Comparison of operating strategies for increased biogas production from thin stillage

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.

Valorisation of bioethanol production residues through anaerobic digestion: Methane production and microbial communities

The organic fraction of municipal solid waste (OFMSW) is an appealing feedstock for bioethanol production due to its richness in cellulosic materials. After fermentation and distillation, the remaining residue constitutes a source of unconsumed carbohydrates, proteins and lipids. These macromolecules can be further used via anaerobic digestion (AD) for bioenergy purposes to offset bioethanol production costs. The present study evaluated the methanogenic potential of the whole fermented residue from a selective collection of OFMSW in a semicontinuous AD at 35 °C (HRT 40 days and OLR 2.09 g VS/Ld). The experimental results showed a methanogenic yield of 212 ± 5 mL CH₄/g VS_in (corresponding to a COD removal of 47 ± 1 %). Microbial analysis revealed key roles of species belonging to Firmicutes (65 %), Bacteroidetes (25 %) and Euryarchaeota (0.5-1 %). Methanosarcina archaea was highlighted as a robust methanogen crucial for methane production in a process in which the stability might be compromised by potential NH₄⁺-N and VFAs inhibitions. This study indicated that the sequential combination of these two biochemical processes (fermentation and anaerobic digestion) allow to further exploit organic residues for their conversion into a marketable bioenergy product.

Effects of thermal hydrolytic pre-treatment on biogas process efficiency and microbial community structure in industrial- and laboratory-scale digesters

This study examined the impact of thermal hydrolysis process (THP) pre-treatment on anaerobic co-digestion of wastewater sludge and household waste and assessed whether THP was vital to achieve higher process capacity. Performance data were collected for both industrial- and laboratory-scale digesters and response in microbial community structure was evaluated by Illumina sequencing. Implementation of THP at the industrial-scale plant increased methane yield by 15% and enhanced substrate degradability. Possibility to extend the sludge retention time due to a higher solid content of the substrate, sanitisation of the digestate and improved fertiliser quality of the digestate were other industrial-scale benefits of THP installation. Continuously-fed laboratory-scale digesters were fed THP-treated or untreated substrate at an organic loading rate (OLR) of 5 g volatile solid (VS)/L/day, a feeding rate necessary at the corresponding industrial-scale plant to meet the estimated population increase within the municipality. The results indicated that the plant could have increased the capacity with unimpaired stability independently of THP installation, even though the retention time was significantly shortened during operation with untreated substrate. Microbial community analyses revealed increased contribution of the Clostridia class after THP installation in industrial-scale digesters and positive correlation between Firmicutes:Bacteriodetes and methane yield in all digesters. Differentiated profiles in laboratory-scale digesters indicated that a temperature increase from 37 to 42 °C in association with THP installation and altered substrate composition were strong determining factors shaping the microbial community. Overall, these findings can assist industrial-scale plants in choosing management strategies aimed at improving the efficiency of anaerobic digestion processes.

Growth Characteristics and Thermodynamics of Syntrophic Acetate Oxidizers

Syntrophic acetate oxidation (SAO) plays a pivotal role in biogas production processes when aceticlastic methanogens are inhibited. Despite the importance of SAO, the metabolic interactions and syntrophic growth of the organisms involved are still poorly understood. Therefore, we studied growth parameters and interactions within constructed defined cocultures comprising the methanogen Methanoculleus bourgensis and one, or several, of the syntrophic acetate oxidizers Syntrophaceticus schinkii, [ Clostridium] ultunense, and Tepidanaerobacter acetatoxydans and a novel, uncharacterized bacterium. Cultivation experiments in a design-of-experiment approach revealed positive effects on methane production rate of increased ammonium levels (up to 0.2 M), temperature (up to 45 °C), and acetate concentrations (0.15-0.30 M). Molecular analyses and thermodynamic calculations demonstrated close interlinkages between the microorganisms, with available energies of -10 kJ/mol for acetate oxidation and -20 kJ/mol for hydrogenotrophic methanogenesis. The estimated generation time varied between 3 and 20 days for all syntrophic microorganisms involved, and the acetate minimum threshold level was 0.40-0.45 mM. The rate of methanogenesis depended on the SAO bacteria present in the culture. These data are beneficial for interpretation of SAO prevalence and competiveness against aceticlastic methanogens in anaerobic environments.

