Integrated production of hydrogen and methane in a dairy biorefinery using anaerobic digestion: Scale-up, economic and risk analyses.

Anaerobic digestion has emerged as the most appealing waste management strategy in biorefineries. Particularly, recent studies have highlighted the energy advantages of waste co-digestion in industrial biorefineries and the use of two-stage systems. However, there are some concerns about moving the system from laboratory testing to industrial scale. One of them is the high level of investment that is required. Therefore, this study carried out a techno-economic analysis (scale-up and energy production, economic and risk analysis, and factorial design) to assess the feasibility of single- and two-stage systems in the treatment of cheese whey and glycerin for the production of hydrogen and methane. Scenarios (S1 to S9) considered thermophilic and mesophilic single and two-stage systems with different applied organic loading rates (OLRA). The analyses of scale-up and energy production revealed that S3 (a thermophilic single-stage system operated at high OLRA 17.3 kg-COD.m-3.d-1) and S9 (a thermophilic-mesophilic two-stage system operated at high OLRA 134.8 kg-COD.m-3.d-1 and 20.5 kg-COD.m-3.d-1, respectively) were more compact and required lower initial investment compared to other scenarios. The risk analysis performed by a Monte Carlo simulation showed low investment risks (10 and 11%) for S3 and S9, respectively, being the electricity sales price, the key determining factor to define whether the project in the baseline scenario will result in profit or loss. Lastly, the factorial design revealed that while the net present value (NPV) is positively impacted by rising inflation and electricity sales price, it is negatively impacted by rising capitalization rate. Such assessments assist in making decisions regarding which system can be fully implemented, the best market circumstances for the investment, and how market changes may favorably or unfavorably affect the NPV and the internal rate of return (IRR).

Biomethane recovery through co-digestion of cheese whey and glycerol in a two-stage anaerobic fluidized bed reactor: Effect of temperature and organic loading rate on methanogenesis.

Anaerobic digestion for CH4 recovery in wastewater treatment has been carried out with different strategies to increase process efficiency, among which co-digestion and the two-stage process can be highlighted. In this context, this study aimed at evaluating the co-digestion of cheese whey and glycerol in a two-stage process using fluidized bed reactors, verifying the effect of increasing the organic loading rate (OLR) (2-20 g-COD.L-1.d-1) and temperature (thermophilic and mesophilic) in the second stage methanogenic reactor. The mesophilic methanogenic reactor (R-Meso) (mean temperature of 22 °C) was more tolerant to high OLR and its best performance was at 20 g-COD.L-1.d-1, resulting in methane yield (MY) and methane production (MPR) of 273 mL-CH4.g-COD-1 and 5.8 L-CH4.L-1.d-1 (with 67% of CH4), respectively. Through 16S rRNA gene massive sequencing analysis, a greater diversity of microorganisms was identified in R-Meso than in R-Thermo (second stage methanogenic reactor, 55 °C). Firmicutes was the phyla with higher relative abundance in R-Thermo, while in R-Meso the most abundant ones were Proteobacteria and Bacteroidetes. Regarding the Archaea domain, a predominance of hydrogenotrophic microorganisms could be observed, being the genera Methanothermobacter and Methanobacterium the most abundant in R-Thermo and R-Meso, respectively. The two-stage system composed with a thermophilic acidogenic reactor + R-Meso was more adequate for the co-digestion of cheese whey and glycerol than the single-stage process, promoting increases of up to 47% in the energetic yield (10.3 kJ.kg-COD-1) and 14% in organic matter removal (90.5%).

Anaerobic Sequencing Batch Reactors Co-digesting Whey and Glycerin as a Possible Solution for Small and Mid-size Dairy Industries: Environmental Compliance and Methane Production.

A significant part of whey generated in Brazil is from small and mid-size dairy companies. Cheese whey has great potential for methane production through anaerobic biological processes but presents instabilities due to its high biodegradability. To study an alternative for the destination of this residue, the aim of this work was to investigate methane from the co-digestion of whey with glycerin and its environmental compliance at 55 °C in an anaerobic sequencing batch biofilm reactor. The best performance indicators were obtained with an influent composed of 88% cheese whey and 12% glycerin (by volume), fed-batch mode and organic loading rate of 19.3 kgCOD m-3 day-1 at 55 °C. This operational condition allowed us to achieve a methane productivity of 203 molCH4 m-3 day-1, a methane yield close to theoretical value, and to remove 68% of all organic matter in the influent. A kinetic metabolic model was fitted to the experimental data, which indicated methanogenesis with preference for the acetoclastic route. Finally, the energy production (approximately 197 MWh month-1) from an industrial scale reactor and its volume (three reactors of 152 m3) were assessed for a mid-size dairy industry, which could save up to US$ 22,000.00 per month in oil demand.

Improvement of Sugarcane Stillage (Vinasse) Anaerobic Digestion with Cheese Whey as its Co-substrate: Achieving High Methane Productivity and Yield.

