Effects of partial maize silage substitution with microalgae on viscosity and biogas yields in continuous AD trials.

The microalga Acutodesmus obliquus was investigated as a feedstock in semi-continuously fed anaerobic digestion trials, where A. obliquus was co-digested with pig slurry and maize silage. Maize silage was substituted by both 10% and 20% untreated, and 20% ultrasonicated microalgae biomass on a VS (volatile solids) basis. The substitution of maize silage with 20% of either ultrasonicated and untreated microalgae led to significantly lower biogas yields, i.e., 560 dm³ kg-1 VScorr in the reference compared to 516 and 509 dm³ kg-1VScorr for untreated and ultrasonicated microalgae substitution. Further, the viscosities in the different reactors were measured at an OLR of 3.5 g VS dm-3 d-1. However, all treatments with microalgae resulted in significantly lower viscosities. While the mean viscosity reached 0.503 Pa s in the reference reactor, mean viscosities were 53% lower in reactors where maize was substituted by 20% microalgae, i.e. 0.239 Pa s, at a constant rotation speed of 30 rpm. Reactors where maize was substituted by 20% ultrasonicated microalgae had a 32% lower viscosity, for 10% microalgae substitution a decrease of 8% was measured. Decreased viscosities have beneficial effect on the bioprocess and the economy in biogas plants. Nonetheless, with regard to other parameters, no positive effect on biogas yields by partial substitution with microalgae biomass was found. The application of microalgae may be an interesting option in anaerobic digestion when fibrous or lignocellulosic substances lead to high viscosities of the digested slurries. High production costs remain the bottleneck for making microalgae an interesting feedstock.

Cyanobacteria Biorefinery - Production of poly(3-hydroxybutyrate) with Synechocystis salina and utilisation of residual biomass.

This study evaluates a biorefinery concept for producing poly(3-hydroxybutyrate) (PHB) with the cyanobacterial strain Synechocystis salina. Due to this reason, pigment extraction and cell disruption were investigated as pre-treatment steps for the harvested cyanobacterial biomass. The results demonstrated that at least pigment removal was necessary to obtain PHB with processable quality (weight average molecular weight: 569-988kgmol-1, melting temperature: 177-182°C), which was comparable to heterotrophically produced PHB. The removed pigments could be utilised as additional by-products (chlorophylls 0.27-1.98mgg-1 TS, carotenoids 0.21-1.51mgg-1 TS, phycocyanin 0-127mgg-1 TS), whose concentration depended on the used nutrient source. Since the residual biomass still contained proteins (242mgg-1 TS), carbohydrates (6.1mgg-1 TS) and lipids (14mgg-1 TS), it could be used as animal feed or converted to biomethane (348 mn3 t-1VS) and fertiliser. The obtained results indicate that the combination of photoautotrophic PHB production with pigment extraction and utilisation of residual biomass offer the highest potential, since it contributes to decrease the environmental footprint of the process and because biomass could be used in a cascading way and the nutrient cycle could be closed.

Processing recommendations for using low-solids digestate as nutrient solution for poly-ß-hydroxybutyrate production with Synechocystis salina.

Within the last decades, environmental pollution with persistent plastics steadily increased; therefore the production of biodegradable materials like poly-ß-hydroxybutyrate (PHB) is essential. Currently, PHB is produced with heterotrophic bacteria from crops. This leads to competition with food and feed production, which can be avoided by using photoautotrophic cyanobacteria, as Synechocystis salina, synthesizing PHB from CO2 at nutrient limitation. This study aims to increase the economic efficiency of PHB production with cyanobacteria by using nutrients from anaerobic digestate. First, growth and PHB production of S. salina in digestate fractions (supernatant and permeate, with/without precipitating agents) and dilutions thereof and then the scale-up (photobioreactor, 200 L working volume) were evaluated. With precipitated and centrifuged digestate diluted 1/3 the highest biomass (1.55gL-1) and PHB concentrations (95.4mgL-1), being 78% of those in mineral media, were achieved. In the photobioreactor-experiments biomass (1.63gL-1) and PHB concentrations (88.7mgL-1), being 79% and 72% of those in mineral medium, were reached, but in a cultivation time 10days longer than in mineral medium. The possibility to use digestate as sustainable and low cost nutrient solution for microalgae cultivation and photoautotrophic PHB production, instead of applying it on fields or processing it to achieve discharge limits, makes this application a highly valid option.

Assessment of the state of the art of technologies for the processing of digestate residue from anaerobic digesters.

Anaerobic digestion is widely used as an important source of renewable energy. With the increasing number and capacity of biogas plants also, adequate treatment technologies for whole digestate - the residue from anaerobic digestion - are gaining attention. In this study the state of the art of digestate processing is analysed, and currently used treatment schemes and the various technological processes involved are evaluated. The study combines data and experiences from existing large-scale digestate processing facilities in Austria, Germany, Switzerland and Italy, as well as know-how from technology providers and relevant research projects. However, the field of digestate processing is still quite new and little detailed information about the performance of different technologies at industrial scale is available. Digestate processing is gaining importance since digestate utilisation can become an important bottleneck when increasing biogas production. In addition, the production of renewable fertiliser from digestate is increasingly of interest to replace fossil fertilisers. This study is the first profound attempt to establish an assessment of the state-of-the-art technologies in use.

Anaerobic digestion of stillage fractions - estimation of the potential for energy recovery in bioethanol plants.

Stillage processing can require more than one third of the thermal energy demand of a dry-grind bioethanol production plant. Therefore, for every stillage fraction occurring in stillage processing the potential of energy recovery by anaerobic digestion (AD) was estimated. In the case of whole stillage up to 128% of the thermal energy demand in the process can be provided, so even an energetically self-sufficient bioethanol production process is possible. For wet cake the recovery potential of thermal energy is 57%, for thin stillage 41%, for syrup 40% and for the evaporation condensate 2.5%. Specific issues for establishing AD of stillage fractions are evaluated in detail; these are high nitrogen concentrations, digestate treatment and trace element supply. If animal feed is co-produced at the bioethanol plant and digestate fractions are to be reused as process water, a sufficient quality is necessary. Most interesting stillage fractions as substrates for AD are whole stillage, thin stillage and the evaporation condensate. For these fractions process details are presented.

Comparing centralised and decentralised anaerobic digestion of stillage from a large-scale bioethanol plant to animal feed production.

A comparison of stillage treatment options for large-scale bioethanol plants was based on the data of an existing plant producing approximately 200,000 t/yr of bioethanol and 1,400,000 t/yr of stillage. Animal feed production--the state-of-the-art technology at the plant--was compared to anaerobic digestion. The latter was simulated in two different scenarios: digestion in small-scale biogas plants in the surrounding area versus digestion in a large-scale biogas plant at the bioethanol production site. Emphasis was placed on a holistic simulation balancing chemical parameters and calculating logistic algorithms to compare the efficiency of the stillage treatment solutions. For central anaerobic digestion different digestate handling solutions were considered because of the large amount of digestate. For land application a minimum of 36,000 ha of available agricultural area would be needed and 600,000 m(3) of storage volume. Secondly membrane purification of the digestate was investigated consisting of decanter, microfiltration, and reverse osmosis. As a third option aerobic wastewater treatment of the digestate was discussed. The final outcome was an economic evaluation of the three mentioned stillage treatment options, as a guide to stillage management for operators of large-scale bioethanol plants.