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Bioresource Technology: L. Castro, H. Escalante, J. Jaimes-Estévez, L.J. Díaz, K. Vecino, G. Rojas, L. Mantilla
Bioresource Technology: L. Castro, H. Escalante, J. Jaimes-Estévez, L.J. Díaz, K. Vecino, G. Rojas, L. Mantilla
Bioresource Technology
journal homepage: www.elsevier.com/locate/biortech
h i g h l i g h t s g r a p h i c a l a b s t r a c t
a r t i c l e i n f o a b s t r a c t
Article history: The purpose of this work was to assess the behaviour of anaerobic digestion of cattle manure in a rural
Received 10 March 2017 digester under realistic conditions, and estimate the quality and properties of the digestate. The data
Received in revised form 5 May 2017 obtained during monitoring indicated that the digester operation was stable without risk of inhibition.
Accepted 6 May 2017
It produced an average of 0.85 Nm3 biogas/d at 65.6% methane, providing an energy savings of 76%. In
Available online 10 May 2017
addition, the digestate contained high nutrient concentrations, which is an important feature of fertiliz-
ers. However, this method requires post-treatment due to the presence of pathogens.
Keywords:
Ó 2017 Elsevier Ltd. All rights reserved.
Anaerobic digestion
Biogas digestate
Cattle manure
Energy
Low-tech digester
Nutrients
Pathogens
http://dx.doi.org/10.1016/j.biortech.2017.05.035
0960-8524/Ó 2017 Elsevier Ltd. All rights reserved.
312 L. Castro et al. / Bioresource Technology 239 (2017) 311–317
in the developing world. The tubular digester is widely used due to width: 1 m; bottom width 0.8 m; long: 7.5 m; and depth: 1 m.
its simple design and construction from readily available materials The biogas produced was stored in a tubular polyvinyl reservoir,
(Kinyua et al., 2016a). Tubular digesters are mainly feed with cattle 5.1 m3 in volume (Martí-Herrero and Cipriano, 2012). Commercial
manure at an organic loading rate between 0.3–2 kg VS/m diges- polyvinyl chloride used for water conduction was employed for
ter*d (Garfí et al., 2016). However, problems reported from field accessories and inlet and outlet pipes. The reactor was operated
surveys indicate that users are not trained in proper tubular diges- with a continuous ORL of 0.7 kg VS/m3digester*d with a 1:3 cattle
ter operation and biogas generation does not meet user manure to rainwater mixture. A hydraulic retention time (HRT) of
expectations. 35 d was calculated according to operational volume. The environ-
Research on low-tech tubular digesters has focused on design, mental temperature varied between 23 ± 5 °C.
construction, optimization in cold climates, odour control, water
pollution from animal facilities, and diminution of pathogens 2.3. Monitoring tubular digester
(Garfí et al., 2016; Martí-Herrero et al., 2014). As example, low-
cost tubular digesters have been adapted to cold climates by add- AD performance in a continuous tubular digester was moni-
ing a greenhouse. This design acts as a solar heat collector, reduc- tored over four months (29 April to 29 August 2016), measuring
ing heat losses to the ground. This configuration maintains the biomethane potential (BMPinfluent), residual methane potential
slurry 8.4 °C above the mean ambient temperature (Perrigault, (BMPeffluent), specific methanogenic activity (SMAinfluent), residual
2012). Moreover, Kinyua et al. (2016a) reviewed small-scale tubu- methanogenic activity (SMAeffluent), organic matter content and
lar anaerobic digesters treating livestock waste in the developing consumption (in terms of VS), volatile fatty acids (VFA), biogas pro-
world. They found that: (i) substrate characteristics, such as total duction, and methane concentration. The stability of the process
ammonium nitrogen (TAN) and pH varied from 0.086 to 1.4 g was evaluated using the VFA/TA ratio and pH.
