Improving Anaerobic

Digestion operations

Matthew Smyth &

Nigel Horan
Aqua Enviro
Front end processing
of feedstocks

Matthew Smyth
Operations’ Director,
Aqua Enviro
 Feedstocks = Sources of Energy
The nature and composition of the feedstock is of critical importance, it influences the overall
economics of digestion, the way the plant is operated and the quality of the whole digestate. The
operator should therefore understand the risks and rewards associated with different feedstocks.

Organic material that can be converted into methane by AD is either composed of:

 Carbohydrates
 Proteins
 Lipids
 (Lignin)

Organic waste feedstocks, which are composed of carbohydrates, proteins and lipids (fats) can be
broken down by the process of anaerobic digestion to produce biogas (principally methane and
carbon dioxide). The rate of conversion to methane and the amount of energy recovered
(biogas) is directly related to the feedstock composition. If the operator understands the
feedstock it becomes possible to set operating ranges for critical metrics to meet plant specific
targets (e.g. maximise throughput, achieve PAS110, maximise methane yield). It is rarely
possible, however to configure a process to meet every target, a balance must be struck.
Wrap, 2010
COD & Energy Potential
Compound Classification Composition Theoretical COD Energy potential
(g COD/g material) from 1kg of
compound (kWh)
Glucose Carbohydrate C6H12O6 1.07 3.81
Alanine Protein C3H8O2 1.68 5.98

Glycerine
Lipid C57H104O6 2.90 10.32
Trioleate

If the chemical formula of the feedstock is known it is possible to calculate the COD (chemical
oxygen demand) of the material.
COD & Energy Potential

1 kg of COD has the potential to deliver 3.56 kWh of energy. On an equivalent dry
weight of different materials, long chain lipids have the potential to deliver up to
three times the energy than the same dry mass of a carbohydrate. Waste glycerol (a
by product of producing bio-diesel) is thus an attractive feedstock from an energy
perspective, but may pose operating problems if the waste characteristics are not
fully understood. For example waste glycerol can be rich in contaminants (e.g.
methanol), of high pH and being very high strength has the potential to organically
overload the digester. Operators accepting third party waste materials should have a
robust quality management system in place to minimise the risk associated with trade
waste imports.
Energy Content of methane
9.97 kWh/Nm3 methane

Therefore with a concentration of methane in

biogas of typically 65% - we have about
6.48kWh/Nm3 biogas of energy.
Feed Carbon to nitrogen ratio
 Total carbon: total nitrogen ratio
 If N is too high (e.g. FYM) then there is a
danger of ammonia inhibition
 If C is too high (e.g. food waste) then too
much VFA production, inadequate alkalinity,
and the pH will drop
Digester operation is the biggest influence on C:N
The management of ammonium-nitrogen levels in the digester is of critical importance and
a challenge for operators. Nitrogen is required as a nutrient by the bacteria, but if present
in too high a concentration becomes toxic.
Ideally the feedstock carbon: nitrogen (C:N) ratio should be balanced to provide an
optimum. Where a digestion plant recycles return liquors from dewatering (e.g. belt press
or centrifuge) or digestate to the head of the process and uses it for dilution water (as
opposed to e.g. fresh water) the potential for ammonia inhibition to occur is greatly
increased.

One of the biggest challenges facing operators is how to dilute down the feedstock which is
generally in the range 20-25% dry solids to a level where contaminants can be removed and
the feedstock pumped, which generally means <14% DS.

This can be done with:

• Water, the disadvantage of this is that it increases the volume out of the digester and
hence transportation costs;
• Recirculating digestate back to the front of the process. Whilst this minimises
transportation costs digestate is rich in ammonium and salts, both of which are inhibitory
to the process, will reduce the biogas yield and increase VFA levels and the RBP of the
digestate.
 Achieving PAS 110 Compliant
Sanitisation and Digestate

Nigel Horan
Director
Aqua Enviro
PAS110
“The purpose of this PAS is twofold: to ensure that
digested materials are made using suitable inputs and
effectively processed by anaerobic digestion (AD) for
sufficient time; and to ensure that the process has been
well managed and monitored so as to produce digested
material that meets market needs and protects the
environment.” (PAS110:2010)
Key elements of PAS110
It specifies:-
 Controls on input materials and management
systems for AD process
 Covers AD system that accept source segregated
biowastes/biodegradable non-wastes that are
depackaged
 Minimum quality of whole digestate, separated fibre
and liquor (pathogens, physical contaminants, PTEs,
stability)
 Information required to be supplied to digestate
recipients
 Anaerobic Digestion Quality Protocol PAS 110

Waste Product

Feedstock Digestion Digestate End-user

Input restrictions HACCP Product quality Industry

(Hazard Analysis & specification
Critical Control Points)

Suitable QMS and auditing procedures

 PAS110 and pasteurisation: Why and what?
• Intended to minimise risk from microbiological hazards –
Human, animal and plant
• Applies to all AD processes within PAS110
– Except where inputs arise, are digested, and used on
the same premises or holding
• Site-specific criteria
• Non-ABP* operators can opt for one of the three
standard approaches in the UK ABPRs**
• No deference to thermo or mesophilic
*ABP-Animal By-Products
**ABPR- Animal By-Products Regulations
 ABPR Definitions of Main Caegories
Many feedstocks must be treated to achieve compliance with the Animal by-Product
Regulations which requires a heat stage. This heat stage is based on a time temperature
relationship that is dependent on the risks posed by the particular feedstock source.

