Influences of the substrate feeding regime on methanogenic activity in biogas reactors approached by molecular and stable isotope methods

Potential of acetic acid to restore methane production in anaerobic reactors critically intoxicated by ammonia as evidenced by metabolic and microbial monitoring

BACKGROUND

Biogas and biomethane production from the on-farm anaerobic digestion (AD) of animal manure and agri-food wastes could play a key role in transforming Europe's energy system by mitigating its dependence on fossil fuels and tackling the climate crisis. Although ammonia is essential for microbial growth, it inhibits the AD process if present in high concentrations, especially under its free form, thus leading to economic losses. In this study, which includes both metabolic and microbial monitoring, we tested a strategy to restore substrate conversion to methane in AD reactors facing critical free ammonia intoxication.

RESULTS

The AD process of three mesophilic semi-continuous 100L reactors critically intoxicated by free ammonia (> 3.5 g_N L-1; inhibited hydrolysis and heterotrophic acetogenesis; interrupted methanogenesis) was restored by applying a strategy that included reducing pH using acetic acid, washing out total ammonia with water, re-inoculation with active microbial flora and progressively re-introducing sugar beet pulp as a feed substrate. After 5 weeks, two reactors restarted to hydrolyse the pulp and produced CH4 from the methylotrophic methanogenesis pathway. The acetoclastic pathway remained inhibited due to the transient dominance of a strictly methylotrophic methanogen (Candidatus Methanoplasma genus) to the detriment of Methanosarcina. Concomitantly, the third reactor, in which Methanosarcina remained dominant, produced CH4 from the acetoclastic pathway but faced hydrolysis inhibition. After 11 weeks, the hydrolysis, the acetoclastic pathway and possibly the hydrogenotrophic pathway were functional in all reactors. The methylotrophic pathway was no longer favoured. Although syntrophic propionate oxidation remained suboptimal, the final pulp to CH4 conversion ratio (0.41 ± 0.10 LN_CH4 g_VS-1) was analogous to the pulp biochemical methane potential (0.38 ± 0.03 LN_CH4 g_VS-1).

CONCLUSIONS

Despite an extreme free ammonia intoxication, the proposed process recovery strategy allowed CH4 production to be restored in three intoxicated reactors within 8 weeks, a period during which re-inoculation appeared to be crucial to sustain the process. Introducing acetic acid allowed substantial CH4 production during the recovery period. Furthermore, the initial pH reduction promoted ammonium capture in the slurry, which could allow the field application of the effluents produced by full-scale digesters recovering from ammonia intoxication.

Demand-driven biogas production from Upflow Anaerobic Sludge Blanket (UASB) reactors to balance the power grid

Future energy systems necessitate dispatchable renewable energy to balance electrical grids with high shares of intermittent renewables. Biogas from anaerobic digestion (AD) can generate electricity on-demand. High-rate methanogenic reactors, such as the Upflow Anaerobic Sludge Blanket (UASB), can react quicker to variations in feeding as compared to traditional AD systems. In this study, experimental trials validated the feasibility of operating the UASB in a demand-driven manner. The UASB was operated with leachate produced from a hydrolysis reactor treating grass silage. The UASB demonstrated a high degree of flexibility in responding to variable feeding regimes. The intra-day biogas production rate could be increased by up to 123% under 4 hours in demand-driven operation, without significant deterioration in performance. A model based on kinetic analysis was developed to help align demand-driven operation with the grid. The findings suggest significant opportunities for UASBs to provide positive and negative balance to the electricity grid.

Model Predictive Control: Demand-Orientated, Load-Flexible, Full-Scale Biogas Production

Biogas plants have the great advantage that they produce electricity according to demand and can thus compensate for fluctuating production from weather-dependent sources such as wind power and photovoltaics. A prerequisite for flexible biogas plant operation is a suitable feeding strategy for an adjusted conversion of biomass into biogas. This research work is the first to demonstrate a practical, integrated model predictive control (MPC) for load-flexible, demand-orientated biogas production and the results show promising options for practical application on almost all full-scale biogas plants with no or only minor adjustments to the standardly existing measurement technology. Over an experimental period of 36 days, the biogas production of a full-scale plant was adjusted to the predicted electricity demand of a “real-world laboratory”. Results with a mean absolute percentage error (MAPE) of less than 20% when comparing biogas demand and production were consistently obtained.

