How Efficient are Agitators in Biogas Digesters? Determination of the Efficiency of Submersible Motor Mixers and Incline Agitators by Measuring Nutrient Distribution in Full-Scale Agricultural Biogas Digesters

A systematic review of the design considerations for the operation and maintenance of small-scale biogas digesters

This review investigates small-scale biogas digesters' design and construction considerations to address biogas digesters' failures shortly after installation. The frequent failures of small-scale or household biogas digesters negatively affect its adoption as a clean domestic cooking fuel in developing countries, affecting the achievement of Sustainable Development Goal (SDG) 7. The study considered Scopus database-indexed peer-reviewed journals published between 2000 and 2022. Selected papers focussed on real-time monitoring, stirring mechanisms, and temperature control systems based on predefined inclusion and exclusion criteria with initial search results of 4751 documents, narrowing to 55 papers. The PRISMA 2020 statement was adopted to conduct the study. The study highlights the importance of incorporating a real-time monitoring system as a design factor in small-scale biogas digesters for successful operation and maintenance. The study's findings may be helpful to practitioners, policymakers, and researchers promoting sustainable energy and waste management solutions in low-resource settings.

Energy performance of compressed biomethane gas production from co-digestion of Salix and dairy manure: factoring differences between Salix varieties

Biogas from anaerobic digestion is a versatile energy carrier that can be upgraded to compressed biomethane gas (CBG) as a renewable and sustainable alternative to natural gas. Organic residues and energy crops are predicted to be major sources of bioenergy production in the future. Pre-treatment can reduce the recalcitrance of lignocellulosic energy crops such as Salix to anaerobic digestion, making it a potential biogas feedstock. This lignocellulosic material can be co-digested with animal manure, which has the complementary effect of increasing volumetric biogas yield. Salix varieties exhibit variations in yield, composition and biomethane potential values, which can have a significant effect on the overall biogas production system. This study assessed the impact of Salix varietal differences on the overall mass and energy balance of a co-digestion system using steam pre-treated Salix biomass and dairy manure (DaM) to produce CBG as the final product. Six commercial Salix varieties cultivated under unfertilised and fertilised conditions were compared. Energy and mass flows along this total process chain, comprising Salix cultivation, steam pre-treatment, biogas production and biogas upgrading to CBG, were evaluated. Two scenarios were considered: a base scenario without heat recovery and a scenario with heat recovery. The results showed that Salix variety had a significant effect on energy output-input ratio (R), with R values in the base scenario of 1.57-1.88 and in the heat recovery scenario of 2.36-2.94. In both scenarios, unfertilised var. Tordis was the best energy performer, while the fertilised var. Jorr was the worst. Based on this energy performance, Salix could be a feasible feedstock for co-digestion with DaM, although its R value was at the lower end of the range reported previously for energy crops.

Enhancing Efficiency of Anaerobic Digestion by Optimization of Mixing Regimes Using Helical Ribbon Impeller

The appropriate mixing system and approach to effective management can provide favorable conditions for the highly sensitive microbial community, which can ensure process stability and efficiency in an anaerobic digester. In this study, the effect of mixing intensity on biogas production in a lab-scale anaerobic digester has been investigated experimentally and via modeling. Considering high mixing efficiency and unique feature of producing axial flow, helical ribbon (HR) impeller is used for mixing the slurry in this experiment under various conditions. Three parallel digesters were analyzed under identical operating conditions for comparative study and high accuracy. Effects of different mixing speeds (10, 30, and 67 rpm for 5 min h−1) on biogas production rate were determined in 5-L lab-scale digesters. The results demonstrated 15–18% higher biogas production at higher mixing speed (67 rpm) as compared to 10 rpm and 30 rpm and the results proved statistically significant (p < 0.05). Biogas production at 10, 30, and 67 rpm were 45.6, 48.6, and 52.5 L, respectively. Higher VFA concentrations (7.67 g L−1) were recorded at lower mixing intensity but there was no significant difference in pH and ammonia at different speeds whereas the better mixing efficiency at higher speeds was also the main reason for increase in biogas production. Furthermore, model simulation calculations revealed the reduction of dead zones and better homogeneous mixing at higher mixing speeds. Reduction of dead zones from 18% at 10 rpm to 2% at 67 rpm was observed, which can be the major factor in significant difference in biogas production rates at various mixing intensities. Optimization of digester and impeller geometry should be a prime focus to scale-up digesters and to optimize mixing in full-scale digesters.

