Numerical simulation of mechanical mixing in high solid anaerobic digester

Computational fluid dynamics (CFD) was employed to study mixing performance in high solid anaerobic digester (HSAD) with A-310 impeller and helical ribbon. A mathematical model was constructed to assess flow fields. Good agreement of the model results with experimental data was obtained for the A-310 impeller. A systematic comparison for the interrelationship of power number, flow number and Reynolds number was simulated in a digester with less than 5% TS and 10% TS (total solids). The simulation results suggested a great potential for using the helical ribbon mixer in the mixing of high solids digester. The results also provided quantitative confirmation for minimum power consumption in HSAD and the effect of share rate on bio-structure.     

Flow pattern visualization in a mimic anaerobic digester using CFD

Three-dimensional steady-state computational fluid dynamics (CFD) simulations were performed in mimic anaerobic digesters to visualize their flow pattern and obtain hydrodynamic parameters. The mixing in the digester was provided by sparging gas at three different flow rates. The gas phase was simulated with air and the liquid phase with water. The CFD results were first evaluated using experimental data obtained by computer automated radioactive particle tracking (CARPT). The simulation results in terms of overall flow pattern, location of circulation cells and stagnant regions, trends of liquid velocity profiles, and volume of dead zones agree reasonably well with the experimental data. CFD simulations were also performed on different digester configurations. The effects of changing draft tube size, clearance, and shape of the tank bottoms were calculated to evaluate the effect of digester design on its flow pattern. Changing the draft tube clearance and height had no influence on the flow pattern or dead regions volume. However, increasing the draft tube diameter or incorporating a conical bottom design helped in reducing the volume of the dead zones as compared to a flat-bottom digester. The simulations showed that the gas flow rate sparged by a single point (0.5 cm diameter) sparger does not have an appreciable effect on the flow pattern of the digesters at the range of gas flow rates used.     

Dissolved hydrogen concentration as an on-line control parameter for the automated operation and optimization of anaerobic digesters

The use of dissolved hydrogen as an early warning signal of digester failure and a control parameter to operate anaerobic digesters was investigated. A sensitive, on-line method was developed for measuring trace levels of dissolved hydrogen in a semi-permeable membrane, situated within the biomass of a 1 L laboratory anaerobic digester, using trace reduction gas analysis. At normal operating conditions, the dissolved hydrogen partial pressure (2 to 8 Pa) was found to be linearly correlated with the loading rate of the digester, and was a sensitive indicator of the effect of shockloads as well as gradual overloading. An increase in hydrogen partial pressure above a critical concentration of 6.5-7 Pa indicated the initial stage of digester overloading (i.e., volatile fatty acids accumulation). A H(2)-based computer control system, using a critical hydrogen partial pressure of 6.5 Pa as the setpoint, was found to be effective for the safe operation of a laboratory digester close to its maximum sustainable loading rate. The existence of a relationship between hydrogen level and organic loading rate was also confirmed on a 600 m(3) industrial digester, with digester overloading occurring at hydrogen concentrations above 7 Pa. The results suggest that the dissolved hydrogen concentration is capable of being a sensitive on-line parameter for the automated management of anaerobic digesters near their maximum sustainable loading capacity. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 56: 626-634, 1997.     

Microbial segregation within anaerobic digester granules treating brewery wastewater

Microbial segregation was observed within granules from a laboratory scale upflow anaerobic sludge blanket (UASB) digester, using fluorescence and electron microscopy. A shift in distribution of methanogens occurred upon alteration of the feed flow rate.     

CFD simulation of non-Newtonian fluid flow in anaerobic digesters

A general mathematical model that predicts the flow fields in a mixed-flow anaerobic digester was developed. In this model, the liquid manure was assumed to be a non-Newtonian fluid, and the flow governed by the continuity, momentum, and k-epsilon standard turbulence equations, and non-Newtonian power law model. The commercial computational fluid dynamics (CFD) software, Fluent, was applied to simulate the flow fields of lab-scale, scale-up, and pilot-scale anaerobic digesters. The simulation results were validated against the experimental data from literature. The flow patterns were qualitatively compared for Newtonian and non-Newtonian fluids flow in a lab-scale digester. Numerical simulations were performed to predict the flow fields in scale-up and pilot-scale anaerobic digesters with different water pump power inputs and different total solid concentration (TS) in the liquid manure. The optimal power inputs were determined for the pilot-scale anaerobic digester. Some measures for reducing dead and low velocity zones were proposed based upon the CFD simulation results.     