Effect of a variable organic loading rate on process kinetics and volatile solids destruction in synthetic food waste-fed anaerobic digesters

With the increasing installation of weather-dependent renewable sources such as solar and wind power, the ability to produce electricity on demand to balance any shortfall in supply is becoming more important. Anaerobic digestion is a low-carbon energy source with the potential to be flexible to meet this need. An investigation was conducted into the response of two laboratory-scale anaerobic digesters at loading rate of 2.5 gVS L^-1 day^-1 over five months using a synthetic food waste as a substrate. One digester was consistently fed at the same rate, whereas the other digester was fed with periods of varying organic loading rate, from 0.1 to 7 gVS L^-1 day^-1, using a feed pattern derived from a record of restaurant food waste. The digester that had been fed at a variable rate showed a pronounced increase in biogas production after feed events and a 9.6% higher VS breakdown than the steady-feed digester (81% compared to 74%), with no effect on digester stability, volatile fatty acid concentration, overall biogas output or biogas quality. These findings support and encourage the use of variable-rate feeding to balance the electricity demand.

Flexible feeding in anaerobic digestion - Impact on process stability, performance and microbial community structures

Biogas has the potential to contribute to some of the most urgent issues of the energy transition, including mobility, energy storage, and grid stability. Flexibilization has been discussed as a means to improve the economics of biogas production, ideally restricting the production of electricity to times of strong need. Here the possibility of demand-driven, flexible biogas production is investigated, which saves substrates and storage capacity, while still enabling control over the production of electricity. Effects of different flexible feeding regimes were tested in a continuously operated 200 L reactor. After a period of 300 days under steady conditions (6.4 kg feed m^-3d^-1), varying flexible feeding patterns were applied over the next 700 days. Biogas production, volatile organic acid concentrations, and microbial dynamics were documented. Reduction of feeding resulted in reducing the gas production by up to 80% within a day. By increasing the feed, gas production could rapidly be reinitiated at similar levels as before even after fasting periods of up to 22 days. CH₄-contents of the produced biogas were nearly constant over the investigation period. As a response to the flexible feeding, a reorganization of the microbial community was observed, which came to an end after 800 days and then was no longer affected by further changes in the feeding patterns or the substrate composition. Dominating archaea were of the order Methanosarcinales. During the experiment, representatives from the class Methanosaetaceae replaced representatives from the class Methanosarcinaceae.

Beneficial effects of intermittent feedstock management on biogas and methane production

Intermittent supply of easily degradable carbohydrates can be used for on-demand biogas production. The study tested the effects of splitting feeding portions of sugar beet silage (S) on biogas production rates and total yield, respectively and if methane production rates follow those ones of biogas. Four experimental AD reactors were operated for 117 days at organic loading rates of 2.0 kg_VS m^-3 d^-1 and VS ratios of maize silage (M) to S of 3:1. While M was supplied hourly (h₀-h₁₂), reactors differed only regarding the intermittent S supply, provided at once (h₀), twice (h₀, h₁) and three times (h₀, h₁, h₂) per twelve-hour observation period. Biogas and methane production rates rose simultaneously after S supply and lasted depending on S intakes. Biogas and methane yields were significantly increased at S given once and twice per period. Appropriate feedstock management can thus influence production rates and increase biogas and methane yields.

