SIMULATION OF A CONTINUOUS STIRRED TANK ANAEROBIC BIOREACTOR

FOR INDUSTRIAL WASTE WATER TREATMENT

BY

KIRUMIRA MARK WILSON

15/U/5185/CHD/PD.

A RESEARCH PROPOSAL SUBMITTED TO THE DEPARTMENT OF CHEMISTRY

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF A
BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING AT KYAMBOGO
UNIVERSITY.

DECEMBER 2018
 ABSTRACT
Industrial wastewater with very high Total Organic Carbon (TOC) is a potential substrate for
anaerobic treatment. Continuous Flow Stirred Tank Reactor (CSTR) is the common model of
reactor used to treat various kind of wastewater and in the process, bio hydrogen can be
produced.

The main focus of this research is to simulate and design a continuous stirred tank bioreactor for
treatment of industrial waste water having a minimum total Chemical Oxygen Demand (COD) of
50 kgCOD/m3. Influent COD total is assumed to be pre-treated to remove particulate COD, thus
COD inlet has nearly 100 % soluble COD. An investigation on bio hydrogen production was
conducted in the granular sludge-based continuous stirred tank reactor (CSTR). Hydrogen and
methane generated by microbial conversion of organic wastes /residues have potential to replace
fossil fuels as environmentally friendly as well as sustainable and renewable energy carriers.
 CHAPTER ONE

INTRODUCTION

1.0 Overview

This chapter comprises a general introduction to the study. It gives the background, problem
statement, objectives, and the justification of the study.

1.1 Background

The world energy consumption is increasing significantly in each year. According to the data
from US Energy Information Administration’s recently released, it will grow by 48 % between
2012 and 2040 (Figure 1-1). The concerns of sustainable energy sources and the effect of fossil
fuel emissions push the countries around the world to find alternative energy source. Renewable
energy and nuclear power are the world’s fastest-growing energy sources over the projection
periods. The consumption of the renewable energy is predicted to be increased by 2.6% per year
through 2040 (Doman, L. 2017). One of the energy source categorized as renewable energy is
biogas.

Figure 1-1 Predicted world energy consumption by source, U.S. EIA

Biogas is a combustible gas, produced from organic material degradation, where the microbial
activity takes place in the process in anaerobic environment and under particular temperature.
Biogas consists of around 60% methane gas and 40% carbon dioxide, and small constituent gas
in small number. The biogas is produced from fermentation process where organic matter is
degraded into smaller particles and produces methane gas as part of the chain reaction.
Anaerobic degradation occurs in conditions where no oxygen present in any form, including
NOx. Anaerobic degradation typically occurs in the stomach of animals, sediments, municipal
landfills, wastewater line, etc. This process can be utilized for human benefits by controlling the
process in wastewater treatment and other facilities.
Industrial wastewater with a high total organic carbon (TOC) content has the potential as a
substrate for biogas production. Typical TOC content of the feed for biogas production ranges
between 10.000-20.000 mg TOC/kg. One of the examples of industrial wastewater, which has
bio-potential as biogas substrate, is waste water from sugar industrial plants and distilleries.
Anaerobic bioreactors can be used to produce biogas from this waste water. A bioreactor refers
to a system or an engineered device that supports a biologically active environment. The process
can be carried out aerobically or anaerobically. These bioreactors are commonly cylindrical
ranging in size from liters to cubic meters and often made of stainless steel.

On basis of mode of operation, a bioreactor may be classified as batch, fed batch or continuous
(a continuous stirred tank reactor model). An example of a continuous bioreactor is a chemostat.
A chemostat is a bioreactor to which fresh medium is continuously added while culture liquid
containing left over nutrients, metabolic end products and microorganisms are continuously
removed at the same rate to keep culture volume constant.(Novick, A et al, 1950). By changing
the rate with which medium is added to the bioreactor the specific growth rate of the
microorganism can be easily controlled within limits.

1.2 Problem Statement

One of the major pollutants in water is the industrial waste water. There are many contaminants
in the waste water and irrespective of their nature, they are all dangerous to the environment.
Industrial wastewater treatment is needed to control the water quality of the wastewaters. The
removal of contaminants from wastewater is the important method in order to obtain the clean
and safe water for human activities.
Today there are quite a number of various conventional methods of water treatment but
unfortunately establishing them is costly and their operation is costly.
However industrial waste water containing a high total carbon can be treated anaerobically in a
bioreactor, producing biogas in the process, which could be used as a source of energy to support
some units.
In my research, I intend to study, simulate and design a continuous stirred tank bioreactor, which
can be installed on a production line where anaerobic fermentation of the high COD waste water
can take place thus producing the biogas.