This study investigated methane production in an anaerobic sequencing batch biofilm reactor (AnSBBR) by co-digesting sugarcane vinasse and cheese whey. The assessment was based on the influence of feed strategy, interaction between cycle time and influent concentration, applied volumetric organic load (OLRA), and temperature over system stability and performance. The system showed flexibility with regard to the feed strategy, but the reduction of cycle time and influent concentration, at the same OLRA, resulted in lower methane productivity. Increasing organic load, up to the value of 15.27 gCOD L-1 day-1, favored the process, increasing methane yield and productivity. Temperature reduction from 30 to 25 °C resulted in worse performance, although increasing it to 35 °C provided similar results to 30 °C. The best results were achieved at an OLRA of 15.27 gCOD L-1 day-1, cycle time of 8 h, fed-batch operation, and temperature of 30 °C. The system achieved soluble COD removal efficiency of 89%, methane productivity of 208.5 molCH4 m-3 day-1 and yield of 15.76 mmolCH4 gCOD-1. The kinetic model fit indicated methanogenesis preference for the hydrogenotrophic route. At the industrial scale estimative, considering a scenario with a sugarcane ethanol plant with ethanol production of 150,896 m3 year-1, it was estimated energy production of 25,544 MWh month-1.

Viability of Using Glycerin as a Co-substrate in Anaerobic Digestion of Sugarcane Stillage (Vinasse): Effect of Diversified Operational Strategies.

Vinasse, from sugar and ethanol production, stands out as one of the most problematic agroindustry wastes due to its high chemical oxygen demand, large production volume, and recalcitrant compounds. Therefore, the viability of using glycerin as a co-substrate in vinasse anaerobic digestion was tested, to increase process efficiency and biogas productivity. The effect of feeding strategy, influent concentration, cycle length, and temperature were assessed to optimize methane production. Glycerin (1.53% v/v) proved to be a good co-substrate since it increased the overall methane production in co-digestion assays. CH4 productivity enhanced exponentially as influent concentration increased, but when temperature was increased to 35 °C, biogas production was impaired. The highest methane productivity and yield were achieved using fed-batch mode, at 30 °C and at an organic loading rate of 10.1 kg COD m-3 day-1: 139.32 mol CH4 m-3 day-1, 13.86 mol CH4 kg CODapplied, and 15.30 mol CH4 kg CODremoved. Methane was predominantly produced through the hydrogenotrophic route. In order to treat all the vinasse produced by a mid-size sugar and ethanol plant, nine reactors with 7263.4 m3 each would be needed. The energy generated by burning the biogas in boilers would reach approximately 92,000 MW h per season and could save up to US$ 240,000.00 per month in diesel oil demand.

Methane Production by Co-Digesting Vinasse and Whey in an AnSBBR: Effect of Mixture Ratio and Feed Strategy.

The most common approach to deal with vinasse (sugarcane stillage) is fertigation, but this technique compromises soil structure and surrounding water bodies. A possible solution is to transport vinasse to local cheese whey producers and perform the co-digestion of these wastewaters together, reducing their organic load and generating bioenergy. Therefore, this study investigated the application of an AnSBBR (anaerobic sequencing batch biofilm reactor) operated in batch and fed-batch mode, co-digesting vinasse and whey at 30 °C. The effect of influent composition and feeding strategy was assessed. In all conditions, the system achieved high organic matter removal (approximately 83%). Increasing the percentage of vinasse from 0 to 100% in the influent resulted in a decrease in methane productivity (76.3 to 51.1 molCH4 m-3 day-1) and yield (12.7 to 9.1 molCH4 kgCOD-1), but fed-batch mode operation improved reactor performance (73.0 molCH4 m-3 day-1 and 11.5 molCH4 kgCOD-1). From the kinetic metabolic model, it was possible to infer that, at the best condition, methane is produced in a similar way from the acetoclastic and hydrogenotrophic routes. A scheme of four parallel reactors with a volume of 16,950 m3 each was proposed in the scale-up estimation, with an energy recovery estimated in 28,745 MWh per month.

In-situ biogas upgrading process: Modeling and simulations aspects.

Biogas upgrading processes by in-situ hydrogen (H2) injection are still challenging and could benefit from a mathematical model to predict system performance. Therefore, a previous model on anaerobic digestion was updated and expanded to include the effect of H2 injection into the liquid phase of a fermenter with the aim of modeling and simulating these processes. This was done by including hydrogenotrophic methanogen kinetics for H2 consumption and inhibition effect on the acetogenic steps. Special attention was paid to gas to liquid transfer of H2. The final model was successfully validated considering a set of Case Studies. Biogas composition and H2 utilization were correctly predicted, with overall deviation below 10% compared to experimental measurements. Parameter sensitivity analysis revealed that the model is highly sensitive to the H2 injection rate and mass transfer coefficient. The model developed is an effective tool for predicting process performance in scenarios with biogas upgrading.

Effect of feed strategy on methane production and performance of an AnSBBR treating effluent from biodiesel production.

The aim of this work was to investigate the effect of different feeding times (2, 4 and 6 h) and applied volumetric organic loads (4.5, 6.0 and 7.5 gCOD L(-1) day(-1)) on the performance of an anaerobic sequencing batch biofilm reactor (AnSBBR) treating effluent from biodiesel production. Polyurethane foam cubes were used as inert support in the reactor, and mixing was accomplished by recirculating the liquid phase. The effect of feeding time on reactor performance showed to be more pronounced at higher values of applied volumetric organic loads (AVOLs). Highest organic material removal efficiencies achieved at AVOL of 4.5 gCOD L(-1) day(-1) were 87 % at 4-h feeding against 84 % at 2-h and 6-h feeding. At AVOL of 6.0 gCOD L(-1) day(-1), highest organic material removal efficiencies achieved with 4-h and 6-h feeding were 84 %, against 71 % at 2-h feeding. At AVOL of 7.5 gCOD L(-1) day(-1), organic material removal efficiency achieved with 4-h feeding was 77 %. Hence, longer feeding times favored minimization of total volatile acids concentration during the cycle as well as in the effluent, guaranteeing process stability and safety.