Short-Term and Annual Variability of Continuously Monitored Biogas Yield from Sewage Sludge at a Wastewater Treatment Plant

Wastewater treatment plants increasingly rely on anaerobic digestion and biogas utilization to reduce operational costs, enhance energy self-sufficiency, and support circular-economy objectives. This study provides a comprehensive, year-round assessment of sludge production, sludge characteristics relevant to digestion, biogas generation, and energy performance at a municipal wastewater treatment plant. The plant generated on average 68.0 m3/d of thickened primary sludge and 24.0 m3/d of excessive sludge (total 92 m3/d), with low daily variability throughout the year. Biogas production remained highly stable, with an annual average of approximately 1300 m3/d and limited daily variation. Although monthly averages ranged from 1004 to 1728 m3/d, within-month variability was low to moderate, indicating that digestion processes responded consistently to changes in sludge quantity and composition. The weak correlation between sludge volume and biogas output (r = 0.29) showed that, besides sludge quantity, factors such as organic content and digester operating conditions also influence biogas yield. Energy performance indicators demonstrated strong self-sufficiency potential: the facility produced 1,095,047 kWh of electricity, covering 56.72% of its annual demand. The high coefficient of determination for self-sufficiency (R2 = 0.871) confirmed a strong linear relationship between biogas-derived energy production and reduced grid dependence. Operational correlations further highlighted system coherence, with cogenerator and boiler usage strongly inversely related (r = −0.85) and biogas production positively associated with heat output (r = 0.66). Overall, the results demonstrate a stable and efficient sludge-to-energy system and provide a detailed dataset supporting future optimization of anaerobic digestion processes.