Inactivation of Salmonella typhi by high levels of volatile fatty acids during anaerobic digestion

Survival of Salmonella typhi was investigated in an anaerobic digester for cattle dung with volatile fatty acid (VFA) levels of 5000 mg l(-1) and pH 6.0. The organism was added to the digester only once in the first experiment and daily in the other. Survival was monitored on alternate days. In the single dose experiment, the counts of Salm. typhi declined rapidly and the pathogen was completely eliminated within 12 d in the experimental digester (VFA ca 5000 mg l(-1) and pH 6.0), whereas 26 d were required in the control digester (VFA ca 100 mg l(-1) and pH 6.8). T90 values for the experimental and control digesters were 2.44 d and 4.80 d, respectively. In the daily dose experiment, a four log reduction in the pathogen count was observed in the experimental digester, but only a two log reduction in the control digester at the end of the experimental period. The mean T90 values for the experimental and the control digester were 4.22 d and 18.63 d, respectively. In both the experiments, statistical analysis of the data showed significant differences in the survival pattern of Salm. typhi in the two digesters.     

Selective desorption of carbon dioxide from sewage sludge for in situ methane enrichment--part I: pilot-plant experiments

In situ methane enrichment in anaerobic digestion of sewage sludge has been investigated by experiments and by modeling. In this first part, the experimental work on the desorption of carbon dioxide and methane from sewage sludge is reported. The bubble column, had a diameter of 0.3 m and a variable height up to 1.8 m. At operation the dispersion height in the column was between 1 and 1.3 m. Outdoor air was used. The column was placed close to a full-scale sewage sludge digester, at a municipal wastewater treatment plant. The digester was operated at mesophilic conditions with a hydraulic retention time of about 20 days. The bubble column was operated to steady-state, at which carbon dioxide concentration and alkalinity were determined on the liquid side, and the concentration of carbon dioxide and methane on the gas side. Thirty-eight experiments were performed at various liquid and gas flow rates. The experimental results show that the desorption rates achieved for carbon dioxide ranges from 0.07 to 0.25 m(3) CO(2)/m(3) sludge per day, which is comparable to the rate of generation by the anaerobic digestion. With increasing liquid flow rate and decreasing gas flow rate the amount of methane desorbed per amount of carbon dioxide desorbed increases. The lowest methane loss achieved is approximately 2% of the estimated methane production in the digestion process.     

Inactivation of Salmonella typhi by high levels of volatile fatty acids during anaerobic digestion

Survival of Salmonella typhi was investigated in an anaerobic digester for cattle dung with volatile fatty acid (VFA) levels of 5000 mg l⁻¹ and pH 6·0. The organism was added to the digester only once in the first experiment and daily in the other. Survival was monitored on alternate days. In the single dose experiment, the counts of Salm. typhi declined rapidly and the pathogen was completely eliminated within 12 d in the experimental digester (VFA ca 5000 mg l⁻¹ and pH 6·0), whereas 26 d were required in the control digester (VFA ca 100 mg l⁻¹ and pH 6·8). T ₉₀ values for the experimental and control digesters were 2·44 d and 4·80 d, respectively. In the daily dose experiment, a four log reduction in the pathogen count was observed in the experimental digester, but only a two log reduction in the control digester at the end of the experimental period. The mean T ₉₀ values for the experimental and the control digester were 4·22 d and 18·63 d, respectively. In both the experiments, statistical analysis of the data showed significant differences in the survival pattern of Salm. typhi in the two digesters.     

