Biological hydrogen methanation systems - an overview of design and efficiency

An overview of biomethanation and the use of membrane technologies as a candidate to overcome H2 mass transfer limitations

Energy produced from renewable sources such as sun or wind are intermittent, depending on circumstantial factors. This fact explains why energy supply and demand do not match. In this context, the interest in biomethanation has increased as an interesting contribution to the Power-to-gas concept (P2G), transforming the extra amount of produced electricity into methane (CH4). The reaction between green hydrogen (H2) (produced by electrolysis) and CO2 (pollutant present in biogas) can be catalysed by different microorganisms to produce biomethane, that can be injected into existing natural gas grid if reaching the standards. Thus, energy storage for both hydrogen and electricity, as well as transportation problems would be solved. However, H2 diffusion to the liquid phase for its further biological conversion is the main bottleneck due to the low solubility of H2. This review includes the state-of-the-art in biological hydrogenotrophic methanation (BHM) and membrane-based technologies. Specifically, the use of hollow-fiber membrane bioreactors as a technology to overcome H2 diffusion limitations is reviewed. Furthermore, the influence of operating conditions, microbiology, H2 diffusion and H2 injection methods are critically discussed before setting the main recommendations about BHM.

Improved biological methanation using tubular foam-bed reactor

BACKGROUND

Power-to-gas is the pivotal link between electricity and gas infrastructure, enabling the broader integration of renewable energy. Yet, enhancements are necessary for its full potential. In the biomethanation process, transferring H2 into the liquid phase is a rate-limiting step. To address this, we developed a novel tubular foam-bed reactor (TFBR) and investigated its performance at laboratory scale.

RESULTS

A non-ionic polymeric surfactant (Pluronic® F-68) at 1.5% w/v was added to the TFBR's culture medium to generate a stabilized liquid foam structure. This increased both the gas-liquid surface area and the bubble retention time. Within the tubing, cells predominantly traveled evenly suspended in the liquid phase or were entrapped in the thin liquid film of bubbles flowing inside the tube. Phase (I) of the experiment focused primarily on mesophilic (40 °C) operation of the tubular reactor, followed by phase (II), when Pluronic® F-68 was added. In phase (II), the TFBR exhibited 6.5-fold increase in biomethane production rate (MPR) to 15.1 ( L CH 4 /L R /d) , with a CH4 concentration exceeding 90% (grid quality), suggesting improved H2 transfer. Transitioning to phase (III) with continuous operation at 55 °C, the MPR reached 29.7L CH 4 /L R /d while maintaining the grid quality CH4. Despite, reduced gas-liquid solubility and gas-liquid mass transfer at higher temperatures, the twofold increase in MPR compared to phase (II) might be attributed to other factors, i.e., higher metabolic activity of the methanogenic archaea. To assess process robustness for phase (II) conditions, a partial H2 feeding regime (12 h 100% and 12 h 10% of the nominal feeding rate) was implemented. Results demonstrated a resilient MPR of approximately 14.8L CH 4 /L R /d even with intermittent, low H2 concentration.

CONCLUSIONS

Overall, the TFBR's performance plant sets the course for an accelerated introduction of biomethanation technology for the storage of volatile renewable energy. Robust process performance, even under H2 starvation, underscores its reliability. Further steps towards an optimum operation regime and scale-up should be initiated. Additionally, the use of TFBR systems should be considered for biotechnological processes in which gas-liquid mass transfer is a limiting factor for achieving higher reaction rates.

