Physical modelling of the composting environment: a review. Part 2: Simulation performance

This paper reviews previously published heat balance data for experimental and full-scale composting reactors, and then presents an evaluation of the simulation performance of laboratory and pilot-scale reactors, using both quantitative and qualitative temperature profile characteristics. The review indicates that laboratory-scale reactors have typically demonstrated markedly different heat balance behaviour in comparison to full-scale systems, with ventilative heat losses of 36-67%, and 70-95% of the total flux, respectively. Similarly, conductive/convective/radiative (CCR) heat losses from laboratory reactors have been reported at 33-62% of the total flux, whereas CCR losses from full-scale composting systems have ranged from 3% to 15% of the total. Full-scale windrow temperature-time profiles from the literature were characterised by the present authors. Areas bounded by the curve and a 40 degrees C baseline (A(40)) exceeded 624 degrees C. days, areas bounded by the curve and a 55 degrees C baseline (A(55)) exceeded 60 degrees C days, and times at 40 and 55 degrees C were >46 days and >24 days, respectively, over periods of 50-74 days. For forced aeration systems at full scale, values of A(40) exceeded 224 degrees C days, values of A(55) exceeded 26 degrees C days, and times at 40 and 55 degrees C were >14 days and >10 days, respectively, over periods of 15-35 days. Values of these four parameters for laboratory-scale reactors were typically considerably lower than for the full-scale systems, although temperature shape characteristics were often similar to those in full-scale profiles. Evaluation of laboratory-, pilot- and full-scale profiles from systems treating the same substrate showed that a laboratory-scale reactor and two pilot-scale reactors operated at comparatively high aeration rates poorly simulated full-scale temperature profiles. However, the curves from two moderately insulated, self-heating, pilot-scale reactors operated at relatively low aeration rates appeared to closely replicate full-scale temperature profiles. The importance of controlling aeration rates and CCR losses is discussed and further work suggested in order to investigate the links between simulation of the composting environment and process performance.     

Composting in small laboratory pilots: performance and reproducibility

Small-scale reactors (<10 l) have been employed in composting research, but few attempts have assessed the performance of composting considering the transformations of organic matter. Moreover, composting at small scales is often performed by imposing a fixed temperature, thus creating artificial conditions, and the reproducibility of composting has rarely been reported. The objectives of this study are to design an innovative small-scale composting device safeguarding self-heating to drive the composting process and to assess the performance and reproducibility of composting in small-scale pilots. The experimental setup included six 4-l reactors used for composting a mixture of sewage sludge and green wastes. The performance of the process was assessed by monitoring the temperature, O₂ consumption and CO₂ emissions, and characterising the biochemical evolution of organic matter. A good reproducibility was found for the six replicates with coefficients of variation for all parameters generally lower than 19%. An intense self-heating ensured the existence of a spontaneous thermophilic phase in all reactors. The average loss of total organic matter (TOM) was 46% of the initial content. Compared to the initial mixture, the hot water soluble fraction decreased by 62%, the hemicellulose-like fraction by 68%, the cellulose-like fraction by 50% and the lignin-like fractions by 12% in the final compost. The TOM losses, compost stabilisation and evolution of the biochemical fractions were similar to observed in large reactors or on-site experiments, excluding the lignin degradation, which was less important than in full-scale systems. The reproducibility of the process and the quality of the final compost make it possible to propose the use of this experimental device for research requiring a mass reduction of the initial composted waste mixtures.     

Practical Simulation Of Composting In The Laboratory

A closed incubation system was developed for laboratory simulation of composting conditions at the interior of a large compost pile. A conductive heat flux control system (CHFC) was used to adjust the temperature of the internal wall to that of the compost center and compensate for heat loss. Insulated small vessels (400 cm³) controlled by the CHFC system were compared with similar vessels maintained at 30°C (mesophilic) and 55°C (thermophilic), and with large vessels (10 000 cm³) with and without the CHFC. Compost temperature rose rapidly to a maximum within 2-4 days, then gradually decreased. In mesophilic treatments (no CHFC), temperature at the matrix center increased to a maximum of 36°C in the small vessel and 50°C in the large vessel, while temperature in both vessels reached 50°C with the CHFC. Microbial activity was maintained by allowing compost to self-heat and controlling temperature externally with the CHFC. Higher temperatures were sustained for longer periods in CHFC vessels than in vessels without the CHFC. Periodic mixing of the compost matrix increased temperature and CO₂ evolution. Small vessels were successfully used in laboratory simulation of field-scale composting of a soil/organic matrix containing TNT and RDX munitions. The small vessel system reduced subsample error in compost monitoring from that of the large vessels. The CHFC has particular utility in research requiring expensive chemicals or hazardous substances.     