Anaerobic treatment of baker's yeast effluent using a hybrid digester with polyurethane as support material

Summary A high-strength baker's yeast effluent was anaerobically treated using a hybrid digester under mesophilic conditions. The digester was subjected to a substrate COD concentration of 21 767 mg/I at three different HRTs. At HRTs of 3.0, 2.0 and 1.0 d, the digester reduced the substrate COD by 76, 61 and 33%, respectively. Although the best COD removal was obtained at an OLR of 7.30 kg COD/m³.d, the highest COD removal rate (6.51 kg COD/M³-d) was found at 10.65 kg COD/m³.d at an HRT of 2.0 d. The low methane yield and VFA accumulation found in the digester effluent, indicated inhibition on methanogenic level and this was considered to be the rate-limiting step during the anaerobic treatment process. The overall efficiency of the digester indicated that this digester design and support medium was suitable for the treatment of a high-strength, sulfate-rich baker's yeast effluent.     

Spatial and temporal variations of microbial community in a mixed plug‐flow loop reactor fed with dairy manure

Mixed plug‐flow loop reactor (MPFLR) has been widely adopted by the US dairy farms to convert cattle manure to biogas. However, the microbiome in MPFLR digesters remains unexplored. In this study, the microbiome in a MPFLR digester operated on a mega‐dairy farm was examined thrice over a 2 month period. Within 23 days of retention time, 55–70% of total manure solid was digested. Except for a few minor volatile fatty acids (VFAs), total VFA concentration and pH remained similar along the course of the digester and over time. Metagenomic analysis showed that although with some temporal variations, the bacterial community was rather stable spatially in the digester. The methanogenic community was also stable both spatially and temporally in the digester. Among methanogens, genus Methanosaeta dominated in the digester. Quantitative polymerase chain reaction (qPCR) analysis and metagenomic analysis yielded different relative abundance of individual genera of methanogens, especially for Methanobacterium, which was predominant based on qPCR analysis but undetectable by metagenomics. Collectively, the results showed that only small microbial and chemical gradients existed within the digester, and the digestion process occurred similarly throughout the MPFLR digester. The findings of this study may help improve the operation and design of this type of manure digesters.     

Psychrophilic anaerobic digestion of guinea pig manure in low-cost tubular digesters at high altitude

Guinea pig is one of the most common livestock in rural communities of the Andes. The aim of this research was to study the anaerobic digestion of guinea pig manure in low-cost unheated tubular digesters at high altitude. To this end, the performance of two pilot digesters was monitored during 7 months; and two greenhouse designs were compared. In the dome roof digester the temperature and biogas production were significantly higher than in the shed roof digester. However, the biogas production rate was low (0.04 m(biogas)(3)m(digester)(-3) d(-1)), which is attributed to the low organic loading rate (0.6 kg(VS)m(digester)(-3)d(-1)) and temperature (23°C) of the system, among other factors. In a preliminary fertilization study, the potato yield per hectare was increased by 100% using the effluent as biofertilizer. Improving manure management techniques, increasing the organic loading rate and co digesting other substrates may be considered to enhance the process.     

Cheese whey anaerobic digestion — Effect of chemical flocculant addition

Summary Two stirred tank digesters were operated with biomass retention by internal settling during effluent removal. In one digester a flocculating agent was used to enhance microbial aggregation and settling. The unflocculated digester achieved a maximum stable loading rate of 8–8.5kg COD/m³. day and biomass density of 19.3g VSS/l compared to the flocculated digester which achieved a (non-maximal) stable loading rate of 12.3kg COD/m³. day and biomass density of 43.3g VSS/l. Both digesters had a COD conversion efficiency greater than 97%. Operation of a stirred tank digester in a mix/settle mode allows a significant increase in biomass levels over conventional continuously stirred digesters. The addition of a chemical flocculant significantly enhances this improvement.     