Investigating the activity of indigenous microbial communities from Italian depleted gas reservoirs and their possible impact on underground hydrogen storage

H2 produced from renewable energies will play a central role in both greenhouse gas reduction and decarbonization by 2050. Nonetheless, to improve H2 diffusion and utilization as a fuel, large storage capacity systems are needed. Underground storage of natural gas in depleted reservoirs, aquifers and salt caverns is a well-established technology. However, new challenges arise when it comes to storing hydrogen due to the occurrence and activity of indigenous microbial populations in deep geological formations. In a previous study, four Italian natural gas reservoirs were characterized both from a hydro-chemical and microbiological point of view, and predictive functional analyses were carried out with the perspective of underground hydrogen storage (UHS). In the present work, formation waters from the same reservoirs were used as inoculant during batch cultivation tests to characterize microbial activity and its effects on different gas mixtures. Results evidence a predominant acidogenic/acetogenic activity, whilst methanogenic and sulfate reducing activity were only marginal for all tested inoculants. Furthermore, the microbial activation of tested samples is strongly influenced by nutrient availability. Obtained results were fitted and screened in a computational model which would allow deep insights in the study of microbial activity in the context of UHS.

Absolute Sustainability Assessment of Flue Gas Valorization to Ammonia and Synthetic Natural Gas

Carbon capture and utilization has gained attention to potentially curb CO2 emissions while generating valuable chemicals. These technologies will coexist with fossil analogs, creating synergies to leverage circular economy principles. In this context, flue gas valorization from power plants can assist in the transition. Here, we assessed the absolute sustainability of a simulated integrated facility producing ammonia and synthetic natural gas from flue gas from a combined-cycle natural gas power plant based in Germany, using hydrogen from three water electrolysis technologies (proton exchange membrane, alkaline, and solid oxide cells), nitrogen, and CO2. For the first time, we applied the planetary boundaries (PBs) framework to a circular integrated system, evaluating its performance relative to the safe operating space. The PB-LCA assessment showed that the alternative technologies could significantly reduce, among others, the impact on climate change and biosphere integrity when compared to their fossil counterparts, which could be deemed unsustainable in climate change. Nevertheless, these alternative technologies could also lead to burden shifting and are not yet economically viable. Overall, the investigated process could smoothen the transition toward low-carbon technologies, but its potential collateral damages should be carefully considered. Furthermore, the application of the PBs provides an appealing framework to quantify the absolute sustainability level of integrated circular systems.

Ex-situ biomethanation for CO2 valorization: State of the art, recent advances, challenges, and future prospective

Ex-situ biomethanation is an emerging technology that facilitates the use of surplus renewable electricity and valorizes carbon dioxide (CO2) for biomethane production by hydrogenotrophic methanogens. This review offers an up-to-date overview of the current state of ex-situ biomethanation and thoroughly analyzes key operational parameters affecting hydrogen (H2) gas-liquid mass transfer and biomethanation performance, along with an in-depth discussion of the technical challenges. To the best of our knowledge, this is the first review article to discuss microbial community structure in liquid and biofilm phases and their responses after exposure to H2 starvation during ex-situ biomethanation. In addition, future research in areas such as reactor configuration and optimization of operational parameters for improving the H2 mass transfer rate, inhibiting opportunistic homoacetogens, integration of membrane technology, and use of conductive packing material is recommended to overcome challenges and improve the efficiency of ex-situ biomethanation. Furthermore, this review presents a techno-economic analysis for the future development and facilitation of industrial implementation. The insights presented in this review will offer useful information to identify state-of-the-art research trends and realize the full potential of this emerging technology for CO2 utilization and biomethane production.

An integrated systems biology approach reveals differences in formate metabolism in the genus Methanothermobacter

Methanogenesis allows methanogenic archaea to generate cellular energy for their growth while producing methane. Thermophilic hydrogenotrophic species of the genus Methanothermobacter have been recognized as robust biocatalysts for a circular carbon economy and are already applied in power-to-gas technology with biomethanation, which is a platform to store renewable energy and utilize captured carbon dioxide. Here, we generated curated genome-scale metabolic reconstructions for three Methanothermobacter strains and investigated differences in the growth performance of these same strains in chemostat bioreactor experiments with hydrogen and carbon dioxide or formate as substrates. Using an integrated systems biology approach, we identified differences in formate anabolism between the strains and revealed that formate anabolism influences the diversion of carbon between biomass and methane. This finding, together with the omics datasets and the metabolic models we generated, can be implemented for biotechnological applications of Methanothermobacter in power-to-gas technology, and as a perspective, for value-added chemical production.

