Optimizing dry anaerobic digestion at pilot scale for start-up strategy and long-term operation: Organic loading rate, temperature and co-digestion

Comprehensive experiences on the operation of a full-scale continuous dry anaerobic digestion plant treating mechanically sorted OFMSW

Anaerobic digestion (AD) of the organic fraction of municipal solid waste (OFMSW) is a crucial waste management method for the diversion of organics from landfills to decrease greenhouse gas emissions while enabling energy recovery. A number of dry AD systems treating OFMSW have notably increased over the last two decades. In this study, mono-digestion of mechanically sorted OFMSW and co-digestion of OFMSW, chicken manure and WWTP sludge were evaluated using triplicate full-scale digesters. Results demonstrated that 5-6.6 m3biogas/m3reactor.day biogas could be produced at an organic loading rate (OLR) of 10.5-12 kg TVS/m3.day, with an HRT of 16-18 days. Beyond this threshold, further increases in OLR resulted in reduced gas production due to ammonia inhibition as a result of broiler chicken manure overload. Biogas yield decline started when the chicken manure content of the feed was increased to 10% (w/w) and accompanied with the VFA/TA ratio rising above 0.8. Process instability and a sharp drop in biogas productivity were observed when the feed contained more than 20% (w/w) chicken manure, where VFA/TA ratio exceeded 1.0. Results underline the importance of balancing different properties (e.g., degradability, carbon to nitrogen (C/N) ratio) of co-substrates to optimize the biogas yield and to ensure process stability.

Machine learning for enhancing prediction of biogas production and building a VFA/ALK soft sensor in full-scale dry anaerobic digestion of kitchen food waste

Based on operational data collected over 1.5 years from four full-scale dry anaerobic digesters used for kitchen food waste treatment, this study adopted eight typical machine learning algorithms to distinguish the best biogas prediction model and to develop a soft sensor based on the VFA/ALK ratio. Among all the eight tested models, the CatBoost (CB) algorithm demonstrated superior performance in terms of prediction accuracy and model fitting. Specifically, the CB model achieved a biogas production prediction accuracy (R2) ranging from 0.604 to 0.915, and a VFA/ALK R2 between 0.618 and 0.768 on the test dataset. Furthermore, the feature importance analysis revealed that biomass amount into the dry anaerobic digester was the primary factor influencing biogas production. Chemical oxygen demand (COD) and free ammonia nitrogen (FAN) were identified as the most significant factors impacting the VFA/ALK indicator during dry anaerobic digestion, collectively contributing to nearly 50% of the influence. Overall, this study verifies the feasibility of using machine learning to predict biogas production in full-scale dry anaerobic digestion and provides a crucial foundation for monitoring the stability of dry anaerobic digesters.

Evaluation of the efficiency of dry anaerobic digester in the production of biogas and fertilizer using activated sludge and plant waste

The process of dry anaerobic digestion (DAD) is an effective economic and environmentally friendly method due to its features such as reducing the volume of waste, destroying pathogens, consuming less energy, and producing biogas rich in energy and fertilizer. This study was conducted on a pilot scale with a reactor volume of 24 L in 30 days for three ratios of C/N: 30, 25, and 20 separately using a mixture of activated sludge and plant waste. During the process, the temperature, pH, and ratio of C/N were measured at certain times, and the percentage of gases produced by the Gas chromatography (GC) device was also measured. The results were compared with the National standard of Iran (Compost, Physical, and Chemical Specifications) at the end of the process. The results showed that the average volume of biogas produced in ratios of C/N: 30, 25, 20 is 1.7, 2.5, and 1.5 L. d-1, respectively. The results showed that in the C/N ratio of 20, and 25, the amount of, C/N ratio and NO3 are in the range the standard of class 1, and the amount of Phosphorus pentoxide (P2O5) is in the range the standard of class 2. The results showed that the average microbial parameters in ratios of C/N: 30, 25, and 20 are lower than the national standard of Iran. The dry digester is an efficient method in waste treatment, methane gas production, and quality fertilizer close to the national standard of Iran.

