Start-up and operation of the first biogas station for

agricultural crops in the Slovak Republic

M. Hutan, A. Kalina, I. Bodk, T. Petheov, . tifner*
Department of Environmental Engineering, Faculty of Chemical and Food Technology, Slovak University of
Technology, Radlinskho 9, 812 37 Bratislava, Slovak Republic, (E-mail: miroslav.hutnan@stuba.sk)
* STIFI, Zelen Hj 2652, Hurbanovo (E-mail: stifner@pnet.sk)

Abstract
The main objective of this work is an anaerobic treatment of maize silage and a biogas production in
a full-scale reactor. Conditions of start-up and trial operation are described. The anaerobic reactor of
the biogas station is seeded with aerobically stabilized sludge from wastewater treatment plant of
brewery Hurbanovo. This material is not frequently used as an inoculating medium for anaerobic
reactors. Results of start-up process have shown suitability of used sludge for this purpose. Maize
silage is treated in the anaerobic mixed reactor under mesophilic conditions. The volume of
anaerobic reactor is 2450 m3; produced biogas is burnt in a cogeneration unit with electrical power
output 270 kW.
Key words: anaerobic treatment; biogas production; cogeneration unit; maize silage

INTRODUCTION
The cultivation of energy crops can be one of possible alternatives how to diversify agricultural
production and improve economy of an agricultural company. This paper deals with an anaerobic
treatment of maize silage in order to produce biogas. The biogas energy can be used to improve the
energy balance of agricultural company itself or it can be offered to further buyers within a
production of excess energy (e.g. as an electricity supply into the electric main). Maize, which in a
form of silage offers relatively interesting yields (up to 30 tons of total solids - TS per hectare), was
selected as an energy crop in this paper.
There is a little information about anaerobic treatment of the maize silage in literature. Generally it
can be said that studies, focused on anaerobic treatment of fresh or silage vegetal materials have not
shown significant differences in the biogas production. This is discussed, e.g. in the work of Zubr
(1986). Advantage of silage application results from its conservation qualities, i.e. from possibility
of its year-round use independently from the season. Insignificant differences in the biogas
production from fresh or silage material are also obvious from Table 1, which summarizes data
from the work of Gunaseelan (1997).
Frequently used material for the anaerobic treatment is silage from clover grass or alfalfa. One- or
two-stage treatment of silage from these materials is a subject matter of the works of Jarvis et al.,
(1995), Jarvis, (1996), Jarvis et al., (1997) and Nordberg, (1996). In the one-stage treatment process
in which the organic loading rate (ORL) achieved the values to 3 kg/m3.d (volatile suspended solids
- VSS), the biogas production was 0.47 m3/kg (VSS). However in the two-stage process the authors
introduce the values of ORL 5.9 kg/m3.d and the biogas production 0.41 m3/kg (VSS). The
abovementioned works also discuss issues such as process inhibition caused by ammonia and the
impact of trace elements on improvement of the process.
The anaerobic treatment of the maize silage is mentioned in the work of Zauner and Kntzel (1986).
In the batch laboratory models specific methane production of 0.270 0.289 m3/kg TS was
achieved. In the laboratory flow reactor the lower values of specific methane production were
obtained 0.181 to 0.184 m3/kg TS.

Tab. 1 Comparison of the methane production from fresh or silage material

(Gunaseelan, 1997)
Material

Stage

CH4 yield (m3/kg VSS*)

Sugar beet tops

fresh
silage

0.360
0.381

Cauliflower leaves

fresh
silage

0.352
0.341

White cabbage leaves

fresh
silage

0.382
0.343

Rape tops

fresh
silage

0.334
0.330

Mustard tops

fresh
silage

0.300
0.326

Rhubarb tops

fresh
silage

0.316
0.345

Energy cane

fresh
silage

0.245
0.265

Jerusalem artichoke tops

fresh
silage

0.309
0.301

*VSS-volatile suspended solids

Tab. 2 Present situation of biogas plants in Slovak Republic

Electric power
output
kWe

Commencement of
the operation

pig manure, to year 2000 also

poultry manure

6x128

1995

cow manure

50

1998

VPP SPU, Ltd.

Kolany

different substrates, mainly cow

and pig manure

22

2001

PD Kapuany

cow and pig manure, maize

silage

120

2005

maize

272

2005

Biogas plant
AGROS Ltd. Btka
PPD Brezov

STIFI Hurbanovo

Main substrate

Amon et al. (2003) dealt with the biogas production from energy crops maize and clover grass, in
more detail. His works were focused on the biogas production from various varieties of maize in
various stages of ripeness (milk ripeness, wax ripeness and full ripeness). Different varieties
reached the harvesting optimum in different stages of ripeness. Specific methane production ranged
from 0.206 to 0.286 Nm3/kg VSS and the methane yield ranged from 5300 to 8530 Nm3/ha. These
results were achieved from mesophilic (40o C) batch tests of anaerobic degradation, which lasted 60

days. Some varieties showed minimal difference in the methane production in dependence from the
stage of harvest. Some varieties showed the difference of more than 25 % (Saxxo variety, vax
ripeness, Amon et al. 2003).
Presented work was focused on an observation of start-up and trial operation of anaerobic digestion
of maize silage in the first biogas station for treatment of energy crops in the Slovak Republic.
Situation of biogas production from organic wastes or energy crops in not very developed in the
Slovak Republic. Some data on operating biogas plants in Slovakia are shown in Tab.2.