Biological Aspects, Advancements and Techno-Economical Evaluation of Biological Methanation for the Recycling and Valorization of CO2

Nowadays, sustainable and renewable energy production is a global priority. Over the past decade, several Power-to-X (PtX) technologies have been proposed to store and convert the surplus of renewable energies into chemical bonds of chemicals produced by different processes. CO2 is a major contributor to climate change, yet it is also an undervalued source of carbon that could be recycled and represents an opportunity to generate renewable energy. In this context, PtX technologies would allow for CO2 valorization into renewable fuels while reducing greenhouse gas (GHG) emissions. With this work we want to provide an up-to-date overview of biomethanation as a PtX technology by considering the biological aspects and the main parameters affecting its application and scalability at an industrial level. Particular attention will be paid to the concept of CO2-streams valorization and to the integration of the process with renewable energies. Aspects related to new promising technologies such as in situ, ex situ, hybrid biomethanation and the concept of underground methanation will be discussed, also in connection with recent application cases. Furthermore, the technical and economic feasibility will be critically analyzed to highlight current options and limitations for implementing a sustainable process.

Physiological Effects of 2-Bromoethanesulfonate on Hydrogenotrophic Pure and Mixed Cultures

Mixed or pure cultures can be used for biomethanation of hydrogen. Sodium 2-bromoethanesulfonate (BES) is an inhibitor of methanogenesis used to investigate competing reactions like homoacetogenesis in mixed cultures. To understand the effect of BES on the hydrogenotrophic metabolism in a biomethanation process, anaerobic granules from a wastewater treatment plant, a hydrogenotrophic enrichment culture, and pure cultures of Methanococcus maripaludis and Methanobacterium formicicum were incubated under H₂/CO₂ headspace in the presence or absence of BES, and the turnover of H₂, CO₂, CH₄, formate and acetate was analyzed. Anaerobic granules produced the highest amount of formate after 24 h of incubation in the presence of BES. Treating the enrichment culture with BES led to the accumulation of formate. M. maripaludis produced more formate than M. formicicum when treated with BES. The non-inhibited methanogenic communities produced small amounts of formate whereas the pure cultures did not. The highest amount of acetate was produced by the anaerobic granules concomitantly with formate consumption. These results indicate that formate is an important intermediate of hydrogenotrophic metabolism accumulating upon methanogenesis inhibition.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

Development of Stable Mixed Microbiota for High Yield Power to Methane Conversion

The performance of a mixed microbial community was tested in lab-scale power-to-methane reactors at 55 °C. The main aim was to uncover the responses of the community to starvation and stoichiometric H2/CO2 supply as the sole substrate. Fed-batch reactors were inoculated with the fermentation effluent of a thermophilic biogas plant. Various volumes of pure H2/CO2 gas mixtures were injected into the headspace daily and the process parameters were followed. Gas volumes and composition were measured by gas-chromatography, the headspace was replaced with N2 prior to the daily H2/CO2 injection. Total DNA samples, collected at the beginning and end (day 71), were analyzed by metagenome sequencing. Low levels of H2 triggered immediate CH4 evolution utilizing CO2/HCO3− dissolved in the fermentation effluent. Biomethanation continued when H2/CO2 was supplied. On the contrary, biomethane formation was inhibited at higher initial H2 doses and concomitant acetate formation indicated homoacetogenesis. Biomethane production started upon daily delivery of stoichiometric H2/CO2. The fed-batch operational mode allowed high H2 injection and consumption rates albeit intermittent operation conditions. Methane was enriched up to 95% CH4 content and the H2 consumption rate attained a remarkable 1000 mL·L−1·d−1. The microbial community spontaneously selected the genus Methanothermobacter in the enriched cultures.

