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Abstract
The main objective of this work is an anaerobic treatment of maize silage and a biogas production in
a full-scale reactor. Conditions of start-up and trial operation are described. The anaerobic reactor of
the biogas station is seeded with aerobically stabilized sludge from wastewater treatment plant of
brewery Hurbanovo. This material is not frequently used as an inoculating medium for anaerobic
reactors. Results of start-up process have shown suitability of used sludge for this purpose. Maize
silage is treated in the anaerobic mixed reactor under mesophilic conditions. The volume of
anaerobic reactor is 2450 m3; produced biogas is burnt in a cogeneration unit with electrical power
output 270 kW.
Key words: anaerobic treatment; biogas production; cogeneration unit; maize silage
INTRODUCTION
The cultivation of energy crops can be one of possible alternatives how to diversify agricultural
production and improve economy of an agricultural company. This paper deals with an anaerobic
treatment of maize silage in order to produce biogas. The biogas energy can be used to improve the
energy balance of agricultural company itself or it can be offered to further buyers within a
production of excess energy (e.g. as an electricity supply into the electric main). Maize, which in a
form of silage offers relatively interesting yields (up to 30 tons of total solids - TS per hectare), was
selected as an energy crop in this paper.
There is a little information about anaerobic treatment of the maize silage in literature. Generally it
can be said that studies, focused on anaerobic treatment of fresh or silage vegetal materials have not
shown significant differences in the biogas production. This is discussed, e.g. in the work of Zubr
(1986). Advantage of silage application results from its conservation qualities, i.e. from possibility
of its year-round use independently from the season. Insignificant differences in the biogas
production from fresh or silage material are also obvious from Table 1, which summarizes data
from the work of Gunaseelan (1997).
Frequently used material for the anaerobic treatment is silage from clover grass or alfalfa. One- or
two-stage treatment of silage from these materials is a subject matter of the works of Jarvis et al.,
(1995), Jarvis, (1996), Jarvis et al., (1997) and Nordberg, (1996). In the one-stage treatment process
in which the organic loading rate (ORL) achieved the values to 3 kg/m3.d (volatile suspended solids
- VSS), the biogas production was 0.47 m3/kg (VSS). However in the two-stage process the authors
introduce the values of ORL 5.9 kg/m3.d and the biogas production 0.41 m3/kg (VSS). The
abovementioned works also discuss issues such as process inhibition caused by ammonia and the
impact of trace elements on improvement of the process.
The anaerobic treatment of the maize silage is mentioned in the work of Zauner and Kntzel (1986).
In the batch laboratory models specific methane production of 0.270 0.289 m3/kg TS was
achieved. In the laboratory flow reactor the lower values of specific methane production were
obtained 0.181 to 0.184 m3/kg TS.
Stage
fresh
silage
0.360
0.381
Cauliflower leaves
fresh
silage
0.352
0.341
fresh
silage
0.382
0.343
Rape tops
fresh
silage
0.334
0.330
Mustard tops
fresh
silage
0.300
0.326
Rhubarb tops
fresh
silage
0.316
0.345
Energy cane
fresh
silage
0.245
0.265
fresh
silage
0.309
0.301
Commencement of
the operation
6x128
1995
cow manure
50
1998
22
2001
PD Kapuany
120
2005
maize
272
2005
Biogas plant
AGROS Ltd. Btka
PPD Brezov
STIFI Hurbanovo
Main substrate
Amon et al. (2003) dealt with the biogas production from energy crops maize and clover grass, in
more detail. His works were focused on the biogas production from various varieties of maize in
various stages of ripeness (milk ripeness, wax ripeness and full ripeness). Different varieties
reached the harvesting optimum in different stages of ripeness. Specific methane production ranged
from 0.206 to 0.286 Nm3/kg VSS and the methane yield ranged from 5300 to 8530 Nm3/ha. These
results were achieved from mesophilic (40o C) batch tests of anaerobic degradation, which lasted 60
days. Some varieties showed minimal difference in the methane production in dependence from the
stage of harvest. Some varieties showed the difference of more than 25 % (Saxxo variety, vax
ripeness, Amon et al. 2003).
Presented work was focused on an observation of start-up and trial operation of anaerobic digestion
of maize silage in the first biogas station for treatment of energy crops in the Slovak Republic.
Situation of biogas production from organic wastes or energy crops in not very developed in the
Slovak Republic. Some data on operating biogas plants in Slovakia are shown in Tab.2.
BIOGAS STATION
The technology of maize silage anaerobic treatment is obvious from Fig. 1.
The biogas station was designed according to laboratory results described in the work of Hutan et
al., (2005).
Effective volume of a full scale anaerobic reactor was 2450 m3. The reactor was mixed by two
propeller mixers with horizontal axis of rotation. Fresh silage was dosed by a chain transporter into
the reactor. Silage pits were situated close to the biogas station. Average moisture content of silage
used for the biogas station start-up was about 75 %. Reactor was operated at 37 oC. Expected
production of biogas was about 4200 m3/d. Biogas was burnt in the cogeneration unit with electrical
power output 270 kW and heat power output 479 kW. For the optimum operation of the
cogeneration unit it is necessary to reach the biogas production about 170-180 m3. Gasholder
volume 80 m3 was sufficient because production of biogas was stable. Biogas can be burnt also in
biogas boiler with heat power output 470 kW. The boiler played its main role at the starting time of
the reactor operation, when the reactor was heated by natural gas burning. On the other hand, the
boiler can be used in the situations when cogeneration unit operation is interrupted or if excess
biogas is produced.
