Optimising the anaerobic co-digestion of urban organic waste using dynamic bioconversion mathematical modelling

Mathematical anaerobic bioconversion models are often used as a convenient way to simulate the conversion of organic materials to biogas. The aim of the study was to apply a mathematical model for simulating the anaerobic co-digestion of various types of urban organic waste, in order to develop strategies for controlling and optimising the co-digestion process. The model parameters were maintained in the same way as the original dynamic bioconversion model, albeit with minor adjustments, to simulate the co-digestion of food and garden waste with mixed sludge from a wastewater treatment plant in a continuously stirred tank reactor. The model's outputs were validated with experimental results obtained in thermophilic conditions, with mixed sludge as a single substrate and urban organic waste as a co-substrate at hydraulic retention times of 30, 20, 15 and 10 days. The predicted performance parameter (methane productivity and yield) and operational parameter (concentration of ammonia and volatile fatty acid) values were reasonable and displayed good correlation and accuracy. The model was later applied to identify optimal scenarios for an urban organic waste co-digestion process. The simulation scenario analysis demonstrated that increasing the amount of mixed sludge in the co-substrate had a marginal effect on the reactor performance. In contrast, increasing the amount of food waste and garden waste resulted in improved performance.

Co-digestion of food and garden waste with mixed sludge from wastewater treatment in continuously stirred tank reactors

Co-digestions of urban organic waste were conducted to investigate the effect of the mixing ratio between sludge, food waste, grass clippings and green waste at different hydraulic retention times (HRTs). Compared to the digestion of 100% sludge, the methane yield increased by 48% and 35%, when co-digesting sludge with food waste, grass clippings and garden waste with a corresponding %VS of 10:67.5:15.75:6.75 (R1) and 10:45:31.5:13.5 (R2), respectively. The methane yield remained constant at around 425 and 385 NmL CH4/g VS in R1 and R2, respectively, when the reactors were operated at HRTs of 15, 20 and 30 days. However, the methane yield dropped significantly to 356 (R1) and 315 (R2) NmL CH4/g VS when reducing the HRT to 10 days, indicating that the process was stressed. Since the methane production rate improved significantly with decreasing HRT, the trade-off between yield and productivity was obtained at 15 days HRT.

Counteracting foaming caused by lipids or proteins in biogas reactors using rapeseed oil or oleic acid as antifoaming agents

Foaming is one of the major operational problems in biogas plants, and dealing with foaming incidents is still based on empirical practices. Various types of antifoams are used arbitrarily to combat foaming in biogas plants, but without any scientific support this action can lead to serious deterioration of the methanogenic process. Many commercial antifoams are derivatives of fatty acids or oils. However, it is well known that lipids can induce foaming in manure based biogas plants. This study aimed to elucidate the effect of rapeseed oil and oleic acid on foam reduction and process performance in biogas reactors fed with protein or lipid rich substrates. The results showed that both antifoams efficiently suppressed foaming. Moreover rapeseed oil resulted in stimulation of the biogas production. Finally, it was reckoned that the chemical structure of lipids, and more specifically their carboxylic ends, is responsible for their foam promoting or foam counteracting behaviour. Thus, it was concluded that the fatty acids and oils could suppress foaming, while salt of fatty acids could generate foam.

Foam suppression in overloaded manure-based biogas reactors using antifoaming agents

Foam control is an imperative need in biogas plants, as foaming is a major operational problem. In the present study, the effect of oils (rapeseed oil, oleic acid, and octanoic acid) and tributylphosphate on foam reduction and process performance in batch and continuous manure-based biogas reactors was investigated. The compounds were tested in dosages of 0.05%, 0.1% and 0.5% v/vfeed. The results showed that rapeseed oil was most efficient to suppress foam at the dosage of 0.05% and 0.1% v/vfeed, while octanoic acid was most efficient to suppress foam at dosage of 0.5% v/vfeed. Moreover, the addition of rapeseed oil also increased methane yield. In contrast, tributylphosphate, which was very efficient antifoam, was found to be inhibitory to the biogas process.

Anaerobic digestion foaming in full-scale biogas plants: a survey on causes and solutions

Anaerobic digestion foaming is a common operation problem in biogas plants with negative impacts on the biogas plants economy and environment. A survey of 16 Danish full-scale biogas plants on foaming problems revealed that most of them had experienced foaming in their processes up to three times per year. Foaming incidents often lasted from one day to three weeks, causing 20-50% biogas production loss. One foaming case at Lemvig biogas plant has been investigated and the results indicated that the combination of feedstock composition and mixing pattern of the reactor was the main cause of foaming in this case. Moreover, no difference in bacterial communities between the foaming and non-foaming reactors was observed, showing that filamentous bacteria were not the main reason for foaming in this case.

Antifoaming effect of chemical compounds in manure biogas reactors

A precise and efficient antifoaming control strategy in bioprocesses is a challenging task as foaming is a very complex phenomenon. Nevertheless, foam control is necessary, as foam is a major operational problem in biogas reactors. In the present study, the effect of 14 chemical compounds on foam reduction was evaluated at concentration of 0.05%, 0.1% and 0.5% v/v(sample), in raw and digested manure. Moreover, two antifoam injection methods were compared for foam reduction efficiency. Natural oils (rapeseed and sunflower oil), fatty acids (oleic, octanoic and derivative of natural fatty acids), siloxanes (polydimethylsiloxane) and ester (tributylphosphate) were found to be the most efficient compounds to suppress foam. The efficiency of antifoamers was dependant on their physicochemical properties and greatly correlated to their chemical characteristics for dissolving foam. The antifoamers were more efficient in reducing foam when added directly into the liquid phase rather than added in the headspace of the reactor.

