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.     

Biogas production: current state and perspectives

Anaerobic digestion of energy crops, residues, and wastes is of increasing interest in order to reduce the greenhouse gas emissions and to facilitate a sustainable development of energy supply. Production of biogas provides a versatile carrier of renewable energy, as methane can be used for replacement of fossil fuels in both heat and power generation and as a vehicle fuel. For biogas production, various process types are applied which can be classified in wet and dry fermentation systems. Most often applied are wet digester systems using vertical stirred tank digester with different stirrer types dependent on the origin of the feedstock. Biogas is mainly utilized in engine-based combined heat and power plants, whereas microgas turbines and fuel cells are expensive alternatives which need further development work for reducing the costs and increasing their reliability. Gas upgrading and utilization as renewable vehicle fuel or injection into the natural gas grid is of increasing interest because the gas can be used in a more efficient way. The digestate from anaerobic fermentation is a valuable fertilizer due to the increased availability of nitrogen and the better short-term fertilization effect. Anaerobic treatment minimizes the survival of pathogens which is important for using the digested residue as fertilizer. This paper reviews the current state and perspectives of biogas production, including the biochemical parameters and feedstocks which influence the efficiency and reliability of the microbial conversion and gas yield.     

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.     

Microbial Community Dynamics of a Continuous Mesophilic Anaerobic Biogas Digester Fed with Sugar Beet Silage

The aim of the study was to investigate the long‐term fermentation of an extremely sour substrate without any addition of manure. In the future, the limitation of manure and therefore the anaerobic digestion of silage with a very low buffering capacity will be an increasing general bottleneck for energy production from renewable biomass. During the mesophilic anaerobic digestion of sugar beet silage (without top and leaves) as the sole substrate (without any addition of manure), which had an extreme low pH of around 3.3, the highest specific gas production rate (spec. GPR) of 0.72 L/g volatile solids (VS) d was achieved at a hydraulic retention time (HRT) of 25 days compared to an organic loading rate (OLR) of 3.97 g VS/L d at a pH of around 6.80. The methane (CH₄) content of the digester ranged between 58 and 67 %, with an average of 63 %. The use of a new charge of substrate (a new harvest of the same substrate) with higher phosphate content improved the performance of the biogas digester significantly. The change of the substrate charge also seemed to affect the methanogenic population dynamics positively, thus improving the reactor performance. Using a new substrate charge, a further decrease in the HRT from 25 to 15 days did not influence the digester performance and did not seem to affect the structure of the methanogenic population significantly. However, a decrease in the HRT affected the size of the methanogenic population adversely. The lower spec. GPR of 0.54 L/g VS d attained on day 15 of the HRT could be attributed to a lower size of methanogenic population present in the anaerobic digester during this stage of the process. Furthermore, since sugar beet silage is a relatively poor substrate, in terms of the buffering capacity and the availability of nutrients, an external supply of buffering agents and nutrients is a prerequisite for a safe and stable digester operation.     

Modeling anaerobic digestion of microalgae using ADM1

The coupling between a microalgal pond and an anaerobic digester is a promising alternative for sustainable energy production by transforming carbon dioxide into methane using solar energy. In this paper, we demonstrate the ability of the original ADM1 model and a modified version (based on Contois kinetics for the hydrolysis steps) to represent microalgae anaerobic digestion. Simulations were compared to experimental data of an anaerobic digester fed with Chlorella vulgaris. The modified ADM1 fits adequately the data for the considered 140 day experiment encompassing a variety of influent load and flow rates. It turns out to be a reliable predictive tool for optimising the coupling of microalgae with anaerobic digestion processes.     

An integrated physical and biological model for anaerobic lagoons

A computational fluid dynamics (CFD) model that integrates physical and biological processes for anaerobic lagoons is presented. In the model development, turbulence is represented using a transition k-ω model, heat conduction and solar radiation are included in the thermal model, biological oxygen demand (BOD) reduction is characterized by first-order kinetics, and methane yield rate is expressed as a linear function of temperature. A test of the model applicability is conducted in a covered lagoon digester operated under tropical climate conditions. The commercial CFD software, ANSYS-Fluent, is employed to solve the integrated model. The simulation procedures include solving fluid flow and heat transfer, predicting local resident time based on the converged flow fields, and calculating the BOD reduction and methane production. The simulated results show that monthly methane production varies insignificantly, but the time to achieve a 99% BOD reduction in January is much longer than that in July.     

