The main purpose of this study was the assessment of the possibility of increasing the production of biogas through the pre-treatment of thickened excess sludge (TES) by means of the hydrodynamic cavitation (HC) conducted at different levels of energy density (EL) i.e., 70, 140 and 210 kJ/L. The experiments were performed on a pilot scale, and a mixture of thickened primary sludge (TPS) and TES was used as digester feed. The results documented that an important parameter determining the possibility of obtaining an enhanced methane production is the value of energy input in the HC process. This parameter determines the changes occurring in sludge as a result of disintegration (i.e., sludge floc deagglomeration, lysis of cells, re-flocculation process and the related release of compounds susceptible to biodegradation from sludge flocs). The maximum increase in methane yield (MY) of 152% was obtained for EL = 140 kJ/L. In this case, HC mainly caused sludge floc deagglomeration. An increase in MY was also recorded when TES was subject to the disintegration process at EL = 210 kJ/L. However, it was 4.3 times lower than that observed for EL = 140 kJ/L. Pre-treatment of TES at EL = 70 kJ/L did not contribute to an increase in methane production.

The study objective was to adjust the hydrodynamic disintegrator dedicated to sewage sludge pre-treatment (HDS) to work with agricultural substrate. This involved the development and implementation of a mathematical model of flow via the device’s domain. An innovative disintegrator (HAD—hydrodynamic disintegrator for agriculture) was designed, built, and tested based on the obtained results. The main improvements to the HDS include the implementation of shredding knives in order to overcome clogging by crushed substrate, and the application of ribs in the recirculation zone, contributing to the development of an additional structure damage zone. The challenge of this study was also to determine the operating parameters of the HDA that would provide for an increase in methane production with positive energy balance. The testing procedures, for which maize silage was selected, involved batch disintegration tests and biochemical methane potential tests. No clogging of rotor or spontaneous shutting off of the device, in other words, problems that had occurred in the HDS, were observed. The applied pre-treatment method permitted an increase in the methane potential of maize silage by 34.4%, 27.0%, and 21.6%, respectively for samples disintegrated at energy densities of 10 kJ/L, 20 kJ/L, and 35 kJ/L with net energy profit.

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This paper presents the results of the first stage of the project, aimed at the assessment of the applicability of the new apparatus for disintegration of excess waste activated sludge. It was documented that the analysed device allows for disintegration of sewage sludge with an efficiency comparable to that obtained in other devices dedicated for mechanical disintegration of sewage sludge described in the literature. The disintegration process at energy density in a range of 35–210 kJ/l resulted in the release from activated sludge flocs of 219–515 mg SCOD/l for 35 kJ/l to 2138–4884 mg SCOD/l for 210 kJ/l.

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