Recovery of energy and nutrient resources from cattle paunch waste using temperature phased anaerobic digestion

Sustainable valorization of slaughterhouse waste through anaerobic digestion: A circular economy perspective

Slaughterhouse waste (SHW) poses significant environmental challenges due to its complex composition. In response, a novel review exploration of anaerobic digestion (AD) as a means of valorising SHW within the context of the circular economy (CE) is presented. The physicochemical properties of individual SHW, representing key parameters for the correct management of the AD process, are scrutinized. These parameters are further connected with identifying suitable pretreatment methods to enhance biogas production. Subsequently, the review examines the diverse technologies employed in the AD of SHW, considering the complexities of mono- or co-digestion. Various AD systems are evaluated for their effectiveness in harnessing the substantial biogas production potential from SHW, encompassing key parameters, reactor configurations, and operational conditions that influence the AD process. Moreover, the review interestingly extends its scope to the recovery and management of digestate, the by-product of AD. Along with the digestate composition, strategies for various utilization of this by-product are discussed. This investigation thus underscores, within the principles of the CE, the dual sustainable benefits of SHW processing via AD in biogas production and utilization of the resultant nutrient-rich digestate in various sectors.

Understanding nitrogen dynamics in the Brazilian beef industry: A comprehensive decadal analysis

Brazil stands as a prominent beef producer and exporter, witnessing major transformations and expansions in its production chain over the past 20 years. These changes have prompted concerns regarding waste generation and environmental pressure. This study employs material flow analysis (MFA) to quantify nitrogen flows throughout the cattle slaughter process and subsequent beef consumption in Brazil, spanning from 2011 to 2021. The analysis encompasses co-production streams like leather, tallow, viscera, and blood. Nitrogen use efficiency (NUE) and the nitrogen cascade indicator (NCI) were used to evaluate efficiency and nitrogen accumulation in the production chain. Nitrogen inputs in the system increased by 8.47 %, while beef production rose by 7.29 %. In contrast, per capita beef consumption decreased by 1.29 kg, despite an overall consumption increase of 2.84 %, attributed to population growth in Brazil. Beef exports witnessed a notable surge of 86.03 %. Conversely, human excreta and food waste losses experienced increments of 10.88 % and 2.84 %, respectively. Examining NUE reveals the highest values during the slaughter phase (90 %), followed by processing, transportation, and storage stages (79-88 %). The consumption phase exhibited the lowest NUE values (29-34 %). Regarding the cumulative nitrogen effect, the NCI varied between 77 % and 82 % throughout the study period. This highlights opportunities for enhancing nitrogen use efficiency, particularly by addressing food waste at the consumer level. Notably, the study observes nitrogen accumulation across the Brazilian beef production chain, potentially contributing to the nitrogen cascade effect and heightening environmental pressure. Recognizing these dynamics provides avenues for targeted improvements, emphasizing the need to address nitrogen-related challenges and enhance sustainability in the beef production and consumption landscape.

Effect of alkaline pre-treatment on hydrolysis rate and methane production during anaerobic digestion of paunch solid waste

Paunch is comprised of the partially digested feed contained in cattle or sheep and contributes 20-50% of organic waste produced at red meat processing facilities. Anaerobic digestion has been identified as a promising technology for paunch treatment, however treatment times can be long and when combined with the moderate degradability of paunch this results in high treatment costs that need to be improved. Pre-treatment was investigated as a strategy to improve AD of paunch, alkaline treatment (NaOH or KOH) was selected due to the high lignin content. A range of alkaline loadings (1-20 g 100gTS-1) were tested with an equivalent hydroxide molar concentration of 9-250 mM [OH-]. Alkaline pre-treatment improved both the hydrolysis rate and the overall degradability of paunch solid by up to 4.4 times and 60%, respectively. The enhanced hydrolysis rate and methane yield was correlated to changes in material composition during pre-treatment. While alkaline concentration was an important factor, there were no significant improvements at alkaline concentrations above 12 g 100gTS-1 (150 mM [OH-]).

