Continuous Digestion Research Articles

Developing a universal equation to estimate the mass of dewatered wastewater sludge during biological digestion at mesophilic and thermophilic temperatures

ABSTRACT A series of dewaterability tests were conducted on various types of sludges to establish a wholistic relationship between sludge water fractions. Sludge samples were obtained from batch and continuous sludge digesters, which were operated anaerobically and aerobically under mesophilic and thermophilic conditions. Dewaterability of the sludge samples and the distribution of water fractions were studied using centrifugation and thermal drying. Thickened waste activated sludge (T-WAS) contained 10–11 g bound water (BW)/g of total solids (TS), and it was more hydrophilic than primary and digested sludges. During anaerobic digestion, BW content fluctuated between and 2.14.24 g BW/g TS. However, aerobic digestion at 55 °C reduced the BW content of the mixed T-WAS + primary sludges from 3.7 to 2.14 g BW/g TS. A linear function was developed to correlate supernatant and BW mass fractions (R2 = 0.995). An equation was derived from the linear function to estimate the mass of dewatered sludge based on the TS concentration of the initial wet sludge. The developed expression is applicable to different kinds of wastewater sludges. It would be helpful for the designers and operators of sludge thickening and dewatering systems to use centrifugal separation.

Investigating role of corn stover biochar supplementation on continuous pilot scale anaerobic digestion: Performance and microbial community dynamics

Biochar supplementation could facilitate microbial colonization and increase biogas and methane yield in anaerobic digestion (AD). This study investigated the impact of corn stover biochar (CSB) augmentation on the continuous pilot scale AD of rice straw. The CSB supplementation exhibited the daily average specific biogas and methane yield of 368.6 L/kg volatile solids (VS) and 230 L/kg VS, which were 35 % and 37 % higher than the control. Principle component analysis indicated that the VS reduction positively correlated with the daily average specific biogas and methane yield. Metagenomic analysis revealed that the CSB supplementation facilitated microbial colonization with the enrichment of unclassified genera from families Planococcaceae, Clostridiaceae, and Ruminococcaceae, and genus Clostridium and methanogenic archaea (Methanosarcina and Methanobacterium). The co-occurrence network revealed a notable shift in microbial interactions following the supplementation of CSB as an additive in AD. These results offer insights for enhancing the performance of the AD using CSB.

Control of continuous digester kappa number using generalized model predictive control

Kappa number variability at the digester impacts pulp yield, physical strength properties, and lignin content for downstream delignification processing. Regulation of the digester kappa number is therefore of great importance to the pulp and paper industry. In this work, an industrial application of model-based predictive control (MPC), based on generalized prediction control, was developed for kappa number feedback control and applied to a dual vessel continuous digester located in Western Canada. The problem was complicated by the need to apply heat at multiple locations in the cook. In this study, the problem was reduced from a multiple to a single input system by identifying three potential single variable permutations for temperature adjustment. In the end, a coordinated approach to the heaters was adopted. The process was perturbed and modeled as a simple first order plus dead time model and implemented in generalized predictive control (GPC). The GPC was then configured to be equivalent to Dahlin’s controller, which reduced tuning parameterization to a single closed loop time constant. The controller was then tuned based on robustness towards a worst-case dead time mismatch of 50%. The control held the mean value of the kappa number close to the setpoint, and a 40% reduction in the kappa number’s standard deviation was achieved. Different kappa number trials were run, and the average fiberline yield for each period was evaluated. Trial results suggested yield gains of 0.3%–0.5% were possible for each 1 kappa number target increase.

