Real-world application of a discrete feedback control system for flexible biogas production

Using renewable energy is increasingly prevalent as part of a global effort to safeguard the environment, with a reduction in $${\mathrm{CO}}_{2}$$ being one of the primary objectives. A biogas plant provides an opportunity to produce green energy, but its profitability prevents it from being utilized more frequently. A suitable response to this economic issue would be flexible biogas production to exploit fluctuating energy prices. Nevertheless, the complex nature of the anaerobic digestion process that proceeds within the biogas plant and the wide range of substrates that may be utilized as the plant’s feeds make it challenging to achieve flexible biogas production truly. Most plant operators will rely on their experience and intuition to run the plant without knowing exactly how much biogas they will produce with the feed substrate. This work combines a system model estimation and feedback controller to provide an intuitive yet precise feedback control system. The system model estimation represents the biogas plant mathematically, and a total of six distinct approaches have been compared and evaluated. A PT1 model most accurately approximated the step-down and the step-up by the time percentage method, with the Akaike Information Criterion as the primary evaluation criterion for selecting the best model. The downward model was controlled by a discrete PI controller modified with the Root Locus Method and an Anti-Windup scheme, and the upward model was controlled by a state space controller. The quality of the controller was evaluated in both simulation and at the actual biogas plant in Grub, and the controller was able to reduce the biogas production rate approaching the setpoint in the expected period. Furthermore, the developed feedback control system is effortless enough to be installed in many biogas plants.