Effect of Localized Temperature Difference on Hydrogen Fermentation

In a lab-scale bioreactor system, (20 L of effective volume in our study) controlling a constant temperature inside bioreactor with a total volume 25 L is a simple process, whereas it is a complicated process in the actual full-scale system. There might exist a localized temperature difference inside the reactor, affecting bioenergy yield. In the present work, the temperature at the middle layer of bioreactor was controlled at 35 °C, while the temperature at top and bottom of bioreactor was controlled at 35 ± 0.1, ±1.5, ±3.0, and ±5.0 °C. The H2 yield of 1.50 mol H2/mol hexoseadded was achieved at ±0.1 and ±1.5 °C, while it dropped to 1.27 and 0.98 mol H2/mol hexoseadded at ±3.0 and ±5.0 °C, respectively, with an increased lactate production. Then, the reactor with automatic agitation speed control was operated. The agitation speed was 10 rpm (for 22 h) under small temperature difference (<±1.5 °C), while it increased to 100 rpm (for 2 h) when the temperature difference between top and bottom of reactor became larger than ±1.5 °C. Such an operation strategy helped to save 28% of energy requirement for agitation while producing a similar amount of H2. This work contributes to facilitating the upscaling of the dark fermentation process, where appropriate agitation speed can be controlled based on the temperature difference inside the reactor.

Demand-oriented biogas production and biogas storage in digestate by flexibly feeding a full-scale biogas plant

This work studied the demand-oriented biogas production and the biogas storage in digestate by flexibly feeding a full-scale research biogas plant. The investigated continuous stirred tank reactor (CSTR) was equipped with a fast-moving submersible motor mixer and a slow-moving inclined shaft agitator. A model for the biogas storage in digestate was introduced and tested in full scale using temporally highly resolved volume flow measurements. An increase in mixing time led to a faster biogas production: A two to five hours reduction of the time to reach the maximum biogas production after feeding occurred in our experiments. However, no influence of the rheology and of the mixing regime on the methane yield could be derived from the measurements. Further, a 30% reduction of the stored biogas in the digestate occurred when the viscosity was lowered by 66%. This knowledge can be used to enhance the existing biogas formation models.

Impact of feeding and stirring regimes on the internal stratification of microbial communities in the fermenter of anaerobic digestion plants

In anaerobic digestion plants (ADs), homogenization of the feed, fermenter content and microbial communities is crucial for efficient and robust biogas production. However, mixing also requires a significant amount of energy. For an 850 m³ agricultural AD equipped with eight sampling ports, we investigated whether different feeding and stirring regimes enable a sufficient homogenization of the microbial community using metaproteomics and terminal restriction fragment length polymorphism (TRFLP) analysis. Systematic comparison of samples taken at the top and the bottom as well as at the rim and the center of the AD using scatter plots and students t-test revealed only a small number of differences in metaproteins, taxonomies and biological processes. Obviously, the applied stirring and feeding conditions were sufficient to largely homogenize the content of the AD.

Operational Parameters of Biogas Plants: A Review and Evaluation Study

The biogas production technology has improved over the last years for the aim of reducing the costs of the process, increasing the biogas yields, and minimizing the greenhouse gas emissions. To obtain a stable and efficient biogas production, there are several design considerations and operational parameters to be taken into account. Besides, adapting the process to unanticipated conditions can be achieved by adequate monitoring of various operational parameters. This paper reviews the research that has been conducted over the last years. This review paper summarizes the developments in biogas design and operation, while highlighting the main factors that affect the efficiency of the anaerobic digestion process. The study’s outcomes revealed that the optimum operational values of the main parameters may vary from one biogas plant to another. Additionally, the negative conditions that should be avoided while operating a biogas plant were identified.

Representative Sampling Implementation in Online VFA/TIC Monitoring for Anaerobic Digestion

This paper describes an automatic sampling system for anaerobic reactors that allows taking representative samples following the guidelines of Gy’s (1998) theory of sampling. Due to the high heterogeneity degree in a digester the sampling errors are larger than the analysis error, making representative sampling a prerequisite for successful process control. In our system, samples are automatically processed, generating a higher density of data and avoiding human error by sample manipulation. The combination of a representative sampling system with a commercial automate titration unit generates a robust online monitoring system for biogas plants. The system was successfully implemented in an operating biogas plant to control a feeding-on-demand biogas system.

