Comparative study on packing materials for improved biological methanation in trickle Bed reactors

Packing materials improve biological methanation efficiency in Trickle Bed Reactors. The present study, which lies in the field of energy production and biotechnology, entailed the evaluation of commercial pelletized activated carbon and Raschig rings as packing materials. The evaluation focused on monitoring process indicators and examining the composition of the microbial community. Activated carbon resulted in enhanced methane purity, achieving a two-fold higher methane percentage than Raschig rings, maintaining a stable pH level within a range of 7-8 and reducing gas retention time from 6 h to 90 min. Additionally, the digestate derived from biogas plant was found to be a sufficient nutrient source for the process. Fermentative species with genes for β-oxidation, such as Amaricoccus sp. and Caloramator australicus could explain the production of hexanoic and valerate acids during reactor operation. Based on the physical properties of packing materials, the efficiency of biological methanation could be maximized.

Ex-situ biogas upgrading in thermophilic trickle bed reactors packed with micro-porous packing materials

Two thermophilic trickle bed reactors (TBRs) were packed with different packing densities with polyurethane foam (PUF) and their performance under different retention times were evaluated during ex-situ biogas upgrading process. The results showed that the TBR more tightly packed i.e. containing more layers of PUF achieved higher H₂ utilization efficiency (>99%) and thus, higher methane content (>95%) in the output gas. The tightly packed micro-porous PUF enhanced biofilm immobilization, gas-liquid mass transfer and biomethanation efficiency. Moreover, applying a continuous high-rate nutrient trickling could lead to liquid overflow resulting in formation of non-homogenous biofilm and severe deduction of biomethanation efficiency. High-throughput 16S rRNA gene sequencing revealed that the liquid media were predominated by hydrogenotrophic methanogens. Moreover, members of Peptococcaceae family and uncultured members of Clostridia class were identified as the most abundant species in the biofilm. The proliferation of hydrogenotrophic methanogens together with syntrophic bacteria showed that H₂ addition resulted in altering the microbial community in biogas upgrading process.

Ex-situ biogas upgrading in thermophilic up-flow reactors: The effect of different gas diffusers and gas retention times

Four different types of ceramic gas distributors (Al₂O₃ of 1.2 μm and SiC of 0.5, 7 and 14 μm) were evaluated to increase biomethane formation during ex-situ biogas upgrading process. Each type of gas diffuser was tested independently at three different gas retention times of 10, 5 and 2.5 h, at thermophilic conditions. CH₄ production rate increased by increasing input gas flow rate for all type of distributors, whereas CH₄ concentration declined. Reactors equipped with SiC gas distributors effectively improved biomethane content fulfilling natural gas standards. Microbial analysis showed high abundance of hydrogenotrophic methanogens and proliferated syntrophic bacteria, i.e. syntrophic acetate oxidizers and homoacetogens, confirming the effect of H₂ to alternate anaerobic digestion microbiome and enhance hydrogenotrophic methanogenesis. A detailed anaerobic bioconversion model was adapted to simulate the operation of the R₁-R₄ reactors. The model was shown to be effective for the simulation of biogas upgrading process in up-flow reactors.

Integrated valorization system for simultaneous high strength organic wastewater treatment and astaxanthin production from Haematococcus pluvialis

High-strength organic wastewater, e.g., potato juice wastewater, exerts high stress on the environment. This study proposes an integrated system for simultaneous high-strength organic wastewater treatment and nutrients upcycling for astaxanthin production by the combination of anaerobic processes and microalgae (Haematococcus pluvialis) cultivation. The potato juice wastewater was pretreated by either acidification or methanation. The effluents of both pretreatments achieved higher biomass yields of H. pluvialis compared to cultivation in standard culture media (control). The high acetate and potassium concentrations of the acidification effluents resulted in significantly higher astaxanthin production (24.5-27.9 mg g^-1, 3 days) compared to the control (14.7 mg g^-1, 12 days) in a shorter period. The integrated system contributed to a final removal efficiency of 51.3-75.8%, 86.5-98.3%, and 69.4-83.4% for COD, phosphorus, and ammonia, respectively. This study presents a promising two-stage process for simultaneous efficient methane and astaxanthin production, as well as remediation of high-strength organic wastewater.

Co-digestion of Laminaria digitata with cattle manure: A unimodel simulation study of both batch and continuous experiments

This work investigated the thermophilic (55 °C) co-digestion performance both in batch and continuous mode operation. The biochemical methane potentials of L. digitata and cattle manure were 308 ± 24 and 203 ± 33 mL CH4/g VS, respectively. The optimum co-digestion feedstock ratio was found to be 80% macroalgae: 20% manure on a volatile solids basis, which produced 290 ± 19 mL CH4/g VS under long-term and stable continuous operation at an organic loading rate of 2 g VS/L/d and hydraulic retention time of 15 days. Simulations of the batch and continuous experiments were, for the first time, carried out using an integrated anaerobic bioconversion model without structural modifications. Close fits between measured and simulated data provided mutual confirmation of experimental reliability and model robustness, and provided new perspectives for the use of the software tool.

