Simon Zielonka

Is the continuous two-stage anaerobic digestion process well suited for all substrates?

Two-stage anaerobic digestion systems are often considered to be advantageous compared to one-stage processes. Although process conditions and fermenter setups are well examined, overall substrate degradation in these systems is controversially discussed. Therefore, the aim of this study was to investigate how substrates with different fibre and sugar contents (hay/straw, maize silage, sugar beet) influence the degradation rate and methane production. Intermediates and gas compositions, as well as methane yields and VS-degradation degrees were recorded. The sugar beet substrate lead to a higher pH-value drop 5.67 in the acidification reactor, which resulted in a six time higher hydrogen production in comparison to the hay/straw substrate (pH-value drop 5.34). As the achieved yields in the two-stage system showed a difference of 70.6% for the hay/straw substrate, and only 7.8% for the sugar beet substrate. Therefore two-stage systems seem to be only recommendable for digesting sugar rich substrates.

Effect of different pH-values on process parameters in two-phase anaerobic digestion of high-solid substrates

In many publications, primary fermentation is described as a limiting step in the anaerobic digestion of fibre-rich biomass [Eastman JA, Ferguson JF. Solubilization of particulacte carbon during the anaerobic digeston. J WPCF. 1981;53:352–366; Noike T, Endo G, Chang J, Yaguchi J, Matsumoto J. Characteristics of carbohydrate degradation and the rate-limiting step in anaerobic digestion. Biotechnol Bioeng. 1985;27:1482–1489; Arntz HJ, Stoppok E, Buchholz K. Anaerobic hydroysis of beet pulp-discontiniuous experiments. Biotechnol Lett. 1985;7:113–118]. The microorganisms of the primary fermentation process differ widely from the methanogenic microorganisms [Pohland FG, Ghosh S. Developments in anaerobic stabilization of organic wastes-the two-phase concept. Environ Lett. 1971;1:255–266]. To optimize the biogas process, a separation in two phases is suggested by many authors [Fox P, Pohland GK. Anaerobic treatment applications and fundamentals: substrate specificity during phase separation. Water Environ Res. 1994;66:716–724; Cohen A, Zoetemeyer RJ, van Deursen A, van Andel JG. Anaerobic digestion of glucose with separated acid production and methane formation. Water Res. 1979;13:571–580]. To carry out the examination, a two-phase laboratory-scale biogas plant was established, with a physical phase separation. In previous studies, the regulation of the pH-value during the acid formation was usually carried out by the addition of sodium hydroxide [Cohen A, Zoetemeyer RJ, van Deursen A, van Andel JG. Anaerobic digestion of glucose with separated acid production and methane formation. Water Res. 1979;13:571–580; Ueno Y, Tatara M, Fukui H, Makiuchi T, Goto M, Sode K. Production of hydrogen and methane from organic solid wastes by phase separation of anaerobic process. Bioresour Technol. 2007;98:1861–1865; Zoetemeyer RJ, van den Heuvel JC, Cohen A. pH influence on acidogenic dissimilation of glucose in an anaerobic digestor. Water Res. 1982;16:303–311]. A new technology without the use of additives was developed in which the pH-regulation is executed by the pH-dependent recycling of effluent from the anaerobic filter into the acidification reactor. During this investigation, the influence of the different target pH-values (5.5, 6.0, 7.0 and 7.5) on the degradation rate, the gas composition and the methane yield of the substrate maize silage was determined. With an increase in the target pH-value from 5.5 to 7.5, the acetic acid equivalent decreased by 88.1% and the chemical oxygen demand-concentration by 18.3% in the hydrolysate. In response, there was a 58% increase in the specific methane yield of the overall system. Contrary to earlier studies, a marked increase in biogas production and in substrate degradation was determined with increasing pH-values. However, these led to a successive approximation of a single-phase process. Based on these results, pH-values above 7.0 seem to be favourable for the digestion of fibre-rich substrates.

Do two-phase biogas plants separate anaerobic digestion phases? – A mathematical model for the distribution of anaerobic digestion phases among reactor stages

In this article a mathematical model is introduced, which estimates the distribution of the four anaerobic digestion phases (hydrolysis, acidogenesis, acetogenesis and methanogenesis) that occur among the leach bed reactor and the anaerobic filter of a biogas plant. It is shown that only the hydrolysis takes place in the first stage (leach bed reactor), while all other anaerobic digestion phases take place in both reactor stages. It turns out that, besides the usually measured raw materials of the acetogenesis and the methanogenesis phases (organic acids), it is also necessary to analyze the process liquid for raw materials of the acidogenesis phase, i.e., sugars, fatty acids, amino acids, etc. The introduced model can be used to monitor the inhibition of the anaerobic digestion phases in reactor stages and can, thus, help to improve the control system of biogas plants.

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.

