State estimation for anaerobic digesters using the ADM1

The optimization of full-scale biogas plant operation is of great importance to make biomass a competitive source of renewable energy. The implementation of innovative control and optimization algorithms, such as Nonlinear Model Predictive Control, requires an online estimation of operating states of biogas plants. This state estimation allows for optimal control and operating decisions according to the actual state of a plant. In this paper such a state estimator is developed using a calibrated simulation model of a full-scale biogas plant, which is based on the Anaerobic Digestion Model No.1. The use of advanced pattern recognition methods shows that model states can be predicted from basic online measurements such as biogas production, CH4 and CO2 content in the biogas, pH value and substrate feed volume of known substrates. The machine learning methods used are trained and evaluated using synthetic data created with the biogas plant model simulating over a wide range of possible plant operating regions. Results show that the operating state vector of the modelled anaerobic digestion process can be predicted with an overall accuracy of about 90%. This facilitates the application of state-based optimization and control algorithms on full-scale biogas plants and therefore fosters the production of eco-friendly energy from biomass.     

Online estimation of VFA, alkalinity and bicarbonate concentrations by electrical conductivity measurement during anaerobic fermentation

This paper describes the use of electrical conductivity for measurement of volatile fatty acids (VFA), alkalinity and bicarbonate concentrations, during the anaerobic fermentation process. Two anaerobic continuous processes were studied: the first was a laboratory reactor for hydrogen production from molasses and the second was a pilot process for anaerobic digestion (AD) of vinasses producing methane. In the hydrogen production process, the total VFA concentration, but not bicarbonate concentration, was well estimated from the on-line electrical conductivity measurements with a simple linear regression model. In the methane production process, the bicarbonate concentration and the VFA concentration were well estimated from the simultaneous on-line measurements of pH and electrical conductivity by means of non-linear regression with neural network models. Moreover, the total alkalinity concentration was well estimated from electrical conductivity measurements with a simple linear regression model. This demonstrates the use of electrical conductivity for monitoring the AD processes.     

Intracellular biopolymer productions using mixed microbial cultures from fermented POME.

This study aimed to produce polyhydroxyalkanoates (PHAs) from organic wastes by mixed bacterial cultures using anaerobic-aerobic fermentation systems. Palm oil mill effluent (POME) was used as an organic source, which was cultivated in a two-step-process of acidogenesis and acid polymerization. POME was operated in a continuous flow anaerobic reactor to access volatile fatty acids (VFAs) for PHAs production. During fermentation, VFA concentration was produced in the range of 5 to 8 g/L and the COD concentration reduced up to 80% from 65 g/L. The VFA from anaerobic fermentation was then utilised for PHA production using a mixed culture in availability of aerobic bioreactor. Production of PHAs was recorded high when using a high volume of substrates because of the higher VFA concentration. Even though the maximum PHA content was observed at only 40% of the cell dried weight (CDW), their production and performance are significant in mixed microbial culture.     

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.     

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.     

活性炭促进UASB处理高浓度啤酒废水效果研究

高浓度啤酒废水在厌氧消化过程中容易酸化,抑制甲烷转化。为提高UASB反应器的稳定性和处理效果,本研究通过序批式试验的方法,以模拟啤酒废水为底物,考察了两种不同粒径的活性炭对加速UASB污泥颗粒化进程和提高甲烷产率的影响。试验运行95 d,进水有机负荷从2.9 kg/(m3·d)增加到12.0 kg/(m3·d),监测反应器内产气量、出水VFA、出水TOC及污泥特性等参数的变化趋势。结果表明:投加活性炭能有效缩短厌氧污泥颗粒化的时间,增强产甲烷菌活性,大幅提升甲烷产量,出水TOC和VFA都维持在较低水平;并且较小粒径的粉末活性炭对UASB反应器的促进作用优于较大粒径的颗粒活性炭,能有效促进底物向甲烷气体转化。     

Anaerobic monodigestion of poultry manure: determination of operational parameters for CSTR

In this work the anaerobic monodigestion for the treatment of turkey manure was evaluated, without its codigestion with another substrate. The effect of the organic loading rate (OLR) and the substrate concentration (high total solids (TS) concentration) or product concentration (high volatile fatty acids (VFA) and/or ammonia (NH(3)-N) concentrations) was studied. The results show that for a continuous stirred tank reactor (CSTR) operation, a maximum of 40 g/L of TS and 4.0 g/L of ammonium (NH(4)(+)) was required. In addition, the maximum organic loading rate (OLR) will not exceed 1.5 kg VS/m(3)d. Higher TS and NH(4)(+) concentrations and OLR lead to a reduction on the methane productivity and volatile solids (VS) removal. During the CSTR operation, a high alkalinity concentration (above 10 g/L CaCO(3)) was found; this situation allowed maintaining a constant and appropriate pH (close to 7.8), despite the VFA accumulation. In this sense, the alkalinity ratio (α) is a more appropriate control and monitoring parameter of the reactor operation compared to pH. Additionally, with this parameter a VS removal of 80% with a methane productivity of 0.50 m(3)(CH4)/m(3)(R)d is achieved.     

