Integrated production of hydrogen and methane in a dairy biorefinery using anaerobic digestion: Scale-up, economic and risk analyses.

Anaerobic digestion has emerged as the most appealing waste management strategy in biorefineries. Particularly, recent studies have highlighted the energy advantages of waste co-digestion in industrial biorefineries and the use of two-stage systems. However, there are some concerns about moving the system from laboratory testing to industrial scale. One of them is the high level of investment that is required. Therefore, this study carried out a techno-economic analysis (scale-up and energy production, economic and risk analysis, and factorial design) to assess the feasibility of single- and two-stage systems in the treatment of cheese whey and glycerin for the production of hydrogen and methane. Scenarios (S1 to S9) considered thermophilic and mesophilic single and two-stage systems with different applied organic loading rates (OLRA). The analyses of scale-up and energy production revealed that S3 (a thermophilic single-stage system operated at high OLRA 17.3 kg-COD.m-3.d-1) and S9 (a thermophilic-mesophilic two-stage system operated at high OLRA 134.8 kg-COD.m-3.d-1 and 20.5 kg-COD.m-3.d-1, respectively) were more compact and required lower initial investment compared to other scenarios. The risk analysis performed by a Monte Carlo simulation showed low investment risks (10 and 11%) for S3 and S9, respectively, being the electricity sales price, the key determining factor to define whether the project in the baseline scenario will result in profit or loss. Lastly, the factorial design revealed that while the net present value (NPV) is positively impacted by rising inflation and electricity sales price, it is negatively impacted by rising capitalization rate. Such assessments assist in making decisions regarding which system can be fully implemented, the best market circumstances for the investment, and how market changes may favorably or unfavorably affect the NPV and the internal rate of return (IRR).

From start-up to maximum loading: An approach for methane production in upflow anaerobic sludge blanket reactor fed with the liquid fraction of fruit and vegetable waste.

This investigation provides a reproducible approach for determining the limits of an upflow anaerobic sludge blanket (UASB) reactor designed for the methanization of the liquid fraction of fruit and vegetable waste (FVWL). Two identical mesophilic UASB reactors were operated for 240 days with a three-day fixed hydraulic retention time and an organic load rate (OLR) increased from 1.8 to 10 gCOD L-1 d-1. Because of the previous estimation of flocculent-inoculum methanogenic activity, it was possible to design a safe OLR for the quick start-up of both UASB reactors. The operational variables obtained from the operation of the UASB reactors did not show statistical differences, ensuring the experiment's reproducibility. As a result, the reactors achieved methane yield close to 0.250 LCH4 gCOD-1 up to the OLR of 7.7 gCOD L-1 d-1. Furthermore, the maximum volumetric methane production rate of 2.0 LCH4 L-1 d-1 was discovered for the OLR ranges between 7.7 and 10 gCOD L-1 d-1. The possible overload at OLR of 10 gCOD L-1 d-1 resulted in a significant reduction of methane production in both UASB reactors. Based on the methanogenic activity of the UASB reactors sludge, a maximum loading capacity of approximately 8 gCOD L-1 d-1 was estimated.

Biomethane recovery through co-digestion of cheese whey and glycerol in a two-stage anaerobic fluidized bed reactor: Effect of temperature and organic loading rate on methanogenesis.

Anaerobic digestion for CH4 recovery in wastewater treatment has been carried out with different strategies to increase process efficiency, among which co-digestion and the two-stage process can be highlighted. In this context, this study aimed at evaluating the co-digestion of cheese whey and glycerol in a two-stage process using fluidized bed reactors, verifying the effect of increasing the organic loading rate (OLR) (2-20 g-COD.L-1.d-1) and temperature (thermophilic and mesophilic) in the second stage methanogenic reactor. The mesophilic methanogenic reactor (R-Meso) (mean temperature of 22 °C) was more tolerant to high OLR and its best performance was at 20 g-COD.L-1.d-1, resulting in methane yield (MY) and methane production (MPR) of 273 mL-CH4.g-COD-1 and 5.8 L-CH4.L-1.d-1 (with 67% of CH4), respectively. Through 16S rRNA gene massive sequencing analysis, a greater diversity of microorganisms was identified in R-Meso than in R-Thermo (second stage methanogenic reactor, 55 °C). Firmicutes was the phyla with higher relative abundance in R-Thermo, while in R-Meso the most abundant ones were Proteobacteria and Bacteroidetes. Regarding the Archaea domain, a predominance of hydrogenotrophic microorganisms could be observed, being the genera Methanothermobacter and Methanobacterium the most abundant in R-Thermo and R-Meso, respectively. The two-stage system composed with a thermophilic acidogenic reactor + R-Meso was more adequate for the co-digestion of cheese whey and glycerol than the single-stage process, promoting increases of up to 47% in the energetic yield (10.3 kJ.kg-COD-1) and 14% in organic matter removal (90.5%).

Two problems in one shot: Vinasse and glycerol co-digestion in a thermophilic high-rate reactor to improve process stability even at high sulfate concentrations.

