2002-01-2521 Anaerobic Digestion for Reduction and Stabilization of Organic Solid Waste During Space Missions: Systems Analysis Qiyong Xu and Tim Townsend Environmental Engineering &. Science University of Florida David Chynoweth, Patrick Haley, John Owens, and Elana Rich Agricultural and Biological. Engineering University of Florida Sabrina Maxwell Boeing Hong-Lim Choi Animal Science and Technology Seoul National University safe treatment of the wastes produced by the crew. The waste stream not only can be deleterious to the crew because of the existence of pathogens or the concentration of toxic substances, but also includes many resources (water, nutrients, etc.) vital to the life support of the crew. So the purpose of treating wastes includes the reduction of waste mass, volume, odor, and toxic materials and the regeneration of inorganic nutrients. Because of the resupply constraints in long duration missions, waste treatment and recycle become a critical component to future long duration space missions. ABSTRACT High Solids Leachbed Anaerobic Digestion (HSLAD) is a biological waste treatment system that has been successfully demonstrated for solid waste treatment in terrestrial applications. The process involves a solid phase leach bed fermentation, employing leachate recycle between new and mature reactors for inoculation, wetting, and removal of volatile organic acids during startup. HSLAD also offers a potential option for treatment of biodegradable wastes on long-duration space missions and for permanent planetary bases. This process would produce 1.5 kg of methane, 4.1 kg of carbon dioxide and 1.9 kg of compost from 7.5 kg of biodegradable solid wastes generated daily from a crew of six. HSLAD can operate at low temperature and pressure and has the potential for being a net energy producer. A detailed analysis of this process was conducted to design the system size required for a space mission with a 6-person crew. The mass, energy and water balance of the process and an equivalent system mass (ESM) analyses are presented. In general, solid waste treatment includes collection, size reduction, conversion, and post-treatment. Processing technologies can be further divided into pre- and post-processing (PPP), and physicochemical (PC) and biological primary (BC) processing [14]. PPP processes are used to separate and size-reduce waste, reduce volume, prepare for primary processing systems and further refine products. Some PC processes, including incineration, electrochemical oxidation, thermal destruction and pyrolysis, can deal with most solid waste stream components and can accommodate very high feed rates, converting the wastes INTRODUCTION One of the prerequisites to a successful long duration space mission is the efficient and 1 Reactor Reactor Stage 2 New Mature Reactor Reactor Stage 1 Reservoir Activated Reservoir Filling Aerobic Reactor Stage 3 Pump C Pump A Pretreatment Pump B Anaerobic Digestion Post-treatment Figure 1. Schematic of HSLAD System almost entirely to end products [1]. However, HIGH SOLIDS LEACHBED PC techniques often require significant ANAEROBIC DIGESTION (HSLAD) power and heat rejection capabilities. Thus, as has been pointed out by numerous PROCESS DESCRIPTION authors, PC is expected to be more suitable for intermediate durations (up to several years)[7], but not necessarily for long Like other composting methods, HSLAD is a duration space missions (of the order of solid state microbial waste treatment process decades) where nutrients contained in waste that yields a stabilized organic residue and need to be recycled. recycles nutrients. Compared with other biological technologies, HSLAD has In contrast, biological processes (BC) can advantages, including simple operation, low efficiently recapture valuable nutrients energy requirements, low temperature and contained in solid waste while providing a pressure working conditions, and is a number of secondary functions such as potential energy producer. [2] oxygen production, carbon dioxide absorption and water purification. However, HSLAD involves three main phases: biological processes require high mass and pretreatment, anaerobic digestion, and volume investment to maintain adequate post-treatment. growth conditions for microorganisms and plants. Also, retention times for biological Pretreatment systems are typically