Semi-continuous feeding combined with traditional domestication improved anaerobic performance during treatment of cassava stillage

The effects of feeding pattern were studied during anaerobic digestion of cassava stillage. Continuous feeding and semi-continuous feeding, were adopted in two internal circulation (IC) reactors (A and B, respectively). The reactors showed different performance in the anaerobic digestion process. The maximum difference, was observed for the soluble chemical oxygen demand (SCOD) removal rate and the biogas production, which were 23.2% and 95.7 L/2 d higher in reactor B than reactor A, respectively. The overall VFAs level of reactor A was higher than that of reactor B. Microbial community analyses indicated that the abundances of dominant bacteria and methanogens became higher in the reactor B than in reactor A as the digestion process progressed. Hence, semi-continuous feeding showed superior performance than continuous feeding for SCOD removal rate, biogas production, and the relative abundances of methanogens in the case of high OLR.

Pseudomonas spp. are key players in agricultural biogas substrate degradation

Anaerobic degradation (AD) of heterogeneous agricultural substrates is a complex process involving a diverse microbial community. While microbial community composition of a variety of biogas plants (BPs) is well described, little is known about metabolic processes and microbial interaction patterns. Here, we analyzed 16 large-scale BPs using metaproteomics. All metabolic steps of AD were observed in the metaproteome, and multivariate analyses indicated that they were shaped by temperature, pH, volatile fatty acid content and substrate types. Biogas plants could be subdivided into hydrogenotrophic, acetoclastic or a mixture of both methanogenic pathways based on their process parameters, taxonomic and functional metaproteome. Network analyses showed large differences in metabolic and microbial interaction patterns. Both, number of interactions and interaction partners were highly dependent on the prevalent methanogenic pathway for most species. Nevertheless, we observed a highly conserved metabolism of different abundant Pseudomonas spp. for all BPs indicating a key role during AD in carbohydrate hydrolysis irrespectively of variabilities in substrate input and process parameters. Thus, Pseudomonas spp. are of high importance for robust and versatile AD food webs, which highlight a large variety of downstream metabolic processes for their respective methanogenic pathways.

Model-based control for a demand-driven biogas production to cover residual load rises

The development of systems for energy storage and demand-driven energy production will be essential to enable the switch from fossil to renewable energy sources in future. To cover the residual load rises, a rigorous dynamic process model based on the Anaerobic Digestion Model No. 1 (ADM1) was applied to analyse the flexible operation of biogas plants. For this, the model was optimised and an operational concept for a demand-driven energy production was worked out. Different substrates were analysed, both by batch fermentation and Weende analysis with van Soest method, to determine the input data of the model. The lab results show that the substrates have got different degradation kinetics and biogas potentials. Finally, the ADM1 was extended with a feeding algorithm which is based on a PI controller. Essential feeding times and quantities of available substrates were calculated so that a biogas plant can cover a defined energy demand. The results prove that a flexible operation of biogas plants with a feeding strategy is possible.

Utilization of Food and Agricultural Residues for a Flexible Biogas Production: Process Stability and Effects on Needed Biogas Storage Capacities

Biogas plants can contribute to future energy systems’ stability through flexible power generation. To provide power flexibly, a demand-oriented biogas supply is necessary, which may be ensured by applying flexible feeding strategies. In this study, the impacts of applying three different feeding strategies (1x, 3x and 9x feeding per day) on the biogas and methane production and process stability parameters were determined for a biogas plant with a focus on waste treatment. Two feedstocks that differed in (1) high fat and (2) higher carbohydrate content were investigated during semi-continuous fermentation tests. Measurements of the short chain fatty acids concentration, pH value, TVA/TIC ratio and total ammonium and ammonia content along with a molecular biology analysis were conducted to assess the effects on process stability. The results show that flexible biogas production can be obtained without negative impacts on the process performance and that production peaks in biogas and methane can be significantly shifted to another time by changing feeding intervals. Implementing the fermentation tests’ results into a biogas plant simulation model and an assessment of power generation scenarios focusing on peak-time power generation revealed a considerable reduction potential for the needed biogas storage capacity of up to 73.7%.