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.     

Organic Matter Degradation Kinetics in an Anaerobic Thermophilic Fluidised Bed Bioreactor

This paper describes the thermophilic anaerobic biodegradation of wine distillery wastewater (vinasses) in a laboratory fluidised bed reactor (AFB) with a porous support medium. The experimental protocol was defined to examine the effect of increasing organic loading rate on the efficiency of AFB and to report on its steady-state performance. Moreover, in order to evaluate treatment efficiency and to investigate fermentation kinetics in an AFB reactor, experimental data were used to estimate the ‘active biomass’ concentration using an autocatalytic kinetic model proposed in this paper, since viable biomass in AFB reactors is very difficult to measure experimentally. The AFB reactor was subjected to a program of steady-state operation over a range of hydraulic retention time (HRTs) of 2.5–0.37 days and organic loading rate (OLRs) up to 5.88 kgCOD/m³/day in order to evaluate its treatment capacity. The AFB reactor was initially operated with organic loading rate of 5.88 kgCOD/m³/day and HRT of 2.5 days. The chemical oxygen demand (COD) removal efficiency was found to be 96.5% in the reactor while the methane content of biogas produced in the digester reached 1.08 m³/m³digester/day. Over 94 days operating period, an OLR of 32 kgCOD/m³/day at a food-to-micro-organisms (F:M) ratio of 0.55 kgCOD/kgVS_att/day was achieved with 81.5% COD removal efficiency in the experimental AFB reactor. At this moment, the methane content of biogas produced in the digester reached 9.0 m³/m³digester/day. The proposed kinetic model is able to estimate kinetic constants of the biodegradation process: non-biodegradable substrate (S_nb) and active adhered biomass concentration (X_a). The parameters of the model were obtained by the curve-fitting method to the proposed kinetic model using the COD as substrate of the anaerobic process and assuming a maximum specific μ_max: 0.72 per day. The comparison of the measured concentration of volatile attached solids (VS_att) with the estimated ‘active’ biomass concentration indicated that extremely high ‘active biomass’ concentrations can be maintained in the system because biofilm thickness is limited by the liquid flow rate applied. This is due to the fact that the anaerobic fluidised bed system retains the growth support medium in suspension by drag forces exerted by upflowing wastewater, and the distribution of biomass holdup (in the form of a biofilm) is thus relatively uniform.     

CFD simulation of mixing in anaerobic digesters

A three-dimensional CFD model incorporating the rheological properties of sludge was developed and applied to quantify mixing in a full-scale anaerobic digester. The results of the model were found to be in good agreement with experimental tracer response curve. In order to predict the dynamics of mixing, a new parameter, UI (uniformity index) was defined. The visual patterns of tracer mixing in simulation were well reflected in the dynamic variation in the value of UI. The developed model and methods were applied to determine the required time for complete mixing in a full-scale digester at different solid concentrations. This information on mixing time is considered to be useful in optimizing the feeding cycles for better digester performance.     

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.     

Continuous anaerobic treatment of wastewater from a kraft pulp mill

A pilot-scale study of the thermophilic anaerobic digestion of high-strength wastewater (evaporator condensate, EC) discharged from a kraft pulp production process was performed. The system consisted of a microfiltration (MF) membrane module for oily substances removal, a stripping system using evolved gas from the digester for sulfur compounds removal, an anaerobic fixed-bed bioreactor for methane fermentation, and an ultrafiltration (UF) membrane module for retention of a high density of bacterial cells. The bioreactor had a fixed-bed with an effective volume of 5 m³ packed with pumice stone. In a continuous run with only the MF membrane module for oily substances removal, the digester efficiency declined because of methanogenic inhibition by sulfur compounds. After fitting of the stripping system which used evolved gas from the digester, the inhibitive sulfur compounds in the EC were removed more than 80%, and high-loading and high-efficiency operation could be attained. The BOD loading and BOD removal of 35.5 kg BOD/m³/d and 93%, respectively were attained. By anaerobic treatment of the evaporator condensate waste before the conventional aerobic activated sludge method, the total costs would be reduced to ¥3.31/m³ wastewater compared with ¥4.53/m³-wastewater by the aerobic activated sludge method only. The stability of digester performance against interruption by feed stoppage was also examined.     