longer than PC systems. These characteristics make To improve treatment efficiency of HSLAD, it biological processes most appropriate for is necessary to pretreat the solid waste longer missions [7]. generated by a 6-person crew. The biodegradable solid wastes, such as inedible This work is part of a project consisting of plant biomass and paper, are collected, three parts: laboratory scale feasibility, coarsely shredded to 2-5 cm, and then system analysis, and prototype digester compacted to 300 kg-ash free dw/m3. design and optimization. The laboratory scale feasibility work focusing on digester Anaerobic Digestion design and optimization is presented in a companion paper by Chynoweth et al. (2002). This paper addresses the current As shown in Figure 1, the AD process design of the anaerobic digestion system, involves three stages of digestion that occur the integration with other station operations, sequentially as conversion proceeds. The and calculation of mass balance and waste does not get removed, but passes equivalent system mass. through the different stages. In Stage 1, after the shredded waste is placed into the new reactor, leachate will be recirculated 2 between the mature reactor and the new reactor, providing nutrients and bacteria from the mature reactor to the new reactor and removing volatile organic acids from the new reactor. Fermentation products, such as volatile acids formed during start-up, are removed to the old reactor where they are converted to methane. In Stage 2, the reactor is activated and leachate is recycled to itself. In stage 3, the reactor is recycled with a new reactor for startup. The residence time of all three anaerobic digestion stages is 15 days [15]. Future long-duration space missions could require crews to go beyond Earth-orbit for periods on the order of two to three years or more. Whether wastes generated by the crew can be treated safely and recycled efficiently or not is one of the limiting factors for long-duration space missions. The HSLAD process may provide bioregenerative solutions to other technical challenges of space missions including water reclamation, reformation of hydrogen and carbon, and air revitalization. APPLIED WASTE STREAM Post-treatment Wastes produced during space missions can be classified into crew waste, life support system waste, and payload waste [14]. Crew waste includes metabolic waste and related materials such as packaging, food containers, and wipes for housekeeping and personal hygiene, and trash. Life support system waste is waste generated by the Environmental Control and Life Support System (ECLSS) itself, and payload waste are any waste generated specific to a payload, such as animal metabolic wastes and plant residues. Table 1 shows the estimated results of a model for daily solid waste streams generated for a 6-person crew in Mars exploration mission [17]. As shown in Figure 2, the most significant components of wastes are inedible plant waste, packing materials and paper. Other solid wastes may be expected from both the air and water processing operation. After anaerobic digestion is complete, the remain solid residues which have been separated, are aerated for 1 day to remove lingering reduced compounds (NH3, H2S and remaining VOA) and dewatered to 30-35% moisture. During this aerobic step, the compost may be heated to 70oC for one hour to ensure removal of pathogens. In practice, HSLAD is a very stable waste management system, which has been proven by successful demonstration on a variety of high-solids feedstocks, including woody biomass, the organic fraction of municipal solid waste, and yard waste. [3]. The conversion efficiency is a function of the biodegradability of the feed components, ranging from 50-90% and the organic matter is converted to methane, carbon dioxide, and compost with a residence time of less than 15 days. The process is resilient and can start up rapidly after being dormant for Table 1. Estimates of daily solid waste streams for a 6-person crew during a 600-day exploratory mission (Adapted from Verostko et al. 2001) Organic Dry Wt., Percent of Ash, % Waste Component Matter, dry Moisture, % Kg total dw kg Dry human waste 0.72 9.4 5 0.68 85 Inedible plant biomass 5.45 51.4 5 5.2 75 Trash 0.56 5.3 5 0.53 10 Paper 1.16 10.9 5 1.1 10 Packaging materials 2.02 19.0 Tape 0.25 2.4 Filters 0.33 3.1 Misc. 0.07 0.7 Total 10.6 100 30 7.5 61 several months. 