Anaerobic degradation of pesticide wastewater: Improving sludge characteristics and reducing membrane fouling with combined tandem UASB+membrane system with high velocity settlers

In this pilot study, a combined tandem UASB+membrane reactor (R2) with high velocity settlers was proposed for the treatment of pesticide wastewater at different hydraulic retention times (HRT) and compared with a control reactor (R1). The average COD removal efficiencies of the R2 at HRTs of 96, 72, and 48 h were 83.7 %, 82.8 %, and 74.2 %, which are 14 %, 17 %, and 21 % higher than those of the R1, respectively. Throughout the operation, the biogas production of R2 was 33 %, 19 % and 28 % higher than that of R1 at the same stage, respectively, and the methane yield of R2 (0.19-0.26 L CH4/gCODremoved) was improved by 10-17 % compared to that of R1. Mean α values (VFA/ALK) of 0.13∼0.22 indicated that R2 did not undergo acidification. R2 reduced the extracellular polymers (EPS) content in the attached sludge by 56-62 % compared to R1. It also successfully delayed membrane fouling rate by 19-22 %. The results demonstrate that the R2 has a high treatment capacity, stability, and methane recovery, while also effectively reducing membrane fouling.

Co-production of biogas and humic acid using rice straw and pig manure as substrates through solid-state anaerobic fermentation and subsequent aerobic composting

Compared with wet anaerobic digestion, solid-state fermentation possesses many merits such as low water consumption, high biogas yield and low processing cost. In this work, co-producing biogas and humic acid (HA) by two-step solid-state fermentation was innovatively investigated using rice straw and pig manure as materials. The result indicates that C/N ratio, straw particle size, and total solid content (TS%) caused significant effects on the solid-state fermentation process. At the first step for anaerobic biogas fermentation, the optimal fermentation conditions included C/N ratio of 27.5, straw particle size of 0.85 mm and TS% of 25%. The maximal biogas productivity and methane content were up to 0.43 m³/(m³·d) and 64.88%, respectively. This means that biogas production was significantly improved by adjusting C/N ratio during the co-fermentation of rice straw and pig manure. Following, the digested residue was aerobically composted for HA biosynthesis to improve the fertilizer efficiency of the fermented substrate. The optimal aeration rate of 0.75 L/min was obtained, and the volatile solid (VS) degradation rate, HA content, and the germination index (GI) value were up to 19.16%, 100.89 mg/g, and 103.07%, respectively, which indicates that HA biosynthesis and compost maturity were significantly enhanced. Therefore, the co-production of biogas and HA using rice straw and pig manure as fermentation materials was achieved by adopting the two-step solid-state fermentation, and the bioconversion efficiencies of livestock manure and straw were significantly improved.

Startup of Demo-Scale Anaerobic Digestion Plant Treating Food Waste Leachate: Process Instability and Recovery

A demo-scale (600 m3 working volume) anaerobic digester treating food waste leachate was monitored during its startup period. The operation strategy was adjusted twice (i.e., three distinct phases) during the operation to recover the process from instability. During the first phase, the organic loading rate (OLR) > 2.7 kg chemical oxygen demand (COD)/m3∙day corresponded to volatile fatty acid (VFA) accumulation along with a decreasing pH, resulting in the drop in biogas yield to 0.43 ± 0.9 m3/kg CODin. During phase 2, fast recovery of this process was aimed at using a sequencing batch operation. One batch cycle (5 to 2 days) consisted of the combined drawing and feeding step (5 h), the reacting step (91 to 17 h), and the settling step (24 h). The duration of the reacting step was determined for each cycle such that (1) the biogas production ceased before the cycle end and (2) the residual VFA concentration was < 1 g/L. In total, 11 cycles were operated with a gradual increase in biogas yield to 0.55 m3/kg CODin with the absence of any sign of system disturbance. After phase 2, the digester was fed at the designed OLR of 4.1 ± 0.3 kg COD/m3∙day. The biogas yield was elevated to 0.58 ± 0.2 m3/kg CODin during phase 3 with the residual VFA concentration maintained at 2.2 ± 0.6 g/L. Methanogen populations, as determined by real-time PCR, did not change significantly throughout the period. These results imply that the adaptation of this process to the OLR of ca. 4 kg COD/m3∙day was not due to the increase in methanogen population but due to the elevation of its activity. Overall, this study suggests that the sequencing batch operation with adjustable cycle duration can be one successful recovery strategy for biogas plants under system instability.

