1. Introduction
The disposal of wastewater and wastes without treatment in water bodies and on land is no longer allowed for the majority of countries, as it produces harmful effects on the health of humans, animals and environment [
1]. Since the wastewater treatment plants require large amounts of electrical and thermal energy, such systems are extremely intensive energy consumers [
2]. The electrical demand for wastewater treatment represents about 1% of total consumption in almost all countries (Germany, Italy, etc.) [
3]. In particular, the high energy consumption is mainly due to their heavy mechanical systems necessary to move and manage wastewater, such as pumps and aeration systems [
4]. Pump systems account for more than 70% of the electricity consumption of such plants [
5]. Due to the energy intensive processes involved with wastewater treatments plants, more energy efficient and sustainable treatments were developed during the past decades [
6], e.g., wastewater may be converted into a stabilized waste in order to simultaneously produce some biological energy vectors (biomethane, biogas, etc.) [
7]. Such gases can be further converted in combined heat and power plants [
8], producing energy vectors (mainly electricity and heat) [
9]. The obtained energy may be used both for the wastewater treatment plant internal loads and to supply energy to municipal district networks [
10]. Biogas can be used as fuel for vehicles, after a cleaning phase and the upgrading to biomethane [
11]. Therefore, according to this paradigm, wastes are no longer an energy and environmental issue, since they become a sustainable energy source. In addition, such an arrangement is also very attractive from the economic point of view, due to the savings in terms of waste disposal and to the incomes related to the produced energy [
12]. In the framework of the biogas production, anaerobic digestion (AD) plants allow one to generate clean power and provide sanitation services by treating organic wastes [
13]. AD consists of a series of reactions mediated by several groups of microorganisms that mineralize organic matter primarily to methane and carbon dioxide (biogas), in the absence of oxygen [
11]. This process is widely used for the treatment of sewage sludge and is currently also being employed for the disposal of several types (municipal, industrial, etc.) of solid wastes [
14].
The anaerobic digestion of OFMSW is a technology widely developed in Europe as it allows the energy recovery from organic matrices according to a perspective of a circular economy. The OFMSW definition varies from one country to another: in the USA, for example, OFMSW is considered as a mixture of food, garden and paper waste, while in the EU it is a mixture of waste from parks, gardens and kitchens [
15]. It can be classified according to the collection strategy used: MS-OFMSW is the organic fraction mechanically sorted from unsorted urban waste and supplied to the biological process, while the SS-OFMSW comes from separate collection from domestic sources. The yield of the anaerobic degradation process of the OFMSW in terms of biogas production mainly depends on the specific features of the substrate and then on the plant configuration. The latter affects the performances of the process converting the biodegradable part of the substrate into biogas. The characteristics of the waste significantly depend on the collection technique. Cecchi et al. [
16] noted that OFMSW from separate collection presents low total solids content (15–30%) and most of them (70–90%) are volatile solids: this means that most of the waste is characterized by putrescible material that will be subjected to anaerobic degradation. On the contrary, OFMSW from mechanical separation has a very high content of total solids, but volatile solids content is lower than 50% of TS: due to the high quantity of inert materials, most of the organic waste will be only partially involved in biodegradation and therefore a high amount of waste products will be obtained. Alvarez et al. [
17] found that, in Catalonia, organic fraction of separated solid waste contained between 10% and 20% of undesirable material such as plastic bags, packing material, glass and textiles. In particular the organic waste coming from the door-to-door collection method has shown better quality than that from the street bin collection method. The work of Cesaro et al. [
18] shows that unwanted materials accounts only for 12% of the total SS-OFMSW and consists mainly of plastics (78%). In order to reduce the amount of non-digestable materials, a pre-treatment phase prior to AD could be expected. Household organic wastes are mainly treated with physical pretreatments, especially the mechanical ones [
19]. These preteatments allow to reduce the risk for mechanical problems in the AD-plant and also to stabilize the composition of the inlet stream, but lead to the loss of organic material following the removal of waste products [
20], as well as an increase in operating costs.
