High rate manure supernatant digestion

Treatment and utilization of swine wastewater - A review on technologies in full-scale application

The management of swine wastewater has become the focus of attention in the farming industry. The disposal mode of swine wastewater can be classified as field application of treated waste and treatment to meet discharge standards. The status of investigation and application of unit technology in treatment and utilization such as solid-liquid separation, aerobic treatment, anaerobic treatment, digestate utilization, natural treatment, anaerobic-aerobic combined treatment, advanced treatment, are reviewed from the full-scale application perspective. The technologies of anaerobic digestion-land application is most appropriate for small and medium-sized pig farms or large pig farms with enough land around for digestate application. The process of "solid-liquid separation-anaerobic-aerobic-advanced treatment" to meet the discharge standard is most suitable for large and extra-large pig farms without enough land. Poor operation of anaerobic digestion unit in winter, hard to completely utilize liquid digestate and high treatment cost of digested effluent for meeting discharge standard are established as the main difficulties.

Anaerobic Digestion of Pig Slurry in Fixed-Bed and Expanded Granular Sludge Bed Reactors

Anaerobic digestion of animal manure is a potential bioenergy resource that avoids greenhouse gas emissions. However, the conventional approach is to use continuously stirred tank reactors (CSTRs) with hydraulic retention times (HRTs) of greater than 30 d. Reactors with biomass retention were investigated in this study in order to increase the efficiency of the digestion process. Filtered pig slurry was used as a substrate in an expanded granular sludge bed (EGSB) reactor and fixed-bed (FB) reactor. The highest degradation efficiency (ηCOD) and methane yield (MY) relative to the chemical oxygen demand (COD) were observed at the minimum loading rates, with MY = 262 L/kgCOD and ηCOD = 73% for the FB reactor and MY = 292 L/kgCOD and ηCOD = 76% for the EGSB reactor. The highest daily methane production rate (MPR) was observed at the maximum loading rate, with MPR = 3.00 m3/m3/d at HRT = 2 d for the FB reactor and MPR = 2.16 m3/m3/d at HRT = 3 d for the EGSB reactor. For both reactors, a reduction in HRT was possible compared to conventionally driven CSTRs, with the EGSB reactor offering a higher methane yield and production rate at a shorter HRT.

Ammonium and Phosphate Recovery from Biogas Slurry: Multivariate Statistical Analysis Approach

Livestock biogas slurry is an effluent containing nutrients such as ammonium and phosphate that are released by the industries. Therefore, recovery and reuse of ammonium and phosphorus is highly necessary. In recent years, many studies have been devoted to the use of different multivariate statistical analyses to investigate the interrelationship of one factor to another factor. The overall objective of this research study was to understand the significance of phosphate and ammonium recovery from biogas slurry using the multivariate statistical approach. This study was conducted using a range of salts that are commonly found in biogas slurry (ZnCl2, FeCl3, FeCl2, CuCl2, Na2CO3, and NaHCO3). Experiments with a biogas digester and aqueous solution were conducted at pH 9, with integration with NH4+, Mg2+, and PO43− molar ratios of 1.0, 1.2, and 1.8, respectively. The removal efficiency of ammonium and phosphate increased from 15.0% to 71.0% and 18.0% to 99.0%, respectively, by increasing the dose of respective ions K+, Zn2+, Fe3+, Fe2+, Cu2+, and CO32−. The elements were increased from 58.0 to 71.0 for HCO3−, with the concentration increasing from 30 mg L−1 to 240 mg L−1. Principal component, regression, path analysis, and Pearson correlation analyses were used to investigate the relationships of phosphate and ammonium recovery under different biochar, pyrolysis temperature, element concentration and removal efficiencies. Multivariate statistical analysis was also used to comprehensively evaluate the biochar and struvite effects on recovery of ammonium and phosphate from biogas slurry. The results showed that combined study of multivariate statistics suggested that all the indicators positively or negatively affected each other. Pearson correlation was insignificant in many ionic concentrations, as all were more than the significant 0.05. The study concluded that temperature, biochar type, and varying levels of components, such as K+, Zn2+, Fe3+, Fe2+, Cu2+, CO32−, and HCO3−, all had a substantial impact on P and NH4+ recovery. Temperature and varying amounts of metal salts enhanced the efficacy of ammonium and phosphate recovery. This research elucidated the methods by which biochar effectively reuses nitrogen and phosphate from biogas slurry, presenting a long-term agricultural solution.

