A membrane biofilm reactor for hydrogenotrophic methanation

Utilization of dissolved CO2 to control methane and acetate production in methanation reactor

This study investigated the influence of dissolved CO2 on the selection of metabolic pathway using a methanation membrane bioreactor supplied with H2/CO2. Various ratios of H2/CO2 were applied (3.3, 3.8, 4.0, 4.5, and 5.0 (v/v)) to manipulate dissolved CO2 levels in the medium. The findings revealed a correlation between the concentration of dissolved CO2 and the production of CH4 (positive) and acetate (negative). Specifically, at a dissolved concentration of CO2 above 2.0 ± 0.2 mmol/L, production of CH4 was favored. At the opposite, acetate production was favored at lower dissolved CO2 concentrations, with a maximum concentration of 1.9 g/L observed at 0.9 mmol/L of dissolved CO2. This study demonstrates that the modification of dissolved CO2 levels in a methanation bioreactor can provide a strategy for the selection of metabolic pathways and microbial communities, thereby offering a promising opportunity for optimizing the conversion of CO2 into high-value products such as CH4 and acetate.

Biofilm application for anaerobic digestion: a systematic review and an industrial scale case

Biofilm is a syntrophic community of microorganisms enveloped by extracellular polymeric substances and displays remarkable adaptability to dynamic environments. Implementing biofilm in anaerobic digestion has been widely investigated and applied as it promotes microbial retention time and enhances the efficiency. Previous studies on anaerobic biofilm primarily focused on application in wastewater treatment, while its role has been significantly extended to accelerate the degradation of lignocellulosic biomass, improve gas-liquid mass transfer for biogas upgrading, or enhance resistance to inhibitors or toxic pollutants. This work comprehensively reviewed the current applications of biofilm in anaerobic digestion and focused on impacting factors, optimization strategies, reactor set-up, and microbial communities. Moreover, a full-scale biofilm reactor case from Norway is also reported. This review provides a state of-the- art insight on the role of biofilm in anaerobic digestion.

Mass transfer in heterogeneous biofilms: Key issues in biofilm reactors and AI-driven performance prediction

Biofilm reactors, known for utilizing biofilm formation for cell immobilization, offer enhanced biomass concentration and operational stability over traditional planktonic systems. However, the dense nature of biofilms poses challenges for substrate accessibility to cells and the efficient release of products, making mass transfer efficiency a critical issue in these systems. Recent advancements have unveiled the intricate, heterogeneous architecture of biofilms, contradicting the earlier view of them as uniform, porous structures with consistent mass transfer properties. In this review, we explore six biofilm reactor configurations and their potential combinations, emphasizing how the spatial arrangement of biofilms within reactors influences mass transfer efficiency and overall reactor performance. Furthermore, we discuss how to apply artificial intelligence in processing biofilm measurement data and predicting reactor performance. This review highlights the role of biofilm reactors in environmental and energy sectors, paving the way for future innovations in biofilm-based technologies and their broader applications.

Enhancing H2-driven CO2 biomethanation performance in bidirectional flow tidal bioreactor by reducing liquid film resistance and heterogeneity

This study presents a bidirectional flow tidal bioreactor designed to enhance H2-driven CO2 biomethanation. The bioreactor alternated biofilms between immersion in nutrient solution and exposure to H2/CO2, creating alternating dry and wet states. This tidal operation minimized liquid film thickness during dry periods and ensured uniform nutrient distribution during wet periods. Bidirectional H2/CO2 supply was used to reduce biofilm thickness heterogeneity across the reactor height. CO2 biomethanation remained stable with an empty bed residence time of 9.7 min, achieving a methane (CH4) formation rate of 26.8 Nm3 CH4/(m3·d). The product gas contained 95.0 ± 2.5 % CH4, with a H2/CO2 conversion efficiency of 90.8 %. Tidal operation mitigated the buildup of dissolved and suspended organics, such as organic acids and detached biofilms. Dominant bacteria in biofilms included fermentative species like Petrimonas and H2-utilizing homoacetogens like Sporomusa. Enriched hydrogenotrophic methanogens, particularly Methanobacterium, were observed. Overall, this study highlights the bioreactor's effectiveness in improving CO2 biomethanation.

Simultaneous Biogas Upgrading and Valuable Chemical Production Using Homoacetogens in a Membrane Biofilm Reactor

Biogas produced from anaerobic digestion usually contains impurities, particularly with a high content of CO2 (15-60%), thus decreasing its caloric value and limiting its application as an energy source. H2-driven biogas upgrading using homoacetogens is a promising approach for upgrading biogas to biomethane and converting CO2 to acetate simultaneously. Herein, we developed a novel membrane biofilm reactor (MBfR) with H2 and biogas separately supplied via bubbleless hollow fiber membranes. The gas-permeable hollow fibers of the MBfR enabled high H2 and CO2 utilization efficiencies (∼98% and ∼97%, respectively) and achieved concurrent biomethane (∼94%) and acetate (∼450 mg/L/d) production. High-throughput 16S rRNA gene amplicon sequencing suggested that enriched microbial communities were dominated by Acetobacterium (38-48% relative abundance). In addition, reverse transcription quantitative PCR of the functional marker gene formyltetrahydrofolate synthetase showed that its expression level increased with increasing H2 and CO2 utilization efficiencies. These results indicate that Acetobacterium plays a key role in CO2 to acetate conversion. These findings are expected to facilitate energy-positive wastewater treatment and contribute to the development of a new solution to biogas upgrading.

