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E-grāmata: Managing Biogas Plants: A Practical Guide

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(Sustainable Technologies SL, Barcelona, Spain)
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Managing Biogas Plants: A Practical GuidePalielināt
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This practical manual provides basic theoretical knowledge about fermentative processes, biochemical laboratory techniques, and an arsenal of practical tricks, recipes, dos, and donts for the biogas plant manager. It explains why some popular tests and techniques are unreliable, how to optimize the feedstocks cost and the energy self-consumption of the digester, and how to analyze experimental error propagation and judge whether a marketing claim or a test result from the literature is correct. All examples are taken from the authors experience as consultant in managing biogas plants in Italy and Spain. It features a glossary of technical jargon and useful reference tables and formulae. By following the procedures described in this manual, anybody can learn in short time how to become a "bacteria farmer."

Recenzijas

" a practical guide that can be useful for day-to-day operation of biogas plants, which can be potentially useful to plant operators, trainers and process engineers." Joseph Akunna, Abertay University, Dundee, Scotland

"The author clearly has vast experience in biogas process monitoring, measurement and control as well as a solid mathematical basis. He is therefore well placed to give an overview and good advice on measuring methods, e.g. basic parameters, necessary size of test reactors, avoiding measurement errors." Joachim Nöller, Helmholtz Centre for Environmental Research, Leipzig, Germany

Foreword xiii
Preface xv
About the Author xix
1 Relevant Aspects for Optimizing the AD Process
1(48)
1.1 What Is Anaerobic Digestion?
1(8)
1.1.1 Theoretical Notions
1(6)
1.1.2 Practical Implications
7(1)
1.1.2.1 Complexity of the System
7(1)
1.1.2.2 Sequential Process
7(1)
1.1.2.3 Multiparametric Process
7(1)
1.1.2.4 Two Degradation Paths of the Organic Matter
8(1)
1.1.2.5 Influence of Temperature
8(1)
1.1.2.6 Need of a Balanced Diet for the Microorganisms
9(1)
1.1.2.7 Criterion for the Selection of Feedstock for AD
9(1)
1.2 Technical Nomenclature
9(11)
1.2.1 Definitions
11(3)
1.2.2 Practical Applications and Numerical Examples
14(1)
1.2.2.1 Approximate Ratio between COD and VS
14(2)
1.2.2.2 Methane Yield of a Substrate with a Known BMP
16(1)
1.2.2.3 Coherent Use of the TS, VS, and BMP values
17(1)
1.2.2.4 Calculation of the HRT
18(1)
1.2.2.5 Checking the OLR
19(1)
1.2.2.6 Optimizing the C/N Ratio of a Substrates Mixture
19(1)
1.3 Managing the Plant "by Tables": Limitations and Risks
20(9)
1.3.1 Conclusions on the Use of Tables
27(2)
1.4 The Dynamic Management of the Biogas Plant
29(10)
1.4.1 The pH
31(1)
1.4.2 The Relationship between pH and Alkalinity
32(1)
1.4.3 The Chemical Composition of the Substrate
33(2)
1.4.4 The VFA Profile
35(1)
1.4.5 Monitoring the Biogas' Flow and Composition
35(1)
1.4.6 Monitoring the ORP
36(1)
1.4.7 Monitoring the Electric Conductivity
37(2)
1.5 The Outsourced Biological Management Service: Limitations of the Traditional Techniques
39(2)
1.5.1 Conclusions
41(1)
1.6 The Automatic Titrator: Myths and Legends
41(8)
Bibliography
47(2)
2 Overview of the Laboratory Methods for the Analysis of Fermentative Processes
49(42)
2.1 Basic Notions of Metrology: Accurateness and Precision or Repeatability
49(9)
2.1.1 Definitions of Accurateness and of Precision or Repeatability
50(1)
2.1.2 Error Propagation
51(7)
2.2 Measure Methods Employed in the Biogas Industry
58(33)
2.2.1 Classical Volumetric and Barometric Methods
58(2)
2.2.1.1 Volumetric Methods
60(7)
2.2.1.2 Barometric Methods
67(7)
2.2.2 Automatic Measure Systems: AMPTS and BRS
74(3)
