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In intensive livestock production areas, farmers must apply manure management systems to comply with governmental regulations. Biogas plants, as a source of renewable energy, have the potential to reduce environmental impacts comparing with other manure management practices. Nevertheless, manure processing at biogas plants also incurs in non-desired gas emissions that should be considered. At present, available emission calculation methods cover partially emissions produced at a biogas plant, with establish which methodology is more reliable. Therefore, more measurements at different biogas plants should be evaluated to validate the methodologies more precisely.

Traditional plug-flow anaerobic reactors (PFRs) are characterized by lacking a mixing system and operating at high total solid concentrations, which limits their applicability for several kinds of manures. This paper studies the performance of a novel modified PFR for the treatment of pig manure, characterized by having an internal sludge mixing system by biogas recirculation in the range of 0.270–0.336 m3 m−3 h−1. The influence on the methane yield of four operating parameters (recirculation rate, hydraulic retention time, organic loading rate, and total solids) was evaluated by running four modified PFRs at the pilot scale in mesophilic conditions. While the previous biodegradability of organic matter by biochemical methane potential tests were between 31% and 47% with a methane yield between 125 and 184 LCH4 kgVS−1, the PFRs showed a suitable performance with organic matter degradation between 25% and 51% and a methane yield of up to 374 LCH4 kgVS−1. Operational problems such as solid stratification, foaming, or scum generation were avoided.

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