1.3 Research Objectives

1.3.1 General Objective

To develop an anaerobic continuous stirred tank bioreactor for industrial waste water treatment.

1.3.2 Specific Objectives

1. To collect data on the operating conditions and parameters for the anaerobic continuous
stirred tank bioreactor.
 2. To simulate an anaerobic continuous stirred tank bioreactor using CHEMCAD software.

3. To determine and optimize the performance of an anaerobic continuous stirred tank

bioreactor(CSTR).

1.4 Significance

The research is expected to generate more information to the already existing pool of knowledge
about recovery of energy resources from industrial waste water. The research results can be used
to evaluate and assess the available process treatment processes and how they can be
incorporated in those processes so as biogas can be collected as well.

1.5 Justification

This is research is about developing an equipment that can be installed in the waste water
treatment line so as to produce biogas from high total carbon waste water. The biogas trapped
and produced can be used to produce energy that can be utilized by some units on the plant thus
providing an alternative energy source. The anaerobic treatment can significantly reduce
contaminants in environmental organic pollutants.
 CHAPTER TWO

LITERATURE REVIEW

2.0 Introduction

This section describes the basic concept of the anaerobic process including the stoichiometry for
measuring biogas potential, type of conventional digester, parameters affecting the gas
production, biological treatment, and pre-treatment for biogas production.

Waste Water

Wastewater is defined as any water that has been adversely affected in quality by human
activities influence. Wastewater is liquid waste discharged by domestic residences, commercial
properties, industry, agriculture, which often contains some contaminants that result from the
mixing of wastewater from different sources.
Wastewaters are usually classified as industrial wastewater or domestic wastewater. Those
contaminants in wastewater are suspended solid, biodegradable organics, pathogens, heavy
metals and etc. (Peavy et al, 1985). Wastewater contaminants will give the impacts on the
environmental, human health and living activities. Environmental problem such pollution, will
damage the aquatic living activities.

Biogas

Biogas is produced from the anaerobic digestion by a consortium of bacteria, including

methanogenic bacteria. Methanogenic bacteria play a crucial role in the final stage in the process
of anaerobic digestion. Under symbiotic effects of various anaerobic bacteria, molecular organic
matters are decomposed into methane and carbon dioxide. (Naik, S.N., et al.,2010). Methane
produced from bio-digestion can be used as an energy source and converted into another form of
energy, such as heat, electricity, or it can also be used directly for cooking because of its
inflammability.

Historically, biogas was discovered by Alessandro Volta, who started collecting the gas
produced from the sludge. He found that the formation of gas shows the process of fermentation
and gas produced in contact with air will explode. At that time, the structure of methane was still
unknown until Avogadro in 1821 successfully identified methane structure. The biogas
generation in anaerobic conditions was firstly stated by Popoff in 1875. In 1876, Herter reported
that based on the stoichiometry, methane and carbon dioxide can be formed from acetate found
in the wastewater sewage (Zehnder, A.J., et al., 1979). After that, Louis Pasteur in 1984 was
trying to produce biogas from manure collected from the streets in Paris. Together with his
student Gavon, he planned to produce 100L of methane from 1m3 dirt under fermentation at a
temperature of 35°C. Pasteur claimed that the rate of biogas production could be sufficient to
illuminate streets of Paris (Kossmann W, P.U., et al., 1997). From here on the application of
renewable energy begins. Until now, the technology of biogas utilization is still in developing
state and currently used as an alternative energy source around the world. Biogas technology is
feasible to implement around the world. However, the cost of biogas production is increasing
inversely proportional to the sinking temperature (Kossmann W, P.U., et al., 1997).

Biogas contains 60-70% methane and 30-40% carbon dioxide. It also contains other gases such
as hydrogen, hydrogen sulfide (H2S) and a variety of gases with low percentages around 1-5%.
The primary objective of biogas production is to utilize the higher content of methane gas
conversion from the substrates. Some methods are used to increase the effectiveness of the gas
production such as pre-treatment of the wastewater sludge before entering the digester.

