Reactor performance and economic evaluation of anaerobic co-digestion of dairy manure with corn stover and tomato residues under liquid, hemi-solid, and solid state conditions

Tomato Residue Management from a Biorefinery Perspective and towards a Circular Economy

The tomato industry is a relevant socio-economic activity in the European Union, while it generates a large variety of residues. Tomatoes unfit for consumption, tomato peels, seeds, industrial pomace, and plants are examples of residues of this industry. Commonly, some of the residues can be left in the field, composted, used for animal feeding, or valorized through anaerobic digestion. However, more economic value can be attributed to these residues if a biorefinery approach is applied. Indeed, many value-added compounds can be obtained by the integration of different processes while closing the carbon and nutrient loops. The extraction of bioactive compounds followed by anaerobic digestion and composting seems to be a viable proposal for a biorefinery approach. Thus, this study aims to review the biorefinery strategies for valorizing tomato residues, highlighting the main processes proposed. The recovery of lycopene, β-carotene, and phenolic compounds has been widely studied at the lab scale, while energy recovery has already been applied at the industrial scale. Although techno-economic analysis is scarce for tomato residue valorization processes, positive net present values (NPV) and low payback times (PBT) have been reported in the literature. Thus, more work comparing multiple extraction technologies and biorefinery strategies coupled with economic and environmental assessment should be performed to select the most promising management route for tomato residues.

Anaerobic co-digestion of corn straw, sewage sludge and fresh leachate: Focusing on synergistic/antagonistic effects and microbial mechanisms

Effects of sewage sludge (SS) and fresh leachate (FL) addition on corn straw (CS) digestion and underlying mechanisms were investigated. Co-digestion of CS, SS and FL significantly increased cumulative methane production by 7.2-61.1%. Further analysis revealed that co-digestion acted mainly on slowly degradable substrates and exerted dual effects on methane production potential, which was closely related to the volatile solids (VS) content. Antagonistic effects of co-digestion resulted from the dominance of norank_c_Bathyarchaeia, a mixotrophic methanogen that may generate methane inefficiently and consume existing methane. The synergistic enhancement of methane production (0.7-12.7%) was achieved in co-digestion with 33.5-45.5% of total VS added as SS and FL. Co-digestion with more balanced nutrients and higher buffering capacity enriched Actinobacteriota, Firmicutes, and Synergistota, thereby facilitating the substrate degradation. Furthermore, the predominant acetoclastic methanogens, increased hydrogenotrophic methanogens, and decreased methylotrophic methanogens in the digester combined to prompt the synergy.

Effects of digestion duration on energy efficiency, compost quality, and carbon flow during solid state anaerobic digestion and composting hybrid process

This study investigated the effects of anaerobic digestion duration on methane yield, net energy production, and humification of compost during solid state anaerobic digestion (SSAD) and composting hybrid process for food waste treatment. Carbon flow and balance were used to evaluate organic methanation and humification inclination of carbon in the whole SSAD and aerobic composting system. Results showed that SSAD for 15 (AD-15) and 21 days (AD-21) could increase net energy production and degraded organic matter contained in the mixtures to achieve high biological stability. The cumulative net energy production between the AD-15 and AD-21 treatments was not significantly different, which was 8.3% higher than that in SSAD for 30 days (AD-30). Furthermore, digestate (AD-15 and AD-21) composting for 3 days reached maturity and absence of phytotoxic substances. Carbon fixed into humus of the AD-21 treatment (11.6%) was not significantly different from that of AD-15 (12.0%). However, the total amount of carbon fixed into compost in AD-15 was 6.6% higher than that in AD-21. Moreover, the CO₂ -C loss of the AD-15 treatment (22.9%) was slightly higher than that of AD-21 (20.6%). Thus, AD-21 treatment achieved the most effective use of carbon during SSAD and composting hybrid process for food waste treatment. These results could provide valuable insights for the effective management of food waste in practice.

Engineering and microbial characteristics of innovative lab and pilot continuous dry anaerobic co-digestion system fed with cow dung and corn straw

Dry anaerobic digestion (dry-AD) allows high-solid digestion; however, dry-AD application is limited because it is prone to blockage and intermediate inhibition. Here, we reported innovative continuous dry co-digestion systems at both lab and pilot scales. The effects of digestate recirculation ratio, dry mass ratio of cow dung to corn straw (CD:CS), and TS content on the digestion performance were investigated. The effects of the three factors were ranked as follows: TS content > CD:CS > digestate recirculation ratio. The daily biogas production rate reached 0.386 NL/d/g VS with the optimal parameter combination, which was determined to be TS content of 30%, a substrate ratio of 1:3, and a digestate recirculation ratio of 40%. In addition, increasing the CD:CS and TS content increased digestate viscosity, which inhibited biogas production; however, increased abundance of Proteiniphilum and acetoclastic methanogens facilitated biogas production. This study provides empirical support for further application of dry-AD.