Since the middle of the last century, several modeling studies were presented to characterize the AD process, widely simulated in literature by using the Anaerobic Digestion Model 1 (ADM1). This model was developed by the International Water Association’s (IWA) Task Group in the year 2002. The model is a universally suitable model for biogas simulations [
21,
22,
23] and it includes 31 processes, described by 19 differential and 12 algebraic equations, with 24 dynamic states variables on 33 groups of fractions. The growth and decay of separate biomass fractions is also considered [
24]. According to the equations of the general ADM1, several recent mathematical models were developed as reported in the following. As an example, Pastor-Poquet et al. [
25] developed a novel model based on ADM1 to simulate the process in case of high-solids AD for the organic fraction of municipal solid waste. With respect to the traditional ‘wet’ ADM1, their model adequately simulates the reactor content mass/volume variation that is significant in case of high removal of total solids. The model also includes the interrelationship between total solid removal and biogas production. Esposito et al. [
26] defined a dynamic mathematical model that considers the influence of OFMSW particle dimension and of the organic loading rate on methane production and COD removal in the anaerobic co-digestion of OFMSW and sewage sludge. The anaerobic degradation of the sewage sludge is simulated using the ADM1, while the disintegration phase of the organic waste is modelled by a surface-based kinetic, in order to take into account that this process depends on the size of the composite material.
Anaerobic digestion is very sensitive to temperature fluctuations that may lead to a decrease in system performances and in biogas yield. The resulting temperature inside the digester depends on the heat exchange phenomena between the anaerobic digester and external environment and these are strongly affected by environmental conditions. For these reasons, AD simulation models must take into account the variation of the operating temperature according to boundary conditions (weather, OFMSW, etc.). The vast majority of the works available in literature are based on 0-D models which neglect any thermal gradients within the reactor, since this approach allows one to dramatically reduce computational times.
Axaopoulos et al. [
27] developed a mathematical model in order to simulate the temperature variation of a swine manure digester heated with flat-plate solar collectors that are integrated into the digester cover. Model and experimental results show that this innovative design allows one to reduce the thermal losses of the reactor. Hreiz R. et al. [
28] studied the influence of climatic conditions on an agricultural digester operating temperature by defining a detailed thermal model which includes the effect of some external factors, such as rainy events or the underground gradual warming during the AD process, on digester heat losses. Adouani et al. [
29] analyzed the effect of working temperature and of the type of treated substrate on the performances of the digester of the previous work by using the ADM1 combined with a thermodynamic model.
The above reported literature review showed that most of the available studies are based on the modeling of the AD, focusing on the biological and kinetic aspects of the process, by appropriately using the ADM1, or on the thermal aspects of the process, without taking into account that biological and thermal behaviors are strictly linked to each other. Therefore, to cover this lack of knowledge, the present paper focuses on the development of a reliable and accurate simulation model of the AD, by considering both the biological and thermal modeling of the process. In particular, the final goal of the present work is the development of a fast and accurate simulation model to be subsequently integrated within a dynamic simulation tool, for the analysis of integrated systems including different types of renewables energies that can be used to meet the energy demand of the digester. Therefore, the main goal of this work is to determine the composition of biogas, paying special attention the amount of produced methane. In fact, the developed simulation code mainly aims at evaluating the energy and mass flows involved during the operation of the digester. For this reason, a simplified version of ADM1 is used, considering the forthcoming works where this model will be integrated into complex dynamic simulation models, including a plurality of additional components (biomethane vehicles, thermal storage tanks, solar thermal collectors, upgrading unit, etc.).
3. Case Study
In
Table 4, a description of the different parameters included in the matrix including the kinetic equations (
φj) of the process j (
Table 3) and their respective values is reported. Note that the maximum hydrolysis reaction rate is calculated as weighted average considering the incoming waste composition shown in
Table 5.
The digester is designed as follows: for a 30-day HRT and a waste flow rate of 15,000 t/d, a reactor volume of 800 m3 is obtained, which is assumed to be filled by ¾ from waste. For a height of 5 m, the diameter of the digester is approximately 14 m.