BIOGAS STATION
The technology of maize silage anaerobic treatment is obvious from Fig. 1.
The biogas station was designed according to laboratory results described in the work of Hutan et
al., (2005).
Effective volume of a full scale anaerobic reactor was 2450 m3. The reactor was mixed by two
propeller mixers with horizontal axis of rotation. Fresh silage was dosed by a chain transporter into
the reactor. Silage pits were situated close to the biogas station. Average moisture content of silage
used for the biogas station start-up was about 75 %. Reactor was operated at 37 oC. Expected
production of biogas was about 4200 m3/d. Biogas was burnt in the cogeneration unit with electrical
power output 270 kW and heat power output 479 kW. For the optimum operation of the
cogeneration unit it is necessary to reach the biogas production about 170-180 m3. Gasholder
volume 80 m3 was sufficient because production of biogas was stable. Biogas can be burnt also in
biogas boiler with heat power output 470 kW. The boiler played its main role at the starting time of
the reactor operation, when the reactor was heated by natural gas burning. On the other hand, the
boiler can be used in the situations when cogeneration unit operation is interrupted or if excess
biogas is produced.

TECHNOLOGY WATER
WATER
FUSE
SILAGE DOSING

ANAEROBIC
REACTOR

WASTEWATER
PUMPING
WASTE HEAT
WASTE
HEAT
EXCHANGER

EXCHANGER

ANORGANIC
POLUTANTS

MIXER 1

DIGESTED
SILAGE

MIXER 2
REACTOR
HEATING

SILAGE
JUJCE
PUMPING

GAS BOILER

COGENERATION UNIT

Fig. 1 Scheme of the biogas station in Hurbanovo

NATURAL GAS
MEMBRANE
GASHOLDER

Start-up and trial operation of biogas station

The anaerobic reactor was seeded with aerobically stabilized sludge from wastewater treatment
plant of brewery in Hurbanovo. This material is not frequently used as an inoculating medium for
anaerobic reactor, but the brewery is situated very close to the biogas station and use of this type of
the sludge eliminated the possibility of contamination of anaerobic sludge with pathogen
microorganisms. Possibility of their presence in anaerobic digested sludge from municipal
wastewater treatment plant, which uses to be the common material for anaerobic reactors
inoculation, cannot be excluded. Amount of aerobically stabilized sludge added into the reactor was
about 1700 m3 with concentration of suspended solids of 30 g/l. The reactor was heated to 37 oC
after inoculation. During start-up of the anaerobic reactor biogas production, pH values,
concentrations of volatile fatty acids (VFA), NH4-N, PO4-P, and concentrations of suspended solids
were monitored. Courses of these parameters during first 200 days of the start-up and trial
operation are illustrated in Figs. 2 - 6.
Dose of silage was gradually increased (Fig. 2). Starting amount of silage was 2 tons per day. As it
is obvious from Fig. 2 and 3 (biogas production and VFA concentrations) operation of anaerobic
reactor was stable and biogas production was proportional to silage dose until 100th day of
anaerobic reactor operation. Maximum dose of silage was 20 tons per day during this period.
Average specific biogas production between 50th and 100th day of reactor operation was 0.726
m3/kg of dry silage. In Fig. 4 concentrations of NH4-N and PO4-P are shown. Increase of ammonia
nitrogen and phosphate phosphorus during the first 20 days of anaerobic reactor operation was
caused by degradation of inoculating sludge (similarly as VFA concentration). After 20 days
concentration of NH4-N fell to the value of 200 mg/l and concentration of PO4-P to the value below
20 mg/l. In the presence of such low concentrations of NH4-N the buffer capacity of sludge water
was not sufficient and pH values gradually decreassed (Fig.5). Concentration of VFA increased to
7500 mg/l and production of biogas decreased significantly.
80

8000
dose of silage

3000

40
2000

20

1000

40

80
120
Time [d]

160

200

Fig. 2 Course of silage dosing and biogas

production in the anaerobic reactor

6000

VFA [mg/l]

Dose of silage [t/d]

60

Production of biogas [m 3 /d]

4000

production of biogas

4000

2000

0
0

40

80
120
Time [d]

160

200

Fig.3 Concentration of VFA in filtered

sludge water from the anaerobic
reactor

Since the 120th day of reactor operation it was started with dosing of aerobically stabilised sludge
(the same one that was used for inoculation) for increasing of NH4-N concentration and for the
stabilisation of pH values. Amount of dosed sludge was 7-10 m3/d (concentration of suspended
solids 30 g/l). Concentration of ammonia nitrogen increased up to 600 mg/l (Fig.4), concentration
of VFA decreased (Fig.3) and pH was stabilised at value approximately 7.2 (Fig.5). Dose of maize

silage after reactor stabilisation was 24 tons per day, average specific production of biogas reached
the amount of 0.7 m3/kg of dry silage and cogeneration unit achieved 100 % its capacity.
Concentration of suspended solids after 200 day of reactor operation was to 60 g/l.
800