Performance and genome-centric metagenomics of thermophilic single and two-stage anaerobic digesters treating cheese wastes

The present research is the first comprehensive study regarding the thermophilic anaerobic degradation of cheese wastewater, which combines the evaluation of different reactor configurations (i.e. single and two-stage continuous stirred tank reactors) on the process efficiency and the in-depth characterization of the microbial community structure using genome-centric metagenomics. Both reactor configurations showed acidification problems under the tested organic loading rates (OLRs) of 3.6 and 2.4 g COD/L-reactor day and the hydraulic retention time (HRT) of 15 days. However, the two-stage design reached a methane yield equal to 95% of the theoretical value, in contrast with the single stage configuration, which reached a maximum of 33% of the theoretical methane yield. The metagenomic analysis identified 22 new population genomes and revealed that the microbial compositions between the two configurations were remarkably different, demonstrating a higher methanogenic biodiversity in the two-stage configuration. In fact, the acidogenic reactor of the serial configuration was almost solely composed by the lactose degrader Bifidobacterium crudilactis UC0001. The predictive functional analyses of the main population genomes highlighted specific metabolic pathways responsible for the AD process and the mechanisms of main intermediates production. Particularly, the acetate accumulation experienced by the single stage configuration was mainly correlated to the low abundant syntrophic acetate oxidizer Tepidanaerobacter acetatoxydans UC0018 and to the absence of aceticlastic methanogens.

Optimization of hydrogen dispersion in thermophilic up-flow reactors for ex situ biogas upgrading

This study evaluates the efficiency of four novel up-flow reactors for ex situ biogas upgrading converting externally provided CO₂ and H₂ to CH₄, via hydrogenotrophic methanogenesis. The gases were injected through stainless steel diffusers combined with alumina ceramic sponge or through alumina ceramic membranes. Pore size, input gas loading and gas recirculation flow rate were modulated to optimize gas-liquid mass transfer, and thus methanation efficiency. Results showed that larger pore size diffusion devices achieved the best kinetics and output-gas quality converting all the injected H₂ and CO₂, up to 3.6L/L_REACTOR·d H₂ loading rate. Specifically, reactors' CH₄ content increased from 23 to 96% and the CH₄ yield reached 0.25L_CH4/L_H2. High throughput 16S rRNA gene sequencing revealed predominance of bacteria belonging to Anaerobaculum genus and to uncultured order MBA08. Additionally, the massive increase of hydrogenotrophic methanogens, such as Methanothermobacter thermautotrophicus, and syntrophic bacteria demonstrates the selection-effect of H₂ on community composition.

Co-digestion of food and garden waste with mixed sludge from wastewater treatment in continuously stirred tank reactors

Co-digestions of urban organic waste were conducted to investigate the effect of the mixing ratio between sludge, food waste, grass clippings and green waste at different hydraulic retention times (HRTs). Compared to the digestion of 100% sludge, the methane yield increased by 48% and 35%, when co-digesting sludge with food waste, grass clippings and garden waste with a corresponding %VS of 10:67.5:15.75:6.75 (R1) and 10:45:31.5:13.5 (R2), respectively. The methane yield remained constant at around 425 and 385 NmL CH4/g VS in R1 and R2, respectively, when the reactors were operated at HRTs of 15, 20 and 30 days. However, the methane yield dropped significantly to 356 (R1) and 315 (R2) NmL CH4/g VS when reducing the HRT to 10 days, indicating that the process was stressed. Since the methane production rate improved significantly with decreasing HRT, the trade-off between yield and productivity was obtained at 15 days HRT.

Biogas Upgrading via Hydrogenotrophic Methanogenesis in Two-Stage Continuous Stirred Tank Reactors at Mesophilic and Thermophilic Conditions

This study proposes an innovative setup composed by two stage reactors to achieve biogas upgrading coupling the CO2 in the biogas with external H2 and subsequent conversion into CH4 by hydrogenotrophic methanogenesis. In this configuration, the biogas produced in the first reactor was transferred to the second one, where H2 was injected. This configuration was tested at both mesophilic and thermophilic conditions. After H2 addition, the produced biogas was upgraded to average CH4 content of 89% in the mesophilic reactor and 85% in the thermophilic. At thermophilic conditions, a higher efficiency of CH4 production and CO2 conversion was recorded. The consequent increase of pH did not inhibit the process indicating adaptation of microorganisms to higher pH levels. The effects of H2 on the microbial community were studied using high-throughput Illumina random sequences and full-length 16S rRNA genes extracted from the total sequences. The relative abundance of archaeal community markedly increased upon H2 addition with Methanoculleus as dominant genus. The increase of hydrogenotrophic methanogens and syntrophic Desulfovibrio and the decrease of aceticlastic methanogens indicate a H2-mediated shift toward the hydrogenotrophic pathway enhancing biogas upgrading. Moreover, Thermoanaerobacteraceae were likely involved in syntrophic acetate oxidation with hydrogenotrophic methanogens in absence of aceticlastic methanogenesis.