3 Filters 3.1% Misc. 0.7% Dry Human Waste 6.8% Tape 2.4% Paper 11.0% Packaging Materials 19.1% Inedible Plant Biomass 51.6% Trash 5.3% Figure 2. Space Mission Waste Composition Dry Wt. Basis Assuming the reactor is rectangular tank, with a height to side ratio of 2 and it is necessary to add an additional 25% to the height for leachate distribution and collection, the practical dimension of the reactor can be calculated as follows: SIZING OF HSLAD REACTOR VOLUME For a typical 15-day anaerobic digestion cycle (5 days for one anaerobic stage), each reactor contains 5-days worth of solid waste. So, the amount of ash free waste in each reactor is: V L2 H ………………………….………(3) 7.5 kg waste/day 5 days = 37.5 kg waste ………………………..………………(1) H H ' / 1.25 …………..……………………(4) H ' / L 2 ………………………..…………(5) After compaction, the density of the biodegradable waste is 300 kg (ash free dw)/m3. If the sides of the reactors are L= 0.43 m, the height of the reactors is H’ = 0.86 m, the waste height is H = 0.69 m, then the practical reactor volume is VP = 0.16 m3 Reactor volume (V) needed for wastes is: V 37 .5 kg 300 kg / m 3 0.125 m3…………………(2) Table 2. Design Parameters of HSLAD for Space Mission (6-person crew) Total Side Volume Pressure Pump Height (m) Leachate length (m) (m3) (kPa) Energy (kJ) 3 Volume (m ) Reactor 0.86 0.43 0.16 7 Water Reservoir 0.86 0.54 0.25 7 Pump A 145 101.5 Pump B 145 101.5 Pump C 145 101.5 4 According to Darcy’s Law, the hydraulic head of leachate (h) can be calculated as follows: WATER RESERVOIR VOLUME As shown in Figure 3, two water reservoirs are used in the HSLAD system, which mainly provide the necessary leachate equal to amount to optimal moisture content of 70%. In addition, the reservoirs can serve as gas separators and replace water lost due to evaporation and due to removal of entrapped biogas bubbles in solid leach-bed. q K i K hH H ……………………..(9) Q Q q 2 A L ……………………….………(10) h = 14.8 m After the dry waste is compacted to 300 kg ash free dry wt/m3, some water and leachate must be added to achieve a wet density of approximately 1000 kg/m3. This is the hydraulic head of water and can be converted to pressure: For one reactor, the total amount of water required will be the sum of required water and the head space water: So, 145 kPa (21 psi) pressure should be provided by pump. And the energy required by pump can be calculated as follows: 0.125 m 3 (1000 300 ) kg / m 3 (0.16 0.125 ) ET P Q 101 .5 kJ…………..……..….(12) P water g h 145 kPa ………...……...(11) 0.123 kg 0.123 m 3 H 2 O And the results of pump design are listed in table 2. ……………………………………..………(6) MASS AND WATER BALANCE ANALYSIS There are two reservoirs in HSLAD system and it is assumed that 25% volume of each reservoir is always filled with leachate. So the total amount of water needed is: As mentioned before, a 6-person crew would generate about 10.6 kg-dw/d, including 7.5 kg ash free organic matter. The organic matter can be biodegradated by bacteria into methane, carbon dioxide, compost and other trace biogases. Biochemical reactions occurring in anaerobic composting include: 0.123m 3 3 2 0.25Vreservoir 2Vreservoir …(7) The volume of reservoir is 0.25 m 3. Assuming reservoir has the same height as the reactor, 0.86m. the side length of reservoir is 0.54 m. C 6 H 12O6 3CH 4 3CO2 …………….(13) PUMP DESIGN Protein CH 4 CO2 H 2 S NH 3 ….(14) To recirculate the leachate from the reservoir to the reactor, a pump must be used to provide energy. As calculated above, for one reactor, the required leachate volume is 0.0875 m3. Based on the operational experience, it is assumed that the total leachate recirculation flow rate is 8 times the required leachate volume per day, (0.0875 m3). However, the pumps operate only 30 minutes every 2 hours. So the average leachate recirculation flow rate is: Q 8 0.0875 Fats CH 4 CO2 …………………….(15) The conversion of organic matter in the HSLAD systems is a function of feedstock, ranging from 50-90%. Based on the composition of solid wastes generated by a 6-person crew, it is assumed that about 75% solid wastes can be biodegraded. According to the mass balance law, the solid waste balanced reaction can be written as follows: m3 24 min ( 30 ) day 2 day ………..