Biogas Production from Thin Stillage on an Industrial Scale—Experience and Optimisation

Biogas and biofertilizer production from organic fraction municipal solid waste for sustainable circular economy and environmental protection in Malaysia

Waste management in Malaysia remains a persistent economic and environmental challenge. Up to date, more than 80% of Malaysian solid waste disposed at landfills and dumpsites. Therefore, Malaysia is facing an urgent need to move towards a sustainable solid waste management and thus resource recovery from organic solid waste. Hence, this study aims to investigate the feasibility of energy and bio fertilizer recovery from organic fraction municipal solid waste (OFMSW) via anaerobic digestion. The economic and environmental benefit analysis was investigated. Approximate and elementary analysis of OFMSW samples were carried out to estimate the potential production of biogas and bio fertilizer. It was found that organic waste contributes about 45% of the total MSW generated in Malaysia. Anaerobic digestion of 50% of organic waste is expected to produce 3941 MWh/day of electrical energy and 2500 t/day of bio fertilizer. In terms of environmental impacts, 2735 t/day of Carbon dioxide (CO₂) emission, 1128 m²/day of landfilling area and 481 m³/day of leachate can be avoided. A net revenue of 3300 million RM (1 US Dollar ≈ 4.15 RM) can be generated by the sales of electricity via Feed-in-Tariff (FiT), sales of biofertilizer to local agricultural industries and inclusive of the saving generated from the reduction of OFMSW landfilling operations and leachate treatment at landfills. Economic development can go hand-in-hand with environmental sound practices in the field of waste management.

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.

Microbial community dynamics in mesophilic and thermophilic batch reactors under methanogenic, phenyl acid-forming conditions

BACKGROUND

Proteinaceous wastes exhibit high theoretical methane yields and their residues are considered valuable fertilisers. The routine anaerobic degradation of proteins often raises problems like high aromatic compound concentrations caused by the entry of aromatic amino acids into the system. A profound investigation of the consequences of aromatic compound exposure on various microorganisms, which cascade-like and interdependently degrade complex molecules to biogas, is still pending.

RESULTS

In mesophilic samples, methane was predominantly produced via acetoclastic methanogenesis. The highest positive correlation was observed between phenylacetate (PAA) and Psychrobacter spp. and between phenylpropionate (PPA) and Haloimpatiens spp. Moreover, Syntrophus spp. negatively correlated with PAA (Spearman's rank correlations coefficient (rs) = - 0.46, p < 0.05) and PPA concentrations (rs = - 0.44, p < 0.05) and was also associated with anaerobic benzene ring cleavage. In thermophilic samples, acetate was predominantly oxidised by Tepidanaerobacter spp. or Syntrophaceticus spp. in syntrophic association with a hydrogenotrophic methanogen. The genera Sedimentibacter and Syntrophaceticus correlated positively with both PAA and PPA concentrations. Moreover, Sedimentibacter spp., Tepidanaerobacter spp., Acetomicrobium spp., and Sporanaerobacter spp. were significant LEfSe (linear discriminant analysis effect size) biomarkers for high meso- as well as thermophilic phenyl acid concentrations. Direct negative effects of phenyl acids on methanogenic properties could not be proven.

CONCLUSIONS

Anaerobic phenyl acid formation is not restricted to specific microbial taxa, but rather done by various meso- and thermophilic bacteria. The cleavage of the highly inert benzene ring is possible in methanogenic batch reactors-at least in mesophilic fermentation processes. The results indicated that phenyl acids rather affect microorganisms engaged in preceding degradation steps than the ones involved in methanogenesis.

