Recent Advances and Prospects in Methane Production from Anaerobic Digestion: Process Intensification, Additives, and Biogas Upgrading

Anaerobic digestion (AD) plays an important role in the circular bioeconomy by converting organic waste into renewable methane and nutrient-rich fertilizer. However, consistent, high-quality biomethane production is hindered by four main factors: hydrolysis limitations, fluctuating feedstock quality, microbial instability, and the high cost/energy demand of purification. This review explores three key areas that improve biomethane production: (i) process intensification (pretreatments and advanced reactors), (ii) microbial regulation through additives, and (iii) biogas upgrading for pipeline use. Anaerobic digestion can be greatly improved by combining thermal or hybrid pretreatments, staged digestion, high-solids technology, and electrochemical systems. These methods speed up hydrolysis and help the system handle higher amounts of organic material more effectively. However, actual performance benefits depend on specific substrate characteristics, heat integration, and control complexity. Optimizing the C:N ratio, buffering capacity, and trace-element supplementation, while simultaneously diluting toxic inhibitors, makes co-digestion an effective and adaptable approach to enhancing anaerobic digestion processes. Additives like carbon, iron nanoparticles, enzymes, and buffers can optimize digestion, but their performance is highly dependent on dosage and substrate. Additionally, they lack validation in long-term, industrial-scale applications. Conventional physicochemical techniques continue to be standard for generating high-quality biomethane, but biological methanation and microalgal systems are playing a growing role in integrating Power-to-Gas technology and using CO2 efficiently. Critical research needs to focus on four areas: (1) standardized reporting metrics, (2) AI-enabled monitoring and control, (3) coupled techno-economic and life-cycle analysis (TEA-LCA), and (4) long-term pilot or full-scale validation. Overall, comprehensive optimization of the entire flow is more effective than improving isolated parts.