Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure

Zinola, Guillermo - Etchebehere, Claudia

Resumen:

Poultry production in Uruguay is concentrated in the southern region of the country, where egg and broiler production generate 26% of agro-industrial waste. The main residues produced in poultry farms are broiler litter (BL) and laying hen manure (LHM), reaching 81,000 and 3,300 tonTS/year, respectively (Benzano et al., 2016). Although the solids wastes have been used as fertilizer in the region, the excessive application and lack of prior stabilization generated the overload of nutrients in the water basin where the poultry production is concentrated. In this context, the valorization of BL and LHM through anaerobic digestion (AD) is proposed to produce biogas and digestate. The research strategy consists of evaluating the technological, economic, and environmental feasibility of implementing centralized anaerobic co-digestion (CoAD) projects using these residues. In order to assess maximum energy production, the Biochemical Methane Potential (BMP) of BL, LHM, and their mixture at the nationally generated ratio (24:1 in TS) was evaluated. To evaluate the technology in full-scale centralized plants, the performance of AD was studied in reactors operated under continuous flow conditions. Specifically, six continuous stirred-tank reactors with 2 L of effective volume (BRS Bioprocess Control) were fed over 176 days with BL, LHM, and the BL:LHM mixture (24:1). The aim was to determine the operating conditions that yield the highest methane (CH₄) production with minimal reactor volume. Reactors were operated at a constant Hydraulic Retention Time (HRT) of 20 days with a progressive increase in Organic Loading Rate (OLR). Process monitoring included biogas volume measurement and digestate analysis of pH, TS, VS, FOS/TAC, and NH₄⁺. Three steady states were established corresponding to OLRs of 1, 2, and 3 kgVS/m³·d, where the CH₄ concentrations, the digestate characterization (COD, TP, TN, volatile fatty acids, macro- and micronutrients), pathogen, antibiotic resistance, and microbial community composition were also determined. Throughout the assay, pH (6.94 - 7.94), FOS/TAC (< 0.3), NH₄⁺ (200 - 1151 mgN-NH₄⁺/L), and NH₃ (52 - 74 mgN-NH₃/L), were in the reported ranges for these type of processes (Mezes et al., 2011; Dai et al., 2016; Guebitz et al., 2015; Yenigün and Demirel, 2013). Maximum methane yields (YCH₄) were obtained at OLR = 1 kgVS/m³·d (BL: 106 NLCH₄/kgVS, LHM: 229 NLCH₄/kgVS, BL:LHM: 103 NLCH₄/kgVS), which decreased as the load increased to 2 kgVS/m³·d (BL and LHM: 23%, BL:LHM: 17%). When the OLR was raised to 3 kgVS/m³·d, RCH₄ remained similar in the LHM reactors (184 NLCH₄/kgVS), while those containing BL and BL:LHM progressively ceased CH₄ production after day 100. It is presumed that the poor degradation of BL, evidenced by the accumulation of solids in the reactors at the end of the assay, led to a 40% reduction in effective reaction volume, thereby reducing HRT and increasing OLR. As a result, the maximum RCH₄ for LHM was 88% of its BMP, while for BL and BL:LHM it was considerably lower than these BMP results (28% and 37%, respectively).

