Simulation and Scale-up of Anaerobic Digestion of Cow Dung for Biogas Production Using SuperPro Designer
1 Department of Chemical Engineering, Faculty of Engineering and Technical Studies, University of El Imam El Mahdi –Kosti – Sudan.
2 Department of Chemical Engineering, Karary University, Khartoum 14411, Sudan.
3 Department of Food Processing Engineering, Faculty of Engineering and Technical Studies, University of El Imam El Mahdi, Kosti – Sudan.
Research Article
Open Access Research Journal of Engineering and Technology, 2025, 09(02), 047-055.
Article DOI: 10.53022/oarjet.2025.9.2.0095
Publication history:
Received on 11 October 2025; revised on 21 November 2025; accepted on 24 November 2025
Abstract:
The global energy sector, heavily reliant on fossil fuels, faces significant challenges including climate change, environmental degradation, and supply constraints. This study explores biogas production from organic waste as a sustainable alternative, focusing on cow dung as a primary feedstock. The research objectives were to model an industrial-scale anaerobic digestion process, determine optimal fermentation conditions, and validate the simulation with theoretical data. A continuous stirred-tank reactor (CSTR) process was designed and simulated using SuperPro Designer software. The model incorporated key unit operations: feedstock mixing and preheating, anaerobic digestion, degasification, and biogas compression. The simulation was configured for mesophilic conditions (37°C) with a hydraulic retention time of 15 days. Results indicated a total biogas output of 1,929.88 kg/h, with a high methane purity of 73.93% (1,426.83 kg/h) following degasification. The carbon dioxide byproduct stream was separated at 503.05 kg/h (26.07%). The compressed biogas stream achieved a methane concentration of 3.70 g/L at 6.01 bar and 40°C, suitable for storage or application. The study confirms the technical viability of cow dung for renewable energy production and demonstrates the efficacy of SuperPro Designer as a tool for scaling and optimizing biogas processes, contributing to waste management and greenhouse gas reduction strategies.
Keywords:
Biogas; Anaerobic Digestion; Cow Dung; Process Simulation; SuperPro Designer; Renewable Energy; Methane
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