AVOIDING INDIGESTION: START-UP OF ANAEROBIC DIGESTERS

Rina Kurian1; John Slade1; Matt Holliday2; Susan Liver2; Wendy Derjugin2
1. R.V. Anderson Associates Limited, 2001 Sheppard Ave. East, Suite 400,
Toronto, Ontario M2J 4Z8, CANADA

2. Halton Region, 1151 Bronte Road, Oakville,

Ontario L6M 3L1, CANADA

INTRODUCTION
Anaerobic digesters are sensitive to the variability in a number of
chemical and physical factors. A variation or fluctuation in factors such as
organic loading rates, influent characteristics, pH, temperature, alkalinity,
hydraulic and sludge retention time, to name a few, can lead to an upset
digester, particularly during the start-up stage.
The Water Environment Federation (WEF) and Environmental
Protection Agency (EPA) publish Manuals of Practice (MOP) and
guidelines to assist in proper startup procedures for anaerobic digesters.
The general outline and concepts included in the WEF and EPA
guidelines / recommendations related to start-up of anaerobic digesters
are discussed in this paper.
This paper also summarizes the two different startup procedures
adopted for:
1. Start-up of a digester treating industrial (rendering) sludges
2. Start-up of a secondary digester treating municipal sludges

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 1

Each of these digester start-up procedures were developed to address

the unique set of challenges associated with the operating and start-up
constraints, including the availability of suitable seed sludge.
MANUALS OF PRACTICE AND RECOMMENDATIONS FOR DIGESTER
START-UP:
The starting up of an anaerobic digester is a challenge considering the
number of physical and chemical variables that can affect the process.
The Water Pollution Control Federation (WPCF) and Environmental
Protection Agency (EPA) have published Manuals of Practice to assist in
relatively smoother start-ups by providing general guidelines on
methodology and parameters that need careful monitoring during and after
start-up.
The following list of digester start-up priority parameters has been
adapted from the WPCF MOP 11, WPCF MOP 16 and EPA 430 /9-76-001
documents.
1. Start-up with Seed Sludge:
The most common method for anaerobic digester start-up is by
using seed sludge from other working digester(s). This method
helps in reducing the start-up period by providing the necessary
bacterial culture.

The general start-up procedure when seed

sludge is available is:

Fill the digester with as much seed sludge as

possible.

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 2

Fill remaining space with raw wastewater, up to the

level required to provide digester cover seal or to the
overflow level.

Start mixing the digester contents and heating to

attain the operating temperature (typically 35C).

Start feeding the digester with raw sludge at a rate not

exceeding 20% of the design loading capacity for
volatile solids for the first 20 days. If possible, the
digester should be fed continuously rather than in bulk
volumes.

Monitor for pH, alkalinity and volatile acids, ensuring

that the volatile acids to alkalinity ratio remains below
0.5 and the alkalinity is not less than 1,500 mg/L.

After 20 days, gradually increase the feed rate to the

design loading rate over the next 10 20 days, all the
time monitoring for minor upsets in physical and
chemical balance that require corrective measures.

2. Start-up without Seed Sludge:

In the absence of seeded sludge, the start-up time period is
extended as acclimation of the bacterial culture in the raw sludge
will take longer. This procedure requires more close monitoring to
pre-empt potential upsets during the start-up period. The general
start-up procedure when seed sludge is not available is:

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 3

Fill the digester with raw wastewater, up to the level

required to provide digester cover seal or to the
overflow level.

Start mixing the digester contents and heating to

attain the operating temperature (typically 35C).

Start feeding the digester with raw sludge at a rate not

exceeding 10% of the design loading capacity for
volatile solids for the first 20 days. If possible, the
digester should be fed continuously rather than in bulk
volumes.

Monitor for pH, alkalinity and volatile acids, ensuring

that the volatile acids to alkalinity ratio remains below
0.5 and the alkalinity is not less than 1,500 mg/L.

After 20 days, gradually increase the feed rate to the

design loading rate over the next 30 40 days, all the
time monitoring for minor upsets in physical and
chemical balance that require corrective measures.

3. Analytical Parameters:
The most important analytical parameters include pH, alkalinity,
volatile acids, volatile solids and digester gas quality and quantity.
These parameters are briefly discussed below:

The pH level for start-up and operation of a digester

should remain between 6.6 and 7.2 to maintain the

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 4

necessary biological activity.

Any change in pH

outside of this range requires corrective action,

usually ceasing feeding until the pH returns to normal
or in extreme cases addition of chemicals to adjust
the pH.

An alkalinity in the range of 1,500 3,000 mg/L is

necessary to prevent digester souring. At the same
time, the volatile acid to alkalinity ratio must be
maintained less than 0.5. If there is too high volatile
acid content, feed to the digester should be stopped
or reduced to maintain the necessary balance. In
cases, where the alkalinity is below the necessary
range, chemical addition may be required to maintain
stable digestion.

Quality and quantity of biogas produced from a

digester is an important factor in determining the
stability of the digester. The quantity of gas should be
in the 0.75 -1.12 m3 /kg volatile solids destruction with
a quality of 25-35% methane content. Changes in
these

ranges

are

generally

an

indication

of

overfeeding.
4. Physical Parameters:

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 5

The most important physical parameters affecting digester start-up

and operation are the hydraulic and sludge retention time,
temperature and mixing. These parameters are briefly discussed
below:

The detention time of a digester is essentially a

function of the digester volume and hence the time
that bacteria will be retained in the digester to
complete the destruction of the volatile solids. The
decrease in detention time can be caused by
operating a digester at varying liquid levels. However,
the most common reason for decreased detention
time is due to overloading / overfeeding, which results
in

incomplete

digestion

generally

causing

the

accumulation of volatile acids and eventual souring of

the digester.