2.1 Anaerobic digestion and necessary process parameters

2.1.1 Anaerobic digestion

The biological gasification process is referred to anaerobic digestive. This process can be carried
out in an anaerobic bioreactor. The process represents the microbial conversion of organic matter
into methane and other gases in the absence of oxygen (Claudius da Costa Gomez, C.G., et
al.,2005). The process can take place at temperatures ranging from 10°C to more than 100oC.
Anaerobic digestion can ferment bio-degradable material in the absence of oxygen to produce
methane and carbon dioxide.
Three stages are included in the anaerobic degradation pathway (Deublin, D.S., A, 2011):

1 Hydrolysis: Stage in which the polymer chains are broken down into simple monomers.
2. Acetogenesis: Volatile fatty acids converted into the acetic acid form, carbon dioxide, and
oxygen.
3. Methanogenesis: Acetate is converted into methane and carbon dioxide, while hydrogen
consumed.

In the absence of inorganic electron acceptors other than H2 and CO2, the stages are; Hydrolysis,
fermentation, β-oxidation, acetogenesis, acetate oxidation, methanogenesis. There are two
pathways to produce methane from methanogenesis stage; organic waste can be broken down
into hydrogen and carbon dioxide or converted to a simpler methyl compounds.

Hydrolysis
At hydrolysis stage, the organic material is converted to soluble compounds, then it is to be
hydrolyzed into monomers. The monomers produced by hydrolysis reaction undergo
fermentation process (Tchobanoglous, G., et al., 2003). Water and other molecules are
transformed into the functional groups that will provide two end products, one of which will
contain hydrogen as cation and the other will contain hydroxyl as an anion. The process of
hydrolysis is a reaction that is used to break polymers into simpler molecules. Insoluble organic
polymers, such as carbohydrates, cellulose, proteins, and fatties, are broken down by hydrolytic
bacteria. For example, the fat is broken down into fatty acids; proteins are converted into amino
acids; polysaccharides are converted into monosaccharides and nucleic acids form purine and
pyrimidine (Puchajda, B., et al.,2006). Hydrolysis of particulates are modelled as a first order
reaction with respect to hydrolysable compounds. Refer to equation below;
𝑟ℎ𝑦𝑑𝑟 = 𝑘ℎ ∗ 𝑥𝑠
𝑘ℎ = 0.3 − 0.7𝑑−1
The fermentation process is rapid and the growth rate of the microorganisms follow Monod
equation model. The microorganisms convert monomers into SCFA (short chain fatty acids),
alcohols and hydrogen. The reactions are presented below.

𝐴𝑐𝑒𝑡𝑖𝑐 𝑎𝑐𝑖𝑑:
𝐶6𝐻12𝑂6+2𝐻2𝑂→2𝐶𝐻3𝐶𝑂𝑂𝐻+2𝐶𝑂2+4𝐻2

𝑃𝑟𝑜𝑝𝑖𝑜𝑛𝑖𝑐𝑎𝑐𝑖𝑑:
𝐶6𝐻12𝑂6+2𝐻2 →2𝐶𝐻3𝐶𝐻2𝐶𝑂𝑂𝐻+2𝐻2𝑂

𝐵𝑢𝑡𝑖𝑟𝑖𝑐𝑎𝑐𝑖𝑑:
𝐶𝐶6𝐻12𝑂6→𝐶𝐻3𝐶𝐻2𝐶𝐻2𝐶𝑂𝑂𝐻+2𝐶𝑂2+2𝐻2

Acetogenesis
At this stage amino acids, sugars, and fatty acids degrade into intermediated products, such as
lactate, succinate, butanol and ethanol by fermentative bacteria called acetogenic bacteria
(Puchajda, B., et al.,2006). Anaerobic conversion of fatty acids and alcohols is running to form
acetic acid by consuming hydrogen and carbon dioxide. The formed of acetic acid is to be used
to produce methane at a later stage. The growth rate of acetogenic organisms is slightly higher
than methanogenic organisms but still lower than fermentation. The μmax (maximum specific
growth rate) of the microorganisms are ~ 0.5 – 0.8 d-1.

