Effects of steam pretreatment and co-production with ethanol on the energy efficiency and process economics of combined biogas, heat and electricity production from industrial hemp.

BACKGROUND: The study presented here has used the commercial flow sheeting program Aspen Plus™ to evaluate techno-economic aspects of large-scale hemp-based processes for producing transportation fuels. The co-production of biogas, district heat and power from chopped and steam-pretreated hemp, and the co-production of ethanol, biogas, heat and power from steam-pretreated hemp were analysed. The analyses include assessments of heat demand, energy efficiency and process economics in terms of annual cash flows and minimum biogas and ethanol selling prices (MBSP and MESP). RESULTS: Producing biogas, heat and power from chopped hemp has the highest overall energy efficiency, 84% of the theoretical maximum (based on lower heating values), providing that the maximum capacity of district heat is delivered. The combined production of ethanol, biogas, heat and power has the highest energy efficiency (49%) if district heat is not produced. Neither the inclusion of steam pretreatment nor co-production with ethanol has a large impact on the MBSP. Ethanol is more expensive to produce than biogas is, but this is compensated for by its higher market price. None of the scenarios examined are economically viable, since the MBSP (EUR 103-128 per MWh) is higher than the market price of biogas (EUR 67 per MWh). The largest contribution to the cost is the cost of feedstock. Decreasing the retention time in the biogas process for low solids streams by partly replacing continuous stirred tank reactors by high-rate bioreactors decreases the MBSP. Also, recycling part of the liquid from the effluent from anaerobic digestion decreases the MBSP. The production and prices of methane and ethanol influence the process economics more than the production and prices of electricity and district heat. CONCLUSIONS: To reduce the production cost of ethanol and biogas from biomass, the use of feedstocks that are cheaper than hemp, give higher output of ethanol and biogas, or combined production with higher value products are primarily suggested. Further, practical investigations on increased substrate concentration in biogas and ethanol production, recycling of the liquid in anaerobic digestion and separation of low solids flows into solid and a liquid fraction for improved reactor applications deserves further attention.

Evaluating the biogas potential of the dry fraction from pretreatment of food waste from households.

At the waste handling company NSR, Helsingborg, Sweden, the food waste fraction of source separated municipal solid waste is pretreated to obtain a liquid fraction, which is used for biogas production, and a dry fraction, which is at present incinerated. This pretreatment and separation is performed to remove impurities, however also some of the organic material is removed. The possibility of realising the methane potential of the dry fraction through batch-wise dry anaerobic digestion was investigated. The anaerobic digestion technique used was a two-stage process consisting of a static leach bed reactor and a methane reactor. Treatment of the dry fraction alone and in a mixture with structural material was tested to investigate the effect on the porosity of the leach bed. A tracer experiment was carried out to investigate the liquid flow through the leach beds, and this method proved useful in demonstrating a more homogenous flow through the leach bed when structural material was added. Addition of structural material to the dry fraction was needed to achieve a functional digestion process. A methane yield of 98 m3/ton was obtained from the dry fraction mixed with structural material after 76 days of digestion. This was in the same range as obtained in the laboratory scale biochemical methane potential test, showing that it was possible to extract the organic content in the dry fraction in this type of dry digestion system for the production of methane.

Improved utilization of fish waste by anaerobic digestion following omega-3 fatty acids extraction.

Fish waste is a potentially valuable resource from which high-value products can be obtained. Anaerobic digestion of the original fish waste and the fish sludge remaining after enzymatic pre-treatment to extract fish oil and fish protein hydrolysate was evaluated regarding the potential for methane production. The results showed high biodegradability of both fish sludge and fish waste, giving specific methane yields of 742 and 828 m(3)CH(4)/tons VS added, respectively. However, chemical analysis showed high concentrations of light metals which, together with high fat and protein contents, could be inhibitory to methanogenic bacteria. The feasibility of co-digesting the fish sludge with a carbohydrate-rich residue from crop production was thus investigated, and a full-scale process outlined for converting odorous fish waste to useful products.

Stable operation during pilot-scale anaerobic digestion of nutrient-supplemented maize/sugar beet silage.

