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Biotechnol Lett

DOI 10.1007/s10529-017-2323-4

ORIGINAL RESEARCH PAPER

Improving EGSB reactor performance for simultaneous


bioenergy and organic acid production from cheese whey
via continuous biological H2 production
Lucas Rodrigues Ramos . Edson Luiz Silva

Received: 6 February 2017 / Accepted: 9 March 2017


Ó Springer Science+Business Media Dordrecht 2017

Abstract Introduction
Objectives To evaluate the influence of hydraulic
retention time (HRT) and cheese whey (CW) substrate The dairy industry generates considerable quantities
concentration (15 and 25 g lactose l-1) on the of residues, one of which is cheese whey (CW). CW is
performance of EGSB reactors (R15 and R25, respec- produced during the precipitation and removal of
tively) for H2 production. casein in the cheese-making process. For every 1 kg of
Results A decrease in the HRT from 8 to 4 h favored cheese, 9 kg CW are produced (Siso 1996). The
the H2 yield and H2 production rate (HPR) in R15, with chemical oxygen demand (COD) of CW varies from
maximum values of 0.86 ± 0.11 mmol H2 g COD-1 50 to 102 kg m-3, with most of the organic load
and 0.23 ± 0.024 l H2 h-1 l-1, respectively. H2 pro- comprising lactose from the milk (39–60 kg m-3)
duction in R25 was also favored at a HRT of 4 h, with (Carvalho et al. 2013). Because of this high carbohy-
maximum yield and HPR values of 0.64 ± 0.023 mmol drate content, CW is an ideal resource for use in
H2 g COD-1 and 0.31 ± 0.032 l H2 h-1 l-1, respec- anaerobic treatment and bioenergy production tech-
tively. The main metabolites produced were butyric, nologies (Karadag et al. 2014). However, anaerobic
acetic and lactic acids. digestion in a single methanogenic stage faces chal-
Conclusions The EGSB reactor was evaluated as a lenges in the low alkalinity of this wastewater and the
viable acidogenic step in the two-stage anaerobic rapid pH decrease via the accumulation of organic
treatment of CW for the increase of COD removal acids. Biological H2 production in the first stage is
efficiency and biomethane production. therefore an alternative allowing for the synergy of
CW treatment and bioenergy production (Karadag
Keywords Cheese whey wastewater  Hydraulic et al. 2014).
retention time  Organic loading rate  Substrate However, the economic feasibility of fermentative
concentration  Whey H2 production from CW depends on the development
and design of reactors that can improve the H2 yield
(HY) and production rate (HPR) (Show et al. 2012).
Regarding the choice of reactor configuration, the
reactor should be able to operate under low hydraulic
L. R. Ramos  E. L. Silva (&) retention time (HRT), high biomass retention, and
Department of Chemical Engineering, Federal University
optimal good mass transfer for the increase of
of São Carlos, Rod Washington Luis, Km 235,
São Carlos, SP CEP 13565-905, Brazil substrate conversion and prevention of high H2 partial
e-mail: edsilva@ufscar.br pressures. For lower-cost substrates, HPR becomes

