the potential for online monitoring of short-term process dynamics in anaerobic digestion using...
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The potential for online monitoring of short-term processdynamics in anaerobic digestion using near-infraredspectroscopy
L. Christian Krapf a,*, Hauke Heuwinkel a, Urs Schmidhalter b, Andreas Gronauer c
a Institute for Agricultural Engineering and Animal Husbandry, Bavarian State Research Center for Agriculture, Voettinger Straße 36, 85354
Freising, GermanybDepartment of Plant Sciences, Technische Universitat Munchen, Emil-Ramann-Straße 2, 85350 Freising, Germanyc Institute of Agricultural Engineering, Department for Sustainable Agricultural Systems, University of Natural Resources and Life Sciences
Vienna, Gregor Mendel Straße 33, 1180 Vienna, Austria
a r t i c l e i n f o
Article history:
Received 10 November 2011
Received in revised form
22 June 2012
Accepted 20 October 2012
Available online 27 December 2012
Keywords:
Biogas production
NIR spectroscopy
PLS regression
Total volatile fatty acids
Volatile solids
* Corresponding author. Tel.: þ49 176 238184E-mail address: [email protected]
0961-9534/$ e see front matter ª 2012 Elsevhttp://dx.doi.org/10.1016/j.biombioe.2012.10.0
a b s t r a c t
This work reports the development of a near-infrared (NIR) spectroscopy online calibration
for monitoring volatile solids (VS) and total volatile fatty acids (VFA) process parameters
during anaerobic digestion (AD). The objective was to investigate its potential to estimate
the dynamics of AD process parameters after feeding events. A recirculation loop was
employed to record online measurements during an eight-month experiment using
a 3.3 m3 pilot plant fed with maize silage under mesophilic conditions. Sampling was
performed to conduct calibrations and subsequent test-set validations, comparing the NIR
spectroscopy estimates to the reference values. The calibrated accuracy in terms of mean
prediction errors (RMSEP) was 3 g kg�1 for VS and 0.9 g kg�1 for VFA in the fresh matter. By
applying the calibrations to time series spectra, the model accuracy provided adequate
indications of the concentration changes, including highly sensitive monitoring of short-
term VFA dynamics.
ª 2012 Elsevier Ltd. All rights reserved.
1. Introduction
Feeding fluctuations can induce process instabilities in agri-
cultural anaerobic digesters used for producing biogas [1],
particularly when using easily hydrolysable feedstock that is
rich in starch, which can result in the rapid formation of
volatile fatty acids (VFA). The accumulation of these inter-
mediates during the anaerobic digestion (AD) process may be
responsible for a drop in pH after depletion of the buffering
capacity [2,3]. This pH drop significantly slows downmethane
formation, inducing the risk of arresting the AD process.
76; fax: þ49 8161 71 4363m (L.C. Krapf).ier Ltd. All rights reserve27
Therefore, digesters are often operated at a less-than-
optimum loading rate [1]. However, from an economical
point of view, full load operation is demanded as long as the
requirements of high conversion efficiencies are being met.
VFA are usually measured offline via wet chemical analysis.
The time delay between sampling and acquiring the analytical
results is a limiting factor, as it does not allow for real-time
assessment [4]. Considering that acid accumulation can
occur within days if not hours, wet chemistry is not an effi-
cient tool for controlling AD. Therefore, to achieve optimum
loading rates, the process must be monitored online. As
.
d.
b i om a s s a n d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0 225
a process analytical technology, near-infrared (NIR) spectros-
copy is considered to be a promising method for biological
process control and has shown its potential in the food sector,
animal nutrition, and the chemical industry [5]. Several
studies focussing on NIR technology for the monitoring of
different AD process indicators have been reported recently.