Emerging bioelectrochemical technologies for biogas production and upgrading in cascading circular bioenergy systems

Biomethane is suggested as an advanced biofuel for the hard-to-abate sectors such as heavy transport. However, future systems that optimize the resource and production of biomethane have yet to be definitively defined. This paper assesses the opportunity of integrating anaerobic digestion (AD) with three emerging bioelectrochemical technologies in a circular cascading bioeconomy, including for power-to-gas AD (P2G-AD), microbial electrolysis cell AD (MEC-AD), and AD microbial electrosynthesis (AD-MES). The mass and energy flow of the three bioelectrochemical systems are compared with the conventional AD amine scrubber system depending on the availability of renewable electricity. An energy balance assessment indicates that P2G-AD, MEC-AD, and AD-MES circular cascading bioelectrochemical systems gain positive energy outputs by using electricity that would have been curtailed or constrained (equivalent to a primary energy factor of zero). This analysis of technological innovation, aids in the design of future cascading circular biosystems to produce sustainable advanced biofuels.

A Framework and Baseline for the Integration of a Sustainable Circular Economy in Offshore Wind

Circular economy and renewable energy infrastructure such as offshore wind farms are often assumed to be developed in synergy as part of sustainable transitions. Offshore wind is among the preferred technologies for low-carbon energy. Deployment is forecast to accelerate over ten times faster than onshore wind between 2021 and 2025, while the first generation of offshore wind turbines is about to be decommissioned. However, the growing scale of offshore wind brings new sustainability challenges. Many of the challenges are circular economy-related, such as increasing resource exploitation and competition and underdeveloped end-of-use solutions for decommissioned components and materials. However, circular economy is not yet commonly and systematically applied to offshore wind. Circular economy is a whole system approach aiming to make better use of products, components and materials throughout their consecutive lifecycles. The purpose of this study is to enable the integration of a sustainable circular economy into the design, development, operation and end-of-use management of offshore wind infrastructure. This will require a holistic overview of potential circular economy strategies that apply to offshore wind, because focus on no, or a subset of, circular solutions would open the sector to the risk of unintended consequences, such as replacing carbon impacts with water pollution, and short-term private cost savings with long-term bills for taxpayers. This study starts with a systematic review of circular economy and wind literature as a basis for the coproduction of a framework to embed a sustainable circular economy throughout the lifecycle of offshore wind energy infrastructure, resulting in eighteen strategies: design for circular economy, data and information, recertification, dematerialisation, waste prevention, modularisation, maintenance and repair, reuse and repurpose, refurbish and remanufacturing, lifetime extension, repowering, decommissioning, site recovery, disassembly, recycling, energy recovery, landfill and re-mining. An initial baseline review for each strategy is included. The application and transferability of the framework to other energy sectors, such as oil and gas and onshore wind, are discussed. This article concludes with an agenda for research and innovation and actions to take by industry and government.

Impact of operational conditions on methane yield and microbial community composition during biological methanation in in situ and hybrid reactor systems

BACKGROUND

Biogas can be upgraded to methane biologically by adding H2 to biogas reactors. The process is called biological methanation (BM) and can be done in situ in a regular biogas reactor or the biogas can be transferred to a separate ex situ upgrading reactor. The hybrid BM concept, a combination of in situ and ex situ BM, has received little attention, and only a few studies have been reported. The hybrid BM has the advantage of resolving the issue of pH increment during in situ BM, while the size of the ex situ BM reactor could be reduced.