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Biotechnol Lett

more important than HY because higher substrate Materials and methods


concentrations can increase HPR. Thus, the feasibility
of H2 production from CW requires that reactors can Substrate feed
operate in high substrate concentrations with low HRT
and high biomass retention. Costs are reduced through The dairy company industry Elegê Laticı́nios S.A.,
the design of smaller reactors (Pawar and van Niel located in Teotônia, Brazil, supplied the CW powder
2013). used in the CW wastewater fed to the EGSB reactors.
H2 production from CW has been evaluated using Different solutions with 10 g CW powder l-1 were
upflow anaerobic sludge bed (UASB) reactors (Ki- characterized as containing 18 ± 1 mg Kjeldalh
rankumar et al. 2016), anaerobic packed-bed reactors nitrogen g CW-1, the equivalent of 116 ± 10 mg
(APBRs) (Perna et al. 2013), anaerobic fluidized-bed protein g CW-1, 7822 ± 697 mg total sugars (lac-
reactors (AFBRs) (Rosa et al. 2014), anaerobic tose) l-1, and 11,009 ± 1030 mg total COD l-1 and
sequencing biofilm batch reactors (AnSBBRs) (Lima having a pH of 6.3 ± 0.1. Nutrients required for cell
et al. 2016), and continuous stirred-tank reactors growth were added to the affluent according to the
(CSTRs) (Venetsaneas et al. 2009). The most used methods of Rosa et al. (2014).
system is the CSTR because it facilitates suspended
cellular growth with high mass transfer between the Description of EGSB reactor
substrate and the microbial community. However,
with a low HRT, a high biomass concentration cannot The reactors were constructed in transparent acrylic
be maintained because the H2-producing microbial using an external water jacket in which water from an
community in suspension is flushed out of the CSTR ultrathermostatic bath controlled the reactor temper-
(Barca et al. 2015). ature at 30 °C. The reactors had a 4.3 cm internal
This drawback can be overcome by biofilm reac- diam., 150 cm ht, and total volume of 2177 cm3. The
tors, such as the expanded granular sludge bed reactor superficial velocity of the reactors was maintained at
(EGSB), via decoupling of the HRT and the biomass 5.5 m h-1 via recycling of the reactor effluent, which
retention time. In biofilm reactors, a carrier material is ensured a granular bed expansion of 30%.
used for bacterial adhesion, increasing the biomass The granules were obtained from the granular
concentration in the reactor (Guo et al. 2008). Thus, sludge of a UASB reactor used for poultry slaughter-
the EGSB stands out among reactor configurations for house wastewater treatment (Avı́cola Dakar S/A,
H2 production, as it favors mass transfer between the Tietê/SP). The granules were heat-treated using a
substrate and the microbial community, allows for method adapted from Kim et al. (2006). The granules
high substrate conversion even at high organic loading were boiled at 100 °C for 1 h and then cooled to
rates (OLR), and reduces HRT (Wang et al. 2009). ambient temperature in an ice bath. The goal of this
Although the EGSB has many advantages, few treatment was to inhibit methanogenic Archaea and
studies have evaluated its efficiency for H2 production select for acidogenic bacteria that could form
using simple substrates (Abreu et al. 2012) and real endospores. A diagram of the EGSB reactors used in
wastewaters (Guo et al. 2008; Wang et al. 2009). In this study is presented in Fig. 1.
addition, identifying the optimal range of operation is of
vital importance to ensuring that substrate overload does Seed sludge
not occur with high H2 production. Thus, for the future
design of high-rate anaerobic reactors with immobilized The seed sludge used for the operational start-up of the
biomass in two-stage anaerobic digestion, identifying mesophilic EGSB reactors was obtained from the
the effects of the operational parameters related to OLR, granulated sludge of a UASB reactor used for poultry
which are HRT and substrate concentration, is neces- slaughterhouse wastewater treatment (Avı́cola Dakar
sary. Therefore, the objective of this study was to S/A, Tietê/SP). For the selection of H2-producing
evaluate the effect of HRT (8–0.5 h) on continuous communities, the sludge was subjected to a thermal
biological H2 production in EGSB reactors with the pretreatment at 90 °C for 10 min and cooled to
substrate concentrations of 15,000 and 25,000 mg ambient temperature in an ice bath according to the
lactose l-1 using CW as a carbon source. methodology of Kim et al. (2006).