Acidogenic fermentation of municipal solid waste and its application to bio-electricity production via microbial fuel cells (MfCs)

Acidogenic fermentation of organic municipal solid waste (MSW) and the bio-electricity production potential from its volatile fatty acid (VFA)-rich leachate using an air-cathode microbial fuel cell (MFC) was investigated in this study. The acidogenic fermentation of 2 kg of MSW has been carried out in a 6 L anaerobic leach-bed reactor (LBR) under mesophilic conditions (30 degrees C). Total production of 92 g VFA expressed as chemical oxygen demand (COD) in 3 L leachate mainly containing acetic, propionic, butyric, and valeric acids has been achieved with manual leachate recirculation and without pH control in 74 days of incubation. Leachate collected on day 32 was used as a feed to an air-cathode MFC after being diluted and supplemented with NaCl or NaHCO3. The maximum power density in the diluted leachate was only 5.9 W/m3, but reached up to 8.6 W/m3 upon the addition of 7 mmol/L NaCl. Increase in coulombic efficiency from 6 to 22% was also observed as a result of NaCl supplementation. On the other hand, NaHCO3 addition did not improve the power output.     

Enhanced biogas recovery by applying post-digestion in large-scale centralized biogas plants.

The main objective of this study was to investigate the degradation efficiency of centralized biogas plants and provide guidance for the design of more efficient digester and post-digestion systems. These centralized biogas plants in Denmark digest manure together with organic waste from the food industry to generate biogas, which is used for electricity and thermal energy. A total of 20 such plants are currently active in Denmark, most of which were included in the investigation. From the plants, samples were obtained from various steps of the process. Samples were analysed and the residual biogas potential determined by batch post-digestion at various temperature levels. Results were correlated with plant characteristics and production statistics in order to judge the efficiency of various digestion concepts. A simplified model based on a two-step biogas production process was developed and experimental data were used to determine kinetic constants. Experimental results and analysis combined with model simulations showed that the residual biogas potential in the main digestion step effluent is originating mainly from undegraded particulate matter in the biomass. For thermophilic plants 93% of the residual biogas potential was originating from particulate matter and 88% for the mesophilic biogas plants. This indicates that the residual biogas potential is mainly due to insufficient retention time in the main digestion step for hydrolysis of particulate material and that the hydrolysis step is the methane yield limiting factor, while conversion of soluble material such as VFA is the rate limiting factor critical for achieving a stable process.     

Two-phase thermophilic anaerobic digestion process for biohythane production treating biowaste: preliminary results

This paper deals with the optimization of a two-phase anaerobic process treating biowaste for hydrogen and methane production. Neither physical nor chemical pre-treatments were used to optimize the process. The work was carried out at pilot scale, using two CSTRs (200 and 380 L working volume respectively) both maintained at thermophilic temperature (55 C) and fed semi-continuously with biowaste. The experiment was divided into three periods; during the first two periods the organic loading rate was maintained at 20 kg TVS/m3 d and the hydraulic retention time was changed from 6.6 to 3.3 days, while in the last period the digestate of the second reactor was recirculated to the first reactor in order to buffer the system and control pH at levels around 5. The HRT was maintained at 3.3 days and the OLR was decreased at 16.5 kg TVS/m3 d. The best yield was obtained in the last period where a specific hydrogen production of 50.9 L/kg VSfed was reached, with a H2 content in biogas from the first reactor of 36%. The methanogenic stage after the hydrogen conversion reached a specific biogas production of 0.62 m3/kg VSfed and an overall organic removal above 70%, without any stability problem. The overall biogas production was some 1.5 m3 per day with a gas composition of 10% H2 and 50% CH4.     

Development and optimisation of VFA driven DEAMOX process for treatment of strong nitrogenous anaerobic effluents.