Detalles Bibliográficos
2025
Agencia Nacional de Investigación e Innovación (ANII)
Instituto Nacional de Investigación Agropecuaria (INIA)
Universidad Tecnológica del Uruguay (UTEC)
Poultry farm wastes
Anaerobic co-digestion
Biomethane potential
Completely stirred tank reactor
Ingeniería y Tecnología
Biotecnología del Medio Ambiente
Biotecnología Medioambiental
Inglés
Instituto de Investigaciones Biológicas Clemente Estable
IIBCE en REDI
https://hdl.handle.net/20.500.12381/5703
Acceso abierto
Reconocimiento-NoComercial-SinObraDerivada 4.0 Internacional. (CC BY-NC-ND)
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author Zinola, Guillermo
author2 Etchebehere, Claudia
author2_role author
author_facet Zinola, Guillermo
Etchebehere, Claudia
author_role author
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bitstream.url.fl_str_mv https://redi.anii.org.uy/jspui/bitstream/20.500.12381/5703/3/license.txt
https://redi.anii.org.uy/jspui/bitstream/20.500.12381/5703/1/SIGERA%209%20Resumen%20-%20Guillermo%20Zinola%20-%2031.07.25.pdf
https://redi.anii.org.uy/jspui/bitstream/20.500.12381/5703/2/Libro%20de%20res%c3%bamenes%20IX%20SIGERA%202025.pdf
collection IIBCE en REDI
dc.creator.none.fl_str_mv Zinola, Guillermo
Etchebehere, Claudia
dc.date.accessioned.none.fl_str_mv 2026-10-02T16:19:58Z
dc.date.available.none.fl_str_mv 2026-10-02T16:19:58Z
dc.date.issued.none.fl_str_mv 2025-11-04
dc.description.abstract.none.fl_txt_mv Poultry production in Uruguay is concentrated in the southern region of the country, where egg and broiler production generate 26% of agro-industrial waste. The main residues produced in poultry farms are broiler litter (BL) and laying hen manure (LHM), reaching 81,000 and 3,300 tonTS/year, respectively (Benzano et al., 2016). Although the solids wastes have been used as fertilizer in the region, the excessive application and lack of prior stabilization generated the overload of nutrients in the water basin where the poultry production is concentrated. In this context, the valorization of BL and LHM through anaerobic digestion (AD) is proposed to produce biogas and digestate. The research strategy consists of evaluating the technological, economic, and environmental feasibility of implementing centralized anaerobic co-digestion (CoAD) projects using these residues. In order to assess maximum energy production, the Biochemical Methane Potential (BMP) of BL, LHM, and their mixture at the nationally generated ratio (24:1 in TS) was evaluated. To evaluate the technology in full-scale centralized plants, the performance of AD was studied in reactors operated under continuous flow conditions. Specifically, six continuous stirred-tank reactors with 2 L of effective volume (BRS Bioprocess Control) were fed over 176 days with BL, LHM, and the BL:LHM mixture (24:1). The aim was to determine the operating conditions that yield the highest methane (CH₄) production with minimal reactor volume. Reactors were operated at a constant Hydraulic Retention Time (HRT) of 20 days with a progressive increase in Organic Loading Rate (OLR). Process monitoring included biogas volume measurement and digestate analysis of pH, TS, VS, FOS/TAC, and NH₄⁺. Three steady states were established corresponding to OLRs of 1, 2, and 3 kgVS/m³·d, where the CH₄ concentrations, the digestate characterization (COD, TP, TN, volatile fatty acids, macro- and micronutrients), pathogen, antibiotic resistance, and microbial community composition were also determined. Throughout the assay, pH (6.94 - 7.94), FOS/TAC (< 0.3), NH₄⁺ (200 - 1151 mgN-NH₄⁺/L), and NH₃ (52 - 74 mgN-NH₃/L), were in the reported ranges for these type of processes (Mezes et al., 2011; Dai et al., 2016; Guebitz et al., 2015; Yenigün and Demirel, 2013). Maximum methane yields (YCH₄) were obtained at OLR = 1 kgVS/m³·d (BL: 106 NLCH₄/kgVS, LHM: 229 NLCH₄/kgVS, BL:LHM: 103 NLCH₄/kgVS), which decreased as the load increased to 2 kgVS/m³·d (BL and LHM: 23%, BL:LHM: 17%). When the OLR was raised to 3 kgVS/m³·d, RCH₄ remained similar in the LHM reactors (184 NLCH₄/kgVS), while those containing BL and BL:LHM progressively ceased CH₄ production after day 100. It is presumed that the poor degradation of BL, evidenced by the accumulation of solids in the reactors at the end of the assay, led to a 40% reduction in effective reaction volume, thereby reducing HRT and increasing OLR. As a result, the maximum RCH₄ for LHM was 88% of its BMP, while for BL and BL:LHM it was considerably lower than these BMP results (28% and 37%, respectively).