Biofilms for Production of Chemicals and Energy

The twenty-first century will be the century of biology. This is not only because of breakthrough advances in molecular biology tools but also because we need to reinvent our economy based on the biological principles of energy efficiency and sustainability. Consequently, new tools for production routines must be developed to help produce platform chemicals and energy sources based on sustainable resources. In this context, biofilm-based processes have the potential to impact future production processes, because they can be carried out continuously and with robust stationary biocatalysts embedded in an extracellular matrix with different properties. We review productive biofilm systems used for heterotrophic and lithoautotrophic production and attempt to identify fundamental reasons why they may be particularly suitable as future production systems.

Impact of Nitrate on the Removal of Pollutants from Water in Reducing Gas-Based Membrane Biofilm Reactors: A Review

The membrane biofilm reactor (MBfR) is a novel wastewater treatment technology, garnering attention due to its high gas utilization rate and effective pollutant removal capability. This paper outlines the working mechanism, advantages, and disadvantages of MBfR, and the denitrification pathways, assessing the efficacy of MBfR in removing oxidized pollutants (sulfate (SO4-), perchlorate (ClO4-)), heavy metal ions (chromates (Cr(VI)), selenates (Se(VI))), and organic pollutants (tetracycline (TC), p-chloronitrobenzene (p-CNB)), and delves into the role of related microorganisms. Specifically, through the addition of nitrates (NO3-), this paper analyzes its impact on the removal efficiency of other pollutants and explores the changes in microbial communities. The results of the study show that NO3- inhibits the removal of other pollutants (oxidizing pollutants, heavy metal ions and organic pollutants), etc., in the simultaneous removal of multiple pollutants by MBfR.

Enhanced process control of trickle-bed reactors for biomethanation by vertical profiling directed by hydrogen microsensor monitoring

Biomethanation is an emerging Power-to-X technology enabling CO₂ valorisation to produce biomethane using renewable H₂. A promising reactor for facilitating biomethanation is the trickle bed reactor (TBR), however, these bioreactors are conventionally operated with a black-box approach, where the system is solely described by the input and output characteristics. This study employed a novel approach for process surveillance of internal dynamics in TBRs by installing multiple H₂ microsensors along its vertical axis. The H₂ microsensor monitoring was demonstrated for 135 days in a TBR integrated into a full-scale biogas plant. Despite achieving an overall CH₄ productivity of 12.6 L L^-1 d^-1, the vertical positioning of microsensors revealed a clear zonation with CH₄ productivity zones reaching 54.8 L L^-1 d^-1 and enabled early warning detection of deteriorating process performance days before detecting it in the product gas. Thus, vertically positioned microsensors present a promising solution for securing process stability.

Impact of carbon monoxide on performance and microbial community of extreme-thermophilic hydrogenotrophic methanation in horizontal rotary bioreactor

A novel horizontal rotary bioreactor was developed for upgrading biogas from coke oven gas at extreme-thermophilic condition. The introduction of CO decreased the outlet methane content from 80% to 50% due to insufficient H₂. This hindrance was overcome by increasing the proportion of incoming hydrogen, coupled with a prolonged gas retention time from 24 to 72 h, leading to a restoration of methane content to 91.6%. Notably, CO and CO₂ exhibited a competitive relationship to hydrogen, which was determined by their contents. The substitution of Methanothermobacter for Methanobacterium as the dominant genus was observed at 70°C, with relative abundance exceeding 98%. Incorporation of CO increased bacteria diversity and fostered a syntrophic relationship between the bacterial community and M. thermautotrophicus. This study provides both theoretical basis and practical support for biogas upgrading from coke oven gas using a biofilm reactor, thus aiding its future industrialization prospects.

Biological Methanation in an Anaerobic Biofilm Reactor—Trace Element and Mineral Requirements for Stable Operation

Biological methanation of carbon dioxide using hydrogen makes it possible to improve the methane and energy content of biogas produced from sewage sludge and organic residuals and to reach the requirements for injection into the natural gas network. Biofilm reactors, so-called trickling bed reactors, offer a relatively simple, energy-efficient, and reliable technique for upgrading biogas via ex-situ methanation. A mesophilic lab-scale biofilm reactor was operated continuously for nine months to upgrade biogas from anaerobic sewage sludge digestion to a methane content >98%. To supply essential trace elements to the biomass, a stock solution was fed to the trickling liquid. Besides standard parameters and gas quality, concentrations of Na, K, Ca, Mg, Ni, and Fe were measured in the liquid and the biofilm using ICP-OES (inductively coupled plasma optical emission spectrometry) to examine the biofilms load-dependent uptake rate and to calculate quantities required for a stable operation. Additionally, microbial community dynamics were monitored by amplicon sequencing (16S rRNA gene). It was found that all investigated (trace) elements are taken up by the biomass. Some are absorbed depending on the load, others independently of it. For example, a biomass-specific uptake of 0.13 mg·g−1·d−1 for Ni and up to 50 mg·g−1·d−1 for Mg were measured.

