Instrumentation and control of anaerobic digestion processes: a review and some research challenges

The final publication is available at Springer via http://dx.doi.org/10.1007/s11157-015-9382-6[EN] To enhance energy production from methane or resource recovery from digestate, anaerobic digestion processes require advanced instrumentation and control tools. Over the years, research on these topics has evolved and followed the main fields of application of anaerobic digestion processes: from municipal sewage sludge to liquid mainly industrial then municipal organic fraction of solid waste and agricultural residues. Time constants of the processes have also changed with respect to the treated waste from minutes or hours to weeks or months. Since fast closed loop control is needed for short time constant processes, human operator is now included in the loop when taking decisions to optimize anaerobic digestion plants dealing with complex solid waste over a long retention time. Control objectives have also moved from the regulation of key variables measured online to the prediction of overall process perfor- mance based on global off-line measurements to optimize the feeding of the processes. Additionally, the need for more accurate prediction of methane production and organic matter biodegradation has impacted the complexity of instrumentation and should include a more detailed characterization of the waste (e.g., biochemical fractions like proteins, lipids and carbohydrates)andtheirbioaccessibility andbiodegradability characteristics. However, even if in the literature several methodologies have been developed to determine biodegradability based on organic matter characterization, only a few papers deal with bioaccessibility assessment. In this review, we emphasize the high potential of some promising techniques, such as spectral analysis, and we discuss issues that could appear in the near future concerning control of AD processes.The authors acknowledge the financial support of INRA (the French National Institute for Agricultural Research), the French National Research Agency (ANR) for the "Phycover" project (project ANR-14-CE04-0011) and ADEME for Inter-laboratory assay financial support.Jimenez, J.; Latrille, E.; Harmand, J.; Robles Martínez, Á.; Ferrer Polo, J.; Gaida, D.; Wolf, C.... (2015). Instrumentation and control of anaerobic digestion processes: a review and some research challenges. Reviews in Environmental Science and Biotechnology. 14(4):615-648. doi:10.1007/s11157-015-9382-6S615648144Aceves-Lara CA, Latrille E, Steyer JP (2010) Optimal control of hydrogen production in a continuous anaerobic fermentation bioreactor. 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Predicting organic acid concentration from UV/vis spectrometry measurements – A comparison of machine learning techniques

The concentration of organic acids in anaerobic digesters is one of the most critical parameters for monitoring and advanced control of anaerobic digestion processes. Thus, a reliable online-measurement system is absolutely necessary. A novel approach to obtaining these measurements indirectly and online using UV/vis spectroscopic probes, in conjunction with powerful pattern recognition methods, is presented in this paper. An UV/vis spectroscopic probe from S::CAN is used in combination with a custom-built dilution system to monitor the absorption of fully fermented sludge at a spectrum from 200 to 750 nm. Advanced pattern recognition methods are then used to map the non-linear relationship between measured absorption spectra to laboratory measurements of organic acid concentrations. Linear discriminant analysis, generalized discriminant analysis (GerDA), support vector machines (SVM), relevance vector machines, random forest and neural networks are investigated for this purpose and their performance compared. To validate the approach, online measurements have been taken at a full-scale 1.3-MW industrial biogas plant. Results show that whereas some of the methods considered do not yield satisfactory results, accurate prediction of organic acid concentration ranges can be obtained with both GerDA and SVM-based classifiers, with classification rates in excess of 87% achieved on test data

Predicting organic acid concentration from UV/vis spectrometry measurements – A comparison of machine learning techniques

The concentration of organic acids in anaerobic digesters is one of the most critical parameters for monitoring and advanced control of anaerobic digestion processes. Thus, a reliable online-measurement system is absolutely necessary. A novel approach to obtaining these measurements indirectly and online using UV/vis spectroscopic probes, in conjunction with powerful pattern recognition methods, is presented in this paper. An UV/vis spectroscopic probe from S::CAN is used in combination with a custom-built dilution system to monitor the absorption of fully fermented sludge at a spectrum from 200 to 750 nm. Advanced pattern recognition methods are then used to map the non-linear relationship between measured absorption spectra to laboratory measurements of organic acid concentrations. Linear discriminant analysis, generalized discriminant analysis (GerDA), support vector machines (SVM), relevance vector machines, random forest and neural networks are investigated for this purpose and their performance compared. To validate the approach, online measurements have been taken at a full-scale 1.3-MW industrial biogas plant. Results show that whereas some of the methods considered do not yield satisfactory results, accurate prediction of organic acid concentration ranges can be obtained with both GerDA and SVM-based classifiers, with classification rates in excess of 87% achieved on test data

Biological investigation and predictive modelling of foaming in anaerobic digester

