Renewable and Sustainable Energy Reviews 97 (2018) 64–73

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Renewable and Sustainable Energy Reviews

journal homepage: www.elsevier.com/locate/rser

A review on CFD simulating method for biogas fermentation material fluid T

a,b c d a b b b
Jun Wang , Qingwen Xue , Ting Guo , Zili Mei , Enshen Long , Qian Wen , Wei Huang ,
⁎
Tao Luoa,b, Ruyi Huanga,b,d,
a
Biogas Institute of Ministry of Agriculture, Key Laboratory of Development and Application of Rural Renewable Energy, Ministry of Agriculture, Chengdu 610041, China
b
College of Architecture and Environment, Sichuan University, Chengdu 610065, China
c
Chengdu Construction Engineering Group Corporation, Chengdu 610000, China
d
Sichuan Rural Energy Office, Chengdu 610041, China

A R T I C LE I N FO A B S T R A C T

Keywords: Fermentation material fluid mixing is an indispensable subsidiary technology for modern biogas engineering,
Biogas which can increase fermentation efficiency substantially. Taking advantage of computational fluid dynamics
Mixing (CFD), the flowing progress of biogas fermentation material fluid in the anaerobic digesters can be reappeared,
Flow pattern the distribution curve of flow pattern can be obtained, the visualization of flow pattern can be achieved, the
CFD
features and defect of flow configuration can be differentiated on the basis of the flow pattern visualization.
Simulation
Scholars quantified and evaluated advantages and disadvantages of fermentation material fluid mixing schemes
Numerical model
by using CFD and setting the parameters of "poor mixing zone", "dead zone" and so on, which became the
important basis of modern biogas engineering design. Meanwhile, the mixing form and running parameters can
be excellently designed and thus no longer added at random. On the basis of the classic k-ε model, researchers
have developed a variety of improved models, which are more suitable for complex and diverse conditions of
biogas fermentation material fluid. In this present study, the applicable algorithm models of various working
conditions are proposed after subdivision research. During the first decade of the 21st century, one research
upsurge of simulating biogas fermentation material mixing by using the CFD simulation is growing up in the
biogas field, which makes a great progress on the aspect of optimal design of digesters shape, mixing form,
mixing running parameters and methods of fluid, promotes the research levels of biogas science and becomes
one of the most important stage of the biogas science phylogeny. All of these represent the development di-
rection of future, accordingly, the summary of progress related with above research aspects is given in this
present study.

1. Introduction
Biogas is one of the most hopeful renewable energy sources in to-
day's world, which has a great benefit both on environmental protection
and energy saving [1–4], especially on dealing with the massive organic
wastewater [5]. Mixing can increase the efficiency of biogas anaerobic
fermentation and evidently improve the biogas productivity and pol-
lutant removal rate [6,7]. Modern biogas engineering generally adds
mixing technology to increase the efficiency of fermentation [8]. But in
terms of the current engineering practice, a large number of projects use
a cheap mixing technology, which causes a little gains to the raise of
fermentation efficiency, even consumes more energy [9]. The reason of
this phenomenon is that the biogas anaerobic digesters should seal off
in the strict anaerobic environment. However, people can’t get the exact
test for inner flow pattern, what causes that constructors add some
mixing measures without understanding flow pattern form, then the
form of real flow pattern is too bad and not suited to digesters shape or
raw material features [10].
For another hand, numerical simulation method is one effective way
to obtain fluid flow pattern mechanism. Namely, numerical simulation
method can be used to analyze the inner flow pattern of biogas anae-
robic digesters accurately. The mixing of fermentation material fluid is
essentially a flowing process under the outside force's working.
Numerical simulation method can help people to get known about its
theoretical flowing progress and flow pattern. Moreover, along with
development of modern computer technology, the accurate calculation
of flow pattern in the fermentation installation is becoming much more
simple and convenient [11].

⁎
Corresponding author at: Biogas Institute of Ministry of Agriculture, Key Laboratory of Development and Application of Rural Renewable Energy, Ministry of
Agriculture, Chengdu 610041, China.
E-mail address: 28209443@qq.com (R. Huang).

https://doi.org/10.1016/j.rser.2018.08.029
Received 27 January 2018; Received in revised form 12 August 2018; Accepted 20 August 2018
1364-0321/ © 2018 Elsevier Ltd. All rights reserved.
J. Wang et al. Renewable and Sustainable Energy Reviews 97 (2018) 64–73