The reactions in acetogenesis step presented below;

𝑃𝑟𝑜𝑝𝑖𝑜𝑛𝑖𝑐𝑎𝑐𝑖𝑑:
𝐶𝐻3𝐶𝐻2𝐶𝑂𝑂𝐻+2𝐻2𝑂→2𝐶𝐻3𝐶𝑂𝑂𝐻+𝐶𝑂2+3𝐻2

𝑃𝑟𝑜𝑝𝑖𝑜𝑛𝑖𝑐𝑎𝑐𝑖𝑑:
𝐶2𝐻5𝑂𝐻+𝐻2𝑂 →2𝐶𝐻3𝐶𝑂𝑂𝐻+2𝐻2

𝐵𝑢𝑡𝑖𝑟𝑖𝑐𝑎𝑐𝑖𝑑:
𝐶𝐻3𝐶𝐻2𝐶𝐻2𝐶𝑂𝑂𝐻→2𝐶𝐻3𝐶𝑂𝑂𝐻+2𝐻2

Methanogenesis

In the final stage, which called methanogenesis, acetate is converted to methane and carbon
dioxide. Hydrogen is used as the electron donor and carbon dioxide as an electron acceptor to
produce methane (Ferry, J.G., 2003). There are two groups of microorganisms responsible in this
step: Organisms that use acetic acid as substrate and the organisms that utilize hydrogen and
carbon dioxide to generate methane. The reactions involved in this step shown below.
2𝐶𝐻3𝐶𝑂𝑂𝐻 →𝐶𝑂2+4𝐻2
𝐶𝑂2+4𝐻2→𝐶𝐻4+2𝐻2𝑂
The growth rate of methanogenic organisms is low, μm are recorded at range ~ 0.3 – 0.5 d-1.
When the wastewater’s COD of influent contain almost soluble COD, hydrolysis became less
significant and methanogenesis becomes the rate limiting reaction (Vavilin, V.A., et al., 1996).
Methanogenic bacteria are naturally found in swamp water and intestine of ruminant animals,
where anaerobic conditions present. These microorganisms are very sensitive to the environment
that is why the bio-reactor should operate at the right temperature, pH and other process
parameters.

2.1.2 Process Parameters

Crucial parameters of the biological processes need to be monitored to preserve the bacteria in
good condition. Consequently, the information about these parameters is required in the design
of the bioreactor. The influence of these parameters is presented below.

Temperature
There are two types of Methanogenic bacteria, which are classified by its optimal temperature:
mesophilic bacteria and thermophilic bacteria. Mesophilic bacteria are active at temperatures
around 32-42 °C or ambient temperature at 20-45 °C. The thermophilic bacteria, on the other
hand, is active at temperatures around 48-55 °C and at high temperatures up to 70 °C.

Methanogenic bacteria that used in biogas industry is mesophilic bacteria, and only a few
systems are using thermophilic bacteria. Methanogenic bacteria are sensitive to temperature
changes. However, thermophilic are more susceptible to temperature changes than mesophilic
bacteria. The effect of changing temperature decreases activity of bacteria. The bacterial activity
is maintained with little change in temperature (stable temperature) over a range of ± 20 °C
(Deublin, D.S.,2011).

pH
The methanogenic microorganisms can live in conditions with neutral pH (~ pH 7) or slightly
alkaline conditions. The optimal pH to form methane is 6.7-8.2. However, the species of bacteria
like methanosarcina. sp are able to survive at pH <6.5. Acidity in the digester needs to be
monitored to ensure that bacteria is always in optimum conditions. The concentration of volatile
fatty acids is an important parameter to control whether the process went well or not. (Deublin,
D.S.,2011).

Type of Substrate
The substrate is food for bacteria. Substrate is composed of large molecules that can be broken
down into smaller molecules by bacteria. The specific kind of substrate is necessary for
determining the rate of anaerobic digestion. For example, the time for hydrolysis and
acidification from sugar is shorter than from cellulose. (Deublin, D.S.,2011).

Nutrients Ratio (C / N)
Microorganisms need carbon and nitrogen in the process of assimilation (Deublin, D.S.,2011).
Deublin stated that proper conditions are the ratio of C: N: P: S is 500-1000: 15-20: 5: 3
respectively, and the ratio of COD: N: P is 800: 5: 1. Nutrients ratio is imperative because if the
C/N ratio is too small, it will increase the production of ammonia and will inhibit the production
of methane. And if the C/N ratio is too high, the nitrogen deficiency can affect the possibility of
the formation of energy derived from protein.

