Optimization of chemical solution concentration and exposure time in the alkaline pretreatment applied to sugarcane bagasse for methane production.

ABSTRACTSugarcane is the most traded crop in the world, with Brazil being the world's largest producer. Sugarcane processing generates up to 28% of sugarcane bagasse (SB) from the entire plant, with only 50% of it used for energy generation. SB is a lignocellulosic biomass that can be converted into biogas. However, the optimization of pretreatment process parameters is essential for its successful scaling up. This study evaluated the effect of mild alkaline pretreatment of SB using NaOH and KOH at concentrations of 1-10% and exposure time of 1-12 hours) on the biochemical methane potential (BMP) under mesophilic temperature. The central composite rotatable design (CCRD) was applied as statistical tool to generate optimal operating pretreatment conditions. The tests were performed in triplicates totalizing 84 batch bottles. The BMP of the untreated SB varied between 297-306 LN CH4 kg VS-1 while the BMP of the pretreated samples with NaOH and KOH were 19% and 20% higher. The optimized conditions were NaOH at 7.7% and KOH at 8.3% KOH for 12 hours. However, the range indicated by the statistical design with CCRD revealed that there was no statistical difference in terms of methane yield when concentrations between 4-10% NaOH and 6-10% KOH during 12 hours were applied, when compared to the specific optimized points. The optimization of the pretreatment parameters demonstrated to be a key-factor to improve the anaerobic digestion of lignocellulosic substrates, leading to a less chemically dependent and more sustainable approach, while allowing a more profitable process.

Long-term thermophilic mono-digestion of rendering wastes and co-digestion with potato pulp.

In this study, mono-digestion of rendering wastes and co-digestion of rendering wastes with potato pulp were studied for the first time in continuous stirred tank reactor (CSTR) experiments at 55°C. Rendering wastes have high protein and lipid contents and are considered good substrates for methane production. However, accumulation of digestion intermediate products viz., volatile fatty acids (VFAs), long chain fatty acids (LCFAs) and ammonia nitrogen (NH4-N and/or free NH3) can cause process imbalance during the digestion. Mono-digestion of rendering wastes at an organic loading rate (OLR) of 1.5 kg volatile solids (VS)/m(3)d and hydraulic retention time (HRT) of 50 d was unstable and resulted in methane yields of 450 dm(3)/kg VS(fed). On the other hand, co-digestion of rendering wastes with potato pulp (60% wet weight, WW) at the same OLR and HRT improved the process stability and increased methane yields (500-680 dm(3)/kg VS(fed)). Thus, it can be concluded that co-digestion of rendering wastes with potato pulp could improve the process stability and methane yields from these difficult to treat industrial waste materials.

The effect of organic loading rate and retention time on hydrogen production from a methanogenic CSTR.

The possibility of shifting a methanogenic process for hydrogen production by changing the process parameters viz., organic loading rate (OLR) and hydraulic retention time (HRT) was evaluated. At first, two parallel semi-continuously fed continuously stirred tank reactors (CSTR) were operated as methanogenic reactors (M1 and M2) for 78 days. Results showed that a methane yield of 198-218 L/kg volatile solids fed (VS(fed)) was obtained when fed with grass silage at an OLR of 2 kgVS/m³/d and HRT of 30 days. After 78 days of operation, hydrogen production was induced in M2 by increasing the OLR from 2 to 10 kgVS/m³/d and shortening the HRT from 30 to 6 days. The highest H2 yield of 42 L/kgVS(fed) was obtained with a maximum H2 content of 24%. The present results thus demonstrate that methanogenic process can be shifted towards hydrogen production by increasing the OLR and decreasing HRT.

Effects of solid-liquid separation on recovering residual methane and nitrogen from digested dairy cow manure.

The feasibility of optimizing methane and nitrogen recovery of samples obtained from farm biogas digester (35 degrees C) and post-storage tank (where digested material is stored for 9-12 months) was studied by separating the materials into different fractions using 2, 1, 0.5 and 0.25 mm sieves. Mass-balances revealed that digested material mainly consists of <0.25 mm (60-69%) and >2 mm (18-27%) fractions, while fractions between 2 and 0.2 mm made the rest. Incubation of solid fractions >0.25 mm of digester material at 35 degrees C resulted in specific methane yields of 0.060-0.085 m(3)kg(-1) volatile solids (VS) during initial 30-50 d and 0.16-0.18 m(3)kg(-1)VS at the end of 340 d incubation. Similarly, fractions >0.25 mm of post-storage tank material produced 0.055-0.092 m(3)kg(-1)VS and 0.13-0.16 m(3)kg(-1)VS of methane after 30-50 d and after 250 d, respectively. Methane yields for fractions <0.25 mm of post-storage tank was 0.03 m(3)kg(-1)VS after 30-50 d and 0.05 m(3)kg(-1)VS after 250 d compared to 0.20 m(3)kg(-1)VS and 0.41 m(3)kg(-1)VS, respectively for the same fraction of digester material. Separation of digested cow manure into solids and liquid fractions to recover methane may be feasible only for post-storage tank material and not for digester material. Nitrogen management would not be feasible with neither material as total nitrogen and ammonium-nitrogen concentrations were equally distributed among the segregated fractions.

