Improving bioreactor efficiencies using advanced sensor system design

The establishment of biogas facilities in developing countries presents significant environmental and economic opportunities. However, structural barriers such as infrastructure deficiencies and insufficient investment severely hinder the effective implementation of biogas technologies in these regions. This situation often results in low efficiency in biogas production or, in some cases, a complete cessation of production. Therefore, enhancing technical capacity and providing institutional support are crucial for the sustainability of biogas projects. Advanced sensor systems enable real-time and high-precision monitoring of critical parameters in bioreactors, thereby facilitating process optimization and enhancing overall efficiency. These systems continuously monitor key variables such as temperature, pH, biogas production, and methane concentration within the bioreactor to ensure the maintenance of optimal operating conditions. By providing real-time data on these variables, they support precise control and regulation of the bioprocess environment. Moreover, smart sensors extend beyond the capabilities of traditional sensors by incorporating data processing and analytical functionalities. As a result, any changes occurring within the bioreactor can be detected instantaneously, allowing for prompt and effective adjustments to be made. The results of the methane sensor calibration conducted in this study demonstrate that variations in methane gas levels within the range of 0-100% can be determined with high accuracy. This enables methane gas measurements, required at the laboratory scale, to be performed in a more cost-effective and time-efficient manner. Both plant-based and animal-based production generate large amounts of organic waste that can be utilized for biogas production. However, this is only successful if biogas facility operators possess adequate expertise, such as preventing the overload of the biogas system. In this study, the anaerobic digestion behavior and optimal biogas production levels of cattle manure and hazelnut shell wastes were determined through laboratory-scale Biochemical Methane Potential (BMP) experiments, where the substrates were digested both individually (mono-) and in combination (co-). The examined wastes yielded 333 and 390 NmL/g COD biogas production for monosubstrate digestion of cattle manure and co-digestion of cattle manure and raw hazelnut shell mixture, respectively. Based on these findings, a model was developed to predict biogas production using the studied agricultural wastes under continuous operation and to propose optimal operating conditions.