Methane conversion efficiency as a simple control parameter for an anaerobic digester at high loading rates

The anaerobic digestion process is globally applied to the treatment of highly concentrated wastes such as industrial and rural effluents, and sewage sludge. However, it is known to be relatively unstable. When loaded with high concentrations of organic material, unwanted volatile fatty acids (VFA) are often produced rather than methane (CH4) gas which can lead to digester acidification and failure. This study investigated digester behaviour under high loading rates, testing the usefulness of stoichiometric methane conversion efficiency as a digester control parameter at high loading rates. Our results show that, in general, the CH4 production rate was proportional to the feed rate (loading rate). However, at very high loading rates, the CH4 production rate was not proportional to the increase in the feeding rate. Consequently, VFA accumulated and the H2 partial pressure increased. The proportionality of the loading rate and gas production rate is stoichiometrically expressed as the conversion efficiency. We found that conversion efficiency was a useful indicator as an early warning of digester imbalance. The digester remained stable at conversion efficiencies above 75%. Dropping below 70% signified the onset of digester failure. As loading rate and methane production data are readily available on-line in most anaerobic digestion plants, the conversion efficiency can be monitored on-line and used as an efficient control technique to maintain safe operation of anaerobic digesters at high loading rates.     

The effect of temperature on the performance and stability of thermophilic anaerobic digestion.

Sustainable operation of an anaerobic sewage sludge digester requires the effective shuttling of carbon from complex organic material to methane gas. The accumulation of intermediates and metabolic products such as volatile fatty acids and hydrogen gas not only reveal inefficiency within the digestion process, but can be detrimental to reactor operation at sufficiently high levels. Eight anaerobic digesters (1 mesophilic and 7 thermophilic) were operated in order to determine the effect of steady-state digestion temperature on the operational stability and performance of the digestion process. Replicate reactors operated at 57.5 degrees C, the highest temperature studied, were prone to accumulation of volatile fatty acids (4052 and 3411 mg/L as acetate) and gaseous hydrogen. Reactors operated at or below 55 degrees C showed no such accumulation of intermediate metabolites. Overall methanogenesis was also greatly reduced at 57.5 degrees C (0.09 L CH4/g VS fed) versus optimal methane formation at 53 degrees C (0.40 L CH4/g VS fed). Microbial community assessment and free energy calculations suggest that the accumulation of fatty acids and hydrogen, and relatively poor methanogenic performance at 57.5 degrees C are likely due to temperature limitations of thermophilic aceticlastic methanogens.     

Thermophilic anaerobic digester with ultrafilter for solids stabilization.

A thermophilic anaerobic digester with ultrafilter (TADU) for solids separation offers potential advantages of higher VS destruction, biomass retention, and pathogen removal. However, potential disadvantages include ultrafilter fouling, decreasing flux, and high VFA concentrations. In this study, a thermophilic anaerobic digester coupled to a sintered titanium, cross-flow ultrafilter was operated for over five months. Dairy manure was digested (HRT of 23 days). The filtrate VFA concentration was low (220 mg/L as HAc), average VS destruction was 49%, and a low average effluent fecal coliform concentration of 10(2) MPN/100 mL was observed. The low coliform value may be beneficial if dewatered biosolids are used for livestock bedding since low pathogen counts help prevent mastitis. Ultrafilter fluxes of 40-80 L/m2-hr were maintained by cleaning using caustic (3.5% NaOH) followed by water and acid (3% phosphoric acid). Sand from livestock bedding was found to damage the pump and ultrafilter. If TADU were implemented at full scale, then replacing sand bedding with dewatered biosolids should be considered.     

