverEnviro’s CBG plant has consistently prompted the supply. We are delighted to contribute to reducing pollution in Indore, known as the cleanest city in India”, say officials from HD Wire.

We intend to source CBG from Indore Clean Energy to mitigate the carbon footprint at the Tata International facility in Indore. EverEnviro has provided us full support, offering a PRS station and three vehicles dedicated to transporting CBG exclusively for Tata International’s Dewas operations, ensuring uninterrupted Bio-CBG supply. This initiative has enabled us to cease using coal within our premises, says Sanjay Kapoor, Tata International. 

“L&T’s TLT Pithampur factory uses CBG as a heating process fuel. The machinery and equipment were installed and maintained by EverEnviro’s Indore Clean Energy Pvt. Ltd. This is considered cleaner and greener than earlier fuel since CBG is being processed and produced from waste and follows the principle of reduce, recycle, and reuse. The CBG supplied has a good calorific value. It is continuous and economical compared to the fuel used earlier. We are happy to use absolute green molecules generated from waste,” says an official from L&T.

Expansion of CBG Facilities: EverEnviro is already executing about 20 CBG projects across the states of Madhya Pradesh, Uttar Pradesh, Delhi, and Punjab. The significant capital investment is nearly 2000 crores, resulting in a robust output of 320 metric tonnes per day (TPD) of CBG.

Fermented Organic Manure Production: The CBG plant also generates Fermented Organic Manure (FOM), which is essential for soil health and could be utilised as an eco-friendly fertiliser, promoting regenerative agriculture. The product will be launched in the mainstream market within FY ’24.

“The organic manure, Kissan Amrit, produced at EverEnviro’s Compressed Biogas plant, has helped improve the physicochemical properties of the soil on our farmland, preserving soil quality and enhancing crop productivity. As a result, the yield has increased, and we are receiving maximum benefits from the production. Moreover, we have seen improvement in the carbon content within the soil,” says Piyush Tiwari from village Tajpura, District Khargone, MP.

The Way Forward

EverEnviro’s Indore Clean Energy Pvt. Ltd. plant is making a positive environmental impact. The facility plays a role in curbing ecological impact by preventing over 1 lakh MT of carbon footprints and replacing 20,000 litres of fossil fuel daily, reducing GHG emissions. Over the next two decades, it is projected to avert the accumulation of more than 4 million tonnes of waste. The plant’s influence extends to transportation, with the Indore Municipal Corporation (IMC) using 50 percent of the CBG produced at the facility. This shift has successfully reduced the dependency on diesel in buses, contributing to a notable decrease in both CO2 and GHG emissions, underscoring its positive contributions to environmental sustainability and cleaner energy practices.

The success story, from tackling cleanliness issues to aiding sustainable agriculture, reflects the positive outcomes of compressed biogas produced at Indore Clean Energy Pvt Ltd., established by EverEnviro Resource Management Pvt Ltd. Challenges along the way have become learning opportunities for growth, shaping a more sustainable future. Looking ahead, with plans for compost production and other sustainable initiatives, the Indore plant illustrates how private entities can champion environmental responsibility.

From revolutionising waste management to catalysing sustainable agriculture, EverEnviro’s Indore Clean Energy Pvt. Ltd. plant is a testament to innovation’s power in fostering environmental sustainability. As it continues to evolve and expand its initiatives, it sets a shining example for other cities and industries, illustrating how private entities can lead the charge toward a cleaner, greener future.

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