Integration of mesophilic biogas plant in the animal slaughter process under real limitations: Techno-economic evaluation of a colombian bovine slaughterhouse

Anaerobic digestion (AD) has been a widely tested alternative for the management and valorization of wastewater from the animal slaughter process. However, the integration of AD in slaughterhouses depends on technical and economic aspects. In Colombian slaughterhouses AD integration is limited by the availability of land. In the present study, a techno-economic evaluation of the AD of offal wastewater (OWW) stream in a laboratory scale mesophilic tubular digester was carried out. The digester was operated at organic loading rates (OLR) of 0.28, 0.50, 1.0, 1.5 and 2.0 kg VS/m³ d. Boilers and a CHP (combined heat and power) system were considered for energy integration of biogas. For the economic study, the cost structure of a Colombian slaughterhouse was considered. The AD of OWW at 2.0 kg VS/m³ d OLR was unstable with risk of inhibition. Increasing the OLR from 0.28 to 1.5 kg VS/m³ d caused a reduction in the specific biogas production (SBP) from 0.474 to 0.069 m³/kg VS However, the biogas production rate (BPR) remained constant at around 0.105 m³/m³dig d for OLRs > 0.28 kg VSm³ d. Therefore, OWW anaerobic digestion in low-cost mesophilic biogas plants is technically feasible with OLRs between 0.28 and 1.5 kg VS/m³ d. The implementation of boilers is economically favorable for OLR ≥ 1.0 kg VS/m³ d. Nevertheless, feasibility is very sensitive to variations in the cost structure. The implementation of CHP was feasible in the range of OLRs evaluated and its viability is not affected by changes in assumed costs.

Current Progress in Optimising Sustainable Energy Recovery From Cattle Paunch Contents, a Slaughterhouse Waste Product

Paunch contents are the recalcitrant, lignocellulose-rich, partially-digested feed present in the rumen of ruminant animals. Cattle forage in Europe is primarily from perennial and Italian ryegrasses and/or white clover, so paunch contents from forage-fed cattle in Europe is enriched in these feedstuffs. Globally, due to its underutilisation, the potential energy in cattle paunch contents annually represents an energy loss of 23,216,548,750–27,804,250,000 Megajoules (MJ) and financial loss of up to ~€800,000,000. Therefore, this review aims to describe progress made to-date in optimising sustainable energy recovery from paunch contents. Furthermore, analyses to determine the economic feasibility/potential of recovering sustainable energy from paunch contents was carried out. The primary method used to recover sustainable energy from paunch contents to-date has involved biomethane production through anaerobic digestion (AD). The major bottleneck in its utilisation through AD is its recalcitrance, resulting in build-up of fibrous material. Pre-treatments partially degrade the lignocellulose in lignocellulose-rich wastes, reducing their recalcitrance. Enzyme systems could be inexpensive and more environmentally compatible than conventional solvent pre-treatments. A potential source of enzyme systems is the rumen microbiome, whose efficiency in lignocellulose degradation is attracting significant research interest. Therefore, the application of rumen fluid (liquid derived from dewatering of paunch contents) to improve biomethane production from AD of lignocellulosic wastes is included in this review. Analysis of a study where rumen fluid was used to pre-treat paper sludge from a paper mill prior to AD for biomethane production suggested economic feasibility for CHP combustion, with potential savings of ~€11,000 annually. Meta-genomic studies of bacterial/archaeal populations have been carried out to understand their ruminal functions. However, despite their importance in degrading lignocellulose in nature, rumen fungi remain comparatively under-investigated. Further investigation of rumen microbes, their cultivation and their enzyme systems, and the role of rumen fluid in degrading lignocellulosic wastes, could provide efficient pre-treatments and co-digestion strategies to maximise biomethane yield from a range of lignocellulosic wastes. This review describes current progress in optimising sustainable energy recovery from paunch contents, and the potential of rumen fluid as a pre-treatment and co-substrate to recover sustainable energy from lignocellulosic wastes using AD.

Enhancement of Bioreactor Performance Using Acclimatised Seed Sludge in Anaerobic Treatment of Chicken Slaughterhouse Wastewater: Laboratory Achievement, Energy Recovery, and Its Commercial-Scale Potential

Lack of good management practice of chicken slaughterhouse wastewater (CSWW) has caused pollution into water bodies. In this study, the potential of seed sludge acclimatised modified synthetic wastewater (MSWW) on bioreactor performance and energy recovery of CSWW treatment was investigated. Two sets of upflow anaerobic sludge blanket (UASB) reactors were employed. The seed sludge in UASB 2 was acclimatised with MSWW for 30 days. In UASB 1, no acclimatisation process was undertaken on seed sludge for control purposes. After the acclimatisation process of UASB 2, both reactors were supplied with CSWW under the same condition of organic loading rate (OLR = 0.5 to 6 gCOD/L/d) and mesophilic condition (37 °C). COD removal efficiencies of UASB 2 were >80% all through the steady-state of the OLR applied. Meanwhile, a drastic decrease in overall performance was observed in UASB 1 when the OLR was increased to 3, 4, 5, and 6 gCOD/L/d. Energy recovery from laboratory scale and projected value from commercial-scale bioreactor were 0.056 kWh and 790.49 kWh per day, respectively. Preliminary design of an on-site commercial-scale anaerobic reactor was proposed at a capacity of 60 m3.

