Method, system and process equipment for optimal control of thermal hydrolysis process

Abstract

The present invention provides methods, systems, process apparatuses, and devices useful for subjecting biomass material to thermal hydrolysis processes (THP) and subsequent treatments (e.g., in the form of anaerobic fermentation, thermal reduction, biological treatments, chemical treatments, or electrochemical treatments, etc.). The present invention also relates to a method for retrofitting an existing plant employing a thermal hydrolysis process (THP).

Description

Technical Field

[0001] The present invention relates to methods, systems, process equipment and devices for subjecting biomass materials with a dry matter content (DS%) of at least 8%, preferably at least 12%, to a hydrothermal hydrolysis process (THP) and subsequent treatment (such as in the form of anaerobic fermentation, thermal reduction, biological, chemical or electrochemical treatment, etc.). The present invention also relates to a method for retrofitting existing devices using the hydrothermal hydrolysis process (THP). Background Art

[0002] Hydrothermal hydrolysis is a process that includes treating a wet or moist material (such as a biomass material) at a high temperature and then rapidly reducing the pressure. In the waste treatment industry, this combination of process steps is generally referred to as the hydrothermal hydrolysis process (THP). The application of THP is not limited to the pretreatment of organic materials before biological downstream processing (such as anaerobic digestion or fermentation for the production of biogas or bioethanol, respectively), but can also be used for non-biological downstream processing, for example, the production of fuel pellets from lignocellulosic materials, or the further extraction and production of value-added compounds (such as amino acids, peptides, proteins, short-chain fatty acids, enzymes, pesticides, bioplastics, bioflocculants and biosurfactants).

[0003] The hydrothermal hydrolysis process (THP) can be designed as batch or continuous. The methods, systems, process equipment and devices of the present invention are applicable to both THP designed as batch and THP designed as continuous. In addition, the methods of the present invention can be integrated into new devices or applied to existing devices through retrofitting (including installing relevant additional equipment and making relevant modifications).

[0004] In THP, the material is treated with the required steam partial pressure. In a batch process, the time the material is held under the required conditions is called the "residence time". For a continuous process, the total average residence time is a value that can be calculated based on the total throughput of the entire process.

[0005] When the material is discharged from the THP system (such as through a nozzle) into a flash tank, it undergoes a rapid pressure drop and a steam explosion occurs. This opens the cell walls of the material, decomposes the organic material, reduces the particle size and the apparent viscosity, such as the static yield stress τ o and / or the dynamic yield stress τ y . The flash steam generated by the steam explosion can be used to preheat the material in a pressure vessel (which can be called a pulper). Preheating the material with flash steam before reactor treatment is crucial for achieving the highest possible energy efficiency and the lowest possible steam consumption.

[0006] The general technology behind THP is described in detail in, for example, WO / 1996 / 009882 and WO / 2008 / 026932. Thus, the material is preheated from ambient temperature using flash steam obtained from at least one subsequent depressurization step. The preheated material is then conveyed to a (hydrolysis) reactor where the pressure is increased to 2.7 - 26 bar, for example by injecting live steam as described in WO / 1996 / 009882. In some cases, this will correspond to a temperature of up to 226°C. In most cases, however, the temperature will be in a slightly lower range because overheating may cause undesirable changes in the chemical composition of the material. On the other hand, since the desired effects of THP cannot be achieved at too low a temperature, for materials such as municipal and industrial sludge, the temperature preferably used in the THP process / system is typically in the range of 130 - 200°C. However, higher temperatures may be beneficial or achieve certain advantages for several other materials. After some time, the material is rapidly discharged from the (hydrolysis) reactor (e.g., through more than one blowdown pipe) into a pressure relief vessel (sometimes also called a flash tank).

[0007] The methods described in, for example, WO / 1996 / 009882 and WO / 2008 / 026932 are batch methods, while, for example, WO / 2000 / 73221 and EP3156374 describe continuous THP methods for hydrolyzing organic materials.

[0008] WO / 2011 / 006854 describes another batch process for THP which reduces the need for the hydrolysis reactor itself to relieve pressure by transferring the sludge to a first pressure relief tank (i.e., flash tank) using a nozzle.

