The main objective of this study was to evaluate the anaerobic conversion of vinasse into biomethane with gradual increase in organic loading rate (OLR) in two upflow anaerobic sludge blanket (UASB) reactors, R1 and R2, with volumes of 40.5 and 21.5 L in the mesophilic temperature range. The UASB reactors were operated for 230 days with a hydraulic detection time (HDT) of 2.8 d (R1) and 2.8–1.8 d (R2). The OLR values applied in the reactors were 0.2–7.5 g totalCOD (L d)−1 in R1 and 0.2–11.5 g totalCOD (L d)−1 in R2. The average total chemical oxygen demand (totalCOD) removal efficiencies ranged from 49% to 82% and the average conversion efficiencies of the removed totalCOD into methane were 48–58% in R1 and 39–65% in R2. The effluent recirculation was used for an OLR above 6 g totalCOD (L d)−1 in R1 and 8 g totalCOD (L d)−1 in R2 and was able to maintain the pH of the influent in R1 and R2 in the range from 6.5 to 6.8. However, this caused a decrease for 53–39% in the conversion efficiency of the removed totalCOD into methane in R2 because of the increase in the recalcitrant COD in the influent. The largest methane yield values were 0.181 and 0.185 (L) CH4 (g totalCOD removed)−1 in R1 and R2, respectively. These values were attained after 140 days of operation with an OLR of 5.0–7.5 g totalCOD (L d)−1 and totalCOD removal efficiencies around 70 and 80%.

Biogas production from sugarcane vinasse has enormous economic, energy, and environmental management potential. However, methane production stability and biodigested vinasse quality remain key issues, requiring better nutrient and alkalinity availability, operational strategies, and knowledge of reactor microbiota. This study demonstrates increased methane production from vinasse through the use of sugarcane filter cake and improved effluent recirculation, with elevated organic loading rates (OLR) and good reactor stability. We used UASB reactors in a two-stage configuration, with OLRs up to 45gCODLd, and obtained methane production as high as 3LLd. Quantitative PCR indicated balanced amounts of bacteria and archaea in the sludge (10-10copiesgVS), and of the predominant archaea orders, Methanobacteriales and Methanosarcinales (10-10copiesgVS). 16S rDNA sequencing also indicated the thermophilic Thermotogae as the most abundant class of bacteria in the sludge.

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