Anaerobic digestion (AD) of waste has been identified as a leading technology for greener renewable energy generation as an alternative to fossil fuel. AD will reduce waste through biochemical processes, converting it to biogas which could be used as a source of renewable energy and the residue bio-solids utilised in enriching the soil. A problem with AD though is with its foaming and the associated biogas loss. Tackling this problem effectively requires identifying and effectively controlling factors that trigger and promote foaming. In this research, laboratory experiments were initially carried out to differentiate foaming causal and exacerbating factors. Then the impact of the identified causal factors (organic loading rate-OLR and volatile fatty acid-VFA) on foaming occurrence were monitored and recorded. Further analysis of foaming and nonfoaming sludge samples by metabolomics techniques confirmed that the OLR and VFA are the prime causes of foaming occurrence in AD. In addition, the metagenomics analysis showed that the phylum bacteroidetes and proteobacteria were found to be predominant with a higher relative abundance of 30% and 29% respectively while the phylum actinobacteria representing the most prominent filamentous foam causing bacteria such as Norcadia amarae and Microthrix Parvicella had a very low and consistent relative abundance of 0.9% indicating that the foaming occurrence in the AD studied was not triggered by the presence of filamentous bacteria. Consequently, data driven models to predict foam formation were developed based on experimental data with inputs (OLR and VFA in the feed) and output (foaming occurrence). The models were extensively validated and assessed based on the mean squared error (MSE), root mean squared error (RMSE), R2 and mean absolute error (MAE). Levenberg Marquadt neural network model proved to be the best model for foaming prediction in AD, with RMSE = 5.49, MSE = 30.19 and R2 = 0.9435. The significance of this study is the development of a parsimonious and effective modelling tool that enable AD operators to proactively avert foaming occurrence, as the two model input variables (OLR and VFA) can be easily adjustable through simple programmable logic controller

ESTIMATION OF GREENHOUSE GAS AND ODOUR EMISSIONS FROM COLD REGION MUNICIPAL BIOLOGICAL NUTRIENT REMOVAL WASTEWATER TREATMENT PROCESSES

Rising human populations and ever-increasing demand for potable water result in increased municipal wastewater production. The collection, treatment, and management of municipal wastewaters include energy-intensive processes leading to the generation and emission of greenhouse, potentially toxic, and odorous gases. The main goal of this thesis was to advance knowledge of greenhouse gas (including carbon dioxide, CO2; methane, CH4; and nitrous oxide, N2O) and smelly compound (including ammonia, NH3; and hydrogen sulphide, H2S) emissions from typical municipal wastewater treatment plants (MWTPs) to accurately describe their emission rate estimates (EREs) using operating parameters. This research included laboratory and field assessments of greenhouse gas (GHG) and odour emissions in conjunction with monitored operating parameters. Laboratory-scale reactors simulating open-to-air treatment processes including primary and secondary clarifiers and anaerobic, anoxic, and aerobic reactors, were used to monitor gas EREs using wastewater samples taken from the analogous MWTP processes in winter and summer seasons. The Saskatoon Wastewater Treatment plan (SWTP) is a state-of-the-art biological nutrient removal (BNR) type MWTP and a Class IV treatment facility in Canada which was selected as a case study given its highly variable seasonal temperatures from −40 °C to 30 °C and its geographic location near the University of Saskatchewan. The experimental results were then used to develop a variety of novel machine learning models describing gas EREs with further optimization of operating parameters using genetic algorithm (GA). Studied machine learning models were artificial data generation algorithms (including generative adversarial network, GAN) and data-driven models (including artificial neural network, ANN; adaptive network-based fuzzy inference systems, ANFIS; and linear/non-linear regression models). To my knowledge, this is the first application of GAN used for MWTP modelling purposes. Results indicated that anaerobic digestion EREs averagely reached 4,443 kg CH4/d, 9,145 kg CO2/d, and 59.7 kg H2S/d. In contrast, GHG and odour ERE variabilities given ambient temperature changes were more noticeable for open-to-air treatment processes such that the winter EREs were 45,129 kg CO2/d, 21.9 kg CH4/d, 3.20 kg N2O/d, and insignificant for H2S and NH3. The higher temperature for the summer samples resulted in increased EREs for CH4, N2O, and H2S EREs of 33.0 kg CH4/d, 3.87 kg N2O/d, and 2.29 kg H2S/d, respectively, and still insignificant NH3 emissions. However, the CO2 EREs were reduced to 37,794 kg CO2/d, and interestingly, NH3 emissions were still negligible. Overall, the aerobic reactor was the dominant source of GHG emissions for both seasons, and changes in the aerobic reactor aeration rates (in reactor) and BNR treatment configurations (from site) further impacted the EREs. The integration of field monitoring data with data-driven models showed that the ANN, ANFIS, and regression models provided reasonable EREs using: (1) volatile fatty acids, total/fixed/volatile solids, pH, and inflow rate for anaerobic digestion biogas generations; and (2) hydraulic retention time, temperature, total organic carbon, dissolved oxygen, phosphate, and nitrogen concentrations for aerobic GHG emissions. However, when both model accuracy and uncertainty were considered there appears to be a compromise between these parameters with no model having simultaneously both high accuracy and low uncertainty. Additionally, and interestingly, virtual data augmentation using GAN was found to be a valuable resource in supplementation of limited data for improved modelling outcomes. GA was also coupled with the data-driven models to determine optimal operating parameters resulting in either GHG emission maximization given biogas could be beneficial for energy generation or GHG emission minimization given the aerobic reactor is an open-to-air process that can impact nearby residential neighbourhood air quality. The current study provides a hybrid methodology of mathematical modelling and experiments that can be used to accurately estimate and optimize the GHG and odour EREs from other MWTPs in Canada and worldwide