RESULTS

In this study, the efficiency of in situ and hybrid biological methanation (BM) for upgrading raw biogas was investigated. The hybrid BM system achieved a CH4 yield of 257 mL gVS-1 when degrading a feedstock blend of manure and cheese waste. This represented an increase in methane yield of 76% when compared to the control reactor with no H2 addition. A 2:1 H2:CO2 ratio resulted in stable reactor performance, while a 4:1 ratio resulted in a high accumulation of volatile fatty acids. H2 consumption rate was improved when a low manure-cheese waste ratio (90%:10%) was applied. Furthermore, feeding less frequently (every 48 h) resulted in a higher CH4 production from CO2 and H2. Methanothermobacter was found to dominate the archaeal community in the in situ BM reactor, and its relative abundance increased over the experimental time. Methanosarcina abundance was negatively affected by H2 addition and was nearly non-existent at the end of the experiment.

CONCLUSIONS

Our results show that hybrid BM outperforms in situ BM in terms of total CH4 production and content of CH4 in the biogas. In comparison to in situ BM, the use of hybrid BM increased CH4 yield by up to 42%. Furthermore, addition of H2 at 2:1 H2:CO2 ratio in in situ BM resulted in stable reactor operation.

Biological methanation of injected hydrogen in a two-stage anaerobic digestion process

In the field of biological hydrogen methanation, ideal process parameters are underexplored for continuous two-stage systems with anaerobic filters. The present study aims at filling this gap for continuous in-situ reactors while applying different hydrogen injection rates. The results of the study demonstrate an almost complete acid degradation on the output side of the anaerobic filter fed by hydrolysate from maize silage and silage effluent. Most of the oxidizable substances were transferred to methane, but hydrogen could not be completely converted. With fully stoichiometric hydrogen addition, a methane production rate of 0.88 ± 0.06 m³d^-1 per m³ reactor volume was reached. With half stoichiometric hydrogen addition, a hydrogen conversion rate of 75.53 ± 3.77% was obtained. The present approach proved to be a promising contribution to power-to-gas technology, as a considerable amount of hydrogen had to be converted into methane while carbon dioxide was fixed.

Photovoltaic-driven microbial protein production can use land and sunlight more efficiently than conventional crops

Population growth and changes in dietary patterns place an ever-growing pressure on the environment. Feeding the world within sustainable boundaries therefore requires revolutionizing the way we harness natural resources. Microbial biomass can be cultivated to yield protein-rich feed and food supplements, collectively termed single-cell protein (SCP). Yet, we still lack a quantitative comparison between traditional agriculture and photovoltaic-driven SCP systems in terms of land use and energetic efficiency. Here, we analyze the energetic efficiency of harnessing solar energy to produce SCP from air and water. Our model includes photovoltaic electricity generation, direct air capture of carbon dioxide, electrosynthesis of an electron donor and/or carbon source for microbial growth (hydrogen, formate, or methanol), microbial cultivation, and the processing of biomass and proteins. We show that, per unit of land, SCP production can reach an over 10-fold higher protein yield and at least twice the caloric yield compared with any staple crop. Altogether, this quantitative analysis offers an assessment of the future potential of photovoltaic-driven microbial foods to supplement conventional agricultural production and support resource-efficient protein supply on a global scale.

Influence of Liquid-to-Gas Ratio on the Syngas Fermentation Efficiency: An Experimental Approach

Syngas fermentation by methanogens is a novel process to purify biogas. Methanogens are able to ferment non-desirable CO₂, H_2, and CO to methane. However, to use methanogens on an industrial scale, more research has to be done. There are studies that discuss the growth of methanogens on syngas in combination with acetate. In this research, growth of methanogens on syngas as sole carbon source is discussed. Effluent of an anaerobic fed-batch was selectively cultivated with syngas in 400 mL Eppendorf© bioreactors. After a period of 7 days, fifteen 120 mL flasks were filled with three different liquid-to-gas ratios (1:1, 1:3, 1:5). Results showed that different liquid-to-gas ratios change the metabolic preference of the anaerobic microbial community. Moreover, complete conversion in a four-to-eight-day period, via the carboxidotrophic pathway, was observed in all three liquid-to-gas ratios.