Utilization of solar energy in sewage sludge composting: Fertilizer effect and application

Three reactors, ordinary, greenhouse, and solar, were constructed and tested to compare their impacts on the composting of municipal sewage sludge. Greenhouse and solar reactors were designed to evaluate the use of solar energy in sludge composting, including their effects on temperature and compost quality. After 40 days of composting, it was found that the solar reactor could provide more stable heat for the composting process. The average temperature of the solar reactor was higher than that of the other two systems, and only the solar reactor could maintain the temperature above 55 °C for more than 3 days. Composting with the solar reactor resulted in 31.3% decrease in the total organic carbon, increased the germination index to 91%, decreased the total nitrogen loss, and produced a good effect on pot experiments.     

Laboratory studies of the remediation of polycyclic aromatic hydrocarbon contaminated soil by in-vessel composting

The biodegradation of 16 polycyclic aromatic hydrocarbons (PAHs), listed as priority pollutants by the USEPA, present in a coal-tar-contaminated soil from a former manufactured gas plant site was investigated using laboratory-scale in-vessel composting reactors to determine the suitability of this approach as a bioremediation technology. Preliminary investigations were conducted over 16 weeks to determine the optimum soil composting temperature (38, 55 and 70 degrees C). Three tests were performed; firstly, soil was composted with green-waste, with a moisture content of 60%. Secondly, microbial activity was HgCl2-inhibited in the soil green-waste mixture with a moisture content of 60%, to evaluate abiotic losses, while in the third experiment only soil was incubated at the three different temperatures. PAHs and microbial populations were monitored. PAHs were lost from all treatments with 38 degrees C being the optimum temperature for both PAH removal and microbial activity. Calculated activation energy values (E(a)) for total PAHs suggested that the main loss mechanism in the soil-green waste reactors was biological, whereas in the soil reactors it was chemical. Total PAH losses in the soil-green waste composting mixtures were by pseudo-first order kinetics at 38 degrees C (k = 0.013 day(-1), R2 = 0.95), 55 degrees C (k = 0.010 day(-1), R2 = 0.76) and at 70 degrees C (k = 0.009 day(-1), R2 = 0.73).     

Mathematical modelling of the composting process: a review

In this paper mathematical models of the composting process are examined and their performance evaluated. Mathematical models of the composting process have been derived from both energy and mass balance considerations, with solutions typically derived in time, and in some cases, spatially. Both lumped and distributed parameter models have been reported, with lumped parameter models presently predominating in the literature. Biological energy production functions within the models included first-order, Monod-type or empirical expressions, and these have predicted volatile solids degradation, oxygen consumption or carbon dioxide production, with heat generation derived using heat quotient factors. Rate coefficient correction functions for temperature, moisture, oxygen and/or free air space have been incorporated in a number of the first-order and Monod-type expressions. The most successful models in predicting temperature profiles were those which incorporated either empirical kinetic expressions for volatile solids degradation or CO2 production, or which utilised a first-order model for volatile solids degradation, with empirical corrections for temperature and moisture variations. Models incorporating Monod-type kinetic expressions were less successful. No models were able to predict maximum, average and peak temperatures to within criteria of 5, 2 and 2 degrees C, respectively, or to predict the times to reach peak temperatures to within 8 h. Limitations included the modelling of forced aeration systems only and the generation of temperature validation data for relatively short time periods in relation to those used in full-scale composting practice. Moisture and solids profiles were well predicted by two models, but oxygen and carbon dioxide profiles were generally poorly modelled. Further research to obtain more extensive substrate degradation data, develop improved first-order biological heat production models, investigate mechanistically-based moisture correction factors, explore the role of moisture tension, investigate model performance over thermophilic composting time periods, provide more information on model sensitivity and incorporate natural ventilation aeration expressions into composting process models, is suggested.     