dc.description.sponsorship.none.fl_txt_mv Agencia Nacional de Investigación e Innovación (ANII)
Instituto Nacional de Investigación Agropecuaria (INIA)
Universidad Tecnológica del Uruguay (UTEC)
dc.identifier.anii.es.fl_str_mv POS_NAC_2023_3_178506
dc.identifier.isbn.none.fl_str_mv 978-65-88155-15-8
dc.identifier.uri.none.fl_str_mv https://hdl.handle.net/20.500.12381/5703
dc.language.iso.none.fl_str_mv eng
dc.rights.*.fl_str_mv Acceso abierto
dc.rights.license.none.fl_str_mv Reconocimiento-NoComercial-SinObraDerivada 4.0 Internacional. (CC BY-NC-ND)
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
dc.source.es.fl_str_mv IX International Symposium of Agricultural and Agroindustrial Waste Management (SIGERA IX). Mar del Plata, 5 de noviembre de 2025
V Simposio de Residuos Agropecuarios y Agroindustriales. Mar del Plata, 5 de noviembre de 2025
dc.source.none.fl_str_mv reponame:IIBCE en REDI
instname:Instituto de Investigaciones Biológicas Clemente Estable
instacron:Instituto de Investigaciones Biológicas Clemente Estable
dc.subject.anii.none.fl_str_mv Ingeniería y Tecnología
Biotecnología del Medio Ambiente
Biotecnología Medioambiental
dc.subject.es.fl_str_mv Poultry farm wastes
Anaerobic co-digestion
Biomethane potential
Completely stirred tank reactor
dc.title.none.fl_str_mv Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
dc.type.es.fl_str_mv Documento de conferencia
dc.type.none.fl_str_mv info:eu-repo/semantics/conferenceObject
dc.type.version.es.fl_str_mv Publicado
dc.type.version.none.fl_str_mv info:eu-repo/semantics/publishedVersion
description Poultry production in Uruguay is concentrated in the southern region of the country, where egg and broiler production generate 26% of agro-industrial waste. The main residues produced in poultry farms are broiler litter (BL) and laying hen manure (LHM), reaching 81,000 and 3,300 tonTS/year, respectively (Benzano et al., 2016). Although the solids wastes have been used as fertilizer in the region, the excessive application and lack of prior stabilization generated the overload of nutrients in the water basin where the poultry production is concentrated. In this context, the valorization of BL and LHM through anaerobic digestion (AD) is proposed to produce biogas and digestate. The research strategy consists of evaluating the technological, economic, and environmental feasibility of implementing centralized anaerobic co-digestion (CoAD) projects using these residues. In order to assess maximum energy production, the Biochemical Methane Potential (BMP) of BL, LHM, and their mixture at the nationally generated ratio (24:1 in TS) was evaluated. To evaluate the technology in full-scale centralized plants, the performance of AD was studied in reactors operated under continuous flow conditions. Specifically, six continuous stirred-tank reactors with 2 L of effective volume (BRS Bioprocess Control) were fed over 176 days with BL, LHM, and the BL:LHM mixture (24:1). The aim was to determine the operating conditions that yield the highest methane (CH₄) production with minimal reactor volume. Reactors were operated at a constant Hydraulic Retention Time (HRT) of 20 days with a progressive increase in Organic Loading Rate (OLR). Process monitoring included biogas volume measurement and digestate analysis of pH, TS, VS, FOS/TAC, and NH₄⁺. Three steady states were established corresponding to OLRs of 1, 2, and 3 kgVS/m³·d, where the CH₄ concentrations, the digestate characterization (COD, TP, TN, volatile fatty acids, macro- and micronutrients), pathogen, antibiotic resistance, and microbial community composition were also