Counteracting foaming caused by lipids or proteins in biogas reactors using rapeseed oil or oleic acid as antifoaming agents

Foaming is one of the major operational problems in biogas plants, and dealing with foaming incidents is still based on empirical practices. Various types of antifoams are used arbitrarily to combat foaming in biogas plants, but without any scientific support this action can lead to serious deterioration of the methanogenic process. Many commercial antifoams are derivatives of fatty acids or oils. However, it is well known that lipids can induce foaming in manure based biogas plants. This study aimed to elucidate the effect of rapeseed oil and oleic acid on foam reduction and process performance in biogas reactors fed with protein or lipid rich substrates. The results showed that both antifoams efficiently suppressed foaming. Moreover rapeseed oil resulted in stimulation of the biogas production. Finally, it was reckoned that the chemical structure of lipids, and more specifically their carboxylic ends, is responsible for their foam promoting or foam counteracting behaviour. Thus, it was concluded that the fatty acids and oils could suppress foaming, while salt of fatty acids could generate foam.

Foam suppression in overloaded manure-based biogas reactors using antifoaming agents

Foam control is an imperative need in biogas plants, as foaming is a major operational problem. In the present study, the effect of oils (rapeseed oil, oleic acid, and octanoic acid) and tributylphosphate on foam reduction and process performance in batch and continuous manure-based biogas reactors was investigated. The compounds were tested in dosages of 0.05%, 0.1% and 0.5% v/vfeed. The results showed that rapeseed oil was most efficient to suppress foam at the dosage of 0.05% and 0.1% v/vfeed, while octanoic acid was most efficient to suppress foam at dosage of 0.5% v/vfeed. Moreover, the addition of rapeseed oil also increased methane yield. In contrast, tributylphosphate, which was very efficient antifoam, was found to be inhibitory to the biogas process.

Ethanol production from glucose and xylose by immobilized Thermoanaerobacter pentosaceus at 70 °C in an up-flow anaerobic sludge blanket (UASB) reactor

The newly isolated extreme thermophilic ethanologen Thermoanaerobacter pentosaceus was immobilized in different support materials in order to improve its ethanol production ability. In batch fermentation, a maximum ethanol yield of 1.36 mol mol(-1) consumed sugars was obtained by T. pentosaceus immobilized on rapeseed straw. Additionally, immobilized T. pentosaceus' ethanol production was improved by 11% in comparison to free cells. In continuous mode, it was shown that hydraulic retention time (HRT) affected ethanol yield, and a dramatic shift from ethanol to acetate and lactate production occurred at an HRT of 6 h. The maximum ethanol yield and concentration, 1.50 mol mol(-1) consumed sugars and 12.4 g l(-1), were obtained with an HRT of 12 h. The latter represented an improvement of 60% in relation to previously obtained results. This indicates that immobilization of T. pentosaceus is an effective strategy to improve its ethanol production ability.

Effect of organic loading rate and feedstock composition on foaming in manure-based biogas reactors

Foaming is one of the major problems that occasionally occur in biogas plants, affecting negatively the overall digestion process. In the present study, the effect of organic loading rate (OLR) and feedstock composition on foaming was elucidated in continuous reactor experiments. By stepwise increasing the OLR and the concentration of proteins or lipids in the substrate, foaming in biogas reactors was investigated. No foam formation was observed at the OLR of 3.5 g volatile solids/(L-reactor·day). Organic loading was the main factor affecting foam formation in manure digester, while the organic composition, such as content of proteins or lipids were factors that in combination with the organic loading were triggering foaming. More specifically, gelatine could initiate foam formation at a lower OLR than sodium oleate. Moreover, the volume of foam produced by gelatine was relatively stable and was not increased when further increasing either OLR or gelatine concentration in the feed.

Improving Anaerobic Digestion of Wheat Straw by Plasma-Assisted Pretreatment

Plasma-assisted pretreatment (PAP) of lignocellulosic biomass has been shown to be an efficient method to decompose lignin and consequently facilitate microbial access to cellulose and hemicellulose. In the present study, PAP was tested for its suitability to enhance bioconversion of wheat straw to methane. In thermophilic batch experiments, methane yields of up to 366 mL/g volatile solids (VSs) were achieved, accounting for a yield increase of 45%. Common lignin-derived inhibitors like 5-hydroxymethylfurfural (5-HMF) and furfural were not detected after PAP, but toxicity test resulted in lower methane yields at higher substrate concentrations, indicating the presence of other unidentified inhibitors. However, in a continuous lab-scale biogas reactor experiment, stable codigestion of cattle manure with 20% PAP wheat straw was demonstrated, while no signs of adverse effects on the anaerobic digestion process were observed. After the introduction of the pretreated wheat straw to the reactor, volatile fatty acid concentrations remained low and stable, while gas production increased. In co-digestion, the PAP wheat straw was converted at an average yield of 343 mL CH4/gVS.

Effect of continuous oleate addition on microbial communities involved in anaerobic digestion process

In the present study, the microbial diversity in anaerobic reactors, continuously exposed to oleate, added to a manure reactor influent, was investigated. Relative changes in archaeal community were less remarkable in comparison to changes in bacterial community indicating that dominant archaeal composition remained relatively stable. Majority of the analyzed bacterial amplicons were phylogenetically affiliated with uncultured bacteria belonging to Firmicutes, Bacteroidetes, Proteobacteria and Thermotogae phyla. Bacterial community changes in response to oleate addition resulted in a less diverse bacterial consortium related to functional specialization of the species towards oleate degradation. For the archaeal domain, the sequences were affiliated within Euryarchaeota phylum with three major groups (Methanosarcina, Methanosaeta and Methanobacterium genera). Results obtained in this study deliver a comprehensive picture on oleate degrading microbial communities in high organic strength wastewater. The findings might be utilized for development of strategies for biogas production from lipid-riched wastes.

