University of San Agustin: Chemical Engineering Department

University Of San Agustin
Chemical Engineering Department

CHE 411 - Biochemical Engineering
Project Design: Biogas Production through Anaerobic Digestion using Chicken Manure and
Corn Stover as Substrates
Submitted by:
Celiz, Hannah Joy L.
Flame, John Francis F.
Matulac, Reynee Shaira L.
Submitted to:
Engr. Edgar Clyde R. Lopez
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Table of Contents
1. Abstract........................................................................................................................................4
2. Introduction..................................................................................................................................6
2.1 Background of the Industry....................................................................................................6
2.2 Market Size and Projections..................................................................................................8
2.2.1 Historical Background.....................................................................................................8
2.2.2 Demand and Supply........................................................................................................8
2.2.3 Deficit and Projection......................................................................................................9

2.3 Objectives of the Study........................................................................................................11
2.4 Process Selection..................................................................................................................11
2.4.1 Batch Digestion System................................................................................................12
2.4.2 Continuous Stirred Tank Bioreactor..............................................................................13
2.4.3 Plug Flow Bioreactor.....................................................................................................14

2.5 Scope and Limitation...........................................................................................................15
3. General Process of the Reactor Design.....................................................................................16
3.1 Block Flow Diagram............................................................................................................16
3.1.1 Preprocessing of Chicken Manure (CM) and Corn Stover (CS)...................................16
3.1.2 Anaerobic Digestion (AD) of CS and CM....................................................................16

3.2 Process Flow Diagram of the Reactor Section.....................................................................18
3.3 Process Description..............................................................................................................19
3.3.1 Mixing Unit and Biodigester.........................................................................................19
3.3.2 Biodigester and Purification Unit..................................................................................19
3.3.3 Biodigester and Waste Treatment Process....................................................................19
Chemical Properties...............................................................................................................19
3.4 Raw Material Specification..................................................................................................20
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3.5 Product Specification...........................................................................................................21

3.6 Handling and Storage of Methane Gas................................................................................23
1. Abstract
Biopower can diversify energy supply and improve energy resiliency. Increasing the biopower
production from sustainable biomass like chicken manure (CM) and corn stover(CS) can provide
many economic and environmental benefits. For example, increasing biogas production through
anaerobic digestion of food waste would increase the use of renewable fuels throughout
Philippines and add to its renewable’s portfolio.
Growth and concentration of the biogas industry create opportunities for the proper disposal of
the large quantities of manures generated from CM and corn CS Environment can be degrade by
the pollutants from livestock waste and methane emittions from decomposing manure can
contribute climate change.
One management system not only provides pollution prevention but also can convert a manure
problem into a new profit center. Economic evaluations and case studies of operating systems
indicate that the anaerobic digestion (AD) of livestock manures is a commercially available
bioconversion technology with considerable potential for providing profitable coproducts,
including a cost-effective renewable fuel for livestock production operations.
Examining some of the current opportunities for the recovery of methane from the AD chicken
manures and corn stover.This livestock operations currently employ AD. The fresh CM will be
collected in a chicken farm located in Pavia, Iloilo City. And the CS will be collected in a corn
farm located in Misamis Oriental, Cagayan de Oro.
After it is collected, both the CS and CM will be subjected to screening where the unwanted dirt
like stones, grass, feathers, eggshell, and other impurities in the raw material is removed. The
CM will be crushed and stored at ambient temperature. And the CS after the screening, it will
then be washed and air dried. After the CS is dried, it will then undergo size reduction process by
cutting and crushing the CS into fragments and will be stored in ambient temperature until it is
utilized in producing biogas.
After preprocessing, CS and CM will undergo mixing process together with the inoculum and
water before going into the biodigester. This will make the raw materials be fluid-like and be
easily transported into the biodigester. The inoculum will be taken from a biogas facility in Iloilo
City.
An introduction to the engineering economies of these technologies is provided, and possible

end-use applications for the methane gas generated by the digestion process are discussed. The
economic evaluations are based on engineering studies of digesters that generate electricity from
the recovered methane. Case studies of operating digesters, with project and maintenance
histories and the operators “lessons learned,” are included as reality checks. Factors necessary
for successful projects, as well as a list of reasons explaining why some AD projects fail, are
provided. The role of farm management is key; not only must digesters be well engineered and
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built with high-quality components, they must also be sited at farms willing to incorporate the
uncertainties of a new technology.
The biodigester will process the substrates and convert it into biogas after which it will be
subjected to purification and compression. After purification and compression, the product will
go to the methane storage unit to be used in electricity generation which will be enough to
increase the Philippines’ biofuel share percentage on electricity generation by 1.5% by the year
2050. The effluent going out of the biodigester will be further treated in the Waste Treatment
Process (WTP) and can be converted into a useful product like fertilizers.
Many researchers has provided much information about how manure can be converted to an
energy source; however, the Filipino farmers has not been motivated to adopt new practices.
Easily managed manure management and more cost-effective techniques are still needed to
encourage farmers to use animal manure specifically CM and also CS for conversion into
energy and nutrients, especially for smaller barns.
AD benefits farmers monetarily and mitigates possible manure pollution problems, thereby
sustaining development while maintaining environmental quality. Moreover, rural economic
development will benefit from the implicit multiplier effect resulting from jobs created by
implementing digester systems. Promising future waste-to-profit activities may add to the
economic performance of AD. New end-use applications, which provide added value to
coproducts, are discussed.
KEYWORDS: anaerobic digestion, bioconversion, engineering economy, environmental

quality,pollution prevention, sustainable development.
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2. Introduction
2.1 Background of the Industry
The Philippines' economy increased by 6.7 percent in the previous year, somewhat less
than the 6.9 percent GDP growth achieved in 2016. During that time, the Philippines were
regarded as one of Asia's fastest-growing economies. One of the main drivers was manufacturing
(PSA, 2019). The demand for energy is expected to rise as the world's economy grows. People
now have the opportunity to purchase and gain access to technology that will become a part of
their daily life, resulting in increased electricity demand. The Philippines has modest indigenous
energy resources, with a total production of 24 million tonnes of oil equivalent (Mtoe) in 2010
and a forecast increase to 31.6 Mtoe by 2035. One-third of these resources are fossil fuels: 3.5
million tons of coal (mostly lignite), 3 million tons of natural gas, and 0.9 million tons of crude
oil. The economy is preparing to drill 25 oil wells every five years, for a total of 100 wells by
2030, under the Department of Energy (DOE, 2010). Fossil fuels take millions of years to form
and are consumed considerably faster than new ones are generated; these energy sources are
considered as non-renewable resources. Because the country’s supply of energy is increasing, it
is preferable to rely on renewable energy. It is expected that most countries would seek
alternative energy sources in the future and will continue to research alternative fuel
developments. By the year 2035, given the abundance of renewable resources in the economy,
more than half of its indigenous energy resources are predicted to come from renewable energy
sources such as hydro and geothermal, as well as other new and renewable energy (RE) sources.
Other renewable energy sources include biomass (such as fuel wood and bagasse, the fiber left
after juice is extracted from sugarcane stalks, etc.), which is mostly used in residential and
commercial applications (Layug, 2012).
Among the RE sources, biogas is one of the promising waste-to-energy alternatives. It is

