Doubling the Space-Time Yield of a Pilot Biogas Reactor with Swine Manure and Cereal Residues by a Closed Loop Feedback Control Based on an Automated Fuzzy Logic Control System

Abstract

The anaerobic digestion of swine manure was performed for more than 2 years in a biogas pilot plant with cereal residues as a mono-input, either by a simple intermittent substrate feeding or by feeding with an automated “autopilot” system under the direction of a Fuzzy logic control (FLC) system, working with a closed-loop feedback control. The pilot plant of the University of Applied Sciences in Nordhausen consisted of a 2.5 m3 dosage tank, a 2.5 m3 digestate tank, and a 1 m3 biogas reactor. Only three control parameters were used for FLC: pH, methane %, and the specific gas production rate (GPR) related to the organic loading rate (OLR), that is GPR/OLR m3 biogas/(kgVS d), vs = volatile solids. The specific GPR was referred to the OLR of the last feeding every 8 h in terms of kgVS/(m3 d). In test period I without an FLC system, a safe process with just an OLR of 4 kgVS/(m3 d) was reached, followed by an overloading and reactor disturbance at ≤6.3 kgVS/(m3 d) as indicated by acidification with volatile fatty acids up to 25,000 mg/L. However, test period II (585 trial days) with an integrated FLC system allowed a safe OLR up to 11 kgVS/(m3 d). Apparently, the microbes themselves directed the speed of substrate feeding by the dynamics of their substrate turnover and by the closed loop feedback control, while the three FLC parameters prevented acidification. Therefore, the application of FLC enabled a doubling of the throughput for a biogas reactor in the same time with a ‘turbo speed’. The concomitant hydraulic residence time (HRT) of only 10 days reduced the stirring and heating costs. The usage of an FLC system should open the door for networked biogas production to enable flexible biogas production on demand.