BPCL-KR Sets August Deadline for Full Operations at Brahmapuram Biogas Facility

Operational Hurdles and Scaling Strategy

The compressed biogas (CBG) facility at Brahmapuram, a project backed by BPCL-Kochi Refinery (BPCL-KR) with a ₹90 crore investment, currently handles an average of 50 tonnes of biodegradable waste daily. While this represents only one-third of its 150-tonne design capacity, project officials state the plant will reach its peak throughput by the third week of August. To facilitate this ramp-up, the refinery plans to implement two eight-hour operational shifts.

Disputes Over Waste Quality and Logistics

Tensions have surfaced between the plant operators and the Kochi Corporation regarding the delay in reaching full capacity. Corporation Health Standing Committee Chairperson Seena Gokulan noted that nearly six months after its February 27, 2026, commissioning, the facility has struggled with volume. However, BPCL-KR representatives reported that initial waste deliveries contained contamination levels far exceeding the 5-10% limit, including hazardous biomedical waste that obstructed conveyor systems. Recent improvements in waste segregation following inter-agency meetings have stabilized the intake process.

Resource Output and Economic Outlook

Once fully operational, the facility is designed to yield specific daily outputs:

• 5.60 tonnes of compressed biogas
• 28 tonnes of solid bio-fertilizer
• 100 tonnes of liquid fermented organic manure

The refinery anticipates piping the purified gas to its own boilers and furnaces starting next week. Managing the liquid manure remains a challenge; BPCL-KR is currently seeking a marketing partner but is prepared to process the byproduct in its own effluent treatment plant if necessary. Despite the significant capital expenditure, refinery sources indicate the project offers a modest 3% return on investment.

Technical Challenges and Solutions

Operational delays were compounded by a recent mechanical failure in the plant's solid waste separator, though engineers have since repaired the unit. Logistical bottlenecks also persist, with the Corporation being asked to provide additional vehicles to manage refuse removal and prevent idling at the site. The refinery rejected a request to treat plant slurry at the city's sewage treatment plant, opting instead for internal processing solutions.

Source: The Hindu — Home