continuously optimized by modern mixing technology [20], which is

Nomenclature table
largely the successful application of CFD method in the field of biogas
technology.
Biogas engineering It's the rural energy project aiming to de-
The biggest difficulty in designing the biogas mixture mixing
velop and utilize the fecal pollution of farm and
scheme is that it is difficult to quantify such parameters as mixing time
achieving a virtuous cycle of agricultural ecology with
and input power. CFD can approximately simulate the influence of
obtaining energy and controlling environmental pollu-
these parameters on flow pattern, which provides designers' reference
tion.
[21]. For example, Terashima [22] provided one method of quantita-
Biogas fermentation It refers to the organic material (such as
tive calculation of mixing material liquid distribution degree in
people and livestock manure, straw and weeds, etc.)
homogeneous by CFD simulation. Meanwhile, he firstly defined a
eventually forms the combustible mixed gas such as
Uniform Index (UI) concept and established one UI and mixing long
methane and carbon dioxide through all kinds of mi-
two-dimensional model, which was very suitable to different material
crobe catabolism, under a certain moisture content,
liquid quantitative guidance for proper mixing time. Moreover, the
temperature and anaerobic conditions.
unsteady simulation found that material liquid UI would continue to
Anaerobic digesters High concentration of organic wastewater
decline in the process of mixing. Dapelo [23] proposed many kinds of
and sludge treatment facilities, its main product is
schemes for optimizing concentric nozzle manifolds and tank type and
methane.
remarkably promoting UI, based on the above basis. Kress [24] had
Computational fluid dynamics The control equations of fluid
verified through experiments that their optimization scheme by using
mechanics are solved by computer and numerical
CFD may increase biogas production to 15%. While using CFD method
method.
to optimize flow pattern, Mohammadrezae [25] compared the re-
lationship between the energy consumption of the optimization scheme
itself and the improvement of biogas production, which demonstrated a
At present, the biogas researchers use the CFD as the most extensive
more perfect CFD optimization method.
hydrodynamics numerical simulation method. In 2002, the US North
In order to comprehensive understanding and application of nu-
Carolina State University published a doctor dissertation named "Novel
merical simulation method in field of biogas anaerobic, this present
simulation of anaerobic digestion using computational fluid dynamics" [12],
study gives the summary and review on published researches of mixing
which was the first thesis that formulated how to use CFD to research
medium, mixing parameters and digesters shape and other aspects
biogas fermentation material fluid mixing flow pattern form. After that,
optimization, CFD model, CFD simulation reliability, problems and
many biogas researchers used this method and some related popular
trends of current research, which may provide guidance for future re-
mature commercial software, and got a great progress on the research
search.
of flow pattern form. Owing to unclearness of the mechanism that
mixing can promote the efficiency of biogas fermentation, there was a
controversy of concrete mixing method among biogas researchers 2. Methodology of CFD application
[13,14]. But researchers can visualize the mixing-formed flow pattern
by using CFD [15], thus they can verify and guide the design of mixing The applications of numerical simulation calculation in biogas fer-
method accurately [16,17] and make the research of biogas fermenta- mentation material fluid mixing research area mainly concentrate on
tion material fluid mixing field be gotten rid of the bound of invisible the analysis of flow pattern during mixing, seen Fig. 1. The most
condition to a great extent, which promotes a research level of scientific common method is simulating flow pattern from some kinds of mixing
and accurate visualization and quantity. It is one of advanced research forms, analyzing its flow pattern graphs, distinguishing defect of flow
areas of biogas field in the 21st century [18]. pattern and improving mixing scheme. Meanwhile, the mixing scheme
In the past 15 years, the remarkable results have been obtained from mainly consists of mixing medium, mixing parameter and digesters-
application of the CFD to guide the optimization of flow pattern in the shape design.
digester and strongly promote the development of biogas technology,
especially medium and large-scale biogas plants. Medium and large- 2.1. Mixing medium
scale biogas plants have many advantages over the traditional rural
household-based biogas digesters, and have higher energy utilization The mediums in the form of solid, liquid and gas can all form mixing
level, pollution removal rate and economy [19]. Therefore, the tradi- to the biogas fermentation material fluid, so the mixing can be divided
tional rural household-based biogas digesters will be replaced by into the mechanical mixing (paddle mixing, impeller mixing), hydraulic
medium and large-scale biogas plants, which may become the main- mixing (jet current mixing, slurry circumfluence mixing, slurry circu-
stream of biogas technology. In the past, large -scale biogas plants had lation mixing), pneumatic mixing (biogas cycle mixing). As to the
the defect of lacking raw material fluidity. Now, the problem is quality of three mixing mediums, there always exists a controversy
among the research circles, and lacks the expressly authoritative

Fig. 1. Researches of numerical simulation in biogas fermentation material fluid mixing research area.