Effects of air flow directions on composting process temperature profile

In this study, chicken manure mixed with carnation wastes was composted by using three different air flow directions: R1-sucking (downward), R2-blowing (upward) and R3-mixed. The aim was to find out the most appropriate air flow direction type for composting to provide more homogenous temperature distribution in the reactors. The efficiency of each aeration method was evaluated by monitoring the evolution of parameters such as temperature, moisture content, CO(2) and O(2) ratio in the material and dry material losses. Aeration of the reactors was managed by radial fans. The results showed that R3 resulted in a more homogenous temperature distribution and high dry material loss throughout the composting process. The most heterogeneous temperature distribution and the lowest dry material loss were obtained in R2.     

Characterization and modelling of the heat transfers in a pilot-scale reactor during composting under forced aeration

The paper focused on the modelling of the heat transfers during composting in a pilot-scale reactor under forced aeration. The model took into account the heat production and the transfers by evaporation, convection between material and gas crossing the material, conduction and surface convection between gas and material in bottom and upper parts of the reactor. The model was adjusted thanks to the measurements practised during fifteen composting experiments in which five organic wastes were, each, composted under three constant aeration rates. Heat production was considered proportional to oxygen consumption rate and the enthalpy per mole oxygen consumed was assumed constant. The convective heat transfer coefficients were determined on basis of the continuous measurements of the temperatures of both the lid and the bottom part of the reactor. The model allowed a satisfying prediction of the temperature of the composting material. In most cases, the mean absolute discard between the experimental and the simulated temperatures was inferior to 2.5°C and the peaks of temperature occurred with less than 8h delay. For the half of the experiments the temperature discard between the simulated peak and the experimental one was inferior to 5°C. On basis of the calculation of a stoichiometric production of water through oxidation of the biodegradable organic matter, the simulation of water going out from material as vapour also allowed a rather satisfying prediction of the mass of water in final mixture. The influence of the aeration rate on every type of heat loss was characterized. Finally, the model was used to evaluate the impacts on material temperature caused by the change of the insulation thickness, the ambient temperature, take the lid away, the increase or the decrease of the mass of waste to compost.     

Prediction of temperature and thermal inertia effect in the maturation stage and stockpiling of a large composting mass

A macroscopic non-steady state energy balance was developed and solved for a composting pile of source-selected organic fraction of municipal solid waste during the maturation stage (13,500 kg of compost). Simulated temperature profiles correlated well with temperature experimental data (ranging from 50 to 70 degrees C) obtained during the maturation process for more than 50 days at full scale. Thermal inertia effect usually found in composting plants and associated to the stockpiling of large composting masses could be predicted by means of this simplified energy balance, which takes into account terms of convective, conductive and radiation heat dissipation. Heat losses in a large composting mass are not significant due to the similar temperatures found at the surroundings and at the surface of the pile (ranging from 15 to 40 degrees C). In contrast, thermophilic temperature in the core of the pile was maintained during the whole maturation process. Heat generation was estimated with the static respiration index, a parameter that is typically used to monitor the biological activity and stability of composting processes. In this study, the static respiration index is presented as a parameter to estimate the metabolic heat that can be generated according to the biodegradable organic matter content of a compost sample, which can be useful in predicting the temperature of the composting process.     

Bioconversion of industrial wastes: paint sludge from automotive manufacturing

The compostability of water-based paint sludge originating from the automotive industry was investigated. Six reactors were operated. Wastewater treatment sludge from the same industry was used as additional substrate, and corncob was used as a bulking agent. The level of paint sludge within the compost mixtures varied between 55 and 85%. All reactors yielded a temperature increase up to thermophilic phase levels (>?40 °C) for a minimum of 5 days, and organic matter and C/N losses were observed. BTEX concentrations decreased during composting. Nickel and tin levels in the final product exceeded the legal compost limits. The calorific value of the compost mixtures increased from 9532 to 18774 kJ/kg at the end of the composting process. It was seen that the process applied in this study can be utilized as a biodrying step before the usage of paint sludge at cement kilns as additional fuel.     