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Fig. 1 Schematic diagram


of reactor setup

Start-up and operation of EGSB reactors via decreasing the HRT to 6, 4, 2, 1, and 0.5 h, for a
total of 260 days of operation.
The reactors were fed with the CW powder solution
with concentrations of 15,000 (R15) and 25,000 Analytical methods
mg l-1 (R25) of total carbohydrates (lactose). The
reactors were operated in batch mode via recycling of Total carbohydrate concentrations were measured
the inoculum with CW in their respective concentra- using the method of Dubois et al. (1956) with lactose
tions in order for microorganisms to adapt to the CW as a standard. COD, pH, and Kjeldahl nitrogen
and attach to the surface of the granules. Following the analyses were performed according to APHA (2012).
inoculation step, the reactors were switched to contin- The concentrations of organic acids and alcohols were
uous mode for 8 h. After verification of steady-state H2 determined by HPLC according to the methodology of
production through the attainment of stable HPR and Penteado et al. (2013). H2 and CO2 gas compositions
HY values, the operational conditions were adjusted were measured by GC according to Rosa et al. (2014).

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The reactor volumetric biogas production was mea- from 8 to 0.5 h in the R25 reactor raised the % H2
sured using the fluid displacement method adapted values from 0.7 ± 0.1% to 37.5 ± 3.1%.
from Walker et al. (2009). The maximum H2 % value was 37.5 ± 3.1% in
R25. This value is higher than those of other studies
that used continuous reactors. For example, Perna
Results and discussion et al. (2013) used a mesophilic APBR (30 °C) for
continuous H2 production from CW and observed a
The carbohydrate conversion values observed in the maximum H2 % value of 10% with an increase in the
R15 and R25 reactors increased with the reduction of substrate concentration from 25 to 37 g COD l-1 at an
the HRT values from 8 to 4 h, with maximum values HRT of 24 h. Similarly, Fernández et al. (2015)
of 60 ± 3.3% (R15) and 38.5 ± 3.94% (R25). By achieved a maximum H2 % of 18.2% by decreasing
decreasing the HRT to values below 2 h, the carbo- the HRT from 3 to 2 days using a CSTR for H2
hydrate conversion values were reduced to the min- production from CW (38 g COD l-1).
imum values of 32.9 ± 4.5% in R15 and 8.7 ± 3.2% pH values between 4 and 4.3 in the R15 and R25
in R25. Reduced conversion of carbohydrates with the reactors favored H2 production and inhibited the
reduction of the HRT has also been observed in other methane producers. The COD removal values were
studies. In evaluating the H2 produced from CW of between 4.6 ± 1.5 and 9.9 ± 1.6%. The maximum
different Thermotoga strains in batch tests, Cappelletti values of 9.9 ± 1.6% (R15) and 7.1 ± 0.9% (R25)
et al. (2012) observed substrate conversions ranging were obtained at the HRT of 4 h.
from 39% to 82%. Using an AFBR in mesophilic HPR is a useful design parameter, as it allows for
conditions, Rosa et al. (2014) evaluated the effect of the evaluation of the production capacity of a reactor
different HRT conditions (1, 2, and 4 h) on the from its volume or estimation of these same values for
production of H2 from CW with an organic matter the achievement of a desired production level. The
concentration of 5000 mg COD l-1. With the reduc- HPR values of reactor R15 increased with the
tion of the HRT, the conversion of lactose was reduced reduction of the HRT from 8 to 4 h, with a maximum
from 95 to 85%. value of 0.228 ± 0.024 l H2 h-1 l-1 (Fig. 3). How-
During the operation of the mesophilic EGSB ever, the further decrease of the HRT restricted H2
reactors, H2 content (H2 %) (Fig. 2) was analyzed for production, which did not occur with HRT values
the evaluation of H2 production. lower than 2 h. In the R25 reactor, the decrease in
The reduction of HRT values from 8 to 4 h favored HRT from 8 to 2 h favored HPR, which reached a
the H2 % of the R15 reactor, which reached a maximum value of 0.312 ± 0.032 l H2 h-1 l-1 at the
maximum value of 23.6 ± 4.9%. However, with HRT of 4 h. At the HRT of 1 h, the HPR was reduced
HRT values lower than 4 h, H2 production was to 0.173 ± 0.051 l H2 h-1 l-1, and at the HRT of
hampered, with no production at HRT values of 1 0.5 h, the HPR was 0.302 ± 0.033 l H2 h-1 l-1.
and 0.5 h. On the other hand, the decrease in HRT Similarly, Fernández et al. (2015), using a mesophilic