[0009] Compared with the above methods, WO / 2014 / 123426 describes a method and apparatus for performing THP in which a vacuum is provided in the hydrolysis reactor by supplying cold water to the hydrolysis reactor and opening a supply valve between the preheating tank and the reactor, thereby transferring the heated organic material from the preheating tank to the reactor by means of vacuum and gravity until a predetermined level is reached.

[0010] WO2015 / 097254 describes a method for continuously hydrolyzing biomass materials with a high dry matter content in which the apparent viscosity of the material is reduced upstream of the hydrolysis by subjecting the material a) to a high speed gradient (i.e., high shear strain) in a so-called dynamic mixer which mechanically deconstructs (i.e., breaks down) the material, and b) heating the material by passing it through a heat exchanger where heat is directly recovered from the hydrolysis sludge (i.e., without using any intermediate heat transfer fluid).

[0011] WO / 2016 / 066752 describes the THP process in which the hydrolyzed material is mixed with a portion of the contents of a downstream digester using a recycle loop before the mixture enters the digester.

[0012] WO / 2020 / 126397 describes a THP process that involves flashing under conditions below ambient pressure and using the resulting flash steam for direct steam injection to preheat a feed in a preheating vessel maintained below ambient pressure to facilitate the transfer of flash steam. The process relies on removing non-condensable gases by using a vacuum system and at least two shredders and a flash tank upstream of the hydrothermal hydrolysis reactor to keep part of the system below ambient pressure.

[0013] As can be clearly seen from the above, several improved THP processes, including batch and continuous processes, have been developed in the prior art, all aimed at: 1) making the THP process more versatile, for example, in terms of materials with a high dry solid content, 2) reducing the total energy consumption of the THP process and / or 3) improving the quality and / or properties of the resulting hydrolyzed material, thereby ensuring the simplification of downstream processing and ultimately using standard equipment for both THP itself and downstream processing units.

[0014] However, so far, different from the present invention, none of these improvements have involved systematically utilizing the relationship between the temperature and apparent viscosity of the biomass material being processed at various stages of the THP process, such as the static yield stress τ o and / or the dynamic yield stress τ y and its importance in optimizing and stabilizing the flow of non-Newtonian biomass materials with a relatively high dry matter content (DS%) (e.g., higher than 8%, preferably at least 12%) through the THP process to ensure a more efficient and stable THP process itself, as well as more efficient downstream processing of the THP-treated material, such as subsequent fermentation in more than one downstream digester.

[0015] More specifically, different from the present invention, the prior art does not describe a shredder that is particularly suitable for homogenizing and preheating non-Newtonian biomass materials with a dry matter content (DS%) higher than 8% (preferably at least 12%) and producing a material with a temperature within a certain predetermined limit for subsequent hydrothermal hydrolysis in a downstream hydrothermal hydrolysis reactor, characterized in that both the total volume of the shredder and the specific position of the shredder outlet nozzle (i.e., the position for discharging the preheated material from the shredder) are based on the average filling volume of the downstream hydrothermal hydrolysis reactor of the THP system.

[0016] Similarly, different from the present invention, the prior art does not describe methods, systems, process equipment, and devices involving THP, in which:

[0017] - The average feed of non-Newtonian biomass material per unit time through the pulper feed line and the pulper;

[0018] - The average feed of preheated biomass material per unit time through the hydrothermal system; and / or

[0019] - The average feed of hydrolyzed biomass material per unit time through the subsequent treatment feed line,

[0020] Based on the following for system control:

[0021] - Continuously or semi-continuously measuring the apparent viscosity of non-Newtonian biomass material, preheated biomass material, and / or hydrolyzed biomass material, such as the static yield stress τ o and / or the dynamic yield stress τ y ; and

[0022] - Continuously or semi-continuously measuring more than one parameter of the subsequent treatment system.

[0023] The method, system, process equipment, and device according to the present invention meet the growing demand for optimizing the energy consumption of the THP process itself and its subsequent treatment system, especially in the case of non-Newtonian biomass materials with a dry matter content (DS%) higher than 8%, preferably at least 12%.