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J. Wang et al.
conclusion [13,14]. Only in terms of the positive effect of the gas
productivity, it's considered that the three mixing mediums can all get
the most improvement for the biogas productivity, which can be ver-
ified by experiment [26–28]. For the biogas engineering design in the
last century, more than 90% vertical constant mixing digesters are
taken and driving the paddle turning by the pump importing, and
forming mixing to the fermentation in the airtight anaerobic digesters
[29]. At present, three kinds of mixing all get widely application, which
is a great progress on studying three kinds of mixing form by using CFD
simulation.
Compared to the CFD simulation of three kinds of mixing medium,
hydraulic mixing is simpler comparatively, as a result of fermentation
material fluid belonging to the liquid phase. If the part of gas storage
space is leaving out in the simulation, it's only simulating the liquid
column and has liquid phase simulation target, so this kind of simula-
tion is easier comparatively [30]. The simulation of pneumatic mixing
should change gas into bubble, but this settlement is inaccurate for the
condition before airflow get into the liquid column [31]. The me-
chanical mixing is more difficult comparatively, which needs to use
dynamic mesh to structure the model of paddle. Therefore, the diffi-
culty and operational character of modeling is much more complicated
[32]. While, the current modeling tool and the operation ability of
computer can all deal with the three kinds of simulation workings.
2.2. Mixing parameters optimization
(1) Kinetic energy diffusion. The primary purpose of mixing is to
change the static fermentation to the dynamic fermentation, so the
purpose of optimization should be that more kinetic energy can be
sent to more space. In 1981, Monteith [33] used the particle tracer
method to roughly measure the flowing velocity of the mixing in
the digesters, then he put forward the concept of "dead space" and
"activity mixed zone", which indicated that the lower flowing ve-
locity space in the mixing digesters was fully flowing and well-
mixed. Karim [34] defined the zone that the absolute value of re-
sultant velocity was lower than the peak 5% as the "poorly mixing
zone". Then through the simulation calculation, when using the
three different injection velocities of to 28.32 L/h, 56.64 L/h and
84.96 L/h pneumatic mix, the poorly mixing zone in the digesters is
31%, 31% and 27%. It indicated that in the low speed interval, the
increasing of flowing velocity has less optimization for the flow
pattern. Vesvikar [35] used the CFD to try a large number of mixing
programs, and then he found that the poorly mixing zone can take
59.7% of the total volume in the digesters, as to the situation of the
worst flow pattern. So there still has a large space to optimize.
Meanwhile, Wu [36] defined the zone that the absolute value of the
resultant velocity was lower than 0.001 m/s as the "dead zone".
Meanwhile, the CFD simulation calculation indicated that the dead
zone was the dead corner of the mixing kinetic energy, even for
increasing the first injection velocity to maximum of 5.7 m/s, which
only can make the kinetic energy of dead zone be more abundant
while the space that was taken by the dead zone can’t be reduced. It
also prompted that it can’t improve the flow pattern form by in-
creasing the power of mixing, but maybe it was possible by using an
optimal design.
(2) Phase distribution. One of the most important purposes of mixing
for optimizing the flow pattern form is to make the phase dis-
tribution of the mixed fermentation material fluid more homo-
geneous. Li [37] found that the anaerobic digesters with the ma-
terial of straw on the top, middle, bottom of the digesters can all
produce the dross, but the potentialities of gas production were
only 0.08 mL g−1, 0.16 mL g−1, 0.23 mL g−1, which was far below
the direct fermentation. Therefore, we should make them become
the main fermentation material fluid by mixing. Yang [38] used one
long barrel anaerobic digester with 2800 mm heights and 50 mm
diameters to conduct the anaerobic fermentation experiment of
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Renewable and Sustainable Energy Reviews 97 (2018) 64–73
piggery experiments, and then he found that after several hours’
gravity precipitation, the feed liquid differentiated into crude
sewage and diluted sewage. Conducting the anaerobic fermentation
biogas production experiments, the efficiency of biogas production
is that concentrated sewage ＞ crude sewage ＞ dilute sewage,
while the disparity is obvious, so it needs the mixing to make the
concentrated sewage be filled into more zone and reduce the dilute
sewage at the same time. However, Luo [39] found that in a long
barrel anaerobic digester, if we put the feed liquid from the top and
wait it to be precipitated by the gravity slowly, the efficiency of
fermentation was excellent while precipitation. Based on the re-
search, Huang [40] thought the reason why mixing can improve the
efficiency of fermentation was that the materiel can overcome
gravity by the mixing, so it can keep suspended in the liquid column
and be in a precipitated slowly state for a long time. The process of
the material blending can all be expressed in the CFD simulation by
the distribution of phases, which can guide the way to improve the
mixing. Jiang Li [41] also thought that except the N, P, and S, the
essential elements for the grown of the anaerobic methane bacteria,
the feed liquid also contained the K, Fe, Co, and Ni, such metal trace
elements. However, the content of those elements is low in the feed
liquid and in the large digester, only the mixing can make the metal
trace elements spread to more space. Meanwhile, the distribution of
the phases in this micro level can’t be marked by the CFD.
(3) Temperature field. The purpose of the mixing is to make the flow
pattern more homogeneous and the distribution of phases more
reasonable, but it also has effect on the distribution of temperature,
which is one of the important factors for the efficiency of fer-
menting biogas [42–45]. The change of temperature may not only
influence the production of the biogas [46], but also the component
of biogas [47]. Yu [48] found that the hydrolytic acidification
would significantly improve the acidification rate of organic was-
tewater and the hydrolysis rate of the protein under the extremely
thermophilic condition of 70 °C, which would greatly increase
production of biogas from the source. The extremely thermophilic
condition of 70 °C also can reduce the content of sulfide in the
biogas, especially the main deadly gas: the hepatic gas (H2S) in the
biogas [49]. Therefore, the modern biogas engineering has a higher
requirement on the temperature, it also needs the CFD to describe
the temperature field [50,51]. If an anaerobic fermentation system
adopts both two technology of the mixing and the calescence, the
mixing will make the spatial heterogeneity in the reactor's tem-
perature field of fluid, so it needs the CFD to well-design the mixing
flow pattern [52]. Bai [53] also holds that the temperature would
change the rheological characteristics of medium, so it should be
considered when we carried the simulation calculation. Moreover,
the heat transfer of digesters should be considered too. Luo [54]
used the CFD method and designed a kind of winding fiberglass as
the insulation layer of anaerobic digesters, it would make the di-
gesters inside temperature be 9 °C higher than the outside and have
a superior biogas production rate of 0.49 m³ ·d·d−1. By the simula-
tion of CFD, Wang [55] found that the heat dissipation of large
digesters was not the wall of digesters but its top cap, which in-
dicated that the designer spending so much on the heat preserva-
tion of wall may be settle for less.
2.3. Digesters shape
The shape of digester has a critical influence on the flow pattern,
which is the main aspect of optimal design. A large number of CFD
studies show that the shape of digester can significantly change the flow
pattern [56]. In the pneumatic mixing model having intake at the top,
Vesvikar [57] adopted and angled vertical Angle 60° bottom design,
which can make the poorly mixing zone decrease from 59.7% to
29.57%. With 25° angle of digester bottom design, it can make the
poorly mixing zone further decrease to 17.39%. Under the same mixing
J. Wang et al. Renewable and Sustainable Energy Reviews 97 (2018) 64–73