Enhancing hydrolysis and syntropy simultaneously in solid state anaerobic digestion: Digester performance and techno-economic evaluation

The present study investigated the effect of alkali and biochar addition for simultaneous increment of hydrolysis and syntropy for higher methane yield from pearl millet straw (PMS) in solid state anaerobic digestion. A taguchi based design of experiment was coupled with grey relation analysis for multiple output optimization. Study showed that 0.5 g (g/100 g PMS) of alkali and 10 g/L of biochar was the optimised dosing. Statistically, contribution of biochar and alkali was 48 and 21% respectively on the multiple output. The confirmation test revealed that hydrolysis rate constant, k and total volatile fatty acid/alkalinity ratio for reactor having optimised conditions was 0.0521 d^-1 and 0.36 while for control, it was 0.0595 d^-1 and 0.76 respectively. Techno-economic assessment showed US$ 25,652 of net present value and 11.29% of internal rate of return. Sensitivity analysis showed that capital expenditure and methane yield was most sensitive to net present value.

Bioenergy Production through Mono and Co-Digestion of Tomato Residues

The agro-industry of tomato generates three types of residues: ripe rotten tomato (unfit for consumption) (RT), green (unripe) tomato (GT), and tomato branches including leaves and stems (TB). These materials are commonly wasted or used as feed for livestock. Energy production through anaerobic digestion is an alternative way to manage and simultaneously valorise these materials. Initially, the operating conditions of mono anaerobic digestion were investigated using RT. Thus, a design of experiments based on a two-level fractional factorial design with resolution V was performed to determine the factors that affect biochemical methane potential (BMP). The substrate to inoculum ratio (SIR), total volatile solids concentration (VSt), working volume (WV), presence of nutrients (Nu), and the pre-incubation of the inoculum (Inc) were investigated. The results showed that SIR is the most important factor. The maximum BMP for RT was 297 NmLCH4/gVS with SIR = 0.5; tVS = 20 g/L; WV = 20%; no pre-incubation and the presence of nutrients. Using these optimum operating conditions, co-digestion was investigated through a mixture design approach. The substrates RT and GT presented similar BMP values, whereas TB led to a significantly lower BMP. Indeed, when high concentrations of TB were used, a significant decrease in methane production was observed. Nonetheless, the highest BMP was achieved with a mixture of 63% RT + 20% GT + 17% TB, with a production of 324 NmLCH4/gVS, corresponding to a synergetic co-digestion performance index of about 1.20. In general, although the substrate RT generates the highest BMP, the mixture with GT did not impair the methane yield. Overall, the co-digestion of tomato residues must be conducted with SIR close to 0.5 and the content of tomato branches in the reaction mixture should be kept low (up to 20%).

Anaerobic digestion of agricultural wastes from liquid to solid state: Performance and environ-economic comparison

Performance and environ-economic impacts were compared for anaerobic digestion (AD) of dairy manure and cucumber residues from liquid to solid state. Environ-economic evaluation of the overall AD process at different total solids (TS) was performed with the estimated treatment capacity of 9600 tons/year and service life of 20 years. Results showed that TS increase from 6% to 22% enhanced both cumulative and volumetric methane (CH₄) production. Further TS increase to 25%, however, reduced CH₄ yield. Environ-economic assessment indicated that TS increase enhanced volumetric waste treatment capacity and thus AD environmental footprints. Environmental credits from digestate and biogas utilization could compensate the adverse environmental impacts of other processes in AD plants. Furthermore, biogas and nutrients in digestate determined AD net-present value. As a result, solid state AD was more profitable with higher CH₄ yield and more nutrients in both biosolids and digested effluent of digestate than its liquid and hemi-solid counterparts.

Strategies to improve solid state anaerobic bioconversion of lignocellulosic biomass: an overview

Solid state anaerobic digestion (SSAD) of lignocellulosic biomass may be attractive solution for its valorisation. Compared to liquid state anaerobic digestion (LSAD), SSAD can handle higher organic loading rates (OLR), requires a less water and smaller reactor volume. It may require lower energy demand for heating or mixing and has higher volumetric methane productivity. Besides numerous benefits of SSAD processes and progress in system design, there are still obstacles, which need to be overcome for its successful implementations. This review aims to compile the recent trends in enhancing the bioconversion of agricultural stubbles in SSAD. Several pretreatment procedures used to breaking lignin and cellulose complex, method to overcome carbon to nitrogen ratio imbalance, use of carbon-based conducting materials to enhance Volatile Fatty Acids (VFA) conversion and additives for achieving nutrient balance will be discussed in this review. Leachate recirculation and its impacts on SSAD of agricultural stubbles are also discussed.