Prediction of total organic acids concentration based on FOS/TAC titration in continuous anaerobic digester fed with food waste using a deep neural network model

In this work, the complexities of anaerobic digestion fed with highly degradable feedstock are investigated, focusing on accumulation of organic acids (OA) as a critical monitoring parameter, and the significance of prediction models for total OA concentration. The anaerobic digestion of food waste (FW) was conducted under the organic loading rate (OLR) range of 2.55–8.80 g COD/L/d and hydraulic retention time (HRT) of 30–15 days. The feasibility of flüchtige organische säuren (FOS), totales anorganisches carbonat (TAC), and the FOS/TAC was investigated by predicting the total OA using a deep neural network (DNN) model. Two digesters, Digester 1 and 2, were fed with FW from four distinct sites. When the OA concentration exceeded 2 g/L as CH3COOH, the feeding was paused to recover the methanogens activity. The total OA concentration was successfully predicted with FOS, TAC, and FOS/TAC using the DNN regression model even though applying on the datasets from two distinct digesters, indicating a R-value of 0.9557, R2 of 0.9133, and mean square error of 0.0329. The predictive capability of DNN regression model shows the feasibility of total OA prediction based on the titrimetric method for monitoring and optimizing continuous anaerobic digestion of highly degradable feedstock.

Optimized carbonylation treatment of Litopenaeus vannamei matrix decreased its immunoreactivity and improved edible quality, simultaneously

The study aimed to investigate how carbonylation affects the immunoreactivity and edible quality of the Litopenaeus vannamei matrix. The carbonylation treatment conditions of the shrimp matrix were optimized. Firstly, the treatment condition is optimized with 1.0 mmol/L malonaldehyde at 37 °C, 12 h. The optimized carbonylated shrimp showed lower immunoreactivity, carbonyl group, and free amino acids. Then the edible quality was evaluated, optimized carbonylated shrimp matrix presented better digestibility and the continuous digestion products showed lower immunoreactivity. Optimized carbonylated shrimp for the other sensory indicators showed better texture properties and an inviting appearance. Looser microstructure by scanning electron microscopy contributed to the higher digestibility, lower immunoreactivity, and better edible quality for optimized carbonylated shrimp matrix. Besides, more potentially modified amino acid residues exposed on the allergen surface may be the other reason. In conclusion, optimized carbonylation treatment reduced the immunoreactivity and improved the edible quality of shrimp.

A multistage biogas slurry reflux and spray anaerobic digestion reactor for high solid anaerobic digestion: Performance and application evaluation

In this study, a new vertical plug-flow continuous dry anaerobic digestion reactor equipped with a spray percolation system was designed for rice straw and cow manure in dry AD. The findings indicated that the methane yield was 290.63 ± 19.16 mL/g VS when the optimal spray time (9 times/d) was used in batch AD. In addition, the results of continuous experiments under optimal spray time conditions showed that the volumetric methane production rate of the system was 1.55 L/(L·d) when the organic loading rate was 20 g VS/(L·d). In addition, hydrolysis and acidification steps were enhanced. This study demonstrated the potential of the new reactor for stable operation of high OLR dry AD. Digestate is already used as a substitute for synthetic fertilizers precisely because of the environmental benefits associated with its agronomic use.

Simultaneous Production of Biogas and Electricity from Anaerobic Digestion of Pine Needles: Sustainable Energy and Waste Management.

Power scarcity and pollution can be overcome with the use of green energy forms like ethanol, biogas, electricity, hydrogen, etc., especially energy produced from renewable and industrial feedstocks. In hilly areas, pine needles are the most abundant biomass that has a low possibility of valorization due to high lignin content. On the other hand, anaerobic digestion (AD) of lignin and animal waste has low biogas yield due to poor conductivity. This study focuses on the simultaneous production of biogas and electricity through the co-digestion of cow dung and pine needles. The digester was initially established and stabilized in the lab to ensure a continuous supply of inoculum throughout the experiment. The optimization process involved the determination of an ideal cow dung-to-water ratio and selecting the appropriate conductive material that can enhance the energy generation from the feedstock. Afterward, both batch and continuous anaerobic digestion experiments were conducted. The results revealed that the addition of powdered graphite (5 mM), activated charcoal (15 mM), and biochar (25 mM) exhibited maximum voltage of 0.71 ± 0.013 V, 0.56 ± 0.013 V, and 0.49 ± 0.011 V on the 30th, 25th and 20th day of AD, respectively. The batch experiment showed that 5 mM graphite powder enhanced electron transfer in the AD process and generated a voltage of 0.77 ± 0.014 V on the 30th day, indicating an increase of ~1.5-fold as compared to the control (0.56 ± 0.019 V). The results from the continuous AD process showed that the digester with cow dung, pine needle, and a conductive material in combination exhibited the maximum voltage of 0.76 ± 0.012 V on the 21st day of AD, while the digester with cow dung only exhibited a maximum voltage of 0.62 ± 0.015 V on the 22nd day of AD, representing a 1.3-fold increase over the control. Furthermore, the current work used discarded plastic items and electrodes from spent batteries to emphasize waste management and aid in attaining sustainable energy and development goals.