Temperature effects on the trophic stages of perennial rye grass anaerobic digestion

Continuous Stirred Tank Reactors (CSTRs), operated in batch mode, were used to evaluate the feasibility of psychrophilic (low temperature) digestion of perennial rye grass in a long term experiment (150 days) for the first time. The reactors were operated in parallel at 3 different temperatures, 10, 15 and 37 degrees C. Hydrolysis, acidification and methanogenesis were assessed by VS degradation, by soluble chemical oxygen demand (SCOD) and volatile fatty acids (VFA) production, and by methane production, respectively. Hydrolysis was the rate-limiting step at all temperatures and the rates and extent of hydrolysis were considerably lower at 15 and 10 degrees C, than at 37 degrees C. The total VS degradation was 53%, 34% and 19% at 37, 15 and 10 degrees C, respectively. Acidification was not affected by temperature and VFA production and consumption was balanced in all cases, except at 10 degrees C. Methane yields were 0.215 m3 CH4 kg(-1) VS(-1) added, 0.160 m3 CH4 kg(-1) VS(-1) added and 0.125 m3 CH4 kg(-1) VS(-1) added at 37, 15 and 10 degrees C, respectively. Methanogenesis was not strongly affected at 15 C but it became rate-limiting at 10 degrees C. Overall, the solid degradation and methane production performance under psychrophilic conditions was encouraging and greater than previously reported. Considering the non-acclimated, mesophilic nature of the inoculum, there are grounds to believe that low-temperature anaerobic digestion of grass could be feasible if coupled to efficient hydrolysis of the biomass.     

Effect of biological additives and micronutrients on the anaerobic digestion of physicochemical sludge.

Two additives (lyophilized bacilli and enzymes) and a solution of micronutrients (Fe, Co, Ni and Mo) were tried separately and in combination, in order to assess their effect on the anaerobic digestion of waste sludge from an enhanced primary treatment (EPT) of municipal wastewater. Three batch tests were carried out in serological bottles. In the first test, addition of bacilli increased production of methane from day 11 and at day 1 7 the production was 95% greater than the control. In that experiment, the concentration of volatile fatty acids (VFAs) was 1,391 mg/L, 40% lower than the control. In the second test, the combination of micronutrients with bacilli, reached from the first days a better methane production than the control, 167% higher in day 17. At the end of the experiment, this combination achieved a lower concentration of VFAs and a greater percentage of volatile solid removal than the rest of the treatments. The third test was based on an experimental design in order to statistically determine the best doses of bacilli additive and micronutrients. The anaerobic thermophilic digestion of sludge from aluminium sulfate EPT will be improved with the addition of Fe: 4.5 mg/g VS, Ni: 0.75 mg/g VS, Co: 0.45 mg/g VS, Mo: 0.09 mg/g VS and bacilli additive: 12 mg/g VS.     

Microalgae growth for nutrient recovery from sludge liquor and production of renewable bioenergy

Proof-of-concept has been demonstrated for a process that will utilize nutrients from sludge liquor, natural light, and CO2 from biogas to grow microalgae at wastewater treatment plants. This process will reduce the impact of returning side-streams to the head of the plant. The produced algae will be fed to anaerobic digesters for increased biogas production. Dewatering of anaerobically digested sludge in centrifuges produces reject water with extremely low transmittance of light. A pretreatment procedure was developed that improved light transmittance for reject water from the FREVAR, Norway, wastewater treatment plant from 0.1% T to 77% T (670 nm, 1 cm path). Chlorella sp. microalgae were found to be suitable for growth in this pre-treated reject water. Typical nitrogen removal was 80-90 g N/kg TSS of produced microalgae. The microalgae were successfully harvested by chemically assisted flocculation followed by straining through a 33 microm sieve cloth, achieving up to 99% recovery. Harvested algae were anaerobically co-digested with wastewater sludge. The specific methane gas production (mL CH4/g VS fed) for the algae varied from less than 65% to 90% of the specific methane gas production for the wastewater sludge, depending on digester temperature, retention time and pre-treatment of the algae biomass.     

Two-stage thermophilic-mesophilic anaerobic digestion of waste activated sludge from a biological nutrient removal plant.