Fig. 2 Variation in H2 % as a function of HRT for R15 and R25 Fig. 3 Variation in HPR as a function of HRT for R15 and R25

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sequencing batch reactor for H2 production from CW,


observed that with the reduction of HRT from 3 to
1.5 days, the HPR increased from 0.15 l H2 l-1 days-1
to 0.19 l H2 l-1 days-1.
The substrate concentration of 25 g carbohydrate
l-1 produced higher HPR values (with a maximum of
0.312 ± 0.032 l H2 h-1 l-1 in R25) than did that of
15 g carbohydrate l-1. Similar results were obtained
by Yu and Fang (2001), who found that the increase in
dairy wastewater concentration from 2 to 30 g COD
l-1 favored H2 production by the inhibition of H2-
consuming microorganisms, such as methanogens. In Fig. 4 Variation in the HY values as a function of HRT in R15
evaluating the H2 production from CW, Kargi et al. and R25
(2012) achieved a maximum cumulative H2 produc-
tion of 257 ml by increasing the substrate concentra- However, in a mesophilic AFBR (30 °C), Amorim
tion from 5 to 20 g total sugars l-1. Similar to this et al. (2012) observed a maximum HY of 2.5 mol
study’s findings for R25, Davila-Vazquez et al. (2008) H2.mol glucose-1 at 2 g glucose l-1 with a decrease in
observed a maximum HPR of 0.2 l H2 h-1 l-1 with the HRT from 8 to 2 h. On the other hand, the HY
CW at 25 g l-1 when evaluating the kinetics of H2 decreased from 2.5 to 0.6 mol H2 mol glucose-1 with
production from CW in concentrations between 0.86 an increase in glucose from 2 to 25 g l-1. The authors
and 29.1 g l-1. Additionally, Amorim et al. (2012) concluded that the progressive increase in H2 produc-
evaluated the effect of HRT values from 1 to 8 h in tion with the increase in glucose concentration was
four mesophilic AFBRs (30 °C) at different concen- attributable to the restriction of effective metabolism
trations of glucose (2–25 g l-1). The authors observed for H2 production by substrate in low concentrations.
a maximum HPR of 1.46 l H2 h-1 l-1 with 10 g l-1 of However, the reduction of HY above the optimum
glucose. In the reactor fed with the concentration of concentration was due to the limited use of glucose
25 g l-1, the HPR obtained a maximum value of during both transport and metabolism.
0.71 l H2 h-1 l-1 at the HRT of 2 h, decreasing to In this study, the reduction of HRT favored both HY and
0.61 l H2 h-1 l-1 at the HRT of 1 h. HPR in reactors R15 and R25 via the increase of the OLR.
Another important parameter, HY relates the pro- With a decrease in the HRT from 8 to 4 h, the OLR of the
duction of H2 per unit time to the organic load applied R15 reactor increased from 67.5 to 135 kg COD m-3
to the reactor, allowing for the observation of the days-1, producing the maximum values of HPR
inhibitive effects of substrate overload. In the R15 and (0.228 ± 0.024 l H2 h-1 l-1) and HY (0.856 ±
R25 reactors, the reduction of HRT from 8 to 4 h 0.106 mmol H2 g COD-1). In the same way, the R25
favored HY, which reached maximum values of reactor achieved maximum values of HPR (0.312 ±
0.856 ± 0.106 (R15) and 0.638 ± 0.023 mmol H2 g 0.032 l H2 h-1 l-1) and HY (0.638 ± 0.023 mmol H2 g
COD-1 (R25) (Fig. 4). Similarly, Kirankumar et al. COD-1) at the HRT of 4 h, equivalent to an OLR of 210 kg
(2016) evaluated the effect of HRT on the continuous COD m-3 days-1, and achieved an HPR of 0.302 ±
production of H2 from dairy wastewater in a 0.033 l H2 h-1 l-1 at an OLR of 1680 kg COD m-3 days-1
mesophilic UASB reactor and obtained a maximum (HRT = 0.5 h). The increase of the OLR guaranteed the
HY of 5.0 mmol H2 g COD-1 by reducing HRT from greater availability of substrate, accelerating bacterial
36 to 6 h. metabolism. Similarly, Kargi et al. (2012) observed that
The strategy used for reactor R15 obtained the the increase of the substrate concentration from 5.2 to
highest HY value of 0.856 ± 0.106 mmol H2 g 20 g l-1 allowed for increases in HY and HPR because low
COD-1. Similarly, in studying the kinetics of H2 concentrations limited the availability of the substrate.
production from CW, Davila-Vazquez et al. (2008) However, when OLR values were greater than 135 kg
observed the maximum HY value of 3.1 mol H2 mol COD m-3 days-1 in R15 and 210 kg COD m-3 days-1 in
lactose-1 in the concentration of 15 g l-1. R25 in this study, in HY values decreased.

