Treatment of thin stillage in a high-rate anaerobic fluidized bed bioreactor (AFBR)

Biohythane production via anaerobic digestion process: fundamentals, scale-up challenges, and techno-economic and environmental aspects

Biohythane, a balanced mixture comprising bioH2 (biohydrogen) and bioCH4 (biomethane) produced through anaerobic digestion, is gaining recognition as a promising energy source for the future. This article provides a comprehensive overview of biohythane production, covering production mechanisms, microbial diversity, and process parameters. It also explores different feedstock options, bioreactor designs, and scalability challenges, along with techno-economic and environmental assessments. Additionally, the article discusses the integration of biohythane into waste management systems and examines future prospects for enhancing production efficiency and applicability. This review serves as a valuable resource for researchers, engineers, and policymakers interested in advancing biohythane production as a sustainable and renewable energy solution.

Characterization of Biofilm Microbiome Formation Developed on Novel 3D-Printed Zeolite Biocarriers during Aerobic and Anaerobic Digestion Processes

Background: Aerobic or anaerobic digestion is involved in treating agricultural and municipal waste, and the addition of biocarriers has been proven to improve them further. We synthesized novel biocarriers utilizing zeolites and different inorganic binders and compared their efficiency with commercially available biocarriers in aerobic and anaerobic digestion systems. Methods: We examined BMP and several physicochemical parameters to characterize the efficiency of novel biocarriers on both systems. We also determined the SMP and EPS content of synthesized biofilm and measured the adherence and size of the forming biofilm. Finally, we characterized the samples by 16S rRNA sequencing to determine the crucial microbial communities involved. Results: Evaluating BMP results, ZSM-5 zeolite with bentonite binder emerged, whereas ZSM-5 zeolite with halloysite nanotubes binder stood out in the wastewater treatment experiment. Twice the relative frequencies of archaea were found on novel biocarriers after being placed in AD batch reactors, and >50% frequencies of Proteobacteria after being placed in WWT reactors, compared to commercial ones. Conclusions: The newly synthesized biocarriers were not only equally efficient with the commercially available ones, but some were even superior as they greatly enhanced aerobic or anaerobic digestion and showed strong biofilm formation and unique microbiome signatures.

Performance and kinetics of a fluidized bed anaerobic reactor treating distillery effluent

The kinetic analysis of an anaerobic fluidized bed bioreactor treating distillery effluent was carried out. Natural zeolite was used as biomass carrier at various organic loading rates and hydraulic retention times (HRT). The degradation followed first order kinetics and fitted Michaelis–Menten kinetic model for substrate utilization. The kinetic analysis showed that 9% of the TOC was nonbiodegradable which corresponds to about 14% COD. The non-biodegradable component was responsible for the dark-brown color of the distillery effluent and therefore there was a need for employing a post-treatment technology for their removal. Biomass yield was found to be 0.4658 g/g while endogenic microorganisms decay coefficient was 0.0293, which suggested that there was a need to install a sludge handling unit prior to post-treatment. The maximum micro-organisms’ growth rate was found to be 0.136 d−1 while the specific growth rate of the micro-organisms reduced with an increase in HRT at constant feed concentration. The specific substrate utilization rate was found to increase linearly with an increase in the ration of food to micro-organisms and the mean cell residence time was found to be at least 2.5 times the HRT due to application of zeolite as microbial support in the reactor.

Valorization of Distillery Stillage for Bioenergy Production: A Review

In alcohol distilleries, the amount of distillery stillage generated can be up to 15 times larger than the amount of alcohol produced. The stillage has high concentrations of organics and nitrogen, a low pH, and a dark brown color. Currently, stillage is mainly used for soil fertilization. For this purpose, it requires thickening and is used seasonally, which creates storage problems and transport costs. To reduce environmental pollution, physicochemical and biological processes have been employed for the treatment of distillery stillage. However, according to bioeconomy principles, the stillage should be transformed into value-added products. Therefore, this review paper focuses on methods of stillage processing that enable energy recovery. Due to its high content of organic compounds, stillage is often used as a raw material for biogas production. Accordingly, anaerobic digestion of stillage is discussed, including an overview of the bioreactors used and the effects of operational parameters on organics removal and biogas production. The necessity of integrating anaerobic stillage treatment with other treatment processes is presented. As complex compounds that are present in the stillage (mainly polyphenols and melanoidin) are difficult to biodegrade and have antibacterial activities, the effect of their recovery on biogas production is described. Next, the possibility of converting distillery stillage to bioethanol and biohydrogen is presented. In addition, bioelectrochemical treatment of distillery stillage using microbial fuel cells is discussed. For all these treatment methods, current challenges and opportunities are given.