In an offline approach, Holm-Nielsen et al. [6] developed
calibrations for total solids (TS), volatile solids (VS), ammo-
nium, organic nitrogen, and VFA, including single acids, using
slurry from two commercial biogas plants. An online
approach under laboratory conditions was conducted by
Lomborg et al. [7], in which cattle manure that had been
partially mixed with maize silage was used for the calibration
of TS, VS, VFA, and single acids. Jacobi et al. [8] investigated
the long-term applicability for the online estimation of
VFA, acetic, and propionic acids at a large-scale biogas
plant fed with maize silage. In previous work, we investigated
the potential for the development of robust feedstock
calibrations [9].
These studies demonstrate the high potential of spectro-
scopic methods for monitoring agricultural AD processes.
However, further research is required to investigate the
capability of these methods to adequately describe the
dynamics of the AD processes that can occur during biogas
plant operations. The aim of the present study was to inves-
tigate the applicability of NIR spectroscopy for the online
monitoring of concentration changes in VS and VFA after
feeding events. For this purpose, a pilot plant biogas digester
fed with maize silage was operated for eight months under
highly variable feeding conditions. Thus, the NIR calibration
stability for long-term indications of VS and VFA concentra-
tion courses was evaluated; its potential to visualise short-
term changes of these two parameters and their interaction
after feeding events was also examined.
Fig. 1 e Concentrations of volatile solids (VS) and total volatile f
induced by excess feeding. The OLR refers to the amount of VS
matter.
2. Material and methods
2.1. Experimental setup and process operation
A standing tank digester stirred at 10-min intervals by a verti-
cally mounted agitator was used. With a total capacity of
3.3 m3 (height, 270 cm; diameter, 126 cm; liquid volume,
2.5 m3), the digester was operated under mesophilic condi-
tions. For more than six months prior to the experiment, the
digester was fed at an organic loading rate (OLR), measured in
terms of VS, of 2 kgm�3 d�1. Gas productionwasmeasured via
a drum-type gasmeter (Ritter GmbH, Bochum,Germany) at 10-
min intervals. The gas quality (CO2 and CH4) was recorded via
infrared sensors (Awite GmbH, Langenbach, Germany) every
2 h. The digester temperature was regulated by a sensor
located on the sidewall of the digester, which automatically
controlled the flow of heating water through the closed heat-
ing circuit. Changes in temperature (logged at 10-min inter-
vals) over the range 31e47 �C were induced during the
experiment to include the effects that temperature may have
on the spectra. The digesterwas fedwithmaize silage using an
averageVS concentration of 33%of freshmatter (FM). Irregular
feeding was administered to generate strong variations in the
AD process, with the OLR ranging from no feeding to
35 kg m�3 d�1 (Fig. 1), which corresponds to a hydraulic
retention time of nine days.
During feeding, digester slurry was pumped from the lower
part of thedigester intoa tankwhere itwasmixedwith thesilage
beforebeingrepumpedintotheupperregionofthedigesterusing
a spiral pump.When theOLRwas increased, the ratioof silage to
digester slurry was kept constant by continuous repumping of
the mixture into the digester while adding silage into the tank.
Five phases of organic overload were induced by strongly
atty acids (VFA) during the five phases of organic overload
fed to the digester during one feeding event. FM [ fresh
b i om a s s an d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0226
increasing the amount of silage that was fed to the digester
during the 240 days of the experiment. To allow the digester to
recover from each overload, feeding was usually stopped if the
methaneconcentration inthegasdroppedbelow45%prior to the
next feedingevent. For thefirstphaseoforganicoverload,anOLR
between4.4and6.4kgm�3d�1waschosen. For thesecond, third,
and fourth phases of overload, feeding was increased up to
27 kg m�3 d�1 (day 147), resulting in a VFA concentration of
9 gkg�1 FM.When feedingwas stopped, a sudden recoveryof the
digester was observed, as the accumulated acids were quickly
degraded. For thefifthoverload, anOLRof 35kgm�3 d�1 (day190)
was selected, which caused long-term process imbalances
accompanied by large amounts of propionic acid.