Wet organic waste treatment via hydrothermal processing: A critical review

There are several recent reviews published in the literature on hydrothermal carbonization, liquefaction and supercritical water gasification of lignocellulosic biomass and algae. The potential of hydrochar, bio-oil or synthesis gas production and applications have also been reviewed individually. The comprehensive review on the hydrothermal treatment of wet wastes (such as municipal solid waste, food waste, sewage sludge, algae) covering carbonization, liquefaction and supercritical water gasification, however, is missing in the literature which formed the basis of the current review paper. The current paper critically reviews the literature around the full spectrum of hydrothermal treatment for wet wastes and establishes a good comparison of the different hydrothermal treatment options for managing wet waste streams. Also, the role of catalysts as well as synthesis of catalysts using hydrothermal treatment of biomass has been critically reviewed. For the first time, efforts have also been made to summarize findings on modelling works as well as techno-economic assessments in the area of hydrothermal treatments of wet wastes. The study concludes with key findings, knowledge gaps and future recommendations to improve the productivity of hydrothermal treatment of wet wastes, helping improve the commercial viability and environmental sustainability.

Simultaneous Synergy in CH4 Yield and Kinetics: Criteria for Selecting the Best Mixtures during Co-Digestion of Wastewater and Manure from a Bovine Slaughterhouse

Usually, slaughterhouse wastewater has been considered as a single substrate whose anaerobic digestion can lead to inhibition problems and low biodegradability. However, the bovine slaughter process generates different wastewater streams with particular physicochemical characteristics: slaughter wastewater (SWW), offal wastewater (OWW) and paunch wastewater (PWW). Therefore, this research aims to assess the anaerobic co-digestion (AcoD) of SWW, OWW, PWW and bovine manure (BM) through biochemical methane potential tests in order to reduce inhibition risk and increase biodegradability. A model-based methodology was developed to assess the synergistic effects considering CH4 yield and kinetics simultaneously. The AcoD of PWW and BM with OWW and SWW enhanced the extent of degradation (0.64–0.77) above both PWW (0.34) and BM (0.46) mono-digestion. SWW Mono-digestion showed inhibition risk by NH3, which was reduced by AcoD with PWW and OWW. The combination of low CH4 potential streams (PWW and BM) with high potential streams (OWW and SWW) presented stronger synergistic effects than BM-PWW and SWW-OWW mixtures. Likewise, the multicomponent mixtures performed overall better than binary mixtures. Furthermore, the methodology developed allowed to select the best mixtures, which also demonstrated energy and economic advantages compared to mono-digestions.

Bio-reserves inventory-improving substrate management for anaerobic waste treatment in a fast-growing Indian urban city, Chennai

India is one among the Asia's newly industrialized countries, in which urban centres generate large amount of municipal solid wastes due to the rapid urbanization. To demonstrate urban waste potentials for biogas production by anaerobic digestion, a comprehensive analysis on the availability of organic waste hotspots and its biogas potential for the exemplary case of Chennai, India, was undertaken. The identified hotspots and their biogas potential were plotted with Geographical Information System as thematic maps. The results of biogas potential tests revealed strong variations in the biogas potentials of individual waste streams from 240.2 to 514.2 mL_N/g oDM (organic dry matter) with oDM reduction in the range of 36.4-61.5 wt.-%. Major waste generation hotspots were identified from the surveyed urban bio-reserves and the biogas potentials within an effective area of 5 km radius surrounding the hotspot were estimated. It was found that the biogas potential of individual hotspots ranged between 38.0-5938.7 m³/day. Further results revealed that the biogas potential during anaerobic co-digestion, by considering nearby bio-reserves in the effective areas of major hotspots, with and without residential organic waste, ranged between 4110.4-18-106.1 m³/day and 253.2-5969.5 m³/day, originating from 144.0-620.0 tons and 3.1-170.5 tons, respectively. Despite variations in the composition of the wastes, the Carbon/Nitrogen ratio, oDM reduction, biogas production and substrate availability were improved during co-digestion of nearby bio-reserves within the major hotspots, thereby improving the prevailing barriers in substrate management during anaerobic digestion of wastes.