Biogas production from maize/sugar beet silage was studied under mesophilic conditions in a continuous stirred tank reactor pilot-scale process. While energy crop mono-digestion is often performed with very long hydraulic retention times (HRTs), the present study demonstrated an efficient process operating with a 50-day HRT and a corrected total solids (TS(corr)) based organic loading rate of 3.4 kg/m(3)d. The good performance was attributed to supplementation with both macro- and micronutrients and was evidenced by good methane yields (318 m(3)/ton TS(corr)), which were comparable to laboratory maximum expected yields, plus low total volatile fatty acid concentrations (<0.8 g/L). A viscoplastic and thixotropic digester fluid behaviour was observed, and the viscosity problems common in crop mono-digestion were not seen in this study. The effluent also complied with Swedish certification standards for bio-fertilizer for farmland application. Nutrient addition thus rendered a stable biogas process, while the effluent was a good quality bio-fertilizer.

Benefits of supplementing an industrial waste anaerobic digester with energy crops for increased biogas production.

Currently, there is increasing competition for waste as feedstock for the growing number of biogas plants. This has led to fluctuation in feedstock supply and biogas plants being operated below maximum capacity. The feasibility of supplementing a protein/lipid-rich industrial waste (pig manure, slaughterhouse waste, food processing and poultry waste) mesophilic anaerobic digester with carbohydrate-rich energy crops (hemp, maize and triticale) was therefore studied in laboratory scale batch and continuous stirred tank reactors (CSTR) with a view to scale-up to a commercial biogas process. Co-digesting industrial waste and crops led to significant improvement in methane yield per ton of feedstock and carbon-to-nitrogen ratio as compared to digestion of the industrial waste alone. Biogas production from crops in combination with industrial waste also avoids the need for micronutrients normally required in crop digestion. The batch co-digestion methane yields were used to predict co-digestion methane yield in full scale operation. This was done based on the ratio of methane yields observed for laboratory batch and CSTR experiments compared to full scale CSTR digestion of industrial waste. The economy of crop-based biogas production is limited under Swedish conditions; therefore, adding crops to existing industrial waste digestion could be a viable alternative to ensure a constant/reliable supply of feedstock to the anaerobic digester.

Ensiling of crops for biogas production: effects on methane yield and total solids determination.

BACKGROUND: Ensiling is a common method of preserving energy crops for anaerobic digestion, and many scientific studies report that ensiling increases the methane yield. In this study, the ensiling process and the methane yields before and after ensiling were studied for four crop materials. RESULTS: The changes in wet weight and total solids (TS) during ensiling were small and the loss of energy negligible. The methane yields related to wet weight and to volatile solids (VS) were not significantly different before and after ensiling when the VS were corrected for loss of volatile compounds during TS and VS determination. However, when the TS were measured according to standard methods and not corrected for losses of volatile compounds, the TS loss during ensiling was overestimated for maize and sugar beet. The same methodological error leads to overestimation of methane yields; when TS and VS were not corrected the methane yield appeared to be 51% higher for ensiled than fresh sugar beet. CONCLUSIONS: Ensiling did not increase the methane yield of the studied crops. Published methane yields, as well as other information on silage related to uncorrected amounts of TS and VS, should be regarded with caution.

Bioconversion of industrial hemp to ethanol and methane: the benefits of steam pretreatment and co-production.

Several scenarios for ethanol production, methane production (by anaerobic digestion) and co-production of these, using autumn harvested hemp as substrate, were investigated and compared in terms of gross energy output. Steam pretreatment improved the methane production rate compared with mechanical grinding. The methane yield of steam pretreated stems was similar both with and without pre-hydrolysis with cellulolytic enzymes. Co-production of ethanol and methane from steam pretreated stems gave a high yield of transportation fuel, 11.1-11.7 MJ/kg processed stem dry matter (DM); more than twice that of ethanol production alone from hexoses, 4.4-5.1 MJ/kg processed stem DM. Co-production from the whole hemp plant would give 2600-3000 L ethanol and 2800-2900 m(3) methane, in total 171-180 GJ per 10,000 m(2) of agricultural land, based on a biomass yield of 16 Mg DM. Of this, the yeast and enzymes from ethanol production were estimated to contribute 700 m(3) (27 GJ) of methane.