2.2. Spectra acquisition
The spectral data were measured using an external-loop that
was specifically developed to enable online measurements
and process sampling (Anamenter, Hogemann GmbH, Garrel,
Germany). The system was directly connected to the sidewall
of the digester. The inlet was located at the bottom of the
digester and the outlet halfway up the side of the digester. The
digester content was pumped through a stainless metal pipe
(5 cm inner diameter) for the duration of the experiment to
provide continuous loop-circulation. The metal pipe of the
loop was insulated to maintain the temperature of the slurry.
A sapphire window was fitted in an upstream section of the
pipe, and a diode-array spectrometer (X-Three, NIR-Online
GmbH, Walldorf, Germany) was mounted on this window.
Spectra from diffuse reflection were recorded, covering the
400e1750 nm region at a spectral resolution of 10 nm (Si and
InGaAs detectors). The measurement area was 13 mm in
diameter. The raw spectral data captured at intervals of 15 s
were averagedover 3min for onedatapoint.White referencing
was performed automatically at irregular intervals depending
on the collection conditions.
2.3. Sampling and reference analyses
In total, 120 samples were collected. During times of intensive
feeding, sampling was conducted directly before and several
hours after each feeding event. During times of reduced
feeding, sampling was usually performed twice a week.
Primary sampleswere collected via a ball valve in the loop that
was situated after the spectrometer. The spectra that were
Table 1 eDescriptive statistics of the calibration and validation(VFA).
Calibration data set (n ¼ 65)a
Range Mean Median
VS (g kg�1 FM) 53.4e86.5 69.7 69.4
VFAa (g kg�1 FM) 0.2e13.1 5.9 4.8
Temperature (�C) 36.4e47.5 39.9 39.8
FM: Fresh matter; SD: Standard deviation.
a For VFA, calculations for the calibration data set were performed after
n ¼ 64.
recorded over a sampling time of 20 s were averaged and
utilised for subsequent calibration. The volume of the primary
sample ranged from 20 to 30 L depending on the viscosity of
the slurry. From this, a 5-L sub-sample was collected before
a 0.5-L sample was bottled and immediately frozen at �18 �Cuntil the wet chemical analysis. Total solid (TS) concentration
was measured after oven drying at 105 �C to constant mass.
The concentration of volatile solids (VS) was determined after
incineration of the oven dried sample at 550 �C in a preheated
muffle furnace (Heraeus GmbH, Hanau, Germany) for 1 h. The
VFA was measured via distillation (UDK 126 D, Velp, Usmate,
Italy) of the untreated sample and subsequent titration of the
distillate to pH 8.8 using NaOH (Titro Line, SI Analytics, Mainz,
Germany). All of the data presented refer to FM. The analyses
were performed in duplicate. If the difference between the
replicates for one sample was higher than 10%, a third
measurement was recorded. The average value of all repli-
cates determined the reference value that was used for cali-
bration. The standard error of the laboratory analysis (SEL) [10]
was 1.7 g kg�1 for VS and 0.19 g kg�1 FM for VFA.
2.4. Multivariate data analysis
Multivariate data analyses were performed with the log (1/R)
spectra of the 1100e1750 nm region using the Unscrambler 9.8
(Camo, Oslo, Norway). For explorative data analysis, principal
component regression (PCR) [11] was conducted with the
complete data set. Each model that was developed for VS and
VFA was tested with a leave-one-out cross-validation. During
this procedure, each sample in the data set was used for
calibration and validation [12]. By looking for unexplained
variances of X (spectra) and Y (reference), the data set was
probed for outliers. Only those samples that were insuffi-
ciently described by the model and at the same time had
a significant influence were removed. This resulted in the
removal of one sample, which was defined as a Y-outlier for
the VFA. The final calibrations for VS and VFAwere developed
using partial least squares (PLS) regression [13] and test-set
validation. The data set was divided into two sub-sets, one
used for calibration and the other for validation. The samples
obtained during the first and second (day 1e83), and fifth (day
159e240) phases of organic overloadwere used for calibration.
