Year-round biogas production in sugarcane biorefineries: Process stability, optimization and performance of a two-stage reactor system

The concept of year-round biogas production to increase the capacity factor of anaerobic digestion (AD) plants in sugarcane biorefineries was investigated for the first time in semi-continuous feeding mode. To simulate the use of sugarcane vinasse during the sugarcane season and sugarcane filter cake (SFC) during the off-season period, a two-stage reactor system based on an acidogenic continuous stirred-tank reactor (1st stage) followed by solid-liquid separation and an upflow anaerobic sludge blanket (UASB) reactor (2nd stage) to convert the COD-rich liquid fraction into biogas was operated. Additionally, to optimize the biogas production from SFC, the effects of its thermo-chemical pre-treatment on AD were investigated in a parallel reactor set-up. The saponification effect provided by autoclaving the substrate with sodium hydroxide improved the hydrolysis/fermentation of SFC in the acidogenic reactor, which in turn resulted in a 28% higher volumetric methane production in the methanogenic reactor (p < 0.05). However, the methane yields observed during operation of the two-stage reactor system were markedly lower than previously found in biochemical methane potential tests using SFC. In this case, the feed-in with low suspended solids required by UASB reactors prevented the utilization of the non-hydrolyzed/fermented solid fraction of SFC (> 60% of the substrate's methane potential). Nevertheless, the capacity factor of the AD plants in sugarcane biorefineries could be increased from 0.55 up to 0.69 when considering a 200 d a−1 sugarcane season (0.66-0.83 for a longer season of 240 d a−1), representing an increase of 25.7%. The average capacity factor for biogas combined heat and power and upgrading units of around 0.91 (8000 h a−1) would be reached if further developments could improve the solubilization of non-hydrolyzed/fermented solids or alternatively allow their direct use in the methanogenic reactor.