Integration of mixing, heat transfer, and biochemical reaction kinetics in anaerobic methane fermentation

An extensive investigation of anaerobic methane fermentation requires identifying the relationship between the physical environment and biological process. In this study, a computational fluid dynamics (CFD) technique was used to characterize bacterial fermentation mechanisms intertwined with mixing and heat transfer in anaerobic digesters. The results demonstrate that the methane yield remains almost unchanged while the energy efficiency decreases with increasing mixing power in a complete‐mix digester, and that the energy output increases nonlinearly with the increase in heating energy in a plug‐flow digester. The CFD method can be applied to other bioreactors to gain valuable insights into their behavior as well. Integrating flow and temperature with kinetic behavior for anaerobic digestion not only solves the controversy about how mixing influences the digestive process, but also assists in optimizing the digester design and increasing the efficiency of energy conversion, and additionally, provides a reference for improving the mixing guidelines recommended by the U.S. Environmental Protection Agency. Biotechnol. Bioeng. 2012; 109: 2864–2874. © 2012 Wiley Periodicals, Inc.     

Potential availability of anaerobic treatment with digester slurry of animal waste for the reclamation of acid mine water containing sulfate and heavy metals

The use of an anaerobic digester slurry of cattle waste for the reclamation of acid mine water was examined. When the digester slurry was mixed with acid mine water, anaerobic digestion, including sulfate reduction and methanogenesis, was enhanced. In the mixture of acid mine water and the digester slurry, sulfate reduction proceeded without diminishing methanogenesis. The digester slurry and its supernatant (SDF-sup) showed a significant capacity to act as a strong alkaline reagent, and the pH of the acid mine water was markedly elevated by the addition of the digester slurry of SDF-sup even at the low ratio of 1% (v/v). Precipitation of heavy metals in the acid mine water occurred as the pH was elevated by the addition of SDF-sup. When the digester slurry was added at the ratio of 5% (v/v) to acid mine water which had been pretreated with SDF-sup, the rate of sulfate reduction increased with increasing the concentration of sulfate in the mixture up to about 1,400 mg·l⁻¹. In acid mine water pretreated with SDF-sup and supplemented with the digester slurry at the ratio of 5% (v/v), the maximum amount of sulfate reduced within 20 d of incubation was about 1,000 mg·l⁻¹, and the maximum rate of sulfate reduction was about 120 mg SO₄²⁻·l⁻¹·d⁻¹.     

Concurrent microscopic observations and activity measurements of cellulose hydrolyzing and methanogenic populations during the batch anaerobic digestion of crystalline cellulose

This study compares process data with microscopic observations from an anaerobic digestion of organic particles. As the first part of the study, this article presents detailed observations of microbial biofilm architecture and structure in a 1.25-L batch digester where all particles are of an equal age. Microcrystalline cellulose was used as the sole carbon and energy source. The digestions were inoculated with either leachate from a 220-L anaerobic municipal solid waste digester or strained rumen contents from a fistulated cow. The hydrolysis rate, when normalized by the amount of cellulose remaining in the reactor, was found to reach a constant value 1 day after inoculation with rumen fluid, and 3 days after inoculating with digester leachate. A constant value of a mass specific hydrolysis rate is argued to represent full colonization of the cellulose surface and first-order kinetics only apply after this point. Additionally, the first-order hydrolysis rate constant, once surfaces were saturated with biofilm, was found to be two times higher with a rumen inoculum, compared to a digester leachate inoculum. Images generated by fluorescence in situ hybridization (FISH) probing and confocal laser scanning microscopy show that the microbial communities involved in the anaerobic biodegradation process exist entirely within the biofilm. For the reactor conditions used in these experiments, the predominant methanogens exist in ball-shaped colonies within the biofilm.     

Analysis of the performance of an anaerobic digestion system at the Regina Wastewater Treatment Plant

From the performance analysis of the anaerobic digestion system at the Regina Wastewater Treatment Plant, it was found that the anaerobic digestion system at the Regina plant was generally operated in a stable condition as indicated by pH, volatile acids and alkalinity levels. The operation of the anaerobic digestion system was not optimal because of the low volatile solids concentration and low volatile solids loading rate, especially because of high HRT. Two options, thickening the primary sludge and increasing the volatile solids loading rate, were recommended for the optimal operation of the digestion system. After examining a number of kinetic models, it was found that the Chen-Hashimoto model could be used to predict the volumetric methane production rate and the first-order model could be used to predict the efficiency of volatile solids reduction. The study showed that utilization of digester gas for power production was the best alternative for the excess digester gas. 13.3% of the electrical demand and 35.5% of the plant's total energy could be met based on digester gas wasted, assuming 25% as the conversion efficiency.     