Non-thermal plasma and ultrasound-assisted open lactic acid fermentation of distillery stillage

Stillage is the main by-product of bioethanol production and the cost of its treatment significantly affects the economy of bioethanol production. A process of thermal sterilization before lactic acid fermentation (LAF) is energy demanding and is causing deterioration of valuable compounds in stillage. In this study, ultrasound (UT) and plasma (PT) treatments were used for microbial inactivation, and a significant reduction in the number of viable microorganisms in the stillage after PT and UT was observed. After application of treatment, LAF by Lactobacillus rhamnosus ATCC 7469 was initiated. The concentration of LA is used to quantify the efficiency of the stillage revalorization. The highest LA productivity of 1.21 g/Lh and yield of 0.82 g/g were obtained after PT, while UT of 10 min provided productivity of 1.02 g/Lh and LA yield of 0.69 g/g. The results were benchmarked against closed LAF. Around 20% better revalorization of stillage by PT was achieved when compared with conventional sterilization. In addition, an excellent L (+) LA stereoselectivity of 95.5% was attained after PT. From the aspect of energy efficiency, that of PT was three times lower than UT and almost ten times lower than thermal sterilization, but it is the most expensive due to the high consumption of gas which could reduce application of closed Ar atmosphere on larger scales. This way, a simpler and energy efficient process for LA production on stillage was accomplished by "open" fermentation.

The use of sugar beet pulp stillage for co-digestion with sewage sludge and poultry manure

The anaerobic mesophilic co-digestion of sugar beet pulp stillage with poultry manure and municipal sewage sludge was investigated in this study. The sugar beet pulp stillage (SBPS) mono-digestion failed owing to an accumulation of volatile fatty acids, leading to a pH value lower than 5.5. A 20% addition of poultry manure to stillage allowed for stable digestion performance despite high volatile fatty acid (total volatile fatty acids) concentrations of 5500-8500 g m^-3 with propionic acid being the predominant one and constituting 72%-76% total volatile fatty acids. For this mixture, the maximum methane production of 418 dm³ kgVS_fed^-1 was achieved when the reactor was operated at a solids retention time of 20 days and an organic loading rate of 4.25 kgVS m^-3 d^-1. The co-digestion of stillage with 60% municipal sewage sludge gave the average methane yield of around 357 dm³ kgVS_fed^-1 for all operational conditions applied, however, the methane percentage of biogas (up to 70%) was far greater than the corresponding values obtained for sugar beet pulp stillage-poultry manure co-digestion. Neither ammonia nor volatile fatty acids destabilised the biogas production, and the volatile fatty acid profile showed the dominance of acetic acid (72%-82% total volatile fatty acids) followed by propionic and butyric acids.

A Review of the Role of Critical Parameters in the Design and Operation of Biogas Production Plants

Many operating parameters, individually or together, may influence the performance of anaerobic digestion towards biogas or digestate yield and quality maximization. The most preferred method of optimizing an anaerobic digestion plant often relies on how carefully the crucial parameters, such as pH, temperature, organic loading rate, hydraulic retention time, and pressure, are chosen. There is a large amount of literature available on optimization of anaerobic digestion; however, given the continued development and implementation of innovative technologies, together with the introduction of increasingly complex systems, it is necessary to update present knowledge on process parameters and their role on operational ranges and flexibilities in real-life anaerobic digestion system. Accordingly, the present review discusses the importance of the selection of operational parameters in existing technologies and their impact on biogas yield. Notably, the four broad areas of feedstock utilization (substrate, inoculum, codigestion and pretreatment), process condition (pH, temperature, pressure, and reactor design), reactor control (HRT and OLR) and inhibition (Ammonia and VFAs) are covered in this review. In addition, particular emphasis is placed on the most recent innovations that have been or may be implemented in current or future biogas plants.

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.

Chemical speciation of sulfur and metals in biogas reactors - Implications for cobalt and nickel bio-uptake processes

This article deals with the interrelationship between overall chemical speciation of S, Fe, Co, and Ni in relation to metals bio-uptake processes in continuous stirred tank biogas reactors (CSTBR). To address this topic, laboratory CSTBRs digesting sulfur(S)-rich stillage, as well as full-scale CSTBRs treating sewage sludge and various combinations of organic wastes, termed co-digestion, were targeted. Sulfur speciation was evaluated using acid volatile sulfide extraction and X-ray absorption spectroscopy. Metal speciation was evaluated by chemical fractionation, kinetic and thermodynamic analyses. Relative Fe to S content is identified as a critical factor for chemical speciation and bio-uptake of metals. In reactors treating sewage sludge, quantity of Fe exceeds that of S, inducing Fe-dominated conditions, while sulfide dominates in laboratory and co-digestion reactors due to an excess of S over Fe. Under sulfide-dominated conditions, metals availability for microorganisms is restricted due to formation of metal-sulfide precipitates. However, aqueous concentrations of different Co and Ni species were shown to be sufficient to support metal acquisition by microorganisms under sulfidic conditions. Concentrations of free metal ions and labile metal complexes in aqueous phase, which directly participate in bio-uptake processes, are higher under Fe-dominated conditions. This in turn enhances metal adsorption on cell surfaces and bio-uptake rates.