Influence of different substrates on the performance of a two-stage high pressure anaerobic digestion system

The two-stage autogenerative high-pressure digestion technique is a novel and promising approach for the production of gaseous fuels or upgraded biogas. This new technique is described in the patent DE 10 2011 015415 A1 and integrates biogas production, its upgrading and pressure boosting in one process. Anaerobic digestion under elevated pressure conditions leads to decreasing pH-values in the digestate due to the augmented formation of carboxylic acid. Model calculations carried out to evaluate the two-stage design showed that the pH-value in the pressurized anaerobic filter has a major influence on the methane content of the biogas produced. Within this study, the influence of the nitrogen content as one of the most important buffering substances on the performance of the system has been tested. The results show that higher NH4 contents lead to higher pH-values in the digester and as a consequence to higher methane contents.

High-pressure anaerobic digestion up to 100 bar: influence of initial pressure on production kinetics and specific methane yields.

ABSTRACT To ensure an efficient use of biogas produced by anaerobic digestion, in some cases it would be advisable to upgrade the biogenic gases and inject them into the transnational gas grids. To investigate biogas production under high-pressure conditions up to 100 bar, new pressure batch methane reactors were developed for preliminary lab-scale experiments with a mixture of grass and maize silage hydrolysate. During this investigation, the effects of different initial pressures (1, 50 and 100 bar) on pressure increase, gas production and the specific methane yield using nitrogen as inert gas were determined. Based on the experimental findings increasing initial pressures alter neither significantly, further pressure increases nor pressure increase rates. All supplied organic acids were degraded and no measurable inhibition of the microorganisms was observed. The results show that methane reactors can be operated at operating pressures up to 100 bar without any negative effects on methane production.

Influence of pressures up to 50 bar on two-stage anaerobic digestion

The concept of pressurized two-stage anaerobic digestion integrates biogas production, purification and pressure boosting within one process. The produced methane-rich biogas can be fed into gas grids with considerably less purification effort. To investigate biogas production under high pressures up to 50bar, a lab scale two-stage anaerobic digestion system was constructed including one continuously operated pressurized methane reactor. This investigation examined the effects of different operating pressures in methane reactor (10, 25, 50bar) on biogas quantity and quality, pH value and process stability. By increasing operating pressures in methane reactor, the pH value decreased from 6.65 at 10bar to 6.55 at 50bar. Simultaneously, methane content increased from 79.08% at 10bar to 90.45% at 50bar. The results show that methane reactors can be operated up to 50bar pressure continuously representing a viable alternative to commonly used gas upgrading methods because of reduced purification effort.

Innovative test method for the estimation of the foaming tendency of substrates for biogas plants

Excessive foaming in anaerobic digestion occurs at many biogas plants and can cause problems including plugged gas pipes. Unfortunately, the majority of biogas plant operators are unable to identify the causes of foaming in their biogas reactor. The occurrence of foaming is often related to the chemical composition of substrates fed to the reactor. The consistency of the digestate itself is also a crucial part of the foam formation process. Thus, no specific recommendations concerning substrates can be given in order to prevent foam formation in biogas plants. The safest way to avoid foaming is to test the foaming tendency of substrates on-site. A possible solution is offered by an innovative foaming test. With the help of this tool, biogas plant operators can evaluate the foaming disposition of new substrates prior to use in order to adjust the composition of substrate mixes.

Kinetics of biogas production in Anaerobic Filters.

This study investigates methane production kinetics from individual volatile fatty acids (VFA) in an Upflow Anaerobic Filter (AF). 1gCOD in the form of acetic (HAc), propionic (HPr) or butyric acid (HBu) was injected into the AF while operating at an organic loading rate (OLRCOD) of 3.5gL(-1)d(-1). A new method is introduced to separate gas production of the baseload from the product formation of VFA degradation after the injection. The lag phase, fractional rate of gas production and half-life has been determined for the methane production of the three VFAs. The half-lives were in the order HAc<HBu<HPr showing a slower gas production from the C3 acid than from the C4 acid. The results can be used for prediction models for on-demand biogas production, a vital approach that provides the transforming energy market with balancing power.

Two-stage anaerobic digestion of sugar beet silage: The effect of the pH-value on process parameters and process efficiency

The study investigated the influence of the target pH-values 4.5, 5, 5.5 and 6 in the acidification reactor on process parameters, such as substrate-specific methane yield and the intermediates, in the two-stage anaerobic digestion of sugar beet silage. The total specific methane yield (Nlkg-1CODd-1) increased with an increase in the pH (pH 4.5: 140.58±70.08, pH 5: 181.21±55.71, pH 5.5: 218.32±51.01, pH 6: 256.47±28.78). The pH-value also had an effect on the dominant intermediate in hydrolysate. At the pH-value of 4.5, almost no acidification and microbial activity was observed. At pH 5 and 5.5, butyric acid production dominated, guided by H2 production. At pH 6 acetic acid was the main product. The absence of H2 and the highest SMY makes it favorable under practical aspects.