determined. Throughout the assay, pH (6.94 - 7.94), FOS/TAC (< 0.3), NH₄⁺ (200 - 1151 mgN-NH₄⁺/L), and NH₃ (52 - 74 mgN-NH₃/L), were in the reported ranges for these type of processes (Mezes et al., 2011; Dai et al., 2016; Guebitz et al., 2015; Yenigün and Demirel, 2013). Maximum methane yields (YCH₄) were obtained at OLR = 1 kgVS/m³·d (BL: 106 NLCH₄/kgVS, LHM: 229 NLCH₄/kgVS, BL:LHM: 103 NLCH₄/kgVS), which decreased as the load increased to 2 kgVS/m³·d (BL and LHM: 23%, BL:LHM: 17%). When the OLR was raised to 3 kgVS/m³·d, RCH₄ remained similar in the LHM reactors (184 NLCH₄/kgVS), while those containing BL and BL:LHM progressively ceased CH₄ production after day 100. It is presumed that the poor degradation of BL, evidenced by the accumulation of solids in the reactors at the end of the assay, led to a 40% reduction in effective reaction volume, thereby reducing HRT and increasing OLR. As a result, the maximum RCH₄ for LHM was 88% of its BMP, while for BL and BL:LHM it was considerably lower than these BMP results (28% and 37%, respectively).
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publishDate 2025
reponame_str IIBCE en REDI
repository.mail.fl_str_mv vcarballo@iibce.edu.uy
repository.name.fl_str_mv IIBCE en REDI - Instituto de Investigaciones Biológicas Clemente Estable
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rights_invalid_str_mv Reconocimiento-NoComercial-SinObraDerivada 4.0 Internacional. (CC BY-NC-ND)
Acceso abierto
spelling Reconocimiento-NoComercial-SinObraDerivada 4.0 Internacional. (CC BY-NC-ND)Acceso abiertoinfo:eu-repo/semantics/openAccess2026-10-02T16:19:58Z2026-10-02T16:19:58Z2025-11-04978-65-88155-15-8https://hdl.handle.net/20.500.12381/5703POS_NAC_2023_3_178506Poultry production in Uruguay is concentrated in the southern region of the country, where egg and broiler production generate 26% of agro-industrial waste. The main residues produced in poultry farms are broiler litter (BL) and laying hen manure (LHM), reaching 81,000 and 3,300 tonTS/year, respectively (Benzano et al., 2016). Although the solids wastes have been used as fertilizer in the region, the excessive application and lack of prior stabilization generated the overload of nutrients in the water basin where the poultry production is concentrated. In this context, the valorization of BL and LHM through anaerobic digestion (AD) is proposed to produce biogas and digestate. The research strategy consists of evaluating the technological, economic, and environmental feasibility of implementing centralized anaerobic co-digestion (CoAD) projects using these residues. In order to assess maximum energy production, the Biochemical Methane Potential (BMP) of BL, LHM, and their mixture at the nationally generated ratio (24:1 in TS) was evaluated. To evaluate the technology in full-scale centralized plants, the performance of AD was studied in reactors operated under continuous flow conditions. Specifically, six continuous stirred-tank reactors with 2 L of effective volume (BRS Bioprocess Control) were fed over 176 days with BL, LHM, and the BL:LHM mixture (24:1). The aim was to determine the operating conditions that yield the highest methane (CH₄) production with minimal reactor volume. Reactors were operated at a constant Hydraulic Retention Time (HRT) of 20 days with a progressive increase in Organic Loading Rate (OLR). Process monitoring included biogas volume measurement and digestate analysis of pH, TS, VS, FOS/TAC, and NH₄⁺. Three steady states were established corresponding to OLRs of 1, 2, and 3 kgVS/m³·d, where the CH₄ concentrations, the digestate characterization (COD, TP, TN, volatile