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.

Treatment of corn ethanol distillery wastewater using two-stage anaerobic digestion

In this study the mesophilic two-stage anaerobic digestion (AD) of corn bioethanol distillery wastewater is investigated in laboratory-scale reactors. Two-stage AD technology separates the different sub-processes of the AD in two distinct reactors, enabling the use of optimal conditions for the different microbial consortia involved in the different process phases, and thus allowing for higher applicable organic loading rates (OLRs), shorter hydraulic retention times (HRTs) and better conversion rates of the organic matter, as well as higher methane content of the produced biogas. In our experiments the reactors have been operated in semi-continuous phase-separated mode. A specific methane production of 1,092 mL/(L·d) has been reached at an OLR of 6.5 g TCOD/(L·d) (TCOD: total chemical oxygen demand) and a total HRT of 21 days (5.7 days in the first-stage, and 15.3 days in the second-stage reactor). Nonetheless the methane concentration in the second-stage reactor was very high (78.9%); the two-stage AD outperformed the reference single-stage AD (conducted at the same reactor loading rate and retention time) by only a small margin in terms of volumetric methane production rate. This makes questionable whether the higher methane content of the biogas counterbalances the added complexity of the two-stage digestion.

Co-digestion of manure and industrial waste--The effects of trace element addition

Manure is one of the most common substrates for biogas production. Manure from dairy- and swine animals are often considered to stabilize the biogas process by contributing nutrients and trace elements needed for the biogas process. In this study two lab-scale reactors were used to evaluate the effects of trace element addition during co-digestion of manure from swine- and dairy animals with industrial waste. The substrate used contained high background concentrations of both cobalt and nickel, which are considered to be the most important trace elements. In the reactor receiving additional trace elements, the volatile fatty acids (VFA) concentration was 89% lower than in the control reactor. The lower VFA concentration contributed to a more digested digestate, and thus lower methane emissions in the subsequent storage. Also, the biogas production rate increased with 24% and the biogas production yield with 10%, both as a result of the additional trace elements at high organic loading rates. All in all, even though 50% of the feedstock consisted of manure, trace element addition resulted in multiple positive effects and a more reliable process with stable and high yield.

Changing Feeding Regimes To Demonstrate Flexible Biogas Production: Effects on Process Performance, Microbial Community Structure, and Methanogenesis Pathways

Flexible biogas production that adapts biogas output to energy demand can be regulated by changing feeding regimes. In this study, the effect of changes in feeding intervals on process performance, microbial community structure, and the methanogenesis pathway was investigated. Three different feeding regimes (once daily, every second day, and every 2 h) at the same organic loading rate were studied in continuously stirred tank reactors treating distiller's dried grains with solubles. A larger amount of biogas was produced after feeding in the reactors fed less frequently (once per day and every second day), whereas the amount remained constant in the reactor fed more frequently (every 2 h), indicating the suitability of the former for the flexible production of biogas. Compared to the conventional more frequent feeding regimes, a methane yield that was up to 14% higher and an improved stability of the process against organic overloading were achieved by employing less frequent feeding regimes. The community structures of bacteria and methanogenic archaea were monitored by terminal restriction fragment length polymorphism (T-RFLP) analysis of 16S rRNA and mcrA genes, respectively. The results showed that the composition of the bacterial community varied under the different feeding regimes, and the observed T-RFLP patterns were best explained by the differences in the total ammonia nitrogen concentrations, H2 levels, and pH values. However, the methanogenic community remained stable under all feeding regimes, with the dominance of the Methanosarcina genus followed by that of the Methanobacterium genus. Stable isotope analysis showed that the average amount of methane produced during each feeding event by acetoclastic and hydrogenotrophic methanogenesis was not influenced by the three different feeding regimes.

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.