not only environmentally beneficial, but it is also simple to create. Biogas is a flammable gas
made from the fermentation of organic matter in the absence of oxygen. This RE is made up of
approximately methane which makes up 60% of the mixture, while carbon dioxide makes up
40%. It has a lingering, unpleasant odor. It's crucial to find solutions to this odor problem
because it can be problematic for those who live near the biogas plant. Table 1.1.1 lists some
technologies that have been utilized to overcome this problem. Biogas produces a bright blue
flame and can be utilized in a variety of applications, including gas lamps, cooking stoves,
generating electricity, and powering diesel and petrol engines (Hankins, 1987). The utilization of
carbohydrates, proteins, and/or lipids in the formation of biogas is required to produce biogas.
Soluble organic matter, volatile fatty acids (mostly acetic acid), amino acids, long chain fatty
acids, organic sulfur, and ammonium compounds are important substrates for methane
production. These can be found in sewage, municipal, and other trash, as well as weeds, leaves,
and non-edible starch (Dutt & Ravindranath, 1993). Biogas production is not a new process.
Many countries are already producing biogas since it is less damaging to the environment and
can be made simply from food waste/reject crops and manure. Biogas technology is not new to
the Philippines, but with increased knowledge of the polluting effects of animal manure and
environmental concerns, it is slowly gaining popularity with both the government and the
population, particularly in livestock producing areas. Dr. Felix D. Maramba, an agricultural
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engineer by profession at the then-Araneta University Foundation, brought biogas technology to

the Philippines in 1965 (Peneyra, 2018).
Rice, corn, coconut, sugarcane, bananas, and other tropical fruits are the Philippines'
primary agricultural crops. The USDA stated that strong crop conditions in the first quarter
boosted corn output estimates for 2021-22 by 150,000 tonnes to 8.15 million tonnes. The
Philippines' corn production for 2020-21 has been revised to 8.352 million tonnes, a huge
increase (Reidy, 2021). Aside from having abundant natural resources, the Philippines has a
large number of farms that raise cattle and poultry, two of the most important agricultural
subsectors. The most popular animals kept for human consumption in the Philippines were hogs
and chickens, which accounted for the majority of the livestock output volume (Department,
2021). The Bureau of Agricultural Statistics estimates that 1.18 million metric tons of chicken
manure are produced annually in the Philippines (Cruz, 1997). To account for the most abundant
resource the Philippines can have, chicken manure and corn stover can be used as the main
substrates for biogas production in this study. AD not only bridges the gap between organic
waste and bioenergy but also solves the problem of environment pollution and energy shortage,
and is undoubtedly one of the suitable methods for dealing with organic solid wastes (Li, R.H, &
Sun, 2015).
Table 2.1.1 Odor Treatment Technologies (Hankins, 1987)
Type of Technology Characteristics

Techniques for the treatment of deducted exhaust air
Washing the air in aqueous solution A solution absorbs the chemical components of
the odors and passes them form the gaseous
phase to the liquid. Effective on all odor
components.
Biotechnology Transform odor components with micro-
organisms.
Particularly effective on organic components.
For example: biofilter, bacterial bed or

percolator filter, biofuel.
Solid support adsorption Trap the odor components with a solid
adsorbent compound, such as activated carbon.
Effective on all odor components if they have a
strong impregnated support.
Palliative techniques for uncontrolled emissions
Odor neutralizing products Reduces odors by physicochemical destruction,
adoption or dissolution of the molecules that
are responsible for them. For example: by
spraying/ misting essential oils, by diffusion of
neutralizing molecules with dry steam, etc.
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2.2 Market Size and Projections
The Philippines' energy usage is expected to skyrocket in the future. The primary energy supply
increased at an annual average rate of 2.5 percent from 28.7 Mtoe in 1990 to 55.9 Mtoe in 2017.
From 2017 to 2050, the country's primary energy supply is expected to increase threefold; from
55.9 Mtoe in 2017 to 176.6 Mtoe in 2050, at an annual average rate of 3.5 percent (Olvido &
Morales, 2021). This creates an opportunity for renewable energy to help meet energy demand in
the face of our current limited energy supply. The Philippines is a country with a lot of bioenergy
potential in its agriculture sector. Without a question, this will play a significant part in
determining the country's future structure. The economic impact of the 1973 energy crisis has
been seen and will continue to be felt in the future (Reurasia, 2020). Officials have finally
realized the gravity of the situation and have begun accepting suggestions to address the growing
problem. Energy Outlook and Energy Saving Potential in East Asia an ambitious government
program is being pushed for the development of an LNG hub in the country to secure future
natural gas supplies (Olvido & Morales, 2021).
2.2.1 Historical Background
Biogas technology is already popular in the Philippines and has been developed in the past. The
People's Reconstruction Movement was the first to supply anaerobic digestion technology to the
public in the Philippines from 1979 to 1986, in partnership with the Philippine Rural
Development Council as part of the Rural Energy and Sanitation Program. As a result, the
initiative began by focusing on a few low-cost digester technologies, such as hydraulic fixed
dome digesters made of bricks. In the 1980s, the Philippine Rural Life Center, a non-
governmental organization, promoted the use of culvert biogas by providing training to both the
public and private sectors. Cavite State University's Non-Conventional Energy Center became
very active in promoting renewable energy technologies including wind, hydro, solar, and
biomass (Conservation, Eastern Research Group, Inc., & PA Consulting Group, 2009). In 1995,
homes in the nation utilized a total of 8,134 gigawatt hours (GWH). During the 6-year period,
this represents an increase of 1,289 GWH, or 18.8%. In 1995, the Philippines used around
3,668,000 tons of biomass leftovers on a total basis. When compared to 1989, urban use of this
type of fuel increased by 131.6 percent. Demand for this sort of gasoline proved to be higher
among rural inhabitants, whose consumption climbed by around 25% during the same time
period (Fuel consumption of Filipino Households - HECS Highlights SR- 1995, 2022)
2.2.2 Demand and Supply
Because there are still energy shortages in this archipelago state, an inexpensive and dependable
energy source is needed. The average price of electricity in the Philippines is around 0.23
USD/kWh. Although energy prices are low in comparison to other nations, most Filipinos still
can’t afford it. While fossil resource depletion is growing rapidly, bioenergy offers an alternative
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to supply clean and sustainable energy. The Philippines, which is known for its agriculture, has a
lot of potential for biomass and biogas energy. Sugar cane and rice production, in addition to the
usage of animal waste, particularly hog and poultry waste, provide a good source of waste to be
utilized as an input material. As of 2015, the GPCCI estimates that waste from sugar mills, rice
farms, and coconut farms have potential production capacities of 90, 40, and 20 MW,
respectively. In any event, the majority of this waste is not properly used. Total renewable
energy capacity will be boosted to 15,304 gigawatts by 2030, adding to the country's energy
security. According to the GPCCI analysis, this amounts to a three-fold increase in capacity in
2010 (Lohne, 2017). According to a Department of Energy (DOE) official, the country will need
at least USD121 billion in renewable energy investments between 2020 and 2040 to achieve the
Clean Energy Scenario (CES). Under the CES, the DOE aims to add at least 10,000 megawatts
of renewable energy capacity by 2040. The DOE also aims to increase the share of renewable
energy in the power generation mix to 35 percent by 2030 and more than 50 percent by 2040
(Crismundo, 2021). Therefore we aim to increase the biofuel share percentage by 1.5% in 2050.
2.2.3 Deficit and Projection
Utilization of biofuel as a source of electricity in the Philippines began in 2010. In terms of