Improvement of sludge characteristics and mitigation of membrane fouling in the treatment of pesticide wastewater by electrochemical anaerobic membrane bioreactor

Electrochemical anaerobic membrane bioreactor attracted attention due to stable treatment quality with low footprint, and draw solute has significant effect on the sludge characteristics and membrane fouling performance. In this pilot-scale study, an electrochemical anaerobic membrane bioreactor (E-AnMBR) was proposed for treating pesticide wastewater at different hydraulic retention times (HRTs), demonstrating that E-AnMBR was superior on improvement of sludge characteristics and mitigation of membrane fouling, compared with the conventional anaerobic membrane bioreactor (C-AnMBR). E-AnMBR reduced sludge yield by 41.2 ± 6.7% and the SVI was significantly decreased by 32.5±13.8%. The accumulation of VFA in E-AnMBR was slighter than that of C-AnMBR, and the minimum average VFA was 255±6 mg/L. The methane yield of E-AnMBR (0.22-0.29 L CH4/g CODremoved) was 1.2-1.4 times than that of C-AnMBR. The EPS contents in suspended and attached sludge of E-AnMBR were significantly reduced by 41.8 ± 3.3% and 77.4 ± 14.5% than that of C-AnMBR, respectively. These results suggested that E-AnMBR has lower sludge disposal pressure, higher stability and methane recovery potential. Not only that, E-AnMBR successfully reduced membrane resistance, delaying the fouling rate by 31.0-38.5%. Finally, the linear relationship between EPS characteristics and membrane pollution was determined.

Impact of temperature, inoculum flow pattern, inoculum type, and their ratio on dry anaerobic digestion for biogas production

This study is aimed to apply dry anaerobic digestion (DAD) for methane (CH₄) enriched biogas production from unsorted organic municipal solid waste (MSW). Cumulative biogas production was monitored for 35 days of operation in batch digesters at fixed feedstock to inoculum (F/I) ratio 2. Anaerobic sludge (AS) and cow manure (CM) were used as inoculum in single and mixed modes. Several process parameters such as inoculum flow pattern (single layer, multilayer, and spiral), digestion temperature (25 to 40 °C), inoculation modes (single and mixed mode), and inoculation proportion (AS:CM = 1:1, 1:2, 1:3, and 2:1) were investigated to determine the optimum DAD conditions to maximize the CH₄ laden biogas yield. The study of inoculum flow pattern showed that digester with multilayer inoculum configuration generated the maximum 555 mL cumulative biogas with the production rate of 195 mL/day (at 25 °C). Biogas production rate and cumulative biogas production were found to increase with a rise in temperature and the maximum values of 380 mL/day and 1515 mL respectively were observed at 37 °C. The mixed mode of inoculation containing AS and CM augmented the biogas yield at previously optimized conditions. Final results showed that digester with multilayer inoculum flow pattern at 37 °C produced 1850 mL cumulative biogas with 1256.58 mL CH₄/kg volatile solid (VS) when the mixed inoculum was used at the AS:CM—1:2 ratio. Biogas production with this significant amount of CH₄ justifies the use of the DAD process for energy (biogas) generation from widely available biomass feedstock (MSW), offering various advantages to the environment.

A waste to energy technology for Enrichment of biomethane generation: A review on operating parameters, types of biodigesters, solar assisted heating systems, socio economic benefits and challenges

Anaerobic Digestion (AD) is one of the promising wastestoenergy (WtE) technologies that convert organic wastes to useful gaseous fuel (biogas). In this process methane is produced in the presence of methanogens (bacteria). The survival and activities of methanogens are based on several parameters such as pH, temperature, organic loading rate, types of biodigester. Moreover, these parameters influence the production of biogas in terms of yield and composition. Maintaining an appropriate temperaturefor AD is highly critical and energy intensive. This study reviews the various hybrid technologies assistedbio gas production schemes particularly from renewable energy sources. Also discuss the direct and indirect solar assisted bio-digester impacts and recommendation to improve its performance. In addition, the performance analysis Solar Photovoltaic (PV) and thermal collector assisted bio gas plants; besides their impact on the performance of anaerobic digesters. Since opportunities of solar energy are attractive, the effective utilization of the same is selected for the discussion. Besides, the various constraints that affect the yield and composition of biogas are also evaluated along with the current biogas technologies and the biodigesters. The environmental benefits, challenges and socio-economic factors are also discussed for the successful implementation of various technologies.