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Table 1 shows the OLR values used in and the HY alcohols, is necessary because of the functions of these
and HPR results obtained from this and past studies. metabolites as regulators of possible routes for the
The findings here are in agreement with those in the metabolism of the microbial community, including the
literature, including that the decrease of the HY is H2 producers and consumers and the competitors for
associated with the increase of the OLR. In evaluating substrate. In addition, some of these metabolites may
mesophilic H2 production from CW in a CSTR, play a toxic or inhibitory role for populations of H2-
Venetsaneas et al. (2009) observed maximum HY producing microorganisms.
(1.56 mol H2 mol lactose-1) and HPR (0.12 l H2 h-1 Lactic, butyric and acetic acids were identified in
l-1) values at the HRT of 24 h, equivalent to the OLR higher contents in R15 (Fig. 5). Other metabolites
of 30 kg COD m-3 days-1 (30 g COD l-1). Further- observed were propionic, formic, and succinic acids.
more, using a fixed-bed mesophilic reactor at an HRT The decrease in HRT from 8 to 0.5 h suppressed
of 24 h, Perna et al. (2013) obtained a maximum HY lactate production, decreasing the molar fraction from
of 1.1 mol H2 mol lactose-1 by raising the OLR to 73.6% at an HRT of 8 h to 1.8% at an HRT of 2 h. This
37 kg COD m-3 days-1 and increasing the substrate decrease in HRT was accompanied by the predomi-
concentration from 22 to 37 g COD l-1. Using a nance of acetate (10.4–43.1%), butyrate (1.5–46.3%),
sequential batch reactor (AnSBBR), Lima et al. (2016) and propionate (1.1–23.2%). The molar fractions of
attained increases in HPR (0.045 l H2 h-1 l-1) and in HFo and HSu remained constant between 2.1–12.7
HY (1.12 mol H2 mol lactose-1) by increasing the and 2.5–5.3%, respectively.
applied OLR from 14.6 to 18.5 kg COD m-3 days-1 In reactor R25, the main metabolites detected were
and the affluent concentration from 4.25 to 5.4 g COD lactate, butyrate and acetate. Other metabolites
l-1, equivalent to 4.8 g carbohydrate l-1. observed were propionate, formate and succinate.
It should be noted that an excessive increase in With a decrease in the HRT from 8 to 0.5 h, HLa
OLR might overload the reactor. Rosa et al. (2014) production was suppressed (74.3–1.8%) in favor of
found a decrease in HY from 1.33 to 0.44 mol H2 mol acetate (4.7–33.1%), butyrate (1.1–53.3%), and pro-
lactose-1 with an increase in the OLR from 30 kg to pionate (0.9–11.9%). The productions of formate and
120 kg COD m-3 days-1 (5 g COD l-1) via decreas- succinate remained constant between 1.9–8.4 and
ing the HRT from 4 to 1 h. According to the authors, 1.7–5.3%, respectively.
the increase in HY is related to the selection of OLR In the R15 and R25 reactors, higher concentrations
values within an appropriate range. The challenge in of lactate (up to 74.3%) were observed with the HRT
the selection of the OLR is associated with the values of 8 and 6 h, while HY and HPR were the
complexity of the microbial community and the lowest. Noike et al. (2002) observed that the lactic acid
dependence of the different metabolic levels on the pathway is substrate-competitive with H2 production.
applied environmental conditions. In this study, H2 When investigating the coexistence of H2-producing
production was not inhibited by the high OLR of bacteria (Clostridium acetobutylicum or Clostridium
1680 kg COD m-3 days-1 (HRT = 0.5 h) in reactor butylicum) and lactic acid bacteria (Lactobacillus
R25 with an HPR of 0.302 ± 0.033 l H2 h-1 l-1. paracasei and Enterococcus durans) using tofu-pro-
The quantification of the liquid metabolites pro- cessing wastewater, the authors also found that H2
duced in the reactor, such as volatile organic acids and production was inhibited by lactic acid bacteria.