A two-stage thermophilic-mesophilic anaerobic digestion pilot-plant was operated solely on waste activated sludge (WAS) from a biological nutrient removal (BNR) plant. The first-stage thermophilic reactor (HRT 2 days) was operated at 47, 54 and 60 degrees C. The second-stage mesophilic digester (HRT 15 days) was held at a constant temperature of 36-37 degrees C. For comparison with a single-stage mesophilic process, the mesophilic digester was also operated separately with an HRT of 17 days and temperature of 36-37 degrees C. The results showed a truly thermophilic stage (60 degrees C) was essential to achieve good WAS degradation. The lower thermophilic temperatures examined did not offer advantages over single-stage mesophilic treatment in terms of COD and VS removal. At a thermophilic temperature of 60 degrees C, the plant achieved 35% VS reduction, representing a 46% increase compared to the single-stage mesophilic digester. This is a significant level of degradation which could make such a process viable in situations where there is no primary sludge generated. The fate of the biologically stored phosphorus in this BNR sludge was also investigated. Over 80% of the incoming phosphorus remained bound up with the solids and was not released into solution during the WAS digestion. Therefore only a small fraction of phosphorus would be recycled to the main treatment plant with the dewatering stream.     

Ammonia, a selective agent for methane production by syntrophic acetate oxidation at mesophilic temperature.

In biogas processes, methane production from acetate proceeds by either aceticlastic methanogenesis or through syntrophic acetate oxidation (SAO). In the present study, the pathway for methane production from acetate was analysed; i) during a gradual increase of the ammonia concentration (final concentration 7 g NH(4)(+) -N/L) in a semi-continuous lab-scale anaerobic digester (4.3 L), operating at mesophilic temperature (37 degrees C) or ii) in diluted enrichment cultures (100 ml) experiencing a gradual increase in ammonia, sodium, potassium and propionic acid. The pathway for methane formation was determined by calculating the (14)CO(2)/(14)CH(4) ratio after incubating samples with (14)C-2-acetate. In the anaerobic digester, as well as in the enrichment cultures, the (14)CO(2)/(14)CH4 ratio clearly increased with increasing ammonium-nitrogen concentration, i.e. as the ammonia concentration increased, a shift from the aceticlastic mechanism to the syntrophic pathway occurred. The shift was very distinct and occurred as the NH(4)(+) -N concentration rose above 3 g/l. No shift in pathway was seen during increasing concentrations of sodium, potassium or propionic acid. The shift to SAO in the biogas digester resulted in a twofold decrease in the specific gas and methane yield.     

Anaerobic digestion elutriated phased treatment of piggery waste.

The performance of a novel high-rate anaerobic process, the anaerobic digestion elutriated phased treatment (ADEPT) process, for treating a slurry-type piggery waste (55 g COD/L and 37 g TS/L) was investigated. The ADEPT process consists of an acid elutriation slurry reactor for hydrolysis and acidification, followed by an upflow anaerobic sludge bed reactor for methanification. This process provides stable and high system performance with short HRT (7.4 d) and better effluent quality (2 g SCOD/L and 0.68 g VSS/L) due to the alkaline pH condition for hydrolysis/acidification phase, high refractory solids removal and ammonia toxicity reduction. The optimum pH and HRT for hydrolysis/acidogenesis of the piggery waste were 9 and 5 days at both 35 degrees C and 55 degrees C conditions. The hydrolysis and acidification rate in the mesophilic reactor were 0.05 d(-1) and 0.11 d(-1), meaning that hydrolysis was a limiting step. SCOD production by the hydrolysis was about 0.26 g SCOD/g VS(fed) (3.6 g SCOD/g VS reduction). Methane production and content in the system were 0.3 L CH4/g VS(fed) (0.67 L CH4/g VS destroyed) and 80%, respectively, corresponding to 0.23 L CH4/g COD removal (@STP).     

Characterization of sludges for predicting anaerobic digester performance.