electricity generation, 41.4% of the electricity demand is produced by geothermal energy, 28%
by coal, 11.4% by hydro, 15% by natural gas and 0.1% by wind, solar, and biofuel. In terms of
installed capacity for generating power, hydro accounts for 63.2%, geothermal for 35.1%,
biomass for 1.1%, wind for 0.6%, and solar for 0.1% (Hartman & Basnet, 2021). Data in Table
1.2.3.1 shows the amount of biofuel used as a source of electricity in TW-h annually in the
Philippines (Mathieu, Macdonald, & Ritchie).
Based on our projections (Fig. 2.2.3.1 and 2.2.3.2), it is expected that the Philippines will have
180.372 TW-h of electricity generation, 1.713 TW-h of biofuel electricity in the year 2050 or
0.949% of the country’s total electricity generation.
Figure 2.2.3.1 Projected Electricity Generation in TW-h from 2021 – 2050 (Data adapted from
Mathieu, Macdonald, & Ritchie)
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Figure 2.2.3.2 Projected Biofuel Electricity in TW-h from 2021 – 2050 (Data adapted from
Mathieu, Macdonald, & Ritchie)
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2.3 Objectives of the Study
The aspirational goal of this project design is to increase the biofuel share percentage by 1.5% in
2050. With this, the required biofuel electricity to be generated is about 2.706 TW-h and 1.713
TW-h being the projected biofuel electricity in 2050. We have a deficit of 0.993 TW-h or
114,933.6 kW which will be the target amount of energy output of the design. To achieve the
required output, methane must flow at a rate of 2.071 kg/s. The design is assumed to have a 10%
loss in the downstream and to account for this, adjustments will be applied, and the flow rate
increases to 2.301 kg/s. Figure 2.3.1 shows the varying flow rates on three different cases (See
appendix 2).
Figure 2.3.1 Product Flow rate of Methane in Three Cases
Case Definition Flowrate(kg/s)
Design 1.10 x Normal 2.531
Normal Calculated flowrate at bioreactor 2.301
Minimum 0.60 x Normal 1.381
2.4 Process Selection
The primary function of all anaerobic digesters is to store manure in the absence of oxygen while
maintaining the proper conditions for methane-forming microbes (methanogens) to thrive.
Anaerobic digesters come in a range of shapes and sizes, each performing the same fundamental
function in somewhat different ways. First, the number of stages, which can be either single or
two, the feed total solids (TS) content, and the operating temperature, which can be either
Mesophilic (about 93°F to 98°F or 34°C to 37°C) or Thermophilic (roughly 131°F to 140°F or
55°C to 60°C). Gas injection, internal mechanical components, and repumping are also included
in agitation. Then there's reactor type, which comprises vertical and horizontal placement, and
process flow, which includes continuous and plug process flows (Nichols, 2004). The following
are a few examples of popular bioreactor designs seen in various publications.
2.4.1 Batch Digestion System
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Figure 2.4.1.1 Typical BEKON batch digestion system (Lutz, 2010).
Figure 2.4.1.1 shows a schematic diagram of the typical BEKON batch digestion system (Lutz,
2010). Bulk materials with a high dry-substance concentration can be digested without requiring
any complicated fermentation material pre-treatment. The BEKON process is a batch-operated
single-step fermentation method. The term "single step" refers to the fact that the multiple
degrading processes (hydrolysis, acidification, and methanisation) are all part of the same
process. The organic waste is gathered in a tipping facility and transported by wheel loader to the
garage-shaped fermenter. Inoculation is accomplished by combining new material with material
that has already been fermented. The fermenter is closed off by a hydraulic gate once it has been
full, and the process of organic waste fermentation begins. A drainage system collects excess cell
fluid (percolation liquid) released during the fermentation process and returns it to the
fermenting material in a cycle to maintain it wet. The temperature of the microorganisms is
maintained by using wall and floor heating. As a result, the conditions in the fermenter are kept
at their optimum level. As a result, the conditions in the fermenter are kept at an optimal level for
the bacteria that produce biogas. This does not need any additional material or mixing of the
ingredients (BEKON, 2016). There are pros and cons for having a batch AD reactor. The Pros
include low maintenance requirements and little systemic energy loss and high TS content
fermentation residues (bio-fertilizer) can be obtained directly, which avoids solid–liquid
separation processes and minimizes the treatment of waste liquid (Sitanrassamee, Babel, &
Fukushi, 2004) (Qian, Li, Wedwitschka, Nelles, Stinner, & Zhou, 2016). On the other hand, the
cons are low and non-constant gas production, no pumpable materials, high emissions (BEKON,
2016).
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2.4.2 Continuous Stirred Tank Bioreactor
Figure 2.4.2.1 Single Thermophilic CSTR
Figure 2.4.2.2 Series Thermophilic CSTR
Table 2.4.2.3 Reactor Operating Data

Parameter Serial Serial CSTR (90/10) Serial CSTR (80/20)
CSTR
R1 R2 R3 R2+R3 R2 R3 R2+R3
Retention 15 13.5 1.5 15 12 3 15