Biorefining of rice straw by sequential fermentation and anaerobic digestion for bioethanol and/or biomethane production: Comparison of structural properties and energy output

Three routes; namely R1 representing direct anaerobic digestion (AD), R2 representing enzymatic hydrolysis followed by fermentation, distillation, then AD, and R3 representing AD of fermentation broth without distillation; of alkali pretreated rice straw were investigated. Results showed that sequential fermentation and AD effectively enhanced fibers degradation with significant changes in the composition. Fermentation through R2 resulted in ethanol yield of 87.4 g kg^-1 dry straw. Maximum biogas yields of 286.9, 233.3 and 372.4 L kg^-1 VS were recorded by AD for R1, R2 and R3 after reaching the steady state at 36, 24 and 33 days, respectively. However, biogas produced through R3 showed the highest significant biomethane content (79.3%) which represented 15 and 8% higher than that of R1 and R2, respectively. Therefore, the highest bioenergy output and energy conversion efficiency of 10.58 GJ ton^-1 and 75.6%, respectively, were obtained through R3 demonstrating the positive effect of fermentation prior to AD.

Detection of novel syntrophic acetate-oxidizing bacteria from biogas processes by continuous acetate enrichment approaches

To enrich syntrophic acetate‐oxidizing bacteria (SAOB), duplicate chemostats were inoculated with sludge from syntrophic acetate oxidation (SAO)‐dominated systems and continuously supplied with acetate (0.4 or 7.5 g l⁻¹) at high‐ammonia levels. The chemostats were operated under mesophilic (37°C) or thermophilic (52°C) temperature for about six hydraulic retention times (HRT 28 days) and were sampled over time. Irrespective of temperature, a methane content of 64–69% and effluent acetate level of 0.4–1.0 g l⁻¹ were recorded in chemostats fed high acetate. Low methane production in the low‐acetate chemostats indicated that the substrate supply was below the threshold for methanization of acetate via SAO. Novel representatives within the family Clostridiales and genus Syntrophaceticus (class Clostridia) were identified to represent putative SAOB candidates in mesophilic and thermophilic conditions respectively. Known SAOB persisted at low relative abundance in all chemostats. The hydrogenotrophic methanogens Methanoculleus bourgensis (mesophilic) and Methanothermobacter thermautotrophicus (thermophilic) dominated archaeal communities in the high‐acetate chemostats. In line with the restricted methane production in the low‐acetate chemostats, methanogens persisted at considerably lower abundance in these chemostats. These findings strongly indicate involvement in SAO and tolerance to high ammonia levels of the species identified here, and have implications for understanding community function in stressed anaerobic processes.

The effect of different mesophilic temperatures during anaerobic digestion of sludge on the overall performance of a WWTP in Sweden

This project was initiated to evaluate the effect of alternative process temperatures to 38 °C at the anaerobic digestion step in a Swedish wastewater treatment plant (WWTP) treating mixed sludge. The efficiency of the different temperatures was evaluated with respect to biogas production, volume of sludge produced and nutrient content in the reject water to find the optimum temperature for the WWTP as a whole. Three temperatures, 34 °C, 38 °C and 42 °C, were compared in laboratory scale. Increasing the process temperature to 42 °C resulted in process instability, reduced methane yield, accumulation of volatile fatty acids and higher treatment costs of the reject water. By decreasing the temperature to 34 °C, slightly higher sludge mass was observed and a lower gas production rate, while the specific methane produced remained unchanged compared to 38 °C but foaming was observed at several occasions. In summary 38 °C was proved to be the most favourable temperature for the anaerobic digestion process treating mixed sludge when the evaluation included effects such as foaming, sludge mass and quality of the reject water.