Techno-Economic Assessment of On-Farm Anaerobic Digestion System Using Attached-Biofilm Reactor in the Dairy Industry

In this study, a techno-economic assessment of an on-farm biogas system using an anaerobic biofilm reactor utilizing cow manure as a fermentation substrate was evaluated. A projection model was developed using Microsoft Excel software with three outputs, the size and dimension of a bioreactor, experimental microbial kinetic studies, and the economic studies based on the experimental results. Characterization analysis of cow manure wastewater showed the total solid (TS), total volatile solid (TVS), total carbohydrate (TC), chemical oxygen demand (COD), and pH values which were 10.95 g/L, 8.65 g/L, 6.65 g/L, 57.80 g/L, and 7, respectively. Using the modified Gompertz equation for the microbial studies, it was found that, at 37 °C and 20 days hydraulic retention time (HRT), the biogas yield was 934.54 mL/gVS, the volume of biogas produced was 11.28 m3/d, and 22.56 kWh of electricity was generated. The Gompertz prediction helps to determine the optimal HRT for the system so that the microorganisms are at their optimum stage to produce biogas. The economic analysis was done, and the results illustrated that, when the rate of cow manure produced was at 55 L/day.cow, the net present value (NPV) was RM 611,936.09, with a 13% internal rate of return (IRR), 0.14 return on investment (ROI), and 7.02 years of payback period (PP). By developing a techno-economic assessment that included all the necessary parameters such as sizing of the bioreactor, microbial kinetic studies, and economics of the plant, farmers could easily implement the system into their farms. This model showed that the anaerobic digestion system utilizing an attached biofilm with cow manure as a fermentation inoculum and substrate was applicable on an industrial scale to generate electricity and reutilize to the farm, at the same time generating additional income from the production of fertilizer.

Thermophilic Methane Production from Hydrothermally Pretreated Norway Spruce (Picea abies)

Norway spruce (Picea abies) is an industrially important softwood species available in northern Europe and can be used to produce bio-methane after proper pretreatment to overcome its recalcitrant complex structure. Hot water extraction (HWE) pretreatment at two different conditions (170 °C for 90 min (severity 4.02) and 140 °C for 300 min (severity 3.65)) was applied to extract hemicellulosic sugars from Norway spruce for thermophilic anaerobic digestion (AD) of the hydrolysate. The methane yield of hydrolysate prepared at the lower pretreatment severity was found to be 189 NmL/gCOD compared to 162 NmL/gCOD after the higher pretreatment severity suggesting higher pretreatment severity hampers the methane yield due to the presence of inhibitors formed due to sugars and lignin degradation and soluble lignin, extracted partially along with hemicellulosic sugars. Synthetic hydrolysates simulating real hydrolysates (H170syn and H140syn) had improved methane yield of 285 NmL/gCOD and 295 NmL/gCOD, respectively in the absence of both the inhibitors and soluble lignin. An effect of organic loadings (OLs) on the methane yield was observed with a negative correlation between OL and methane yield. The maximum methane yield was 290 NmL/gCOD for hydrolysate pretreated at 140 °C compared to 195 NmL/gCOD for hydrolyate pretreated at 170 °C, both at the lowest OL of 6 gCOD/L. Therefore, both pretreatment conditions and OL need to be considered for efficient methane production from extracted hydrolysate. Such substrates can be utilized in continuous flow industrial AD with well-adapted cultures with stable organic loading rates.

Lessons Learned from an Experimental Campaign on Promoting Energy Content of Renewable Biogas by Injecting H2 during Anaerobic Digestion

Direct injection of H2 to an anaerobic reactor enables biological fixation of CO2 into CH4 (biomethanation) and consequently boosts methane content in the produced biogas. However, there has been only a small amount of literature reporting results on this technique in a continuous reactor framework to date. To fill this gap, the present study devoted an experimental work to direct H2 addition to a fed-batch semi-continuous reactor, where the injected H2 concentration increased gradually (~3–30 mmol), spanning a moderate operational period of about 70 days. As the results revealed, the reactor continued anaerobic operation for each level of H2 dosing and produced an average methane content in the biogas ranging between 65% and 72%. The exhibited biogas upgrading trend appeared to be under-developed, and thereby suggests the need for further research.

