This paper is a critical evaluation of the effect of mixing on biogas production rates in an anaerobic digester. Mixing plays a prominent role in determining the efficiency of the anaerobic digestion process. This review analyzes the miscellaneous effects of mixing (on the microbial community, methane content and volatile fatty acids) at various mixing intensities and during different stages of the digestion process. Intermittent mixing (mixing at intervals) seems preferable in terms of the quality and quantity of biogas produced, and results in lower power consumption and maintenance costs associated with large-scale biogas production. Preferable mixing time (the length at intervals) and the intensity depends on the geometry of the digester and impeller. The conclusion is drawn that the study of the slurry rheology is very crucial in the designing of the mixing equipment, the shape and size of the digester, and the pipe transport system which can assist in minimizing the initial investment and operational costs. Accordingly, this paper focuses on the parameters which determine the potency of mixing, such as viscosity, total solid content and digester design. Empirical data demonstrated by various researchers regarding rheological characteristics is compared and reviewed. Consequently, close attention should be paid toward the optimization of mixing in terms of its speed, mixing time and impeller geometry, especially during different stages of the digestion process (hydrolysis, acidogenesis, acetogenesis and methanogenesis). Finally, readers will be guided to the extensive publications regarding optimization, directions of future research, and troubleshooting of the mixing operation in an anaerobic digester. This investigation will help to improve mixing efficiency with biogas plants.

The appropriate mixing system and approach to effective management can provide favorable conditions for the highly sensitive microbial community, which can ensure process stability and efficiency in an anaerobic digester. In this study, the effect of mixing intensity on biogas production in a lab-scale anaerobic digester has been investigated experimentally and via modeling. Considering high mixing efficiency and unique feature of producing axial flow, helical ribbon (HR) impeller is used for mixing the slurry in this experiment under various conditions. Three parallel digesters were analyzed under identical operating conditions for comparative study and high accuracy. Effects of different mixing speeds (10, 30, and 67 rpm for 5 min h⁻¹) on biogas production rate were determined in 5-L lab-scale digesters. The results demonstrated 15–18% higher biogas production at higher mixing speed (67 rpm) as compared to 10 rpm and 30 rpm and the results proved statistically significant (p < 0.05). Biogas production at 10, 30, and 67 rpm were 45.6, 48.6, and 52.5 L, respectively. Higher VFA concentrations (7.67 g L⁻¹) were recorded at lower mixing intensity but there was no significant difference in pH and ammonia at different speeds whereas the better mixing efficiency at higher speeds was also the main reason for increase in biogas production. Furthermore, model simulation calculations revealed the reduction of dead zones and better homogeneous mixing at higher mixing speeds. Reduction of dead zones from 18% at 10 rpm to 2% at 67 rpm was observed, which can be the major factor in significant difference in biogas production rates at various mixing intensities. Optimization of digester and impeller geometry should be a prime focus to scale-up digesters and to optimize mixing in full-scale digesters.

The effect of slurry mixing in an anaerobic digester on biogas production was intensively studied in the last few years. This subject is still debatable due to fact that this process involves three phases, solid-gas-liquid, along with the involvement of microbes during biochemical reactions, which are highly vulnerable to changes in hydrodynamic shear stresses and mixing conditions. Moreover, the complexity in the direction of optimization of mixing magnifies due to the implication of both fluid mechanics and biochemical engineering to study the effect of mixing in anaerobic digestion (AD). The effect of mixing on AD is explored using recent literature and theoretical analysis, concentrating on the multi-phase and multi-scale aspects of AD. The tools and methods available to experimentally quantify the function of mixing on both the global and local scales are summarized in this study. The major challenge for mixing in an anaerobic digester is to minimize dead zones and maintain uniform distribution of viscosity and shear at low mixing intensities without disrupting the microbial flocs and syntrophic relationships between the bacteria during the AD process. This study is a critical analysis of various techniques and approaches adopted by researchers to evaluate the effectiveness of mixing regimes and mixing equipment. Most studies describe biogas production performance and hydrodynamic characteristics of the digesters separately, but the evaluation of mixing requires interdisciplinary experts, which include mechanical engineers, microbiologists and hydrodynamic experts. Through this review, the readers will be guided through intensive literature regarding agitation, the best possible way to scrutinize the agitation problems and the approach to answering the question “why is the optimization of mixing in an anaerobic digester still a debatable subject?”.