Overview of recent progress in exogenous hydrogen supply biogas upgrading and future perspective

With the rapid development of renewable and sustainable energy, biogas upgrading for producing high-quality biomethane as an alternative to natural gas has attracted worldwide attention. This paper comprehensively reviews the current state of biogas upgrading technologies. The advances in physicochemical, photosynthetic autotrophic, and chemical autotrophic biogas upgrading technologies are briefly described with particular attention to the key challenges. New chemical autotrophic biogas upgrading strategies, such as direct and indirect exogenous hydrogen supply, for overcoming barriers to biogas upgrading and realizing highly efficient bioconversion of carbon dioxide are summarized. For each approach to exogenous hydrogen supply for biogas upgrading, the key findings and technical limitations are summarized and critically analyzed. Finally, future developments are also discussed to provide a reference for the development of biogas upgrading technology that can address the global energy crisis and climate change issues related to the application of biogas.

Coupling of (methane + air)-membrane biofilms and air-membrane biofilms: Treatment of p-nitroaniline wastewater

Membrane biofilm (MBf) technology is a promising biological water treatment process that combines membrane aeration with biofilms. To expand its application in the treatment of toxic organic wastewater, methane/air gas mixture-MBfs ((CH₄ + Air)-MBfs) and air-MBfs were coupled to enhance the treatment of p-nitroaniline (PNA) wastewater. Based on exploration of the membrane permeability of methane and oxygen, a hybrid MBf reactor was constructed, and the degradation characteristics of PNA and the coupling effects of (CH₄ + Air)-MBfs and air-MBfs were studied. The permeation flux of methane was found to be 1.114 g/(m² d) when using a methane/air gas mixture at an aeration pressure of 10 kPa, and this result was better than that when methane was used as the aeration gas alone. Aeration with a methane/air gas mixture provided conditions for realizing aerobic methane oxidation; the aerobic methane oxidation that occurred in the (CH₄ + Air)-MBfs promoted the reduction of PNA, and the intermediates of PNA degradation were further degraded by the air-MBfs. At an influent PNA membrane area load of 1.67 g/(m² d), the PNA removal load reached 187.30 g/(m³ d). The coupling of MBfs took advantage of different matrix-based MBfs and promoted the degradation of PNA by utilizing the synergistic effects of various functional microorganisms.

Syngas biomethanation: Current state and future perspectives

In regions highly dependent on fossil fuels imports, biomethane represents a promising biofuel for the transition to a bio-based circular economy. While biomethane is typically produced via anaerobic digestion and upgrading, biomethanation of the synthesis gas (syngas) derived from the gasification of recalcitrant solid waste has emerged as a promising alternative. This work presents a comprehensive and in-depth analysis of the state-of-the-art and most recent advances in the field, compiling the potential of this technology along with the bottlenecks requiring further research. The key design and operational parameters governing syngas production and biomethanation (e.g. organic feedstock, gasifier design, microbiology, bioreactor configuration, etc.) are critically analysed.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

In-situ biogas upgrading by bio-methanation with an innovative membrane bioreactor combining sludge filtration and H2 injection

A bioreactor using membrane technologies was used to demonstrate the feasibility of in-situ bio-methanation coupled to industrial wastewater treatment for biogas upgrading. High biogas productivity (1.7 Nm³_Biogas/m³_Bioreactor/day) with high CH₄ content (97.9%) was reached. In-situ bio-methanation did not affect the COD removal efficiency of anerobic digestion (>94%). Process resilience has been tested for both substrate overload and H₂ intermittence injection. Recovery of high CH₄ content after 7 days without H₂ injection occurred within few hours. Influence of microbial community has been studied showing that both hydrogenotrophic and homoacetogenic-acetoclastic pathways were involved.

Biological biogas upgrading in a membrane biofilm reactor with and without organic carbon source

Biogas upgrading is a necessary step to minimize the CO₂ of raw biogas and to make it suitable for gas liquefaction or introduction into the national gas grid. Biomethanation is a promising approach since it converts the CO₂ to more methane on site, while taking advantage of the organisms responsible for biogas production in the first place. This study investigates the suitability of a pseudo-dead-end membrane biofilm reactor (MBfR) for ex-situ biogas upgrading using biogas as sole carbon source as well as for additional acetoclastic methanation when an organic carbon source is provided. Results prove that the concept of MBfR is especially advantageous for ex-situ hydrogenotrophic methanation of biogas CO₂, yielding high product gas qualities of up to 99% methane. It is discussed that cross-flow membrane operation could reduce mass flux of inert methane through membranes, attached biofilms, and reactor liquid, and, thus, improve methanation space time yields.