CFD simulation of mixing for high-solids anaerobic digestion

A computational fluid dynamics (CFD) model that simulates mechanical mixing for high-solids anaerobic digestion was developed. Numerical simulations of mixing manure slurry which exhibits non-Newtonian pseudo-plastic fluid behavior were performed for six designs: (i) one helical ribbon impeller; (ii) one anchor impeller; (iii) one curtain-type impeller; (iv) three counterflow (CF-2) impellers; (v) two modified high solidity (MHS 3/39°) impellers; and (vi) two pitched blade turbine impellers. The CFD model was validated against measurements for mixing a Herschel-Bulkley fluid by ribbon and anchor impellers. Based on mixing time with respect to mixing energy level, three impeller types (ribbon, CF-2, and MHS 3/39°) stand out when agitating highly viscous fluids, of these mixing with two MHS 3/39° impellers requires the lowest power input to homogenize the manure slurry. A comparison of digestion material demonstrates that the mixing energy varies with manure type and total solids concentration to obtain a given mixing time. Moreover, an in-depth discussion about the CFD strategy, the influences of flow regime and impeller type on mixing characteristics, and the intrinsic relation between mixing and flow field is included.     

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.     

Multi stage high rate biomethanation of poultry litter with self mixed anaerobic digester

A multi stage high rate biomethanation process with novel self mixed anaerobic digester (SMAD) was developed in the present study to reduce the hydraulic residence time (HRT), increase the volatile solids (VS) loading rate, improve the VS destruction efficiency and enhance the methane yield. Specific design features of SMAD were useful in mixing the digester contents without consuming power and de-alienated the problem of scum formation. In the first phase, poultry litter having 10% total solids (TS) was subjected to high rate biomethanation in multi stage configuration (SMAD-I and II in series with UASB reactor). It was observed that gross VS reduction of 58%, gross methane yield of 0.16 m³ kg⁻¹ (VS reduced) and VS loading rate of 3.5 kg VS m⁻³ day⁻¹ at HRT of 13 days was obtained. In the second phase SMAD-II was bypassed from the process scheme keeping the other parameters same as in the first phase. The results obtained were not as encouraging as in the first phase. The study showed that multi stage configuration with SMAD design improved the anaerobic digestion process efficiency of poultry litter.     

Single-stage, batch, leach-bed, thermophilic anaerobic digestion of spent sugar beet pulp

Spent sugar beet pulp as received was digested in a single-stage, batch, unmixed, leach-bed, laboratory scale thermophilic anaerobic digester. Biogasification of each 0.450 kg (wet weight) batch of spent pulp was initiated by inoculating with anaerobically digested liquor from previous run. The average methane yield was 0.336 m3 CH4 at STP (kgVS)(-1), the maximum methane production rate was 0.087 m3 CH4 at STP (kgVS)(-1)d(-1), average lag time to initiate methanogenesis was only 0.44 days and time required to achieve 95% methane yield was 8 days. The pH in the digesters ranged between 8.0 and 9.5. High rates of methane generation were sustained even at high pH values. The equivalent organic loading rate in the batch digesters was 4 kgCODm(-3)d(-1). The digestion process used here offers significant improvements over one-stage and two-stage systems reported in the literature with comparable performance as it is a single-stage system where the feedstock does not require size reduction, and mixing is not required in the digester.     

