Nisseem India: Your Vision, Our Elite EPC.
Unlocking Commercial Bio-CNG Excellence.
We engineer, procure and construct commercial compressed-biogas plants end-to-end — from Napier-grass pre-treatment and anaerobic digestion to ≥99% CH₄ Bio-CNG at a 250-bar dispensing cascade, plus FOM/LFOM bio-manure recovery.
Everything about the plant, one click away.
⚙️ Animated Process Lab
Click through all 9 stages — live animated schematics with gas flowing through the plant, a digester cutaway, spinning compressors, plus Process / Engineering / Equipment / Safety tabs.
📊 Plant Data & Configurator
Select any capacity from 4.8 to 45 TPD and the full datasheet, mass balance and economics recalculate live.
🌱 FOM / LFOM
The second revenue line — digestate to FCO-grade bio-manure with MDA support of ~₹1,500/MT.
Technical mastery, engineered into every cubic metre of gas.
Nisseem India Private Limited is an elite EPC firm built for the commercial compressed-biogas era. We convert dedicated Napier grass, agricultural residue, municipal organics and industrial effluent into pipeline-grade Bio-CNG — profitably, safely, and at industrial scale.
Our engineers deliver plants that meet IS 16087 gas specification and clear PESO, CPCB and OMC inspection without rework — treating a biogas plant as a precision chemical facility, not a farm digester.
| Attribute | Bio-CNG (our spec) | Fossil CNG |
|---|---|---|
| Source | Napier grass / waste | Natural-gas wells |
| Methane content | ≥99% | ~88–95% |
| Carbon footprint | Net-negative | Fossil |
| Interchangeable? | Yes — same engines & grid | Yes |
Process Mastery
In-house chemical & process engineers model methane potential, OLR/HRT and FOS/TAC balance before a single foundation is poured — yields are designed in, not discovered late.
Error-Free Delivery
HAZOP, LOPA and third-party FAT gate every work package. Plants pass the Performance Guarantee Run on the first attempt.
Full-Stack Integration
Civil, mechanical, E&I and automation under one accountable roof. One contract, one guarantee, one owner.
A market with law-mandated demand.
Structural tailwinds
Mandatory blending from FY 2025-26 · ~50% gas imports to displace · stubble-burning & landfill pressure · green finance & carbon credits.
Revenue streams
Bio-CNG (assured OMC off-take) · FOM/LFOM + MDA · food-grade CO₂ · carbon credits.
Blending ramp
CBG blend in CNG/PNG: 1% → 3% → 4% → 5%+ from FY28-29.
Deep-stack engineering across every discipline.
Process, civil, mechanical, piping, electrical, instrumentation and automation — in-house and governed by a single EPC project-controls system.
- HAZOP · LOPA · QRA safety studies on every project
- NACE MR0175 sour-service material selection
- Primavera P6 schedule & earned-value cost control
- Bankable DPR/TEV with DSCR & IRR sensitivity
The full 9-stage plant — live, animated, clickable.
Click any stage on the left (or a card below) to load its animated engineering schematic — gas flows through the pipes in real time. Then switch the Process · Engineering · Equipment · Control & Safety tabs for the full detail.
Feedstock
Napier reception
Pre-treatment
Break the fibre
Digestion
Make biogas
H₂S removal
Desulfurise
Upgrading
CO₂ → ≥99%
Drying
Dehydrate
Compression
To 250 bar
Dispensing
Store & sell
FOM / LFOM
Bio-manure line
Choose capacity, feedstock & commercial options — every number updates.
Pick a CBG capacity, one or more feedstocks (co-digestion supported) and the commercial options. The complete technical datasheet, mass balance and financial model below all recalculate from the same engineering basis, so every figure stays consistent with your choices.
Engineering basis for 4.8 TPD.
Derived from methane demand: CH₄ required → raw biogas at the blend's CH₄ fraction → feedstock at the blend's specific yield. Physically consistent at every capacity.
| Process parameter | At your selection |
|---|---|
| Bio-CNG output | ~4.8 t/day |
| Annual CBG production | ~1,584 t/yr |
| CBG energy delivered | ~67 MWh/day |
| Raw biogas generated | ~12,316 Nm³/day |
| Feedstock intake | ~134 t/day |
| Annual feedstock | ~44,220 t/yr |
| CO₂ separated in upgrading | ~11 t/day |
| Plant parameter | At your selection |
|---|---|
| Digestate produced | ~114 t/day |
| FOM (solid bio-manure) | ~10 t/day |
| LFOM (liquid bio-manure) | ~26 t/day |
| Digester working volume | ~4,288 m³ |
| Hydraulic retention time | ~35 days |
| Indicative plant area | ~6 acres |
| Indicative manpower | ~20 persons |
Mass flow (per day)
| Stream | Quantity | Destination |
|---|---|---|
| Feedstock in | ~134 t | Pre-treatment → digester |
| Raw biogas | ~12,316 Nm³ | Clean-up & upgrading |
| Bio-CNG (≥99%) | ~4.8 t | 250-bar cascade → OMC |
| CO₂ removed | ~11 t | Vent / food-grade capture |
| Digestate | ~114 t | FOM + LFOM + recycle |
| FOM (dried) | ~10 t | Farms (FCO) |
Technical benefits
- ≥99% CH₄ — well above the IS 16087 90% floor, so the gas is accepted at any OMC gate and can be injected into CGD grids.