Phosphorus recovery by ion exchange in a solid carbonate: modeling of the process

Phosphorus (P) is a nutrient for plant growth but also a pollutant in water bodies causing eutrophication. The source of P is mainly human and animal wastewater and runoffs from different land uses. The objective of the present study is to evaluate P removal and recovery processes by ion exchange (IE) with solid carbonate (SC) in biodigestor-treated swine effluent (BTSE) using hydrogeochemical modeling. For this, BTSE compositions were obtained by literature review. A synthetized and characterized SC was used and the ion exchange site concentration ([SC-IE]) and the IE constants (K_ie) were obtained experimentally and applied to model P and major anion removal and recovery processes. P recovery was evaluated for different BTSE compositions and several concentrations of SC, dissolved P (HPO₄^2-), competing anions such as SO₄^2-, and CO₃^2-. The simulations suggest that a [SC-IE]:[HPO₄] of 1.4 molar ratio would allow the recovery of 90% of HPO₄ in BTSE, and at average alkalinity concentrations in BTSE, CO₃^2- would compete with HPO₄ for the SC-IE. The P recovery by the SC-IE process was compared with two other methods commonly used in P removal from BTSE: removal with aluminum sulfate and precipitation of struvite as a function of pH. The results suggest that SC-IE is the most efficient method in the pH range of BTSE. Besides, HPO₄^2- was readily recovered as inorganic P that may be reused in agriculture and industrial processes.

Influences of Temperature and Substrate Particle Content on Granular Sludge Bed Anaerobic Digestion

Influences of temperature (25–35 °C) and substrate particulate content (3.0–9.4 g total suspended solids (TSS)/L) on granular sludge bed anaerobic digestion (AD) were analyzed in lab-scale reactors using manure as a substrate and through modeling. Two particle levels were tested using raw (RF) and centrifuged (CF) swine manure slurries, fed into a 1.3-L lab-scale up-flow anaerobic sludge bed reactor (UASB) at temperatures of 25 °C and 35 °C. Biogas production increased with temperature in both high- and low-particle-content substrates; however, the temperature effect was stronger on high-particle-content substrate. RF and CF produced a comparable amount of biogas at 25 °C, suggesting that biogas at this temperature came mainly from the digestion of small particles and soluble components present in similar quantities in both substrates. At 35 °C, RF showed significantly higher biogas production than CF, which was attributed to increased (temperature-dependent) disintegration of larger solid particulates. Anaerobic Digestion Model No.1 (ADM1) based modeling was carried out by separating particulates into fast and slow disintegrating fractions and introducing temperature-dependent disintegration constants. Simulations gave a better fit for the experimental data than the conventional ADM1 model.

Enhanced anaerobic treatment of swine wastewater with exogenous granular sludge: Performance and mechanism

Anaerobic biotechnology has been widely used to the treatment of swine wastewater, but its organic loading rate is far lower than the expected. In this study, the fatigue effect was observed for indigenous anaerobic sludge (IAS) of anaerobic digestion system treating swine wastewater. On the contrary, the enhancement effect was demonstrated for exogenous granular sludge (EGS) originated from the internal circulation reactor treating pulping wastewater. The results showed the anaerobic digestion of swine wastewater with acclimatized EGS was much better than with IAS, 10th-day COD removal efficiency of 85% and 37% respectively. The better performance of acclimatized EGS was attributed to the more efficient degradation of volatile fatty acids (VFAs) as well as a stronger tolerance to the ammonia inhibition of swine wastewater. Revealed by molecular techniques, the acclimatized EGS contained more abundant syntrophic bacteria and methanogens than IAS. These functional microbes colonized in the acclimatized EGS could overcome the fatigue effect of IAS which contained a similar microbial community to pig gastrointestinal tract microbes. This study provides a feasible and promising way to enhance the efficiency of anaerobic digestion of swine wastewater.

