Mathematical modeling of non-ideal mixing continuous flow reactors for anaerobic digestion of cattle manure

Integrating biokinetics with computational fluid dynamics for energy performance analysis in anaerobic digestion

Anaerobic digestion (AD) is an effective process for decomposing organic matter in wastewater treatment plants (WWTPs) where highly efficient digesters properly mix the sludge. To ensure a uniform substance distribution, a comprehensive modeling method is necessary. Computational fluid dynamics (CFD) helps in the modeling of AD tanks but few studies have focused on integrating hydrodynamics with biokinetics because of complex AD processes. The current study presents a new CFD platform for estimating the biokinetics of WWTPs to assess the energy performance of AD tanks. The presented method is validated by numerical and experimental studies, and facilitates a link between methane production and mixing energy consumption. The on-site settings of the recirculation mixing system in the studied WWTP was able to prepare a uniform mixture of the material. However, reducing mixing rate to decrease energy consumption did not lead to proper mixing quality.

Study of the Behavior of Alkalinities Predicted by the AM2 Model

Anaerobic digestion (AD) is an efficient wastewater bioprocess, suitable for treating agroindustrial residues with high organic loads and characterized by both a low environmental impact and energy generation. This process is conformed by several chemical and biological reactions in an oxygen free atmosphere, that degrades high molecular weight organic compounds into carbon dioxide and methane mainly but also into traces of hydrogen and ammonia. This process is potentially unstable to volatile fatty acids (VFA), and the alkalinity. variations and is satisfactorily described by the non-linear AM2 model. In this contribution, the AM2 model is modified to include a more general expression for the pH, a cheap and continuous measurement, and also to add more detail in the interactions of the VFA, bicarbonates, and the alkalinity, key factors in the process stability. The stability of the AM2 modified model is explored through a rigorous bifurcation analysis that identifies unstable operation zones and viability of operation trajectories as a function of the dilution rate. Finally, an experimental validation is carried out to show the feasibility and accuracy of the proposed modifications.

Comprehensive ADM1 Extensions to Tackle Some Operational and Metabolic Aspects in Anaerobic Digestion

Modelling in anaerobic digestion will play a crucial role as a tool for smart monitoring and supervision of the process performance and stability. By far, the Anaerobic Digestion Model No. 1 (ADM1) has been the most recognized and exploited model to represent this process. This study aims to propose simple extensions for the ADM1 model to tackle some overlooked operational and metabolic aspects. Extensions for the discontinuous feeding process, the reduction of the active working volume, the transport of the soluble compound from the bulk to the cell interior, and biomass acclimation are presented in this study. The model extensions are included by a change in the mass balance of the process in batch and continuous operation, the incorporation of a transfer equation governed by the gradient between the extra- and intra- cellular concentration, and a saturation-type function where the time has an explicit influence on the kinetic parameters, respectively. By adding minimal complexity to the existing ADM1, the incorporation of these phenomena may help to understand some underlying process issues that remain unexplained by the current model structure, broadening the scope of the model for control and monitoring industrial applications.

Modelling of an anaerobic plug-flow reactor. Process analysis and evaluation approaches with non-ideal mixing considerations

This study shows the implementation of the Anaerobic Digestion Model (ADM1) in an anaerobic plug-flow reactor (PFR) with two approaches based on the use of consecutive continuous stirred tank reactors (CSTR) connected in serie for considering non-ideal mixing. The two-region (TR) model splits each CSTR into two regions, while the particulate retention (PR) model adds a retention parameter. The models were calibrated and validated based on experimental data from a bench-scale reactor treating cow manure. The PFR conventional model slightly outperformed the non-ideal mixing approaches. However, the PR model showed an increase in biomass retention time treating high solid content substrate. Biogas production was not sensitive to variations of the mixing parameters. The liquid fraction content was better represented by the PR model than the PFR and TR models. The study shows how reactor modelling is useful for monitoring and supervising biogas plants.

Model selection, identification and validation in anaerobic digestion: a review

Anaerobic digestion enables waste (water) treatment and energy production in the form of biogas. The successful implementation of this process has lead to an increasing interest worldwide. However, anaerobic digestion is a complex biological process, where hundreds of microbial populations are involved, and whose start-up and operation are delicate issues. In order to better understand the process dynamics and to optimize the operating conditions, the availability of dynamic models is of paramount importance. Such models have to be inferred from prior knowledge and experimental data collected from real plants. Modeling and parameter identification are vast subjects, offering a realm of approaches and methods, which can be difficult to fully understand by scientists and engineers dedicated to the plant operation and improvements. This review article discusses existing modeling frameworks and methodologies for parameter estimation and model validation in the field of anaerobic digestion processes. The point of view is pragmatic, intentionally focusing on simple but efficient methods.