NH4-N/l and 6.5–8.8, respectively; (ii) operation parameters, such
as Organic Load Rate (OLR) and temperatures ranged from 0.33 2.4. Energetic and economic consideration
to 8.00 and 17 to 31 °C, respectively; and (iii) performance of tubu-
lar digesters yielded biogas at 0.012–0.50 Nm3 biogas/kg VSadded In order to determinate the economic saving using biogas (ESB;
and CH4 contents from 21 to 76%. Subsequently, Kinyua et al. S$), Eq. (1) was used to compare biogas with commercial gas
(2016b) investigated the performance of a tubular digester for (propane).
treating livestock waste in through experimental studies and bio-
ESB ¼ gbiodigester PC ð1Þ
process modelling; they found reductions of >75% in volatile solids
and biochemical oxygen demand (BOD5). In contrast, studies of where PC is propane cost (US$). gbiodigester is the digester energetic
tubular reactors have emphasized the need to decrease pathogens efficiency with respect to propane and is calculated as follows:
content at the end of the digestion process. An anaerobic process
LCP biogas Bflow
removed 60% of Cryptosporidium parvum and 90% Giardia lamblia, gbiodigester ¼ PC ð2Þ
which are common pathogens in swine (Kinyua et al., 2016c). LCP propane Pflow
However, the majority of studies analyse biodigester perfor-
where LCPbiogas is the biogas low calorific power (MJ/m3), LCPpropane is
mance with limited parameters. Generally, biogas production rate,
the propane low calorific power (MJ/m3; Li et al., 2017), and Bflow
specific biogas production, and methane percentage are the most
and pflow are the volumetric biogas flow (m3/s) and volumetric pro-
studied variables. This represents a limited knowledge of opera-
pane flow (m3/s), respectively. LCPbiogas was determined as:
tional conditions, biogas digestate, and microbiological behaviour
under real conditions. Here this study investigated the operational LCPbiogas ¼ LCP CH4 ð%CH4 Þbiogas ð3Þ
dynamics and methanogenic activity in anaerobic transformation
3
of cattle manure in digester at real scale. Consequently, the aims where LCPCH4 is the methane low calorific power (MJ/m ) and
of this research were: (a) to assess the behaviour of anaerobic ð%CH4 Þbiogas is methane percent in biogas.
digestion of cattle manure in a rural tubular digester under realistic
conditions, and (b) to estimate the quality and properties of the 2.5. Biogas digestate quality
biogas digestate.
In order to evaluate the digestate quality, two aspects were con-
sidered: (i) physicochemical characterization, including carbohy-
2. Materials and methods drates, lipids, proteins, K, Mg, Ca, Cl, Na, PO4-P, NH4-N and heavy
metals and (ii) microbiological analysis, including fecal coliforms,
2.1. Site description helminth eggs and salmonella spp.
tion was quantified daily in situ using a MetrexÒ model G2.5 HRT of 90 and 39 d and OLR of 0.34 and 1.01 kg VS/m3digester*d
flowmeter. Biogas measurements were normalized (1 atm; 25 °C) respectively. These previous results are in agreement with our cur-
according to Poling et al. (2001). Methane content was measured rent investigation, and show that VS reduction can be high even
using gas chromatography as described in APHA (2005). Emission, when digesters are operated at low mesophilic temperatures (16–
atomic absorption, volumetric, colorimetric, and photometric 27 °C).
methods were used to determine physicochemical digestate prop- VFA represents the easily biodegradable organic matter avail-
erties (Kinyua et al., 2016c). Fecal coliform, helminth eggs and sal- ability during anaerobic process. Fig. 2 shows that the VFA concen-
monella spp. indicators were determined using methods reported trations were between 1780 ± 102–660 ± 98 mg/l in the influent
in Rivera et al. (2012). and effluent, respectively. Sawatdeenarunat et al. (2017) reported
that anaerobically digested cattle manure is an ideal inoculum
for VFA production. In the currently research, the effluent VFA con-
3. Results and discussion
centrations were under the inhibition limit concentration for con-
tinuous reactors (1500 mg/l; Søndergaard et al., 2015). This
3.1. Specific methanogenic activity
indicates that the organic loading rate (OLR) was at the appropriate
operating condition for the anaerobic biochemical process.
The Colombian farm tubular digester was neither stirred nor
The VFA/TA fluctuated between 0.52–0.94 mg Acetic Acid/mg
heated, and it was operated at local environmental temperatures
CaCO3 in the influent, while effluent values remained at
(23 ± 5 °C). Under these conditions, SMAinfluent (fresh cattle man-
0.36 ± 0.07 mg Acetic Acid/mg CaCO3. This demonstrates the high
ure) and SMAeffluent (biogas digestate) were 0.02 and 0.04 g COD/
buffering capacity of cattle manure (Fig. 3a). VFA/TA values under
g VS*d, respectively. Methanogenic activity was double in the efflu-
0.6 mg Acetic Acid/mg CaCO3 are adequate to process stability.