Effect of temperature and active biogas process on passive separation of digested manure.

The objective of the study was to identify the optimum time interval for effluent removal after temporarily stopping stirring in otherwise continuously stirred tank reactors. Influence of temperature (10 and 55 degrees C) and active biogas process on passive separation of digested manure, where no outside mechanical or chemical action was used, within the reactor was studied in three vertical settling columns (100 cm deep). Variations in solids and microbial distribution at top, middle and bottom layers of column were assessed over a 15 day settling period. Results showed that best solids separation was achieved when digested manure was allowed to settle at 55 degrees C with active biogas process (pre-incubated at 55 degrees C) compared to separation at 55 degrees C without active biogas process (autoclaved at 120 degrees C, for 20 min) or at 10 degrees C with active biogas process. Maximum solids separation was noticed 24h after settling in column incubated at 55 degrees C, with active biogas process. Microbiological analyses revealed that proportion of Archaea and Bacteria, absent in the autoclaved material, varied with incubation temperature, time and sampling depth. Short rod shaped bacteria dominated at 55 degrees C, while long rod shaped bacteria dominated at 10 degrees C. Methanosarcinaceae were seen more abundant in the surface layer at 55 degrees C while it was seen more common in the top and bottom layers at 10 degrees C. Thus, passive separation of digester contents within the reactor can be used effectively as an operating strategy to optimize biogas production by increasing the solids and biomass retention times. A minimum of 1-2h "non-stirring" period appears to be optimal time before effluent removal in plants where extraction is batch-wise 2-4 times a day.

Operational strategies for thermophilic anaerobic digestion of organic fraction of municipal solid waste in continuously stirred tank reactors.

Three operational strategies to reduce inhibition due to ammonia during thermophilic anaerobic digestion of source-sorted organic fraction of municipal solid waste (SS-OFMSW) rich in proteins were investigated. Feed was prepared by diluting SS-OFMSW (ratio of 1:4) with tap water or reactor process water with or without stripping ammonia. Three continuously stirred tank reactors were operated at 55 degrees C with 11.4 gVS d(-1) loading rate and 15 d retention time. Total ammonia nitrogen (TAN) level in the reactor fed with recirculated water alone was spiked to 3.5 and 5.5 g-N l(-1) through ammonium bicarbonate additions. Dilution of SS-OFMSW with fresh water showed a stable performance with volatile fatty acids of < 1g l(-1) and methane yield of 0.40 m3 kg(-1) volatile solids (VS). Use of recirculated process water after stripping ammonia showed even better performance with a methane yield of 0.43 m3 kg(-1) VS. Recirculation of process water alone on the other hand, resulted in process inhibition at both TAN levels of 3.5 and 5.5 g-N l(-1). However, after a short period, the process recovered and adapted to the tested TAN levels. Thus, use of recirculated process water after stripping ammonia would not only evade potential inhibition due to ammonia but could avoid the use of fresh water for dilution of high solids protein-rich SS-OFMSW.

Thermophilic anaerobic digestion of industrial orange waste.

Thermophilic anaerobic digestion of industrial orange waste (pulp and peel) with subsequent aerobic post-treatment of the digestate was evaluated. Methane production potential was first determined in batch assays and the effects of operational parameters such as hydraulic retention times (HRT) and organic loading rates (OLR) on process performance were studied through semi-continuous digestion. In batch assays, methane production potential of about 0.49 m(3) kg(-1) volatile solids (VS)(added waste) was achieved. In semi-continuous digestion, loading at 2.8 kgVS m(-3) d(-1) (2.9 kg total solids (TS) m(-3) d(-1)) and HRT of 26 d produced specific methane yields of 0.6 m(3) kg(-1) VS (added waste) (0.63 m(3) kg(-1) VS(added waste)). Operating at a higher OLR of 4.2 kgVS m(-3) d(-1) (4.4 kg TS m(-3) d(-1)) and 40 d HRT produced 0.5 m(3) of methane kg(-1) VS (added waste) (0.63-0.52 m(3) kg(-1) TS (added waste). Up to 70% of TS of industrial orange waste (11.6% TS) was methanised. Further increase in OLR to 5.6 kg VS m(-3) d(-1) (5.9 kg TS m(-3) d(-1); HRT of 20 d) resulted in an unstable and non-functional digester process shown directly through complete cessation of methanogenesis, drop in methane content, reduced pH and increase in volatile fatty acid (VFA) concentrations, especially acetate and soluble chemical oxygen demand. A pH adjustment (from an initial 3.2 to ca. 8) for the low pH orange waste was necessary and was found to be a crucial factor for stable digester operation as the process showed a tendency to be inhibited due to accumulation of VFAs and decrease in digester pH. Aerobic post-treatment of digestate resulted in removal of ammonia and VFAs.