200

7.4

160

7.2

NH4-N

120
400
80
200

0
0

40

80
120
Time [d]

160

7.0

pH

NH4- N [mg/l]

600

PO4- P [mg/l]

PO4-P

6.8

40

6.6

6.4

200

Fig. 4 Concentration of NH4-N and PO4-P in

filtered sludge water from the anaerobic
reactor

40

80
120
Time [d]

160

200

Fig. 5 Course of pH values in the

anaerobic reactor

During operation of the anaerobic reactor some interesting phenomena were observed. After each
dose of silage temporary increase of biogas production was observed. In Fig. 7 increase of biogas
production (expressed as increase of power output of cogeneration unit) for silage dosing every 8
hours (16 tons per day, each dose 2 t) is shown. Overall production of biogas in these days was
2800 m3 and cogeneration unit was operated at 67 % of maximum capacity (140th day of operation).
Period of higher biogas production duration was about 1 hour. Increase of biogas production after
silage dose shown in Fig. 7 represents 5.13 % of overall production of biogas per one dose of silage.

Power output of cogeneration unit [kW]

Suspended solids in reactor [g/l]

60

50

40

30

20

260
240
220
200
Silage dose

Silage dose

180
160

10
0

40

80
120
Time [d]

160

Fig. 6 Concentration of suspended solids

in the anaerobic reactor

200

2
3
Time [h]

Fig. 7 Increase of power output of cogeneration

unit (biogas production) after silage
dosing

This increase can be caused by degradation of easily biodegradable VFA, alcohols or lower
carbohydrates included in maize silage. Content of these substances in the silage can range between
2.1-11.1 % - Tab. 3.
Tab. 3 Concentration of volatile and readily biodegradable matter in maize silage
(% of dry matter)
Dry matter
(%)

Acid
Lactic Acetic Propionic Butyric

39,2
36,0
31,0
41,0
28,5

6,2
4,2
5,21
2,12
0,56

2,6
1,5
1,28
0,86
0,47

0,2
0,32
0,05
0,01

<1
1,04
0,24
0,01

Ethanol Glucose Fructose Reference*

1,1
1,5
0,17
0,27

0,29
-

0,47
-

1
2
3
4
4

* 1-Offer et al. (2001), 2-McEniry et al. (2006), 3-Danner et al. (2003), 4-Steidlov a Kala (2003)
In the period between two doses quality of biogas also changed. Average concentration of methane
in biogas was 54.5. %; concentration of H2S was 160 ppm. Immediately after the silage dosing the
concentration of methane in biogas decreased by 2 %; similarly in two hours after silage dosing (53
% vs. 55 %). This fact can be explained in such way that during first phases of anaerobic
degradation of silage the acidogenesis with higher CO2 production prevailed. More significant
change of biogas content was achieved during the period of 5-day reactor operation interruption. In
this period concentration of methane in biomass was increased from 52.8 % to 65 %.
For stabilisation of pH values and for production of biogas different substrates were used during
periods when sufficient amount of maize silage was not at disposition. Specific production of
biogas for used substrates is shown in Tab. 4.
In the presence, daily consumption of maize silage is 20 tons per day; average moisture content is
70 %. Concentration of suspenden solids in the reactor is 110-130 g/l. Daily production of biogas is
4200 m3, production of electricity 6000 kWh/d and production of thermal energy ca 9000 kWh/d.
Produced electric (PE) and heat (PH) power output can be approximately calculated as follows:
PE = 2 . (V - 30)

[kW]

V biogas production [m3/h] ang 30 biogas consumption of gas engine [m3]

PH = 2 . (V - 30) . 1,5

[kW]

Tab. 4 Specific production of biogas from various substrates

Substrate
maize silage
corn rests from drying
meat and bone meal
molasses distillery slops

Specific production of
biogas
3
m /kg of dry matter
0.7
1.1
0.36
0.74

CONCLUSIONS

Results of start-up process of the biogas station treating maize silage showed suitability of use
of aerobically digested sludge for inoculation of the anaerobic reactor;

Start-up period of biogas station for maize silage processing was about 100 days;

Daily production of 4200 m3 of produced biogas represents approximately 6000 kWh of

electrical power output per day and about 9000 kWh of heat power output per day;

Part of the heat, obtained by this way, is used to maintain the temperature of the anaerobic
reactor. The rest of obtained energy will be used to heat the companys greenhouses, and in
summer it will be used for the drying of produced crops;

The produced electricity is transferred to the public electric main. The excess sludge from the
anaerobic reactor is used directly as fertilizer or is mixed with straw with the aim to produce
compost.
Acknowledgement: This work was supported by the Grant of Norwegian Financial Mechanism
(NFM), EEA Financial Mechanism and from Slovak State Budget in the frame of project SK0023.
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