Risk Assessment of Biogas Production from Sugarcane Vinasse: Does the Anaerobic Bioreactor Configuration Affect the Hazards?

Anaerobic digestion of sugarcane vinasse is integral to enhancing ethanol distilleries’ environmental and energy performance by converting organic waste into biogas; however, the flammable and toxic nature of biogas has led to significant safety concerns, particularly in anaerobic bioreactors where biogas is produced and stored. This study provides a comparative risk assessment of different anaerobic reactor configurations—a covered lagoon biodigester (CLB), a continuous stirred-tank reactor (CSTR), an upflow anaerobic sludge blanket reactor (UASB), and an anaerobic structured-bed reactor (AnSTBR)—processing vinasse, focusing on fire, explosion, and hydrogen sulfide (H₂S) toxicity hazards. Jet fire scenarios posed the most severe threat, with fatal outcomes extending up to 66 m, while the fireball scenario exhibited no lethal range. The risks to human life from explosions were minimal (1.2%). H₂S toxicity was identified as the most critical consequence, with particularly severe impacts in CLB systems, where the hazardous zone was up to 20 times larger than in AnSTBR. Therefore, the design of anaerobic bioreactors for vinasse treatment must primarily address the risks associated with H₂S-rich biogas, as reactor configuration plays a key role in mitigating or amplifying these hazards—high-rate systems such as AnSTBR and UASB demonstrating safer profiles due to their compact design and lower gas storage volumes.