Loading Rate

Level of substrate loading or loading rate plays a significant role in determining the amount of
substrate that will be fed into digester every day. If there is a shortage of substrate, the resulting
production is not maximum but if there is excess of substrate volume, an effect of accumulating
of fatty acids will inhibit the production of methane. Therefore, the exact loading rate is vital for
this process. (Deublin, D.S.,2011).

Retention Time
Retention time is the time substrate is kept in the reactor under digestion process. In the
continuous system, retention time is determined by dividing the volume of the digester with a
given amount of substrate daily (organic loading rate).

The batch system retention time is the time during the experiment because there is no movement
of the batch system turnover reactants, so worth staying. For example, for 10 L of digesters with
500 mL of Organic Loading Rate (OLR), Hydraulic Retention Time (HRT) is 20 days. Thus the
substrates will be kept in the reactor during 20 days. (Deublin, D.S.,2011).

Recycled Solids and Wasted Solids

By definition, the recycled solids are the sludge that carried out to the effluent of the digester and
then recycled back into the inlet stream of the digester. Wasted solids are solids that removed
from the reactor due to the limitation of the reactor design and size. (Deublin, D.S.,2011).
The flow rate of recovery sludge (Qr) and wasted solids (Qw) can be determined using the
following equations;

𝑄𝑟= 𝑄𝑖𝑛∙(1−𝐻𝑅𝑇𝑆𝑅𝑇)/ (𝑋𝑢𝑋𝑇𝑆𝑆)

𝑄𝑤= 𝑀_𝑥𝑇𝑆𝑆/𝑆𝑅𝑇∙𝑋𝑇𝑆𝑆

Chemical Oxygen Demand (COD)

Fraction of COD in Wastewater

The first major sub-parts of total influent COD are non-biodegradable COD (Sui) and
biodegradable COD (Sbi) fractions. Biodegradable is divided into soluble readily biodegradable
COD (Sbsi) and particulate slowly biodegradable COD (Sbpi). Non-biodegradable COD consists
of two part; soluble non-biodegradable COD (Susi) and particulate non- biodegradable COD
(Supi).
Susi is the part of the COD that will not get treated in the biodegradation process and will be
discharged with the effluent. The Supi is retained in the sludge system. The biodegradable COD
fraction is the part of COD that will be degraded by microorganisms and broken down into
simple molecules. (Ferry, J.G.,2003).

COD Correlation with Methane Production

Chemical oxygen demand (COD) directly measures the electrons available in the substrate of
organic matter, and is mostly expressed in form of the amount oxygen needed for the substance
to be completely oxidized (Ferry, J.G.,2003).
The number of electrons donated by oxidant is expressed as oxygen equivalent in g O2/m3 (see
equations below).
1 1
𝐻2𝑂→𝐻++ 4𝑂2+ 𝑒−
2

1
𝑚𝑜𝑙𝑒𝑂2. 32 𝑔𝑚𝑜𝑙𝑒=8 𝑔 𝑂
4

1 eeq = 8 g COD

The theoretical COD of molecule CnHaOb can be calculated by the chemical oxidation reaction,
assuming a complete oxidation that illustrated in Equation below:
1 𝑎
𝐶𝑛𝐻𝑎𝑂𝑏+4(4𝑛+𝑎−2𝑏) 𝑂2→𝑛𝐶𝑂2+2𝐻2𝑂

1
1 mole of organic matter requires4(4𝑛+𝑎−2𝑏) 𝑂2mole of O2 or 8(4𝑛+1−2𝑏) 𝑔𝑂2. For organic
matter containing nitrogen (N), the equation is expressed as:
1 𝑎−3
𝐶𝑛𝐻𝑎𝑂𝑏𝑁𝑑+2(2𝑛+0.5𝑎−1.5𝑑−𝑏) 𝑂2→𝑛𝐶𝑂2+𝑑𝑁𝐻3+ 𝑑𝐻2𝑂
2

The theoretical COD can be calculated by the oxidation stoichiometry of glucose as

𝐶6𝐻12𝑂6+6𝑂2→6𝐶𝑂2+6𝐻2𝑂

C6H12O6=180 g 6O2=192 g
1-gram glucose represents 1.067 g COD (192 g/180 g).
𝐶𝑂𝐷𝐶𝐻4=4𝑔𝐶𝑂𝐷/𝑔𝐶𝐻4 (Ferry, J.G.,2003).