The samples from the third and fourth (day 84e158) phases of
overload were used as a test-set (Fig. 1). Therefore, the cali-
bration and validation sets originated from the same data set
data sets for volatile solids (VS) and total volatile fatty acids
Validation data set (n ¼ 55)
SD Range Mean Median SD
7.2 66.3e91.1 78.5 77.7 6.1
4.5 0.6e8.3 4.2 4.0 2.1
2.3 31.2e40.3 38.8 39.4 1.6
the removal of one sample that was defined as an outlier resulting in
b i om a s s a n d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0 227
and were only independent with respect to time. In total,
65 (64 for VFA) and 55 samples were used for calibration
and validation, respectively. PLS regression was performed
using the raw spectra. Additionally, a first derivative was
applied to reduce morphological structure in the spectra
[14]. The calibrationswith the smallest rootmean square error
of prediction (RMSEP) [15] were selected for time series
evaluation.
2.5. Time series
The selected calibrations were applied to the continuously
measured spectra during the third and fourth phases of organic
overload. The NIR estimates were compared to the 55 reference
values obtained for each parameter. Whether the NIR spec-
troscopy correctly described the long-term trends in the
concentration of both parameters during the variable feeding
was examined. Subsequently, the suitability of the models to
capture short-term changes was tested by focussing on a more
detailed picture of the VS and VFA dynamics estimated by the
PLSmodel. For thispurpose, twodifferent sectionscharacterised
by a VS feed varying from 1.9 to 8.7 kgm�3 d�1 (days 89e93) and
from 7.5 to 20 kg m�3 d�1 (days 144e148) were selected.
3. Results and discussion
3.1. Reference data set characteristics
Descriptive statistics of the calibration and validation data sets
are shown in Table 1. The VS concentrations in the calibration
set varied from 53 to 87 g kg�1 FM; the VS concentrations in the
validation set slightly exceeded this concentration range.
Compared to the validation set, the samples used for calibra-
tion were spread over a wider range with respect to VFA,
ranging from 0.2 to 13.1 g kg�1 FM. The upper value reflects an
acidified AD process, as it is clearly>3 g kg�1 FM, a value that is
Fig. 2 e PLS regression results of the test-set validation (val). LEF
components calculated from the raw spectra (1100e1750 nm). C
fatty acids (VFA) with five PLS components calculated from the
smoothing points, 2nd degree polynomial). Cal n [ 64 (one outli
prediction (g kgL1 FM), FM [ fresh matter.
potentially acritical limit forADinagricultural biogasplants [6].
As collinearity can reduce model stability, correlations in the
calibrationdata set areof interest. A strong correlation (r¼ 0.99)
between the TS and VS was observed, as they differed only by
ash content. Although the VS and VFA concentrations showed
similar behaviour during the experiments (feeding resulted in
a concentration increase, non-feeding in a decrease), only
a small correlation (r ¼ 0.26) was found between the two
parameters within the calibration data set. In contrast, for the
test-set samples, a high correlation between VS and VFA
(r ¼ 0.86) was found. Within the whole data set, a small corre-
lation (r ¼ 0.20) between the two parameters was found, indi-
cating that the parameters vary independently of each other
over the complete experimental period.