condition, Karim compared digester bottom and the horizontal plane
Angle 0°, 25°, 45° three cans, poorly mixing zone were 33.6%, 31.9%,
29.6% [58], visible effect was remarkable. Niu [59] believed that di-
gester design was more important than the method of mixing, and
proposed that the most beneficial was to eliminate the dead angle and
sediment, but both the construction cost and maintenance cost were too
high. Wei [60] echoed Niu's viewpoint. Zhang [61] used CFD method to
compare the push flow reactor feed tube respectively, which was 15°,
30°, 45°, 60°, 70° inclination of the inner flow pattern of the found dead
zones minimum 30°, provided an important basis for structure design of
reactor.
The shape design of digester is also influenced by the convection
flow pattern. Martí-Herrero [62] had used plastic ring set grid in the
pool, optimized the flow mixing flow pattern, the biogas production
was increased by 44%, and the biogas digesters can run smoothly under
low temperature of 6.1 °C. Under the guidance of CFD, Markus [63] had
optimized the design of a kind of isolated continuous flow reactor to set
the suitable position of baffle in the biogas anaerobic digesters, and the
flow pattern was optimized in a more optimized way. On this basis,
Stamou [64] optimized the design of a diversion wall under the gui-
dance of CFD, controlled the flow pattern in the large reactor and
greatly optimized the flow pattern. Sozzi and Taghipour [65] designed
the two kinds digesters of L and U type structure of the hydraulic
mixing device under the guidance of CFD. Moreover, Eulerian method
and Lagrangian method were used to simulate and calculate the flow
pattern, respectively, the results found that U-shaped structure in the
center of the jet entrance near axial had unstable turbulence, L-shaped
structure could provide a more even and stable flow pattern.
2.4. Other optimization
In addition to the above major aspects, the mixing flow pattern
influences the anaerobic fermentation efficiency in other ways, some of
which can also be simulated by CFD method, shown in Table 1. The first
is hydraulic retention time (HRT). Generally speaking, the longer the
hydraulic retention time of the fermentation liquid was, the higher the
methane content in the biogas production was [66]. In some chemical
industry wastewater treatments with denitrification treatment of
anaerobic fermentation technology, HRT for the removal rate of COD
and nitrophenol was essential [67], and HRT was very suitable for
calculation with CFD software [68].
Luo [69] used CFD software to calculate the flow law of grit in
mixing, and used the guidance of flowing chart to optimum design of
the mixing flow form, the reactor of sand removal rate increased by
281%, greatly optimizing the anaerobic fermentation environment.
Wang [70] advanced that mixing could improve the efficiency of fer-
mentation. Principle was proposed that mixing of the hydraulic shear
stress could damage the material surface and loosed flocculating or-
ganization, which revealed dense part and enhanced the material
contact with the surface of the water effect. But it was difficult to use
microscope to observe the microscopic process, while simulation of CFD
method showed the flow shear stress distribution. Formed in the fer-
mented liquid by using solid carrier biofilm stability and mass transfer,
the fuel filter was useless [71]. Zhao [72] invented a method of scrap
tire rubber particles as hanging membrane carrier, experiment verified
that the method could increase 50~100% of the amount of biofilm
based on the traditional technology. This method could use CFD to
design the rubber particles distribution in the fermented liquid. And

Table 1
Optimization effects of biogas based on the researchers using CFD.
Researchers Application of CFD Optimization effects

Monteith [33] CFD was used to calculate the "dead space" and "activity zone" in mixing. The flow pattern was optimized by reducing dead space or adding activity
mixed zone.
Karim [34] The area with speed absolute value lower than peak value by 5% was increasing jet speed to reduce the poorly mixing zone was little success.
defined as "poorly mixing zone".
Vesvikar [35] CFD was used to simulate poorly mixing zone for kinds of tank type. Poorly mixing zone was up to 59.7%, optimization had the enormous
potential.
Wu [36] The area with speed absolute value less than 0.001 m/s was defined as It was found that the increase of jet velocity could only increase the kinetic
"poorly mixing zone". energy of the non-dead zone, but not decrease the dead zone.
Li [38] A 2800 mm long tube was used to conduct gravity precipitation, and the It was found that the gas production efficiency of thick sewage was more
pig manure raw materials were divided into concentrated sewage and than that of raw sewage, then more than that of thin sewage.
dilute sewage.
Huang [40] CFD was used to simulate the process of resisting gravity precipitation by It was found that the CFD could be used to guide the mixing to keep the
mixing. materials in a suspended state of slow precipitation, and the fermentation
efficiency was the highest.
Bi [51] & Shi [52] CFD was used to simulate the spatial heterogeneity of temperature It was found that the space heterogeneity in the tank could occur when two
increasing mixing. processes were added: mixing and warming.
Luo [54] The heat transfer model of tank wall was established with CFD. Designing a kind of advanced wire winding FRP tanks, it could make the tank
inside temperature in winter be higher than outside by 9 °C.
Wang [55] Through CFD simulation, it was found that the main heat dissipation The key points of heat insulation design of tank wall were corrected.
path of the fermentation tank of large biogas plant was the top cover
rather than the tank wall.
Vesvikar [57] CFD was used to simulate tank bottom design with different angles. It could make the poorly mixing zone decreased from 59.7% to 29.57%, then
fell to 17.39%.
Karim [58] Three tanks with different types were simulated with CFD. Poor mixing zone were accounted for 33.6%, 31.9% and 33.6%, respectively.
Zhang [61] CFD was used to compare the flow field at different inlet pipe angles of When feeding tube angle was 30°, dead zone was the smallest, which
the thrust-flow reactor. provided important design basis.
Martí-Herrero [62] CFD was used to guide the design of the grille in biogas digester. Increasing biogas production by 44%.
Sozzi and Taghipour Hydraulic agitator of L and U configurations was simulated by CFD. It was found that the U-shaped structure would generate unstable turbulence
[65] near the central axis of the jet inlet, which proved that the L-shaped structure
was a better design.
Wu [68] HRT was calculated using CFD simulation. Guiding the design of larger HRT mixing methods.
Luo [69] CFD was used to optimize the flow field shape of sand and gravel during The sand removal rate of the reactor was increased by 281%.
mixing.
Zhao [72] The distribution of rubber particles in fermentation broth was simulated The amount of biofilm was increased by 50–100%.
with CFD.
Yang [73] The hydraulic shear stress was monitored by CFD. Hydraulic shear force was controlled to be not "overspeed", biofilm was
protected.