Increasing the Content of Olive Mill Wastewater in Biogas Reactors for a Sustainable Recovery: Methane Productivity and Life Cycle Analyses of the Process

Anaerobic codigestion of olive mill wastewater for renewable energy production constitutes a promising process to overcome management and environmental issues due to their conventional disposal. The present study aims at assessing biogas and biomethane production from olive mill wastewater by performing biochemical methane potential tests. Hence, mixtures containing 0% (blank), 20% and 30% olive mill wastewater, in volume, were experimented on under mesophilic conditions. In addition, life cycle assessment and life cycle costing were performed for sustainability analysis. Particularly, life cycle assessment allowed assessing the potential environmental impact resulting from the tested process, while life cycle costing in conjunction with specific economic indicators allowed performing the economic feasibility analysis. The research highlighted reliable outcomes: higher amounts of biogas (80.22 ± 24.49 NL.kg_SV⁻¹) and methane (47.68 ± 17.55 NL.kg_SV⁻¹) were obtained when implementing a higher amount of olive mill wastewater (30%) (v/v) in the batch reactors. According to life cycle assessment, the biogas ecoprofile was better when using 20% (v/v) olive mill wastewater. Similarly, the economic results demonstrated the profitability of the process, with better performances when using 20% (v/v) olive mill wastewater. These findings confirm the advantages from using farm and food industry by-products for the production of renewable energy as well as organic fertilizers, which could be used in situ to enhance farm sustainability.

A comparative analysis of biogas production from tomato bio-waste in mesophilic batch and continuous anaerobic digestion systems

Annually, agricultural activity produces an enormous amount of plant biomass by-product. Many studies have reported the biomethane potential of agro-industrial wastes, but only a few studies have investigated applying the substrates in both batch and continuous mode. Tomato is one of the most popular vegetables globally; its processing releases a substantial amount of by-product, such as stems and leaves. This study examined the BMP of tomato plant (Solanum lycopersicum Mill. L. cv. Alfred) waste. A comparative test revealed that the BMPs of corn stover, tomato waste,and their combination were approximately the same, around 280 mL methane/g Volatile Solid. In contrast, the relative biogas production decreased in the presence of tomato waste in a continuous mesophilic anaerobic digestion system; the daily biogas productions were 860 ± 80, 290 ± 50, and 570 ± 70 mL biogas/gVolatile Solid/day in the case of corn stover, tomato waste, and their mixture, respectively. The methane content of biogas was around 46–48%. The fermentation parameters of the continuous AD experiments were optimal in all cases; thus, TW might have an inhibitory effect on the microbial community. Tomato plant materials contain e.g. flavonoids, glycoalkaloids (such as tomatine and tomatidine), etc. known as antimicrobial and antifungal agents. The negative effect of tomatine on the biogas yield was confirmed in batch fermentation experiments. Metagenomic analysis revealed that the tomato plant waste caused significant rearrangements in the microbial communities in the continuously operated reactors. The results demonstrated that tomato waste could be a good mono-substrate in batch fermentations or a co-substrate with corn stover in a proper ratio in continuous anaerobic fermentations for biogas production. These results also point to the importance of running long-term continuous fermentations to test the suitability of a novel biomass substrate for industrial biogas production.

Reactor performance and economic evaluation of singular, binary, and ternary mixing of feedstocks for anaerobic digestion

This study compared the performance of singular, binary, and ternary mixing of feedstocks for anaerobic digestion. Three wastes, including organic fraction of municipal solid waste (OFMSW), dairy manure, and corn stover, were tested under the mesophilic condition. Results showed that the binary and ternary mixing stabilised digesters while solely processing OFMSW resulted in pH drop and over accumulation of volatile fatty acids. The highest methane yield of 302.3 L/kg-VS was achieved with 50% OFMSW, 33% corn stover, and 17% dairy manure, which was about 5 times of that obtained from digesting OFMSW alone. The binary and ternary mixing led to multiple peaks in daily methane production, which evened out methane production throughout the 50-day digestion process. Economic analysis showed that solid digestate price, direct fixed capital cost, and labour cost significantly affected net present value (NPV). Ternary mixtures had the highest NPV and internal rate of return and were financially attractive under analysis conditions.