Assessment of the start-up process of anaerobic digestion utilizing swine manure: 13C fractionation of biogas and microbial dynamics

The aim of this study was to investigate how the microbial community structure adapts during the start-up phase and how the ¹³C fractionation of biogas reflects the microbial population dynamics in two parallel swine manure-fed anaerobic digesters. Two swine manure-fed reactors for the start-up of continuously stirred tank reactors at mesophilic condition were evaluated. Changes in community structure were monitored using 16S rRNA high-throughput sequencing to measure the abundance of fermenting bacteria and methanogens. Digesters with relatively stable Methanosarcinaceae started up successfully and contained high gas production and low levels of propionate. In contrast, the digester that experienced a difficult start-up period had reduced Methanosarcinaceae along with accumulated propionate and low gas production. Specific gas production, specific methane production, and ¹³C fractionation of biogas were influenced significantly by Methanosarcinaceae, Methanobacteriaceae, and Clostridiaceae, indicating that the ¹³C fractionation of biogas had significant potential to reflect microbial population changes and digester performance during the start-up period.

Feeding frequency influences process performance and microbial community composition in anaerobic digesters treating steam exploded food waste

In anaerobic digestion, studies of feeding frequency have produced conflicting results. Hence, the effect of feeding frequency on process variables and microbial community structure was investigated by comparing a laboratory-scale digester fed steam exploded food waste 10 times daily vs. one fed an equivalent amount once daily. The Frequently Fed Digester (FFD) produced on average 20% more methane and had lower effluent concentrations of long-chain fatty acids. Greater daily fluctuations in acetate, pH and biogas production rate could explain the lower specific methane yield and β-oxidation. Feeding frequency also influenced the microbial community whereby Tenericutes (42%) dominated in FFD but Firmicutes (31%) was most abundant in the Daily Fed Digester (DFD). Feeding frequency effects are therefore postulated to occur more often in digesters fed labile feedstocks at high organic loading rates.

Determining Biogenic Content of Biogas by Measuring Stable Isotopologues 12CH₄, 13CH₄, and CH₃D with a Mid-Infrared Direct Absorption Laser Spectrometer

A tunable laser absorption spectrometer (TLAS) was developed for the simultaneous measurement of δ¹³C and δD values of methane (CH₄). A mid-infrared interband cascade laser (ICL) emitting around 3.27 µm was used to measure the absorption of the three most abundant isotopologues in CH₄ with a single, mode-hop free current sweep. The instrument was validated against methane samples of fossil and biogenic origin with known isotopic composition. Three blended mixtures with varied biogenic content were prepared volumetrically, and their δ¹³C and δD values were determined. Analysis demonstrated that, provided the isotopic composition of the source materials was known, the δ¹³C and δD values alone were sufficient to determine the biogenic content of the blended samples to within 1.5%.

Modelling a demand driven biogas system for production of electricity at peak demand and for production of biomethane at other times

Four feedstocks were assessed for use in a demand driven biogas system. Biomethane potential (BMP) assays were conducted for grass silage, food waste, Laminaria digitata and dairy cow slurry. Semi-continuous trials were undertaken for all feedstocks, assessing biogas and biomethane production. Three kinetic models of the semi-continuous trials were compared. A first order model most accurately correlated with gas production in the pulse fed semi-continuous system. This model was developed for production of electricity on demand, and biomethane upgrading. The model examined a theoretical grass silage digester that would produce 435kWe in a continuous fed system. Adaptation to demand driven biogas required 187min to produce sufficient methane to run a 2MWe combined heat and power (CHP) unit for 60min. The upgrading system was dispatched 71min following CHP shutdown. Of the biogas produced 21% was used in the CHP and 79% was used in the upgrading system.

Lessons learned from the microbial ecology resulting from different inoculation strategies for biogas production from waste products of the bioethanol/sugar industry

BACKGROUND

During strategic planning of a biogas plant, the local availability of resources for start-up and operation should be taken into consideration for a cost-efficient process. Because most bioethanol/sugar industries in Brazil are located in remote areas, the use of fresh cattle manure from local farms could be a solution for the inoculation of the biogas process. This study investigated the diversity and dynamics of bacterial and archaeal communities and the performance of biogas reactors inoculated with manure and a mixed inoculum from different biogas reactors as for a controlled start-up until steady state.