[0024] In addition, the method, system, process equipment, and device according to the present invention enable the optimization of any subsequent (i.e., downstream of THP) treatment steps, again especially in the case of non-Newtonian biomass materials with a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%. Summary of the Invention

[0025] As described above, the prior art does not describe a pulper that is particularly suitable for homogenizing and preheating non-Newtonian biomass materials with a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%, and producing a material with a temperature within a certain predetermined limit for subsequent hydrothermal hydrolysis in a downstream hydrothermal reactor, characterized in that both the total volume of the pulper and the specific position of the pulper outlet nozzle (i.e., the position for discharging the preheated material from the pulper) are based on the average filling volume of the downstream hydrothermal reactor.

[0026] In contrast, a preferred embodiment of the pulper according to the present invention is characterized in that:

[0027] - The total volume of the pulper is based on the average filling volume of the downstream hydrothermal reactor of the relevant THP system,

[0028] - The pulper includes an outlet nozzle for discharging the preheated material from the pulper, and the outlet nozzle is placed in such a way that:

[0029] - The portion of the total volume of the pulper that is located below the outlet nozzle is a multiple of the average filling volume of the downstream hydrothermal reactor of the relevant THP system;

[0030] - The portion of the total volume of the pulper that is not located below the outlet nozzle is a multiple of some other factor of the average filling volume of the hydrothermal reactor of the relevant THP system.

[0031] Due to these specific features, namely that both the total volume of the pulper and the specific position of the outlet nozzle of the pulper are based on the filling volume of the downstream hydrothermal reactor of the THP system, this preferred embodiment of the pulper according to the invention makes it possible to effectively control and stably maintain the relevant characteristics (including but not limited to temperature) of the preheated biomass material discharged from the pulper through the nozzle. In particular, in the case of preheated biomass based on non-Newtonian biomass materials having a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%, this preferred embodiment of the pulper according to the invention thus makes it possible to ensure that the preheated biomass fed into any downstream hydrothermal reactor of the THP system and / or the preheated biomass fed from the THP system into any subsequent treatment step has uniform characteristics conforming to any predetermined desired characteristics (such as a certain predetermined temperature). In particular, the features of the present invention ensure that the preheated biomass material produced from non-Newtonian biomass materials in the pulper, and the preheated biomass material fed into any downstream hydrothermal reactor of the THP system, and / or the preheated biomass material fed from the THP system into any subsequent treatment step, have a uniform temperature, that is, when the temperature standard deviation is calculated based on a temperature measurement resolution of < 5 seconds and used to calculate the overall average for each individual reactor filling, the average standard deviation of this temperature is < 12 °C or more preferably < 6 °C, even more preferably < 2 °C.

[0032] In addition, none of the THP systems known in the prior art systematically utilize the relationship between the temperature and apparent viscosity of non-Newtonian biomass materials processed at various stages of the THP process, for example, the static yield stress τ o and / or the dynamic yield stress τ y , and their importance in optimizing the flow of non-Newtonian biomass materials with a relatively high dry matter content (DS%) (for example, higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%) through the THP process to ensure a more efficient THP process itself, as well as more efficient downstream processing of THP-treated materials, such as subsequent fermentation in more than one downstream digester.

[0033] In contrast, the method, system, process equipment and device according to the present invention determine based on measurements:

[0034] - The average feed of non-Newtonian biomass material per unit time through the pulper feed line and the pulper, the non-Newtonian biomass material showing a certain apparent viscosity, for example, a static yield stress τ o and / or a dynamic yield stress τ y ;

[0035] - The average feed of preheated biomass material per unit time through the hydrothermal hydrolysis feed line and the hydrothermal hydrolysis system, the preheated biomass material showing a certain apparent viscosity, for example, a static yield stress τ o and / or a dynamic yield stress τ y ; and / or

[0036] - The average feed of hydrolyzed biomass material per unit time through the subsequent treatment system feed line, the hydrolyzed biomass material showing a certain apparent viscosity, for example, a static yield stress τ o and / or a dynamic yield stress τ y ,

[0037] characterized by more than one parameter of the relevant subsequent treatment steps, relative to a given system for the subsequent treatment of the THP-treated material.