A Comparative Study of Biogas Production from Cattle Slaughterhouse Wastewater Using Conventional and Modified Upflow Anaerobic Sludge Blanket (UASB) Reactors

Cattle slaughterhouses generate wastewater that is rich in organic contaminant and nutrients, which is considered as high strength wastewater with a high potential for energy recovery. Work was undertaken to evaluate the efficiency of the 12 L laboratory scale conventional and a modified upflow anaerobic sludge blanket (UASB) reactors (conventional, R1 and modified, R2), for treatment of cattle slaughterhouse wastewater (CSWW) under mesophilic condition (35 ± 1 °C). Both reactors were acclimated with synthetic wastewater for 30 days, then continuous study with real CSWW proceeds. The reactors were subjected to the same loading condition of OLR, starting from 1.75, 3, 5 10, 14, and 16 g L-1d-1, corresponding to 3.5, 6, 10, 20, 28, and 32 g COD/L at constant hydraulic retention time (HRT) of 24 h. The performance of the R1 reactor drastically dropped at OLR 10 g L-1d-1, and this significantly affected the subsequent stages. The steady-state performance of the R2 reactor under the same loading condition as the R1 reactor revealed a high COD removal efficiency of 94% and biogas and methane productions were 27 L/d and 89%. The SMP was 0.21 LCH4/gCOD added, whereas the NH3-N alkalinity ratio stood at 651 mg/L and 0.2. SEM showed that the R2 reactor was dominated by Methanosarcina bacterial species, while the R1 reactor revealed a disturb sludge with insufficient microbial biomass.

Enhancing hyper-thermophilic hydrolysis pre-treatment of chicken manure for biogas production by in-situ gas phase ammonia stripping

Hydrolysis is normally the rate limiting step for anaerobic digestion (AD). In this study, hyper-thermophilic (70 °C) pre-treatment of chicken manure under HRTs of 10, 5, 3, 2 and 1 d(s) was investigated to enhance the hydrolysis efficiency for biogas production. In-situ phase gas stripping was integrated into the pre-treatment reactor to remove ammonia-N and to enhance the hydrolysis performance. The results showed that in-situ gas stripping removed 18%-31% of ammonia-N and improved hydrolysis by 2.6%-31.1%. The methane yield of pre-hydrolyzed chicken manure reached 518 mL g-VS^-1 under optimal HRT 3 days, which was 54.6% higher than that obtained from the control reactor. However, shortening HRTs below 3 days resulted in a significant reduction in hydrolysis efficiency. The percent of hydrolysis and acidogenesis bacteria reduced to 40.6% at HRT 1 d. 16sRNA results indicated existence of methanogens in pre-hydrolysis reactor. Further optimizing of ammonia stripping was thus needed for hydrolysis pre-treatment.

Biogas Production and Fundamental Mass Transfer Mechanism in Anaerobic Granular Sludge

Anaerobic granules are responsible for organic degradation and biogas production in a reactor. The biogas production is entirely dependent on a mass transfer mechanism, but so far, the fundamental understanding remains poor due to the covered surface of the reactor. The study aimed at investigating the fundamental mass transfer characteristics of single anaerobic granules of different sizes using microscopic imaging and analytical monitoring under single and different organic loadings. The experiment was conducted in a micro reactor and mass transfer was calculated using modified Fick’s law. Scanning electron microscopy was applied to observe biogas production zones in the granule, and a lab-scale microscope equipped with a camera revealed the biogas bubble detachment process in the micro reactor for the first time. In this experiment, the granule size was 1.32, 1.47, and 1.75 mm, but 1.75 mm granules were chosen for further investigation due to their large size. The results revealed that biogas production rates for 1.75 mm granules at initial Chemical Oxygen Demand (COD) 586, 1700, and 6700 mg/L were 0.0108, 0.0236, and 0.1007 m3/kg COD, respectively; whereas the mass transfer rates were calculated as 1.83 × 10−12, 5.30 × 10−12, and 2.08 × 10−11 mg/s. It was concluded that higher organic loading and large granules enhance the mass transfer inside the reactor. Thus, large granules should be preferred in the granule-based reactor to enhance biogas production.

