Optimization of Anaerobic Digestion Systems for Biomethane Recovery from Septic Tank Sludge

Ahmed Mohammed Inuwa , Mohammed Alhassan Adam , Umar Salim Ibrahim , Atiku Yakubu Musa , Maryam Ibrahim , Usman Mohammed Aliyu , Victor Oluwafemi Fatokun , Emmanuel Kweinor Tetteh , Sudesh Rathilal

Clean Energy Sustain. ›› 2026, Vol. 4 ›› Issue (2) : 10013

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Clean Energy Sustain. ›› 2026, Vol. 4 ›› Issue (2) :10013 DOI: 10.70322/ces.2026.10013
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Optimization of Anaerobic Digestion Systems for Biomethane Recovery from Septic Tank Sludge
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Abstract

This study presents a process design, simulation, and optimization framework for converting septic sludge into biomethane using Aspen Plus®. The sludge was characterized, revealing carbon, hydrogen, and volatile matter contents of 33.80, 5.86, and 34.86 wt.%, respectively. The developed Aspen Plus® model was validated against three literature datasets, achieving percentage errors below unity. Optimization using Response Surface Methodology-Central Composite Design (RSM-CCD) showed that the maximum biomethane yield was 58.227 vol% under optimal conditions: 25 °C hydrolysis temperature, 60 °C digester temperature, 35 days hydraulic retention time (HRT), and an organic loading rate (OLR) of kg·VS·m−3·day−1, with a desirability score of 1.0. A techno-economic evaluation using the Aspen Process Economic Analyser (APEA) demonstrated the system’s economic feasibility, with a total capital investment of USD 3.19 million, an annual operating cost of USD 1.29 million, and a payback period of approximately 3.8 years. The optimized system achieved a net energy gain of 82.6%, IRR of 16.6%, and NPV of $4.64 M, confirming strong economic viability. Sensitivity analysis further revealed that CAPEX, OPEX, feedstock cost, and upgrading energy demand significantly influence system profitability, emphasizing the importance of process optimization and energy-efficient upgrading strategies. Environmental assessment showed that the optimized system improved methane recovery efficiency to 98.7% and achieved a CO2 emission reduction potential of 0.49 kg CO2-eq/kg CH4, demonstrating strong greenhouse gas mitigation potential. Overall, the findings establish anaerobic digestion of septic sludge as a sustainable and cost-effective waste-to-energy pathway suitable for decentralized urban wastewater management, supporting circular economy and clean energy objectives in developing regions.

Keywords

Anaerobic digestion / Bio-methane / Energy recovery / Optimization / Circular economy / Waste-to-energy

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Ahmed Mohammed Inuwa, Mohammed Alhassan Adam, Umar Salim Ibrahim, Atiku Yakubu Musa, Maryam Ibrahim, Usman Mohammed Aliyu, Victor Oluwafemi Fatokun, Emmanuel Kweinor Tetteh, Sudesh Rathilal. Optimization of Anaerobic Digestion Systems for Biomethane Recovery from Septic Tank Sludge. Clean Energy Sustain., 2026, 4 (2) : 10013 DOI:10.70322/ces.2026.10013

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Statement of the Use of Generative AI and AI-Assisted Technologies in the Writing Process

The authors acknowledge the use of digital tools, Aspen Plus and Design Expert Software as well as ChatGPT (OpenAI) and Grammarly, to enhance the clarity, grammar, and readability of this manuscript. All contents generated with these tools were critically reviewed, verified, and edited by the authors to ensure accuracy, originality and compliance with the journal standard. The authors take full responsibility for the final version of the manuscript.

Acknowledgments

The authors gratefully acknowledge the Green Engineering Research Group for providing the essential simulation tools and technical support required for this study.

Author Contributions

A.M.I. and E.K.T.: Conceptualization, methodology, formal analysis, writing original draft. E.K.T., U.M.A. and S.R.: supervision, resources. M.A.A., U.S.I., M.I and A.Y.M.: writing—review and editing, project administration. A.M.I., E.K.T., V.O.F., M.I. and S.R.: writing—review and editing, validation. All authors have read and agreed to the published version of the manuscript.

Ethics Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

Data will be available on request.

Funding

This research received no external funding.

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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