A value-added step towards promoting the serviceability of fluidized bed bioreactor in treating wastewater with low carbon to nitrogen ratio

Reusing microplastics and zeolite waste as free ammonia (FA)-mitigating carrier particle was proven a value-added step towards promoting the serviceability of fluidized bed bioreactor (FBBR) in treating wastewater with a low carbon to nitrogen ratio (i.e. C/N <3.0) in this study. Ammonia (NH₄⁺) adsorption property capacitates zeolite as an FA mitigator. The microplastics and reused zeolite were processed into reused-zeolite/microplastic composite particle (RZ), whose merit of FA mitigation was fully developed via an optimally thermal modification to process modified-zeolite/microplastic particle (MZ). The 171-day biological nutrient removal (BNR) performance in a single integrated fluidized bed bioreactor (SIFBBR) shows that the bioreactor with MZ particle (SIFBBR-MZ) achieved nitrogen removal efficiency 10.0% higher than the bioreactor with RZ particle (SIFBBR-RZ) over the enhanced short-cut nitrification and denitrification. Analysis of microbial community structure unveils that the long-term lower FA inhibition favored more significant ammonia-oxidizing bacteria (AOB) enrichment and acclimated specific MZ biofilm predominant by nitrite (NO₂^-) denitrifier, contributing to the outperformance in nitrogen removal. Apart from fluidization energy conservation, the techno-economic analysis confirms that using MZ as an FA-mitigating carrier could be of great benefit for FBBR system: realizing waste utilization, reducing carbon addition and alleviating sludge treatment.

Using an expended granular sludge bed reactor for advanced anaerobic digestion of food waste pretreated with enzyme: The feasibility and its performance

The high content of solid organics in food waste (FW) results in a low and unstable anaerobic digestion (AD) efficiency. Improving methane production rate and process stability is attracting much attention towards advanced AD of FW. The feasibility of advanced AD of FW pretreated with enzyme was investigated by batch experiments and 164 days running of an expanded granular sludge bed (EGSB) reactor. Simulation study based on the results of batch experiments indicates it is possible to treat enzymatically pretreated FW using an EGSB reactor. During the running of an EGSB reactor, the organic loading rate went up to 20 g chemical oxygen demand (COD)/L.d, and the total COD removal rate reached 88%. The significance of this study is to achieve an advanced AD of enzymatically pretreated FW with a stable and efficient methane production with biogas residue being reduced greatly.

Advanced treatment of sewage by membrane bioreactor associate with genetically engineered autotrophic nitrifying bacteria

This study introduced a process of MBR combing with genetically engineered bacteria of expressing nirs and ppk genes (GEB-Nirs/PPK) for advanced treatment of sewage in scenic area. An industrial scale application was staged anaerobic digestion, aerobic digestion. Over more than 150 days of continuous operation, TMP in this system was less than 0.18 bar. With a membrane flux of 6.48 m³/h, TMP remained below 0.2 bar and effluent remained above 70 m³ during continuous operation. Average COD and BOD removals averaged 94.2% and 93.6%, and were obtained with average effluent COD and BOD below 10.4 mg/L and 4.2 mg/L, respectively. The TN and TP removals averaged 98.8% and 94.3%, and never higher than 3.2 mg/L and 0.2 mg/L, respectively, in the processing system. In conclusion, these results indicate that the process of MBR associate with genetically engineered autotrophic nitrifying bacteria is of high-efficiency for advanced treatment of sewage.

Granular Sludge Bed Processes in Anaerobic Digestion of Particle-Rich Substrates

Granular sludge bed (GSB) anaerobic digestion (AD) is a well-established method for efficient wastewater treatment, limited, however, by the wastewater particle content. This review is carried out to investigate how and to what extent feed particles influence GSB to evaluate the applicability of GSB to various types of slurries that are abundantly available. Sludge bed microorganisms evidently have mechanisms to retain feed particles for digestion. Disintegration and hydrolysis of such particulates are often the rate-limiting steps in AD. GSB running on particle-rich substrates and factors that affect these processes are stdied especially. Disintegration and hydrolysis models are therefore reviewed. How particles may influence other key processes within GSB is also discussed. Based on this, limitations and strategies for effective digestion of particle-rich substrates in high-rate AD reactors are evaluated.