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.

Sludge blanket anaerobic baffled reactor for source-separated blackwater treatment

The performance of a sludge blanket anaerobic baffled reactor was tested as an integrated treatment system for source-separated blackwater. The system consists of a stirred equalization tank, a buffer inlet tank, and two identical reactors, each with a working volume of 16.4 L, operated in parallel. Both reactors run at 3-days hydraulic retention time with different intermittent pulse feeding. Pulse lengths of 12 and 24 seconds per feed were set with respective rates of 114 L h^-1 and 52 L h^-1 for the short-pulse fed reactor (RI) and the long-pulse fed reactor (RII). Stable performance of the reactors was attained after 120 and 90 days, for RI and RII, respectively. After stable conditions attained, total chemical oxygen demand (COD) removal efficiency stabilized above 78%. Biogas production ranged from 0.52 to 1.16 L d^-1 L^-1 reactor volume, with 67-82% methane concentration and an average conversion of 0.69 ± 0.2 and 0.73 ± 0.2 g CH₄-COD g^-1COD_in for RI and RII, respectively. The results imply that source-separated blackwater can be treated effectively in an anaerobic sludge blanket process on average loading rate of 2.3 ± 0.5 g COD d^-1 L^-1 reactor volume with high methane production potential and more than 80% removal of organic and particulate matter.

Mapping anaerobic sludge bed community adaptations to manure supernatant in biogas reactors

In upflow anaerobic sludge bed (UASB) reactors, biomass present as granules allows for long solids retention time. Here, granules from a process treating pulp and paper industrial wastewater were successfully applied as inoculum in UASB reactors treating pig manure supernatant, despite high particle content and high ammonium concentrations in the influent. We did a detailed characterization of archaeal and bacterial communities associated with the inoculum and with the aggregated and dispersed fractions of the influent and the reactors after one year of operation. The granular communities underwent major changes and adapted to the highly distinct conditions without disintegration of the granules. Although the granules persisted in the reactors, non-granular aggregates accumulated, and partly replaced the granules. Particles introduced to the reactors by the pig manure influent apparently contributed both as food and biofilm growth support. Archaeal communities in the dispersed reactor phase were similar to those dispersed in the influents, implying successful retention and little loss of archaeal biomass due to detachment or disintegration of granules and other aggregates. Unique bacterial communities developed in the dispersed fraction of the reactors despite of low hydraulic retention times. They probably consisted of fast growing organisms consuming readily degradable organic matter.

Performance of pilot scale anaerobic biofilm digester (ABD) for the treatment of leachate from a municipal waste transfer station

The anaerobic treatment of leachate from a municipal waste transfer station in Malaysia was tested using a pilot scale anaerobic biofilm digester system that was operated under HRT sequence of 30-day, 25-day, 20-day and 10-day for 163 days under mesophilic conditions. Despite the leachate's complex characteristics, the system showed great performance given its maximum COD, BOD₅ and total phosphorus removal efficiencies of 98 ± 1%, 99 ± 1% and 92 ± 9% respectively. The system was stable throughout its operation and showed optimal average values for the monitored parameters such as pH (7.53 ± 0.14), total VFA (79 ± 66 mg HOAc/L), alkalinity (10,919 ± 1556 mg CaCO₃/L) and a non-toxic value for accumulated ammonia (960 ± 106 mg NH₃-N/L). Measurement of the average daily biogas production yielded a value of 25 ± 1 m³/day throughout the system's operation with a composition of 57 ± 12% methane and 26 ± 6% carbon dioxide.