Elucidating the role of sub-thermophilic temperature and pre-hydrolyzation for effective upgrading scheme of old swine manure digesters

Solids concentration, temperature, and digester configuration were subjected to biomethanation study to identify effective retrofitting schemes for old swine waste digesters. Batch assays were commenced to determine an appropriate scenario at 30–55 °C and total solids 1–3 %TS. Sub-thermophilic temperature (45 °C) was found desirable with an additional 11.1 % methane yield, while digestion at higher TS induced ammonium inhibition. Subsequent batch experiments lasted 72 hrs for hydrolytic-acidogenic assessment under various temperatures. Heating control at 45 °C and 55 °C for 24 hrs increased hydrolysis efficiency 4.6–5.7 folds above control but showed no significant difference (α = 0.05) between them. Limited heat supply from biogas engine dictated the continuous digestion study to operate pre-hydrolysis reactor at maximum temperature of 45 °C. The two-stage strategy demonstrated best overall performances at the sub-thermphilic combination, raising methane yield by 35.4 %. Next-Generation Sequencing indicated remarkable shifts in abundance and diversity, especially for hydrolytic organisms, which expanded from 54 to 70.2 % by sub-thermophilic temperature.

Modeling of biogas production from hydrothermal carbonization products in a continuous anaerobic digester.

The coupling between anaerobic digestion and hydrothermal carbonization (HTC) is a promising alternative for sustainable energy production. This study presents a dynamic model tailored for a lab-scale anaerobic digester operating on HTC products, specifically hydrochar and HTC liquor derived from sewage and agro-industrial digestate. Leveraging a modified version of the Anaerobic Model 2 (AM2), our simplified model of four states integrates pH and biomass decay rates into biomass kinetics. Simulation results of the mode were compared with experimental data collected over 164 days from the digester. The obtained results have proven the ability of the proposed model to predict the trend of the biogas production as well as important measured outputs of the bioreactor. The developed model could be used to control and optimize the performance of the digester, which provides potential for bioenergy production from waste streams such as digestate and digestate treated through the HTC process.

Continuous digester rapid thinning

Carbon steel continuous digesters built after the early 1980s are fully stress relieved, so stress corrosion cracking has been less of a concern. However, these newer digesters were designed to run modified cooking processes that have turned out to be much more corrosive than those running with conventional cooking. This corrosion is mainly associated with softwood digesters and appears to be flow related. Average corrosion rates of 40 mil/year are possible on the exposed shell between the wash and extraction screens. The corrosion patterns are visually distinct from surfaces in the upper digester and below the wash screens. This paper goes into practical detail on where it occurs, the causes, visual identification, inspection planning and results evaluation, and finally, how to mitigate this damage, which consists of applying a corrosion resistant barrier. Some discussion on dealing with general corrosion throughout the digester is included.

