Performance of trickle-bed bioreactors for converting synthesis gas to methane

Coupled model for microbial growth and phase mass transfer in pressurized batch reactors in the context of underground hydrogen storage

A rising interest in a strong hydrogen economy as a part of the future net-zero economy results in an increasing necessity to store hydrogen as a raw material or an energy carrier. Experience and studies show that storing hydrogen in deep underground sites could enable microbial conversion of hydrogen. To predict and examine the loss of hydrogen, laboratory studies, and analysis are essential. A growth model is required to interpret batch or chemostat experiments. With this model, the parameters of microbial growth, and the conversion of hydrogen can be specified. This study presents experiments with methanogens and a hydrogen/carbon dioxide gas mixture performed in batch reactors. Further, the microbial growth was modeled by a double Monod model with hydrogen and carbon dioxide as the limiting substrates. As the amount of carbon dioxide dissolved in the water phase can not be neglected, both phases were considered in the proposed model. The mass-transfer rate between the gas and water phase was implemented by a linear relation including the concentrations in both phases and the mass-transfer coefficient. With the resulting coupled model, it was possible to match the pressure behavior in the reactor and conclude the microbial growth kinetics. Two types of methanogenic species were tested to validate the model. The mass transfer coefficient proves to impact the growth behavior in porous media. The mathematical model and experimental data are necessary to determine the growth rate and yield coefficient.

Preliminary gas flow experiments identify improved gas flow conditions in a pilot-scale trickle bed reactor for H2 and CO2 biological methanation

Biological methanation of H₂ and CO₂ is a potential energy conversion technology that can support the energy transition based on renewable sources. The methanation performance in trickle bed reactors can be improved by approaching the gas flow through the reactor towards plug flow. Through preliminary gas flow experiments without biological conversion, this study investigated operational and constructional conditions that enhance plug flow in a pilot-scale trickle bed reactor with 1 m³ gas volume. An improved gas flow was observed when the feed gas was applied in a top-to-bottom direction and when the process liquid was not trickled through the packing bed. Furthermore, the gas flow experiments identified reactor-specific properties, such as unused or dead volumes. Applying gas flow experiments prior to reactor start-up is recommended as a simple and convenient method to identify individual reactor properties and optimization potentials for higher methanation performance.

Microbial community development during syngas methanation in a trickle bed reactor with various nutrient sources

Microbial community development within an anaerobic trickle bed reactor (TBR) during methanation of syngas (56% H₂, 30% CO, 14% CO₂) was investigated using three different nutrient media: defined nutrient medium (241 days), diluted digestate from a thermophilic co-digestion plant operating with food waste (200 days) and reject water from dewatered digested sewage sludge at a wastewater treatment plant (220 days). Different TBR operating periods showed slightly different performance that was not clearly linked to the nutrient medium, as all proved suitable for the methanation process. During operation, maximum syngas load was 5.33 L per L packed bed volume (pbv) & day and methane (CH₄) production was 1.26 L CH₄/L_pbv/d. Microbial community analysis with Illumina Miseq targeting 16S rDNA revealed high relative abundance (20-40%) of several potential syngas and acetate consumers within the genera Sporomusa, Spirochaetaceae, Rikenellaceae and Acetobacterium during the process. These were the dominant taxa except in a period with high flow rate of digestate from the food waste plant. The dominant methanogen in all periods was a member of the genus Methanobacterium, while Methanosarcina was also observed in the carrier community. As in reactor effluent, the dominant bacterial genus in the carrier was Sporomusa. These results show that syngas methanation in TBR can proceed well with different nutrient sources, including undefined medium of different origins. Moreover, the dominant syngas community remained the same over time even when non-sterilised digestates were used as nutrient medium. KEY POINTS: • Independent of nutrient source, syngas methanation above 1 L/L_pbv/D was achieved. • Methanobacterium and Sporomusa were dominant genera throughout the process. • Acetate conversion proceeded via both methanogenesis and syntrophic acetate oxidation.