Anaerobic digestion of pig manure supernatant at high ammonia concentrations characterized by high abundances of Methanosaeta and non-euryarchaeotal archaea

We examined the effect of ammonium and temperature on methane production in high rate upflow anaerobic sludge bed reactors treating pig manure supernatant. We operated four reactors at two ammonium concentrations (‘low’ at 1.9, ‘high’ at 3.7 g L⁻¹, termed LA and HA reactors, respectively) and at variable temperatures over 358 days. Archaeal and bacterial communities were characterized by Illumina sequencing of 16S rRNA amplicons. Ammonium was a major selective factor for bacterial and archaeal community structure. After ~200 days of adaptation to high ammonium levels, acetate and propionate removal and methane production improved substantially in HA reactors. Aceticlastic Methanosaeta was abundant and positively correlated to methane yield in the HA reactors, whereas Methanosarcina was more abundant in LA reactors. Furthermore, a group of monophyletic OTUs that was related to Thaumarchaeota in phylogenetic analysis was highly abundant in the archaeal communities, particularly in the HA reactors. The most abundant bacterial OTU in LA reactors, representing Syntrophomonadaceae, was also positively correlated to methane yield in the HA reactors, indicating its importance in methane production under ammonia stress. In conclusion, efficient methane production, involving aceticlastic methanogenesis by Methanosaeta took place in the reactors at free ammonia concentrations as high as 1 g L⁻¹.

Evaluation of different types of anaerobic seed sludge for the high rate anaerobic digestion of pig slurry in UASB reactors

Three different types of anaerobic sludge (granular, thickened digestate and anaerobic sewage) were evaluated as seed inoculum sources for the high rate anaerobic digestion of pig slurry in UASB reactors. Granular sludge performance was optimal, allowing a high efficiency process yielding a volumetric methane production rate of 4.1LCH₄L^-1d^-1 at 1.5days HRT (0.248LCH₄g^-1COD) at an organic loading rate of 16.4gCODL^-1d^-1. The thickened digestate sludge experimented flotation problems, thus resulting inappropriate for the UASB process. The anaerobic sewage sludge reactor experimented biomass wash-out, but allowed high process efficiency operation at 3days HRT, yielding a volumetric methane production rate of 1.7LCH₄L^-1d^-1 (0.236LCH₄g^-1COD) at an organic loading rate of 7.2gCODL^-1d^-1. To guarantee the success of the UASB process, the settleable solids of the slurry must be previously removed.

Source analysis of organic matter in swine wastewater after anaerobic digestion with EEM-PARAFAC

Swine wastewater is one of the most serious pollution sources, and it has attracted a great public concern in China. Anaerobic digestion technology is extensively used in swine wastewater treatment. However, the anaerobic digestion effluents are difficult to meet the discharge standard. The results from batch experiments showed that plenty of refractory organic matter remained in the effluents after mesophilic anaerobic digestion for 30 days. The effluent total COD (tCOD) and soluble COD (sCOD) were 483 and 324 mg/L, respectively, with the sCOD/tCOD ratio of 0.671. Fluorescence excitation-emission matrix (EEM) coupled with parallel factor analysis (PARAFAC) revealed that the dissolved organic matter in the effluents was tryptophan-like substance, humic acid substance, and fulvic acid substance. Based on the appearance time during anaerobic digestion, tryptophan-like substance and humic acid substance were inferred to originate from the raw swine wastewater, and the fulvic acid substance was inferred to be formed in the anaerobic digestion. This work has revealed the source of residual organic matter in anaerobic digestion of swine wastewater and has provided some valuable information for the post-treatment.

Effect of temperature on continuous dry fermentation of swine manure

Laboratory-scale experiments were performed on the dry digestion of solid swine manure in a semi-continuous mode using 4.5 L down plug-flow anaerobic reactors with an organic loading rate of 3.46 kg volatile solids (VS) m(-3) d(-1) to evaluate the effects of temperature (15, 25 and 35 °C). At 15 °C, biogas production was the poorest due to organic overload and acidification, with a methane yield of 0.036 L CH4 g(-1) VS added and a volumetric methane production rate of 0.125 L CH4 L(-1) d(-1). The methane yield and volumetric methane production rate at 25 °C (0.226 L CH4 g(-1) VS added and 0.783 L CH4 L(-1) d(-1), respectively) were 6.24 times higher than those at 15 °C. However, the methane yield (0.237 L CH4 g(-1) VS added) and the volumetric methane production rate (0.821 L CH4 L(-1) d(-1)) at 35 °C were only 4.86% higher than those at 25 °C, which indicated similar results were obtained at 25 °C and 35 °C. The lower biogas production at 35 °C in dry digestion compared with that in wet digestion could be attributed to ammonia inhibition. For a single pig farm, digestion of solid manure is accomplished in small-scale domestic or small-farm bioreactors, for which operating temperatures of 35 °C are sometimes difficult to achieve. Considering biogas production, ammonia inhibition and net energy recovery, an optimum temperature for dry digestion of solid swine manure is 25 °C.