[0038] The method, system, process equipment and device according to the present invention, further, especially in the case of non-Newtonian biomass materials having a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%, by controlling the feed of raw biomass, preheated biomass and / or hydrolyzed biomass materials showing a certain apparent viscosity (for example, a static yield stress τ o and / or a dynamic yield stress τ y ) per unit time through the THP system, makes it possible to control the relevant parameters of the THP system and the subsequent treatment steps.

[0039] Especially in the case of non-Newtonian biomass materials having a dry matter content (DS%) higher than 8% (preferably at least 12%), preferably at least 16%, more preferably at least 18%, this first makes it possible to combine a certain average feed rate of the material per unit time in controlling the apparent viscosity (for example, a static yield stress τ o and / or a dynamic yield stress τ y ) shown by the biomass material before and after passing through the different steps of the THP, in order to optimize the THP itself, for example, to optimize the total energy consumption of the THP relative to the characteristics of the biomass material to be treated.

[0040] However, still especially in the case of non-Newtonian biomass materials having a dry matter content (DS%) of more than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%, it is also possible to optimize any subsequent processing step in terms of controlling the apparent viscosity (such as the static yield stress τ o and / or the dynamic yield stress τ y ) shown by the given hydrolyzed biomass material produced per unit time in the THP, so as to optimize, for example, the yield or total energy consumption of any subsequent processing step that needs to further process the hydrolyzed biomass material.

[0041] As described above, compared with the prior art processes, the method, system, process equipment and device according to the present invention meet the growing demand for optimizing energy consumption by achieving a lower total energy consumption of the THP process itself and any subsequent processing system, especially in the case of non-Newtonian biomass materials having a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%.

[0042] In addition, the method, system, process equipment and device according to the present invention also make it possible to optimize other parameters (such as yield) of any subsequent (i.e., downstream of THP) processing step, especially in the case of non-Newtonian biomass materials having a dry matter content (DS%) higher than 8%, preferably at least 12%, preferably at least 16%, more preferably at least 18%.

[0043] Therefore, an object of the present invention is to provide a method, system, process equipment and device to ensure that the preheated biomass material produced from non-Newtonian biomass materials in a pulper, and the preheated biomass material subsequently sent to any downstream hydrothermal hydrolysis reactor of the THP system, and / or the preheated biomass material subsequently sent from the THP system to any subsequent processing step, has uniform characteristics conforming to any predetermined desired characteristics (such as a certain predetermined temperature). Specifically, the object of the present invention is to provide a method, system, process equipment and device to ensure that the preheated biomass material produced from non-Newtonian biomass materials in a pulper, and the preheated biomass material subsequently sent to any downstream hydrothermal hydrolysis reactor of the THP system, and / or the preheated biomass material subsequently sent from the THP system to any subsequent processing step, has a uniform temperature, that is, when the temperature standard deviation is calculated based on a temperature measurement resolution of <5 seconds and used to calculate the overall average value for each individual reactor filling, the average standard deviation of this temperature is <12 °C or more preferably <6 °C, even more preferably <2 °C.

[0044] Another object of the present invention is to provide a method, system, process equipment and device for processing non-Newtonian biomass materials, which optimize the energy consumption in the process involving THP compared with the prior art processes.

[0045] Another object of the present invention is to provide a method, a system, a process equipment and a device, which, compared with the prior art processes, optimize other parameters (such as yield) of any subsequent (i.e., downstream of THP) processing steps in the process of THP involving non-Newtonian biomass materials, and are simple and easy to be integrated into existing devices using THP by retrofit.

[0046] The present invention solves these and other objects.

[0047] Thus, a first aspect of the present invention provides a system for processing biomass materials having a dry matter content (DS%) higher than 8%, preferably at least 12%, such as higher than 14%, such as higher than 16%, preferably higher than 18%, the system comprising:

[0048] - a pulper for homogenizing and preheating the biomass materials; and

[0049] - a hydrothermal hydrolysis reactor,

[0050] The system is characterized in that:

[0051] - the total volume of the pulper is > 2.6 times and < 20 times, preferably 2.6 to 6 times, the average filling volume of the hydrothermal hydrolysis reactor;

[0052] - the pulper includes an outlet nozzle for discharging the preheated material from the pulper, and the outlet nozzle is placed in such a way that:

[0053] - the part of the total volume of the pulper below the outlet nozzle is ≥ 1.6 times the average filling volume of the hydrothermal hydrolysis reactor; and

[0054] - the part of the total volume of the pulper not below the outlet nozzle is > 1 times the average filling volume of the hydrothermal hydrolysis reactor.