Comparison of anaerobic digestion strategies of nitrogen-rich substrates: Performance of anaerobic reactors and microbial community diversity

In the present study, the application of different operating strategies on performance of three continuous stirred tank reactors digesting chicken manure at mesophilic temperature and constant organic loading rate (OLR) of 3.5g_VSL^-1d^-1 was investigated. Control reactor (RC) and reactor (RH) with the decreasing hydraulic retention time (HRT) had the comparable specific biogas production (SBP) with maximum values of 334-351mLg^-1_{VS (added)} during days 84-93, while the SBP from reactor with zeolites (RZ) was higher and achieved 426-432mLg^-1_{VS (added)}. Attachments of microorganisms to zeolite particles as the operational environment, exchanged cations released from zeolites as well as lower total ammonium nitrogen (TAN) levels observed in RZ (6.2-6.3gL^-1; days 71-93) compared to RC (6.6-6.9gL^-1; days 71-93) resulted in a more effective process in RZ. Moreover, microbial community structure and dynamics were comprehensively characterized using Illumina sequencing, pyrosequencing and T-RFLP analysis of 16SrRNA genes. Methanogenic archaeal activity was additionally assessed by the expressed mcrA genes encoding the alpha subunit of methyl-CoM reductase. Within the major class Clostridia, Caldicoprobacter, Alkaliphilus, Gallicola, Sporanaerobacter and Tepidimicrobium spp. were the notable bacteria developed during operation of all tested reactors. Archaeal communities were dominated by methanogens belonging to the genus Methanosarcina followed by the genus Methanoculleus during the experimental period. Results of this study indicate that attachment of microorganisms to the zeolite particles as the operational environment might have led to the higher microbial activity at high ammonia concentrations.

Reduction of the hydraulic retention time at constant high organic loading rate to reach the microbial limits of anaerobic digestion in various reactor systems

The effects of hydraulic retention time (HRT) reduction at constant high organic loading rate on the activity of hydrogen-producing bacteria and methanogens were investigated in reactors digesting thin stillage. Stable isotope fingerprinting was additionally applied to assess methanogenic pathways. Based on hydA gene transcripts, Clostridiales was the most active hydrogen-producing order in continuous stirred tank reactor (CSTR), fixed-bed reactor (FBR) and anaerobic sequencing batch reactor (ASBR), but shorter HRT stimulated the activity of Spirochaetales. Further decreasing HRT diminished Spirochaetales activity in systems with biomass retention. Based on mcrA gene transcripts, Methanoculleus and Methanosarcina were the predominantly active in CSTR and ASBR, whereas Methanosaeta and Methanospirillum activity was more significant in stably performing FBR. Isotope values indicated the predominance of aceticlastic pathway in FBR. Interestingly, an increased activity of Methanosaeta was observed during shortening HRT in CSTR and ASBR despite high organic acids concentrations, what was supported by stable isotope data.

Ammonia threshold for inhibition of anaerobic digestion of thin stillage and the importance of organic loading rate

Biogas production from nitrogen-rich feedstock results in release of ammonia (NH3), causing inhibition of the microbial process. The reported threshold ammonia value for stable biogas production varies greatly between studies, probably because of differences in operating conditions. Moreover, it is often difficult to separate the effect of ammonia inhibition from that of organic loading rate (OLR), as these two factors are often interrelated. This study attempted to distinguish the effects of ammonia and OLR by analysis of two laboratory-scale biogas reactors operating with thin stillage and subjected to an increase in free ammonia (from 0.30 to 1.1 g L(-1)) either by addition of an external nitrogen source (urea) or by increasing the OLR (3.2-6.0 g volatile solids L(-1) d(-1)). The results showed that ammonia concentration was detrimental for process performance, with the threshold for stability in both processes identified as being about 1 g NH3-N L(-1), irrespective of OLR. Analysis of the methanogenic community showed limited differences between the two reactors on order level and a clear increase in the abundance of Methanomicrobiales, particularly Methanoculleus sp., in response to increasing ammonia concentration. Further comprehensive molecular analysis revealed that diverse Methanoculleus species dominated in the reactors at a given ammonia level at different OLR. The acetogenic community was clearly affected by both ammonia concentration and OLR, suggesting that the volatile fatty acid load in relation to the higher OLR was important for the dynamics of this community.