2.2.3 Reactors for Biological Tests: Which Are Better?---Big or Small Ones?
77(1)
2.2.4 The Most Frequent Errors in the Measure of Small Gas Flows
78(1)
2.2.4.1 Normalization
78(2)
2.2.4.2 Correction of the Moisture
80(1)
2.2.4.3 Elimination of Carbon Dioxide
80(1)
2.2.5 Auxiliary Physicochemical Tests
81(1)
2.2.5.1 Measure of the pH and the ORP
81(1)
2.2.5.2 Determination of the DM and VS of Biomass
82(2)
2.2.5.3 Determination of the COD of Sludge and Liquid Substrates
84(3)
2.2.6 The In Situ Laboratory for the Real-Time Control of the Biological Process
87(1)
Bibliography
88(3)
3 How to Perform Tests under Optimum Conditions
91(50)
3.1 Scope
91(1)
3.2 Measuring the DM and VS
91(7)
3.2.1 Measuring the DM with a Moisture Analyzer
92(1)
3.2.1.1 Confusing the "Moisture" and the "DM" Scales
93(1)
3.2.1.2 Wrong Setting of the Drying Temperature
93(1)
3.2.1.3 Wrong Installation of the Moisture Analyzer
94(1)
3.2.1.4 Measuring the DM of Silage
94(1)
3.2.1.5 Interpretation of the Scale's Technical Sheet
95(1)
3.2.2 Measurement of the DM with an Oven and a Scale
95(1)
3.2.3 Measuring the Ash Content and VS
96(2)
3.3 Measuring the COD and Total N
98(3)
3.4 How to Design a Biological Experiment
101(1)
3.5 The Preparation of Both Inoculum and Sample
102(6)
3.6 The Inoculum/Substrate Ratio, I/S
108(2)
3.7 Defining the Mix ratio (Intensity of Stirring)
110(6)
3.8 The BMP Test: One General Procedure, Multiple Applications
116(1)
3.8.1 General Procedure for Measuring the BMP
116(1)
3.9 Processing the Measured Data
117(6)
3.9.1 Step-by-Step Data Processing
117(1)
3.9.2 Frequent Causes of Problems during the BMP Test
118(1)
3.9.2.1 Problems Caused by Human Errors
118(2)
3.9.2.2 Problems Caused by Instrumental or Method Errors
120(3)
3.10 The Hydrolytic and Methanogenic Activity Tests: Checking the Bacteria's Health
123(10)
3.10.1 Degradation of Polysaccharides (Glucose, Starch, and Cellulose)
124(1)
3.10.2 Casein and Gelatin in Powder
125(1)
3.10.3 Propionic and Butyric Acids
126(1)
3.10.4 Fatty Acids (Lipids)
127(2)
3.10.5 Acetic Acid and Sodium Acetate
129(1)
3.10.5.1 Stoichiometry of Acetic Acid and Sodium Acetate
129(1)
3.10.5.2 First Step: Checking the Methanogenic Capacity of Acetate or Acetic Acid
130(2)
3.10.5.3 Second Step: The SMA Calculation
132(1)
3.11 Analysis of the Error Propagation in the BMP Assay and Its Variants
133(3)
3.12 A Controversial Technique: Correcting the pH, the Alkalinity, and Adding Nutrients before Starting the Batch Tests
136(5)
Bibliography
138(3)
4 Application of Laboratory Experimental Results to the Management of the Biogas Plant
141(36)
4.1 Practical Applications of the VS Test
141(6)
4.1.1 Measuring the Organic Load (OL) and the Organic Load Rate (OLR)
141(1)
4.1.1.1 Practical Application
142(1)
4.1.2 Measuring the Efficiency of the Feedstock's Conversion into Methane
143(1)
4.1.3 Corrective Actions in the Case ηDA < 45%
144(3)
4.2 Practical Applications of the BMP Test
147(15)
4.2.1 The Right Price for the Feedstock
147(3)
4.2.2 Optimizing the Biogas Plant's Diet
150(2)
4.2.3 Preventing the Inhibition Caused by "Difficult" Substrates
152(1)
4.2.4 Checking the Digestion Efficiency of the Biogas Plant
153(2)
4.2.5 Determination of the Optimum SRT/HRT
155(1)
4.2.6 Determining the Efficacy of Additives and Pretreatments
156(4)
4.2.7 Frequent Errors in Planning and Performing Biological Tests
160(2)
4.3 Using Reference Substrates to Check the Hydrolytic Activity: How to Find Out if Something Is Going Wrong