Modification of Anaerobic Digestion Model No. 1 for modeling anaerobic digestion of cattle manure with changing solids retention time

In this study, Anaerobic Digestion Model No.1 (ADM1) was modified to incorporate changes in biochemical parameters due to solids retention time (SRT) variations. Cattle manure (CM) and thermally hydrolyzed CM were selected for testing. Continuous anaerobic digestion reactors were operated under different SRT conditions ranging from 6.6 to 36.0 days for both samples. The biochemical parameters (kch, kli, kpr, um,ac, um,bu, um,pro, um,va, Kac, Kbu, Kpro, and Kva) for each SRT condition were determined. To modify ADM1, the equations obtained through linear regression were substituted into biochemical parameters as a function of SRT. The modified ADM1 demonstrated superior accuracy compared with conventional ADM1. This study implies the feasibility of optimizing biochemical parameters for modeling in response to changes in environmental variables.

Data-driven modeling and multi-objective optimization of a continuous kraft pulping digester

Understanding wood characteristics is essential for enhancing the economic sustainability of the kraft process. In a recent work, we included wood characteristics in the phenomenological modeling of digesters. The developed model allows the optimization of the process. Here, we propose a constrained multi-objective optimization approach to minimize the residual lignin content while maximizing the carbohydrate content in the cellulose pulp, using the Non-dominated Sorting Genetic Algorithm II. In order to reduce computational costs during the optimization, we developed a surrogate model, based on simulated data, to predict key performance indicators. We evaluated two machine learning techniques: Multilayer Perceptron (MLP) and decision tree-based methods, considering single and multiple outputs. The combination between the multiple-output approach and MLP performed well and resulted in a more simplified surrogate model. The results for the simulation and the surrogate model were similar, and the computational cost was approximately 50 times lower for the surrogate model. An uncertainty was associated with the multiplicative factor of the delignification rate as a way to observe how its estimate interferes with the Pareto curve. The present work presents contributions to data-driven modeling and multi-objective optimization of digesters, allowing us to determine the importance of wood characteristics in operation.

Fully Organic Sensors for Continuous Real-Time Digestion Monitoring.

Monitoring the gastric digestive function is important for the diagnosis of gastric disorders and drug development. However, there is no report on the in situ and real-time monitoring of digestive functions. Herein, we report a flexible fully organic sensor to effectively monitor protein digestion in situ in a simulated gastric environment for the first time. The sensors are made of a blend of gluten that is a protein and poly(3,4-ethylenedioxythiophene):polystyrenesulfonate (PEDOT:PSS) that is a conducting polymer. During the protein digestion, the breakdown of the polypeptides increases the level of separation among the PEDOT chains, thereby increasing the resistance. The resistance variation is sensitive to various conditions, including the concentration of pepsin that is the enzyme for protein digestion, temperature, pH value, and digestive drugs. Hence, these sensors can provide real-time information about the digestion and efficacy of digestive drugs. In addition, the signals can be collected via a convenient wireless communication manner.

Matheuristic for the lot-sizing and scheduling problem in integrated pulp and paper production

Vertical pulp and paper production is challenging from a process point of view. Managers must deal with floating bottlenecks, intermediate storage levels, and by-product production to control the whole process while reducing unexpected downtimes. Thus, this paper aims to address the integrated lot sizing and scheduling problem considering continuous digester production, multiple paper machines, and a chemical recovery line to treat by-products. The aim is to minimize the total production cost to meet customer demands, considering all productive resources and encouraging steam production (which can be used in power generation). Production planning should define the sizes of production lots, the sequence of paper types produced in each machine, and the digester working speed throughout the planning horizon. Furthermore, it should indicate the rate of by-product treatment at each stage of the recovery line and ensure the minimum and maximum storage limits. Due to the difficulty of exactly solving the mixed integer programming model representing this problem for real-world instances, mainly with planning horizons of over two weeks, constructive and improvement heuristics are proposed in this work. Different heuristic combinations are tested on hundreds of instances generated from data collected from the industry. Comparisons are made with a commercial Mixed-Integer and Linear Programming solver and a hybrid metaheuristic. The results show that combining the greedy constructive heuristic with the new variation of a fix-and-optimize improvement method delivers the best performance in both solution quality and computational time and effectively solves realistic size problems in practice. The proposed method achieved 69.41% of the best solutions for the generated set and 55.40% and 64.00% for the literature set for 1 and 2 machines, respectively, compared with the best solution method from the literature and a commercial solver.