ABPR clearly outlines the type of wastes that fall within each of the three categories.

Category Definitions
1 Animals suspected of infection with BSE, specific risk materials,
catering wastes from international transport.

Manures, digestive tract content, milk not fit for human

2 consumption, killed or fallen animals, solid particles >6mm from
the wastewater stream from slaughterhouses. Default status of
any animal by-product not defined as either category 1 or
category 3 material.

3 Animals fit for slaughter but not intended for human consumption.
Animal by-products from food production and catering waste.
Digester feedstocks and their
impact on the digestion process

Matthew Smyth
Operations’ Director
Aqua Enviro
 The 4 Stages of Anaerobic Digestion
What happens
1. Hydrolysis Bonds in molecules are broken through the
addition of water

2. Acidogenesis Fermentation of dissolved, complex organics

into volatile fatty acids (pH 4.5-6.5)

3. Acetogenesis Volatile fatty acids broken down into Acetic

acid

4. Methaneogenesis Acetic acid converted into methane

and carbon dioxide (pH 6.8-7.2)
Digester Operation – VFAs (Volatile Fatty Acids) The final stage of anaerobic
digestion is methanogenesis.
The bacteria which carry out
VFAs this reaction are sensitive to
changes in the digester and are
Formic thus often the first to be
inhibited or upset if the process
Acetic
is non-optimal. When this
Propionic and Lactic occurs the methanogens are
unable to complete the final
Butyric step of converting volatile fatty
acids into methane, therefore
Iso-Butyric
the first thing that will be
Valeric observed in the data is a
change in the quantity and type
Iso-Valeric of volatile fatty acids in the
digestate.
We want our digester to be undertaking
methanogenesis – if it is not the above tell us
what it is doing – and that tells us why!
Alkalinity

Whether or not VFAs shift

the pH is dependent upon
another factor, the
alkalinity.
The alkalinity refers to the
Base Name
buffering capacity of the
digester, its ability to HCO3- Bicarbonate
withstand fluctuations in
VFAs. CO32- Carbonate
The ratio of VFAs:
alkalinity is an important
OH- Hydroxyl
critical metric and NH4+ Ammonium
indicator of plant stability.
PO43- Phosphate
 Effect of pH on Methanogen Growth
The resulting pH is critical to the performance of the digester and should ideally be within
the range 6.8-7.2. Should the pH fall below 6.0 or register over 8.5 there is risk of
catastrophic process failure.
 Co and Se dilute-out curves - VFA profile
Food waste has been shown to be deficient in trace nutrients, for example selenium is a
component of shampoo, but would not be expected to form part of the feedstock to a
digester. It is now standard practice to add in a solution of trace nutrients for food waste
digestion plants. It is important to monitor levels in the digestate over time as too many
micro-nutrients can also be bad for the digester.

0.70 Co - measured 3500

Control OLR=2

Se - measured Control OLR=3

0.60 Co - calculated 3000 Se, Mo

Se - calculated Se, Mo, Co, W
Co, Se (mg l-1)

VFA (mg l-1)

0.50 VFA measured 2500 Se, Mo, Co, W, Fe, Ni
Se, Mo, Co, W, Fe, Ni,
Zn, Cu, Mn, Al, B
0.40 2000

0.30 1500

VFA (mg l-1)

0.20 1000

0.10 500

0.00 0
112 162 Time212
(days) 262 312 0 50 100 150 200 250 300 350

Time (days)

Banks, 2011
 Digestion occurs
Temperature optimally between 32
and 42oC. Should plant
operation fall outside of
this range the ability of
the methanogenic
18 31% reduction in bacteria to convert VFAs
methanogenesis is measurably reduced.
16
It is common practice to
14 therefore reduce the
12 31% reducion in load to the digester in
methanogenesis
10 this or any other
scenario where the
(k)

8 5oC reduction process is identified as

6
7°C reduction
being stressed. Failure
4 to reduce the loading
2 rate can exacerbate the
problem and lead to an
0
extended recovery time
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 and unstable whole
Temp (°C) digestate, fiber or
digestate.
Optimising digester
performance and operation
Nigel Horan
Digester Design
1. The Shell
 Organic loading rate
 Hydraulic retention time
 Feed solids concentration
 Shape
2. The peripherals
 Mixing
 Heating
 Feeding
 Gas collection
 Digestate removal
Organic Loading Rate (OLR)
• Takes into account the feed strength
OLR = kg VS/(m3.d) or kg
TS/(m3.d)
• Increase the feed strength - OLR
increases, HRT stays constant
• Increase the feed flow rate – OLR
increases, HRT reduces
 14
4% TS
OLR (kg TS/[(m3.d)] 12