Anaerobic digestion of thin stillage of corn ethanol plant in a novel anaerobic baffled reactor

In this study, the performance of a conventional anaerobic baffled reactor (ABR) and a novel configuration of hybrid ABR for the treatment of thin stillage was evaluated. The hybrid ABR achieved the chemical oxygen demand (COD) removal, sulfate removal and methane yield of 97-94%, 94-97% and 294-310 mL CH₄ g^-1 COD_removed, respectively at organic loading rate (OLR) of 1-3.5 kg COD m^-3 d^-1. On the other hand, the value of COD and sulfate removal and methane yield for the conventional ABR were 75-94%, 67-76% and 140-240 mL CH₄ g^-1 COD_removed, respectively at OLR range of 1.1-1.8 kg COD m^-3 d^-1. The enhanced performance and robustness of the novel ABR was demonstrated to be the result of incorporation of solid/liquid/gas separators into the configuration of the conventional ABR, leading to reduced biomass washout, higher solid retention time and significantly improved phase separation.

Phytofiltration of anaerobically digested sugarcane ethanol stillage using a macrophyte with high potential for biofuel production

Anaerobically digested stillage (ADS) requires treatment before being discharged into water bodies or soils to avoid adverse effects. Phytofiltration systems are eco-friendly technologies for wastewater treatment, and they simultaneously serve as a source of biomass for biofuel production. The aim of the present study was to investigate the phytofiltration of ADS using Azolla sp. The effects of the ADS strength (dilutions 1: 50 and 1 : 25 v/v) and initial biomass density (IBD) [15.44 (IBD1) and 23.16 (IBD2) g dry weight (dw) m^-2] on plant growth and pollutant removal were assessed. Productivities obtained at ADS 1: 50 (2.93 and 3.04 g m^-2 d^-1 for IBD1 and IBD2, respectively) were not significantly different from those of a synthetic medium (2.56 and 3.15 g m^-2 for IBD1 and IBD2, respectively). Higher organic matter removal was found using ADS at 1: 25 than that obtained using ADS 1: 50 (52.16-53.34 vs 32.29-38.16%), while no IBD effect was observed. The nutrient concentrations in ADS were reduced significantly, especially the concentrations of NH₄-N (75.11-82.54%), PO₄-P (88.72-92.90%) and SO₄-S (55.95-66.61%). The conversion of nutrients from ADS into Azolla biomass may result in an effective way to produce an attractive feedstock for biofuel production.

Fertirrigation with sugarcane vinasse: Foreseeing potential impacts on soil and water resources through vinasse characterization

This paper reports the characterization of the polluting potential of sugarcane vinasse, the main wastewater from ethanol production. Compositional data from vinasse samples collected from sugarcane biorefineries were used to predict negative effects on the soil, water resources and crops potentially associated with fertirrigation, the primary final destination of vinasse in Brazil. High risks of soil salinization were associated with the land disposal of vinasse, as evidenced by the high levels of total dissolved solids (TDS; >4,000 mg L^-1) and electrical conductivity (>6.7 dS m^-1). The high TDS levels coupled with the high biodegradable organic content of vinasse (>14 g L^-1) also favor organic overloading events, leading to local anaerobiosis conditions. Conversely, soil sodification should not be observed in areas fertirrigated with sugarcane vinasse, given the low Na concentrations (<66 mg L^-1) relative to Mg (>145.1 mg L^-1) and Ca (>458.4 mg L^-1) levels. Priority pollutants (Cu, Cr, Ni, Pb and Zn) and phytotoxic elements (Al and Fe) were also found in the analyzed samples; however, relevant environmental impacts should not be associated with these particular constituents. Overall, the relatively simple methodology used herein could efficiently replace massive field data collection to provide a basic understanding of the fate of vinasse in the environment in order to highlight the priority points to be considered in the management of this effluent. In summary, the prompt implementation of treatment plants in distilleries, in addition to a continuous and broad compositional characterization of vinasse, is essential to guarantee its adequate reuse.

Bioenergy from stillage anaerobic digestion to enhance the energy balance ratio of ethanol production