The recently proposed DEAMOX (DEnitrifying AMmonium OXidation) process combines the anammox reaction with autotrophic denitrifying conditions using sulphide as an electron donor for the production of nitrite from nitrate within an anaerobic biofilm. This paper firstly presents a feasibility study of the DEAMOX process using synthetic (ammonia + nitrate) wastewater where sulphide is replaced by volatile fatty acids (VFA) as a more widespread electron donor for partial denitrification. Under the influent N-NH+4/N-NO3(-) and COD/N-NO3(-) ratios of 1 and 2.3, respectively, the typical efficiencies of ammonia removal were around 40% (no matter whether a VFA mixture or only acetate were used) for nitrogen loading rates (NLR) up to 1236 mg N/l/d. This parameter increased to 80% by increasing the influent COD/N-NO3(-) ratio to 3.48 and decreasing the influent N-NH4 +/N-NO3(-) ratio to 0.29. As a result, the total nitrogen removal increased to 95%. The proposed process was further tested with typical strong nitrogenous effluent such as reject water (total N, 530-566 mg N/l; total COD, 1530-1780 mg/l) after thermophilic sludge anaerobic digestion. For this, the raw wastewater was split and partially ( approximately 50%) fed to a nitrifying reactor (to generate nitrate) and the remaining part ( approximately 50%) was directed to the DEAMOX reactor where this stream was mixed with the nitrified effluent. Stable process performance up to NLR of 1,243 mg N/l/d in the DEAMOX reactor was achieved resulting in 40, 100, and 66% removal of ammonia, NOx(-), and total nitrogen, respectively.     

Biodegradation of 2-chlorophenol (2CP) in an anaerobic sequencing batch reactor (ASBR)

The aim of this study is to contribute to the knowledge about anaerobic digestion of 2-chlorophenol (2CP) in an anaerobic sequencing batch reactor (ASBR). Two reactors were set up (ASBR(A) and ASBR(B)). The ASBR(A) was fed with 2-chlorophenol (28-196 mg 2CP-C/L) and no other exogenous electron donor. The ASBR(B) was fed with a mixture of 2CP (28-196 mg 2CP-C/L) and phenol (28-196 mg phenol-C/L) as an electron donor. The process evaluation was conducted by three means: first by substrate consumption efficiency (E(2CP)), second, by biogas yield (Y(biogas-C/2CP-C)) and third, by the specific consumption rates (q(2CP)) as response variables. The 2CP consumption efficiency (90 ± 0.4%) was not influenced by the increase in the concentrations tested. In both reactors ASBR(A) and ASBR(B), both concentration as well as speed increased. Concentration increased from 28 to 114 mg 2CP-C/L. The specific consumption rate (q(2CP)) values were fivefold higher. However, a decrease of 37% was observed at 140 mg 2CP-C/L and one of 72% at 196 mg 2CP-C/L. The biogas yields (0.80 ± 0.06) remained stable in both reactors. In both reactors the biogas yield decreased to 78 ± 3% at 196 mg 2CP-C/L. We might assume this decrease was due to the accumulation of VFA. Finally, poor sludge settleability was determined only in the SBR(B) reactor at 140 and 196 mg 2CP-C/L. An increase was observed in both SVI ≤ 140 ± 5 mL/g and over exopolymeric protein ≤120 mg EP/L.     

Application of an anaerobic hybrid reactor for petrochemical effluent treatment

An anaerobic hybrid reactor (UASB/Filter) was used for petrochemical wastewater treatment in mesophilic conditions. The seeded flocculent sludge from a UASB plant treating dairy wastewater, acclimatized to the petrochemical wastes in a two-stage operation. After start up, under steady-state conditions, experiments were conducted at OLRs of between 0.5 and 24 kg TCOD m(-3) d(-1), hydraulic retention times (HRT) of 4-48 h and up-flow velocities 0.021-0.25 mh(-1). Removal efficiencies in the range of 42-86% were achieved at feed TCOD concentrations of 1,000-4,000 mg L(-1). The results of reactor performance at different operational conditions and its relations are presented and discussed in this paper. Then, the obtained data are used for determination of kinetic models. The results showed that a second-order model and a modified Stover-Kincannon model were the most appropriate models for this reactor. Finally, the biogas production data were used for the determination of biogas production kinetics.     

Extremum-seeking with variable gain control for intensifying biogas production in anaerobic fermentation.

A state-dependent variable-gain control system is implemented to follow the characteristics of a laboratory-scale up-flow anaerobic fixed-bed reactor dynamically. The transition from one state to another is determined on an hourly basis, depending on difference between the setpoint of the reactor pH and its true value. Considerable improvement of the process stability--reduction of oscillation in both the reactor pH and biogas production rate during high-rate operation, has been achieved, although the control structure is simple and intuitive.     

Integration of equalisation tanks within control strategies for anaerobic reactors. Validation based on ADM1 simulations.

The combination of equalisation tanks and anaerobic digesters represents a typical design scenario within the treatment of industrial wastewaters. In this context, if the hydraulic capacity of the equalisation tanks is effectively handled, significant improvements in the performance of anaerobic digesters can be achieved in terms of process stability and biogas production. This paper presents a rule-based control strategy for anaerobic reactors with the objective of maximising in the long-term the net production of biogas. The control algorithm combines real-time information about the state of the anaerobic digester with on-line measurements about the wastewater volume of the equalisation tank in order to set permanently the appropriate production of biogas. Such a strategy guarantees a continuous influent flow so that emptying and overflowing episodes in the equalisation tank can be prevented. Aiming at a further full-scale implementation, only reliable and cost-effective on-line instrumentation has been considered within the control architecture. The performance of the proposed control approach has been validated for an anaerobic hybrid configuration (AHR) by simulation using the IWA ADM1 model.     