In this study the digester is covered by a gasometric dome consisting of two PVC membranes anchored to the edge of the reactor: the external membrane forms the outer cover and has a fixed volume with a fixed height of 2 m; the biogas is stored under the internal membrane, so the volume under this membrane changes because the amount of biogas varies during the process. Between the two membranes there is a chamber containing air in order to compensate the level variations of the internal membrane: by adding or extracting air, the chamber and biogas are kept at constant pressure, regardless of the quantity of biogas produced.
Most of the heat losses occur along at the gasometric dome. The total thermal resistance along the gasometric dome was calculated under the following assumptions: the biogas below the internal membrane remains stationary and its convective coefficient is fixed equal to 10 W/(m2 K); the resistance in the air gap between the two membranes is fixed equal to 0.13 (m2 K)/W; the membranes thermal resistance is negligible because they are thin and consists of plastic material with relatively high conductivity.
The structural and thermal parameters used for the calculation of the global heat transmission coefficients are shown in
Table 6. Note that steel sheet thermal resistance in the calculation of digester walls’ transmittance was neglected since its low thickness and high thermal conductivity.
The heat exchanger is designed to reach the set point temperature of digester Tsetpoint equal to 40 °C and assuming a reduction in water temperature from 55 to 45 °C. It consists of four high density cross-linked polyethylene coils, operating in parallel with a diameter of 2.5 cm and a length of each pipe equal to the perimeter of digester. The obtained rated total hot water mass flow rate necessary to heat the digester at the desired temperature is equal to 0.557 kg/s. Note that the value of the calculated parameters for the estimation of UHE,n will vary as a function of water flow rate, as shown in the sensitivity analysis carried out subsequently.
The inlet parameters of the developed model are summarized in
Table 7. Note that the specific heat of the digestate is assumed equal to water one at 40 °C. As regards the estimation of gaseous flow rates, the fixed biogas composition is 65% CH
4 and 35% CO
2, according to the range of values reported in literature [
37,
38,
39]. The hydrogen gas flow rate was neglected due to its very small concentration. The simplified assumption related to the composition of the biogas mixture, 65% of CH
4 and 35% of CO
2 and CO
2 production is due to the following reasons: i) it is extremely difficult to implement a detailed calculation of solid/gas transfer for the CO
2 production; ii) the main aim of the carried out analysis is the evaluation of the methane production, since this component is the only one affecting the energy balances. However, it can be observed that as CH
4 percentage increases, the biogas mass flow rate decreases and the biogas specific heat increases. This globally results in a negligible decrease of digester operating temperature, passing from 38.11 to 37.32 °C when CH
4 percentage increases from 50% to 70%. The specific heat of the biogas mixture, taking into account the specific heat of each component, i.e., 35.844 kJ/kmol K for CH
4 and 37.748 kJ/kmol K for CO
2 and the molecular weight of the mixture, assumed equal to 26 kg/kmol, is equal to 1.42 kJ/kgK.
4. Results and Discussion
In the hydrolysis phase (
Figure 2a), the simple substance, obtained in the disintegration phase, subsequently decomposes, with the consequent production of soluble compounds that rapidly disappear in the acidogenesis phase. The production of the soluble substance leads to the growth of acidogenic biomass and the formation of organic acids. The trend of the concentration of organic acids shows a slope variation due to the gradual disappearance of the soluble substrate, causing a slowdown of the growth of biomass (
Figure 2b). During the acetogenesis phase, organic acids are consumed by acetogenic biomass, with the production of acetate and hydrogen. Hydrogen rapidly disappears due to the high rate of degradation of the hydrogenotrophic methanogenic biomass (
Figure 2c). The trend of methane concentration shows a first increase due to the rapid degradation of hydrogen and a second increase due to the degradation of acetate (
Figure 2d).
Figure 3 shows the trend of the volumetric gas flow rates,
,
and
for an operating temperature of 40 °C. As mentioned in the biological model section, the trend of gas flow rates follows the same trend of
SCH4,
Figure 2d. The duration of the initial transient is about 26 days; subsequently, the produced flow rates reach steady values. The obtained concentrations of the analyzed components after 60 days of operation are reported in
Table 8. The produced biogas mass flow rate is equal to 2299 kg/d, composed by 40% CH
4 (927 kg/d). The volumetric biogas flow rate results of 1997 Nm
3/d, composed by 1298 Nm
3/d of methane and 699 Nm
3/d of carbon dioxide, (
Figure 3).