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J. Wang et al.
Yang [73] thought that mixing speed must be strictly controlled, be-
cause when hydraulic shear force reached a certain critical value, it
would cause the fall off of biofilm. In order to deal with this problem,
we could use CFD method to simulate monitoring “overspeed” in the
space area and optimization control.
3. Results of CFD arithmetic research
3.1. CFD model
The algorithm is the basis of CFD simulation, and now many fairly
mature algorithms have been formed for choosing, but there is still some
controversy. The most commonly used computing software in the aca-
demic circle is Fluent 6.3 that is released by ANSYS in 2006. The software
adopts a classic k-ε model which is the turbulence model founded by
Launder and Spalding [74], but there are some slightly revised versions
those are suitable for the special conditions such as the RNG k–ε and
realizable k–ε, et al. Having summarized 12 modified turbulence models
and divided its applicable range of Reynolds number, Wu [75] indicated
that the mixing of biogas liquid was a kind of low Reynolds number
turbulence, which was the most suitable for the SST-k-ε model. What
more detailed than Binxin Wu was the 35 examples of turbulence models,
which were applicable to the working conditions listed by Bitog [76] of
Seoul national university in South Korea. Wu [77] also compared the
variance value of using the turbulence models with various low Reynolds
number, and considered that the low-Reynolds number of k-ε model of
the Chang-Hsieh-Chen version was the best performing. Multiphase flow
simulation was commonly used in the simulation of CFD biogas en-
gineering, and there were two kinds of the most commonly used methods
of multiphase flow calculation: Eulerian-Lagrangian method and Euler-
Euler method, seen Fig. 2. Wu [78] thought that Euler-Euler method,
especially the Euler model, was the most suitable multiphase model for
biogas engineering. Dapelo [79] made an Euler-Lagrange CFD model be
applied to a full-scale, biogas-mixed anaerobic digester to improve mixing
efficiency and overall performance. The biogas reforming reactor was
modeled in CFD that included reaction kinetics [80]. In addition, a novel
Euler-Lagrangian CFD finite volume-based model for simulating the gas
mixing of sludge for anaerobic digestion was developed and described
[81].
What the most important pre-work of CFD simulation is building a
grid model, which often costs more time than its calculation [82].
Karim [83] pointed out that the grid density had a slight effect on the
accuracy of the calculation results, but the trend was very similar, so it
was no essential difference. Therefore, the researchers can adjust the
grid density appropriately according to the actual situation of com-
puting power. In addition, he also listed 21 kinds of grid construction
methods applied to working conditions and recommended grid density
in the background of current computer performance [84]. Hong [85,86]
tried to calculate a grid modeling method of the extra large digesters, in
which he cut huge liquid column into 16 sections, then calculated re-
spectively by using the high-density grid, finally, made a relatively
accurate result through gathering all the data. It provided a good
Fig. 2. Multiphase flow models.
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Renewable and Sustainable Energy Reviews 97 (2018) 64–73
reference for oversized model calculation. However, Lee In-Bok, Hong
Se-Woon and many other South Korean scholars also deliberately
pointed out that there were still many defects in utilizing CFD to si-
mulate the mixing flow pattern of biogas engineering at present. And
what the major reason was that CFD was still confined to the liquidity
equation that can’t add the links to the biological and chemical reac-
tion, and unable to show the process in which material properties
changed continuously [87].
3.2. CFD simulation reliability
CFD is a simulation calculation, its reliability is always on attention,
but because that biogas fermentation needs to work at the anaerobic
environment, the container is strict airtight, it's difficult to measure the
flowing parameters truly. But in recent years educational circles take
many methods to measure the parameter of fermentation material fluid
flowing, which verifies the accuracy of CFD simulation calculation, seen
Table 2.
Early in 1974, Verhoff [88] tried to arrange the gauging points to
measure the flowing velocity in the strict airtight anaerobic digesters.
But because of the limited technology at that time, the experiment
wasn’t successful. In 2010, Wu [89] used the modern undersea velocity
measurement element and arranged several gauging points in a simple
digester, measured their flowing velocity, and verified it's fit to the
forecast of CFD calculation. Karim [34] used some advanced methods
like CT and CARPT, got the real flow pattern graphs while mixing,
compared to the graphs of CFD simulation result, verified the facticity
and accuracy of CFD simulation. On the base of Karim, Vesvikar and
Dahhan [57] compared the CFD calculation data with the measured
data of flow direction of tracer particle, average flowing velocity, swift
current kinetic energy, shearing stress, particle circulation time and gas
uplifted distribution, verified that the result of CFD calculation was
identical to the fact. Rauen [90] used the 3D Doppler ultrasonic velo-
cimeter to measure the flow pattern of the anaerobic digesters, found
that it's fit to the result of CFD calculation, and the accuracy rate was
more than 90% in the typical mixed area, which verified the reliability
of CFD again.
In recent years, PIV has been used to verify the accuracy of CFD
simulation in China [91–94], but the effect isn’t ideal [95]. Besides that,
Han [96] of HeHai University tried LDV to measure the flowing velo-
city, but LDV was a optic velocity measurement, the ingredient of
biogas fermentation material fluid was too difficult, and the raw ma-
terial of pollutant was always opaque, so it's hard to measure. Huang
[97] in Beijing University of Chemical Technology measured the
flowing velocity of part continuous phase (liquid phase) by using
double electrode conductance needle method, which got a better fitness
of CFD simulation, and under the multiphase flow reactor, changing the
mixing parameter was mainly changing the flow pattern of solid phase,