Batch anaerobic digestion tests of primary sludge and waste activated sludge were conducted for a duration of 123 days to determine the ultimate degradability of the sludges. For primary sludges the inert fraction of the particulate COD that was predicted by the wastewater models could be employed to predict their biodegradability under anaerobic conditions. The degradation of waste activated sludge was adequately characterized for the first 60 days of digestion using a model that assumed equivalent biodegradability of particulate COD components under aerobic and anaerobic conditions. However after 60 days of anaerobic digestion it appeared that decay of the endogenous products was occurring. This could be described with a first order decay function with a coefficient of 0.0075 d(-1). For continuous flow digesters operating at SRTs of 30-60 days, the predicted VSS destruction with the modified model was approximately 10% higher than that predicted on the basis of inert endogenous decay products.     

Continuous thermal hydrolysis and energy integration in sludge anaerobic digestion plants.

A thermal hydrolysis pilot plant with direct steam injection heating was designed and constructed. In a first period the equipment was operated in batch to verify the effect of sludge type, pressure and temperature, residence time and solids concentration. Optimal operation conditions were reached for secondary sludge at 170 degrees C, 7 bar and 30 minutes residence time, obtaining a disintegration factor higher than 10, methane production increase by 50% and easy centrifugation In a second period the pilot plant was operated working with continuous feed, testing the efficiency by using two continuous anaerobic digester operating in the mesophilic and thermophilic range. Working at 12 days residence time, biogas production increases by 40-50%. Integrating the energy transfer it is possible to design a self-sufficient system that takes advantage of this methane increase to produce 40% more electric energy.     

Control of C/N ratio for butyric acid production from textile wastewater sludge by anaerobic digestion

Increasing textile wastewaters and their biotreatment byproduct-waste activated sludge are serious pollution problems. Butyric acid production from textile wastewater sludge by anaerobic digestion at different C/N ratios was investigated. Adding starch to textile wastewater sludge with a C/N ratio of 30 increased the butyric acid concentration and percentage accounting for total volatile fatty acids (TVFAs) to 21.42 g/L and 81.5%, respectively, as compared with 21.42 g/L and 10.6% of textile wastewater sludge alone. The maximum butyric acid yield (0.45 g/g VS), conversion rate (0.74 g/g VS(digest)) and production rate (2.25 g/L d) was achieved at a C/N ratio of 30. The biological toxicity of textile wastewater sludge also significantly decreased after the anaerobic digestion. The study indicated that the anaerobic co-digestion of textile wastewater sludge and carbohydrate-rich waste with appropriate C/N ratio is possible for butyric acid production.     

Fermentative hydrogen production in a system using anaerobic digester sludge without heat treatment as a biomass source.

Hydrogen produced from anaerobic fermentation of organic matter is a sustainable energy source. Anaerobic hydrogen-producing systems have been typically seeded with heat-treated inocula to eliminate hydrogen-consuming methanogens. This can be both energy- and economically-intensive. In this work, operational parameters were modified to determine if operating a reactor at low pH (5.5) and low SRT (10 hours) would result in a hydrogen-producing system free of methanogens using anaerobic digester sludge with no heat treatment as an inoculum. Initially, the reactor exhibited a hydrogen productivity of approximately 7.9% when fed glucose. After purging was begun with 10% CO2/90% N2, the hydrogen productivity increased to > 20% for the first day. Hydrogenotrophic methanogens then established themselves in the reactor, reducing the hydrogen productivity in the second non-purged phase by 80%. The operational controls examined were not sufficient to eliminate hydrogen-consuming methanogens for longer than approximately one week, and thus further methods must be developed.     

Effect of hydraulic retention time on pretreatment of blended municipal sludge

The objective of the present work was to evaluate the effect of hydraulic retention time (HRT) on hydrolysis and acidogenesis for the pretreatment processes: acid phase digestion (APD) and autothermal thermophilic aerobic digestion (ATAD) using blended municipal sludge. The effect of the different pretreatment steps on mesophilic anaerobic digestion (MAD) was evaluated in terms of methane yield, keeping the operating conditions of the MAD the same for all systems. Best operating conditions for both APD and ATAD were observed for 2.5 d HRT with high total volatile fatty acids (tVFA), and the highest methane yield observed for MAD. No significant difference was observed between the two processes in terms of overall volatile solids (VS) reduction with same total HRT. The autothermal process produced heat of 14,300 J/g VS removed from hydrolytic and acetogenic reactions without compromising overall methane yields when the HRT was 2.5 d or lower and the total O2 used was 0.10 m3 O2/g VS added or lower. However, the process needs the input of oxygen and engineering analysis should balance these differences when considering the relative merits of the two pretreatment processes. This is the first study of its kind directly comparing these two viable pretreatment processes with the same sludge.     