ent compared to the influent, which suggests that the archaea con-
Anaerobic microbes are sensitive to temperature changes as
tained in cattle manure satisfactorily adapted to the anaerobic
small as 1–3 °C. A variation in the temperature affects the stability
process. If microbial activity is compared to catalytic activity in a
of the fermenting bacteria. This change in stability may cause pH
chemical process, these results are considered successful. Com-
changes and decrease methane yield (Gerardi, 2003). The pH range
monly, stabilized cow manure SMA is low compared to other man-
for a healthy and continuous AD process is 6.8–8.2 (Fotidis et al.,
ure. In the work of Regueiro et al. (2012), SMA activity was not
2016). In the present study, the pH value for both the influent
detected in cow manure digestate. In contrast, Quintero et al.
and effluent was 7.47 ± 0.2 (Fig. 3b) at low mesophilic tempera-
(2012) and Alzate-Moncada and Quintero (2016) used a pre-
ture. Therefore, the low cost digester was operating properly with-
acclimated cattle manure at 37 °C, reaching SMA values between
out inhibition risk. Similar studies report pH ranges around 6.24–
0.03 and 0.15 g COD/g VS*d respectively. In these studies, the
7.7 and 6.58–7.61 for influent and effluent, respectively, for plug
researchers employed a Continuously Stirred Tank Reactor (CSTR)
flow digesters operating at temperatures between 16 and 27 °C
digester. The present investigation demonstrates that with a tubu-
(Lansing et al., 2008a; Garfí et al., 2011).
lar digester at the lower portion of the mesophilic range, cattle
manure is an ideal inoculum because of its capacity to promote
biogas production and its accessibility in rural areas. 3.3. BMP versus specific methane yield under realistic conditions
3.2. Changes in control parameters in the low cost tubular digester 3.3.1. BMP and residual methane potential
The BMPinfluent and residual methane potential of the digestate
Regarding organic matter, the average VS of the influent were 0.16 and 0.04 m3 CH4/kg VS, respectively (Fig. 4). The driving
decreased from 33 ± 2 g VS/kg to 8 ± 0.4 g VS/kg (Fig. 1), indicating force methane potential, 0.12 m3 CH4/kg VS, represents a favour-
76% removal, when the process was operated with a HRT of 35 d able transformation of the composite cow manure into biogas in
and an OLR of 0.7 kg VS/m3digester*d. VS reduction implies a high the tubular digesters at realistic climate conditions. Cattle manure
transformation of cattle manure, assuring anaerobiosis in the tubular presents BMP smaller yields than another manures due to cattle
low cost digester. Investigations of tubular digesters with cattle manure having low lipid contents (2.44%). BMPinfluent values have
manure as raw material, carried out by Garfí et al. (2011) and been reported as 0.19–0.32 m3 CH4/kg VS (Møller et al., 2014;
Lansing et al. (2008a), shown removals of VS between 22 to 80% with Fotidis et al., 2016; Kafle and Chen, 2016). Those higher reported
Fig. 3. (a) Volatile fatty acid/total alkalinity ratio (VFA/TA) and (b) pH variability during monitoring.
values are likely due to reactor type and operating conditions (e.g., plant are between 5–25% depending on HRT (Angelidaki et al.,
temperature and stirring). 2005). In the case of digestate from cattle manure, Rico et al.
Residual methane recovery from digestate represents 6% of the (2011) reported 4.2% of residual methane in the digestate from cat-
methane yield obtained in the tubular digester. This result is in tle manure digester with a 20 d HRT and 2 kg VS/m3*d OLR. The
agreement with previous research, where losses from a biogas authors concluded that the biogas content in the digestate is inver-
L. Castro et al. / Bioresource Technology 239 (2017) 311–317 315
sely proportional to the HRT. In current investigation HRT (35 d) specific methane yield was 0.10 CH4/kg VS. Real methane yield
and OLR (0.7 kg VS/m3*d) were not response variables and represents 63% of the BMP test. These results indicate that the
0.14 m3/d of digestate were produced. AD implementation from cattle manure at full scale in a low cost
Therefore, based on residual methane experiments and biogas tubular digester was successful.
digestate rate, this research suggests implementing a degasifica- The volatile solids removed and BMP percent were 76% and 75%
tion process to recover the retained biogas, avoid disagreeable respectively. The quantitative similarity of these variables indi-
odour emissions, and reduce greenhouse gas release. cates that biomethane potential percent could be used as a control
parameter to evaluate tubular digester performance.