Two-stage anaerobic digestion enables heavy metal removal.

To fully exploit the environmental benefits of the biogas process, the digestate should be recycled as biofertiliser to agriculture. This practice can however be jeopardized by the presence of unwanted compounds such as heavy metals in the digestate. By using two-stage digestion, where the first stage includes hydrolysis/acidification and liquefaction of the substrate, heavy metals can be transferred to the leachate. From the leachate, metals can then be removed by adsorption. In this study, up to 70% of the Ni, 40% of the Zn and 25% of the Cd present in maize was removed when the leachate from hydrolysis was circulated over a macroporous polyacrylamide column for 6 days. For Cu and Pb, the mobilization in the hydrolytic stage was lower which resulted in a low removal. A more efficient two-stage process with improved substrate hydrolysis would give lower pH and/or longer periods with low pH in the hydrolytic stage. This is likely to increase metal mobilisation, and would open up for an excellent opportunity of heavy metal removal.

Performance of biofilm carriers in anaerobic digestion of sisal leaf waste leachate

Three methanogenic biofilm bioreactors were studied to evaluate the performance of three types of carriers. The carrier material were consisted of sisal fibre waste, pumice stone and porous glass beads, and the bioprocess evaluated was the methanogenesis anaerobic digestion of sisal leaf waste leachate. Process performance was investigated by increasing the organic loading rate (OLR) step-wise. The best results were obtained from the bioreactor packed with sisal fibre waste. It had the highest chemical oxygen demand (COD) removal efficiencies in the range of 80-93 percent at OLRs in the range of 2.4-25 g COD L-1d-1. The degradation pattern of volatile fatty acids (VFAs) showed that the degradation of propionate was limiting at higher OLRs. The stable pH and higher partial alkalinity (PA) of the outflow illustrated that packed-bed bioreactors have a good ability to withstand the variations in load and volatile fatty acid concentrations that can occur in a two-stage anaerobic process. In conclusion, sisal fibre waste was shown to be a novel promising biofilm carrier and would work very well in methanogenic biofilm bioreactors treating sisal leaf tissue waste leachate. Furthermore both sisal wastes are available in the neighbourhood of sisal industries, which makes anaerobic digestion scale up at sisal factory level feasible and cost-effective.

Enhancing performance in anaerobic high-solids stratified bed digesters by straw bed implementation.

Anaerobic high-solids single-stage stratified bed digesters have been found to be simple and flexible design candidates for small-scale reactors located in medium- to low-technology environments. In the present study, wheat straw was used as the starter material for the stratified bed. Upon green mass feeding, the anaerobically stabilised straw bed functioned both as a biofilm support and as a particulate filter. It enabled a direct onset of 7 kg VSm(-3) batch loads, added twice a week, and permitted a low but consistent bed permeability during feeding at an average superficial flow velocity of 1 m d(-1) to be achieved. Fed-batch tests with sugar beet tops in pilot- and laboratory-scale setups at an average loading rate of 2 kg VSm(-3) d(-1) resulted in average biogas production rates of 1.2-1.4 m3 m(-3) d(-1) and methane yields of 0.31-0.36 m3 kg(-1) VS(added). At the end of the laboratory-scale feeding trial, the 200 day old straw bed had compacted to 50% of its initial volume, without any negative effects on performance being detectable.

An update and optimisation of oligonucleotide probes targeting methanogenic Archaea for use in fluorescence in situ hybridisation (FISH).

Fluorescence in situ hybridisation (FISH) is a common and popular method used to investigate microbial populations in natural and engineered environments. DNA oligonucleotide probes require accurate determination of the optimal experimental conditions for their use in FISH. Oligonucleotides targeting the rRNA of methanogenic Archaea at various taxonomic levels have previously been published, although when applied in FISH, no optimisation data has been presented. In this study, 3000 Euryarchaeota 16S rRNA gene sequences were phylogenetically analysed and previously published oligonucleotides were evaluated for target group accuracy. Where necessary, modifications were introduced or new probes were designed. The updated set of probes was optimised for use in FISH for a more accurate detection of methanogenic Archaea.