Microbial population dynamics in a thermophilic methane digester fed with garbage.

The diversity of microbial communities in three full-scale thermophilic anaerobic digesters which treated garbage, sewage sludge and livestock wastes (hereafter called TGD, TSD and TLD, respectively) was investigated using 16S rDNA clone libraries in triplicate. The population dynamics of TGD were also studied. The purposes were to show the microbial diversity in each reactor and to suggest which key microbes in a thermophilic methane digester fed with garbage, including a check of reproducibility and the suggestion of an error range in this molecular biology method. 736 clones were identified, and the maximum error was estimated to be around +/-10% for the same OTU (operational taxonomic unit) and for most detected OTUs. The most frequently detected OTU shows a close relationship to Uncultured bacterium clone MBA08, Unidentified bacterium clone TUG22 and Uncultured archaeal symbiont PA204 in TGD, TSD and TLD, respectively. The microbial population dynamics in TGD were studied over a period of 90 days, and the occupying ratios of Bacillus infernus and Methanothermobacter wolfeii were shown to change with the change in VFA concentration. From the dynamic change and characteristics of the microbes, it is concluded that Bacillus infernus and Methanothermobacter wolfeii played an important role and were recommended as key microbes in TGD.     

Odor control during post-digestion processing of biosolids through bioaugmentation of anaerobic digestion.

The effects of bioaugmenting anaerobic biosolids digestion with a commercial product that contained selected strains of bacteria from genera Bacillus, Pseudomonas, and Actinomycetes, along with ancillary organic compounds containing various micronutrients were evaluated. The main objective of the study was to investigate the effects of bioaugmentation specifically on the performance of methanogenesis during anaerobic digestion, as well as on the generation and fate of odor-causing compounds during the storage of the digested biosolids. The bench-scale digester with 5 g/L bioaugment generated 29% more net CH4 than a control during the eight weeks of operation. In addition, the average residual propionic acid concentration in the bioaugmented digester was 46% lower than that in the control. The biosolids digested in the bioaugmented digester generated a negligible amount of methyl mercaptan (CH3SH) during 10 days of post-digestion storage, while CH3SH concentration in the control reached nearly 300 ppmv during the same period. Similarly peak dimethyl sulfide (CH3SCH3) generated by stored biosolids from the bioaugmented digester was only 37% of that from the control. Similar results were obtained in a subsequent short term study designed to confirm the repeatability of the findings.     

Alkaline and acid hydrolytic processes in aerobic and anaerobic sludges: effect on total EPS and fractions.

Sludge samples from an upflow anaerobic sludge blanket (UASB) reactor and four submerged aerated biofilters (BFs) of a wastewater treatment plant (1,000 inhab.) were processed at bench scale by alkaline and acid hydrolysis with the objective to evaluate the organic matter solubilization, volatile solids (VS) destruction and the effect of hydrolytic processes on the extracellular polymeric substances (EPS) fraction of the sludge samples. The results showed that alkaline hydrolysis of sludge samples treatment with 1.0% total solids (TS) using NaOH 20 meq L(-1) was more efficient on organic matter solubilization and VS destruction than acid hydrolysis. The EPS sludge content was also affected by the alkaline treatment of anaerobic sludge samples. The EPS concentrations (mg EPS/gVSS) on the anaerobic sludge after the alkaline treatment were significantly lowered according to sample height in the UASB reactor. Data indicated that the EPS sludge fraction is the main component affected by the alkaline hydrolytic process of anaerobic sludge samples.     