while the liquid phase flow pattern and clear water single-phase flow
pattern was less changeable by comparison. Li [98] in Xi'an University
Of Architecture & Technology used an innovation method, which used
acridine orange staining method to dye RNA, DNA in the microbes, and
J. Wang et al.
Table 2
Verification method for accuracy of CFD simulation.
Researches Verification method
Verhoff [88] The measurement points were set up in the closed fermentation tank to
measure the flow velocity, which was compared with the calculated
results.
Wu [89] An underwater velocity measuring element was arranged in the tank,
which was compared with the predicted value calculated by CFD.
Karim [34] CT, CARPT and other medical instruments were used to scan the material
fluid tomography.
Vesvikar [57] Six aspects of tracer particle data was measured.
Rauen [90] The velocity in the tank was measured by 3D Doppler ultrasound.
Ma [91–95] The flow trace lines simulated by CFD were validated by PIV method.
Han [96] The velocity in the transparent tank was measured by LDV method.
Huang [97] The local liquid - phase velocity was measured by double-electrode
needle method.
analyzed the space distribution of microbes’ activity through the
dyeing. The result showed that the sludge floc structure in the mixing
system was loose, the pellet was tiny but easy to subside. RNA/DNA
(Characterization of relative areas of fluorescence) and dehydrogenase
activity were both higher than non-mixing system in mixing system,
what explained that moderate mixing could promote the microbial
activity in anaerobic sludge digestion system.
4. Discussion on problems and future outlook of CFD method
4.1. Problems
In the past 15 years, the academic community has made great
progress in using the CFD method to improve the design level of biogas
engineering, but there are still many problems.
(1) Simulation reliability. The primary issue in this field is still the si-
mulation reliability problem. Despite numerous studies have used
various methods to verify the authenticity of CFD simulation, but
researchers only can roughly approximate by creating a few custom
mediums to express fermentation raw material, owing to various
biogas fermentation materials. However, in fact, the fermentation
material has continuous phase change during the fermentation
process. How to accurately determine the physical parameters of
simulation media is a tough problem all along [87]. At present, the
common practice is to take the state of material fluid at some point
as the simulation object in the industry. Karim [83] thought that the
viscosity of the fluid did not affect the flow state, while Wu [36]
disagreed, saying that the algorithm of Newtonian fluid and non-
Newtonian fluid should be different, Huang [40] also hold the view
that the time of biogas anaerobic fermentation was very long, the
material forms would change with the ongoing of fermentation, and
the situation of the solid material eventually converting to pseu-
doplastic fluid could even be happened in the experiments. Bai [53]
pointed that the temperature, pH value and continuous feeding
would change the rheological properties of medium and should be
considered in the simulation calculation. In the view of engineering,
Table 3
Working conditions for kinds of suggested algorithms.
Algorithms Models Raw material condition
Euler-Lagrange method Discrete phase Small particulate solid materials with very low concentration
model (volume fraction < 1%).
Euler-Euler method Volume fraction Bubble conditions, straw, waste paper, domestic waste
model materials.
Mixing model Feces, distillers' grains, medical waste water, and kitchen
waste without regard to grease.
Euler model All kinds of solid and liquid mixing conditions.
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Renewable and Sustainable Energy Reviews 97 (2018) 64–73
Verification results
The comparison was not successful under the technical conditions of 1974.
The accuracy of CFD simulation was preliminarily confirmed.
The part of flow trace lines of some materials could be consistent with CFD simulation
results.
It was very consistent with CFD calculation results.
It was proved that the accuracy of the typical hunhe region was more than 90%.
The verification was not satisfactory due to the poor follow-up of tracer particles.
As the biogas slurry was not transparent, it was difficult to measure accurately.
It was in good agreement with CFD simulation, and it was found that the change of
stirring parameters only changed the solid phase flow field, and the liquid phase and
clean water flow field had little variation.
the viscous liquid could be stuck or blocked in some key channels,
so the viscosity of materials could not be ignored. Craig [99] stu-
died the extreme situations of non-Newtonian fluid, Rheological
properties of the mixing Hans-Charles Barkley fluid in anaerobic
fermentation tank could be used as a simulation calculation method
for some particular fermentation raw materials.
(2) Simulation computing power. CFD simulation computing power is
subject to advances in computer science, shown in Table 3. Initially,
biogas digesters are small and simple, but in recent years they have
become big and complex [100]. Many scholars have also proposed
to optimize the flow pattern through the shape of digesters [59,60],
making the accurate simulation of the shape of digesters more
complicated. On the other hand, the test of large digesters lacked
the condition for experimental verification, Wu [101] tried to cal-
culate the mechanical impeller mixing conditions of large-scale
biogas plants, and compared the optimization of single blade,
double blade, three-blade and four-blade side mixing to the flow
pattern. But he clarified that there were not experimental condi-
tions to verify, just a preliminary exploration.
(3) Improvement mechanism of fermentation efficiency by mixing. The
study of using CFD simulation to improve the mixing of biogas is
subject to a fundamental premise: Why does mixing increase the
efficiency of fermentation? What kind of flow pattern can be called
a good flow pattern? Since the fundamental mechanism is not clear
enough at present, most scholars only can use mixing kinetic energy
or phase distribution in the digesters to optimize the direct target
[40]. A few scholars have suggested other possible reasons. For