time, day
Working 3200 3200 35 3556 320 800 4000

volume, mL 6 0
Feed rate, 213 237 23 237 267 267 267

mL/day 7

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In figure 2.4.2.1 is a schematic diagram of a single thermophilic continuous flow stirred tank
reactor (CSTR) and a Serial CSTR. The serial configuration shown in figure 2.4.2.2 consists of
two CSTR reactors joined in series with a volume distribution ratio between the first and second
reactors (referred to as R2 and R3, respectively). The reactors are made of double glass cylinders
with stainless steel plates on top and bottom. The mixer, mixer motor, feed tube and effluent
tube, temperature measurement port, and sample port were all supported by the top plate. There
was only one sampling port on the bottom plate. The operating pressure was around 1 atm. The
effluents from the liquid surface were driven out through the effluent tube on top of the reactor
by pressure from the new feed and biogas inside the reactors. Effluent bottles were used to
collect the effluents. Biogas from the effluent bottles flowed to gas meters to be measured for
biogas production. In this experiment, reactor R2 had the same operational volume as R1,
therefore when R3 was added, the total volume of the serial CSTR system became larger than the
single CSTR (Boe & Angelidaki, 2008).
There are advantages and disadvantages to having a CSTR reactor. The benefits include: mixing
is completed outside the digestive system, materials spend less time in the reactor, a high degree
of percolate recirculation effectively recycles anaerobic bacteria and waste heat, and a TS
content of 30% to 40% is maintained over long periods of time. The disadvantages include lack
of defined retention duration, sinking and swimming layers, and no biogas separation.
2.4.3 Plug Flow Bioreactor
Figure 2.4.3.1 Linde-KCA Continuous System (Adapted from Huang , Zhang, & Xia, 2013).
Figure 2.4.3.1 shows how the Linde-KCA system works as a plug flow reactor with separate
tanks for aerobic and anaerobic digestion (Huang , Zhang, & Xia, 2013). The TS concentration
in the feedstock could range from 15% to 40%. Many axle mixers agitate and homogenize the
slurry. PFR has both advantages and disadvantages. The advantages are that impellers in the
digesters provide good substrate mixing, improve microorganism access to the substrates, and
thus efficient substrate conversions; high OLR can be achieved due to effective mixing; and
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there is an additional operating cost associated with aerobic pretreatment (Patinvoh, Kalantar,
Sarvari, & Taherzadeh, 2016). The cons include recirculation with bacteria and difficult
maintenance (Casaretto, 2019).
A thermophilic single CSTR will be used in the Design Project (Figure 2.4.2.1). The advantages
of a thermophilic digester include better biogas generation, pathogen destruction, and substrate
decomposition, while a mesophilic digester is considerably easier to operate and more stable.
(Vindis , Mursec, Janzekovic , & Cus, 2009). Although mesophilic digesters are more stable,
they produce significantly less biogas than thermophilic digesters. According to a study that
compared the performance of mesophilic and thermophilic anaerobic reactors, the thermophilic
would produce 20.0 l/d of biogas at an organic loading rate (OLR) of 15 kg COD, which is
higher than the mesophilic's 13.5 l/d. As of now, no comparison of acclimation between
mesophilic and thermophilic settings has been made (Jeong, Son, Pyon, & Park, 2014).
Continuous reactors contain the following characteristics: continuous production, stable state
after start-up, no concentration variation over time, constant reaction rate, and ease of balancing
to determine kinetics. Because our study will be solving Methane production kinetics, one of the
purposes of choosing a CSTR is the simplicity of calculation. Four models were used to model
this study, including a first-order kinetic model (1), the cone model. (2), modified Gompertz
model (3) and the Logistic Model (4) (Yu, et al., 2020).
B=Bo ¿
Bo
B= −n
Equation 2.3.2
1+(kt)
{¿¿
B=Bo ×e
1−exp ⁡[−k (t−λ)]

B=Bo Equation 2.3.4
1+exp ⁡[−k ( t− λ ) ]
2.5 Scope and Limitation]

The scope of this thesis is to design a thermophilic biogas using reactor in Anaerobic Digestion
given chicken manure and corn stover as substrate. It will not focus on the design of pre-
processing equipment as well as the required downstream processing. The reactor will be limited
to one AD reactor operating in CSTR.

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3. General Process of the Reactor Design
3.1 Block Flow Diagram
The purpose of this Block Flow Diagram (BFD) is to explain the details of the proposed
Anaerobic biodigester design.
3.1.1 Preprocessing of Chicken Manure (CM) and Corn Stover (CS)
The fresh CM will be collected in a chicken farm located in Pavia, Iloilo City. And the
CS will be collected in a corn farm located in Misamis Oriental, Cagayan de Oro. After it is
collected, both the CS and CM will be subjected to screening where the unwanted dirt like
stones, grass, feathers, eggshell, and other impurities in the raw material is removed. The CM
will be crushed and stored at ambient temperature. And the CS after the screening, it will then be
washed and air dried. After the CS is dried, it will then undergo size reduction process by cutting
and crushing the CS into fragments and will be stored in ambient temperature until it is utilized
in producing biogas.
3.1.2 Anaerobic Digestion (AD) of CS and CM
After preprocessing, CS and CM will undergo mixing process together with the inoculum
and water before going into the biodigester. This will make the raw materials be fluid-like and be
easily transported into the biodigester. The inoculum will be taken from a biogas facility in Iloilo
City. The inoculum was passed through a series of filters before being used. The biodigester will
process the substrates and convert it into biogas after which it will be subjected to purification
and compression. The target purified methane production for this design is 2.301 kg per second
or 138.06 kg per day. After purification and compression, the product will go to the methane
storage unit to be used in electricity generation which will be enough to increase the Philippines’
biofuel share percentage on electricity generation by 1.5% by the year 2050. The effluent going
out of the biodigester will be further treated in the Waste Treatment Process (WTP) and can be
converted into a useful product like fertilizers.
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Figure 2.1 Block Flow Diagram for the preprocessing of raw materials and biogas production plant
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3.2 Process Flow Diagram of the Reactor Section
Figure 3.2.1 Process flow diagram of the methane production unit
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3.3 Process Description
3.3.1 Mixing Unit and Biodigester
The incoming feed stream will be consisting of CS, CM, water, and the inoculum. These
are to be combined inside the mixing unit. The feed mixture will then pass through the strainer to
ensure that no particles will come into contact with the heat exchanger and the pump. Next, the
substrate is modified until it reaches optimal temperature by passing it through the heat
exchanger and is transported to the thermophilic biodigester by pumping. To ensure that the
temperature inside the biodigester remains in optimal conditions, there is a circulation of hot
water from a reservoir that will flow between the walls of the biodigester. The water is then
recirculated back to the reservoir and is heated again in order to continuously regulate the
reactor’s temperature to the optimum level.
3.3.2 Biodigester and Purification Unit
The biodigester will produce biogas and it is transported to a knock-out drum. The
purpose of the knock-out drum is to remove any oil or water from the biogas. The gas going out
of the KO drum will then be transported in the purification unit. The purpose of a purification
unit is to separate O2(can cause explosions), H2S(toxic to human health and destructive to
pipelines) and any components that reduces the heat value of the biogas. Biogas purification is a
vital process before it is delivered to electric generation power plants.
3.3.3 Biodigester and Waste Treatment Process
The biodigester waste going out of the system will be transported in waste treatment
process where the waste will be converted to useful products like fertilizer.
Chemical Properties
Two thirds of the total methane produced is derived by converting the acetic acid or by
fermentation of alcohol formed in the second stage such as methanol. The other one third of the
produced methane is a result of the reduction of the carbon dioxide by hydrogen. The reactions
that occur during this stage are as follows (Ostrem & Themelis, 2004).
Acetate Conversion
2CH3CH2OH+ CO2 ⇿ 2CH3COOH + CH4
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Methanol Conversion
CH3OH+H2 ⇿ CH4 + H2O