Combining the thermal and biological model, the digester operating temperature, as a function of the heating capacity of the heat exchanger immersed inside the digester, is obtained. By implementing an iterative process and fixing the inlet mass flow rate
of hot water circulating inside the immersed heat exchanger equal to 0.557 kg/s, with the corresponding temperature
Tin,water at 55 °C, the ambient temperature
Tamb at 15 °C and the inlet mass flow rate of organic fraction of municipal solid wastes
of 0.174 kg/s, the results obtained by the developed model are as follows (
Table 9):
A sensitivity analysis is performed in order to detect the most significant parameters of the model affecting on the biogas production. The alternatively variated parameters are: from 0.4 kg/s to 0.7 kg/s, Tin,water from 49 to 61 °C, from 0.15 kg/s to 0.21 kg/s and Tamb from −2 to 38 °C. The analyzed outputs of the model are: the digester temperature Tdigester, outlet temperature of the hot water Tout,water, biogas mass flow rate , thermal flow rate absorbed by the mass flow rate of OFMSW , thermal flow rate loss of the digester and thermal flow rate of the hot water .
In
Figure 4, the effects of the variation of
are reported. Obviously, the higher the
, the higher the
, i.e. the thermal flow rate exchanged by the water, and as a consequence, an increase of the thermal flow rate absorbed by the OFMSW is detected. This leads to an increase of the operating temperature of the digester
Tdigester, and therefore, of the produced biogas
. Note that the growth of the operating temperature also leads to an increase of heat losses, due to the higher temperature difference between the digester and ambient. The thermal flow rate exchanged by the inlet hot water increases. In fact, considering that
increases, being fixed the area of the internal heat exchanger, the water velocity inside the tube increases: this determines the intensification of the thermal flow rate by convection, and in turns, an increase of the internal convective coefficient and consequently, of the heat exchange coefficient
UHE,n of heat exchanger. For values of
higher than 0.6 kg/s, a stable value of
is obtained. This means that an increase of
does not lead to a significant increase of the thermal flow rate exchanged by the water, because the exchange area available of the immersed heat exchanger remains constant. For the same reason, with the same inlet temperature
Tin,water= 55 °C, if the flow rate
increases, the outlet temperature of the hot water
Tout,water increases too. Finally, it is possible to assess that the increase of
leads only to an increase of the energy consumption of the circulation pumps not determining any significant positive effect in terms of operating temperature of the digester and biogas production. In fact, for an increase of
from the design value of 0.557 kg/s to 0.7 kg/s,
Tdigester increases only from 37 to 39 °C and a negligible increase of
, equal to 0.2%, is obtained.
The analysis of the variation of
Tin,water is reported in
Figure 5. For higher values of
Tin,water, all investigated parameters vary according to a growing linear trend. This is easily understood, because higher values of
Tin,water correspond to higher exchanged thermal flow rates,
. However, the increase of operating temperature
Tdigester also leads to a negative increase of the loss thermal flow rate,
. The increase of the inlet water temperature
Tin,water with respect to the design value, with the same water flow rate, leads to a potential increase of the thermal flow rate provided to the digester
. If
is produced by a natural gas fired boiler, a grater yearly fuel consumption is detected corresponding to higher operating costs. The high operating costs could be not balanced by an important increase of the biogas production, rising only by 0.7% in case of
Tin,water is equal to 61 °C.