2.2 Biogas Digester Design

This section explains the anaerobic biogas digester types based on its configuration and setting of
the reactor. Merits and demerits of the anaerobic continuous stirred tank digester are explained in
details.
CSTR is a tank in which the liquid inside is mixed with an agitation system. The standard type of
CSTR digester used in German is presented in figure below. It is constructed with concrete with
the size between 500 and 1,500 m3. The height is around 5-6 m, and diameter varies between 10-
20 m.

Fig 2-1 Standard CSTR digester with internal blade agitator and heat blanket

The heating system in the tank delivers hot water into tubes fixed along the wall-like blanket
surrounding the tank. The mixer can be one unity with the tank or equipped with a motor and
located outside of the tank. The agitation system can be divided into three categories: gas
injection system, mechanical stirring system and mechanical pumping system. Using a
combination of agitation system increase efficiency of mixing inside the digester compared to
single agitation system. (van Groenestijn et al., 2002; Hawkes et al., 2007)

The suspended continuously stirred tank reactor (CSTR)

Continuous reactors are considered to be practical and economical for industrial biogas
production, particularly via mixed culture fermentation (van Groenestijn et al., 2002; Hawkes et
al., 2007). The two main bio-reactor configurations: suspended and attached, or immobilized,
growth types have been applied to optimize mixed culture fermentation process for biogas
production through advancements in active biomass concentration and substrate conversion
efficiency (Gavala et al., 2006; Wu et al., 2008).

Most studies on biogas production from carbohydrate rich substrates have been conducted in
suspended CSTRs, which are simple to construct, easy to regulate both acidity and temperature,
and give complete homogeneous mixing for direct contact
between the substrate and active biomass (Li and Fang, 2007; Hawkes et al., 2007; Hallenbeck
and Ghosh, 2009).

Furthermore, the CSTR is very suitable for substrates with a high suspended solid (SS) content,
typically with a volatile solid (VS) content greater than 2% (Liu et al., 2008). However, in this
reactor category, HRTs must be greater than the specific growth rate of the micro-organisms in
order to control the proper concentration of microbial biomass, but faster dilution rates risk
active biomass washout (Hawkes et al., 2007; Hallenbeck and Ghosh, 2009), leading to process
failure. In addition, cell density retained in CSTRs is limited, since the activebiomass has the
same retention time as HRT, resulting in process instability caused by the fluctuation of
environmental parameters, including acidity or HRT and then having the consequence of limiting
substrate degradation and biogas production

Pre-Treatment of Methane Production

Pre-treatment of biogas is known to increase the efficiency of biogas production. It can be

classified into three categories; thermal treatment, mechanical treatment and thermochemical
treatment. However, overall the methods presented until now have their drawback and does not
have breakthrough. Mechanical pre-treatment often appears to require high capital cost and
consume high energy in the process, while the thermal treatment requires high temperature to get
significant improvement.

Microbial communities
A consortium of hydrogenotrophic methanogens of Methanothermobacter defluvii and
Methanothermobacter thermautotrophicuscan be used in the generation of biogas. These work
best at reactor temperatures of 55oC. (O-Thong et al., 2007; van Niel et al., 2002; van Niel et al.,
2003).

Nutrients and buffers

Carbohydrate based substrates are used as they provide good carbon and energy sources for
biogas producing bacteria. The fermentation process needs buffering of the growth medium, and
to be supplemented with nutrients to enhance the growth of microorganisms and resist the pH
change caused by organic acids produced (O-Thong et al., 2007; van Niel et al., 2002; van Niel
et al., 2003). Nutrients used for the digestion include mainly macro-nutrients (Nitrogen,
Phosphorus, Potassium, Magnesium, and Calcium etc.), growth factor vitamins and micro-
nutrients of trace metals (e.g. Iron, Chromium and Copper etc.).All nutrients and buffers are
generally mixed as basic anaerobic (BA) medium (Angelidaki and Sanders, 2004).