Carbon Dioxide reduction by Hydrogen
CO2 + 4H2 ⇿ CH4 + H20
3.4 Raw Material Specification
The parameters of substrates and inoculum are shown in Table 3.4.1. The VS (percent TS) of CS
and CM were 80.64 and 77.98 percent, respectively, indicating that organic matter is the main
component of dried CS and CM. Based on the elemental composition values in Table 3.4.1, the
chemical compositions of CS and CM were C50.08H74.80O26.12N and C10.82H11.21O6.81N, respectively.
Because of their high organic matter content, the CS and CM can be used for AD to make
biogas. CS was made up of cellulose, hemicelluloses, lignin, extractive, and other ingredients.
Natural resins, tannins, essential oils, pigments, lignans, and a minor amount of alkaloids, pectin,
starch, protein, and other extractives are among them. The high concentration of lignin (12.52%),
cellulose (34.43%), and hemicellulose (31.61%) in CS could explain why it converts to biogas so
slowly. As a result, pretreatment for CS is required in order to boost biogas output. After
pretreatment, the VS of CS dropped by 44.51–63.77 percent. Pretreatment can break the ester
bond between cellulose, hemicellulose, and lignin, allowing part of the cellulose and
hemicellulose to dissolve into monosaccharide, disaccharide, oligosaccharide, non-structural
sugar, and part of the lignin to dissolve into acetic acid, phenol compounds, and other
compounds (Yan, Song, Li, Yuan, & Zheng, 2015). Non-structural sugar and acetic acid are
among them.
Table 3.4.1 The Characteristics of Substrates and Inoculum (Yu, et al., 2020)
Characteristics Inoculum CM CS Pretreated CS (Urea)
TS (%WW) 2.05 ± 0.03 19.04 ± 0.17 25.88 ± 0.29 12.67 ± 0.24
VS (%WW) 1.06 ± 0.02 14.85 ± 0.14 20.87 ± 0.39 11.58 ± 0.19
VS (% TS) 51.98 ± 0.21 77.98 ± 0.60 80.64 ± 0.87 91.43 ± 2.56
Cellulose (%TS) NA NA 34.43 ± 0.07 29.84 ± 0.27
Hemicellulose (%TS) NA NA 31.61 ± 0.17 28.29 ± 0.21
Lignin (%TS) NA NA 12.52 ± 0.24 10.54 ± 0.16
20
pH 8.83 ± 0.05 7.91 ± 0.04 NA NA
TAN (mg/L) 899 ± 83 9510 ± 37 NA NA
FAN (mg/L) 26.79 ± 6.83 48.84 ± 4.24 NA NA
TA (mg CaCO3/L) 11,261 ± 330 23,682 ± 613 NA NA
VFAs
188.24 ±2.57 NA NA NA
(mgCH3COOH/L)
C (%TS) 27.67 ± 0.15 38.57 ± 0.91 43.78 ± 0.00 NA

H (%TS) 4.01 ± 0.12 3.33 ± 0.25 5.45 ± 0.02 NA
O (%TS) NA 32.37 ± 0.39 30.45 ± 0.29 NA
N (%TS) 3.31 ± 0.11 4.16 ± 0.26 1.02 ± 0.00 NA
S (%TS) 1.12 ± 0.05 < 0.1 < 0.1 NA
C/N 8.35 9.27 42.92 NA
Acronyms: WW, wet weight; TS, total solids; VS, volatile solids; TAN, total ammonia nitrogen;
FAN, free ammonia nitrogen; TA, total alkalinity
3.5 Product Specification
Methane, carbon dioxide, and a little quantity of other gases make up the majority of biogas.
Biogas is a mixture of gases made up primarily of methane (40-70 percent), carbon dioxide (30-
60 percent), and other gases (1-5 percent) such as hydrogen (H2) 0-1 percent and hydrogen
sulfide (H2S) 0-3 percent. Biogas is a mixture of gases that is composed chiefly of methane 40-
70 vol.%, carbon dioxide 30-60 vol.% and other gases 1-5 vol.% including hydrogen (H2) 0-1
vol.% and hydrogen sulfide 0-3 vol.% (EESI, 2017). Specifically in our study, the maximum
methane content is 77.88% from 1:3 ratio (CS/CM) (Sun, Liu, R. H., Cao, W. X., Yin, R. Z., &
Mei, Y. F., 2015).
Table 3.5.1: Properties of Biogas, Landfill gas and Natural gas (Energigaser och miljö, Svenskt
Gastekniskt Center, 2006)
Properties Units Landfill gas Biogas Natural gas
Lower calorific value MJ/Nm3 16 23 39

kWh/Nm3 MJ/kg 4.4 6.5 11
12.3 20 48
Density kg/Nm3 1.3 1.1 0.82
Relative density - 1.1 0.9 0.63
21
Wobbe index, MJ/Nm3 18 27 55

upper
Methane - >130 >135 73
number
Methane Vol-% 45 65 90
Methane, range Vol-% 35-65 60-70 85-92
Heavy Vol-% 0 0 9
hydrocarbons
Hydrogen Vol-% 0-3 0 -
Carbon dioxide Vol-% 40 35 0.7
Carbon dioxide, Vol-% 15-40 30-40 0.2-1.5
range
Nitrogen Vol-% 15 0.2 0.3
Nitrogen, range Vol-% 5-40 - 0.3-1.0
Oxygen Vol-% 1 0 -
Oxygen, range Vol-% 0-5 - -
Hydrogen sulphide Ppm <100 <500 3.1
Hydrogen Ppm 5 100 -
sulphide, range
Total chlorine mg/Nm3 20-200 0-5 -
as Cl-
Table 3.5.2 The Range Composition of Biogas in Anaerobic Digestion.
Gas Concentration %
CH4 50-70
CO2 25-30
N2 0-10
H2O 0-5
H2S 0-3
O2 0-3
CXHY 0-1
NH3 0-0.5
Since the composition of biogas produced by agricultural plants varies greatly, explosion limits
should be determined experimentally for each composition. This would, however, necessitate a
substantial investment, time and effort required (Schroeder, Schalau, & Molnarne, 2014).
22
3.6 Handling and Storage of Methane Gas
Methane is a highly combustible gas. When combined with air, it can create explosive
combinations. The flammability of methane gas is depicted in figure 3.6.1. It indicates that open
flames, sparks, static discharge, and oxidizing materials are all dangerous in the presence of
these items or situations. To maintain safety, methane gas must be handled and stored properly.
It's critical to avoid heat and ignition sources including sparks, open flames, hot surfaces, and
static discharge when working with methane. Put up signs that say "No Smoking." Check for
oxygen deficit before workers enter and throughout work if they are working in a confined
location. Place the cylinder in a standing position. Ensure that cylinders are not damaged. To
transfer cylinders, use an appropriate hand truck; do not drag, roll, slide, or dump them. Avoid
coming into contact with incompatible compounds by accident. Before transferring, cool the
receiving container. To avoid boiling and splashing, slowly fill containers or place things into
liquefied gas. The proper storage of methane gas is also critical. According to a website named
CCOHS, methane gas should be stored in a cold, well-ventilated, temperature-controlled
environment free of combustible and flammable objects, out of direct sunlight and away from
heat and ignition sources. Always secure cylinders to a wall, rack, or other substantial structure
in an upright posture (CCOHS, 2022).
Figure 3.6.1: Physical and chemical Properties of Methane Gas (SAFETY DATA SHEET, 2020)
Appearance
Physical State : Gas. (compressed gas)
Color : Colorless
Odor : Odorless
Melting Point : -187.6 ◦C
Boiling Point : -161.48 ◦C
Critical Temperature : -82.45 ◦C
Flammability : Extremely flammable in the presence of the
following materials or conditions: open flames,
sparks and static discharge and oxidizing
materials.
Lower and upper explosive (flammable) limits : Lower 5%
: Upper 14%
Vapor density : 0.6
Specific Volume (ft3 /lb) : 23.6407
Gas density (lb/ft3) : 0.0423
Solubility in water : 0.02
Partition coefficient n-octanol/ water : 1.09
Heat of combustion, J/kg : -50048542
23
4. Mass and Energy Balance
4.1 Kinetic Study (Microorganism growth Kinetics)
There are two methods for studying the kinetics of microbial development. The first is
determining the concentrations of substrates during the experiment (Beba & F.S, 1986).
However, monitoring substrate concentration is time consuming and inconvenient. The second
method is to track gas production rates during tests. This approach is simpler than the first, and it
also takes less time to complete. To begin, write material balances around the continuous
fermenter.
4.1.1 Microorganism Balance: Accumulation=Net growth;
¿ dX
=μX Equation 4.1 .1
dt
4.1.2 Substrate Balance:
dS
=−consumed Equation 4.1.2
dt
Substrate consumption rate can be written using the growth yield constant for
microorganisms as follows:
−dS μX
= Equation 4.1.3
dt Y
−dX
Y= Equation4.1 .4
dS
Equation 4.1.5 is generated after integrating Equation4.1.4 using initial conditions and applying
total material balance.
dS dG
=−α Equation 4.1.5
dt dt
In this section, you'll find the specific growth rate equations that have been employed in Table
4.1.1. Contois Equation 4.1.6 is used to calculate the mass gas production rate, and it comprises
three kinetic parameters (μ, B, K).
Equation 4.1.6
dG 1 μm ( S −αG ) ( X 0 +YαG)
= [ 0
]
dt Yα BX 0 + S0 + αG ( K−1 )
24
Table 4.1.1 Specific growth rate (model) and derived equations
Name Model Derived