3.2. NIR calibration results
Fig. 2 provides an overview of the PLS regression results for VS
and VFA based on test-set validations. Both parameters were
estimated with acceptable accuracy. A mean estimation error
(RMSEP) of 3 g kg�1 FM for the VS is in accordance with results
from another study that reported a RMSECV of 2.6 g kg�1 FM
[6]. Smaller errors were obtained by Lomborg et al. [7], which
may have been because of a reduction in heterogeneity
resulting from the use of ground maize silage in their exper-
iment. The relatively low coefficient of determination
(r2 ¼ 0.76) for VS in the present work compared to Holm-
Nielsen et al. [6] is presumably because of the small overall
variation, which ranges from 66 to 91 g kg�1 FM. To examine
the robustness of the model with respect to temperature
effects, samples measured at different temperatures in the
calibration set were included [16]. Within the calibration set,
the temperature varied from 36 to 47 �C. As larger errors in the
estimates were not observed for the test-set samples at lower
temperatures, it is assumed that the calibration for VS also
accounted for the temperature effects under moderate
extrapolation conditions. The VFA concentration was
T: Calibration (cal) for the volatile solids (VS) with three PLS
al n [ 65, val n [ 55. RIGHT: Calibration results for volatile
first derivative (1100e1750 nm, Savitsky Golay, three
er removed), val n[ 55. RMSEP[ root mean square error of
Fig. 3 e Long-term validation for the third and the fourth phases of overload. NIR estimates and reference values for volatile
solids (VS) and total volatile fatty acids (VFA) are shown together with the OLR and the temperature profile in the digester.
FM [ fresh matter. See also Fig. 1.
b i om a s s an d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0228
estimated with a RMSEP of approximately 0.9 g kg�1 FM
(r2 ¼ 0.85) using the first derivative. In the literature, the error
for this parameter ranges between 0.2 and 1.6 g kg�1 FM and
has been reported for varying experimental conditions and
different validation methods [6,7]. Jacobi et al. [8] performed
an online calibration using a digester fed with maize silage
and employing an experimental setup comparable to the one
reported here. With a RMSECV of approximately 0.8 g kg�1 FM
(r2 ¼ 0.94), a similar VFA performance was achieved.
3.3. Validation: long-term
The models for the two parameters with the spectral
measurements during the third and fourth phases of overload
are illustrated in Fig. 3. Owing to feeding, an increase in VS
was observed in the digester, and this is adequately described
by the model. Additionally, a steady decrease was observed in
the concentration level after feeding was temporarily stopped
(day 94). However, at times, the reference value for VS obvi-
ously differed from the estimates. The dominant contribution
to this difference seems to be associated with the sampling
error. On day 103, the reference value showed an increase in
VS concentration, a change that seems unlikely, as feeding
was stopped on day 94. In contrast, the NIR estimates indi-
cated a smooth downward trend, which presumably describes
the continuous biodegradation of the organic matter in the
digester. Constitutional and distributional heterogeneity of
the digester slurry may be considered important factors that
can influence the sampling error [17].
As in the case of VS, the estimates for VFA also followed
the feeding-induced trend of the reference analyses. The
differences between the estimated and experimental values
were less pronounced compared to those observed for VS.
This is probably because the determination of VFA is less
sensitive to the sampling error because the acids are present
in the aqueous phase. Starting on day 123, the estimates
decreased and approached an implausible value of �2 g kg�1
FM, which was quite different from the reference data. At that
time, the temperature in the digester had been reduced to
approximately 31 �C. After a stepwise increase of the
temperature to 40 �C (day 129), the estimated values again
resembled the reference values. This drift in the estimates
indicates that, in contrast to that of the VS, the model for VFA
was sensitive to temperature changes that were not consid-
ered during calibration. However, before and after this period,
the estimates for VFA also sometimes fell below zero. This
finding most likely reflects the random error of the model at
low acid concentrations and may also indicate a weakness in
the calibration owing to an offset. During the validation phase,
a decrease in temperature coincided with low VFA concen-
tration, and no clear distinction between the temperature
effect and model stability at low concentrations could be
elucidated. At VFA concentrations below 1 g kg�1 FM, Jacobi
et al. [8] also reported different behaviour to that of the esti-
mates, and similarly, Reed et al. [18] for VFA concentrations
below 0.3 g L�1 in sewage sludge. Hansson et al. [19] previously
suggested that this behaviour is related to the detection limit
of the NIR method, which was found to be 0.3 g L�1 for pro-
pionic acid. For the data presented here, further research is
required to assess the calibration stability at the lower model
boundary for both temperature and VFA.