162(6)
4.3.1 Hydrolysis Test of Cellulose
162(1)
4.3.2 Hydrolysis Test of Sugar and Starch
163(1)
4.3.3 Hydrolysis of Proteins
164(1)
4.3.4 Lipolytic Activity Test
165(2)
4.3.5 General Substrate Inhibition Test
167(1)
4.4 Applications of the SMA Test: Preventing the Biological Collapse and Selecting the Best Inoculum to Start a Biogas Plant
168(7)
4.4.1 Practical Example on How to Test an Inoculum Suspected of Methanogenic Inhibition Using Wine Vinegar
169(2)
4.4.2 Practical Example of the SMA Test for the Selection of the Inoculum Necessary for Starting a New Biogas Plant
171(2)
4.4.3 How to Determine the Dosage of Trace Elements if SMA < 10
173(2)
4.5 Conclusions
175(2)
4.5.1 Usefulness of the Test with Vinegar, Acetic Acid, or Acetate as Reference Substrate
175(1)
4.5.2 Reference Substrates
175(1)
Bibliography
176(1)
5 Some Simple Tricks to Improve the Laboratory's Operativity
177(30)
5.1 Foreword
177(1)
5.2 Measuring the Percentage of Methane in the Biogas with the Double Reactor Set and with the Syringe Method
177(6)
5.2.1 Necessary Materials for the Syringe Test
180(1)
5.2.2 Performing the Test with the Syringe
181(1)
5.2.3 Error Analysis of the Syringe Method
182(1)
5.3 Solving the Problem of the Thermostatic Bath's Evaporation
183(4)
5.3.1 Seal the Gap between the Reactors and the Plexyglass Cover by Means of O-rings or Rubber Bands
184(1)
5.3.2 Add Some Very Soluble Salt to the Water
184(1)
5.3.3 Replacing the Water in the Thermostatic Bath with Any Fluid Having Low Vapor Pressure
185(2)
5.4 Improved Connection of the DC Stirrer Motors
187(9)
5.4.1 Description and Theoretical Analysis of the Problem
187(3)
5.4.2 Step-by-Step Procedure to Connect the Power Supply at the Center of the Line
190(4)
5.4.3 Using Brushless Motors
194(2)
5.5 Checking the Calibration (Volumetric Methods)
196(3)
5.5.1 Gravimetric Calibration Method
196(1)
5.5.2 Volumetric Calibration Method
197(2)
5.6 Flushing the Head Volume of the Reactor with a Gas Lighter Recharge
199(2)
5.7 Finding Gas Leaks
201(3)
5.8 Some Safety Rules for the Biological Laboratory in the Biogas Plant
204(3)
Bibliography
206(1)
6 Critical Review of the Scientific Literature from the Biogas Plant Manager's Perspective
207(48)
6.1 Introduction
207(1)
6.2 Three Methods to Find Out Absolute Truths: The Aristotelian Syllogism, the Cartesian Doubt Principle, and Avoiding Logic Fallacies
207(10)
6.2.1 The Correlation between BMP and Electrical Conductivity
209(4)
6.2.1.1 Conclusion
213(1)
6.2.2 Assessing the Validity of the VFA/TA (FOS/TAC) Method
214(1)
6.2.3 The Causal Fallacy
215(1)
6.2.3.1 Information from the Literature
215(1)
6.2.3.2 Checking the Logic Flaws
216(1)
6.2.3.3 Checking the Efficacy of Enzymes in the Correct Way
216(1)
6.3 Misconceptions of the Scientific Literature Amplified by the Marketing
217(20)
6.3.1 The Importance of pH and the Use of Sodium Bicarbonate as Buffer Agent in Anaerobic Plants
217(4)
6.3.2 The Hyped Importance of Trace Elements
221(1)
6.3.3 The Use of "Special Products" for Desulfurization
222(3)
6.3.4 Databases and Mathematical Models of BMP
225(1)
6.3.4.1 Conclusion
226(1)
6.3.5 The Conservation of the Inoculum
226(2)
6.3.6 The "Equivalent Corn Silage Unit"
228(1)
6.3.6.1 Olive Mill Pomace
229(1)
6.3.6.2 Fatty Waste and Glycerol
229(1)
6.3.6.3 Mixtures of Substrates
230(1)
6.4.6.4 Substrates with Low Concentration of Degradable Organic Matter
231(1)
