Green Earth 3D BioWorks · Technology
Engineering the Future of Circular Bioenergy
Advanced bioenergy systems transforming agricultural residue into clean fuel, renewable infrastructure, and sustainable agricultural value chains.
Full Process
From Field to Fuel — 7 Stages
Click any stage to explore the technology, equipment, and specifications behind it.
Stage 01 of 07
Multi-Feedstock Intelligence
Paddy straw, corn stalks, sugarcane bagasse, and Napier grass arrive from registered farming households. Each batch is weighed at the plant weighbridge, sampled, and tested for moisture content and volatile solids before entering covered storage bays — ensuring only quality-approved material enters the digestion line.
Philosophy
Built Around Efficiency, Reliability & Circular Sustainability
Every engineering decision at Green Earth 3D BioWorks is evaluated against three criteria: does it maximise energy yield, does it minimise waste, and does it strengthen the circular loop between the plant and the farming communities that supply it?
Multi-feedstock flexibility
Paddy straw, Napier grass, agri residues — year-round supply
Industrial-grade gas purification
PSA technology achieving ≥ 95% methane purity
Automated plant monitoring
SCADA-based real-time process control and safety interlocks
High-efficiency digestion
CSTR mesophilic operation optimised for lignocellulosic feedstocks
Low-waste infrastructure
Digestate fully recovered as certified biofertilizer
Core Systems
Technology Stack Deep-Dives
Three core process modules — each engineered for maximum performance and minimum waste.
Inside the Digester
30days
HRT
37°C
Temperature
3×2000m³
Volume
The 4-Stage Biological Process
Hydrolysis
Complex polymers broken into monomers
Acidogenesis
Monomers converted to volatile fatty acids
Acetogenesis
VFAs converted to acetic acid + H₂
Methanogenesis
Methane produced from acetate and H₂
Key Output
Raw biogas: 55–65% CH₄, 35–45% CO₂
Generated continuously over the 30-day retention cycle
Purification
Upgrading Raw Biogas Into High-Purity Green Fuel
The purification stage transforms a mixed gas stream into a consistent, fuel-grade product. Pressure swing adsorption selectively captures CO₂ while passing methane through — achieving pipeline quality in a continuous, energy-efficient cycle.
< 2%
CO₂ residual
≥ 95%
CH₄ purity
IS 16087
Standard
Raw Biogas In
~60% CH₄ · ~40% CO₂ · trace H₂S
H₂S Scrubbing
Chemical or biological removal to < 10 ppm
Moisture Knockout
Water vapour removed via condensation
PSA Separation
Molecular sieve adsorbs CO₂ from 40% → < 2%
Biomethane Output
≥ 95% CH₄ · IS 16087 certified
Compression
Industrial Precision Compression & Cascade Storage
Purified biomethane is compressed through a multi-stage reciprocating compressor to 200–250 bar — the same pressure standard as commercial CNG. Cascade cylinder banks stage the product for rapid, accurate loading into OMC tube trailer modules, with integrated safety interlocks throughout the compression train.
200–250bar
Operating pressure
10TPD
CBG output capacity
CNG-equivalent
Pressure standard
PESOCertified
Equipment standard
Automation
Intelligent Monitoring for Reliable Operations
A SCADA-based control architecture provides real-time visibility across every process variable — temperature, pressure, pH, gas composition, and safety systems — from a central operations console.
Process Control
Environmental
Safety Systems
SCADA System
Real-time process control
Cloud Logging
Continuous data archiving
Remote Access
Off-site monitoring console
Alarm Management
Multi-tier alert hierarchy
Circular Economy
From Waste to Renewable Agricultural Value
The plant is not simply a fuel production facility. It is a circular infrastructure node — taking a material that would otherwise be burned, extracting maximum energy value from it, and returning the residual nutrients to the farmland that produced it.
This closed-loop model strengthens the supply chain, improves farmer economics, and progressively reduces the plant's own input costs as soil health improves across the catchment area.
Agricultural Residue
Paddy straw, crop waste
Biogas Plant
Anaerobic digestion
CBG Fuel
Compressed Biogas → OMC depots
Digestate Recovery
Solid + liquid separation
Organic Biofertilizer
NPK-enriched · returned to farms
Performance
Environmental Performance
Measured, verifiable impact — every year of operation.
0+
Tonnes CO₂e avoided
Per year
0K
Tonnes crop waste diverted
Annually processed
0 T
CBG produced
Renewable fuel annually
0%
Fossil fuel offset potential
vs CNG baseline
0 T
Biofertilizer output
Per year to farmland
Significance
Why This Technology Matters
Beyond the engineering — the social and environmental case for compressed biogas at scale.
Cleaner Air
Every tonne of feedstock processed is a tonne of crop residue not burned in the open field. The plant directly eliminates a major source of PM2.5 and CO₂ in Chhattisgarh.
Energy Transition
CBG is chemically identical to CNG and can replace fossil natural gas in existing vehicle fleets and refuelling infrastructure — enabling a near-zero-carbon fuel pathway without new infrastructure.
Rural Value Creation
By converting a disposal cost (straw burning) into a paid commodity, the plant creates a new income stream for smallholder farmers — increasing household income while strengthening feedstock supply chains.
Sustainable Agriculture
Biofertilizer returned to farmland contains NPK nutrients and beneficial microorganisms, improving soil health and reducing dependency on synthetic fertilizers over multiple growing seasons.
Scalability
Infrastructure Designed for Scale
The technology platform is not fixed to one plant. It is the foundation of a replicable, national-scale clean energy infrastructure.
Modular Architecture
Each plant unit is self-contained and stackable — additional digester capacity can be commissioned in phases without disrupting operations.
Multi-Feedstock Ready
The pre-processing and digestion system is designed to handle any lignocellulosic or slurry feedstock — enabling adaptation to local agricultural profiles in any Indian state.
Digital-First Operations
SCADA-based monitoring, cloud data logging, and remote diagnostics ensure the technology can be operated and maintained from regional centres as the network scales.
SATAT Network Integration
Each new plant slots directly into India's existing SATAT framework and OMC distribution network — no new regulatory pathway required to replicate the model.
Technology Enabling India's Circular Energy Future
A Platform Built for the Next Billion Tonnes of Clean Fuel
Partner with India's most forward-looking biogas infrastructure team — as an investor, offtake partner, or technology collaborator.