Effects of trace element addition on process stability during anaerobic co-digestion of OFMSW and slaughterhouse waste

This study used semi-continuous laboratory scale biogas reactors to simulate the effects of trace-element addition in different combinations, while degrading the organic fraction of municipal solid waste and slaughterhouse waste. The results show that the combined addition of Fe, Co and Ni was superior to the addition of only Fe, Fe and Co or Fe and Ni. However, the addition of only Fe resulted in a more stable process than the combined addition of Fe and Co, perhaps indicating a too efficient acidogenesis and/or homoacetogenesis in relation to a Ni-deprived methanogenic population. The results were observed in terms of higher biogas production (+9%), biogas production rates (+35%) and reduced VFA concentration for combined addition compared to only Fe and Ni. The higher stability was supported by observations of differences in viscosity, intraday VFA- and biogas kinetics as well as by the 16S rRNA gene and 16S rRNA of the methanogens.

Biogas process parameters--energetics and kinetics of secondary fermentations in methanogenic biomass degradation

Pool sizes of short-chain fatty acids (formate, acetate, propionate, and butyrate), hydrogen, and carbon monoxide were assayed in digesting sludge from four different methanogenic reactors degrading either sewage sludge or agricultural products and wastes at pH 8.0 and 40 or 47 °C. Free reaction energies were calculated for the respective degradation reactions involved, indicating that acetate, propionate, and butyrate degradation all supplied sufficient energy (-10 to -30 kJ per mol reaction) to sustain the microbial communities involved in the respective processes. Pools of formate and hydrogen were energetically equivalent as electron carriers. In the sewage sludge reactor, homoacetogenic acetate formation from H2 and CO2 was energetically feasible whereas syntrophic acetate oxidation appeared to be possible in two biogas reactors, one operating at enhanced ammonia content (4.5 g NH4 (+)-N per l) and the other one at enhanced temperature (47 °C). Maximum capacities for production of methanogenic substrates did not exceed the consumption capacities by hydrogenotrophic and aceticlastic methanogens. Nonetheless, the capacity for acetate degradation appeared to be a limiting factor especially in the reactor operating at enhanced ammonia concentration.

Trace element and temperature effects on microbial communities and links to biogas digester performance at high ammonia levels

BACKGROUND

High levels of ammonia and the presence of sulphide have major impacts on microbial communities and are known to cause operating problems in anaerobic degradation of protein-rich material. Operating strategies that can improve process performance in such conditions have been reported. The microbiological impacts of these are not fully understood, but their determination could help identify important factors for balanced, efficient operation. This study investigated the correlations between microbial community structure, operating parameters and digester performance in high-ammonia conditions.

METHOD

Continuous anaerobic co-digestion of household waste and albumin was carried out in laboratory-scale digesters at high ammonia concentrations (0.5-0.9 g NH3/L). The digesters operated for 320 days at 37 or 42 °C, with or without addition of a trace element mixture including iron (TE). Abundance and composition of syntrophic acetate-oxidising bacteria (SAOB) and of methanogenic and acetogenic communities were investigated throughout the study using 16S rRNA and functional gene-based molecular methods.

RESULTS

Syntrophic acetate oxidation dominated methane formation in all digesters, where a substantial enhancement in digester performance and influence on microbial community by addition of TE was shown dependent on temperature. At 37 °C, TE addition supported dominance and strain richness of Methanoculleus bourgensis and altered the acetogenic community, whereas the same supplementation at 42 °C had a low impact on microbial community structure. Both with and without TE addition operation at 42 °C instead of 37 °C had low impact on digester performance, but considerably restricted acetogenic and methanogenic community structure, evenness and richness. The abundance of known SAOB was higher in digesters without TE addition and in digesters operating at 42 °C. No synergistic effect on digester performance or microbial community structure was observed on combining increased temperature with TE addition.

CONCLUSIONS

Our identification of prominent populations related to enhanced performance within methanogenic (high dominance and richness of M. bourgensis) and acetogenic communities are valuable for continued research and engineering to improve methane production in high-ammonia conditions. We also show that a temperature increase of only 5 °C within the mesophilic range results in an extreme dominance of one or a few species within these communities, independent of TE addition. Furthermore, functional stable operation was possible despite low microbial temporal dynamics, evenness and richness at the higher temperature.