Performance and microbial community evaluation of full-scale two-phase anaerobic digestion of waste activated sludge

"Temperature Staging and Biological Phasing" (TSBP) is an improved two-phase anaerobic digestion (AD) technology. This technology hydrolyzes waste activated sludge (WAS) at 45 °C and converts methane at mesophilic temperature (35-38 °C), with hydraulic retention times of 3-5 d and 14-17 d, respectively. In this study, the performance and microbial community dynamics of full-scale TSBP-based sludge anaerobic digestion system were studied, and the technology was evaluated by energy balance and ecological benefit analysis. The stable operation for 390 d showed that the cumulative biogas yield was about 349,041 m³, the maximum biogas yield rate was 563.68 L/kg VS, and the VS degradation rate of organic matters in the sludge was 47.19%. Proteobacteria and Firmicutes were found to be the dominant bacteria in both thermophilic and mesophilic reactors. Methanobacterium and Methanosarcina were the two most abundant methanogenic genera in the AD samples. The aceticlastic methanogenesis was likely the predominant production pathway of methane in AD processes based on metagenomics. The TSBP system operated stably, and the recovered energy could achieve energy self-sufficiency, which provided technical reference for the anaerobic treatment of sludge.

Biochar for agronomy, animal farming, anaerobic digestion, composting, water treatment, soil remediation, construction, energy storage, and carbon sequestration: a review

In the context of climate change and the circular economy, biochar has recently found many applications in various sectors as a versatile and recycled material. Here, we review application of biochar-based for carbon sink, covering agronomy, animal farming, anaerobic digestion, composting, environmental remediation, construction, and energy storage. The ultimate storage reservoirs for biochar are soils, civil infrastructure, and landfills. Biochar-based fertilisers, which combine traditional fertilisers with biochar as a nutrient carrier, are promising in agronomy. The use of biochar as a feed additive for animals shows benefits in terms of animal growth, gut microbiota, reduced enteric methane production, egg yield, and endo-toxicant mitigation. Biochar enhances anaerobic digestion operations, primarily for biogas generation and upgrading, performance and sustainability, and the mitigation of inhibitory impurities. In composts, biochar controls the release of greenhouse gases and enhances microbial activity. Co-composted biochar improves soil properties and enhances crop productivity. Pristine and engineered biochar can also be employed for water and soil remediation to remove pollutants. In construction, biochar can be added to cement or asphalt, thus conferring structural and functional advantages. Incorporating biochar in biocomposites improves insulation, electromagnetic radiation protection and moisture control. Finally, synthesising biochar-based materials for energy storage applications requires additional functionalisation.

Engineering and microbial characteristics of innovative lab and pilot continuous dry anaerobic co-digestion system fed with cow dung and corn straw

Dry anaerobic digestion (dry-AD) allows high-solid digestion; however, dry-AD application is limited because it is prone to blockage and intermediate inhibition. Here, we reported innovative continuous dry co-digestion systems at both lab and pilot scales. The effects of digestate recirculation ratio, dry mass ratio of cow dung to corn straw (CD:CS), and TS content on the digestion performance were investigated. The effects of the three factors were ranked as follows: TS content > CD:CS > digestate recirculation ratio. The daily biogas production rate reached 0.386 NL/d/g VS with the optimal parameter combination, which was determined to be TS content of 30%, a substrate ratio of 1:3, and a digestate recirculation ratio of 40%. In addition, increasing the CD:CS and TS content increased digestate viscosity, which inhibited biogas production; however, increased abundance of Proteiniphilum and acetoclastic methanogens facilitated biogas production. This study provides empirical support for further application of dry-AD.

Strategies to improve solid state anaerobic bioconversion of lignocellulosic biomass: an overview

Solid state anaerobic digestion (SSAD) of lignocellulosic biomass may be attractive solution for its valorisation. Compared to liquid state anaerobic digestion (LSAD), SSAD can handle higher organic loading rates (OLR), requires a less water and smaller reactor volume. It may require lower energy demand for heating or mixing and has higher volumetric methane productivity. Besides numerous benefits of SSAD processes and progress in system design, there are still obstacles, which need to be overcome for its successful implementations. This review aims to compile the recent trends in enhancing the bioconversion of agricultural stubbles in SSAD. Several pretreatment procedures used to breaking lignin and cellulose complex, method to overcome carbon to nitrogen ratio imbalance, use of carbon-based conducting materials to enhance Volatile Fatty Acids (VFA) conversion and additives for achieving nutrient balance will be discussed in this review. Leachate recirculation and its impacts on SSAD of agricultural stubbles are also discussed.