3.3.2. Biogas production in the Colombian farm tubular digester
The digester start-up lasted 35 d in order to stimulate the 3.4. Energy and economic considerations
methanogen growth rate. In this period, biogas production fluctu-
ated between 0.08–0.65 Nm3/d (Fig. 5). During the continuous pro- Table 1 shows the energy consideration for this experiment and
cess, biogas production stabilized at an average value of traditional energy source. In this study, the biogas produced could
0.85 Nm3 biogas/d with a quality of 65.6% of CH4; the cattle man- replace 80% of the traditional fuel (propane). The biogas production
ure acts as both substrate and inoculum. These results correspond was enough to supply cooking requirements for five people for five
with the volatile solid removal (76%) and a favourable cattle man- hours per day. While the propane gas yield is higher than biogas
ure to rainwater ratio (1:3). Previous work investigating the design yield, users (farmers) can save 76% in terms of energy and USD
and operation of the low cost tubular digester indicated that for $50/month in fuel and transport.
every 1 kg of cattle manure, 0.032 Nm3 biogas was produced
(Martí-Herrero and Cipriano, 2012). Based on this previous work, 3.5. Digestate quality
biogas production of 1.0 Nm3 was expected in this study. However,
biogas production was 0.85 Nm3, suggesting a mass transfer that Biogas digestate physicochemical characteristics include nutri-
retained 0.15 Nm3 of biogas in the digestate. ents, Na: 0.39 g/kg, Mg: 0.15 g/kg, Ca: 0.88 g/kg, and K: 1.58 g/kg;
Martí-Herrero et al. (2015) defined BPR and SBP as digester and macromolecules, lipids: 1.97 g/kg, carbohydrates: 8.51 g/kg, and
anaerobic digestion process efficiencies, respectively. In this study, proteins: 3.46 g/kg; and heavy metals, Al: 0.02 g/kg.
a BPR of 0.13 m3biogas/m3digester*d and a SBP of 0.15 m3biogas/kg VS were Na concentration is an important factor to assess the suitability
obtained with a 35 d HRT and 0.7 kg VS/m3digester*d OLR. Lansing et al. of effluent irrigation. Large concentrations can inhibit the soil
(2008a) obtained efficiencies of 0.37 m3biogas/m3digester*d in the diges- hydraulic conductivity, reduce aeration, and induce soil hardening.
ter and 0.35 m3biogas/kg VS in AD process. Those values were higher To assess the suitability of a treated effluent for agricultural use,
than the current study, due to differences in operating conditions Na, Mg, and Ca concentrations in the digestate were used to deter-
(1.01 kg VS/m3digester*d OLR and 39 d HRT). Otherwise, Garfi et al. minate the sodium adsorption ratio (SAR). The SAR in the effluent
(2011), located the digester at 2800 m.a.s.l, and had a significantly was 3.19, implying a low Na hazard (Clark and Mason, 2006;
higher HRT (90 d) and reduced OLR (0.34 kg VS/m3digester*d), which Turner et al., 2010).
led to the efficiencies of 0.11 m3biogas/m3digester*d BPR and 0.32 m3biogas/ Macromolecules in the effluent indicate that the organic matter
kg VS SBP. In comparison, this study had a lower efficiency in the (cattle manure) transformation was carried out successfully in the
digester, probably due to the operating temperature range digester, even at environmental temperatures of 23 ± 5 °C. Lipids,
(23 ± 5 °C). In summary, previous studies indicate that the overall carbohydrates and proteins in digestate represents the easily
efficiency of the AD implementation, expressed as a function of the decomposed fraction of organic matter for plants and are the main
rising BPR and SBP, depends on designing and controlling the HRT food supply for various organisms in the soil. Digestate gradually
and OLR variables. releases plant nutrients under microbial mineralization and acts
The BMP test, is a key parameter in the design, economy, and as soil amendment (Monlau et al., 2016). Digestate land applica-
management of full-scale AD implementations. Many studies have tion can improve soil properties, which is represented in the
addressed differences in BMP tests in a variety of substrates (Bauer increase of crops yield. A yield increase between 15% and 28% have
et al., 2009; Nkemka and Murto, 2013; Wang et al., 2015). How- been reported for organic cropping systems, where fertilization is
ever, in those studies, comparisons between methane yield at the based on AD of crop residues or greenmanure (Stinner et al.,
laboratory and realistic scale were limited. In this study BMPinfluent, 2008; Gunnarsson et al., 2011; Möller and Müller, 2012). In terms
under optimal conditions for AD, was 0.16 m3 CH4/kg VS and real of soluble organic matter, the VFA concentration was
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