The challenges associated with the availability of fossil fuels in the past decades intensified the search for alternative energy sources, based on an ever-increasing demand for energy. In this context, the application of anaerobic digestion (AD) as a core treatment technology in industrial plants should be highlighted, since this process combines the pollution control of wastewaters and the generation of bioenergy, based on the conversion of the organic fraction to biogas, a methane-rich gaseous mixture that may supply the energetic demands in industrial plants. In this context, this work aimed at assessing the energetic potential of AD applied to the treatment of stillage, the main wastewater from ethanol production, in an attempt to highlight the improvements in the energy balance ratio of ethanol by inserting the heating value of methane as a bioenergy source. At least 5-15% of the global energy consumption in the ethanol industry could be supplied by the energetic potential of stillage, regardless the feedstock (i.e. sugarcane, corn or cassava). The association between bagasse combustion and stillage anaerobic digestion in sugarcane-based distilleries could provide a bioenergy surplus of at least 130% of the total fossil fuel input into the ethanol plant, considering only the energy from methane. In terms of financial aspects, the economic gains could reach US$ 0.1901 and US$ 0.0512 per liter of produced ethanol, respectively for molasses- (Brazil) and corn-based (EUA) production chains. For large-scale (∼1000 m(3)EtOH per day) Brazilian molasses-based plants, an annual economic gain of up to US$ 70 million could be observed. Considering the association between anaerobic and aerobic digestion, for the scenarios analyzed, at least 25% of the energetic potential of stillage would be required to supply the energy consumption with aeration, however, more suitable effluents for agricultural application could be produced. The main conclusion from this work indicates that anaerobic processes should be considered the core technology to treat stillage, based mainly on the attractive relation energy generation-financial return and on the possibility to keep the advantages inherent to the common fertigation when using the treated effluent in agriculture.

Implications of stillage land disposal: a critical review on the impacts of fertigation

Stillage is the main wastewater from ethanol production, generated specifically in the step of distillation. Regardless the feedstock, stillage contains high concentrations of organic matter, potassium and sulfates, as well as acidic and corrosive characteristics. Currently almost the entire volume of stillage generated in Brazilian distilleries is directed to the fertigation of sugarcane fields, due to its fertilizer character. However, the polluting potential of stillage characterizes its land disposal as problematic, considering probable negative impacts on the soil structure and water resources in case of excessive dosages. Since the literature lacks critical content describing clearly the cons related to the reuse of stillage in agriculture in the long-term, this review aimed to assess the real polluting potential of stillage, and the implications of its land disposal and/or discharge into water bodies. Evidence from the literature indicate that the main obstacles to reuse stillage in natura include risks of soil salinization; clogging of pores, reduction in the microbial activity and the significant depletion of dissolved oxygen concentrations in water bodies; contamination per nitrates and eutrophication; soil structure destabilization due to high concentrations of potassium and sodium; and, possible acidification of soil and water resources, considering the low pH of stillage (∼4,5). Toxic metals, such as cadmium, lead, copper, chromium and nickel, were also identified in concentrations above the recommended limits in stillage samples, increasing risks to human health (e.g. carcinogenic potential) and to crops (e.g. productivity loss). In short, although some studies report benefits from the land application of stillage, its treatment prior to disposal is essential to make fertigation an environmentally suitable practice.

Influence of upflow velocity on performance and biofilm characteristics of Anaerobic Fluidized Bed Reactor (AFBR) in treating high-strength wastewater

One of the key parameters in Fluidized Bed reactors is the control of biofilm thickness and configuration. The effect of upflow velocity on performance and biofilm characteristics of an Anaerobic Fluidized Bed Reactor was studied in treating Currant wastewater at various loading rates. The reactor used this study was made of a plexiglass column being 60 mm diameter, 140 cm height, and a volume of 3.95 L. The results demonstrated that the AFBR system is capable of handling an exceptionally high organic loading rate. At organic loading rates of 9.4 to 24.2 (kg COD m(-3)) at steady state, reactor performances with upflow velocities of 0.5, 0.75 and 1 (m min(-1)) were 89.3- 63.4, 96.9 - 79.6 and 95 - 73.4 percent, respectively. The average biomass concentration per unit volume of the AFBR (as gVSSatt L(-1) expended bed) decreased with the increase of upflow velocity in the range of 0.5-1 m min(-1) at all applied organic loading rates. The total biomass in the reactor increased with increases in the organic loading rate. The peak biomass concentration per unit volume (as gVSSatt L(-1) expended bed) was observed at the bottom part of the reactor, then it droped off slowly towards the top. The biofilm thickness increased from the bottom to the top of the reactor representing a stratification of the media in the AFBR. The bed porosity increased from the bottom to the top of the reactor.