Sulfide production and wastewater quality in pressure mains

An empirical model for predicting sulfide production in pressure mains (Hvitved-Jacobsen et al., 1988) was evaluated and modified based on results obtained from two intercepting pressure mains located in the Northern part of Jutland, Denmark. Mass balances in pipe influent and effluent were made for volatile fatty acids, VFA (formate, acetate, propionate and butyrate), dissolved COD, DOC and sulfide and biofilm surface rate for sulfide and organic matter were calculated. Relatively high sulfide formation rates were observed at low temperatures (5–12°C). The sulfide production rate strongly depended on wastewater quality in terms of VFA and dissolved carbohydrate concentration. Based on these two sets of observations — wastewater quality and temperature — the original empirical model was modified.     

Co-digestion of ruminal content and blood from slaughterhouse industries: influence of solid concentration and ammonium generation.

At the present time, organic solid wastes from industries and agricultural activities are considered to be promising substrates for biogas production via anaerobic digestion. Moreover solids stabilisation is required before reutilization or disposal. Slaughterhouses are among the most important industries in Uruguay and produce 150,000 tons of ruminal content (RC) and 30,000 tons of blood per year. In order to determine the influence of the solids and blood contents, the ammonia inhibition and the inoculum adaptation co-digestion batch tests were performed. A set of experiences with TS concentration of 2.5%, 5% and 7.5% and different ratios of RC/blood were carried out using an inoculum from an UASB reactor. In all experiences fast blood hydrolisation was observed. A higher methane production was detected in the experiences with higher TS content. However, the fraction of solids degradation was lower in these experiences. A plateau in the biogas production was found. The free ammonia level, which was above the reported inhibitory levels, could explain this behaviour. After the inhibition period the biogas production restarted probably due to the biomass acclimatisation to the ammonia. In order to determine the inoculum adaptation a new experiment was performed. The inoculum used was the sludge coming from the first set of experiences. Based upon batch tests a 3.5 m3 pilot reactor was designed and started up. Ammonia inhibition was avoided by the start-up strategy and in two weeks the biogas production was 3.5 m3/d. The VS stabilisation with a solid retention time of 20 days was of 43%. The pilot reactor working at steady state had a TS concentration of 3-4% with a ratio of RC/blood of 10:1 at the entrance.     

Maximising biogas in anaerobic digestion by using engine waste heat for thermal hydrolysis pre-treatment of sludge.

Dublin's Ringsend WWTP was designed to serve a population of approximately 1.2 million p.e. with a sludge production of 37,000 dry tonnes per year after upgrading to full secondary treatment. Several technical solutions were put forward as part of a design, build, finance and operate (DBFO) competition, with the chosen solution being a proposal by Black and Veatch for a combination of sequencing batch reactor (SBR) technology and anaerobic digestion with Cambi thermal hydrolysis pre-treatment (THP). The THP plant was built by Cambi and handed over to B&V in 2002. The plant is now operated by Celtic Anglian Water. In September 2004 a test was carried out on the mass and energy balance of the plant following 2 years of operation and is detailed in this paper. The process enables digestion at very high dry solids feed and low hydraulic retention time. The plant was built with three digesters of 4250 m3 each and is fed with hydrolysed sludge at 11% DS. There are four no. 1 MW Jenbacher engines operating mainly on biogas. Each pair of engines is fitted with a waste heat boiler with a capacity of one tonne steam per hour. These boilers have sufficient capacity to provide 80% of the steam required for the THP, which in turn provides all the heat for the subsequent digestion in the form of hydrolysed feed. There are two main biogas boilers for top up steam and other uses of the biogas including thermal oxidation of concentrated odours.     

Improving biogas yields using an innovative concept for conversion of the fiber fraction of manure

The potential of a new concept to enable economically feasible operation of manure-based biogas plants was investigated at laboratory scale. Wet explosion (WEx) was applied to the residual manure fibers separated after the anaerobic digestion process for enhancing the biogas yield before reintroducing the fiber fraction into the biogas reactor. The increase in methane yield of the digested manure fibers was investigated by applying the WEx treatment under five different process conditions. The WEx treatment at 180 °C and a treatment time of 10 min without addition of oxygen was found to be optimal, resulting in 136% increase in methane yield compared with the untreated digested manure fibers in batch experiments. In a continuous mesophilic reactor process the addition of WEx-treated digested fibers in co-digestion with filtered manure did not show any signs of process inhibition, and the overall methane yield was on average 75% higher than in a control reactor with addition of non-treated digested fibers.