Influence of solid-liquid separation strategy on biogas yield from a stratified swine production system

As the fourth largest swine producer and exporter, Brazil has increased its participation in the global swine production market. Generally, these units concentrate a large number of animals and generate effluents that must be correctly managed to prevent environmental impacts, being anaerobic digestion is an interesting alternative for treating these effluents. The low-volatile solid concentration in the manure suggests the need for solid-liquid separation as a tool to improve the biogas generation capacity. This study aimed to determine the influence of simplified and inexpensive solid-liquid separation strategies (screening and settling) and the different manures produced during each swine production phase (gestating and farrowing sow houses, nursery houses and finishing houses) on biogas and methane yield. We collected samples in two gestating sow houses (GSH-a and GSH-b), two farrowing sow houses (FSH-a and FSH-b), a nursery house (NH) and a finishing house (FH). Biochemical methane potential (BMP) tests were performed according to international standard procedures. The settled sludge fraction comprised 20-30% of the raw manure volume, which comprises 40-60% of the total methane yield. The methane potential of the settled sludge fraction was approximately two times higher than the methane potential of the supernatant fraction. The biogas yield differed among the raw manures from different swine production phases (GSH-a 326.4 and GSH-b 577.1; FSH-a 860.1 and FSH-b 479.2; NH -970.2; FH 474.5 NmLbiogas.gVS(-1)). The differences were relative to the production phase (feed type and feeding techniques) and the management of the effluent inside the facilities (water management). Brazilian swine production has increased his participation in the global market, been the fourth producer and the fourth exporter. The segregation of swine production in multiple sites has increased its importance, due to the possibilities to have more specialized units. Generally, these units concentrate a large number of animals and generate effluents that must be correctly managed to avoid environmental impact. Due to the biodegradability of manure, anaerobic digestion is an interesting alternative to treat these effluents. The low volatile solid concentration in the swine manure suggests the need for solid-liquid separation as a tool to improve biogas generation capacity. The present study aimed to determine the influence of simplified and cheap solid-liquid separation strategies (based on screening and settling) and different manure of each swine production phases (gestating and farrowing sows houses, nursery houses and finishing houses) on biogas and methane yield. We collected samples in two gestating sows house (GSH-a and GSH-b), two farrowing sows house (FSH-a and FSH-b), a nursery house (NH) and a finishing house (FH). The Biochemical Methane Production (BMP) tests were performed according to international standard procedure (VDI 4630). The settled sludge fraction responds for 20-30% of raw manure volume, producing 40-60% of the total methane yield. The methane potential of settled sludge fraction was about 2 times higher than the supernatant fraction. There are differences on biogas yield between the raw manure of different swine production phases (GSH-a 326.4 and GSH-b 577.1; FSH-a 860.1 and FSH-b 479.2; NH 970.2; FH 474.5 NmLbiogas.gVS(-1)). The differences are relative to production phase (feed type, feeding techniques, etc.), but also the management of the effluent inside the facilities (water management).

Load limit of a UASB fed septic tank-treated domestic wastewater

Performance of a 250 L pilot-scale up-flow anaerobic sludge blanket (UASB) reactor, operated at ambient temperatures, fed septic tank effluents intermittently, was monitored for hydraulic retention time (HRT) from 18 h to 4 h. The total suspended solids (TSS), total chemical oxygen demand (CODT), dissolved chemical oxygen demand (CODdis) and suspended chemical oxygen demand (CODss) removal efficiencies ranged from 20 to 63%, 15 to 56%, 8 to 35% and 22 to 72%, respectively, for the HRT range tested. Above 60% TSS and 47% CODT removal were obtained in the combined septic tank and UASB process. The process established stable UASB treatment at HRT≥6 h, indicating a hydraulic load design limit. The tested septic tank-UASB combined system can be a low-cost and effective on-site sanitation solution.