Maximizing biogas production from leftover injera: influence of yeast addition to anaerobic digestion system

Abstract Injera is a staple food in Ethiopian dine. This study aimed to investigate on leftover injera (LI) for producing biogas via anaerobic digestion (AD), while leftover injera is full of easily biodegradable components. Aiming to examine the impact of yeast addition on biogas production efficiency, it was found that the addition of 2 % volatile solids (VS) of stimulated yeast, daily biogas output increased by 520 and 550 ml after 12 and 37 days of anaerobic digestion, respectively, with rather steady biogas production. The rate at which gas production increased was drastically cut in half when yeast was left out of the control group. Biogas production increased by only 60 ml despite the addition of two portions of substrate and yeast. Biogas output in the yeast group after fermentation was also up 33.2 % compared to the control group. The yeast group’s anaerobic digesting system was more stable, as determined by the study of markers including volatile organic acids, alkalinity, and propionic acid. The findings can be used as a benchmark for future trials aiming to industrialise continuous anaerobic digestion, allowing for more flexible response to feed as waste LI as organic load.

From grass to gas and beyond: Anaerobic digestion as a key enabling technology for a residual grass biorefinery

Roadside grass clippings hold potential as a sustainable source of bioenergy as they do not compete with crops for land use, and are only partially utilized for low-value applications. In this study, we proposed using roadside grass as a sole feedstock for anaerobic digestion (AD) in three different settings, and assessed the potential of producing biomaterials and fertilizers from grass-based digestate. Wet continuous digestion at pilot scale and dry batch digestion at pilot and large scales resulted in biogas yields up to 700 Nm3.t−1 DOM with a methane content of 49–55 %. Despite promising results, wet AD had operational problems such as clogging and poor mixing; once upscaled, the dry digestion initially also presented an operational problem with acidification, which was overcome by the second trial. Digested grass fibers from the pilot dry AD were processed into biomaterials and performed similarly or better than the undigested fibers, while around 20 % performance reduction was observed when compared to reference wood fibers. A mass balance indicated reduced fiber recovery when higher biogas production was obtained. The liquid fraction from the pilot dry AD was characterized for its nutrient content and used as a biofertilizer in another study. In contrast, the leachate collected from the large-scale dry AD had a low nitrogen content and high chloride content that could hinder its further use. Finally, a regional market analysis was conducted showing that the biocomposites produced with the available grass fibers could substitute at least half of the current European market based on our results.

Towards a sustainable energy future: Evaluating Arundo donax L. in continuous anaerobic digestion for biogas production

AbstractIn response to the EU's REPowerEU initiative (COM (2022) 108) which encourages an increase in biogas production by 20% in member states by 2030 to boost energy independence, it has become essential to identify sustainable alternatives to traditional feedstocks for biogas production, especially in the EU Member states where there is still high dependence on corn silage as the main raw material in biogas plants. While corn silage, predominantly used in the European biogas plants today, serves primarily for the livestock sector, alternative sources need to be explored. Therefore, this study aimed to evaluate the potential of Arundo donax, a perennial energy crop, as an alternative feedstock in a continuous anaerobic process. The biogas yield and its quality, characterized by CH4, CO2, H2S and O2 content, were determined during a continuous process with A. donax, compared with two mixed feedstocks of A. donax and corn silage over a 5‐month period in a continuous anaerobic digestion process. The results revealed that A. donax exhibits a biogas yield and methane content comparable to corn silage, indicating its potential as a viable and sustainable alternative feedstock for biogas production.