In
Figure 6, the results of the sensitivity analysis performed by changing the inlet mass flow rate of organic fraction of municipal solid wastes
is presented. In this analysis, the capacity of the digester and of its immersed heat exchanger is tested for different values of
with respect to the designed one, equal to 0.174 kg/s. The higher the inlet mass flow rate
, the higher the thermal flow rate transferred by the hot
. Therefore, at the same inlet temperature of 55 °C, the outlet hot water temperature of the heating system
Tout,water decreases with the increase of
. Obviously, for a greater amount of waste to be treated, a higher thermal flow rate
absorbed by the waste and a lower digester operating temperature
Tdigester is obtained. As a consequence, the thermal losses
decrease. A greater amount of the available waste for anaerobic degradation leads to an increase of the produced mass flow rate of biogas
. The final aim of this analysis is to detect the amount of biogas produced corresponding to the possible different inlet OFMSW flow rates
to the plant. However, the AD process must work at constant operating conditions. Therefore, only slight variations of
can be accepted. The analysis shows that for each kg of OFMSW 0.132 Nm
3 of biogas are produced.
The sensitivity analysis is performed by varying the ambient temperature
Tamb (
Figure 7), in order to investigate the biogas production as a function of the weather conditions. Note that for the model assumption, the waste temperature is equal to
Tamb. Therefore, for higher values of
Tamb, the heat absorbed by the waste decreases as well as
Tout,water increases
. For hot weather zones, the thermal losses decrease, therefore, the available heat for the waste increases. This leads to higher digester operating temperatures, therefore, greater biogas flow rates produced. By comparing the results obtained from this analysis it is possible to observe that among the varied parameters, i.e.,
Tamb, ,
,
Tin,water the main parameter of the model is the ambient temperature
Tamb. In fact, the variation from −2 to 38 °C leads to a very significant variation of the operating temperature, from 32 to 45 °C.
Tamb is a crucial parameter, dramatically affecting the biological process. Therefore, it also affects the velocity and efficiency of the process. For this reason, in cold weather zones, it is more difficult to achieve suitable operating conditions for the anaerobic digestion. This problem could significantly increase the energy consumption of the plant as well as the yearly operating costs. For the same reason, it is important to control the operating temperature of digester also during winter season when the ambient temperature dramatically decreases also in mild climates.
4.1. Sensitivity Analysis: Digester Wall Insulation Thickness
In this paper, a specific wall of the digester was considered. However, from the technical point of view several options are available. Therefore, in order to analyze the effects of digester wall features on the system performance a sensitivity analysis is also performed by varying the global transmittance values of digester walls. When the insulation thickness increases assuming values from 0.05 to 0.35 m,
Udigester reduces in the range 0.102–0.644 W/(m
2 K). This results in a slightly improvement of system performances: the digester operating temperature and the methane flow rate increase by about 1 °C and 3 Nm
3/d, respectively (
Figure 8). As
Tdigester increases, the thermal power required to heat the OFMSW also increases, however the losses decrease due to the better system insulation, so the overall thermal power exchanged by the heating system decreases (
Figure 9). Note that thermal losses along digester walls account for 11% of total losses, mainly caused by gasometric dome, so even increasing the insulation thickness, no significant increase in digester temperature is observed. Details of the results obtained by this analysis are summarized in
Table 10.
Figure 10 shows the variation in biogas production and operating temperature by varying insulation thickness and therefore the walls’ transmittance. An increase of s
XPS-XL,w until 20 cm results in a rapid improvement of system performances; after this value the parameters begin almost constant, so increasing insulation thickness results unnecessary and expensive.
4.2. Sensitivity Analysis: Effect of Fouling in the Internal and External Side of the Heat Exchanger
In this paper the effect of fouling in the internal side of the heat exchanger was neglected since only pre-treated water is used in this kind of systems and fouling will be a very limited phenomenon. Thus, a sensitivity analysis by considering the synergistic effect of an internal and external fouling on
UHE,n value is carried out. Results of this analysis is represented in
Figure 11 and
Figure 12 and
Table 11.