Comparison of UASB and EGSB reactors performance, for treatment of raw and deoiled palm oil mill effluent (POME)

Anaerobic digestion of palm oil mill effluent (POME) and deoiled POME was investigated both in batch assays and continuous reactor experiments using up-flow anaerobic sludge blanket (UASB) and expanded granular sludge bed (EGSB) reactors. The methane potential determined from batch assays of POME and deoiled POME was 503 and 610 mL-CH(4)/gVS-added, respectively. For the treatment of POME in continuously fed reactors, both in UASB and EGSB reactors more than 90% COD removal could be obtained, at HRT of 5 days, corresponding to OLR of 5.8 gVS/(L-reactor.d). Similar methane yields of 436-438 mL-CH(4)/gVS-added were obtained for UASB and EGSB respectively. However, for treatment of deoiled POME, both UASB and EGSB reactors could operate at lower OLR of 2.6 gVS/(L-reactor.d), with the methane yield of 600 and 555 mL-CH(4)/gVS-added for UASB and EGSB, respectively. The higher methane yield achieved from the deoiled POME was attributed to lower portion of biofibers which are more recalcitrant compared the rest of organic matter in POME. The UASB reactor was found to be more stable than EGSB reactor under the same OLR, as could be seen from lower VFA concentration, especially propionic acid, compared to the EGSB reactor.

Biogas production from potato-juice, a by-product from potato-starch processing, in upflow anaerobic sludge blanket (UASB) and expanded granular sludge bed (EGSB) reactors

In this study, the utilization of potato-juice, the organic by-product from potato-starch processing, for biogas production was investigated in batch assay and in high rate anaerobic reactors. The maximum methane potential of the potato-juice determined by batch assay was 470 mL-CH(4)/gVS-added. Anaerobic digestion of potato-juice in an EGSB reactor could obtain a methane yield of 380 mL-CH(4)/gVS-added at the organic loading rate of 3.2 gCOD/(L-reactor.d). In a UASB reactor, higher organic loading rate of 5.1 gCOD/(L-reactor.d) could be tolerated, however, it resulted in a lower methane yield of 240 mL-CH(4)/gVS-added. The treatment of reactor effluent was also investigated. By acidification with sulfuric acid to pH lower than 5, almost 100% of the ammonia content in the effluent could be retained during the successive up-concentration process step. The reactor effluent could be up-concentrated by evaporation to minimize its volume, and later be utilized as fertilizer.

Anaerobic co-digestion of by-products from sugar production with cow manure

Sugar beet leaves (SBL), sugar beet top (SBT), sugar beet pulp (SBP) and desugared molasses (DM) are by-products from the sugar production. In the present study we investigated the potential of SBL, SBT and SBP as feedstock for biogas production. The maximum methane potential of SBL, SBT and SBP determined by batch assays was found to be 490, 500 and 240 mL-CH(4)/gVS-added respectively. Three reactor experiments were carried out to investigate the effect of co-digestion of SBP, DM and manure at different ratios, on biogas process efficiency and stability. The results showed that DM was potentially inhibiting the biogas process and the co-digestion of SBP and DM was only successful at high dilution with manure or water. In contrast, SBP was shown to be a good substrate for biogas production and the methane yield of 280 mL-CH(4)/gVS-added was obtained in a thermophilic continuously operated reactor, co-digesting 50% of SBP with cow manure.

A simple and novel volumetric method to metre low gas flows from laboratory-scale bioreactors and its application on laboratory sludge digesters

A novel, cheap and easy to use method has been developed to measure low gas yields in bioreactors, based on the principle of bubble counting via digital imaging techniques and pattern recognition. No external hardware control is required for the measurements, and the device can be turned into a multichannel tool without further detector accessories. The method proved to perform outstandingly according to the testing and calibrating measurements against standard gas flow and revealed a short periodicity in the gas yields of two parallel laboratory-scale mesophilic biogas reactors providing well analysable data about them. For exact characterization of the oscillation, the data were converted into Morell wavelet spectra, which showed that every feeding period had a characteristic and similarly shaped wavelet profile, thereby this rhythm must have had an immanent source in the community metabolism, and it was not an artefact.

Anaerobic co-digestion of desugared molasses with cow manure; focusing on sodium and potassium inhibition

Desugared molasses (DM), a syrup residue from beet-molasses, was investigated for biogas production in both batch and in continuously-stirred tank reactor (CSTR) experiments. DM contained 2-3 times higher concentration of ions than normal molasses, which could inhibit the biogas process. The effect of sodium and potassium concentration on biogas production from manure was also investigated. Fifty percent inhibition occurred at sodium and potassium concentration of 11 and 28 g/L, respectively. The reactor experiments were carried out to investigate the biogas production from DM under different dilutions with water and co-digestion with manure. Stable operation at maximum methane yield of 300 mL-CH4/gVS-added was obtained at a mixture of 5% DM in cow manure. The biogas process was inhibited at DM concentrations higher than 15%. Manure was a good base substrate for co-digestion, and a stable anaerobic digestion could be achieved by co-digesting DM with manure at the concentration below 15% DM.