equation
dG
Monod    S(K  S)1 =μm ( S −αG ) ¿ ¿
m s dt 0
Equation
Monod
  [ S(K  S)1  b]
m s
Equation μ m (S −αG)
dG 1
With = [ 0
−b]( X 0 +YαG)
dt Yα K s + S0 + αG
Decay
Rate
Contois    S(BX  S)1 dG 1 μm ( S −αG ) ( X 0 +YαG)
= [ 0
]
m
dt Yα BX 0 + S0 + αG ( K−1 )
Equation
Contois
  [ S(BX  S)1  b] μm ( S −αG )
Equation m dG 1
= [ 0
−b ](X 0 +YαG)
dt Yα BX 0 + S0 + αG ( K−1 )
With
Decay
Rate
   [1 (K / S)  (S/ K )]1 dG μ m ( X 0−YαG )❑
m s i
= [ ]
Substrate dt Yα KsS −αG
1+ + 0
S0 −αG Ki
Inhibitio
n
Substrate dG 1 μm
   [1 (K / S)  (S/ K )]1  b = [ −b]( X 0 +YαG)
dt Yα Ks S0−αG
Inhibitio 1+ +
S0 −αG Ki
n With
Decay
Rate
25
The model equations for gas production for all specific growth rates in Table 4.1.1
are calculated using the same procedure. Using a nonlinear regression approach, the
mass of gas generated by chicken fermentation was applied to the model equations
supplied in table above, and the best suited model linking the specific growth rate
of microorganism for each waste was obtained. Table 4.1.2 shows the results of the
modeling studies as well as the kinetic parameters derived from the waste's best
model equation.
Table 4.1.2. The kinetic parameters calculated for the best fit model equations.
Waste Best fit model Kinetic parameters

equation
α  B K b Ks Ki
m
Chicken manure Contois equation with 7 0. 15 1 0. - -
decay rate 3 5
Chicken manure with Substrate inhibition 7 0. - - - 236. 10
inoculation 7 91 0
Nomenclature:
B coefficient of Contois (-)
Equation
Ki inhibition coefficient (g/
L)
Ks saturation concentration (g/
L)
S substrate concentration (g/
L)
X microorganism (g/
concentration L)
Y growth yield of (g/g)
microorganism
26
Greek Letters
 specific growth rate of

microorganism (day-1)
m maximum specific growth rate (day-1)
4.2 Reaction kinetics of the anaerobic treatment process
Based on the approach given in this research, mathematical models explaining the kinetics of
substrate utilization and methane production in anaerobic treatment processes are built (Momoh,
Anyata, & Saroj, 2013). The method posits that Alzheimer's disease progresses in three stages.
First, acidogenic bacteria hydrolyze/acidogenize organic substrates in wastewater to generate
acidified substrate. The acetogenic/methanogenic bacteria then take up the acidified substrate
and assimilate it, which leads to growth and biogas production.
Stage 1: Hydrolysis and acidogenesis
Many constituents of organic wastes behave as complex substrates (polysaccharides, proteins,

fats etc.). The Grau model presented in Eq. 4.2.1, which has widely been used to model multiple
substrate removal kinetics (Kim, Chun, Oh, & Kim, 2006) was therefore adopted for this study
−dS
=k n ( s) X ¿
dt
where −dS /dt represents the rate of decrease in concentration of substrate being hydrolyzed, S
is the concentration of initial substrate left at every instant following onset of hydrolysis, So is
the concentration of initial substrate, kn (s) is the rate of substrate degradation by acidogenic
bacteria, X is the concentration of acidogenic bacteria and n defines the degree of adaptation by
acidogenic bacteria for substrate degradation. Where, K ha is the maximum rate of substrate
degradation by acidogenic bacteria.
−dS
=k n ( s) X ¿
dt
Stage 2: Substrate uptake by acetogenic/methanogenic microorganism.
27
The hydrolytic model of (Momoh, Anyata, & Saroj, 2013) Equation 4.2.3, which represents a
modified version of the hydrolytic model presented by previous studies (Barthakur, Bora, &
Singh, 1991) was adopted:
Su=S 0 A f ¿
This model accounts for both the acidified substrate produced by acidogenic bacteria and the
consumption of acidified substrate by acetogenic/methanogenic bacteria. Su is the actual amount
of substrate acidified and used by the acetogenic/methanogenic bacteria, whereas b denotes the
proportion of initial volatile solids still present in the effluent. The coefficient Af =K ha/(Kam(−α)
+K ha) represents the rate limiting coefficient for very slow (case of 0<α<1) or very fast (case of
α=1) metabolism of acidified substrate by the acetogenic/ methanogenic bacteria (Momoh,
Anyata, & Saroj, 2013). The constant Kam is the maximum rate of substrate utilization by the
acetogenic/methanogenic microorganisms.
Stage 3: Kinetics of bacteria growth and biogas production
Ks is the Monods’ half saturation constant for substrate uptake, µmax is the maximum specific
growth rate for methanogenic archae, m is the coefficient of acetogenic/methanogenic microbial
adaptation for cooperativity, Si is the initial concentration of substrate taken up by acetogenic/
methanogenic microorganism, k is the kinetic constant of Chen and Hasshimoto, and ki is the
substrate concentration where bacteria growth is reduced to 50% of the maximum specific
growth rate due to substrate inhibition. Taking the case of the Monod model for growth of aceto-
genic/methanogenic microorganisms, and using product and cell yield coefficients, the rate of
biogas production can be expressed by
dy t Y ps μ max S u
= × × X am Equation 4.2 .4
dt Y xs K s + Su
5. Design Calculations
5.1 Key Assumptions, Design Criteria, Constraints of the Design, Codes Used
5.1.1 Key Assumptions
28
The performance of any fermenter depends on the following key factors:
1.Agitation rate
2.Oxygen transfer
3.pH
4.Temperature and Pressure
5. Design of fermenter
5.1.2 Design Criteria source: https://slideplayer.com/slide/10680806/
Substrate conditions:
 The design and mode of operation of a reactor mainly depends on the production of
organisms, optimal operating condition required for target product formation, product
value and scale production.
 The design also takes into consideration the capital investment and running cost.
 The design of a bioreactor take into considerations the aspect of biological processes:
o The concentrations of substrate materials and products in the reaction mixture are
frequently low. Both substrates and products may inhibit the process.
o Cell growth, product formation depend on the nutritional needs of the cell and on
the maintenance of optimum biological conditions (temperature, concentration of
reactants and pH)
o Microorganism can metabolize unconventional or even contaminated raw
materials.
The basic points of consideration while designing a reactor:
 Productivity and yield