RESULTS

Laboratory-scale biogas reactors were fed semi-continuously with sugarcane filter cake alone (mono-digestion) or together with bagasse (co-digestion). At the initial start-up, the reactors inoculated with the mixed inoculum displayed a less diverse taxonomic composition, but with higher presence of significant abundances compared to reactors inoculated with manure. However, in the final steady state, the communities of the differently inoculated reactors were very similarly characterized by predominance of the methanogenic genera Methanosarcina and Methanobacterium, the bacterial families Bacteroidaceae, Prevotellaceae and Porphyromonadaceae (phylum Bacteroidetes) and Synergistaceae (phylum Synergistetes). In the mono-digestion reactors, the methanogenic communities varied greater than in the co-digestion reactors independently of the inoculation strategy.

CONCLUSION

The microbial communities involved in the biogas production from waste products of the Brazilian bioethanol/sugar industry were relatively similar and stable at the reactor's steady phase independently of the inoculum source (manure or mixed inoculum). Therefore, the locally available manure can be used as inoculum for start-up of the biogas process, since it also contains the microbial resources needed. The strong fluctuation of methanogenic communities in mono-digestion reactors indicates higher risk of process instability than in co-digestion reactors.

Biogas Production: Microbiology and Technology

Biogas, containing energy-rich methane, is produced by microbial decomposition of organic material under anaerobic conditions. Under controlled conditions, this process can be used for the production of energy and a nutrient-rich residue suitable for use as a fertilising agent. The biogas can be used for production of heat, electricity or vehicle fuel. Different substrates can be used in the process and, depending on substrate character, various reactor technologies are available. The microbiological process leading to methane production is complex and involves many different types of microorganisms, often operating in close relationships because of the limited amount of energy available for growth. The microbial community structure is shaped by the incoming material, but also by operating parameters such as process temperature. Factors leading to an imbalance in the microbial community can result in process instability or even complete process failure. To ensure stable operation, different key parameters, such as levels of degradation intermediates and gas quality, are often monitored. Despite the fact that the anaerobic digestion process has long been used for industrial production of biogas, many questions need still to be resolved to achieve optimal management and gas yields and to exploit the great energy and nutrient potential available in waste material. This chapter discusses the different aspects that need to be taken into consideration to achieve optimal degradation and gas production, with particular focus on operation management and microbiology.

Changing Feeding Regimes To Demonstrate Flexible Biogas Production: Effects on Process Performance, Microbial Community Structure, and Methanogenesis Pathways

Flexible biogas production that adapts biogas output to energy demand can be regulated by changing feeding regimes. In this study, the effect of changes in feeding intervals on process performance, microbial community structure, and the methanogenesis pathway was investigated. Three different feeding regimes (once daily, every second day, and every 2 h) at the same organic loading rate were studied in continuously stirred tank reactors treating distiller's dried grains with solubles. A larger amount of biogas was produced after feeding in the reactors fed less frequently (once per day and every second day), whereas the amount remained constant in the reactor fed more frequently (every 2 h), indicating the suitability of the former for the flexible production of biogas. Compared to the conventional more frequent feeding regimes, a methane yield that was up to 14% higher and an improved stability of the process against organic overloading were achieved by employing less frequent feeding regimes. The community structures of bacteria and methanogenic archaea were monitored by terminal restriction fragment length polymorphism (T-RFLP) analysis of 16S rRNA and mcrA genes, respectively. The results showed that the composition of the bacterial community varied under the different feeding regimes, and the observed T-RFLP patterns were best explained by the differences in the total ammonia nitrogen concentrations, H2 levels, and pH values. However, the methanogenic community remained stable under all feeding regimes, with the dominance of the Methanosarcina genus followed by that of the Methanobacterium genus. Stable isotope analysis showed that the average amount of methane produced during each feeding event by acetoclastic and hydrogenotrophic methanogenesis was not influenced by the three different feeding regimes.