Self-heating of dried industrial wastewater sludge: Lab-scale investigation of supporting conditions

We studied the reactivity of dried sludge produced by treatment of wastewater, mainly from tanneries. The solids transformations have been first characterized with thermal analysis (TGA and DSC) proving that exothermic transformation takes place at fairly low temperature, before the total organic combustion that occurs in air above 400 °C. The onset of low temperature reactions depends on the heating rate and it can be below 100 °C at very small heating rate.Then, we reproducibly determined the conditions to trigger dried sludge self-heating at the laboratory scale, on samples in the 0.2–0.3 kg size. Thermal insulation, some aeration and addition of water are key factors. Mastering the self-heating at this scale allows more detailed investigations as well as manipulation of conditions, to understand its nature, course and remediation. Here we report proves and discussions on the role of air, water, particle size, porosity and biological activity, as well as proving that also dried sludge from similar sources lead to self-heating.Tests demonstrate that air and water are simultaneously required for significant self-heating to occur. They act in diverging directions, both triggering the onset of the reactions and damping the temperature rise, by supporting heat loss. The higher the O₂ concentration, the higher the solids heating rate. More added water prolongs the exothermic phase. Further additions of water can reactivate the material. Water emphasizes the exothermic processes, but it is not sufficient to start it in an air-free atmosphere. The initial solid moisture concentration (between 8% and 15%) affects the onset of self-heating as intuitive. The sludge particles size strongly determines the strength and extent of the heat release, indicating that surface reactions are taking place. In pelletized particles, limitations to water and air permeability mitigates the reaction course.     

Microbiological assessments of compost toilets: in situ measurements and laboratory studies on the survival of fecal microbial indicators using sentinel chambers

Compost toilet systems were assessed for their ability to reduce microbial indicators and pathogens. Bacterial pathogens were not detected in any samples indicating a low survival rate in composting feces and/or an initial low occurrence. Indicator bacteria showed large variations with no clear trend of lower bacterial numbers after longer storage. In controlled composting experiments, thermophilic conditions were only reached when amendments were made (grass and a sugar solution). Even then it was impossible to ensure a homogenous temperature in the composting fecal material and therefore difficult to achieve a uniform reduction and killing of indicator organisms. Presumptive thermotolerant coliforms, Salmonella typhimurium Phage 28 B and eggs of Ascaridia galli, proved useful as indicators. However, regrowth was detected for enterococci and total numbers of bacteria grown at 36 degrees C. These indicator parameters may therefore overestimate the level of other (pathogenic) bacteria present in the material and can not be recommended for use as reliable indicator organisms in composting toilet systems. The addition of indicator bacteria to fecal material contained in semi-permeable capsules proved to be a useful technique to ensure that microorganisms were contained in a small test volume.     

Composting kinetics in full-scale mechanical–biological treatment plants

This study focuses on the investigation of the kinetics of municipal solid waste composting in three full-scale mechanical–biological treatment (MBT) plants. The aims were to test a kinetic model based on volatile solids (VS) content change for describing the composting process in MBT plants, and to identify the model parameters that affected the estimation of the reaction rate constant most. To achieve this, VS content and several environmental conditions, namely temperature, moisture content, oxygen concentration and total bulk density were monitored throughout the composting process. Experimental data was fitted with a first-order kinetic model, and a rate constant (k) characteristic of composting under optimum environmental conditions was obtained. The kinetic model satisfactorily described the experimental data for the three MBT plants. k values ranged from 0.043 ± 0.002 d^?1 to 0.082 ± 0.011 d^?1. Sensitivity analysis showed that the model parameters that most affected the estimation of k were the initial biodegradable volatile solids content, the maximum temperature for biodegradation and the optimum moisture content. In conclusion, we show for the first time that full-scale MBT plants can be successfully modelled with a composting kinetic model.     