Energy Utilization from Wastewater

Biogas production from a different source type was calculated under ideal condition. The data
were obtained from biogas world website (https://www.biogasworld.com/biogas-calculations).
The table below shows the estimated biogas production, electricity, and heat generated from a
different type of wastewater.
Waste type Total solids Volatile Biogas Electricity Heat
solids production generated generated
% % m3/d kWh GJ/year
WWTP 5 80 360 262,800.00 1,131.00
Sludge
municipal 13 90 1680 1,208,880.0 5,200.00
(wet) 0
Fats, oils, 36 84 9048 6,508,680.0 28,101.00
and grease 0
(FOG)
Cow slurry 8 80 504 359,160.00 1,551.00
(dairy)

Biogas production from different type of wastewater

Note: WWTP: wastewater treatment plant

Feed: 10000 tons/year
Digester type: wet
Biogas usage: CHP (Combined heat and power)

2.3 Focus of the research

Many biogas installations have been successfully implemented, whether using solid bio-waste or
wastewater. Biogas installations can have a wide variation in term of design, depending on
substrate and the requirement for optimal conditions. This study is aimed to simulate and specify
optimal design parameters for an anaerobic continuous stirred tank reactor which can be used to
generate biogas from distillery waste water.
 CHAPTER THREE

MATERIALS AND METHODS

3.1 Introduction

This section deals with the practical part of the study. It entails the methods, techniques,
procedures and equipment to be used to achieve the research objectives. It includes the study
area, research instruments and the study design.

3.2 Study Area

Any designing process begins with collection of operational data. To design the anaerobic
continuous stirred tank bioreactor, waste water with a high COD is required. Subjectively, waste
water from a distillery plant is proposed because of its high carbon content. Data will be
obtained from Kakira Sugar Works (Distillery Section).
The operational data(parameters) are to be obtained from the waste water treatment plant of the
distillery and will be used in the simulation of the anaerobic continuous stirred tank reactor. This
data includes;

Flow rates.
This refers to the rate at which the waste water flows from the production sections to and through
the different units of the waste water treatment plant. These will be read directly from the
different flow meters.

pH
The pH of the influent to the waste water treatment plant will also be measured. A sample will be
obtained and analyzed for the pH using a pH meter (Mettler Toledo 320 model).

Temperature
The temperature of the influent will be measured because temperature is a very important factor
affecting biological reactions. It is measured as degrees on a standard scale such as Fahrenheit or
Celsius. The temperature value will be read off while measuring the Total dissolved solids.

Turbidity
This is the cloudiness of a liquid and gives an image of the suspended solids in a stream.
Turbidity levels will be measured in Nephelometric units(NTUs) using the HACH 2100A
turbidity meter.

Chemical oxygen demand(COD)

Chemical oxygen demand is the amount of oxygen required to completely oxidize the organic
matter in the waste water by using a strong oxidant and to convert it to carbon dioxide and water.
The COD of the influent will be obtained.
Biochemical oxygen demand(BOD)
This refers to the amount of dissolved oxygen needed by aerobic biological organisms to break
down the organic material present in a given water sample. This information regarding the BOD
of the waste water will be obtained from the industry.

Total dissolved solids(TDS)

The total dissolved solids in the waste water will be measured from the plant.

3.2 Research instruments

Below are the measurement tools that will be used to obtain the data; pH meter, TDS meter,
turbidity test kit, COD and BOD test kits. These will be used to test the chemical and physical
properties of the waste water.

CHEMCAD simulation package

This software will be used to simulate the anaerobic continuous stirred tank bioreactor. The data
obtained from the industry will be used, and manipulated using the software to come with the
optimum conditions. This is a computer simulation programme used mostly chemical engineers
to design, develop and simulate processes.

The following data will also be specified: Retention time, Agitator RPM, volume of the reactor,
material of construction and the thickness of the bioreactor. For the microbial population growth,
the bioreactor was fed continuously with the industrial wastewater, as the sole carbon source.
A master flex peristaltic pump polytetrafluoroethylene (PTFE) tubing was used to pump slurry
phase to the reactor (inoculum).

3.3 Study design

A culture bioreactor equipped with temperature and pH controllers was used as shown in fig. 3.1
below. It will be designed to have a working volume of 6 L with an internal diameter of 160mm
and a height of 345 mm.
A level sensor and effluent peristaltic pump are to be used to control the culture volume at a
constant level. The reactor design temperature and pH are 37◦C and 5.5 ± 0.05 respectively. The
reactor culture is to be mixed continuously at 160 rpm using two disc impellers, each having 6
flat blades (∅ = 64mm), which are located at a height of 20mm above the reactor bottom. A
three-phase separator is to be installed inside the CSTR to promote retention of granular sludge.
Fig 3.1: Schematics of anaerobic continuous stirred tank reactor system.
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