IoT-Based Intelligent Monitoring System for Efficient Biogas Production

Abstract

In semi-urban and rural regions, biogas plants play a paramount role in converting organic waste into clean, usable energy. The main issue faced by most small-scale biogas systems is that they do not have any capability for real-time measurement and control, leading to system failures and poor gas yield over time. The proposed system offers the capability of IoT-based smart biogas monitoring and control, which would enhance reliability as well as the performance of small-scale biogas plants. The embedded controller in the system monitors key parameters such as methane concentration, temperature, gas content, and pH. The real-time sensor data is updated on a cloud dashboard via the Wi-Fi integrated controller, where the user can visualize and take necessary actions on the web dashboard. The architecture is also implemented with automation functions, which includes system status control and safety alerts. The proposed model is developed as a research-oriented model for studying bio-digester behaviour, stability of operation using digital monitoring tools, validation of the model using sample slurry to ensure reliable communication of modules, effective system integration, and stable data acquisition. This framework lays out an expandable footwork for smart energy research, educational training, and fact-based engineering design.

Introduction

Biogas plants convert organic waste into renewable energy through anaerobic digestion, but traditional small- and medium-scale systems lack monitoring and control, making them inefficient and unreliable. Critical parameters like temperature, pH, and gas composition are often unmonitored, leading to reduced performance and system failures. While IoT-based solutions exist, most are designed for large-scale plants and are too complex or costly for smaller applications.

To address this gap, the study proposes an IoT-based smart monitoring and control system for small-scale biogas digesters. The system uses sensors (temperature, pH, methane, and level) connected to an ESP32 microcontroller, which collects and transmits data to a cloud platform (Blynk) for real-time monitoring and visualization. The system also includes automation features, where predefined thresholds trigger actions such as alerts, mixing, or safety responses.

The methodology involves designing a floating-drum biogas digester integrated with strategically placed sensors and a wireless data flow model. The system architecture includes hardware (sensors, controllers, actuators) and software (firmware, cloud dashboard) for continuous monitoring and control.

Results show that real-time monitoring improves system stability, maintains optimal digestion conditions, and ensures consistent biogas production. The system effectively detects abnormalities, reduces manual intervention, and enhances safety and efficiency.

Overall, the proposed solution provides a cost-effective, reliable, and scalable approach for improving small-scale biogas systems, with applications in academic research and smart waste management, contributing to sustainable energy and smart city development.

Conclusion

This work presented a low-cost IoT-enabled Smart Biogas Monitoring and Control System developed as a research-oriented prototype for domestic and small-scale biogas ap plications. Embedded sensing, real-time monitoring, cloud-based control, and visualization of key parameters of a biogas digester plant were included in the system in an effort to improve biogas plant efficiency. Experimental monitoring and observation inferred that real-time monitoring and control help understand digester behaviour, and the implemented system successfully collected and communicated the data under various operating conditions. This prototype acts as a testbed for educational research rather than being just a product. This model acts as a base for studying waste-to-energy systems and their operational behaviours and improving general awareness. This study shows that low-cost IoT-based monitoring systems can effectively contribute to the sustainable utilization of biogas plants.

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Copyright

Copyright © 2026 Thomas Manoj Chacko, Jerin Biju, Sankeerth Sadanandan, Aibel Jaison, Tintu George T. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.