Integration of membrane filtration in two-stage anaerobic digestion system: Specific methane yield potentials of hydrolysate and permeate

Two-stage biogas systems consisting of a CSTR-acidification reactor (AR) and an anaerobic filter (AF) were frequently described for microbial conversion of food and agricultural wastes to biogas. The aim of this study is to investigate the integration of a membrane filtration step in two-stage systems to remove inert particles from hydrolysate produced in AR in order to increase the efficiency of the subsequent AF. Hydrolysates from vegetable waste (VW) and grass/maize silage (G/M) were treated in cross-flow ceramic membrane filtration system (pore size 0.2 µm). Organic acids were extracted efficiently through filtration of hydrolysate. For both the substrates, membrane permeability was stable and high (46.6-49.3 L m^-2 h^-1 bar^-1). Filtration process effectively improved the specific methane yield of permeate by 40% (VW) and 24.5% (G/M) compared to hydrolysate. It could be shown that, the filtration-step increased hydrolysate's degradability, which lead to higher conversion efficiency in the following AF.

Influence of mixing on anaerobic digestion efficiency in stirred tank digesters: A review

A comprehensive review was carried out on the influence of mixing on anaerobic digestion (AD) efficiency in stirred tank anaerobic digesters. Though traditionally, stirred tank digesters operated as continuous stirred tank reactors (CSTRs), this review revealed that there is no motivation to continue to operate stirred tank anaerobic digesters as CSTRs if AD energy efficiency is to be improved. AD energy production efficiency can be achieved with optimized intermittent mixing. AD efficiency should include an assessment of the net energy production efficiency and should be the criteria in determining the mixing mode, mixing intensity, mixing time and mixing interval for every anaerobic digestion operating plan.

Ammonia and methane emissions during drying of dewatered biogas digestate in a two-belt conveyor dryer

Aim of the present study was to identify type and amount of emissions during the drying of biogas digestate in a two-belt conveyor dryer at different temperature settings and to investigate the effect on its nutrient content. Furthermore, the possibility of recovering nitrogen from the exhaust air was investigated. Emissions of CH₄, CO₂ and NH₃ were measured by Fourier transform infrared spectroscopy. Biogas is mainly composed of CH₄ and CO₂, hence gas release from the digestate during drying was expected to increase the concentration of these components. Although CO₂ concentration was elevated above the background concentration, CH₄ did not exceed the background concentration. Maximum NH₃ concentration of 183.3mg·m^-3 was detected during drying. A NH₃ concentration of 10.8mg·m^-3 was measured in the exhaust air of the ammonia scrubber, which is equal to a NH₃ reduction rate of 94%.

Effects of target pH-value on organic acids and methane production in two-stage anaerobic digestion of vegetable waste

Vegetable waste is one of the major organic residues available for sustainable bioenergy production. The aim of this work is to study the influence of pH-value on process stability, hydrolysis, degradation degree and methane production in two-stage anaerobic system. A mixture of vegetable wastes with carrot mousse, carrots, celery, cabbage and potatoes was treated in two-stage system at target pH-values 5.5 and 6 in acidification reactor (AR). At pH 6, high concentrations of organic acids were recorded whereas high amount of hydrolysate was produced at pH 5.5. The chemical oxygen demand (COD) concentration in the hydrolysate produced in AR was 21.85% higher at pH 6 compared to pH 5.5, whereas the overall specific methane yield was slightly higher at pH 5.5 (354.35±31.95 and 326.79±41.42Lkg^-1 oDM_added, respectively). It could be shown, that the described two-stage system is well suited for manure-free digestion of vegetable waste.

Effect of agitation time on nutrient distribution in full-scale CSTR biogas digesters

The aim of this work was to study the impact of reduced mixing time in a full-scale CSTR biogas reactor from 10 to 5 and to 2min in half an hour on the distribution of DM, acetic acid and FOS/TAC as a measure to cut electricity consumption. The parameters in the digestate were unevenly distributed with the highest concentration measured at the point of feeding. By reducing mixing time, the FOS/TAC value increases by 16.6%. A reduced mixing time of 2min lead to an accumulation of 15% biogas in the digestate.