Effect of organic loading rate and feedstock composition on foaming in manure-based biogas reactors

Foaming is one of the major problems that occasionally occur in biogas plants, affecting negatively the overall digestion process. In the present study, the effect of organic loading rate (OLR) and feedstock composition on foaming was elucidated in continuous reactor experiments. By stepwise increasing the OLR and the concentration of proteins or lipids in the substrate, foaming in biogas reactors was investigated. No foam formation was observed at the OLR of 3.5 g volatile solids/(L-reactor·day). Organic loading was the main factor affecting foam formation in manure digester, while the organic composition, such as content of proteins or lipids were factors that in combination with the organic loading were triggering foaming. More specifically, gelatine could initiate foam formation at a lower OLR than sodium oleate. Moreover, the volume of foam produced by gelatine was relatively stable and was not increased when further increasing either OLR or gelatine concentration in the feed.

Effect of substrates and intermediate compounds on foaming in manure digestion systems

Manure contains several compounds that can potentially cause foaming during anaerobic digestion. Understanding the effect of substrates and intermediate compounds on foaming tendency and stability could facilitate strategies for foaming prevention and recovery of the process. In this study, the effect of physicochemical properties of substrates and intermediate compounds on liquid properties such as surface tension, surfactant property, and hydrophobicity were investigated and compared with the effect on foaming tendency and foam stability. The results showed that there was no consistent correlation between foaming potential and hydrophobicity, oil displacement area (ODA) or surface tension of the tested solutions, and the best way to determine the foaming property of the solution was to directly measure foaming tendency and foam stability. Na-oleate and acetic acid showed the highest potential to create foam in a manure digester. Moreover, high organic loading of lipids and protein, and high concentrations of acetic and butyric acids also showed a strong tendency to create foaming during anaerobic digestion. Due to their great ability to stabilize foam, high organic loadings of Na-oleate or gelatine were considered to be the main potential foaming problem.

Pilot-scale application of an online VFA sensor for monitoring and control of a manure digester

A volatile fatty acids (VFA) sensor based on headspace chromatography was tested for online monitoring and control of a pilot-scale manure digester. The sensor showed satisfying results in terms of sensitivity and reliability for monitoring of the digester. The online VFA and biogas production data were used for automatic control of the digester based on feed flow manipulation. The control approach was based on optimization of biogas production while using VFA concentration as the alarm threshold. A rule-based supervisory system with a cascade controller was used to optimize the biogas production from the digester. The alarm state was set at 40 mM total VFA and 10 mM propionate concentration. The control algorithms could successfully maximize the biogas production without overloading the process. However, as the algorithm was based on a fixed biogas yield parameter and only used the biogas parameter for optimization, it could not distinguish between the decreases of biogas production from inhibition and from lower organic content in the substrate, which resulted in undesired decreasing of the control gas setpoint when the substrate was diluted. It was necessary to adjust the yield parameter in order to get this control approach to function properly, which is not suitable for the full-scale biogas plant where the organic content of waste streams can vary. An alternative approach could be a modified rule-based algorithm that includes VFA parameters to help distinguish between different process scenarios.

Effect of operating conditions and reactor configuration on efficiency of full-scale biogas plants

A study on 18 full-scale centralized biogas plants was carried out in order to find significant operational factors influencing productivity and stability of the plants. It was found that the most plants were operating relatively stable with volatile fatty acids (VFA) concentration below 1.5 g/l. VFA concentration increase was observed in occasions with dramatic overloading or other disturbances such as operational temperature changes. Ammonia was found to be a significant factor for stability. A correlation between increased residual biogas production and high ammonia was found. When ammonia was higher than approx. 4g-N/l the degradation efficiency of the plant decreased and as a consequence, the residual methane potential was high. Decrease of the residual methane potential with increasing hydraulic retention time was found. Digestion temperature was very important for effective post-digestion. Post-digestion for recovering the residual methane potential at temperatures below 15 degrees C was very inefficient.

Online headspace chromatographic method for measuring VFA in biogas reactor

A headspace chromatographic method has been applied to measure volatile fatty acids in anaerobic digesters using gas phase extraction at pH less than 2 and temperature higher than 65 degrees C. The concentration of volatile fatty acids in liquid and gas phase can be correlated in the form of Henry's coefficient. Analysis of different factors in the batch indicated that pH, temperature, and salt addition had a strong impact on apparent solubility, while liquid/gas volume ratio and organic acid concentration had little impact. Larger liquid volume had a positive impact on extraction efficiency, while increased gas headspace had a negative impact, indicating that the system was total mass-limited. The best conditions were at pH < 2.0, and temperatures above 75 degrees C. The advantage of an automated gas-extraction system for organic acid analysis, compared to an automated liquid system is that it contains no filter element, which is 4 susceptible to fouling in manure samples or samples with high solid content. An automated system which included a valerate pulse to the parent reactor was implemented, and operated for a short period.