Removal of hydrogen sulfide from biogas using activated carbon synthesized from different locally available biomass wastes - a case study from Palestine

The main aim of this study was to remove hydrogen sulfide (H₂S) from biogas by adsorption using synthesized activated carbon prepared using locally available biomass. The effect of the type of precursors, impregnation reagent and bed height was studied in continuous reactors. Three types of biomass wastes (almond shells, eucalyptus and coffee grains) were collected, grinded, sieved, pyrolyzed at 500°C and impregnated with chemical reagents such as potassium hydroxide or zinc chloride. Adsorption tests were performed using a fixed bed filter filled with the produced activated carbon. The highest biochar yield of 36% was obtained eucalyptus followed by almond shells (28.5%) and coffee grains (24%), respectively. The highest adsorption capacity and removal efficiency were obtained with eucalyptus followed by almond shells and coffee grains, respectively. For instance, eucalyptus showed an adsorption capacity of ~690 (mg hydrogen sulfide/g adsorbent) followed by almond (230 mg hydrogen sulfide/g adsorbent) and coffee grains (22 mg hydrogen sulfide/g adsorbent). As an impregnation reagent, potassium hydroxide gave the highest adsorption efficiency and capacity than zinc chloride. Furthermore, the breakthrough time with KOH (180 min) was higher than ZnCl₂ (70 min). Increasing the bed height during continuous breakthrough tests increased the adsorption capacity and hydrogen sulfide removal efficiency. The results of this study showed that the adsorption efficiency of the synthesized activated carbon and consequently the hydrogen sulfide removal efficiency could be fine-tuned by selecting an appropriate biomass precursor and proper impregnation reagent.

Microbial Consortiums of Hydrogenotrophic Methanogenic Mixed Cultures in Lab-Scale Ex-Situ Biogas Upgrading Systems under Different Conditions of Temperature, pH and CO

In this study, hydrogenotrophic methanogenic mixed cultures taken from 13 lab-scale ex-situ biogas upgrading systems under different temperature (20–70 °C), pH (6.0–8.5), and CO (0–10%, v/v) variables were systematically investigated. High-throughput 16S rRNA gene sequencing was used to identify the microbial consortia, and statistical analyses were conducted to reveal the microbial diversity, the core functional microbes, and their correlative relationships with tested variables. Overall, bacterial community was more complex than the archaea community in all mixed cultures. Hydrogenotrophic methanogens Methanothermobacter, Methanobacterium, and Methanomassiliicoccus, and putative syntrophic acetate-oxidizing bacterium Coprothermobacter and Caldanaerobacter were found to predominate, but the core functional microbes varied under different conditions. Multivariable sensitivity analysis indicated that temperature (p < 0.01) was the crucial variable to determine the microbial consortium structures in hydrogenotrophic methanogenic mixed cultures. pH (0.01 < p < 0.05) significantly interfered with the relative abundance of dominant archaea. Although CO did not affect community (p > 0.1), some potential CO-utilizing syntrophic metabolisms might be enhanced. Understanding of microbial consortia in the hydrogenotrophic methanogenic mixed cultures related to environmental variables was a great advance to reveal the microbial ecology in microbial biogas upgrading process.

Resource recovery and circular economy from organic solid waste using aerobic and anaerobic digestion technologies

With the inevitable rise in human population, resource recovery from waste stream is becoming important for a sustainable economy, conservation of the ecosystem as well as for reducing the dependence on the finite natural resources. In this regard, a bio-based circular economy considers organic wastes and residues as potential resources that can be utilized to supply chemicals, nutrients, and fuels needed by mankind. This review explored the role of aerobic and anaerobic digestion technologies for the advancement of a bio-based circular society. The developed routes within the anaerobic digestion domain, such as the production of biogas and other high-value chemicals (volatile fatty acids) were discussed. The potential to recover important nutrients, such as nitrogen through composting, was also addressed. An emphasis was made on the innovative models for improved economics and process performance, which include co-digestion of various organic solid wastes, recovery of multiple bio-products, and integrated bioprocesses.