(8) 1.9 10 3 m 3 / min 5 Table 3. Mass and Energy Balance of HSLAD System Balance Input Output Mass(kg) 7.5 kg biodegradable waste 1.5 kg methane, 4.1 kg carbon dioxide and 1.9 kg compost Energy(kJ) 3.18104 5.8104 7.5 kg biodegradable solids 1.5 kg CH 4 ETotal E heat E pump 3.18 10 4 kJ …….(20) (1.3 m 3 ) 4.1kg CO2 (1.3 m 3 ) 1.9 kg compost ……………………....(16) Energy Potential Moisture content plays an important role in HSLAD operation and the optimal moisture content is about 70%. After pretreatment, the moisture content of solid waste is lower than 70%. So, it is necessary to add extra water for HSLAD operation. Biogas produced from the HSLAD process is similar to “ natural” gas except for dilution by CO2. The biogas has a lower calorific value than natural gas, approximately 22,248 kJ/cubic meter for biogas versus 40,789 kJ/cubic meter of natural gas. According to (16), the volume of biogas produced by the solid waste is 1.3+1.3 =2.6 m 3. So, the energy containing in the biogas can be calculated as follows: As mentioned above, the total amount of water needed to operate the HSLAD system is the total volume of the reservoirs, 0.5 m 3. The only water consumption in the process is loss via evaporation in the biogas (very small amount) and the water that leaves in the final compost. Because 75% solid waste can be degraded in HSLAD system and the moisture content of the final compost is 70%, the amount water that should be added to compensate water consumption is: (1.3 1.3) m 3 22248 kJ/m3 5.8 10 4 kJ .per day………………………………………..(21) If additional energy conversion equipment and enough oxygen can be provided, the process energy requirements could be offset by the fuel value of the biogas. 7.5 (1 75%) 70% 1.3 kg / day ………(17) As shown in Table 3, the HSLAD process would produce 1.5 kg of methane, 4.1 kg of carbon dioxide, and 1.9 kg of compost daily from 7.5 kg of biodegradable solid waste generated daily from a crew of six. According to the energy balance analysis, the energy potential of the biogas produced by solid waste is greater than the energy requirement of HSLAD. In other words, the HSLAD system would be used as energy producer if additional energy conversion equipment and enough oxygen are provided. ENERGY BALANCE ANALYSIS Although electrical energy will be required to operate the pump and heat systems, the HSLAD process has the potential for being a net energy producer. Energy Requirement Because the anaerobic reactors are self-heating systems and can keep themselves at 350C without significant additional heat input, the main energy consumption is pump operation and water heating from 200C to 350C INTEGRATION POTENTIAL ANALYSIS WASTEWATER RECLAMATION Eheat m w T 3.1510 4 kJ ………..(18) One of the potential advantages of HSLAD is that it can pretreat wastewater through reducing Biochemical Oxygen Demand (BOD), volatile organics, and dissolved and suspended solids in wastewater. For any E pump 3 101 .5 10 4 305 kJ …………..(19) 6 biological system, moisture plays a vital role in growth, metabolism, solute transport, and other functions. Moisture content can range from 55 to 70% for a solid-phase system such as composting, and approximately 98% for an aqueous system. The optimal moisture content for the HSLAD operation is 70%; however, after the shredding and compaction process in pretreatment, the moisture content of solid waste is less than 70%. The wastewater from clothes washing and dish washing would be used as the makeup water needed for the HSLAD conversion of solid waste. As calculated above, 1.3 kg waste water must be added per day for HSLAD operation. biomethanogenesis reaction and can be accomplished in the same reactor used for the proposed anaerobic stages of solid waste conversion. H2 consumption could be used for intermittent fine control of LSS gases and CH2 could be disposed to space to eliminate C without the loss of O. BIOFILTRATION OF AMBIENT AIR In the post-treatment of the HSLAD system, the remaining solids are treated with ambient air to oxidize reduced residues and control pathogens in the compost. A possible use of compost is to absorb air contaminants, such as VOCs and NH3, because compost contains organic material and has a large surface area where microorganisms can attach and grow. When the ambient air passes through the compost, the compost can absorb particles and chemicals in ambient air and the microbial population in compost can degrade a wide array of VOCs