Performance of compostable baby used diapers in the composting process with the organic fraction of municipal solid waste

In modern societies, disposable diapers constitute a significant percentage of municipal solid wastes. They have been traditionally landfilled or incinerated as only limited recycling processes are being implemented in some parts of Europe. With the implementation of separated collection systems for the organic fraction of municipal solid wastes (OFMSWs) and the need to preserve the environment, compostable diapers have appeared in the market to avoid the main environmental impacts associated to non-biodegradable disposable diapers. In this study, a full-scale composting of door-to-door collected OFMSW with a 3% (w/w) of compostable diapers has also been carried out. Previously, lab-scale experiments confirmed that almost 50% of carbon of compostable diapers is emitted as CO₂ under aerobic controlled conditions. The results obtained at full-scale demonstrate that both the composting process and the final end product (compost) are not altered by the presence of compostable diapers in crucial aspects such as pathogenic content, stability and elemental composition (including nutrients and heavy metals). The main conclusion of this study is that the collection of the OFMSW with compostable diapers can be a new way to transform this waste into high-quality compost.     

Feasibility study of a passive aeration reactor equipped with vertical pipes for compost stabilization of cow manure.

Pilot-scale composting was carried out with cow manure to evaluate the performances of two passive aeration systems: a conventional passive aeration system equipped with horizontal pipes and an unusual passive aeration method based on air delivery by means of vertical pipes. The effects of both types of passive aeration apparatus were investigated in order to determine the degree of composting rate by continuously monitoring temperature, moisture content, organic matter, electrical conductivity, pH and C/N ratio in the piles. Temperatures in the range of thermophily (55-65 degrees C) were reached in all runs within 1-2 days then lasting for about 1 week, a span long enough for pathogen abatement. Results suggest that passive aeration carried out by vertical pipes is more effective for air delivery into compost piles than conventional passive aeration of air adduction with horizontal pipes. The variation in the number of vertical pipes was revealed to be an important parameter for the control of composting rate and temperature. Composting rates estimated from the heat balance equation were substantially in agreement with those computed through the conversion ratio of total organic matter decrement. The conversion ratios and composting rates obtained in this study using passive aeration with vertical pipes were well aligned with those found using forced air delivery systems.     

Simple technologies for on-farm composting of cattle slurry solid fraction

Composting technologies and control systems have reached an advanced stage of development, but these are too complex and expensive for most agricultural practitioners for treating livestock slurries. The development of simple, but robust and cost-effective techniques for composting animal slurries is therefore required to realise the potential benefits of waste sanitation and soil improvement associated with composted livestock manures. Cattle slurry solid fraction (SF) was collected at the rates of 4m(3)h(-1) and 1m(3)h(-1) and composted in tall (1.7 m) and short (1.2m) static piles, to evaluate the physicochemical characteristics and nutrient dynamics of SF during composting without addition of bulking agent materials, and without turning or water addition. Highest maximum temperatures (62-64 °C) were measured in tall piles compared to short piles (52 °C). However, maximum rates of organic matter (OM) destruction were observed at mesophilic temperature ranges in short piles, compared to tall piles, whereas thermophilic temperatures in tall piles maximised sanitation and enhanced moisture reduction. Final OM losses were within the range of 520-660 g kg(-1) dry solids and the net loss of OM significantly (P<0.001) increased nutrient concentrations during the composting period. An advanced degree of stabilization of the SF was indicated by low final pile temperatures and C/N ratio, low concentrations of NH(4)(+) and increased concentrations of NO(3)(-) in SF composts. The results indicated that minimum intervention composting of SF in static piles over 168 days can produce agronomically effective organic soil amendments containing significant amounts of OM (772-856 g kg(-1)) and plant nutrients. The implications of a minimal intervention management approach to composting SF on compost pathogen reduction are discussed and possible measures to improve sanitation are suggested.     