Table 1 Optimum values of HY, HPR, HRT, and OLR observed in studies using CW
Reference Reactor HRT (h) OLR (kg COD m-3 days-1) HPR (l H2 h-1 l-1) HY (mol H2 mol lactose-1)

Venetsaneas et al. (2009) CSTR 24 30 0.12 1.56


Perna et al. (2013) APBR 24 37 0.042 1.1
Rosa et al. (2014) AFBR 4 30 0.023 1.33
Lima et al. (2016) AnSBBR 3 18.5 0.045 1.12
R15 EGSB 4 135 0.228 0.96 ± 0.07
R25 EGSB 4 210 0.312 0.96 ± 0.10

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Fig. 5 Distribution of the


main metabolites produced
as a function of HRT in
a R15 and b R25

The distribution of metabolites in all reactors (0.86 mmol H2 g COD-1) in R15 and maximum
indicates the greater production of acetate and butyrate HPR (0.312 l H2 h-1 l-1) in R25. Similarly, Perna
with the decrease in the HRT from 8 to 0.5 h. These et al. (2013) observed a maximum HY of 1.1 mol H2
are the major metabolites related to high HPR. The mol lactose-1 associated with high production of
production of H2 through the acetic and butyric routes butyrate (10,000 mg l-1) and a reduction in lactate
can result in maximum HY values of 8 and 4 mol H2 production (2000 mg l-1). Rosa et al. (2014) observed
mol lactose-1, respectively, as shown in Eqs. 1 and 2 increased production of acetate and butyrate with the
(Davila-Vazquez et al. 2008), as follows: decrease in HRT from 4 to 1 h.
The presence of acetate at 30.1 to 43.1% in the HRT
C12 H22 O11 þ 5H2 O ! 8H2 þ 4CO2 þ 4CH3 COOH
of 4 and 0.5 h, conditions with greater H2 production,
ð1Þ indicates that the increases in OLR from 67.5 to
135 kg COD m-3 days-1 (R15) and 105 to 210 kg
C12 H22 O11 þ H2 O ! 4H2 þ 4CO2
COD m-3 days-1 (R25) have directed H2 production
þ 2CH3 CH2 CH2 COOH ð2Þ
via the acetic route. A similar profile of acetate and H2
At the HRT of 4 h, reactors R15 and R25 produced production was observed by Guo et al. (2008). In their
high concentrations of acetate (37.3%) and butyrate study, with an increase in the OLR to 120 kg COD
(46.3%) and also resulted in the maximum HY m-3 days-1 via a decrease in the HRT from 6 to 2 h,

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the acetate and ethanol concentrations reached their Acknowledgements This work was supported by the CNPq
maximum values, representing 89% of the metabolites (National Council for Scientific and Technological Development),
CAPES (Coordination for the Improvement of Higher Education
produced. In this condition, the maximum HPR value Personnel), and FAPESP (São Paulo Research Foundation).
of 0.71 l H2 h-1 l-1 was observed.
High production of HPr (18.1–23.2%) in reactor
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