Anaerobic digestion of different agricultural wastes: A techno-economic assessment

In this work, techno-economic evaluation of anaerobic digestion (AD) system (8000 metric tons (MT)/year) with singular (dairy manure), binary (dairy manure and corn stalk), and ternary mixture (dairy manure, corn stalk, and tomato residues) under bio-methane and combined heat and power (CHP) pathways based on a plant service life of 20 years were carried out. Solid state-AD (SS-AD) of ternary mixture improved the efficiency of investment, benefited the digestate price, and was shown to be economic viability. The introduction of a CHP unit highly improved the economics of SS-AD. SS-AD of the binary mixture under CHP pathway was able to compensate the initial required investment, however was not financially attractive under bio-methane pathway. Besides, SS-AD of the ternary mixture under CHP pathway had higher net present value (NPV) ($0.60 million vs $0.40 million) and internal rate of return (IRR) (23% vs 20%) than that under bio-methane pathway.

Food-processing wastes

Literature published in 2018 and literature published in 2019 related to food-processing wastes treatment for industrial applications are reviewed. This review is a subsection of the Treatment Systems section of the annual Water Environment Federation literature review and covers the following food-processing industries and applications: general, meat and poultry, fruits and vegetables, dairy and beverage, and miscellaneous treatment of food wastes. PRACTITIONER POINTS: This article summarizes literature reviews published in 2018 and in 2019 related to food processing wastes treatment for industrial applications are reviewed. This review is a subsection of the Treatment Systems section of the annual Water Environment Federation literature review and covers the following food processing industries and applications: general, meat and poultry, fruits and vegetables, dairy and beverage, and miscellaneous treatment of food wastes.

Methane production from the co-digestion of pig manure and corn stover with the addition of cucumber residue: Role of the total solids content and feedstock-to-inoculum ratio

This study investigated performance and stability of increasing total solids (TS) content (10-30%) and feedstock-to-inoculum (F/I) ratios (1, 2) on anaerobic co-digestion of agricultural wastes. The cumulative methane yields generally decreased with the increasing TS content except for the TS content of 30% at F/I ratio of 1 and TS content of 10% at F/I ratio of 2. This was consistent with the maximum methane production rate (Rmax) and rate of the hydrolysis (Kh) stage in reactors. The pH, VFAs and NH4+-N content were positively correlated with increasing TS contents and F/I ratios. Economic analysis results indicated the net present value generally increased with increasing TS contents and TS content of 30% at F/I ratio of 1 had the highest net present value (5.7 million US$) and internal rate of return (41.9%). This indicated solid-state anaerobic digestion was financially attractive under analyzed conditions.

The significance of biomass in a circular economy

A circular economy relies on the value of resources being maximised indefinitely, requiring that virtually no unrecoverable waste occurs. Biomass is highly significant in a circular economy in terms of material products and the provision of energy. To establish a circular bioeconomy, the practical implications of biomass use need to be appreciated by stakeholders throughout the value chain, from product design to waste management. This review addresses sustainable biomass production and its function as a feedstock from a European perspective. Anaerobic digestion of food waste is used as a case study to represent appropriate waste treatments. Crucial challenges are (1) Uncoupling the petrochemical industry and biomass production with renewable fertilisers; (2) Providing plentiful biomass for bio-based products by prioritising other renewable sources of energy; (3) Waste arising from food and agriculture must be minimised and returned to the economy; (4) Enhancing stakeholder cooperation across value chains.

Effects of biochar parent material and microbial pre-loading in biochar-amended high-solids anaerobic digestion

This study characterises the effect of biochar (pyrolysed biomass) produced from wood pellets, wheat straw and sheep manure on high-solids anaerobic digestion (HSAD) of poultry litter. Also, pre-loading biochar with microorganisms before addition to HSADs was investigated. The addition of wood pellet biochar provides a 32% increase to the methane yield compared with control digesters. The addition of biochar produced from either wheat straw or sheep manure has detrimental effects on digester performance compared with controls. The addition of wood pellet biochar pre-loaded by placing it in a high-solids digester for 90 days provides a 69% increase in the total methane yield, 44% increase in the peak daily methane yield and a 33% reduction in the lag time compared with controls. This study highlighted a need for careful selection of parent material for biochar production and, for the first time, the opportunities to re-use wood pellet biochar for further improvements.