Combining a robust thermophilic methanogen and packing material with high liquid hold-up to optimize biological methanation in trickle-bed reactors

The hydrogen gas-to-liquid mass transfer is the limiting factor in biological methanation. In trickle-bed reactors, mass transfer can be increased by high flow velocities in the liquid phase, by adding a packing material with high liquid hold-up or by using methanogenic archaea with a high methane productivity. This study developed a polyphasic approach to address all methods at once. Various methanogenic strains and packings were investigated from a microbial and hydrodynamic perspective. Analyzing the ability to produce high-quality methane and to form biofilms, pure cultures of Methanothermobacter performed better than those of the genus Methanothermococcus. Liquid and static hold-up of a packing material and its capability to facilitate attachment was not attributable to a single property. Consequently, it is recommended to carefully match organism and packing for optimized performance of trickle-bed reactors. The ideal combination for the ORBIT-system was identified as Methanothermobacter thermoautotrophicus IM5 and DuraTop®.

Biological conversion of carbon monoxide and hydrogen by anaerobic culture: Prospect of anaerobic digestion and thermochemical processes combination

Waste biomass is considered a promising renewable energy feedstock that can be converted by anaerobic digestion. However, anaerobic digestion application can be challenging due to the structural complexity of several waste biomass kinds. Therefore, coupling anaerobic digestion with thermochemical processes can offset the limitations and convert the hardly biodegradable waste biomass, including digestate residue, into value-added products: syngas and pyrogas (gaseous mixtures consisting mainly of H₂, CO, CO₂), bio-oil, and biochar for further valorisation. In this review, the utilisation boundaries and benefits of the aforementioned products by anaerobic culture are discussed. First, thermochemical process parameters for an enhanced yield of desired products are summarised. Particularly, the microbiology of CO and H₂ mixture biomethanation and fermentation in anaerobic digestion is presented. Finally, the state-of-the-art biological conversion of syngas and pyrogas to CH₄ mediated by anaerobic culture is adequately described. Extensive research shows the successful selective biological conversion of CO and H₂ to CH₄, acetic acid, and alcohols. The main bottleneck is the gas-liquid mass transfer which can be enhanced appropriately by bioreactors' configurations. A few research groups focus on bio-oil and biochar addition into anaerobic digesters. However, according to the literature review, there has been no research for utilising all value-added products at once in anaerobic digestion published so far. Although synergic effects of such can be expected. In summary, the combination of anaerobic digestion and thermochemical processes is a promising alternative for wide-scale waste biomass utilisation in practice.

"Biomethanation of syngas by enriched mixed anaerobic consortium in pressurized agitated column"

In a circular economy approach, heterogeneous wastes can be upgraded to energy in the form of syngas via pyrogasification, and then to methane via biomethanation. Working at high pressure is a promising approach to intensify the process and to reduce gas-liquid transfer limitations. However, raising the pressure could lead to reaching the CO inhibition threshold of the microorganisms involved in syngas-biomethanation. To investigate the impact on pressure on the process, a 10L continuous stirred tank reactor working at 4 bars and 55 °C was implemented. Syngas (40% CO, 40% H₂, 20% CO₂) biomethanation was performed successfully and methane productivity as high as 6.8 mmol_CH4/L_reactor/h with almost full conversion of CO (97%) and H₂ (98%) was achieved. CO inhibition was investigated and carboxydotrophs appeared less resistant to high CO exposition than methanogens.

Optimized biological CO2-methanation with a pure culture of thermophilic methanogenic archaea in a trickle-bed reactor

In this study, a fully automated process converting hydrogen and carbon dioxide to methane in a high temperature trickle-bed reactor was developed from lab scale to field test level. The reactor design and system performance was optimized to yield high methane content in the product gas for direct feed-in to the gas grid. The reaction was catalyzed by a pure culture of Methanothermobacter thermoautotrophicus IM5, which formed a biofilm on ceramic packing elements. During 600 h in continuous and semi-continuous operation in countercurrent flow, the 0.05 m³ reactor produced up to95.3 % of methane at a methane production rate of 0.35 [Formula: see text] . Adding nitrogen as carrier gas during startup, foam control and dosing of ammonium and sodium sulfide as nitrogen and sulfur source were important factors for process automation.