Enhancement of anaerobic batch digestion of sisal pulp waste by mesophilic aerobic pre-treatment.

Pre-treatment of sisal pulp prior to its anaerobic digestion was investigated using an activated sludge mixed culture under aerobic conditions in batch bioreactors at 37 degrees C. The progression of aerobic pre-treatment of the residue in relation to the activities of some extracellular hydrolytic enzymes in the slurry was monitored. The highest activity of hydrolytic enzymes was obtained at 9 h of pre-treatment. Filter paper cellulase had a maximum activity of 0.90 IU/ml, while carboxymethyl cellulase, amylase and xylanase were produced to a maximum of about 0.40 IU/ml. The methane yield obtained after anaerobic digestion of the pre-treated pulp ranged between 0.12 and 0.24 m3 CH4/kg VS added. The highest and lowest values were obtained for 9 and 72 h of pre-treatment, respectively. Nine hours of pre-treatment of sisal pulp prior to anaerobic digestion demonstrated a 26% higher methane yield when compared to the sisal pulp without pre-treatment. The consortia of microorganisms in activated sludge demonstrated a useful potential in the production of hydrolases acting on major macromolecules of sisal pulp. The fact that a correlation was observed between high enzyme activity and high methane yield at 9 h of aerobic pre-treatment suggests that such a short pre-treatment period could be an alternative option for increasing solubilization of sisal pulp and promoting methane productivity.

Filamentous Chloroflexi (green non-sulfur bacteria) are abundant in wastewater treatment processes with biological nutrient removal.

Most filamentous bacteria in biological nutrient removal (BNR) processes have not been identified beyond their morphotype and simple staining reactions. Furthermore, the majority of sludge filaments observed under the microscope do not hybridize to commonly used phylogenetic probes for well characterized bacterial phyla such as the Proteobacteria, Actinobacteria, Firmicutes and BACTEROIDETES: Specific 16S rRNA-targeted oligonucleotide probes were designed for the phylum Chloroflexi (green non-sulfur bacteria) and optimized for use in fluorescence in situ hybridization. Chloroflexi have been implicated in BNR systems by phylogenetic identification of filamentous bacteria isolated by micromanipulation from sludge and culture-independent molecular phylogenetic surveys. The predominant morphotype responding to the probes was filamentous and these filaments were generally abundant in 10 Australian full-scale and two laboratory-scale BNR samples examined. Filamentous bacteria responding to a subdivision 1 Chloroflexi probe were rare in the samples, whereas subdivision 3 Chloroflexi filaments were very common in some sludges. This is in direct contrast to results obtained from molecular phylogenetic surveys of BNR systems where most sludge 16S rDNA clones belong to subdivision 1 and only a few to subdivision 3. It is suggested that filamentous bacteria belonging to the Chloroflexi phylum account for a large fraction of phylogenetically uncharacterized filaments in BNR systems and are likely to be abundant in such systems on a global scale.

Evaluation of straw as a biofilm carrier in the methanogenic stage of two-stage anaerobic digestion of crop residues.

Straw was evaluated as a biofilm carrier in the methanogenic stage of the two-stage anaerobic digestion of crop residues. Three reactor configurations were studied, a straw-packed-bed reactor, a glass packed-bed reactor and a reactor containing suspended plastic carriers. The reactor with the packed straw bed showed the best results. It had the highest methane production, 5.4 11(-1) d(-1), and the chemical oxygen demand (COD) removal ranged from 73-50% at organic loading rates from 2.4-25 g COD l(-1) d(-1). The degradation pattern of volatile fatty acids showed that the degradation of propionate and longer-chain fatty acids was limiting at higher organic loading rates. A stable effluent pH showed that the packed-bed reactors had good ability to withstand the variations in load and volatile fatty acid concentrations that can occur in the two-stage process. The conclusion is that straw would work very well in the intended application. A further benefit is that straw is a common agricultural waste product and requires only limited resources concerning handling and cost.