Anaerobic digestion of municipal wastewater sludges using anaerobic fluidized bed bioreactor

The anaerobic digestion of primary sludge (PS) and thickened waste activated sludge (TWAS) using an anaerobic fluidized bed bioreactor (AnFBR) employing zeolite particles as the carrier media was investigated at different organic loading rates (OLRs). PS was tested at OLRs from 4.2 to 39kgCOD/m(3)-d corresponding to hydraulic retention times (HRTs) from 1.0 to 8.9days. The highest COD removal and VSS destruction efficiencies for primary sludge of 85% and 88%, respectively, were achieved at an HRT of 8.9days and OLR of 4.2kgCOD/m(3)-d. For TWAS, VSS destruction efficiencies varied from 42% at an HRT of 2.6days and OLR of 13.1kgCOD/m(3)-d to 69% at an HRT of 8.8days and an OLR of 4.2kgCOD/m(3)-d. The first-order COD biodegradation rates in the AnFBR for PS and TWAS were 0.4d(-1) and 0.1d(-1), respectively, almost double the rates in conventional high-rate digesters.

Combined process for ethanol fermentation at high-solids loading and biogas digestion from unwashed steam-exploded corn stover

A combined process was designed for the co-production of ethanol and methane from unwashed steam-exploded corn stover. A terminal ethanol titer of 69.8 g/kg mass weight (72.5%) was achieved when the fed-batch mode was performed at a final solids loading of 35.5% (w/w) dry matter (DM) content. The whole stillage from high-solids ethanol fermentation was directly transferred in a 3-L anaerobic digester. During 52-day single-stage digester operation, the methane productivity was 320 mL CH₄/g volatile solids (VS) with a maximum VS reduction efficiency of 55.3%. The calculated overall product yield was 197 g ethanol + 96 g methane/kg corn stover. This indicated that the combined process was able to improve overall content utilization and extract a greater yield of lignocellulosic biomass compared to ethanol fermentation alone.

An integrated anaerobic digestion and UV photocatalytic treatment of distillery wastewater

Anaerobic up-flow fixed bed reactor and annular photocatalytic reactor were used to study the efficiency of integrated anaerobic digestion (AD) and ultraviolet (UV) photodegradation of real distillery effluent and raw molasses wastewater (MWW). It was found that UV photodegradation as a stand-alone technique achieved colour removal of 54% and 69% for the distillery and MWW, respectively, with a COD reduction of <20% and a negligible BOD reduction. On the other hand, AD as a single treatment technique was found to be effective in COD and BOD reduction with efficiencies of above 75% and 85%, respectively, for both wastewater samples. However, the AD achieved low colour removal efficiency, with an increase in colour intensity of 13% recorded when treating MWW while a colour removal of 51% was achieved for the distillery effluent. The application of UV photodegradation as a pre-treatment method to the AD process reduced the COD removal and biogas production efficiency. However, an integration in which UV photodegradation was employed as a post-treatment to the AD process achieved high COD removal of above 85% for both wastewater samples, and colour removal of 88% for the distillery effluent. Thus, photodegradation can be employed as a post-treatment technique to an AD system treating distillery effluent for complete removal of the biorecalcitrant and colour imparting compounds.

Thermophilic anaerobic co-digestion of poultry litter and thin stillage

The purpose of this study was to test whether the performance of a thermophilic CSTR digester that has been stabilized on poultry litter will be enhanced or diminished by the addition of thin stillage as co-substrate. Replicate laboratory digesters, derived from a stable pilot-scale digester, were operated with increasing ratios (w/w) of thin stillage/poultry litter feedstock. After a period of adaptation to 20% and 40% thin stillage, digester performance showed increases in biogas, percent methane and COD removal, as well as a decrease in volatile acids. Peak performance occurred with 60% thin stillage. However, 80% thin stillage caused significant reduction of performance, including declines of methanogenic activity and COD removal. In conclusion, supplementing the thermophilic digestion of poultry litter with thin stillage improved the bioenergy (methane) output, but thin stillage became inhibitory at high concentrations.

Industrial symbiosis: corn ethanol fermentation, hydrothermal carbonization, and anaerobic digestion

The production of dry-grind corn ethanol results in the generation of intermediate products, thin and whole stillage, which require energy-intensive downstream processing for conversion into commercial animal feed products. Hydrothermal carbonization of thin and whole stillage coupled with anaerobic digestion was investigated as alternative processing methods that could benefit the industry. By substantially eliminating evaporation of water, reductions in downstream energy consumption from 65% to 73% were achieved while generating hydrochar, fatty acids, treated process water, and biogas co-products providing new opportunities for the industry. Processing whole stillage in this manner produced the four co-products, eliminated centrifugation and evaporation, and substantially reduced drying. With thin stillage, all four co-products were again produced, as well as a high quality animal feed. Anaerobic digestion of the aqueous product stream from the hydrothermal carbonization of thin stillage reduced chemical oxygen demand (COD) by more than 90% and converted 83% of the initial COD to methane. Internal use of this biogas could entirely fuel the HTC process and reduce overall natural gas usage.