Anaerobic co-digestion (AcoD) of sugarcane vinasse and glycerol can be profitable because of the destination of two biofuel wastes produced in large quantities in Brazil (ethanol and biodiesel, respectively) and the complementary properties of these substrates. Thus, the objective of this study was to assess the effect of increasing the organic loading rate (OLR) from 2 to 20 kg COD m-3 d-1 on the AcoD of vinasse and glycerol (50 %:50 % on a COD basis) in a thermophilic (55 °C) anaerobic fluidized bed reactor (AFBR). The highest methane production rate was observed at 20 kg COD m-3 d-1 (8.83 L CH4 d-1 L-1), while the methane yield remained stable at around 265 NmL CH4 g-1 CODrem in all conditions, even when influent vinasse reached 1811 mg SO42- L-1 (10 kg COD m-3 d-1). Sulfate was not detected in the effluent. Bacterial genera related to sulfate removal, such as Desulfovibrio and Desulfomicrobium, were observed by means of shotgun metagenomic sequencing at 10 kg COD m-3 d-1, as well as the acetoclastic archaea Methanosaeta and prevalence of genes encoding enzymes related to acetoclastic methanogenesis. It was concluded that process efficiency and methane production occurred even in higher sulfate concentrations due to glycerol addition.

One waste and two products: choosing the best operational temperature and hydraulic retention time to recover hydrogen or 1,3-propanediol from glycerol fermentation.

This study aimed to compare the production of hydrogen and 1,3-propanediol from crude glycerol (10 g/L) in mesophilic (30 °C) and thermophilic (55 °C) anaerobic fluidized bed reactors, namely AFBR30 °C and AFBR55 °C, respectively, at hydraulic retention times (HRT) reduced from 8 to 1 h. In AFBR30 °C, the absence or low hydrogen yields can be attributed to the production of 1,3-propanediol (maximum of 651 mmol/mol glycerol), and the formation of caproic acid (maximum of 1097 mg/L) at HRTs between 8 and 2 h. In AFBR55 °C, the hydrogen yield of 1.20 mol H2/mol glycerol consumed was observed at the HRT of 1 h. The maximum yield of 1,3-propanediol in AFBR55 °C was equal to 804 mmol/mol glycerol at the HRT of 6 h and was concomitant with the production of hydrogen (0.87 mol H2/mol glycerol consumed) and butyric acid (1447 mg/L).

Anaerobic Biodegradation of Biodiesel Industry Wastewater in Mesophilic and Thermophilic Fluidized Bed Reactors: Enhancing Treatment and Methane Recovery.

In the past few years, the extraction of value-added compounds from the anaerobic digestion of glycerol has been an option to add value to this waste because biodiesel production is increasing worldwide. The evolution of research on glycerol valorization by anaerobic digestion has reached the use of high-rate reactors. However, no study has evaluated glycerol digestion in an anaerobic fluidized bed reactor (AFBR), a configuration with potential advantages in methane production. Still, the best operating temperature for high-rate glycerol digestion remains unclear. To clarify these gaps, the present study aimed to compare glycerol digestion in mesophilic AFBR (30 °C) and thermophilic AFBR (55 °C). In both reactors, glycerol concentration was increased from 1.0 to 7.0 g L-1 at a fixed hydraulic retention time of 24 h, resulting in an increase at the organic loading rate from 1.2 to 7.6 kg COD m-3 day-1. Thermophilic digestion of glycerol achieved superior removals of organic matter (67.7-94.2%) and methane yield (330.8 mL CH4 g-1 COD) than the mesophilic digestion (48.6-93.0% and 266.6 mL CH4 g-1 COD). Additionally, the application of the kinetic model of substrate utilization (modified Stover-Kincannon model) indicated a higher substrate utilization coefficient in the thermophilic AFBR (23.09 g L-1 day-1) than the mesophilic AFBR (7.14 g L-1 day-1). Therefore, the application of glycerol concentrations higher than 7.0 g L-1 in thermophilic AFBR should be further investigated. Also, given only operational results, the application of the AFBR in the two-stage anaerobic digestion of glycerol is recommended.

Controlling methane and hydrogen production from cheese whey in an EGSB reactor by changing the HRT.

This study assessed the effects of hydraulic retention time (HRT; 8 h-0.25 h) on simultaneous hydrogen and methane production from cheese whey (5000 mg carbohydrates/L) in a mesophilic (30 °C) expanded granular sludge bed (EGSB) reactor. Methane production was observed at HRTs from 4 to 0.25 h. The maximum methane yield (9.8 ± 1.9 mL CH4/g CODap, reported as milliliter CH4 per gram of COD applied) and methane production rate (461 ± 75 mL CH4/day Lreactor) occurred at HRTs of 4 h and 2 h, respectively. Hydrogen production increased as methane production decreased with decreasing HRT from 8 to 0.25 h. The maximum hydrogen yield of 3.2 ± 0.3 mL H2/g CODap (reported as mL H2 per gram of COD applied) and hydrogen production rate of 1951 ± 171 mL H2/day Lreactor were observed at the HRT of 0.25 h. The decrease in HRT from 8 to 0.25 h caused larger changes in the bacterial populations than the archaea populations. With the decrease in HRT (6 h-0.25 h), the Shannon diversity index decreased (3.02-2.87) for bacteria and increased (1.49-1.83) for archaea. The bacterial dominance increased (0.059-0.066) as the archaea dominance decreased (0.292-0.201) with the HRT decrease from 6 to 0.25 h.