Modelling of slaughterhouse solid waste anaerobic digestion: determination of parameters and continuous reactor simulation

A model based on the work of Angelidaki et al. (1993) was applied to simulate the anaerobic biodegradation of ruminal contents. In this study, two fractions of solids with different biodegradation rates were considered. A first-order kinetic was used for the easily biodegradable fraction and a kinetic expression that is function of the extracellular enzyme concentration was used for the slowly biodegradable fraction. Batch experiments were performed to obtain an accumulated methane curve that was then used to obtain the model parameters. For this determination, a methodology derived from the "multiple-shooting" method was successfully used. Monte Carlo simulations allowed a confidence range to be obtained for each parameter. Simulations of a continuous reactor were performed using the optimal set of model parameters. The final steady-states were determined as functions of the operational conditions (solids load and residence time). The simulations showed that methane flow peaked at a flow rate of 0.5-0.8 Nm(3)/d/m(reactor)(3) at a residence time of 10-20 days. Simulations allow the adequate selection of operating conditions of a continuous reactor.

Flow patterns of super-high-rate anaerobic bioreactor

The super-high-rate anaerobic bioreactor (SAB) possesses outstanding potential to treat concentrated wastewater. The flow patterns of SAB were investigated through tracer pulse stimulus-response technique and cold-model tests. The flow patterns were demonstrated to be analogous to plug flow at low loading rate and to completely mixed flow at super-high loading rate. Mean dead spaces of SAB caused by biomass and hydraulic behavior were 6.98 % and 21.01 %, respectively. The relationship among the hydraulic dead spaces (V(h)), the volumetric hydraulic loading rate (L) and the volumetric biogas production rate (G) was represented by: V(h)=0.7603 L+0.1627 G - 4.0620. The V(h) was greatly influenced by G over L value. The volumetric efficiency could further be improved when SAB was operated at super-high loading rate. The volume ratio of V(N) and V₁ decreased as N increased and the optimum N was 3.00 or so.

Kinetics of anaerobic degradation of screened dairy manure by upflow fixed bed digesters: effect of natural zeolite addition

The effect of the hydraulic retention time (HRT) on the performance of two up-flow anaerobic fixed bed digesters (UFAFBDs) packed with waste tire rubber (D1) and waste tire rubber and zeolite (D2) as micro-organism immobilization supports was studied. It was found that a first-order kinetic model described well the experimental results obtained. The kinetic constants for COD, BOD5, total solids (TS) and volatile solids (VS) removal were determined to be higher in digester D2 than in digester D1 or control. Specifically, they were 0.28 +/- 0.01, 0.32 +/- 0.02, 0.16 +/- 0.01 and 0.24 +/- 0.01 d(- 1) respectively for D1 and 0.33 +/- 0.02, 0.40 +/- 0.02, 0.21 +/- 0.01 and 0.28 +/- 0.01 d(- 1) respectively for D2. This was significant at the 95% confidence level. In addition, the first-order model was also adequate for assessing the effect of the HRT on the removal efficiency and methane production. Maximum methane yield and the first-order constant for methane production were determined and the results obtained were comparable with those obtained by other authors but operating at higher HRTs. Maximum methane yields and the kinetic constant for methane production were 11.1% and 29.4% higher in digester D2 than in D1.

Treatment of screened dairy manure by upflow anaerobic fixed bed reactors packed with waste tyre rubber and a combination of waste tyre rubber and zeolite: effect of the hydraulic retention time

Two laboratory-scale anaerobic fixed bed reactors were evaluated while treating dairy manure at upflow mode and semicontinuous feeding. One reactor was packed with a combination of waste tyre rubber and zeolite (R1) while the other had only waste tyre rubber as a microorganism immobilization support (R2). Effluent quality improved when the hydraulic retention time (HRT) increased from 1.0 to 5.5 days. Higher COD, BOD5, total and volatile solids removal efficiencies were always achieved in the reactor R1. No clogging was observed during the operation period. Methane yield was also a function of the HRT and of the type of support used, and was 12.5% and 40% higher in reactor R1 than in R2 for HRTs of 5.5 and 1.0 days, respectively. The results obtained demonstrated that this type of reactor is capable of operating with dairy manure at a HRT 5 times lower than that used in a conventional reactor.