example, Tavares [102] proposed that the faster the mixing rate
was under the multi-phase flow conditions, the thinner and denser
the biofilm formed was, which was more conducive to the trans-
mission of biomass, thus improving the fermentation efficiency.
Yang [73] pointed out that the mixing rate should not only be in-
creased, owing to that biofilm began to fall off at a certain rate.
Therefore, CFD simulation should be used to determine a reason-
able rate interval, simulation work could not be carried out unless
people find out the reasonable rate range.
Note
Only calculating kinetic energy, no phase distribution.
Coarse particles and bubbles that are insoluble in water, not
containing sludge particles.
High viscosity fluid, thin solid materials, including sludge
particles and water-soluble solids.
High computational cost.
J. Wang et al.
4.2. Future outlook
According to the main progress and problems in the current re-
search field, the research on the application of CFD software to simulate
the mixing flow pattern of biogas liquid and the improvement of design
level has the following development trends.
(1) The main direction of CFD method is to optimize the mixing
parameters, the most urgent need in the current research field is to
further reveal the inner mechanism that mixing can improve the
efficiency of anaerobic fermentation, at least elucidate the influence
of mixing on a key factor at a certain stage, in order to clarify the
optimal targets of basic parameters, such as medium, power,
duration and time interval. Under the premise of this goal, the CFD
method can be used to get the optimization plan and improve the
design level.
(2) Using more advanced methods is to measure the actual flow pattern
more accurately and further verify the reliability of CFD simulation.
Using CFD is to describe flow pattern, guide the setting of mixing
scheme, especially the optimization design of tank shape, impeller
shape, fluidic device and other hardware.
(3) With continuous fermentation, complex biochemical reactions
occur in the fluid, and the physical parameters of materials con-
tinue to change. Is it possible to figure out these biochemical re-
actions, build a generic model, be loaded into CFD software in the
form of a user-defined function (UDF), describe the physical para-
meters of materials accurately, and load the continuously changing
parameters into the iterative operation.
(4) According to findings of this study, the appropriate policies of si-
mulating biogas fermentation material fluid flow by CFD include: a)
it's necessary to accurately determine the physical parameters of
simulation media; b) high computing power is needed to simulate
large and complex biogas digesters by CFD; c) reasonable rate range
should be determined for obtaining great CFD simulation work.
4.3. Impact of CFD on traditional biogas industry
The application of CFD is undoubtedly an important milestone in
the development history of biogas industry, and numerical simulation
has largely helped people to get rid of one of the biggest limitations of
the biogas industry non-visibility [11]. In fact, for a long time, people
have designed the biogas slurry fluidization scheme under un-
predictable conditions [10], which is usually only satisfied with the
smooth flow in and out of the materials without silting up, without
considering the advantages and disadvantages of the flow field. Now
using the CFD simulation can clearly show a lot of poor mixing zone
[41] and dead zone [43], provide intuitive basis for optimization design
of the flow field by designers. In the optimization design, the designer
can also use CFD to verify the activity mixed zone of optimized flow
pattern [40], so as to quantitatively evaluate the optimization effect of
flow pattern.
In fact, academic circles have experienced tremendous twists and
turns during getting knowledge of biogas slurry mixing. People ori-
ginally don't think mixing is good for enhance methane anaerobic fer-
mentation. On the contrary, people think the mixing will impact the
fermentation system, reduce the fermentation efficiency [103]. As late
as the 1990s, scholars have gradually realized that the mixing reducing
gas generating rate is only due to that the concrete mixing way is
wrong. For example, continuous mixing is actually a kind of excessive
mixing. If it can take the right way of mixing, taking appropriate in-
termittent mixing is indeed for improving the biogas production [104].
However, the so-called correct mixing method can no longer be de-
signed based on experience and guess as before. Instead, the basic flow
pattern must be plotted with CFD and optimization can be carried out
after mastering the flow pattern. The optimization target mainly con-
tains kinetic energy transmission, heat transfer, mass transfer and other
70
Renewable and Sustainable Energy Reviews 97 (2018) 64–73
aspects, all of which can be calculated with CFD to obtain specific
parameters. According to Xuan's latest research [105], a two-dimen-
sional numerical model was developed based on the integration of CFD
and chemical kinetics, the mass transport, chemical reactions and heat
transfer can be analyzed simultaneously in the porous domain. Further
research referred to the influence of mixing on fermentation has been
carried out to the chemical reaction, which may be another milestone in
the scientific research of biogas.
The use of CFD has also prompted the biogas industry to rethink the
basic shape of fermentation tanks. The traditional view has always been
that the fermentation tank of large biogas project should be vertical
cylindrical, which is mainly for the consideration of the stress structure
and the saving of building materials, without considering the effect on
the fermentation efficiency. But through a lot of CFD application, more
and more scholars now have realized the vertical cylindrical fermen-
tation tank has a large number of so-called dead zone or poor mixing
zone, which is not the most suitable type tank of biogas fermentation
[56–65]. Moreover, for different rheological properties of fermentation
raw materials, the impact is not the same, designers should design ac-
cording to actual condition [106], which requires the designer to firstly
obtain the specific flow pattern of fermentation raw material in this
type tank, and then to think about the optimization. Currently, CFD is