 Fermenter operability and reliability
 Energy requirements
 Design in features so that process control will be possible over reasonable ranges of
process variables.
 Operation should be reliable
 Operation should be contamination free
29
 Pressure gauges and safety pressure valves must be incorporated, (required during
sterilization and operation).
 For transfer of media pumps are used. Centrifugal pumps (generate high shear forces and
path for easy contaminations), magnetically coupled, jet and peristaltic pumps. Alternate
methods of liquid transfer are gravity feeding or vessel pressurization.
 In fermentations operating at high temperatures or containing volatile compounds, a
sterilizable condenser may be required to prevent evaporation loss.
5.1.3 Constraints of the Design
1. Temperature
Changes in the temperature should not be out of thermophilic temperature range, which
could inhibit the biodigester’s methane production by killing bacteria whether by adding
too much heat or freezing the microorganisms.
2. Pressure and Gas Production Rate (GPR)
Regular monitoring of the unit's operation, particularly the pressure and gas production
rate inside the reactor, is required for safety reasons. Pressure must be higher than
atmospheric pressure; it should not be higher than X mbar or lower than Y mbar.
3. Rate of Methane Production
A well-trained operator on bio-digestion technology is a must to avoid any problems with

the digester’s day to day operation. To monitor the rate of production, the manometer
measurement should be recorded often. Different gas production could be an indication
for different feedstocks on the digester’s performance, it is also an indication that the
biodigester is overfed and the buffer capacity is reduced. By any means, the GPR should
not be less than the target production rate.
4. Reaction Inhibitors
The design should take into consideration kinetic parameters, to avoid reaction inhibition
or what we call reactor shock.
5.1.4 Codes Used
MX0001, CSTR00001 etc. put details. (flame)
5.2 Reactor Conditions
5.3 DPDT and Material Selection
30
5.4 Bioreactor Calculations
5.4.1 Pressure Vessel Sizing Equations (Nkoi, Lebele-Alawa, & Odobeatu, 2018)
A simple basic geometry formula is used to determine the height of the pressure vessel. where r
= Radius (mm), t = Thickness (mm).
2 4 3
V =π r h+ π r Equation 5.4 .1
3
5.4.2 Impeller design (Pannucharoenwong, 2018)
Table 5.4. 1 Summary of characteristic of different type of impeller observed in the research
Type Code Flow Pattern Np

6- straight blade SB-6 Radial 5.59
4-pitched blade PB-4 Mix 0.66
6- blade Marine MP-6 Axial 0.32
Table 5.4.1 shows different types of impeller including 6-blade marine (MP-6), 6-straightblade
(SB-6), and 4-pitched-blade (PB-6) .Each type of impeller have different characteristics such as
the Power Number (Np) and flow pattern as shown in Table 5.4.1. Np indicated the power
required to turn the impeller during agitation, which is related to the energy consumption of each
impeller. A higher Np value mean that more power is required to rotate the impeller which
suggest a greater energy consumption.
Figure 5.4.1: Diagram of the dimension of anaerobic digester and impeller position.
(Pannucharoenwong, 2018)
31
Figure 5.4.2: Different configuration impellers: 6-blade marine a), 6-straight-blade b), and 4-
pitched-blade.
Table 5.4.2: Power number of different impellers according to shape factors and Reynolds
number (Ravi, Lindner, Oechsner, & Lemmer, 2018)
32
Impeller Np
Marine propeller with four blades without 0.35

pitch/angle
Curve full blade turbine with six blades 2.7

without pitch/angle
Flat blade turbine with four blades without 6

pitch/angle
Pitched blade turbine with six blades and 1.5

45 degrees
Flat paddle with two blades without 1.8

pitch/angle
The installation of agitator inside the digester was observed to have a positive effect on the rate
of biogas production. Anaerobic digestion with MP-6 propeller was found to give the highest and
the most stable production of methane compared with PB4 and SB-6, which indicate the
effectiveness of axial flow pattern compared with mix and radial flow. Due to the result of the
literature, the best propeller to achieve the highest methane production will be the MP-6 which is
the 6-blade Marine Impeller.
The selection of the motors is one of the important regulations for the effective power
consumption by a mixing system as the motors are the largest part of the energy consumers. The
power consumed by a mixer in a process fluid can be calculated with Eq. 5.4.2.
33
3 5
Np Ns Dim SG
Pw= 13
Equation5.4 .2
1.53 ×10
where Pw, NP, Ns, SG, and 1.53 x 1013 are power (hp), power number of impeller, impeller
speed (rpm), specific gravity, and conversion factor, respectively. As can be seen from the
equation, changes in Ns and Dim have a major impact on required Pw to operate the impeller.
The NP can be decided depending on the slurry viscosity indicated by the modified Reynolds
number (NRe). The NRe is defined as Eq. 5.4.2 (Kress, Nägele, Oechsner, & Ruile, 2018)
Ns Dim 2 ρ
NRe= Equation 5.4 .3
μ
The x-axis is the NRe calculated by Eq. 5.4.3. The y-axis is the experimentally determined NP.
The plot indicates that at various stages of flow regimes; laminar, transitional, and turbulent, the
NP varies with the NRe (Kress, Nägele, Oechsner, & Ruile, 2018). It can be seen from the plot,
which as the NRe is increased from early stages of turbulence (NRe > 10,000) to increasingly
larger NRe, the NP becomes constant (Ravi, Lindner, Oechsner, & Lemmer, 2018). The NP
constants in turbulence stage for the various impeller types according to impeller shape factors
listed in (Ravi, Lindner, Oechsner, & Lemmer, 2018). The higher torque (not necessarily higher
Pw) equal with the higher mixer cost. In flow-controlled mixing processes, torque equal with
mixer flow 3 a constant, which is in turn equal to process result (Jiang, et al., 2017). The torque
required for any mixing process will affect the size and type of mixer drive and also have a direct
impact on mixer shaft design.
Pw ×73025
Torque= Equation5.4 .4
Ns
34
Figure 5.4.3: The impeller power number changes with Reynolds number (Ravi, Lindner,
Oechsner, & Lemmer, 2018).
5.5 Equipment Data Sheet
Control System
35
36
REFLECT ADDED APPENDICES ON ALL