The internal fouling is caused by precipitation of impurities in the heat transfer fluid and causes the reduction of the available cross area to water flow. This is modeled replacing a lower value of pipe rated diameter
DN in the calculation of
UHE,n, assuming that fouling occurs along the whole pipe internal surface:
where
sfouling is fouling thickness. Assuming the formation of a limestone fouling varying in thickness from 1 × 10
−4 to 5 × 10
−3 m with a thermal conductivity
λCaCo3=1.6 W/m K and considering an additional thermal resistance
Rfouling,est =2 × 10
−3 m
2 K/W caused by organic deposits on external side of the heat exchanger pipes, both internal and external fouling are taken into account. It is possible to observe that the global transmittance
UHE,n is considerably decreased with respect to the design value 187 W/(m
2 K) and a significant reduction in system performance occurs (
Figure 11 and
Figure 12). External fouling alone results in a reduction of
UHE,n from 187 to 136 W/(m
2 K) with a decrease in temperature of about 1 °C (
Table 11). The formation of limestone further reduces
UHE,n value and it causes a reduction of operating temperature of about half degree per millimeter of fouling (
Figure 11).
5. Conclusions
In this work, a model simulating the biological and thermal processes of the AD of the organic fraction of solid urban waste was developed. The model evaluates the dynamic trend of the concentrations of the main components and estimates the production of biogas according to the operating temperature of the digester, depending on the heat exchange occurring inside the digester between the waste and heating system. The simplified version of the ADM1 is used in order to simply predict the biomethane production. This can be a useful estimation when the developed model will be integrated within a more complex system, including different components: biomethane vehicles, thermal storage tanks, solar thermal collectors, photovoltaic (PV) panels, upgrading unit, etc. The main results can be summarized as follows:
For a 21% increase of waste flow rate with respect the design value (from 626 a 756 kg/h), a proportional increase of the biogas flow rate (from 96 to 115 kg /h) is obtained. In this case, a reduction of the operating temperature of about 1 °C is noted.
For a 26% increase of the heating water with respect to designed value (from 2005 to 2520 kg/h), the digester operating temperature increases of about 1°C and the produced biogas only of 0.2% (from 95.54 to 95.75 kg/h).
When the inlet water temperature varies from 49 to 61°C, the digester operating temperature ranges in the desired mesophilic regime (34–41 °C) and the produced biogas flow rate varies of about 1.3 kg/h.
The increase of the insulation thickness on the wall of the digester leads to a reduction in the digester heat losses, but because the main heat losses of digester are due to the geometric dome, the digester temperature only slightly increases.
The fouling in the internal side of the heat exchanger could reduce the available cross area to water flow. However, this effect can be neglected when the heat transfer fluid is pre-treated.
External fouling leads to a reduction of the global transmittance of the heat exchanger and therefore, also of the operating temperature (half degree per millimeter of fouling).
The following general considerations can be made by analysing the obtained results:
The calculated biogas production is 0.132 Nm3 per kg of OFMSW.
To increase the operating temperature Tdigester by 1 °C, inlet hot water temperature Tin, water must be increased by about 1.5 °C, fixing all the remaining parameters.
A variation of 1 °C in the environmental temperature Tamb leads to a reduction of about 0.3°C in the operating temperature Tdigester, due to the higher heat losses.
For a fluctuation of 1 tonne of the OFMSW daily flow rate, the digester operating temperature varies by 0.5 °C, due to the larger amount of heat required to preheat the inlet OFMSW.
With a suitable control system all the main parameters of the model, such as the flow rate and temperature of the heating system, can be appropriately varied in order to maintain the operating temperature of the digester at the design value, if fluctuations in OFMSW flow rate and environmental temperature occur.
The simplified model of the anaerobic digestion is useful for the prediction of the biomethane production, but it is definitely more advantageous if integrated with other simulation models. For example, in order to reduce the contribution of the conventional fossil fuels to meet the energy demand of the digester. In particular, solar thermal collectors could be used to provide the thermal energy of the anaerobic digestion process as well as PV panels to provide the electric energy to the upgrading unit process. In addition, in a wider prospective, the contribution of such systems is definitively positive for the development of a sustainable mobility scenario based on the use of methane vehicles. Future developments of the present model will be oriented to a better characterization of the inlet substrate and to the modeling of physical-chemical reactions and inhibition phenomena that can occur during the AD process and that can vary the amount of the produced methane. These improvements will increase the reliability of the model under dynamic operating conditions.