Effect of total solids content on anaerobic digestion of poultry litter with biochar

Methane production via anaerobic digestion of poultry litter provides a pathway for energy production from an abundant waste product. Recent studies have shown the use of biochar (pyrolysed biomass) can decrease methane production lag times and increase peak daily yields from ammonia-stressed low-solids anaerobic digesters. Due to the variety of feedstocks and digester configurations used, research to date has not yet determined the effect of biochar addition as a function of the digester total solids content. This study shows the addition of biochar reduces the lag time by a greater percentage in the digesters with a higher total solids content. There was a 17%, 27% and 41% reduction lag time due to biochar addition at total solids contents of 5%, 10% and 20%, respectively. The peak daily methane yield increased by 136% at 10% total solids. There was no significant increase in the peak yield at 5% total solids, while there was a 46% increase at 20% total solids. Real-time PCR analysis confirms the Methanosaetaceae family, which is a key methanogen due to its ability to facilitate direct interspecies electron transfer while attached to biochar, preferentially attaches to biochar. Furthermore, this research shows the attachment of the Methanosaetaceae family, does not decrease with increasing total solids content. A potential negative effect of biochar addition, a reduced volumetric efficiency, can be negated by using a shorter retention time. This new understanding will help to improve predictions of the impact of biochar addition for new digester designs operating in semi-solids and high-solids conditions.

Evaluation of methane production and energy conversion from corn stalk using furfural wastewater pretreatment for whole slurry anaerobic co-digestion

In this study, corn stalk (CS) was pretreated with furfural wastewater (FWW) for whole slurry anaerobic digestion (AD), which increased the degradability of CS components, changed the parameters in pretreatment slurry and improved the biochemical methane potential (BMP). The ultimate goal was to optimize the time and temperature for FWW pretreatment and evaluate whether FWW pretreatment is feasible from BMP and energy conversion. The results of path analysis suggested that lignocellulosic degradability (LD) was the main factor affecting methane production with the comprehensive decision of 0.7006. The highest BMP (166.34 mL/g VS) was achieved by the pretreatment at 35 °C for 6 days, which was 70.36% higher than that of control check (CK) (97.64 mL/g VS) and the optimal pretreatment condition was predicted at 40.69 °C for 6.49 days by response surface methodology (RSM). The net residual value (NRV) for the pretreatment of 35 °C and 6 days was the highest (0.6201), which was the most appropriate condition for AD in real application.

Mesophilic anaerobic co-digestion of acorn slag waste with dairy manure in a batch digester: Focusing on mixing ratios and bio-based carbon accelerants

Co-digestion of acorn slag waste (ASW) and dairy manure (DM) with two bio-based carbon (BC) accelerants are investigated via batch experiments under mesophilic condition. With the favorable synergistic effect of the mixed substrate and BC accelerant, the anaerobic digestion (AD) systems assembled with aloe peel-derived BC (2.16 g/L) show significantly improved methanogenesis on the basis of the optimum wet weight ratio of ASW to DM (1:3). The cumulative biogas yield is 580.9 mL/g VS, and the total chemical oxygen demand reduction is 79.37%. These results are higher than those of the AD systems without carbon-based accelerants. The feasibility of digestate utilization is evaluated by thermal and fertilizer analyses, which manifest outstanding stability and excellent fertility (6.93%-7.40%) of digestate in co-digestion systems. A general strategy for understanding the enhanced methanogenesis pathways, induced by BC in AD systems, is demonstrated. These important findings open an innovative opportunity for developing carbon-based accelerants in anaerobic co-digestion.

Sequencing batch dry anaerobic digestion of mixed feedstock regulating strategies for methane production: Multi-factor interactions among biotic and abiotic characteristics

This study investigated the synergistic effects and regulation strategy of multiple factors for improving methane production in sequencing batch dry anaerobic digestion (SBD-AD) using corn stalks (CS) and cow dung (CD). The regulation of the spray frequency (SF) and inoculum content (IC) significantly improved methane yield, which increased feedstock ratios (FRs) by 12.4-121.3%. Moreover, the relationship between SF and IC produced distinct interaction modes. An FR of 4:6 increased the SF to 2 h for the CD-rich condition, and an FR of 6:4 decreased the SF during a 6 h interval and increased the IC for the CS-rich condition, resulting in increases in methane yield and the conversion efficiency of volatile fatty acids (VFAs). Methanogenesis (Methanogens) played a key role in SBD-AD. The nutrient substrate (NH₄-N⁺) and key enzyme activities of methanogens were significantly affected such that the synergistic effect of the acetoclastic and hydrogenotrophic methanogenesis pathways was likely strengthened.