Zone 4 - Compression & Bottling Equipments - Capacity, specification & price ranges
Equipment specifications and indicative price ranges for Zone 4 — the compression and bottling stage of a CBG plant — covering the five main items from the high-pressure compressor to the emergency shut-off system.
| Equipment | Capacity / Throughput | Key Specifications | Price Range (Approx. INR) |
| High-Pressure CNG Compressor | 100 - 150 m^3/hr | 3 or 4 Stage Reciprocating; 40-60 kW Motor; Water-cooled | ₹35,00,000 – ₹55,00,000 |
| Storage Cascade | 1,500 - 3,000 Liters (WC) | Seamless Steel Cylinders; 250 Bar working pressure; PESO approved | ₹12,00,000 – ₹20,00,000 |
| Bottling Manifold | 10 - 20 Points | High-pressure SS tubing; Individual control valves; Burst-proof hoses | ₹3,00,000 – ₹6,00,000 |
| CNG Dispenser | Single/Dual Hose | Mass Flow Meter (Coriolis type); Electronic display; Flameproof | ₹4,00,000 – ₹7,00,000 |
| Emergency Shut-Off (ESD) | System-wide | Pneumatic/Electric valves; Integrated with gas sensors | ₹1,00,000 – ₹2,00,000 |
| TOTAL ZONE 4 ESTIMATE | High-Pressure Stage | PESO Standard Compliance | ₹55L – ₹90 Lakhs |
Beyond definitions
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How to read this table
- Price ranges are indicative for Indian market procurement. Actual quotes from vendors will vary based on make, delivery terms, and installation scope.
- The final row (TOTAL ZONE 4 ESTIMATE) summarises the combined range — it is not an additional item but a sum of the five rows above.
- All equipment in this zone must comply with PESO standards for high-pressure gas handling.
- Capacity figures refer to the gas throughput the equipment is rated to handle — match these to your plant's daily gas production when sizing.
About this table
Zone 4 is where Compressed Biogas (CBG) reaches its final commercial form. After gas cleaning and upgrading in Zone 3, the purified biomethane enters Zone 4 to be compressed to 200–250 bar, stored in high-pressure cascades, dispensed into cylinders, and sent to market. This table lists the five core equipment items in that stage with capacity ratings, key technical specifications, and indicative price ranges for Indian procurement.
The High-Pressure CNG Compressor is the most expensive single item in Zone 4 — a 3 or 4-stage reciprocating unit with a 40–60 kW motor, typically water-cooled, capable of processing 100–150 m³ per hour of purified gas. The Storage Cascade — seamless steel cylinders approved by the Petroleum and Explosives Safety Organisation (PESO) rated at 250 bar working pressure — provides the buffer between continuous compression and batch-mode cylinder filling. Cascade capacity of 1,500–3,000 litres (water capacity) is standard for a 10 TPD plant.
The Bottling Manifold and CNG Dispenser handle the final transfer to cylinders or vehicles. The dispenser uses a Coriolis-type mass flow meter with a flameproof electronic display — accurate measurement is critical because CBG is sold by kilogram, not by volume. An Emergency Shut-Off (ESD) system integrating pneumatic or electric valves with gas sensors is mandatory under PESO safety rules and is the least expensive item in the zone.
Combined, Zone 4 equipment carries an indicative total ranging from roughly ₹55 lakh to ₹90 lakh for a 10 TPD plant. This forms one defined portion of the overall capital equipment budget a developer must plan for, separate from Zone 3 (upgrading) costs.
Key insights
- The High-Pressure CNG Compressor is the dominant cost item in Zone 4, accounting for roughly 60–65% of total zone equipment spend.
- All Zone 4 equipment must meet PESO safety standards — this is a non-negotiable regulatory requirement, not an optional upgrade.
- The CNG Dispenser uses a Coriolis mass flow meter because CBG is sold by weight (kilograms), making measurement accuracy directly tied to revenue.
- The Emergency Shut-Off system is the lowest-cost item but among the most critical — PESO mandates integration with gas sensors for automatic shutdown on leak detection.
Methodology & sources
Price ranges are indicative for Indian-market equipment procurement at 10 TPD plant scale, based on industry data as of 2024–2025. Prices vary with make (Indian vs imported compressors differ significantly), installation complexity, and freight. All prices exclude GST and civil works. Verify with at least two Indian vendors before finalising your detailed project report.
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