Techno-economic analysis of single-stage and temperature-phase anaerobic co-digestion of sewage sludge, wine vinasse, and poultry manure

Anaerobic digestion of thermal hydrolysis pretreated sludge: Process performance, metagenomic analysis, techno-economic and life cycle assessment

This study assessed the potential of thermal hydrolysis process (THP) combined with anaerobic digestion (AD) for high solids sewage sludge treatment across various hydraulic retention times (HRTs). Optimal performance was achieved at a 10-day HRT (6 kg VS/m3·day), yielding 408 L CH4/kg VS added and 54 % volatile solids (VS) removal under THP conditions of 160 °C, 30 min, and 6 bar pressure. Microbial analysis revealed predominant acetoclastic and hydrogenotrophic methanogens. Four scenarios were designed and analyzed for environmental and economic performance: Scenario 1 (conventional AD-CHP), Scenario 2 (conventional AD-BioCNG), Scenario 3 (THP AD-BioCNG), and Scenario 4 (THP AD-CHP). The results showed that scenarios with CHP integration achieved better environmental performance by generating sufficient energy to meet demand, with energy consumption as a key factor. Notably, scenario 4 had the lowest global warming potential (GWP) at -0.0185 kg CO2-eq, outperforming conventional AD (Scenario 1) with CHP, which had a GWP of -0.00232 kg CO2-eq. However, profitability analysis showed that Scenario 3 was the most economically viable, with a net present value (NPV) of $4.3 million, an internal rate of return (IRR) of 10.21 %, and a 17-year payback period. Although it had higher capital ($58 million) and operational costs ($12.5 million/year) than Scenario 4 ($45 million and $8.6 million/year), its greater biomethane yield resulted in higher revenue ($20.7 million/year), making it the most profitable option. While Scenario 4 offered the best environmental benefits, Scenario 3 emerged as the most financially sustainable choice. These findings highlight the environmental and economic advantage of utilizing THP-AD process over conventional AD, suggesting that THP-AD optimizes methane production, solids reduction, and environmental impact, making the Bio CNG pathway a sustainable and economically viable option.

Effect of single and hybrid microplastic exposures on anaerobic sludge in microbial electrochemical technology (MET)

Microplastics (MPs) in wastewater treatment pose significant environmental risks. While microbial electrochemical technology (MET) is effective in removing refractory pollutants, most studies focus on single MP types, despite real-world wastewater often containing mixtures. This study examines the effects of single and hybrid MPs (HD-MPs) on wastewater treatment performance and microbial communities in MET systems. Results show that MPs significantly impair methanogenesis, reducing methane production by 25.27-36.46 %, decreasing COD removal efficiency by 26.82-33.33 %, and increasing volatile fatty acid accumulation by 17.23-26.79 %, with PVC exhibiting the strongest inhibition. Electrical stimulation (0.7 V) exacerbates oxidative stress, elevating reactive oxygen species (ROS) and lactate dehydrogenase (LDH) release in biofilm sludge (BFS) compared to anaerobic granular sludge (AGS). Extracellular polymeric substances (EPS) shift from protein-dominant (65-77 % under PVC-MPs and HD-MPs) to polysaccharide-rich (52-55 % under PE-MPs), reflecting type-specific microbial responses. High-throughput 16S rRNA sequencing reveals that applied voltage selectively enriches fermentative bacteria (Firmicutes and Bacteroidota), creating distinct microbial profiles between AGS and BFS. Metatranscriptomic analyses show that HD-MPs under electrical stimulation induce structural reorganization of key functional microorganisms, including a 144 % increase in fermentation bacteria, 61.7 % rise in acetogens, and 3.89-fold enhancement of electrogenic bacteria at the BFS anode compared to AGS. Transcriptional upregulation of genes in glycolysis, TCA cycle, and methane metabolism confirms the dominance of the acetoclastic methanogenic pathway (79.18-86.97 % of total methanogenesis). This study enhances understanding of electrostimulated microbial consortia in complex pollutant environments and proposes practical MET configurations for real-world applications.

Membrane aerated biological reactors (MABRs) to enhance the biological treatment process at a WWTP

The goal of climate neutrality, under the provision of the European Green Deal, will require great efforts to wastewater treatment plants (WWTPs) to reduce and optimize their energy consumption. The utilization of membrane aerated biological reactors (MABRs) to renovate existing WWTPs could be an opportunity in this sense. In this study, the control of the flow at the outlet of a pure, open-end MABR was used as a strategy to minimize the oxygen consumption and obtain high oxygen transfer efficiencies (OTEs). OTE values of more than 80% were observed, which are not so common in the literature and are comparable to those obtained with a close-end configuration. High efficiencies (85%) were found for the removal of both COD and total nitrogen from samples of real wastewater. A techno-economic analysis, comparing a conventional activate sludge (CAS) plant with a MABR, both with a treatment capacity of 25,000 equivalent inhabitants (e.i.), found that the MABR only needed approx. 1/5 of the energy required by the CAS. A MABR plant could become a profitable investment, under a fixed return time of 5 years, compared to a CAS with a CAPEX of 123.7 k€, if the overall cost of the cassettes was inferior to 237 k€. A sensitivity analysis imposing a variation of ±50% on the input parameters (cost of blower, diffusers, electric energy, and opportunity cost of capital) demonstrated that the cost of electric energy had the highest impact on the maximum allowable value of the MABR investment, which was affected by ± 26% with respect to the value calculated in the reference scenario.