3.4. Validation: short-term
The VS and VFA concentrations followed a similar pattern
during the full validation phase and so did the NIR estimates.
To investigate whether the estimation of VFA was indepen-
dent of VS concentration changes, Fig. 4 illustrates a more
detailed time course between days 89e93 and days 144e148.
In the first period, six different feedings ranging from 1.9 to
8.7 kg m�3 d�1 were administered. After each feeding, the
estimated VS displayed an abrupt increase. Within less than
1 h, the VS reached a new level and then steadily declined,
reflecting the conversion of organic matter into biogas. The
Fig. 4 e Short-term validation: NIR estimates of volatile solids (VS) and total volatile fatty acids (VFA) for days 89e93 and
days 144e148. Between two consecutive feeding events, the correlation coefficient (r) for the estimated values of VS and VFA
were calculated. On day 148, plugging of the external-loop pump resulted in temporarily erroneous measurements.
FM [ fresh matter. See also Figs. 1 and 3.
b i om a s s a n d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0 229
intensity of the feeding had a direct impact on the estimates of
both parameters, and even the second feeding of
1.9 kgm�3 d�1 on day 91 was reflected in the NIR estimates. As
in the case of VS, the VFA estimates also showed a continuous
build up in concentration level after feeding. However, when
the VS concentration was already declining, the estimated
VFA still continued to rise and reached its peak several hours
later. This rise then began to drop comparatively fast, but did
not reach the level prior to feeding. Therefore, owing to the
high overall feeding, a steady accumulation of the acids was
observed over this five-day period. In this regard, the NIR
estimates nicely reflected the expectations of the process
behaviour, both for the quite stable VS parameter and the
highly variable VFA parameter. The high degree of indepen-
dence of the two parameters during the initial hours after
feeding is underlined by their consistently low correlation (r),
which was calculated at each interval between the two
feeding events (Fig. 4). Comparison of the estimated values
with the reference values for both parameters demonstrates
that the relative (precision) as well as the absolute (accuracy)
changes in the concentration levels could mostly be captured
via NIR spectroscopy. Thus, the accumulation of VFA could be
observed even at early stages with 2e3 g kg�1 FM.
The estimates for days 144e148 illustrate the reproduc-
ibility of the results within this work. Owing to a feeding of up
to 20 kg m�3 d�1, both parameters were affected more during
this interval. Unfortunately, a malfunction due to plugging of
the loop-circulation pump occurred on day 148, which
affected the estimates. By comparing the VS concentration
before and after feeding on days 144, 145, and 147, the sharp
increase in the NIR estimates and in the reference values is
less than the increase calculated from the actual amount of VS
fed to the digester. This result is possibly explained by the
formation of a floating layer after these heavy feeding events.
This layer of fresh silage did not enter the loop system as its
inlet was located at the bottom of the digester.
4. Conclusions
Highly reproducible NIRmeasurements can be used for online
indication of short-term dynamics of VS and VFA during AD.
The independence and high sensitivity in the estimation of
both parameters underline that (1) the estimates for VFA were
independent of the VS content and (2) the high potential this
technology offers for theoptimisedprocess operationof biogas
digesters. Themonitoring of relative VS and VFA changesmay
be the key to further process control via NIR spectroscopy, as
feedingmay be adjusted to the current AD process conditions.
b i om a s s an d b i o e n e r g y 4 8 ( 2 0 1 3 ) 2 2 4e2 3 0230
Acknowledgements
This project was financially supported by the Agency for
Renewable Resources (FNR) and the Bavarian State Ministry of
Agriculture and Forests. The authors thank NIR-Online GmbH
and Hogemann GmbH for providing the spectrometer and the
Anamenter.We thank Thomas Schneider and Tomas Qvarfort
for constant support throughout this work.
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