Opportunities for holistic waste stream valorization from food waste treatment facilities: a review

Difficult-to-biodegrade fractions (DBFs) generated from the biological treatment of food waste (FW) account for approximately 30% of the actual waste. These wastes are difficult to degrade or are considered indigestible residues of the aerobic and anaerobic fermentation treatment of FW treatment facilities. The currently applied disposal routes for DBFs exert environmental pressure and underutilize waste as resources. Therefore, these challenges must be overcome. An innovative strategy for the enhancement of the energy value and beneficial products from FW and the associated DBFs is proposed in this review. We propose conceptual future optimization routes for FW and DBFs via three types of technology integration. Pyrolysis techniques thoroughly treat DBFs to produce various value-added bio-energy products, such as pyrogenic bio-char, syngas, and bio-oil. Anaerobic digestion treats FW while utilizing pyrolysis products for robust performance enhancement and bio-methane upgrade. This holistic route offers conceptual information and proper direction as crucial knowledge for real application to harness the inherent resources of waste streams generated from FW treatment facilities.

Biogas upgrading and biochemical production from gas fermentation: Impact of microbial community and gas composition

The present study proposes a novel alternative method of the current biogas upgrading techniques by converting CO₂ (in the biogas) into valuable chemicals (e.g., volatile fatty acids) using H₂ as energy source and acetogenic mixed culture as biocatalyst. The influence of thermal treatment (90 °C) on the inhibition of the methanogenic archaea and enriching the acetogenic bacteria in different inocula (mesophilic and thermophilic) was initially tested. The most efficient inoculum that achieved the highest performance through the fermentation process was further used to define the optimum H₂/CO₂ gas ratio that secures maximum production yield of chemicals and maximum biogas upgrading efficiency. In addition, 16S rRNA analysis of the microbial community was conducted at the end of the experimental period to target functional microbes. The maximum biogas content (77% (v/v)) and acetate yield (72%) were achieved for 2H₂:1CO₂ ratio (v/v), with Moorella sp. 4 as the most dominant thermophilic acetogenic bacterium.

Biological CO2-Methanation: An Approach to Standardization

Power-to-Methane as one part of Power-to-Gas has been recognized globally as one of the key elements for the transition towards a sustainable energy system. While plants that produce methane catalytically have been in operation for a long time, biological methanation has just reached industrial pilot scale and near-term commercial application. The growing importance of the biological method is reflected by an increasing number of scientific articles describing novel approaches to improve this technology. However, these studies are difficult to compare because they lack a coherent nomenclature. In this article, we present a comprehensive set of parameters allowing the characterization and comparison of various biological methanation processes. To identify relevant parameters needed for a proper description of this technology, we summarized existing literature and defined system boundaries for Power-to-Methane process steps. On this basis, we derive system parameters providing information on the methanation system, its performance, the biology and cost aspects. As a result, three different standards are provided as a blueprint matrix for use in academia and industry applicable to both, biological and catalytic methanation. Hence, this review attempts to set the standards for a comprehensive description of biological and chemical methanation processes.