Nitrogen removal from digested slurries using a simplified ammonia stripping technique

This study assessed a novel technique for removing nitrogen from digested organic waste based on a slow release of ammonia that was promoted by continuous mixing of the digestate and delivering a continuous air stream across the surface of the liquid. Three 10-day experiments were conducted using two 50-L reactors. In the first two, nitrogen removal efficiencies were evaluated from identical digestates maintained at different temperatures (30°C and 40°C). At the start of the first experiment, the digestates were adjusted to pH 9 using sodium hydroxide, while in the second experiment pH was not adjusted. The highest ammonia removal efficiency (87%) was obtained at 40°C with pH adjustment. However at 40°C without pH adjustment, removal efficiencies of 69% for ammonia and 47% for total nitrogen were obtained. In the third experiment two different digestates were tested at 50°C without pH adjustment. Although the initial chemical characteristics of the digestates were different in this experiment, the ammonia removal efficiencies were very similar (approximately 85%). Despite ammonia removal, the pH increased in all experiments, most likely due to carbon dioxide stripping that was promoted by temperature and mixing. The technique proved to be suitable for removing nitrogen following anaerobic digestion of livestock manure because effective removal was obtained at natural pH (≈8) and 40°C, common operating conditions at typical biogas plants that process manure. Furthermore, the electrical energy requirement to operate the process is limited (estimated to be 3.8kWhm^-3digestate). Further improvements may increase the efficiency and reduce the processing time of this treatment technique. Even without these advances slow-rate air stripping of ammonia is a viable option for reducing the environmental impact associated with animal manure management.

Improving methane production from digested manure biofibers by mechanical and thermal alkaline pretreatment

Animal manure digestion is associated with limited methane production, due to the high content in fibers, which are hardly degradable lignocellulosic compounds. In this study, different mechanical and thermal alkaline pretreatment methods were applied to partially degradable fibers, separated from the effluent stream of biogas reactors. Batch and continuous experiments were conducted to evaluate the efficiency of these pretreatments. In batch experiments, the mechanical pretreatment improved the degradability up to 45%. Even higher efficiency was shown by applying thermal alkaline pretreatments, enhancing fibers degradability by more than 4-fold. In continuous experiments, the thermal alkaline pretreatment, using 6% NaOH at 55°C was proven to be the most efficient pretreatment method as the methane production was increased by 26%. The findings demonstrated that the methane production of the biogas plants can be increased by further exploiting the fraction of the digested manure fibers which are discarded in the post-storage tank.

Development of an in-line process viscometer for the full-scale biogas process

An in-line viscometer was developed to determine the rheological properties of biogas slurries at a full-scale biogas plant. This type of viscometer allows the investigation of flow characteristics without additional pretreatment and has many advantageous aspects in contrast to the rotational viscometer. Various effects were studied: alterations in the feedstock structure, increasing total solid (TS) of the slurry and the disintegration of the feedstock on the rheological properties. The results indicate that the Power-Law model is sufficient for the description of the flow curve of biogas slurries. Furthermore, the use of more fibrous materials increases in viscosity. The increase in TS of 10.1-15.1% resulted in a sharp increase of the viscosity. The mechanical disintegration of the feedstock positively influenced the rheological properties, but the effects were more apparent at higher TS.

Effects of mechanical treatment of digestate after anaerobic digestion on the degree of degradation

The aim of this study was to increase the biogas production from different substrates by applying a mechanical treatment only to the non-degraded digestate after the fermentation process in order to feed it back into the process. To evaluate this approach, digestates were grounded with a ball mill for four different treatment time periods (0, 2, 5, 10 min) and then the effects on the particle size, volatile organic substances, methane yield and degradation kinetic were measured. A decrease of volatile fatty acids based on this treatment was not detected. The mechanical treatment caused in maximum to a triplication of the methane yield and to a quadruplicating of the daily methane production.

Effect of substrate pretreatment on particle size distribution in a full-scale research biogas plant

The objective of this study was to investigate the pretreatment effects of high-fibre substrate on particle size distribution in a full-scale agricultural biogas plant (BGP). Two digesters, one fed with pretreated material and one with untreated material, were investigated for a period of 90days. Samples from different positions and heights were taken with a special probe sampling system and put through a wet sieve. The results show that on average 58.0±8.6% of the particles in both digesters are fine fraction (<0.063mm). A higher amount of particles (13.1%) with a length >4mm was measured in the untreated digester. However, the volume distribution over all positions and heights did not show a clear and uniform distribution of particles. These results reveal that substrate pretreatment has an effect on particle size in the fermenting substrate, but due to the uneven distribution mixing, is not homogeneous within the digester.