10
7% TS

8 10% TS
6

0
0 10 20 30
HRT (d)
OLR is a dependent variable and a function of HRT and TS
concentration.
HRT is independent of the TS concentration
Sludge feed is usually 4 – 5% (thickener limitations), thus OLR
typically 3.5 to 4.5 kg VS/(m3.d)
Waste feeds up to 10% and OLR 4.0 - 7.0 kg VS/(m3.d)
Organic Loading Rate
• The amount of food we give the
bacteria each day
• Too much and they don’t convert it
all to methane (low gross yield)
• Too little and it all goes to methane
(high net yield) but the specific yield
is low
 Yield and RBP (Residual biogas Potential)
0.35

0.3

0.25
Methane/kg VS added

0.2

0.15

0.1

0.05

0
0 10 20 30 40 50 60 70
HRT (d)
Methane production for the vast majority of wastes decays exponentially which means that the majority of methane potential in
the waste feedstock can be recovered in a relatively short time. It is an operator decision as to how much of the methane is
recovered, reduce the HRT and the methane potential of the remaining digested material exiting the digester increases. Increase
the retention time to recover more energy from the feedstock, but note that the amount recovered decreases with time.
 0.35
Yield and RBP
0.3

0.25
Methane/kg VS added

0.2

0.15

0.1

0.05

0
0 10 20 30 40 50 60 70
HRT (d)

A site must therefore determine its optimum HRT and OLR for
its own business case.
 VFA: alkalinity

Start-up Acclimatisation
To asses if the OLR is too high VFA and alkalinity levels are measured, the higher the ratio the
more likely plant operation will become less stable.
Impact of Mixing
• Mixing often a major cause of problems
• Thick feeds (>10%) difficult to mix
• Mixing power often under specified (needs >4W/m3
drawn power)
• Solids and plastic accumulate in digester
• Foaming attributed to poor mixing
Common Operational
problems and their solutions

Matthew Smyth
Operations’ Director
Aqua Enviro
Comparison of Mesophilic & Thermophilic
Digesters
Feature Mesophilic digester Thermophilic digester

Loading rates Lower Higher

Destruction of pathogens Lower Higher

Sensitivity to toxicants Lower Higher

Operational costs Lower Higher

Temperature control Less difficult More difficult

Source: Gerardi, 2003

Maintaining temperature
 Volatile fatty acid analysis is an important parameter to measure to evaluate
VFAs plant stability and performance. Increasingly there is a trend not only to
measure total VFAs but also species present. Analysis of the different species
helps the informed operator to understand where the process is struggling and
can be optimised. The relative toxicity of VFAs varies according to the species
present and the digester pH.

50% inhibition concentration

pH Acetate Propionate
mg/l COD
5.0 44 13
5.5 100 30
6.0 300 80
6.5 912 241
7.0 2851 745
7.5 8976 2358
8.0 28368 7398
Operational Conditions Associated with
Foam Production
Condition Contributing factor
Alkalinity increase Lysis of nocardiaforms or microthrix

CO2 increase Change in fermentation reactions

VFA increase Excess grease, and fats
Mixing Gas vs mechanical
Polymers Excess from thickening units
Surfactants Present within feedstock
Temperature fluctuations Intermittent \ slug feeding

Scum Rapid breakdown leading to increased VFA’s

Source: Adapted from Gerardi, 2003

Team working for
successful plant operation

Nigel Horan
Who does what?
• Smaller digesters can be package, or off-the-shelf
plants and involve a vendor, eg: Dragon Anaerobic
Digester
• But usually a bespoke design is needed involving:
– Consultant (designs the facility)
– Legal team (draws up the contract)
– Contractor (builds it)
– Operator (operates and maintains it)
• And sometimes venture capital is involved
Delivery routes
The main parties are generally integrated:
• Turnkey delivery (probably the commonest)
• BOO (Build Own Operate), BOT (Build, Own, Transfer),
BOOT (Build Own Operate Transfer)- (Municipalities)
• Service vehicles (private finance projects and a variation
of the above)
Taking Control of the Digester
• Takeover is the key point for a Client, for this point onwards
the digester is your responsibility
• So the contractually binding take-over tests must be designed
to show it meets all contractual requirements (but not so
arduous and expensive they can’t be carried out!).
• Describe the tests clearly and unambiguously, keep them
simple and ensure they are realistic
• Ensure the appropriate teamwork to make them happen
(they are really important)
It is important to define the point at which the digester is
completed at which point its operation is solely your
responsibility and any outstanding retention payments are
made. It is crucial by this stage to ensure it is fit for purpose
and will do what you expect of it. The role of takeover tests is
to demonstrate this. There is a tendency by Clients to
provide an arduous and complicated round of takeover tests
under the impression it provides them better protection.
Often at the point of takeover, they cannot be undertaken,
because (for instance) the volume of feedstock is not
available, or the cost of testing is simply to expensive. Keep
them simple and cheap and they will be more effective.
Preparing for the Worst
• The contract protects both the Client and Contractor
• But often favours the Contractors (lack of data to meet
contractual onus)
• So check any contractual protections
• Many routes for contractual disputes
– Mitigation
– Mediation
– Arbitration
• If things go badly wrong, the courts are the last resort