the most suitable method for mastering flow pattern of airtight con-
tainer [15]. It can be predicted that the change of tank type will be a
new revolution in the biogas industry, in which CFD will play an ex-
tremely important role.
4.4. Impact of CFD on development of medium and large-scale biogas plants
Medium and large-scale biogas plants are a new industrial tech-
nology after 1950s, marking the development of the biogas industry
from the traditional household-based biogas digesters stage to a new
stage. However, due to the high initial investment and operation cost of
large-scale biogas plants, some traditional viewpoints once believed
that it's difficult to promote in the underdeveloped countries. It could
only continue to build household-based biogas digesters in the vast
rural areas. But such viewpoint is clearly wrong, advanced, centralized
renewable energy projects such as biogas are more suitable for devel-
oping countries. Agriculture accounts for a higher proportion in the
industrial structure of developing countries, and more agricultural
waste can be used to produce biogas. The construction of a large
number of centralized biogas projects is not a heavy financial burden
for developing countries, but a dual opportunity to control pollution
and develop renewable energy industries [107]. Moreover, due to the
late-development advantages of developing countries, it is cheaper to
replace traditional fossil fuels with renewable energy. In 2012, the
United Nations set a target to increase the share of global renewable
energy in primary energy consumption to 30% by 2030 [108]. Sovacool
[109] believes that the focus is on developing countries and provides
twelve design principles for renewable energy programs in developing
countries, biogas being in the main position. He is also clearly pointed
out that the traditional household-based biogas digesters can’t complete
this task in terms of construction speed and production efficiency.
Large-scale biogas plants must be constructed in large quantities to
meet the requirements.
Taking China as an example, as one of countries with the world's
largest biogas industry, China began to use biogas as as renewable
energy one hundred years ago. Currently, China has about 42 million
household-based biogas digesters [110]. China's biogas industry is
faced with the requirement of comprehensive upgrading from decen-
tralized household biogas digester to centralized large and medium-
sized biogas digester project [111]. The Chinese government has been
investing a large amount of money in the cause of biogas. In recent
years, the investment structure has changed from household based
biogas subject to medium and large-scale biogas plants [112]. The an-
nual direct investment of the central government alone has been around
J. Wang et al.
5 billion CNY (about 0.8 billion USD) and maintained a steady growth
[113]. According to the investment estimation of the Chinese govern-
ment, the average cost of large-scale biogas plants is about 2500 CNY/
m3, and 5 billion CNY could build 2 million cubic meters medium and
large-scale biogas plants. The huge market demand has raised higher
requirements for the design level of biogas engineering, which can only
be realized with the help of advanced methods such as CFD.
Medium and large-scale biogas plants are not only simple geometric
amplifiers compared to the traditional household-based biogas diges-
ters, but also coming with many new problems. For example, house-
hold-based biogas digesters are subject to the problem of fermenting
materials being easy to crust [114], but which can be broken by simple
agitation. When the material liquid fermentation product reaches
100 m3 or even magnitude order of thousands of cubic meters, simple
mixing is ineffective, flow pattern in CFD simulation is characterized by
a large number of dead zone or poor mixing zone [115]. Before being
able to master the flow pattern with CFD, the designer can only increase
the mixing power blindly, and simply aim to open the hydraulic
channel [30]. In fact, this will not only consume the power of the
mixing motor, but may even worsen the flow pattern and reduce the
biogas production [9]. For example, in terms of tank insulation, tank
shape and material mixing, household-based biogas digesters are small
and buried in the ground, these problems are not serious and can be
solved to a certain extent. But the problem of medium and large-scale
biogas plants is greatly amplified and difficult to solve, so its promotion
prospect has been greatly questioned [116]. However, the CFD method
has solved a series of problems of medium and large-scale biogas plants
to a large extent, which has strongly promoted the rapid development
of biogas business towards greater scale and intensification.
5. Conclusion
In the past 15 years, with the rapid development of electronic
computing technology, desktop computing costs (including hardware
and computing time) continue to decline rapidly. CFD will become
more and more convenient and practical research method. Using CFD to
make biogas fermentation material fluid flow pattern visualization and
carry out the industry research and design has the intuitive basis and
gets rid of the limitations under the condition of invisible speculation
by intuition, which is the largest scientific and technological progress in
the industry in the past. With the solving of some difficulties, more
researchers and designers will use CFD to accurately simulate the flow
pattern in the future, which gradually becomes the main research and
design method of the industry. With the booming development of the
biogas industry, especially the accelerated development of medium and
large-scale biogas plants, the requirements for the mixing technology
are getting higher and higher. CFD method has made a great con-
tribution to this and will continue to lead the research direction of the
biogas mixing technology.
Acknowledgements
This paper was funded by the Agricultural Science and Technology
Innovation Program (ASTIP) of Chinese Academy of Agricultural
Sciences; Huimin Project of Chengdu Science and Technology Grant No.
2015-HM01-00548-SF and Science and Technology Plan Project in
Sichuan Province Grant No. 2014GZ0133; the National Natural Science
Foundation of China under Grant No.51308361 and the National Key
Technology Support Program (2015BAD21B03).
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