Steady state characteristics of acclimated hydrogenotrophic methanogens on inorganic substrate in continuous chemostat reactors

A Monod model has been used to describe the steady state characteristics of the acclimated mesophilic hydrogenotrophic methanogens in experimental chemostat reactors. The bacteria were fed with mineral salts and specific trace metals and a H(2)/CO(2) supply was used as a single limited substrate. Under steady state conditions, the growth yield (Y(CH4)) reached 11.66 g cells per mmol of H(2)/CO(2) consumed. The daily cells generation average was 5.67 x 10(11), 5.25 x 10(11), 4.2 x 10(11) and 2.1 x 10(11) cells/l-culture for the dilutions 0.071/d, 0.083/d, 0.1/d and 0.125/d, respectively. The maximum specific growth rate (mu(max)) and the Monod half-saturation coefficient (K(S)) were 0.15/d and 0.82 g/L, respectively. Using these results, the reactor performance was simulated. During the steady state, the simulation predicts the dependence of the H(2)/CO(2) concentration (S) and the cell concentration (X) on the dilution rate. The model fitted the experimental data well and was able to yield a maximum methanogenic activity of 0.24 L CH(4)/g VSS.d. The dilution rate was estimated to be 0.1/d. At the dilution rate of 0.14/d, the exponential cells washout was achieved.

Hydrolysis kinetics in anaerobic degradation of particulate organic material: an overview

The applicability of different kinetics to the hydrolysis of particulate organic material in anaerobic digestion is discussed. Hydrolysis has traditionally been modelled according to the first-order kinetics. For complex substrate, the first-order kinetics should be modified in order to take into account hardly degradable material. It has been shown that models in which hydrolysis is coupled to the growth of hydrolytic bacteria work well at high or at fluctuant organic loading. In particular, the surface-related two-phase and the Contois models showed good fits to experimental data from a wide range of organic waste. Both models tend to the first-order kinetics at a high biomass-to-waste ratio and, for this reason, they can be considered as more general models. Examples on different inhibition processes that might affect the degradation of solid waste are reported. Acetogenesis or methanogenesis might be the rate-limiting stages in complex waste. In such cases, stimulation of hydrolysis (mechanically, chemically or biologically) may lead to a further inhibition of these stages, which ultimately affects hydrolysis as well. Since the hydrolysis process is characterized by surface and transport phenomena, new developments in spatially distributed models are considered fundamental to provide new insights in this complex process.

Anaerobic digestion of solid material: multidimensional modeling of continuous-flow reactor with non-uniform influent concentration distributions

A new multidimensional (3 and 2D) anaerobic digestion model for cylindrical reactor with non-uniform influent concentration distributions was developed to study the way in which mixing intensity affects the efficiency of continuous-flow anaerobic digestion. Batch experiments reported and simulated earlier by Vavilin and Angelidaki (2005) were used to modernize a kinetic scheme and to obtain the corresponding kinetic coefficients. In the new models, hydrolytic microorganisms were included using Contois kinetics for the hydrolysis/acidogenesis degradation of municipal solid waste (MSW). Monod kinetics was applied for description of methanogenesis. Both hydrolytic and methanogenic microorganisms were assumed to be inhibited by high volatile fatty acids (VFA) concentration. According to the new distributed models, the mixing level reduction expressed by increasing dimensionless Peclet number may improve the continuous flow reactor performance at the relatively low influent methanogenic biomass concentration. In the continuously stirred tank reactor (CSTR) there are two steady states with and without methane production at slightly different values of initial methanogenic biomass concentration. In the system, the threshold methanogenic biomass concentration existed because of inhibition by high VFA concentration. High methanogenic biomass concentration is required for efficient anaerobic digestion of MSW in order to avoid possible inhibition due to high VFA build-up. Thus, CSTR configuration might have unstable dynamics at high organic loading as shown in earlier experiments carried out by Stroot et al. (2001). A gradual increase of organic loading during the start up of a completely mixed digester causing an accumulation of methanogenic biomass is a solution to prevent a probable digester failure. According to the distributed models a plug-flow reactor with non-uniform influent concentration distributions where methanogenic and hydrolytic microorganisms are separated has significant methane production and solids removal at the relatively low influent methanogenic biomass concentration.

CFD simulation of non-Newtonian fluid flow in anaerobic digesters

A general mathematical model that predicts the flow fields in a mixed-flow anaerobic digester was developed. In this model, the liquid manure was assumed to be a non-Newtonian fluid, and the flow governed by the continuity, momentum, and k-epsilon standard turbulence equations, and non-Newtonian power law model. The commercial computational fluid dynamics (CFD) software, Fluent, was applied to simulate the flow fields of lab-scale, scale-up, and pilot-scale anaerobic digesters. The simulation results were validated against the experimental data from literature. The flow patterns were qualitatively compared for Newtonian and non-Newtonian fluids flow in a lab-scale digester. Numerical simulations were performed to predict the flow fields in scale-up and pilot-scale anaerobic digesters with different water pump power inputs and different total solid concentration (TS) in the liquid manure. The optimal power inputs were determined for the pilot-scale anaerobic digester. Some measures for reducing dead and low velocity zones were proposed based upon the CFD simulation results.