6.3.7 Estimating the Accuracy and Reliability of Data Published in the Literature
231(4)
6.3.7.1 Conclusions
235(2)
6.4 Norms on the BMP Test Procedure for Industrial Biogas Plants
237(12)
6.4.1 An Overview of the German VDI 4630/2014
237(1)
6.4.2 IWA's Proposal of Standardized BMP Test
237(1)
6.4.3 The Draft of Italian Norm E0209F670 UNI/TS
237(1)
6.4.4 Critical Analysis of the Flaws in the Existing Norms
238(1)
6.4.4.1 The VDI 4630
238(6)
6.4.4.2 The IWA Guideline for the BMP Assay
244(3)
6.4.4.3 The Italian Draft of Standard
247(2)
6.5 Conclusions
249(6)
Bibliography
251(4)
7 Glossary of Terms and Abbreviations
255(4)
8 Useful Tables for Quick Reference
259(8)
8.1 Specific Weight of Silage as a Function of Its TS
263(1)
8.2 Using Wine Vinegar to Carry Out the SMA Test
263(1)
8.3 Monitoring the Electrical Conductivity of the Sludge
263(1)
8.4 Reference Values for Checking the AD Process with the VFA/TA (FOS/TAC) Test
264(1)
8.5 VFA Profile
265(1)
8.6 Oligoelements (a.k.a. Trace Elements or Micronutrients)
265(1)
8.7 Guidelines for the Determination of VS
266(1)
Index 267
Mario A. Rosato is an electrical, electronic, and environmental engineer, as well as a scientific journalist. He built his first home-sized digester in Argentina when he was aged 16. The son of a university professor and researcher, he learnt to employ sophisticated instruments in his favorite playground: his fathers lab. At the age of 25 he obtained a scholarship to specialize in renewable energies in Italy. At 28 he chose to leave the academic research world and devoted himself to the development of industrial solutions. In 1990 he settled in Italy and in 2000 he moved to Spain. In 2004 he became partner and scientific director of Bioenergia Aragonesa SL. In 2006 he patented the AFADS system, a multitrophic bioreactor for wastewater treatment. In 2009 he founded Sustainable Technologies SL in Barcelona. From 2010 he expanded his companys activity to Italy, where he became professor at several private professional institutes. Since then he has trained more than 100 biogas plant managers in Italy and Spain. He installed a laboratory for applied research and routine anaerobic digestion tests in the Technologic Park of Pordenone in 2011. The same year he won The Economists award for the best entrepreneurial idea to tackle global climate change, based on the production of biohydrogen and the cultivation of bamboo in a circular economy cycle. Some months later, he received the Green Vision Award from Modus Vivendi magazine in Rome. His industrial solutions, based on original applied research, place him 4th in the worldwide Top Solvers list on Innocentive.com. In 2012, during the research project H2Ocean, funded by the European Commissions 7th Framework Program, he develops a novel type of digester for marine biomass, specially conceived for offshore operation. In 2013 he won two international awards for the conceptual design of a domestic garbage digester, meant for low-income Indian families. Since 2014 he has been in charge of the column on bioenergy for agronotizie.it, a specialized e-zine for agronomists and farming professionals. In 2015 he was a member of the technical commission in charge of redacting the Italian norm on the biochemical methane potential (BMP) test protocol, and his contribution focused on the error propagation analysis and improving both accuracy and precision.
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