Appendices SECTIONS OF THE MANUSCRIPT
Appendix 1: Projected Electricity Generation & Biofuel Electricity Data
Biofuel share
Biofuel share in Electricity Biofuel Electricity Electricity Biofuel Electricity
YEAR YEAR in electricity
electricity (%) Generation (TW-h) (TW-h) Generation (TW-h) (TW-h)
(%)
2000 0 43.66 0 Projected years (2021-2050)
2001 0 45.208 0 2021 0.631 98.542 0.622
2002 0 46.525 0 2022 0.651 101.364 0.660
2003 0 50.674 0 2023 0.669 104.186 0.697
2004 0 53.646 0 2024 0.687 107.007 0.735
2005 0 54.188 0 2025 0.703 109.829 0.772
2006 0 54.505 0 2026 0.719 112.651 0.810
2007 0 57.08 0 2027 0.734 115.472 0.848
2008 0 58.31 0 2028 0.748 118.294 0.885
2029 0.762 121.116 0.923
2009 0 59.317 0
2030 0.775 123.938 0.960
2010 0.042 64.669 0.027
2031 0.787 126.759 0.998
2011 0.175 66.121 0.116
2032 0.799 129.581 1.036
2012 0.261 69.688 0.182
2033 0.811 132.403 1.073
2013 0.295 71.844 0.212
2034 0.821 135.224 1.111
2014 0.266 73.724 0.196
2035 0.832 138.046 1.148
2015 0.467 78.637 0.367
2036 0.842 140.868 1.186
2016 0.838 86.587 0.726
2037 0.852 143.690 1.224
2017 1.124 90.002 1.012 2038 0.861 146.511 1.261
2018 0.564 94.514 0.533 2039 0.870 149.333 1.299
2019 0.499 100.381 0.501 2040 0.878 152.155 1.336
2020 0.51 98.293 0.501 2041 0.887 154.976 1.374
2042 0.895 157.798 1.412
2043 0.902 160.620 1.449
2044 0.910 163.441 1.487
2045 0.917 166.263 1.525
2046 0.924 169.085 1.562
2047 0.931 171.907 1.600
2048 0.937 174.728 1.637
2049 0.943 177.550 1.675
2050 0.949 180.372 1.713
37
Appendix 2: Calculation of Design Flowrates (Product flowrate)
Projected electricity generation by 2050 = 180.7317 TW-h
Projected biofuel electricity generation by the year 2050 = 1.71255 TW-h
The goal is to increase the biofuel share percentage by 1.5% in 2050.
Target biofuel electricity generation = projected electricity gen. in 2050 × 1.5%
Target biofuel electricity generation = (180.7317 TW-h)×0.015 = 2.705576 TW-h
Market deficit = target biofuel electricity gen. 2050 - projected biofuel electricity gen. 2050
Market deficit = 2.705576 - 1.71255 = 0.993026 TW-h
Assuming that the plant is operational 330 days per year, we can calculate the required energy
output of the plant:
)( )
kJ
1
( )( )( )(
9
0.993026 TWh 1 y 1 d 1x 10 kW s kJ
Output = = 114,933.6
y 360 d 24 h 1 TW 1 kW s
Heat of combustion of methane = 55,514 kJ/kg (Combustion Heat, 2022)
Product flowrate = output ÷ heat of combustion of methane
kJ
114,933.6
s
Product flowrate = = 2.071 kg/sec
kJ
55,510
kg
Assuming 10% downstream losses,
kg
2.071
s
Product flowrate at bioreactor= =2.301 kg/sec
0.9
From this, we can define the following cases:
Design: 1.10 x normal = 1.10(2.301 kg/s) = 2.531 kg/s
Normal: Flowrate at bioreactor = 2.301 kg/s
Minimum: 0.60 x normal = 0.60(2.301 kg/s) = 1.381 kg/s
38
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University Of San Agustin

Chemical Engineering Department

Celiz, Hannah Joy L.

Flame, John Francis F.

Matulac, Reynee Shaira L.

Engr. Edgar Clyde R. Lopez

2.2.1 Historical Background.....................................................................................................8

2.2.2 Demand and Supply........................................................................................................8

2.2.3 Deficit and Projection......................................................................................................9

2.4.1 Batch Digestion System................................................................................................12

2.4.2 Continuous Stirred Tank Bioreactor..............................................................................13

2.4.3 Plug Flow Bioreactor.....................................................................................................14

3.1.1 Preprocessing of Chicken Manure (CM) and Corn Stover (CS)...................................16

3.1.2 Anaerobic Digestion (AD) of CS and CM....................................................................16

3.3.1 Mixing Unit and Biodigester.........................................................................................19

3.3.2 Biodigester and Purification Unit..................................................................................19

3.3.3 Biodigester and Waste Treatment Process....................................................................19

3.5 Product Specification...........................................................................................................21

An introduction to the engineering economies of these technologies is provided, and possible

KEYWORDS: anaerobic digestion, bioconversion, engineering economy, environmental

Among the RE sources, biogas is one of the promising waste-to-energy alternatives. It is

engineer by profession at the then-Araneta University Foundation, brought biogas technology to

Table 2.1.1 Odor Treatment Technologies (Hankins, 1987)

Type of Technology Characteristics

For example: biofilter, bacterial bed or

2.2 Market Size and Projections

2.2.1 Historical Background

2.2.2 Demand and Supply

2.2.3 Deficit and Projection

Utilization of biofuel as a source of electricity in the Philippines began in 2010. In terms of

2.3 Objectives of the Study

Figure 2.3.1 Product Flow rate of Methane in Three Cases

Case Definition Flowrate(kg/s)

Design 1.10 x Normal 2.531

Normal Calculated flowrate at bioreactor 2.301

Minimum 0.60 x Normal 1.381

2.4 Process Selection

2.4.1 Batch Digestion System

Figure 2.4.1.1 Typical BEKON batch digestion system (Lutz, 2010).

2.4.2 Continuous Stirred Tank Bioreactor

Figure 2.4.2.1 Single Thermophilic CSTR

Figure 2.4.2.2 Series Thermophilic CSTR

Table 2.4.2.3 Reactor Operating Data

Retention 15 13.5 1.5 15 12 3 15

Working 3200 3200 35 3556 320 800 4000

Feed rate, 213 237 23 237 267 267 267

2.4.3 Plug Flow Bioreactor

1−exp ⁡[−k (t−λ)]

2.5 Scope and Limitation]

3. General Process of the Reactor Design

3.1 Block Flow Diagram

3.1.1 Preprocessing of Chicken Manure (CM) and Corn Stover (CS)

3.1.2 Anaerobic Digestion (AD) of CS and CM

3.2 Process Flow Diagram of the Reactor Section

Figure 3.2.1 Process flow diagram of the methane production unit

3.3 Process Description

3.3.1 Mixing Unit and Biodigester

3.3.2 Biodigester and Purification Unit

3.3.3 Biodigester and Waste Treatment Process

Characteristics Inoculum CM CS Pretreated CS (Urea)

TS (%WW) 2.05 ± 0.03 19.04 ± 0.17 25.88 ± 0.29 12.67 ± 0.24

VS (%WW) 1.06 ± 0.02 14.85 ± 0.14 20.87 ± 0.39 11.58 ± 0.19

VS (% TS) 51.98 ± 0.21 77.98 ± 0.60 80.64 ± 0.87 91.43 ± 2.56