The temperature of the digester contents should be

maintained at the optimal value (mesophilic or
thermophilic temperature ranges depending on the
intended operation of the digester) and as steady as
possible during start-up and operation to prevent
upsets. In the case of start-up procedures, varying
temperature or too low a temperature will result in
longer start-up times.

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 6

Improper of incomplete mixing can result in pockets of

sludge souring due to uneven temperature, bacterial
culture etc. It can also lead to accumulation of solids
resulting in a dead space and effective reduction of
the digester volume.

5. Typical Problems and Solutions:

One of the typical problems related to digester start-up and
operation is foaming.
The possible reasons for foaming can be overfeeding, resulting in
lower detention time and washout of the acclimated or seed sludge,
and /or insufficient mixing. In the event of foaming during start-up,
generally scaling back on the feed and adhering to feed rate that
maintains the analytical parameters reduces or resolves the
foaming problem.
ANAEROBIC DIGESTER TREATING RENDERING WASTE:
The anaerobic digester referred to here is located in a small town in
southwestern Ontario and was constructed to treat waste from a rendering
facility. The digester provided with a top entry mechanical mixer has a
volume of 1,800 m3 and was designed to provide a hydraulic retention
time of 30 days.
Challenges:
The major challenge in starting a digester as a treatment process in
this case, was with regards to the extremely high oil and grease content in

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 7

the wastewater. It is a well-known fact that anaerobic digesters are

sensitive to oil & grease and the separation of oil & grease within the
digester can prevent the release of the generated biogas, eventually
leading to the digester failure. Therefore, the wastewater was only fed to
the digester after removal of over 95% of the oil & grease by means of a
dissolved air flotation unit (DAF).
In addition to this, the wastewater generated at the rendering facility
had a variable temperature, ranging from 35 80C, depending on the
process operation for the day. As a result, on days when the wastewater
temperature exceeded 60C, the oil & grease could not be separated
satisfactorily enough by the DAF, to feed the complete waste stream to
the digester.
Start-Up Methodology:
Due to the unique nature of the waste to be treated, acclimated sludge
was not available to seed the digester. The digester was, therefore, first
seeded with approximately 30-35 m3 (one truckload) of local municipal
digester seed sludge. The remainder volume of the digester was then
gradually filled with the wastewater over a 4-6 week period. During this
period the digester was also seeded with fresh cow manure for a week to
create a varied and viable bacteria consortium.
The digester was continuously mixed and allowed to sit without further
feed for 100 days, over which the pH, temperature, volatile acids,

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 8

alkalinity, gas generation and volatile solids destruction was monitored

regularly.
At the end of the 100 day incubation period it was deemed that the
volatile acid level was low enough that a small amount of feed could be
started. Approximately 20% of the wastewater was fed to the digester with
occasional scale backs when the volatile acid to alkalinity ratio exceeded
1.0.
After approximately three months of feeding at this rate, based on the
monitored parameters, it was deemed that the feed rate could be
increased. The feed rate was gradually increased to the full loading rate
with occasional scale backs when the oil & grease could not be
satisfactorily removed by the DAF unit and when high volatile acid to
alkalinity ratios were observed.
Analytical and Physical Parameters:
During the start-up of this digester which extended over approximately
12 months, the digester was closely monitored with immediate corrective
measures being implemented as required.
The digester was monitored at a frequency of 3 5 times a week for: pH,
temperature, volatile solids, volatile acids, alkalinity and biogas volume
generated. The digester gas quality was monitored on a bi-monthly basis,
to corroborate the volatile solids destruction rate.

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 9

ANAEROBIC DIGESTER TREATING MUNICIPAL SLUDGES:

The anaerobic digester treating municipal sludges referred to here is
located at the Georgetown WWTP, located in the Town of Halton Hills,
Ontario. The digester was constructed to operate as either a primary or a
secondary digester depending on the treatment plant capacity needs. As
the digester is intended to operate primarily as a secondary digester, it is
the intent to start-up the digester as a secondary digester.
As the municipal wastewater treatment plant which currently has two
anaerobic digesters in operation, is located within a residential
neighborhood, it is necessary to minimize the odours that may arise during
the start-up of the digester.
The new and third digester which has a volume of approximately 2,200
m3 is equipped with a floating cover for maximum biogas storage and
biogas system pressure maintenance, hydraulic mixing and complete
sludge heating capabilities.
Challenges:
The major challenge in the start-up of this digester is the need to
minimize odours, in the context that the digester is equipped with a
floating cover.
Start-up Methodology:
Due to the concern regarding odour, the digester will be filled with the
treatment plant effluent water up to a suitable level to attain a seal around

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 10

the floating digester cover before introducing sludge. The effluent water
will then be heated to 35C.
As this digester will be started as a secondary digester, raw sludge will
be fed to the primary digester currently in operation and the mixed
contents of the primary digester will overflow into this digester. The liquid
level in the secondary digester will be allowed to reach the normal
operating level and then the diluted sludge will be directed back to the
treatment plant until the sludge has reached quality suitable for removal.
SUMMARY:
The current manuals of practice for start-up of digesters provide useful
guidelines and recommendations that will help in a successful start-up.
Though these must be recognized as guidelines, and not prevent the
employment of additional checks when starting up digesters with unique
constraints or challenges.
As indicated by the experience in starting-up of the industrial digester,
diligent monitoring and immediate implementation of corrective measures
are can help in the start-up of even the most challenging of digesters.

WEAO 2012 Technical Conference, Ottawa, Ontario

Page 11