fatty acids, macro- and micronutrients), pathogen, antibiotic resistance, and microbial community composition were also determined. Throughout the assay, pH (6.94 - 7.94), FOS/TAC (< 0.3), NH₄⁺ (200 - 1151 mgN-NH₄⁺/L), and NH₃ (52 - 74 mgN-NH₃/L), were in the reported ranges for these type of processes (Mezes et al., 2011; Dai et al., 2016; Guebitz et al., 2015; Yenigün and Demirel, 2013). Maximum methane yields (YCH₄) were obtained at OLR = 1 kgVS/m³·d (BL: 106 NLCH₄/kgVS, LHM: 229 NLCH₄/kgVS, BL:LHM: 103 NLCH₄/kgVS), which decreased as the load increased to 2 kgVS/m³·d (BL and LHM: 23%, BL:LHM: 17%). When the OLR was raised to 3 kgVS/m³·d, RCH₄ remained similar in the LHM reactors (184 NLCH₄/kgVS), while those containing BL and BL:LHM progressively ceased CH₄ production after day 100. It is presumed that the poor degradation of BL, evidenced by the accumulation of solids in the reactors at the end of the assay, led to a 40% reduction in effective reaction volume, thereby reducing HRT and increasing OLR. As a result, the maximum RCH₄ for LHM was 88% of its BMP, while for BL and BL:LHM it was considerably lower than these BMP results (28% and 37%, respectively).Agencia Nacional de Investigación e Innovación (ANII)Instituto Nacional de Investigación Agropecuaria (INIA)Universidad Tecnológica del Uruguay (UTEC)engIX International Symposium of Agricultural and Agroindustrial Waste Management (SIGERA IX). Mar del Plata, 5 de noviembre de 2025V Simposio de Residuos Agropecuarios y Agroindustriales. Mar del Plata, 5 de noviembre de 2025reponame:IIBCE en REDIinstname:Instituto de Investigaciones Biológicas Clemente Estableinstacron:Instituto de Investigaciones Biológicas Clemente EstablePoultry farm wastesAnaerobic co-digestionBiomethane potentialCompletely stirred tank reactorIngeniería y TecnologíaBiotecnología del Medio AmbienteBiotecnología MedioambientalEvaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manureDocumento de conferenciaPublicadoinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/conferenceObjectInstituto de Investigaciones Biológicas Clemente Estable (IIBCE)Universidad Tecnológica (UTEC)//Ingeniería y Tecnología/Biotecnología del Medio Ambiente/Biotecnología MedioambientalZinola, GuillermoEtchebehere, ClaudiaLICENSElicense.txtlicense.txttext/plain; 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científico-tecnológicohttps://www.gub.uy/ministerio-educacion-cultura/iibcehttps://redi.anii.org.uy/oai/requestvcarballo@iibce.edu.uyUruguayopendoar:9421_32026-10-02T16:19:59IIBCE en REDI - Instituto de Investigaciones Biológicas Clemente Establefalse
spellingShingle Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
Zinola, Guillermo
Poultry farm wastes
Anaerobic co-digestion
Biomethane potential
Completely stirred tank reactor
Ingeniería y Tecnología
Biotecnología del Medio Ambiente
Biotecnología Medioambiental
status_str publishedVersion
title Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
title_full Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
title_fullStr Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
title_full_unstemmed Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
title_short Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
title_sort Evaluation of the operation of continuously stirred tank reactors (CSTR) for the anaerobic co-digestion of broiler litter and laying heng manure
topic Poultry farm wastes
Anaerobic co-digestion
Biomethane potential
Completely stirred tank reactor
Ingeniería y Tecnología
Biotecnología del Medio Ambiente
Biotecnología Medioambiental
url https://hdl.handle.net/20.500.12381/5703