Additionally, NH3 can be captured and converted to nitrate through nitrification for return to a plant growth system [11]. REFORMATION OF CARBON DIOXIDE AND HYDROGEN A closed Advanced Life Support (ALS) system must include a CO2 removal subsystem to reduce carbon dioxide produced from crew respiration and combustion. Since the oxygen supply from plants is relative limited especially in the space mission with low food closure, water could be electrolyzed to provide oxygen, but hydrogen would be produced as a byproduct. So it is desirable to develop a subsystem to reduce both CO2 and H2. The compost biofilter can handle a wide range of loading rates with low mass, water, power and maintenance requirements and simultaneously remove many trace air contaminants. HSLAD can provide a bioregenerative alternative for hydrogen oxidation using carbon dioxide as the electron acceptor. PLANT GROWTH SUBSTRATE CO2 4H 2 CH 4 2H 2 O …………….(22) Another potential use of HSLAD compost is as a nutrient-rich plant growth medium. Compost contains substantial amounts of inorganic nutrients vital for plant growth. The reaction is a well-known CO2 Reduction Subsystem Biogas Processing Subsystem Wastewater Treatment Subsyste Air Cleaning Subsystem 2 m H S Waste Biodegradable Size Collection Reduction Material Subsystem Macerate Leachate Recirculation Pretreatment Wastewater L Anaerobic Digestion D Aeration Post-treatment Ambient Air CO +H 2 A 2 7 Figure 3. Schemic of HSLAD with other subsystems Plant Growth System Plants themselves can effectively extract nutrients that remain in the compost. Additionally, for some nutrients that are poorly extracted during short-term aqueous extraction, it is possible from them to be recovered over the long term through direct extraction by the plant root system. [11]. parameters of HSLAD must be determined MASS Because of practical and budget limitations, the mass of the full-scale test unit under construction is expected to be around 1000 lb. However, an actual system for space applications is anticipated to have a mass of less than 400 pounds (181 kg) by taking advantage of lighter, durable materials. EQUIVALENT SYSTEM MASS (ESM) CALCULATION OF HSLAD Equivalent System Mass (ESM) is a technique by which several physical quantities that describe a system or subsystem may be reduced to a single physical parameter—mass [9]. In 1999, ESM was selected as the basis of the NASA Advanced Life Support (ALS) Project Research and Technology Development Metric. The advantage of ESM analysis is that it allows the comparison of two life support systems with different parameters using a single scale. VOLUME The arrangement of five reactors and two water reservoirs is shown in Figure 5. So, the volume of HSLAD (V) follows: can be calculated as V 2 11 2 m 3 …………………………(23) POWER AND COOLING As stated in the energy balance analysis, the energy requirements of HSLAD is 3.18104 kJ. The power requirement is: The computation of ESM depends on the mission being considered. In the ALS Metric, three missions are baselined; namely, low-earth orbit (LEO), Mars Transit, and Martian surface. The HSLAD would be considered the Mars Surface mission. To calculate the ESM of HSLAD, the operation 0.43 0.43 0.43 0.43 In general, the cooling requirement is 8 times as the power requirement. So the cooling requirement is 2.9 kW. 3.18 10 4 kJ / day 0.37 kW ……………(24) 86400 sec/ day CREW TIME Based on practical operational it 0.43 0.54 experience, 0.54 0.43 Reservoir 0.86 Reactor 1.00 0.54 1.00 0.43 ESM may be used to objectively evaluate different systems based on their mass, volume, power, cooling, crew time and resupply requirements. The technology with the lowest ESM value is the most cost effective option for the mission being considered, provided the options have the same function reliability [13]. Reservoir Reactor 1.00 2.00 (a) Plain view (b) Elevation view Figure 4 Arrangement of Reactors and Reservoirs 8 Table 4. ESM of HSLAD Parameter of HSLAD Cost Factors for Mars Surface ESM (kg) 181 kg 1 kg/kg 181 Volume 2 m3 2.08 kg/m3 4.16 Power 0.37 kW 86.9 kg/kW 32 Cooling 2.9kW 66.7 kg/kW 193 0.417 hr/person-wk 4923 kg( hr/person-wk) 2053 0 kg 1 kg/kg 0 Mass Crew Time Logistics Sum 2463 is assumed that the crew time for operating the HSLAD system is 10 min per day for regular operation, 2 hours per month for inspection and