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

Pilot-scale in-situ biomethanation of sewage sludge: Effects of gas recirculation method

The methanation efficiency and operational stability of a 2 m3 pilot-scale in-situ biomethanation reactor were investigated using on-site sewage sludge as the substrate, at a wastewater treatment plant. In parallel, a laboratory-scale study was conducted. Hydrogen conversion efficiencies of 96.7 and 97.5 %, and average methane contents of 84.2 and 83.2 % were obtained, for the laboratory and pilot experiments, respectively. The pilot-scale digester was operated at various conditions for 137 d, of which the last 30 d were stable with a high biomethanation efficiency and an average pH of 8.2. Gas recirculation increased the hydrogen conversion efficiency. When hydrogen injection and gas recirculation were applied separately, a 96 % lower gas recirculation rate was needed to achieve the same hydrogen conversion efficiency, compared to a mixture of hydrogen injection and gas recirculation in the same line. These findings may facilitate the selection of suitable gas recirculation concepts for practical biomethanation applications.

In-situ biological biogas upgrading using upflow anaerobic polyfoam bioreactor: Operational and biological aspects

A high rate upflow anaerobic polyfoam-based bioreactor (UAPB) was developed for lab-scale in-situ biogas upgrading by H2 injection. The reactor, with a volume of 440 mL, was fed with synthetic wastewater at an organic loading rate (OLR) of 3.5 g COD/L·day and a hydraulic retention time (HRT) of 7.33 h. The use of a porous diffuser, alongside high gas recirculation, led to a higher H2 liquid mass transfer, and subsequently to a better uptake for high CH4 content of 56% (starting from 26%). Our attempts to optimize both operational parameters (H2 flow rate and gas recirculation ratio, which is the total flow rate of recirculated gas over the total outlet of gas flow rate) were not initially successful, however, at a very high recirculation ratio (32) and flow rate (54 mL/h), a significant improvement of the hydrogen consumption was achieved. These operational conditions have in turn driven the methanogenic community toward the dominance of Methanosaetaceae, which out-competed Methanosarcinaceae. Nevertheless, highly stable methane production rates of 1.4-1.9 L CH4/Lreactor.day were observed despite the methanogenic turnover. During the different applied operational conditions, the bacterial community was especially impacted, resulting in substantial shifts of taxonomic groups. Notably, Aeromonadaceae was the only bacterial group positively correlated with increasing hydrogen consumption rates. The capacity of Aeromonadaceae to extracellularly donate electrons suggests that direct interspecies electron transfer (DIET) enhanced biogas upgrading. Overall, the proposed innovative biological in-situ biogas upgrading technology using the UAPB configuration shows promising results for stable, simple, and effective biological biogas upgrading.

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.

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.

Ex-situ biomethanation for CO2 valorization: State of the art, recent advances, challenges, and future prospective

Ex-situ biomethanation is an emerging technology that facilitates the use of surplus renewable electricity and valorizes carbon dioxide (CO2) for biomethane production by hydrogenotrophic methanogens. This review offers an up-to-date overview of the current state of ex-situ biomethanation and thoroughly analyzes key operational parameters affecting hydrogen (H2) gas-liquid mass transfer and biomethanation performance, along with an in-depth discussion of the technical challenges. To the best of our knowledge, this is the first review article to discuss microbial community structure in liquid and biofilm phases and their responses after exposure to H2 starvation during ex-situ biomethanation. In addition, future research in areas such as reactor configuration and optimization of operational parameters for improving the H2 mass transfer rate, inhibiting opportunistic homoacetogens, integration of membrane technology, and use of conductive packing material is recommended to overcome challenges and improve the efficiency of ex-situ biomethanation. Furthermore, this review presents a techno-economic analysis for the future development and facilitation of industrial implementation. The insights presented in this review will offer useful information to identify state-of-the-art research trends and realize the full potential of this emerging technology for CO2 utilization and biomethane production.

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.

Biological methanation in trickle bed reactors - a critical review

Biological methanation of H₂ and CO₂ in trickle bed reactors is a promising energy conversion and storage approach that can support the energy transition towards a renewable-based system. Research in trickle bed reactor design and operation has significantly increased in recent years, but most studies were performed at laboratory scale and conditions. This review provides a comprehensive overview of the trickle bed reactor concept and current developments to support the decision-making process for future projects. In particular, the key design and operational parameters, such as trickling or nutrient provision, are presented, introducing the most recent advances. Furthermore, reactor operation, including the inoculation, long-term and dynamic operation, is described. To better assess the reactor upscaling, several parameters that enable reactor comparison are discussed. On the basis of this review, suitable operational strategies and further research needs were identified that will improve the overall trickle bed reactor performance.

Biogas upgrading in a pilot-scale trickle bed reactor - Long-term biological methanation under real application conditions

The biological methanation of H₂ and CO₂ in trickle bed reactors is one promising energy conversion technology for energy storage, but experiences at pilot-scale under real application conditions are still rare. Therefore, a trickle bed reactor with a reaction volume of 0.8 m³ was constructed and installed in a wastewater treatment plant to upgrade raw biogas from the local digester. The biogas H₂S concentration of about200 ppm was reduced by half, but an artificial sulfur source was required to completely satisfy the sulfur demand of the methanogens. Increasing the ammonium concentration to > 400 mg/L was the most successful pH control strategy, enabling stable long-term biogas upgrading at a CH₄ production of 6.1 m³/(m³_RV·d) with synthetic natural gas quality (CH₄ > 98%). The results of this study with a reactor operation period of nearly 450 days, including two shutdowns, represents an important step towards the necessary full-scale integration.

Pilot-scale study of biomethanation in biological trickle bed reactors converting impure CO2 from a Full-scale biogas plant

Research within biological methanation has been a great development using biotrickling filters (BTF), as a power-to-x solution, but research within up scaling is missing. This study investigates the commercial potential of biomethanation in BTF by operating two 1 m³ reactors which was implemented into a full-scale biogas plant. Several areas were investigated, such as enrichment and start-up, long-term steady state operation, serial operation, and intermittent feed. A methane productivity of [Formula: see text] with a product gas of 95.7 % CH₄ was obtained for parallel operation, whereas during serial operation a methane productivity of [Formula: see text] at 97.4 % CH₄ was achieved. The flexibility of the biomethanation was demonstrated with unintentional loss of H₂ feed in periods of 12 to 72 h, where initial performance was regained within 6 to 12 h. The results from this study demonstrate the potential for commercial use of biomethanation in BTF for future Power-to-X solutions.