Evaluation of parameters for monitoring an anaerobic co-digestion process

The system investigated in this study is an anaerobic digester at a municipal wastewater treatment plant operating on sludge from the wastewater treatment, co-digested with carbohydrate-rich food-processing waste. The digester is run below maximum capacity to prevent overload. Process monitoring at present is not extensive, even for the measurement of on-line gas production rate and off-line pH. Much could be gained if a better program for monitoring and control was developed, so that the full capacity of the system could be utilised without the risk of overload. The only limit presently set for correct process operation is that the pH should be above 6.8. In the present investigation, the pH was compared with alkalinity, gas production rate, gas composition and the concentration of volatile fatty acids (VFA). Changes in organic load were monitored in the full-scale anaerobic digester and in laboratory-scale models of the plant. Gas-phase parameters showed a slow response to changes in load. The VFA concentrations were superior for indicating overload of the microbial system, but alkalinity and pH also proved to be good monitoring parameters. The possibility of using pH as a process indicator is, however, strongly dependent on the buffering capacity. In this study, a minor change in the amount of carbohydrates in the substrate had drastic effects on the buffering effect of the system. Received: 21 January 2000 / Received revision: 10 July 2000 / Accepted: 16 July 2000     

In situ methane enrichment in anaerobic digestion

A major cost consideration in the use of anaerobic digestion to convert biomass and waste to utility-grade gas is the expense of separating CO(2) from the product gas. Anaerobic digestion has a number of inherent properties that can be exploited to increase the methane content of the gas directly produced by the digester, the most important of which is the high solubility of CO(2)(40-60 times that of methane) in water under digestion conditions. The methane enrichment concept examined in this study involved the recirculation of a liquid stream from the digester through a CO(2) desorption process and the return of the liquid stream back to the digester for absorption of additional CO(2) produced by the conversion of organic materials. A steady-state equilibrium model predicted that a digester gas methane content exceeding 94% could be achieved with this scheme using modest recirculation rates provided a desorption process could be designed to achieve a 60+% CO(2) removal efficiency in the degassing of the liquid recycle stream. Using fixed-film laboratory digesters operated on synthetic feedstocks, the technique of methane enrichment was tested under pressurized and unpressurized conditions. A 93 + 2% methane gas stream was produced from a volatile-acid-fed bench-scale digester simulating the methanogenic stage of two-phase digestion under conditions of (1) a pH swing achieved without caustic addition that allowed digestion at pH 7. 5 and air stripping at pH 6. 5-7. 0, (2) digester pressurization to 30 psig, and (3) a recycle rate of 0. 33 L/L reactor/day. Significant but lower levels of methane enrichment were achieved with the single-stage digester at the low experimental recycle rate. However, the narrow range among all experiments of CO(2) desorption efficiencies achieved in air stripping the recycle stream (35-60% CO(2) removal) suggests that comparable methane enrichment-may be achieved with unpressurized single-stage digestion using greater recycle rates. A materials balance analysis of data from an unpressurized, single-stage digester employing no chemical addition and using laboratory degassing efficiencies indicated that 94% methane could be produced at recycle rates of less than 1. 4 L/L reactor/day with a methane loss of less than 2%.     

Starting-up an anaerobic hybrid filter for the fermentation of wastewater from food industry

The wastewater from a food processing factory, characterised by fluctuations of flow rate, organic strength, and pH, were originally treated by a traditional suspended-biomass digester working at about 25?°C. In order to improve the digester efficiency, either in terms of degradation ability or biogas production yield, a set of tests has been carried out on laboratory scale, whose results indicated the way to correctly transform it into an anaerobic hybrid filter. The unacceptable conversion yield of organic substances into biogas observed in the original system has been improved by the presence of the filling medium, due to a marked increase in biomass retention time. The start-up of anaerobic digestion has been studied in this reactor at two different temperatures (25 and 30?°C), in order to evaluate the possible advantage of heating the system, simulating continuous variations in feed strength, pH, and composition.