State indicators for monitoring the anaerobic digestion process

Anaerobic process state indicators were used to monitor a manure digester exposed to different types of disturbances, in order to find the most proper indicator(s) for monitoring the biogas process. Online indicators tested were biogas production, pH, volatile fatty acids (VFA), and dissolved hydrogen. Offline indicators tested were methane and hydrogen content in the biogas. A CSTR reactor with 7.2 L working volume was operated at a varying hydraulic loading rate (HRT 10-20 days) for 200 days. During this period, the reactor was overloaded with extra organic matter such as glucose, lipid, gelatine, and bio-fibers, in order to create dynamic changes in the process state. Biogas production increased in response to the increase in organic load with a slight decrease in methane content. pH was relatively stable and did not show clear response to hydraulic load changes. However, pH changes were observed in response to extra organic load. Individual VFA concentrations were an effective indicator, with propionate persistent for the longest time after introduction of the disturbance. Dissolved hydrogen was very sensitive to the addition of easily degradable organics. However, it responded also to other disturbances such as slight air exposure which had no impact on process performance. A combination of acetate, propionate and biogas production is an effective combination to monitor this type of digesters effectively.

Effect of post-digestion temperature on serial CSTR biogas reactor performance

The effect of post-digestion temperature on a lab-scale serial continuous-flow stirred tank reactor (CSTR) system performance was investigated. The system consisted of a main reactor operated at 55 degrees C with hydraulic retention time (HRT) of 15 days followed by post-digestion reactors with HRT of 5.3 days. Three post-digestion temperatures (55 degrees C, 37 degrees C and 15 degrees C) were compared in terms of biogas production, process stability, microbial community and methanogenic activity. The results showed that the post-digesters operated at 55 degrees C, 37 degrees C and 15 degrees C gave extra biogas production of 11.7%, 8.4% and 1.2%, respectively. The post-digester operated at 55 degrees C had the highest biogas production and was the most stable in terms of low VFA concentrations. The specific methanogenic activity tests revealed that the main reactor and the post-digester operated at 55 degrees C and 37 degrees C had very active acidogens and methanogens. In contrast, very low methanogenic activity was observed at 15 degrees C.

Optimisation of biogas production from manure through serial digestion: lab-scale and pilot-scale studies

In the present study, the possibility of optimizing biogas production from manure by serial digestion was investigated. In the lab-scale experiments, process performance and biogas production of serial digestion, two methanogenic continuously stirred tank reactors (CSTR) connected in series, was compared to a conventional one-step CSTR process. The one-step process was operated at 55 degrees C with 15d HRT and 5l working volume (control). For serial digestion, the total working volume of 5l was distributed as 70/30%, 50/50%, 30/70% or 13/87% between the two methanogenic reactors, respectively. Results showed that serial digestion improved biogas production from manure compared to one-step process. Among the tested reactor configurations, best results were obtained when serial reactors were operated with 70/30% and 50/50% volume distribution. Serial digestion at 70/30% and 50/50% volume distribution produced 13-17.8% more biogas and methane and, contained low VFA and residual methane potential loss in the effluent compared to the one-step CSTR process. At 30/70% volume distribution, an increase in biogas production was also noticed but the process was very unstable with low methane production. At 13/87% volume distribution, no difference in biogas production was noticed and methane production was much lower than the one-step CSTR process. Pilot-scale experiments also showed that serial digestion with 77/23% volume distribution could improve biogas yields by 1.9-6.1% compared to one-step process. The study thus suggests that the biogas production from manure can be optimized through serial digestion with an optimal volume distribution of 70/30% or 50/50% as the operational fluctuations are typically high during full scale application. However, process temperature between the two methanogenic reactors should be as close as possible in order to derive the benefits of serial coupling.

Serial CSTR digester configuration for improving biogas production from manure

A new configuration of manure digesters for improving biogas production has been investigated in laboratory scale. A single thermophilic continuous-flow stirred tank reactor (CSTR) operated with a hydraulic retention time (HRT) of 15 days was compared to a serial CSTR configuration with volume distribution ratio of 80/20 and 90/10, and total HRT of 15 days. The results showed that the serial CSTR could obtain 11% higher biogas yield compared to the single CSTR. The increased biogas yield in the serial CSTR was mainly from the second reactor, which accounted for 16% and 12% of total biogas yield in the 90/10 and 80/20 configuration, respectively. VFA concentration in the serial CSTR was high in the first reactor but very low in the second reactor. The results from organic pulse load test showed that the second reactor in serial CSTR helped utilizing VFA produced from overloading in the first reactor, which improved the effluent quality and conversion efficiency of the serial CSTR.

A biogas meter with adjustable resolution and minimal back-pressure

A new biogas meter was developed to satisfy the need for an adjustable resolution meter that has minimal back-pressure and wide flow rate capability. The new meter had three main components; a timed bellows pump that delivered fixed volumes, a pressure sensor, and a data logger. The meter was built from off-the-shelf components and was thus easy to build and cost effective. The meter also proved to be accurate, precise, sensitive, and simple to calibrate.