- >99% methane recovery — multi-stage membranes with recycle keep slip below 0.5%, protecting both yield and GHG performance.
- H₂S < 5 ppm & dew point −40 °C — protects compressors, cascade and dispensers from corrosion and hydrate plugging.
- SIL-2 safety & >95% uptime — 2oo3 gas detection, ESD, redundant compression and hot-standby PLC.
- Closed nutrient & water loop — digestate becomes FOM/LFOM and clarified liquor returns to feed-prep (ZLD-ready).
What the plant earns and costs.
Indicative annual P&L for 4.8 TPD on Napier Grass at ₹55/kg. Every line responds to your capacity, feedstock blend and options above.
Revenue streams (₹ Cr / yr)
| Stream | ₹ Cr/yr |
|---|---|
| Bio-CNG sales (OMC / SATAT) | 8.7 |
| FOM / LFOM bio-manure (incl. MDA) | 1.2 |
| Bottled CO₂ (if recovered) | 0.0 |
| Total revenue | 9.9 |
Operating cost (₹ Cr / yr)
| Cost head | ₹ Cr/yr |
|---|---|
| Feedstock (largest opex) | 6.2 |
| Power & utilities | 1.0 |
| Manpower | 0.1 |
| O&M, consumables & spares | 1.4 |
| Total opex | 8.7 |
Project economics
| Total project cost (capex) | 47.5 |
| MNRE capital subsidy (CFA) | 4.0 |
| Net capex after subsidy | 43.5 |
| EBITDA (revenue − opex) | 1.2 |
| Simple payback | — yrs |
MNRE CFA modelled at ₹4 Cr per 4.8 TPD, capped at ₹10 Cr/project. Simple payback = net capex ÷ EBITDA; excludes financing, tax, depreciation and working capital.
Financial benefits of the model
- Assured off-take — OMCs are obligated buyers under SATAT and the CBG blending mandate, so volume risk is low.
- Three revenue lines — CBG plus FOM/LFOM (with ~₹1,500/MT MDA) and optional food-grade CO₂ materially lift EBITDA.
- Capital support — MNRE CFA plus priority-sector lending cut the equity cheque and improve DSCR.
- Feedstock economics dominate — toggle between feedstocks above and watch payback move; cheap residues beat energy crops on cost, energy crops win on security of supply.
- Concessional tax & GST — 5% GST on CBG and accelerated depreciation on plant & machinery.
What this plant displaces.
Eight proven feedstocks — pick what your site can secure.
A Bio-CNG plant is only as good as its feedstock. Each option below changes yield, digester sizing, pre-treatment, capex and — most of all — operating cost. Click Use this feedstock on any card to load it into the configurator and see the full technical and financial impact.
Side-by-side comparison
Yields are per tonne of fresh feedstock as received and are indicative field values; actual figures depend on total/volatile solids, seasonality and pre-treatment. Gate prices vary widely by region and contract.
The second product: Fermented Organic Manure.
Digestate isn't waste — it's a bankable co-product. Screw-press / decanter separation yields a solid cake (~20–25% TS) cured, dried and bagged as FOM to the Fertiliser (Control) Order 1985/2021, plus a liquor stream concentrated into LFOM and largely recycled as process water (ZLD-ready).
- Second revenue line — sold to farms & fertiliser companies.
- Market Development Assistance ~₹1,500/MT (SATAT / GOBARdhan).
- Returns organic carbon & NPK to soil — strong ESG story.
- FCO fertiliser registration; effluent to CPCB/SPCB norms.
Run it safely, clear every gate.
Utilities & Balance of Plant
Grid + DG power, MCC/PCC, VFDs · IBR boiler (steam/hot water) · raw + recycled water · instrument/plant air, N₂ · flare, firefighting, gas detection · weighbridge, QC lab, ZLD.
Manpower & O&M
3-shift 24×7 crew · SCADA/PLC + predictive maintenance · AMC for compressors & upgrading skids · consumables: enzymes, desulph. media, membranes, nutrients.
Process Safety
HAZOP · LOPA · QRA · hazardous-area (Zone 1/2, IIA/IIB) · SIL-2 SIS with 2oo3 voting · ESD & flare · H₂S electrochemical detection.
Environment · Safety · Gas
| Approval | Authority |
|---|---|
| Consent to Establish / Operate | SPCB / PCB |
| Environmental clearance (if triggered) | SEIAA / MoEF&CC |
| Groundwater NOC | CGWA |
| PESO — compression & 250-bar storage | PESO / CCOE |
| Gas Cylinder Rules 2016 · SMPV(U) | PESO |
| Fire NOC · OISD-179 | State Fire Dept |
Product · Scheme · Statutory
| Approval | Authority |
|---|---|
| CBG quality — IS 16087 | BIS / OMC |
| FOM / LFOM fertiliser registration | FCO 1985/2021 |
| SATAT LOI + OMC off-take | IOCL/BPCL/HPCL/GAIL |
| CBG blending registration (CBO/CRB) | MoPNG · Central Repository |
| Factory license · Boiler (IBR) | Factories Dept · IBR |
| Electrical inspectorate (CEIG) | CEIG |
EPC delivery — concept to commissioning.
Typical 18–24 months; phases overlap under fast-track EPC, approvals run in parallel.
Ready to turn your feedstock into a bankable Bio-CNG asset?
Share your site, feedstock and off-take plan. Our engineers will return a feasibility view and indicative DPR framework — no obligation.
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