A techno-economic assessment of hydrogen and methane production from the anaerobic treatment of vinasse and glycerol: single- vs. two-stage process

The best-case scenario for anaerobic digestion (AD) could include co-digestion and two-stage systems, a combination that has not yet been extensively studied. This study aimed at evaluating the effect of increasing the organic loading rate from 5 to 20 kg-COD/m3/d in second-stage thermophilic (55 °C, CH4-RThermo) and mesophilic (25 ± 5 °C, CH4-RMeso) anaerobic fluidized bed reactors (AFBR) fed with sugarcane vinasse and glycerol (1:1 on a COD basis) previously fermented in a thermophilic AFBR. AD was stable with high methane production and COD removal up to 20 kg-COD/m3/d for CH4-RThermo (4.53 L-CH4/L/d; 79%) and CH4-RMeso (3.85 L-CH4/L/d; 66%), respectively. At 20 kg-COD/m3/d, CH4-RMeso failed due to acid accumulation (1,279mg/L), which probably inhibited methanogenic activity. Results of two-stage thermophilic + thermophilic (H2-RThermo + CH4-RThermo) were compared with a thermophilic single-stage AFBR. In comparison to the two-stage system, for 10, 15, and 20 kg- COD/m3/d, the single-stage energetic yields were higher at 33, 26 and 22%, respectively. A techno-economic assessment was conducted. The scale-up and economic analyses revealed that the single-stage would be the most compact system (17,820 vs. 20,560 m3) with the lowest initial investment (USD 45M vs. USD 52M), highest net present value (NPV) (USD 58M vs. USD 47M), and internal rate of return (IRR) (18 vs. 16%) compared to the best two-stage system (thermophilic + thermophilic). A Monte Carlo simulation indicated a 12% risk of financial loss at 20 kg-COD/m3/d for the single-stage system. Furthermore, it showed that variation on the capitalization rate, inflation, and the electricity sales price can significantly affect the NPV. Therefore, in addition to better laboratory performance, the single-stage system is simpler to operate, less costly, and would be more suitable for industrial scale implementation.