The effects of post-treatments and temperature on recovering the methane potential of >2 mm solid fraction of digested cow manure.

The effects of thermal and chemical treatments, mechanical maceration and freezing and thawing on recovering the remaining methane potential of the >2 mm solid fraction of digested cow manure - which accounted for 30% of the original potential of digested cow manure - were studied in laboratory batch assays at 5-20 degrees C and at 35-55 degrees C to evaluate the treatment effects both under long-term (340 d) storage of solids and during active digestion (30 d), respectively. The effects of different treatments on the methane production of the solids varied with incubation temperatures and time. However, in all cases, methane productions at 15 degrees C and lower were slow and low for both untreated and treated solids even after long-term incubation. At 35 and 55 degrees C more methane was recovered from untreated solids producing up to 61-82 ml g(-1) volatile solids (VS)added in 30 d and 179-215 ml g(-1) VSadded in 340 d. Only chemical treatment with or without thermal treatment enhanced the methane yields while some treatments even decreased the yields. An increase in temperature to 35 degrees C of the assays incubated for 6 months at < or =20 degrees C initiated more significant methane production. In conclusion, the methane potential of the digested solids in a farm-scale biogas system can be recovered by active digestion at 35 or 55 degrees C and can be improved to a smaller extent through chemical treatment of separated solids fraction, while methane recovery at lower temperatures and with some of the treatments studied would not be effective.

Effects of temperature on post-methanation of digested dairy cow manure in a farm-scale biogas production system.

A post-methanation process that could be adopted at farm-scale, operating at temperatures prevailing in farm manure digester post-storage tanks, was evaluated. Digested manure samples from a farm digester (35 degrees C) and post-storage tank (5-10 degrees C) were incubated in parallel batches at 5-20 degrees C and as reference at 35 and 55 degrees C. Specific methane yields (kg(-1) volatile solids (VS)(added waste)) were 0.20-0.26 m3 at 35-55 degrees C and 0.085-0.09 m3 at 10-20 degrees C for digester material (345 days of incubation) and 0.16-0.21 m3 at 35-55 degrees C, 0.053-0.087 kg(-1) VS(added waste) m3 at 15-20 degrees C and 0.026 m3 at 10 degrees C for post-storage tank material (250 days). Both materials produced less than 0.005 m3 at 5 degrees C. However, an increase in temperature to 35 degrees C (40 days) improved methane production in assays pre-incubated at 5-20 degrees C (9 months). These results suggest that the untapped methane potential of the digested manure cannot effectively be recovered at temperatures prevailing in farm digested manure storage tanks during the winter in Northern latitudes. Nevertheless, as ambient temperatures increase during the late spring, an increase in methanogenesis can be expected.

Co-digestion of energy crops and industrial confectionery by-products with cow manure: batch-scale and farm-scale evaluation.

The possible co-digestion of energy crops and industrial confectionery by-products with cow manure was evaluated firstly, through long-term batch experiments and secondly, in a farm-scale digester. In batch assays, digestion with mesophilically digested cow manure as inoculum resulted in specific methane yields (m3 kg(-1) VS added waste) of 0.35 for grass hay (particle size <1.0 cm); 0.26 for oats (0.5 cm) and 0.21 for clover (2.0 cm) harvested at vegetative stage and 0.14 (2.0 cm) for clover harvested at flowering stage. Specific methane yields (m3 kg(-1) VS added waste) for confectionery by-products were 0.37 for chocolate, 0.39 for black candy and 0.32 for confectionery raw material. Out the three particle sizes (2.0, 1.0 and 0.5 cm) tested, particle size of 1.0 cm was found ideal for digestion of grass hay and clover while, particle size reduction did not influence methane production from oats. Stage of the crop influenced the methane yields, with clover harvested at vegetative stage yielding 33% higher methane than when harvested at flowering stage. An approximate 60% enhancement in methane yield was noticed with the co-digestion of industrial confectionery wastes with cow manure in a full-scale farm digester.