maintenance, and 2 days per year for parts replacement. RESEARCH NEEDS Evaluation of HSLAD for reduction and stabilization of waste during space missions is at the initial stage. Some areas that need to be researched to refine this analysis include: So, crew time = 0.417 hr/person-wk. The calculation of ESM for HSLAD is shown in Table 4. Designing hypo-gravity In Table 5, ESM assessments were made for Mars Planetary Missions. These calculations only represent the crew time independent costs as insufficient data exists on the technologies. As a result, the HSLAD system has a relatively low ESM value, which substantiates that HSLAD is one technology that should be considered for further R&TD. Testing proposed feeds and for Designing for optimization, automation, and safety controls Determining the effectiveness pretreatment of station wastewater Evaluating the conversion yields and kinetics of reformatting carbon dioxide Table 5. ESM comparison of different waste technologies Mass Volume Power Cooling Technology (kg) (m3) (kW) (kW) storage 50 1.01 0 0 bulk compaction 50.1 0.81 0.35 0.35 pyrolysis 42.5 0 0.6 0.4 sterilization 85 1.29 0.3 0.3 pyrolysis/scw 6 0 2 0.4 batch incineration 220.2 0.64 0.38 2.01 drying 132.5 1.02 2 2 composting,7days 401.5 2.03 0.09 0.8 dry size reduction 135 4.21 2 2 scwo 633.2 0.36 0.73 3.81 lyophilization 342.1 0.74 0.95 7.79 composting, 21days 1046.5 4.24 0.1 0.8 continuous incineration 323.2 4.63 6.68 7.81 wet size reduction 223.5 5.15 16 14.4 plasma arc 1170.2 3.97 34.88 38.81 activated carbon production 26.7 0.12 31 110.7 single cell protein 113.5 80.68 80 80 electrochemical oxidation 3330.2 5.17 20.08 700.71 HSLAD 181 2 0.37 2.9 9 operating ESM of Mars Surface 71 121 121 157 207 401 461 505 530 959 960 1197 1522 2683 6877 10110 14090 51923 410 for and hydrogen Determining nutrient balance 2. Evaluating finished anaerobic compost as a medium for biofiltration Determining the extent and kinetics of conversion in aerobic post treatment 3. The results of some of these needs are presented in another paper at this conference [18]. 4. CONCLUSIONS High Solids Leachbed Anaerobic Digestion (HSLAD) uses a combination of solid phase fermentation and leachate recycle to provide a simple, reliable process that inoculates the new batch, removes volatile organic acids, and concentrates nutrients. It not only operates at low temperature and pressure, but can also transform the biodegradable waste into resources without production of any noxious odors or pollution, and has the potential for being a net energy producer. 5. 6. 7. HSLAD has a potential ability to integrate with other subsystems, such as wastewater treatment and the carbon dioxide reduction system. With proper integration with other subsystems, it can effectively reduce the total equipment mass and improve the treatment efficiency of wastewater and air purification. 8. 9. Compared with other biological waste processes, HSLAD system has a relative low ESM value, which indicates to some extent that HSLAD is a cost effective technology. 10. ACKNOWLEDGEMENTS 11. The authors would like to gratefully thank Hwidong Kim, Belinda Grothpietz, Valerie Paredeo and Heng Li for their aid in the research. This work was supported by a grant from the NASA/UFL Environmental Systems Commercial Space Technology Center. 12. 13. REFERENCES 1. Blersch, D.M., Biermann, E., and Kangas, P. 2000. Preliminary Design Considerations on Biological Treatment 14. 10 Alternatives for a Simulated Mars Base Wastewater Treatment System. 2000-01-2467. Chynoweth, D.P., Bosch, G, and Earle, J.F.K.,et. al 1991. A Novel Process for Anaerobic Composting of Municipal Solid Waste. 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DEFINITIONS, ACRONYMS, ABBREVIATIONS HSLAD: High Solids Leachbed Anaerobic Digestion ESM: Equivalent System Mass PPP: Pre- and Post-Processing PC: Physicochemical SEBAC: Sequential Batch Anaerobic Composting ECLSS: Environmental Control and Life Support System ALS: Advanced Life Support LEO: Low-Earth Orbit BOD: Biochemical Oxygen Demand VP: Practical Reactor Volume (m3) H’: Height of Reactor (m) H: Height of Waste (m) L: Length of Reactor Side (m) A: Area of Reactor (m2) Q: Flow (m3/min) q: Area flow rate (m/min) i: Gradient K: Hydraulic Conductivity,4.5103 m/min h: Hydraulic Head (m) P: Pressure (Pa) w: Specific heat of water ,4.3 kJ/kg.0C 11