Effects of mixing on methane production during thermophilic anaerobic digestion of manure: lab-scale and pilot-scale studies

The effect of mixing on anaerobic digestion of manure was evaluated in lab-scale and pilot-scale experiments at 55 degrees C. The effect of continuous (control), minimal (mixing for 10 min prior to extraction/feeding) and intermittent mixing (withholding mixing for 2h prior to extraction/feeding) on methane production was investigated in three lab-scale continuously stirred tank reactors. On comparison to continuous mixing, intermittent and minimal mixing strategies improved methane productions by 1.3% and 12.5%, respectively. Pilot-scale studies also supported the lab-scale results with an average 7% increase in biogas yields during intermittent mixing compared to continuous mixing. The effect of mixing intensities (minimal, gentle or vigorous) in batch assays at 55 degrees C showed that when the process was overloaded by high substrate to inoculum ratio (40/60), gentle (35 times per minute) or minimal mixing (10 min mixing before feeding) was advantageous compared to vigorous mixing (110 times per minute). On the other hand, under low substrate to inoculum ratio (10/90), gentle mixing was the best. The study thus indicated that mixing schemes and intensities have some effect on anaerobic digestion of manures.

Evaluation of continuous ethanol fermentation of dilute-acid corn stover hydrolysate using thermophilic anaerobic bacterium Thermoanaerobacter BG1L1

Dilute sulfuric acid pretreated corn stover is potential feedstock of industrial interest for second generation fuel ethanol production. However, the toxicity of corn stover hydrolysate (PCS) has been a challenge for fermentation by recombinant xylose fermenting organisms. In this work, the thermophilic anaerobic bacterial strain Thermoanaerobacter BG1L1 was assessed for its ability to ferment undetoxified PCS hydrolysate in a continuous immobilized reactor system at 70 degrees C. The tested strain showed significant resistance to PCS, and substrate concentrations up to 15% total solids (TS) were fermented yielding ethanol of 0.39-0.42 g/g-sugars consumed. Xylose was nearly completely utilized (89-98%) for PCS up to 10% TS, whereas at 15% TS, xylose conversion was lowered to 67%. The reactor was operated continuously for 135 days, and no contamination was seen without the use of any agent for preventing bacterial infections. This study demonstrated that the use of immobilized thermophilic anaerobic bacteria for continuous ethanol fermentation could be promising in a commercial ethanol process in terms of system stability to process hardiness and reactor contamination. The tested microorganism has considerable potential to be a novel candidate for lignocellulose bioconversion into ethanol.

An innovative online VFA monitoring system for the anerobic process, based on headspace gas chromatography

A new method for online measurement of volatile fatty acids (VFA) in anerobic digesters has been developed based on headspace gas chromatography (HSGC). The method applies ex situ VFA stripping with variable headspace volume and gas analysis by gas chromatography-flame ionization detection (GC-FID). In each extraction, digester sample was acidified with H(3)PO(4) and NaHSO(4), then heated to strip the VFA into the gas phase. The gas was sampled in a low friction glass syringe before injected into the GC for measurement. The system has been tested for online monitoring of a lab-scale CSTR reactor treating manure for more than 6 months and has shown good agreement with off-line analysis. The system is capable of measuring individual VFA components. This is of advantage since specific VFA components such as propionic and butyric acid can give extra information about the process status. Another important advantage of this sensor is that there is no filtration, which makes possible application in high solids environments. The system can thus be easily applied in a full-scale biogas reactor by connecting the system to the liquid circulation loop to obtain fresh sample from the reactor. Local calibration is needed but automatic calibration is also possible using standard addition method. Sampling duration is 25-40 min, depending on the washing duration, and sensor response is 10 min. This is appropriate for full-scale reactors, since dynamics within most biogas reactors are of the order of several hours.

Thermophilic anaerobic digestion of source-sorted organic fraction of household municipal solid waste: start-up procedure for continuously stirred tank reactor

Two feeding strategies for start-up of continuously stirred tank reactors (CSTR) treating source-sorted organic fraction of household municipal solid waste (SS-OFMSW) at 55 degrees C were evaluated. Two reactors were started up separately with a limited amount of initial inoculum (i.e. 10% of the final volume of 3.5l) and operated in a fed batch mode until the reactors were filled (30 days). A reference reactor was filled up with 3.5l of inoculum and fed at a constant rate (11.4 g volatile solids (VS)/d). Loading at progressively increasing rate (from 1.7 to 15 gVS/d), as calculated based on an activated biomass concept, showed superior process performance compared to a fixed feed rate (5.7 gVS/d). Methane yield of 0.32 m(3)/kg VS was produced during the start-up in reactor filled at progressively increasing rate and was comparable to the reference reactor. On the contrary, significant inhibition due to volatile fatty acid (VFA) build-up, mainly due to butyrate, was noticed in the reactor filled at constant rate. Thus, low initial and progressive increasing inoculum loading rate could be used as a strategy for a successful start-up of CSTR treating SS-OFMSW as it allowed a gradual acclimation of the biomass. Lab-scale results were further reaffirmed from the start-up of a full-scale plant (7000 m(3) total capacity) which was supplied with inoculum corresponding to approx. 16% of final volume and operated in a fed batch mode until the reactors were filled (58 days). Stable biogas production with low VFA (<3 g/L; based on titration method) were noticed during the start-up period when fed at progressively increasing rate. Thus, a controlled and reliable start-up procedure was found essential, which could allow rapid process stabilization and time to focus on other technical aspects of plant operation. In addition, the influence of substrate to inoculum amount (1.5-30% TS) and temperature (5-65 degrees C) on anaerobic degradation and methane production of SS-OFMSW was investigated in batch assays as a protocol for start-up procedure.