Modeling of substrate degradation and oxygen consumption in waste composting processes

A multi-component modeling system was developed to simulate substrate degradation and oxygen consumption in waste composting processes. Levels of soluble substrate (Ss), insoluble substrate (Si), active biomass (X), inert material, moisture, temperature, and oxygen concentration were considered as state variables. The relationships among these variables were also incorporated within the modeling framework. Three conversion reactions, including growth of aerobic biomass, decay of aerobic biomass, and solubilisation of insoluble substrate, were considered in the simulation system. The modeling inputs included temperature, moisture, oxygen concentration, and initial conditions of the state variables, while the outputs included oxygen uptake accumulation (OUA), oxygen uptake rate (OUR), Ss, Si, and X for representing the substrate degradation and oxygen consumption status. The effectiveness of the developed model was demonstrated through its application to a case study in a 30L vessel over 200h. Through verification-based composting experiments, it was shown that the modeling solutions were consistent with the experimental results with an acceptable accuracy level. Sensitivity analyses of the model showed that an increased maximum microbial growth rate would result in raised OUA, OUR, Ss, and X levels; a decreased biomass decay rate constant would help enhance the composting process. Moreover, variations in the maximum growth rate would affect the composting process more significantly than those of the biomass decay rate constant.     

Evaluation of the potential of applying composting/bioremediation techniques to wastes generated within the construction industry

The objective of the present study was to evaluate the viability of reducing landfill requirements to satisfy EC Landfill Directive requirements by applying composting/bioremediation techniques to the construction and demolition (C&D) industry waste stream at laboratory scale. The experimental study was carried out in nine test rigs to examine different wood mixtures; untreated timber, creosote treated timber and chromated copper arsenate (CCA) treated timber. Several experimental variables affecting the process were characterised and optimised. These include the best nitrogen additive and optimum moisture content required for composting. Poultry manure was found to be the best nitrogen additive. The optimum moisture content was decreased after the addition of poultry manure. The composting/bioremediation process was evaluated through monitoring the microbial activity, carbon dioxide emissions and toxicity examination of the composted product. A typical temperature profile suggested that untreated and CCA treated mix could be classified as hot composting whereas creosote treated mix could be classified as cold composting. The paper reports on the results obtained during this investigation.     

Emission assessment at the Burj Hammoud inactive municipal landfill: Viability of landfill gas recovery under the clean development mechanism

This paper examines landfill gas (LFG) emissions at a large inactive waste disposal site to evaluate the viability of investment in LFG recovery through the clean development mechanism (CDM) initiative. For this purpose, field measurements of LFG emissions were conducted and the data were processed by geospatial interpolation to estimate an equivalent site emission rate which was used to calibrate and apply two LFG prediction models to forecast LFG emissions at the site. The mean CH(4) flux values calculated through tessellation, inverse distance weighing and kriging were 0.188±0.014, 0.224±0.012 and 0.237±0.008lCH(4)/m(2)hr, respectively, compared to an arithmetic mean of 0.24l/m(2)hr. The flux values are within the reported range for closed landfills (0.06-0.89l/m(2)hr), and lower than the reported range for active landfills (0.42-2.46l/m(2)hr). Simulation results matched field measurements for low methane generation potential (L(0)) values in the range of 19.8-102.6m(3)/ton of waste. LFG generation dropped rapidly to half its peak level only 4yrs after landfill closure limiting the sustainability of LFG recovery systems in similar contexts and raising into doubt promoted CDM initiatives for similar waste.     

Potential of olive mill wastes for soil C sequestration

The present work deals with the potential of olive mill wastes as a C source for soil C sequestration strategy, which is based on the high lignocellulosic content that makes these wastes to degrade slowly during composting and after land application. A C balance was performed during the whole life cycle of two different two-phase olive mill wastes (TPOMW): C losses were calculated during the composting process and after soil application of the composting mixtures under laboratory conditions. The effect of the degree of stabilization of TPOMW on the overall C waste conservation efficiency was also evaluated. C losses after 34 weeks of TPOMW composting ranged from 40.58% to 45.19% of the initial C, whereas the amount of C evolved as CO2 after 8 months of incubation of soil amended with mature composts only represented between 20.6% and 21.9% of the added C. The total C losses considering the whole life cycle of the TPOMW showed lower losses compared to composts prepared with organic residues of different origin. Conversely to the typical behaviour of other organic wastes, the stabilisation degree of the TPOMW composting mixtures did not show any significant effect on the total C losses measured during composting and later land application. The low rate of degradation of TPOMW both during composting and after soil application makes the use of TPOMW as a C source an attractive strategy for soil C sequestration.