Improved Monitoring of Semi-Continuous Anaerobic Digestion of Sugarcane Waste: Effects of Increasing Organic Loading Rate on Methanogenic Community Dynamics

The anaerobic digestion of filter cake and its co-digestion with bagasse, and the effect of gradual increase of the organic loading rate (OLR) from start-up to overload were investigated. Understanding the influence of environmental and technical parameters on the development of particular methanogenic pathway in the biogas process was an important aim for the prediction and prevention of process failure. The rapid accumulation of volatile organic acids at high OLR of 3.0 to 4.0 gvs·L⁻¹·day⁻¹ indicated strong process inhibition. Methanogenic community dynamics of the reactors was monitored by stable isotope composition of biogas and molecular biological analysis. A potential shift toward the aceticlastic methanogenesis was observed along with the OLR increase under stable reactor operating conditions. Reactor overloading and process failure were indicated by the tendency to return to a predominance of hydrogenotrophic methanogenesis with rising abundances of the orders Methanobacteriales and Methanomicrobiales and drop of the genus Methanosarcina abundance.

Flexible biogas production for demand-driven energy supply--feeding strategies and types of substrates

Purpose of this work was the evaluation of demand driven biogas production. In laboratory-scale experiments it could be demonstrated that with diurnal flexible feeding and specific combination of substrates with different degradation kinetics biogas can be produced highly flexible in CSTR systems. Corresponding to the feedings the diurnal variation leads to alternations of the methane, carbon dioxide and acid concentrations as well as the pH-value. The long-time process stability was not negatively affected by the dynamic feeding regime at high OLRs of up to 6 kg VS m(-3) d(-1). It is concluded that the flexible gas production can give the opportunity to minimize the necessary gas storage capacity which can save investments for non-required gas storage at site.

Microbiology and Molecular Biology Tools for Biogas Process Analysis, Diagnosis and Control

Many biotechnological processes such as biogas production or defined biotransformations are carried out by microorganisms or tightly cooperating microbial communities. Process breakdown is the maximum credible accident for the operator. Any time savings that can be provided by suitable early-warning systems and allow for specific countermeasures are of great value. Process disturbance, frequently due to nutritional shortcomings, malfunction or operational deficits, is evidenced conventionally by process chemistry parameters. However, knowledge on systems microbiology and its function has essentially increased in the last two decades, and molecular biology tools, most of which are directed against nucleic acids, have been developed to analyze and diagnose the process. Some of these systems have been shown to indicate changes of the process status considerably earlier than the conventionally applied process chemistry parameters. This is reasonable because the triggering catalyst is determined, activity changes of the microbes that perform the reaction. These molecular biology tools have thus the potential to add to and improve the established process diagnosis system. This chapter is dealing with the actual state of the art of biogas process analysis in practice, and introduces molecular biology tools that have been shown to be of particular value in complementing the current systems of process monitoring and diagnosis, with emphasis on nucleic acid targeted molecular biology systems.

Stable isotope composition of biogas allows early warning of complete process failure as a result of ammonia inhibition in anaerobic digesters

Four 15-L lab-scale continuous stirred tank reactors were operated under mesophilic conditions to investigate the effect of ammonia inhibition. Stable isotope fingerprinting of biogas was applied as a process monitoring tool. Ammonia inhibition was initiated by amendment of chicken manure to maize silage fed reactors. During the accumulation of ammonia, the concentration of volatile fatty acids increased while the biogas production and pH decreased. However, in one reactor, an inhibited steady state with stable gas production even at high ammonia levels was achieved, while the other reactor proceeded to complete process failure. A depletion of the δ(13)CH4 and δ(13)CO2 values preceded the process inhibition. Moreover, the stable isotope composition of biogas also forecasted the complete process failure earlier than other standard parameters. The stable isotope analyses of biogas have a potential for mechanistic insights in anaerobic processes, and may be used to pre-warn process failure under stress conditions.