Hydrogen and methane production from household solid waste in the two-stage fermentation process

A two-stage process combined hydrogen and methane production from household solid waste was demonstrated working successfully. The yield of 43 mL H(2)/g volatile solid (VS) added was generated in the first hydrogen production stage and the methane production in the second stage was 500 mL CH(4)/g VS added. This figure was 21% higher than the methane yield from the one-stage process, which was run as control. Sparging of the hydrogen reactor with methane gas resulted in doubling of the hydrogen production. pH was observed as a key factor affecting fermentation pathway in hydrogen production stage. The optimum pH range for hydrogen production in this system was in the range from 5 to 5.5. The short hydraulic retention time (2 days) applied in the first stage was enough to separate acidogenesis from methanogenesis. No additional control for preventing methanogenesis in the first stage was necessary. Furthermore, this study also provided direct evidence in the dynamic fermentation process that, hydrogen production increase was reflected by acetate to butyrate ratio increase in liquid phase.

Strategies for changing temperature from mesophilic to thermophilic conditions in anaerobic CSTR reactors treating sewage sludge

Thermophilic anaerobic digestion presents an advantageous way for stabilization of sludge from wastewater treatment plants. Two different strategies for changing operational process temperature from mesophilic (37 degrees C) to thermophilic (55 degrees C) were tested using two continuous flow stirred tank reactors operated at constant organic loading rate of 1.38 g VS/l reactor/day and hydraulic retention time of 20 days. In reactor A, the temperature was increased step-wise: 37 degrees C-->42 degrees C-->47 degrees C-->51 degrees C-->55 degrees C. While in reactor B, the temperature was changed in one-step, from 37 degrees C to the desired temperature of 55 degrees C, The results showed that the overall adaptation of the process for the step-wise temperature increment took 70 days in total and a new change was applied when the process was stabilized as indicated by stable methane production and low volatile fatty acids concentrations. Although the one-step temperature increase caused a severe disturbance in all the process parameters, the system reached a new stable operation after only 30 days indicating that this strategy is the best in changing from mesophilic to thermophilic operation in anaerobic digestion plants.

Thermal wet oxidation improves anaerobic biodegradability of raw and digested biowaste

Anaerobic digestion of solid biowaste generally results in relatively low methane yields of 50-60% of the theoretical maximum. Increased methane recovery from organic waste would lead to reduced handling of digested solids, lower methane emissions to the environment, and higher green energy profits. The objective of this research was to enhance the anaerobic biodegradability and methane yields from different biowastes (food waste, yard waste, and digested biowaste already treated in a full-scale biogas plant (DRANCO, Belgium)) by assessing thermal wet oxidation. The biodegradability of the waste was evaluated by using biochemical methane potential assays and continuous 3-L methane reactors. Wet oxidation temperature and oxygen pressure (T, 185-220 degrees C; O2 pressure, 0-12 bar; t, 15 min) were varied for their effect on total methane yield and digestion kinetics of digested biowaste. Measured methane yields for raw yard waste, wet oxidized yard waste, raw food waste, and wet oxidized food waste were 345, 685, 536, and 571 mL of CH/g of volatile suspended solids, respectively. Higher oxygen pressure during wet oxidation of digested biowaste considerably increased the total methane yield and digestion kinetics and permitted lignin utilization during a subsequent second digestion. The increase of the specific methane yield for the full-scale biogas plant by applying thermal wet oxidation was 35-40%, showing that there is still a considerable amount of methane that can be harvested from anaerobic digested biowaste.

Purification of bioethanol effluent in an UASB reactor system with simultaneous biogas formation

In this study, the prospect of using an Upflow Anaerobic Sludge Blanket (UASB) reactor for detoxification of process water derived from bioethanol production has been investigated. The bioethanol effluent (BEE) originated from wet oxidized wheat straw fermented by Saccharomyces cerevisiae and Thermoanaerobacter mathranii A3M4 to produce ethanol from glucose and xylose, respectively. In batch experiments the methane potential of BEE was determined to 529 mL-CH(4)/g-VS. In batch degradation experiments it was shown that the presence of BEE had a positive influence on the removal of the inhibitors 2-furoic acid, 4-hydroxyacetophenone, and acetovanillone as compared to conversion of the inhibitors as sole substrate in synthetic media. Furthermore, experiments were carried out treating BEE in a laboratory-scale UASB reactor. The results showed a Chemical Oxygen Demand (COD) removal of 80% (w/w) at an organic loading rate of 29 g-COD/(L. d). GC analysis of the lignocellulosic related potentially inhibitory compounds 2-furoic acid, vanillic acid, homovanillic acid, acetovanillone, syringic acid, acetosyringone, syringol, 4-hydroxybenzoic acid, and 4-hydroxybenzaldehyde showed that all of these compounds were removed from the BEE in the reactor. Implementation of a UASB purification step was found to be a promising approach to detoxify process water from bioethanol production allowing for recirculation of the process water and reduced production costs.