Novel membrane bioreactor: Able to cope with fluctuating loads, poorly water soluble VOCs, and biomass accumulation

We determined the effect of different mixing intensities on the performance, methanogenic population dynamics, and juxtaposition of syntrophic microbes in anaerobic digesters treating cow manure from a dairy farm. Computer automated radioactive particle tracking in conjunction with computational fluid dynamics was performed to quantify the shear levels locally. Four continuously stirred anaerobic digesters were operated at different mixing intensities of 1,500, 500, 250, and 50 revolutions per min (RPM) over a 260-day period at a temperature of 34 +/- 1 degrees C. Animal manure at a volatile solids (VS) concentration of 50 g/L was fed into the digesters daily at five different organic loading rates between 0.6 and 3.5 g VS/L day. The different mixing intensities had no effect on the biogas production rates and yields at steady-state conditions. A methane yield of 0.241 +/- 0.007 L CH(4)/g VS fed was obtained by pooling the data of all four digesters during steady-state periods. However, digester performance was affected negatively by mixing intensity during startup of the digesters, with lower biogas production rates and higher volatile fatty acids concentrations observed for the 1,500-RPM digester. Despite similar methane production yields and rates, the acetoclastic methanogenic populations were different for the high- and low-intensity mixed digesters with Methanosarcina spp. and Methanosaeta concilii as the predominant methanogens, respectively. For all four digesters, epifluorescence microscopy revealed decreasing microbial floc sizes beginning at week 4 and continuing through week 26 after which no microbial flocs remained. This decrease in size, and subsequent loss of microbial flocs did not, however, produce any long-term upsets in digester performance.     

Microbial rRNA gene expression and co‐occurrence profiles associate with biokinetics and elemental composition in full‐scale anaerobic digesters

This study examined whether the abundance and expression of microbial 16S rRNA genes were associated with elemental concentrations and substrate conversion biokinetics in 20 full‐scale anaerobic digesters, including seven municipal sewage sludge (SS) digesters and 13 industrial codigesters. SS digester contents had higher methane production rates from acetate, propionate and phenyl acetate compared to industrial codigesters. SS digesters and industrial codigesters were distinctly clustered based on their elemental concentrations, with higher concentrations of NH₃‐N, Cl, K and Na observed in codigesters. Amplicon sequencing of 16S rRNA genes and reverse‐transcribed 16S rRNA revealed divergent grouping of microbial communities between mesophilic SS digesters, mesophilic codigesters and thermophilic digesters. Higher intradigester distances between Archaea 16S rRNA and rRNA gene profiles were observed in mesophilic codigesters, which also had the lowest acetate utilization biokinetics. Constrained ordination showed that microbial rRNA and rRNA gene profiles were significantly associated with maximum methane production rates from acetate, propionate, oleate and phenyl acetate, as well as concentrations of NH₃‐N, Fe, S, Mo and Ni. A co‐occurrence network of rRNA gene expression confirmed the three main clusters of anaerobic digester communities based on active populations. Syntrophic and methanogenic taxa were highly represented within the subnetworks, indicating that obligate energy‐sharing partnerships play critical roles in stabilizing the digester microbiome. Overall, these results provide new evidence showing that different feed substrates associate with different micronutrient compositions in anaerobic digesters, which in turn may influence microbial abundance, activity and function.     

Mathematical modelling of the anaerobic digestion process: Application of dynamic mass-energy balance

The method of mass and energy balance was used in the design of a dynamic model of anaerobic digestion of complex organic substrates with production of methane. Distribution of mass flow, represented by the most abundant elements (C, H, N, O), and energy flow, represented by redoxons (available electrons), into gas and liquid output streams is influenced by environmental conditions in a continuous flow digester. Two pathways of methane generation,via cleavage of acetate andvia carbon dioxide reduction by hydrogen, are described in the model. The model was compared with experimental data from laboratory and pilot-plant experiments     

Mixing in anaerobic digestion

The mixing of the anaerobic digester contents significantly influences the efficiency of this operation; in particular, hydraulic dead zones are extremely detrimental to the reaction kinetics involved in anaerobic digestion. An analysis of the relative importance of thermal fluid movement in the digester to those caused by fluid inflow and outflow is presented. As an example, these principles are applied to a digester at the South Bend Wastewater Treatment Plant. Experimental measurements, which have general applicability for the measurement of digester mixing volume, confirm the theoretical conjectures. Various types of optimizations can be attempted on this mixing operation. One such optimization applied to gas lift mixers, as employed in the South Bend Treatment Plant, is illustrated.