Feasibility of biogas upgrading at a WWTP after pre-treatment application: Techno-economic assessment validation with pilot test data

Improving the efficiency of anaerobic digestion (AD) of sewage sludge (SS) is a critical step toward the achievement of energy neutrality in wastewater treatment plants (WWTPs), as required by the European Green Deal. This study used a comparative techno-economic assessment (TEA) to evaluate the feasibility of producing biomethane, at a WWTP, through upgrading biogas with a double-stage permeation membrane plant. The biogas was originally generated from the AD of a mixture of primary sludge (PS) and either raw or pre-treated waste activated sludge (WAS), where biological or thermo-alkali pre-treatments were applied to increase the WAS intrinsic low degradability. The TEA was supported by the results of pilot-scale tests, carried out on WAS, which mimicked (i) a traditional mesophilic AD process; (ii) a two-stage AD process, where a temperature-phased anaerobic digestion (TPAD, 3 days, 55 °C + 20 days, 38 °C) was performed to biologically pre-treat WAS; (iii) a traditional mesophilic AD process preceded by a thermo-alkali (4 g NaOH/100 g TS, 90 °C, 90 min) pre-treatment. The TEA was carried out in two phases. In the first, the minimum size of the WWTP capable of making the costs necessary for the implementation of the biogas upgrading plant equal to the revenues coming from selling biomethane (at 62 €/MWh) in 10 years was calculated in the absence of pre-treatments. It resulted of 500,000 equivalent inhabitants (e.i.). In the second phase, for the WWTP size found previously, the effect of either biological or thermo-alkali pre-treatments on the economic balance was evaluated, that is the gain (or the loss) associated to the selling of biomethane, compared to the reference price of 62 €/MWh. It was found that the TPAD increased the biogas productivity by only 23.6%, too little to compensate the amount of heat necessary for the pre-treatment and the purchase cost of the additional reactor. Conversely, the thermo-alkali pre-treatment, which enhanced the WAS biogas productivity by 110%, increased the biomethane revenues by approx. 10 €/MWh, compared to the scenario without pre-treatments. This study offers useful data to WWTP managers who want to introduce WAS pre-treatments, combined with interventions for biogas upgrading, in a new or existing sludge line of a WWTP.

Agronomic and phytotoxicity test with biosolids from anaerobic CO-DIGESTION with temperature and micro-organism phase separation, based on sewage sludge, vinasse and poultry manure

This study deals with energy and agronomic valorisation by anaerobic co-digestion with temperature and microorganism phase separation of sewage sludge, vinasse and poultry manure, with the aim of achieving an integral waste management, obtaining bioenergy and biofertilizer that returns nutrients to the soil in a natural way. The yields obtained were 40 mL H2/gVS and 391 mLCH4/gVS. The resulting effluent showed more than 98 % removal of E. coli and Total Coliforms, as well as total removal of Salmonella. The results obtained in the phytotoxicity tests showed that all the proportions studied had phytostimulant and phytonutrient properties, with 20 % having the highest germination index (GI) with mean values of 145.30 %. Finally, the agronomic trial carried out with strawberry crops (Fragaria sp.) showed that the addition of this biosolid has fertilising properties and can be used as an agronomic amendment, with an increase of 145 % in fresh weight and 102.5 % in dry weight, and fruit production doubled with respect to the control. The ANOVA statistical study corroborated that there were significant differences in crop growth when applying different proportions of biofertilizer in the fertilizer. Therefore, these results show that this technology is promising and would contribute environmentally, socially and economically to the transfer towards a circular economy model.

Mesophilic anaerobic digestion of waste activated sludge in an intermittent mixing reactor: Effect of hydraulic retention time and organic loading rate

An anaerobic digester was operated at mesophilic temperature and with intermittent mixing conditions to treat waste activated sludge. The organic loading rate (OLR) was increased by decreasing the hydraulic retention time (HRT), and the effect on process performance, digestate characteristics and inactivation of pathogens was investigated. The removal efficiency of total volatile solids (TVS) was also measured by biogas formation. The HRT varied from 50 to 7 days, corresponding to OLR from 0.38 to 2.31 kgTVS.m^-3.d^-1. The acidity/alkalinity ratio remained within stable limits (lower than 0.6) at 50-, 25- and 17-day HRT; due to an imbalance between the production and consumption of volatile fatty acids, the ratio increased to 0.7 ± 0.2 at HRT of 9 days and 7 days. The highest TVS removal efficiencies were 16, 12 and 9%, which were obtained at 50-, 25- and 17 day-HRT, respectively. Intermittent mixing provided solids sedimentation greater than 30% for almost all HRT tested. The highest methane yields (0.10-0.05 m³.kgTVS_fed^-1.d^-1) were obtained when the reactor was operated at a higher HRT (50-17 days). At lower HRT, methanogenic reactions were likely limited. Zinc and copper were the main heavy metals found in the digestate, while the most probable number (MPN) of coliform bacteria remained below 10⁶ MPN.g TVS^-1. Neither Salmonella nor viable Ascaris eggs were found in the digestate. In general, increasing the OLR by decreasing the HRT to 17 days under intermittent mixing conditions provided an attractive alternative to treat sewage sludge despite some limitations due to biogas and methane yields.