Behavior of cellulose-degrading bacteria in thermophilic anaerobic digestion process.

Previously, we found that the newly isolated Clostridium sp. strain JC3 became the dominant cellulose-degrading bacterium in thermophilic methanogenic sludge. In the present study, the behavior of strain JC3 in the thermophilic anaerobic digestion process was investigated quantitatively by molecular biological techniques. A cellulose-degrading experiment was conducted at 55 degrees C with a 9.5 L of anaerobic baffled reactor having three compartments (Nos. 1, 2, 3). Over 80% of the COD input was converted into methane when 2.5 kgCOD m(-3) d(-1) was loaded for an HRT of 27 days. A FISH probe specific for strain JC3 was applied to sludge samples harvested from the baffled reactor. Consequently, the ratio of JC3 cells to DAPI-stained cells increased from below 0.5% (undetectable) to 9.4% (compartment 1), 13.1% (compartment 2) and 21.6% (compartment 3) at day 84 (2.5 kgCOD m(-3)d(-1)). The strain JC3 cell numbers determined by FISH correlated closely with the cellulose-degrading methanogenic activities of retained sludge. A specific primer set targeting the cellulase gene (cellobiohydrolaseA: cbhA) of strain JC3 was designed and applied to digested sludge for treating solid waste such as coffee grounds, wastepaper, garbage, cellulose and so on. The strain JC3 cell numbers determined by quantitative PCR correlated closely with the cellulose-sludge loading of the thermophilic digester. Strain JC3 is thus important in the anaerobic hydrolysis of cellulose in thermophilic anaerobic digestion processes.     

Mesophilic-thermophilic-mesophilic anaerobic digestion of liquid dairy cattle manure.

The potential of a mesophilic-thermophilic-mesophilic anaerobic digestion system was investigated with respect to improvement of both digestion and sanitation efficiencies during treatment of liquid cattle manure. The pilot plant produced a high methane yield from liquid dairy cattle manure of 0.24 m3 (kg VSfed)(-1) Considering the low system loading rate of 1.4-1.5 kg VS (m3 d)(-1), digestion efficiency compared to conventional processes did not appear improved. The minimum guaranteed retention time in the tubular thermophilic reactor was increased compared to a continuously stirred tank reactor. Levels of intestinal enterococci in raw liquid manure as determined with cultivation methods were reduced by 2.5 -3 log units to a level of around 10(2) cfu/mL. This sanitizing effect was achieved both during mesophilic-thermophilic-mesophilic and thermophilic-mesophilic treatment, provided the thermophilic digester was operated at 53-55 degrees C. A change in feeding interval from 1 h to 4 h did not significantly alter methane yield and sanitation efficiency. It was proposed that a two-stage, thermophilic-mesophilic anaerobic digestion system would be able to achieve the same sanitizing effect and equal or better digestion efficiency at lower costs.     

Application of the IWA anaerobic digestion model (ADM1) for simulating full-scale anaerobic sewage sludge digestion.

A steady-state implementation of the IWA Anaerobic Digestion Model No. 1 (ADM1) has been applied to the anaerobic digesters in two wastewater treatment plants. The two plants have a wastewater treatment capacity of 76,000 and 820,000 m3/day, respectively, with approximately 12 and 205 dry metric tons sludge fed to digesters per day. The main purpose of this study is to compare the ADM1 model results with full-scale anaerobic digestion performance. For both plants, the prediction of the steady-state ADM1 implementation using the suggested physico-chemical and biochemical parameter values was able to reflect the results from the actual digester operations to a reasonable degree of accuracy on all parameters. The predicted total solids (TS) and volatile solids (VS) concentration in the digested biosolids, as well as the digester volatile solids destruction (VSD), biogas production and biogas yield are within 10% of the actual digester data. This study demonstrated that the ADM1 is a powerful tool for predicting the steady-state behaviour of anaerobic digesters treating sewage sludges. In addition, it showed that the use of a whole wastewater treatment plant simulator for fractionating the digester influent into the ADM1 input parameters was successful.