The urgent need to meet climate goals provides unique opportunities to promote small-scale farm anaerobic digesters that valorize on-site wastes for producing renewable electricity and heat, thereby cushioning agribusinesses against energy perturbations. This study explored the economic viability of mono-digestion of cow manure (CWM) and piglet manure (PM) in small manured-based 99 kW_el plants using three treatment schemes (TS): (1) typical agricultural biogas plant, (2) a single-stage expanded granular sludge bed (EGSB) reactor, and (3) a multistage EGSB with a continuous stirred tank reactor. The economic evaluation attempted to take advantage of the financial incentives provided by The Renewable Energy Sources Act in Germany. To evaluate these systems, batch tests on raw and solid substrate fractions were conducted. For the liquid fraction, data of continuous tests obtained in a laboratory was employed. The economical evaluation was based on the dynamic indicators of net present value and internal return rate (IRR). Sensitivity analyses of the electricity and heat selling prices and hydraulic retention time were also performed. Furthermore, an incremental analysis of IRR was conducted to determine the most profitable alternative. The most influential variable was electricity selling price, and the most profitable alternatives were TS1 (CWM) > TS1 (PM) > TS3 (CWM). However, further studies on co-digestion using TS3 are recommended because this scheme potentially provides the greatest technical flexibility and highest environmental sustainability.

Anaerobic digestion of animal manure is a potential bioenergy resource that avoids greenhouse gas emissions. However, the conventional approach is to use continuously stirred tank reactors (CSTRs) with hydraulic retention times (HRTs) of greater than 30 d. Reactors with biomass retention were investigated in this study in order to increase the efficiency of the digestion process. Filtered pig slurry was used as a substrate in an expanded granular sludge bed (EGSB) reactor and fixed-bed (FB) reactor. The highest degradation efficiency (η_COD) and methane yield (MY) relative to the chemical oxygen demand (COD) were observed at the minimum loading rates, with MY = 262 L/kg_COD and η_COD = 73% for the FB reactor and MY = 292 L/kg_COD and η_COD = 76% for the EGSB reactor. The highest daily methane production rate (MPR) was observed at the maximum loading rate, with MPR = 3.00 m³/m³/d at HRT = 2 d for the FB reactor and MPR = 2.16 m³/m³/d at HRT = 3 d for the EGSB reactor. For both reactors, a reduction in HRT was possible compared to conventionally driven CSTRs, with the EGSB reactor offering a higher methane yield and production rate at a shorter HRT.

Anaerobic co-digestion (AcoD) is a widely employed technique to produce biogas from simultaneous digestion of various biomasses. However, the selection of the optimal proportions of the substrates in the mixtures presents a challenge. This research used a mixture design to investigate the interactions between the liquid fraction of piglet manure (PM), cow manure (CWM), and starch wastewater (SWW). A modified Gompertz model was used to identify the statistically significant parameters of the methane production curves. The optimal compositions of the mixtures were identified based on multi-objective optimization of the maximal methane yield (Y_CH4) and maximal methane specific production rate (r_CH4) parameters. The study was validated using a double mixture of PM and CWM and a triple mixture. The estimated degradation rates for both mixtures were faster than the predicted ones. The absolute relative errors of r_CH4 were 27.41% for the double mixture and 5.59% for the triple mixture, while the relative errors of Y_CH4 were 4.64% for the double mixture and 10.05% for the triple mixture. These relative errors are within the normal limits of a process with high variability like AD. Thus, mixture design supported by the tested models is suitable for the definition of practically advisable mixtures of substrates.

Livestock farming and manure management contribute substantially to greenhouse gas (GHG) emissions in agriculture. Anaerobic digestion (AD) of manure is a promising strategy for mitigating these emissions. This study aimed to assess the biomethane potential (BMP) of various types of pig slurry, investigate factors that influence biomethane production, analyze degradation kinetics, and propose AD process optimization approaches. Thus, substrate analysis, BMP tests in batch assays, kinetic modeling, and principal component analysis (PCA) were conducted. In order to further quantify the effects of different substrate qualities in full-scale operation, biomethane production was simulated under steady-state conditions. Results indicated that piglet slurry had the highest volatile solids (VS)–specific BMP (203 ± 72 L kg⁻¹ VS), followed by mixed slurry (202 ± 132 L kg⁻¹ VS), fattening pig slurry (117 ± 56 L kg⁻¹ VS), and sow slurry (86 ± 17 L kg⁻¹ VS). The PCA revealed different substrate types and significant roles for VS, crude fat, volatile fatty acids concentration, and the carbon/nitrogen ratio in achieving high BMPs. First-order two-step kinetic modeling identified hydrolysis as the rate-limiting step, showing a determinant of rate-limiting step of < 0 for each sample. The simulation of continuous operation revealed notable differences in daily biomethane production (36.7–42.7 L day⁻¹) between the different slurries at the same hydraulic retention time and BMP. This research underscores the variability in pig slurry characteristics, exemplified by a total solids range of 1.4–12.1%, and provides crucial insights for optimizing AD processes in livestock waste management.

Anaerobic co-digestion often improves the yields and stability of single anaerobic digestion. However, finding the right substrate proportions within mixtures and corresponding optimal operating conditions using a particular reactor technology often presents a challenge. This research investigated the anaerobic digestion of three mixtures from the liquid fractions of piglet manure (PM), cow manure (CWM), starch wastewater (SWW), and sugar beet (SBT) using three 30 L expanded granular sludge bed (EGSB) reactors. The synergistic effects of two three-substrate mixtures (i.e., PM+CWM+SWW and PM+CWM+SBT) were studied using the PM+CWM mixture as a benchmark. These were used to detect the predicted synergistic interactions found in previous batch tests. The methane productivity of both three-substrate mixtures (~1.20 L_CH4/L_react/d) was 2× the productivity of the benchmark mixture (0.64 L_CH4/L_react/d). Furthermore, strong indications of the predicted synergistic effects were found in the three-substrate mixtures, which were also stable due to their appropriate carbon-to-nitrogen ratio values. Moreover, the lowest averaged solid to hydraulic retention times ratio calculated for samples obtained from the top of the reactors was > 1. This confirmed the superior biomass retention capacity of the studied EGSB reactors over typical reactors that have been used in agricultural biogas plants with a continuous stirred tank reactor.