Design considerations for a farm-scale biogas plant based on pilot-scale anaerobic digesters loaded with rice straw and piggery wastewater

Two pilot-scale (1 m3) digesters filled with untreated rice straw and co-digested with raw pig wastewater were operated to obtain design parameters for a farm-scale biogas plant. Both digesters contained 50 kg of dry straw mixed with diluted pig wastewater to create dry digestion conditions (20% TS) and operated for 189 days with leachate recirculation. Digester A was designed for optimum performance (150 L of pig wastewater and mesophilic temperatures) while Digester B was designed to establish minimum inputs (60 L of pig wastewater at ambient temperatures). The pig wastewater provided sufficient buffering capacity to maintain appropriate pH values (between 7.0 and 8.1) and nutrient balances (TOC to TKN ratios of 20 in Digester A and 32 in Digester B). Total biogas production was 22,859 L in Digester A and 1420 L from Digester B, resulting in specific methane yields of 231 and 12 L CH4/kgVS added, respectively. Gas production in Digester A was directly correlated with temperature, but the overall lack of methanogenic activity was caused primarily by the reduced wastewater volume. Two theoretical farm-scale scenarios (considering both untreated and pretreated rice straw) were developed for a 100-ha rice farm. Either scenario can produce 100,000 m3CH4 per year, yielding 328 MWh. Major differences including heat input, space requirements, loading frequency, digester volume, engine size, wastewater quantities, and additives are quantitatively defined. The appropriate choice for a farm-scale operation is the simplest model using untreated rice straw without additives, although six times more heat and twice as much reactor volume is required.