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.

New data on temperature optimum and temperature changes in energy crop digesters.

As a result of self-heating in anaerobic digesters when using energy crops in the feedstock, the influence of temperature on the digestion process came back into focus. The aim of this study was to investigate the impact of such temperature increases on process stability. Furthermore, different strategies for the transition from mesophilic to thermophilic conditions and the resulting methane yields at different temperature levels were evaluated. Two main effects were identified with different bio-slurries from agricultural biogas plants: (1) a failure of methane production connected to changes in the microbial community; and (2), a slow but continuous accumulation of propionic acid, though without an immediate effect on methane production. All strategies for increasing the operating temperature showed negative effects on digester performance, some with serious economic consequences for the operator. It was shown that methane yields at different temperature levels in the mesophilic and sub-thermophilic ranges are similar.