Soft sensor development and process control of anaerobic digestion

This thesis focuses on soft sensor development based on fuzzy logic used for real time online monitoring of anaerobic digestion to improve methane output and for robust fermentation. Important process parameter indicators such as pH, biogas production, daily difference in pH and daily difference in biogas production were used to infer alkalinity, a reliable indicator of process stability. Additionally, a fuzzy logic and a rule-based controller were developed and tested with single stage anaerobic digesters operating with cow slurry and cellulose. Alkalinity predictions from the fuzzy logic algorithm were used by both controllers to regulate the organic loading rate that aimed to optimise the biogas process. The predictive performance of a software sensor determining alkalinity that was designed using fuzzy logic and subtractive clustering and was validated against multiple linear regression models that were developed (Partner N° 2, Rothamsted Research 2010) for the same purpose. More accurate alkalinity predictions were achieved by utilizing a fuzzy software sensor designed with less amount of data compared to a multiple linear regression model whose design was based on a larger database. Those models were utilised to control the organic loading rate of a twostage, semi-continuously fed stirred reactor system. Three 5l reactors without support media and three 5l reactors with different support media (burst cell reticulated polyurethane foam coarse, burst cell reticulated polyurethane foam medium and sponge) were operated with cow slurry for a period of seven weeks and twenty weeks respectively. Reactors with support media were proven to be more stable than the reactors without support media but did not exhibit higher gas productivity. Biomass support media were found to influence digester recovery positively by reducing the recovery period. Optimum process parameter ranges were identified for reactors with and without support media. Increased biogas production was found to occur when the loading rates were 3-3.5g VS/l/d and 4-5g VS/l/d respectively. Optimum pH ranges were identified between 7.1-7.3 and 6.9-7.2 for reactors with and without support media respectively, whereas all reactors became unstable at ph<6.9. Alkalinity levels for system stability appeared to be above 3500 mg/l of HCO3 - for reactors without media and 3480 mg/l of HCO3 - for reactors with support media. Biogas production was maximized when alkalinity was 3 between 3500-4500 mg/l of HCO3 - for reactors without support media and 3480- 4300 mg/l of HCO3 - for reactors with support media. Two fuzzy logic models predicting alkalinity based on the operation of the three 5l reactors with support media were developed (FIS I, FIS II). The FIS II design was based on a larger database than FIS I. FIS II performance when applied to the reactor where sponge was used as the support media was characterized by quite good MAE and bias values of 466.53 mg/l of HCO3- and an acceptable value for R2= 0.498. The NMSE was close to 0 with a value of 0.03 and a slightly higher FB= 0.154 than desired. The fuzzy system robustness was tested by adding NaHCO3 to the reactor with the burst cell reticulated polyurethane foam medium and by diluting the reactor where sponge was used as the support media with water. FIS I and FIS II were able to follow the system output closely in the first case, but not in the second. FIS II functionality as an alkalinity predictor was tested through the application on a 28l cylindrical reactor with sponge as the biomass support media treating cow manure. If data that was recorded when severe temperature fluctuations occurred (that highly impact digester performance), are excluded, FIS II performance can be characterized as good by having R2= 0.54 and MAE=Bias= 587 mg/l of HCO3-. Predicted alkalinity values followed observed alkalinity values closely during the days that followed NaHCO3 addition and water dilution. In a second experiment a rulebased and a Mamdani fuzzy logic controller were developed to regulate the organic loading rate based on alkalinity predictions from FIS II. They were tested through the operation of five 6.5l reactors with biomass support media treating cellulose. The performance indices of MAE=763.57 mg/l of HCO3-, Bias= 398.39 mg/l of HCO3-, R2= 0.38 and IA= 0.73 indicate a pretty good correlation between predicted and observed values. However, although both controllers managed to keep alkalinity within the desired levels suggested for stability (>3480 mg/l of HCO3-), the reactors did not reach a stable state suggesting that different loading rates should be applied for biogas systems treating cellulose.New Generation Biogas (NGB