A hybrid approach of anaerobic digestion model no. 1 and machine learning to model and optimize continuous anaerobic digestion processes

Anaerobic digestion is a promising approach to dispose of biodegradable waste and wastewater, generating biogas as an alternative energy resource. This work proposed a so-called M-CADM1 for continuous anaerobic digestion simulation, which combined the machine learning and anaerobic digestion model No.1 (ADM1). The detailed reaction path and intermediate products in different stages of anaerobic digestion are specified in ADM1. The kinetic parameters were modified by machine learning. The characteristics (elemental composition) of feedstocks were used to predict kinetic parameters. A total of 75 biomass samples were used to establish for machine learning models. Five element contents (C, H, O, N, S), feedstock feed rate, and anaerobic digestion temperature were used as the input. The kinetic parameters were set as output. The sensitivities of 17 kinetic parameters were evaluated. 7 kinetic parameters with the highest sensitivities were selected as ADM1 model inputs by sensitivity analysis. The R2 and RMSE were used as the index to evaluated the accuracy of machine learning model. The best R2 and RMSE reached 0.84 and 0.196. The TIC was used as the index to evaluated the accuracy of M-CADM1. By comparing the simulated value with the experimental value, the accuracy of the overall M-CADM1 expressed by TIC of kitchen waste was 0.036. The organic acid content and pH in the reactor were considered as indicators to study the accuracy and stability of the M-CADM1. Trends in organic acids, free ammonia or hydrogen inhibition, and pH were consistent with experimental continuous anaerobic digestion results.

Effect of iron powder on hydrogen sulfide reduction and phosphate removal in semi‐continuous anaerobic digestion treating primary sludge

AbstractBACKGROUNDTo our best knowledge, no experimental study has previously investigated the simultaneous effects of adding Fe powder for the decrease of hydrogen sulfide (H2S) in biogas and the removal of phosphate (PO4‐P) in continuous anaerobic digestion (AD). This study investigated the effects of iron (Fe) powder (5 g L−1) in AD to remove H2S and PO4‐P. A comparative experiment was conducted using two semi‐continuous‐flow anaerobic digesters treating primary sludge at decreasing hydraulic retention times (HRTs) of 20 to 10 days.RESULTSThe addition of Fe powder to AD removed > 98% of H2S at all HRTs, and removed 64–72% of PO4‐P, with the highest removal efficiency at HRT = 10 d. The addition of Fe powder to AD had no noticeable effect on biogas production or pH, but it increased the CH4 content (62.7–66.0% in Fe‐treated vs 58.2–60.4% in the Control) partly due to the greater presence of Methanoregulaceae. The relative abundance of the microbial groups was more affected by HRT than by the addition of Fe powder. The presence of Fe powder notably increased the abundance of Spirochaetaceae and Syntrophaceae.CONCLUSIONAs shown, the addition of Fe powder can improve the management of both H2S in the biogas and PO4‐P in the digested sludge in the AD system. © 2024 Society of Chemical Industry (SCI).

The Bioenergetic Potential from Coffee Processing Residues: Towards an Industrial Symbiosis

Coffee processing generates a large amount of organic waste, which has the potential for energy use through biogas production. Although Brazil dominates world coffee production, treating its residue with biogas technology is not a practice, especially due to this product’s seasonality, which hampers continuous digester operation. The implementation of biogas production from coffee residues in a concept of industrial symbiosis could overcome this. This work evaluates the biogas energy potential from the main liquid residues of coffee processing (i.e., mucilage and wash water) and their integration with glycerin and cattle manure. Around 2773 m3 biogas day−1 would be produced (75% CH4), used as biomethane (734 thousand m3 year−1), or thermal energy (23,000,000 MJ year−1), or electricity (2718 MWh year−1), which could supply, respectively, all the liquefied petroleum gas (LPG) and diesel demands of the farm, all the thermal energy demands of the grain drying process, as well as electricity for 30 residences. Considering the short coffee season, the results have a broader context for the application of biogas production on coffee processing farms, envisaging that the Agroindustrial Eco-Park concept has the potential to integrate various agroindustrial sectors for energy production, residue exchange, and water recirculation.