Effect of Organic Loading Rate on Anaerobic Digestion Performance of Mesophilic (UASB) Reactor Using Cattle Slaughterhouse Wastewater as Substrate

In this study, the performance of a laboratory scale upflow anaerobic sludge blanket (UASB) reactor operating at mesophilic temperature (35 °C) was examined. Cattle slaughterhouse wastewater (CSWW) was used as the main substrate. The total and effective volumes of the reactor were 8 L and 6 L, respectively. Twelve different organic loading rates (OLR) were applied and the performance was evaluated. The chemical oxygen demand (COD) removal efficiency was more than 90% during batch study. In the continuous study, COD removal was also approximately 90% at OLR 0.4 g/L d⁻¹ which subsequently dropped to below 50% when the loading rate increased to 15 g/L d⁻¹. Approximately 5 L/d of biogas was obtained with high methane concentration at stages VI and XI corresponding to OLR of 2 and 10 g/L d⁻¹, respectively. It was observed that the concentration of volatile fatty acids was low and that the alkalinity of the wastewater was sufficient to avoid acidification. Specific methane yields of 0.36 and 0.38 LCH₄/g COD added were achieved at OLR 7 and 10 g/L d⁻¹. A hydraulic retention time (HRT) of 1 day was sufficient to remove greater than 70% of COD which correspond to 89% methane concentration. Parameters like soluble COD, NH₃-N, pH, alkalinity, total suspended solid (TSS), fats, oil, and grease were also investigated. The results show that the UASB reactor could serve as a good alternative for anaerobic treatment of CSWW and methane production.

Biochemical methane potential (BMP) tests: Reducing test time by early parameter estimation

Biochemical methane potential (BMP) test is a key analytical technique to assess the implementation and optimisation of anaerobic biotechnologies. However, this technique is characterised by long testing times (from 20 to >100days), which is not suitable for waste utilities, consulting companies or plants operators whose decision-making processes cannot be held for such a long time. This study develops a statistically robust mathematical strategy using sensitivity functions for early prediction of BMP first-order model parameters, i.e. methane yield (B₀) and kinetic constant rate (k). The minimum testing time for early parameter estimation showed a potential correlation with the k value, where (i) slowly biodegradable substrates (k≤0.1d^-1) have a minimum testing times of ≥15days, (ii) moderately biodegradable substrates (0.1<k<0.2d^-1) have a minimum testing times between 8 and 15 days, and (iii) rapidly biodegradable substrates (k≥0.2d^-1) have testing times lower than 7days.

Effect of bacterial lipase on anaerobic co-digestion of slaughterhouse wastewater and grease in batch condition and continuous fixed-bed reactor

Background

This study aimed to investigate the effects of bacterial lipase on biogas production of anaerobic co-digestion of slaughterhouse wastewater (SHWW) and hydrolyzed grease (HG). A neutrophilic Staphylococcus xylosus strain exhibiting lipolytic activity was used to perform microbial hydrolysis pretreatment of poultry slaughterhouse lipid rich waste.

Results

Optimum proportion of hydrolyzed grease was evaluated by determining biochemical methane potential. A high biogas production was observed in batch containing a mixture of slaughterhouse composed of 75% SHWW and 25% hydrolyzed grease leading to a biogas yield of 0.6 L/g COD introduced.

Fixed bed reactor (FBR) results confirmed that the proportion of 25% of hydrolyzed grease gives the optimum condition for the digester performance. Biogas production was significantly high until an organic loading rate (OLR) of 2 g COD/L. d.

Conclusion

This study indicates that the use of biological pre-treatment and FBR for the co-digestion of SHWW and hydrolyzed grease is feasible and effective.

Waste management in the meat processing industry: Conversion of paunch and DAF sludge into solid fuel

This article addresses the novel dewatering process of immersion-frying of paunch and dissolved air flotation (DAF) sludge to produce high energy pellets. Literature have been analysed to address the feasibility of replacing conventional boiler fuel at meat processing facilities with high energy paunch-DAF sludge pellets (capsules). The value proposition of pelleting and frying this mixture into energy pellets is based on a Cost-Benefit Analysis (CBA). The CBA is based on information derived from the literature and consultation with the Australian Meat Processing Industry. The calorific properties of a mixture of paunch cake solids and DAF sludge were predicted from literature and industry consultation to validate the product. This study shows that the concept of pelletizing and frying paunch is economically feasible. The complete frying and dewatering of the paunch and DAF sludge mixture produces pellets with energy content per kilogram equivalent to coal. The estimated cost of this new product is half the price of coal and the payback period is estimated to be between 1.8 and 3.2years. Further research is required for proof of concept, and to identify the technical challenges associated with integrating this technology into existing meat processing plants.

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.