TECHNOLOGY WATER
WATER
FUSE
SILAGE DOSING
ANAEROBIC
REACTOR
WASTEWATER
PUMPING
WASTE HEAT
WASTE
HEAT
EXCHANGER
EXCHANGER
ANORGANIC
POLUTANTS
MIXER 1
DIGESTED
SILAGE
MIXER 2
REACTOR
HEATING
SILAGE
JUJCE
PUMPING
GAS BOILER
COGENERATION UNIT
NATURAL GAS
MEMBRANE
GASHOLDER
8000
dose of silage
3000
40
2000
20
1000
40
80
120
Time [d]
160
200
6000
VFA [mg/l]
60
4000
production of biogas
4000
2000
0
0
40
80
120
Time [d]
160
200
Since the 120th day of reactor operation it was started with dosing of aerobically stabilised sludge
(the same one that was used for inoculation) for increasing of NH4-N concentration and for the
stabilisation of pH values. Amount of dosed sludge was 7-10 m3/d (concentration of suspended
solids 30 g/l). Concentration of ammonia nitrogen increased up to 600 mg/l (Fig.4), concentration
of VFA decreased (Fig.3) and pH was stabilised at value approximately 7.2 (Fig.5). Dose of maize
silage after reactor stabilisation was 24 tons per day, average specific production of biogas reached
the amount of 0.7 m3/kg of dry silage and cogeneration unit achieved 100 % its capacity.
Concentration of suspended solids after 200 day of reactor operation was to 60 g/l.
800
200
7.4
160
7.2
NH4-N
120
400
80
200
0
0
40
80
120
Time [d]
160
7.0
pH
NH4- N [mg/l]
600
PO4- P [mg/l]
PO4-P
6.8
40
6.6
6.4
200
40
80
120
Time [d]
160
200
During operation of the anaerobic reactor some interesting phenomena were observed. After each
dose of silage temporary increase of biogas production was observed. In Fig. 7 increase of biogas
production (expressed as increase of power output of cogeneration unit) for silage dosing every 8
hours (16 tons per day, each dose 2 t) is shown. Overall production of biogas in these days was
2800 m3 and cogeneration unit was operated at 67 % of maximum capacity (140th day of operation).
Period of higher biogas production duration was about 1 hour. Increase of biogas production after
silage dose shown in Fig. 7 represents 5.13 % of overall production of biogas per one dose of silage.
60
50
40
30
20
260
240
220
200
Silage dose
Silage dose
180
160
10
0
40
80
120
Time [d]
160
200
2
3
Time [h]
This increase can be caused by degradation of easily biodegradable VFA, alcohols or lower
carbohydrates included in maize silage. Content of these substances in the silage can range between
2.1-11.1 % - Tab. 3.
Tab. 3 Concentration of volatile and readily biodegradable matter in maize silage
(% of dry matter)
Dry matter
(%)
Acid
Lactic Acetic Propionic Butyric
39,2
36,0
31,0
41,0
28,5
6,2
4,2
5,21
2,12
0,56
2,6
1,5
1,28
0,86
0,47
0,2
0,32
0,05
0,01
<1
1,04
0,24
0,01
0,29
-
0,47
-
1
2
3
4
4
* 1-Offer et al. (2001), 2-McEniry et al. (2006), 3-Danner et al. (2003), 4-Steidlov a Kala (2003)
In the period between two doses quality of biogas also changed. Average concentration of methane
in biogas was 54.5. %; concentration of H2S was 160 ppm. Immediately after the silage dosing the
concentration of methane in biogas decreased by 2 %; similarly in two hours after silage dosing (53
% vs. 55 %). This fact can be explained in such way that during first phases of anaerobic
degradation of silage the acidogenesis with higher CO2 production prevailed. More significant
change of biogas content was achieved during the period of 5-day reactor operation interruption. In
this period concentration of methane in biomass was increased from 52.8 % to 65 %.
For stabilisation of pH values and for production of biogas different substrates were used during
periods when sufficient amount of maize silage was not at disposition. Specific production of
biogas for used substrates is shown in Tab. 4.
In the presence, daily consumption of maize silage is 20 tons per day; average moisture content is
70 %. Concentration of suspenden solids in the reactor is 110-130 g/l. Daily production of biogas is
4200 m3, production of electricity 6000 kWh/d and production of thermal energy ca 9000 kWh/d.
Produced electric (PE) and heat (PH) power output can be approximately calculated as follows:
PE = 2 . (V - 30)
[kW]
[kW]
Substrate
maize silage
corn rests from drying
meat and bone meal
molasses distillery slops
Specific production of
biogas
3
m /kg of dry matter
0.7
1.1
0.36
0.74
CONCLUSIONS
Results of start-up process of the biogas station treating maize silage showed suitability of use
of aerobically digested sludge for inoculation of the anaerobic reactor;
Start-up period of biogas station for maize silage processing was about 100 days;
Part of the heat, obtained by this way, is used to maintain the temperature of the anaerobic
reactor. The rest of obtained energy will be used to heat the companys greenhouses, and in
summer it will be used for the drying of produced crops;
The produced electricity is transferred to the public electric main. The excess sludge from the
anaerobic reactor is used directly as fertilizer or is mixed with straw with the aim to produce
compost.
Acknowledgement: This work was supported by the Grant of Norwegian Financial Mechanism
(NFM), EEA Financial Mechanism and from Slovak State Budget in the frame of project SK0023.
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