Biodegradation of phthalate esters during the mesophilic anaerobic digestion of sludge

Phthalic acid esters (PAE) are commonly found in the sludge generated in the wastewater treatment plants. Anaerobic digestion followed by land application is a common treatment and disposal practice of sludge. To date, many studies exist on the anaerobic biodegradation rates of PAE, especially of the easily biodegradable ones, whereas the higher molecular weight PAE have reported to be non-biodegradable under methanogenic conditions. Furthermore, there is no information on the effect of the PAE on the performance of the anaerobic digesters treating sludge. In this study, the anaerobic biodegradation of di-n-butyl phthalate (DBP), di-ethyl phthalate (DEP) and di-ethylhexyl phthalate (DEHP) was investigated and their relative rates of anaerobic degradation were calculated. Also, the biological removal of PAE during the anaerobic digestion of sludge in bench-scale digesters was investigated using DBP and DEHP as model compounds of one biodegradable and one recalcitrant PAE respectively. The degradation of all the PAE tested in this study (DEP, DBP and DEHP) is adequately described by first-order kinetics. Batch and continuous experiments showed that DEP and DBP present in sludge are rapidly degraded under mesophilic anaerobic conditions (a first-order kinetic constant of 8.04 x 10(-2) and 13.69 x 10(-2)-4.35 day(-1) respectively) while DEHP is degraded at a rate between one to two orders of magnitude lower (0.35 x 10(-2)-3.59 x 10(-2) day(-1)). It is of high significance that experiments with anaerobic sludge of different origin (US and Europe) showed that degradation of DEHP occurs under methanogenic conditions. Accumulation of high levels of DEHP (more than 60 mg/l) in the anaerobic digester has a negative effect on DBP and DEHP removal rates as well as on the biogas production.

Monitoring and control of anaerobic reactors

The current status in monitoring and control of anaerobic reactors is reviewed. The influence of reactor design and waste composition on the possible monitoring and control schemes is examined. After defining the overall control structure, and possible control objectives, the possible process measurements are reviewed in detail. In the sequel, possible manipulated variables, such as the hydraulic retention time, the organic loading rate, the sludge retention time, temperature, pH and alkalinity are evaluated with respect to the two main reactor types: high-rate and low-rate. Finally, the different control approaches that have been used are comprehensively described. These include simple and adaptive controllers, as well as more recent developments such as fuzzy controllers, knowledge-based controllers and controllers based on neural networks.

A new VFA sensor technique for anaerobic reactor systems

A key parameter for understanding and controlling the anaerobic biogas process is the concentration of volatile fatty acids (VFA). However, this information has so far been limited to off-line measurements using labor-intensive methods. We have developed a new technique that has made it possible to monitor VFA on-line in one of the most difficult media: animal slurry or manure. A novel in situ filtration technique has made it possible to perform microfiltration inside a reactor system. This filter enables sampling from closed reactor systems without large-scale pumping and filters. Furthermore, due to its small size it can be placed in lab-scale reactors without disturbing the process. Using this filtration technique together with commercially available membrane filters we have constructed a VFA sensor system that can perform automatic analysis of animal slurry at a frequency as high as every 15 minutes. Reproducibility and recovery factors of the entire system have been determined. The VFA sensor has been tested for a period of more than 60 days with more than 1,000 samples on both a full-scale biogas plant and lab-scale reactors. The measuring range covers specific measurements of acetate, propionate, iso-/n-butyrate and iso-/n-valerate ranging from 0.1 to 50 mM (6-3,000 mg). The measuring range could readily be expanded to more components and both lower and higher concentrations if desired. In addition to the new VFA sensor system, test results from development and testing of the in situ filtration technique are being presented is this article.

Toxicity of di-(2-ethylhexyl) phthalate on the anaerobic digestion of wastewater sludge

Previous studies on the microbial degradation of individual phthalic acid esters (PAEs) have demonstrated that the compounds with short ester hydrocarbon chains are easily biodegraded and mineralized, but PAEs with long ester chains are less susceptible to degradation and some of them are considered recalcitrant. Moreover, they inhibit methanogenesis. However, studies have not been made on the effect of feeding a combination of recalcitrant and biodegradable PAEs into anaerobic digesters treating wastewater sludge. The present study was conducted with wastewater sludge from the Los Angeles Bureau of Sanitation's Hyperion Treatment Plant. Di (2-ethylhexyl) phthalate (DEHP), the most common persistent PAE found in wastewater, and di-n-butyl phthalate (DBP), a common PAE with short ester chains, were sorbed into the sludge fed to a bench-scale digester for a period of 12 weeks. DEHP degradation was always poor, and accumulation of DEHP was correlated with inhibition of the microbial degradation of DBP and with process instability of the test digester. Inhibition of the DBP removal was completely reversed after DEHP addition was discontinued, but biogas production never recovered to the level observed in a control digester. Other process parameters of digester performance were not affected by DEHP accumulation. These results are similar to the toxic effects of long chain fatty acids on sludge digestion, suggesting that DEHP or its degradation products affect all the microbial populations in the anaerobic bioreactor. Our results imply that high levels of DEHP or other recalcitrant PAEs in wastewater sludge are likely to compromise methanogenesis and removal of biodegradable PAEs in sludge digesters.