Floating Membrane Bioreactors with High Gas Hold-Up for Syngas-to-Biomethane Conversion

The low gas-to-liquid mass transfer rate is one of the main challenges in syngas biomethanation. In this work, a new concept of the floating membrane system with high gas hold-up was introduced in order to enhance the mass transfer rate of the process. In addition, the effect of the inoculum-to-syngas ratio was investigated. The experiments were conducted at 55 °C with an anaerobic mixed culture in both batch and continuous modes. According to the results from the continuous experiments, the H2 and CO conversion rates in the floating membrane bioreactor were approximately 38% and 28% higher in comparison to the free (suspended) cell bioreactors. The doubling of the thickness of the membrane bed resulted in an increase of the conversion rates of H2 and CO by approximately 6% and 12%, respectively. The highest H2 and CO consumption rates and CH4 production rate recorded were approximately 22 mmol/(L·d), 50 mmol/(L·d), and 34.41 mmol/(L·d), respectively, obtained at the highest inoculum-to-syngas ratio of 0.2 g/mL. To conclude, the use of the floating membrane system enhanced the syngas biomethanation rates, while a thicker membrane bed resulted in even higher syngas conversion rates. Moreover, the increase of the inoculum-to-syngas ratio of up to 0.2 g/mL favored the syngas conversion.

High performance biological methanation in a thermophilic anaerobic trickle bed reactor

In order to enhance energy efficiency of biological methanation of CO₂ and H₂, this study investigated the performance of a thermophilic (55°C) anaerobic trickle bed reactor (ATBR) (58.1L) at ambient pressure. With a methane production rate of up to 15.4m³_CH4/(m³_{trickle bed}·d) at methane concentrations above 98%, the ATBR can easily compete with the performance of other mixed culture methanation reactors. Control of pH and nutrient supply turned out to be crucial for stable operation and was affected significantly by dilution due to metabolic water production, especially during demand-orientated operation. Considering practical applications, inoculation with digested sludge, containing a diverse biocenosis, showed high adaptive capacity due to intrinsic biological diversity. However, no macroscopic biofilm formation was observed at thermophilic conditions even after 313days of operation. The applied approach illustrates the high potential of thermophilic ATBRs as a very efficient energy conversion and storage technology.

Gas fermentation: cellular engineering possibilities and scale up

Low carbon fuels and chemicals can be sourced from renewable materials such as biomass or from industrial and municipal waste streams. Gasification of these materials allows all of the carbon to become available for product generation, a clear advantage over partial biomass conversion into fermentable sugars. Gasification results into a synthesis stream (syngas) containing carbon monoxide (CO), carbon dioxide (CO2), hydrogen (H2) and nitrogen (N2). Autotrophy-the ability to fix carbon such as CO2 is present in all domains of life but photosynthesis alone is not keeping up with anthropogenic CO2 output. One strategy is to curtail the gaseous atmospheric release by developing waste and syngas conversion technologies. Historically microorganisms have contributed to major, albeit slow, atmospheric composition changes. The current status and future potential of anaerobic gas-fermenting bacteria with special focus on acetogens are the focus of this review.

Ethanol production during semi-continuous syngas fermentation in a trickle bed reactor using Clostridium ragsdalei

An efficient syngas fermentation bioreactor provides a mass transfer capability that matches the intrinsic kinetics of the microorganism to obtain high gas conversion efficiency and productivity. In this study, mass transfer and gas utilization efficiencies of a trickle bed reactor during syngas fermentation by Clostridium ragsdalei were evaluated at various gas and liquid flow rates. Fermentations were performed using a syngas mixture of 38% CO, 28.5% CO2, 28.5% H2 and 5% N2, by volume. Results showed that increasing the gas flow rate from 2.3 to 4.6sccm increased the CO uptake rate by 76% and decreased the H2 uptake rate by 51% up to Run R6. Biofilm formation after R6 increased cells activity with over threefold increase in H2 uptake rate. At 1662h, the final ethanol and acetic acid concentrations were 5.7 and 12.3g/L, respectively, at 200ml/min of liquid flow rate and 4.6sccm gas flow rate.

New materials and technology for cell immobilization

The choice of the most effective manner in which to operate an immobilized cell system is both complicated and, to some extent, a matter of guesswork. There is increasing awareness of the factors affecting reactor choice, and present work is aimed at making reactor performance more predictable.