Real-Time Substrate Feed Optimization of Anaerobic Co-Digestion Plants

In anaerobic co-digestion plants a mix of organic materials is converted to biogas using the anaerobic digestion process. These organic materials, called substrates, can be crops, sludge, manure, organic wastes and many more. They are fed on a daily basis and significantly affect the biogas production process. In this thesis dynamic real-time optimization of the substrate feed for anaerobic co-digestion plants is developed. In dynamic real-time optimization a dynamic simulation model is used to predict the future performance of the controlled plant. Therefore, a complex simulation model for biogas plants is developed, which uses the famous Anaerobic Digestion Model No. 1 (ADM1). With this model the future economics as well as stability can be calculated resulting in a multi-objective performance criterion. Using multi-objective nonlinear model predictive control (NMPC) the model predictions are used to find the optimal substrate feed for the biogas plant. Therefore, NMPC solves an optimization problem over a moving horizon and applies the optimal substrate feed to the plant for a short while before recalculating the new optimal solution. The multi-objective optimization problem is solved using state-of-the-art methods such as SMS-EMOA and SMS-EGO. The performance of the proposed approach is validated in a detailed simulation studyAlgorithms and the Foundations of Software technolog

Automated Fault Detection in an Upflow Anaerobic Sludge Blanket Reactor: Comparisons of Biogas Production and Physicochemical Quantities

A system capable of rapidly detecting toxic loads entering high-rate anaerobic reactors would greatly enhance their reliability, and could thereby increase their commercial acceptance. A high-rate anaerobic wastewater treatment process, called the failure-causing load detector (FCLD), consisting of a small (4-liter) upflow anaerobic sludge blanket (UASB) reactor having a short (10-min) hydraulic retention time (HRT), was used as a biosensor to rapidly detect potential problems with the influent wastewater. Sensors were used to monitor biogas production in the reactor, as well as pH, conductivity, and turbidity in the effluent from the reactor. The FCLD system was tested using the following failure-causing loads: organic overload, sodium toxic load (using NaCl), sodium hypochlorite (NaOCl, bleach), milk, sodium hydroxide (NaOH), and hydrochloric acid (HCl). Two different classifiers were implemented to identify the type of failure-causing load based upon the sensor outputs. Each classifier was tested using data collected during experiments with the FCLD system. The first classifier was a crisp classifier: it classified the failure-causing loads based on pH, conductivity, and turbidity, and was generated based on graph theory definitions. The second classifier was fuzzy logic based: it used a fuzzy inference system (FIS) to classify the failure-causing loads. Biogas flow rate data under normal operating conditions was analyzed over ranges based on mean ± 1, ± 2, and ± 3 standard deviations, and was shown to be normally distributed. When using interval 2 (mean ± 2 sd), only 4 % of false positives (biogas alteration detection before addition of toxicant) were obtained, and it had 64 % of false negatives (no alteration detection after addition of toxicant). However, 5 of the 9 failure-causing loads tests could still be detected using this interval. Due to variability in the biogas measurement and because classification could be performed using only pH, conductivity and turbidity as inputs, biogas was disregarded as an input for both classification processes. Even without biogas as an input for the classifiers, the FCLD reactor still was needed as part of the system because other monitored parameters (e.g. pH) in the effluent line are modified not only by changes in composition of the influent wastewater, but also from imbalances of by-products of the anaerobic digestion. The graph theory based classifier did not show false positives, and it reached 3.7 % correct classification 10 min after addition of the failure-causing load (test time), increasing to 48 % 15 min after test time, and reaching 100 % 20 min after test time. There were no false positives for FIS based classifier, and correct classification occurred with 7.4 % at 10 min after test time, 59 % 15 min after test time, increasing to 96 % 20 min after test time, and it reached 100 % correct classification 25 min after test time. Results from both classifiers showed that the FIS based classifier has more misclassifications (125 % more) than the graph theory based classifier. Response time was checked for biogas detection and for both classifiers. Biogas detection was 5 min faster than the classifiers for the loads that could be detected. One improvement for both classifiers would be the inclusion of biogas as an input, which would accelerate the detection of the failure-causing loads that cause significant change in biogas production