[0055] In some embodiments of the first aspect of the present invention, the system is further characterized in that:

[0056] - the total volume of the pulper is > 3 times the average filling volume of the hydrothermal hydrolysis reactor;

[0057] - the part of the total volume of the pulper below the outlet nozzle is ≥ 1.6 times the average filling volume of the hydrothermal hydrolysis reactor; and

[0058] - the part of the total volume of the pulper not below the outlet nozzle is > 1.4 times the average filling volume of the hydrothermal hydrolysis reactor.

[0059] In some embodiments of the first aspect of the present invention, the system further has the following features:

[0060] - The total volume of the pulper is > 3.2 times the average filling volume of the hydrothermal reactor;

[0061] - The portion of the total volume of the pulper located below the outlet nozzle is ≥ 1.6 times the average filling volume of the hydrothermal reactor; and

[0062] - The portion of the total volume of the pulper not located below the outlet nozzle is > 1.6 times the average filling volume of the hydrothermal reactor.

[0063] In some embodiments of the first aspect of the present invention, the system is further characterized in that:

[0064] - The total volume of the pulper is > 3.4 times the average filling volume of the hydrothermal reactor;

[0065] - The portion of the total volume of the pulper located below the outlet nozzle is ≥ 1.6 times the average filling volume of the hydrothermal reactor; and

[0066] - The portion of the total volume of the pulper not located below the outlet nozzle is > 1.8 times the average filling volume of the hydrothermal reactor.

[0067] In one embodiment of the first aspect of the present invention, the system is further characterized in that the preheating in the pulper is at least partially achieved by the injection of flash steam from the hydrothermal system.

[0068] In another embodiment of the first aspect of the present invention, the system is further characterized in that:

[0069] - The portion of the total volume of the pulper located below the outlet nozzle, and

[0070] - The portion of the total volume of the pulper not located below the outlet nozzle,

[0071] are provided in the form of at least two independent interconnected chambers or tanks.

[0072] In another embodiment of the first aspect of the present invention, the system is further characterized in that the outlet nozzle is in the form of an overflow edge, knife-shaped or similar outlet, and is installed on the first chamber or tank of the at least two independent interconnected chambers or tanks, which ensures that a volume corresponding to ≥ 1.6 times the average filling volume of the hydrothermal reactor continuously exists below the edge, knife-shaped or similar outlet in the first chamber or tank of the at least two independent interconnected chambers or tanks.

[0073] In a further embodiment of the first aspect of the present invention, the system is further characterized in that the pulper comprises a biomass material distributor, preferably designed as an extruder, for dividing the incoming cold biomass material into smaller pieces before the biomass material enters the pulper.

[0074] In another embodiment of the first aspect of the present invention, the system is further characterized in that the pulper comprises a recirculation loop for recovering preheated biomass material from the pulper and for mixing the preheated biomass material with cold biomass material either before the preheated biomass material enters the biomass material distributor or in the biomass material distributor.

[0075] In another embodiment of the first aspect of the present invention, the system is further characterized in that the recirculation loop is capable of recovering from the pulper an amount of preheated biomass material that is at least 0.5 times, preferably more than 1 times, and even more preferably more than 2 times the amount of cold biomass material feed.

[0076] In a further embodiment of the first aspect of the present invention, the system is further characterized in that the biomass material distributor is located in the headspace above the liquid level of the pulper, in the upper (half) part of the total volume of the pulper or in the bottom part of the total volume.

[0077] A second aspect of the present invention provides a method for treating non-Newtonian biomass material having:

[0078] - a dry matter content (DS%) of at least 8%, preferably at least 12%, such as at least 14%, such as at least 16%, preferably at least 18%;

[0079] - a ratio of chemical oxygen demand (COD) to volatile solids content (VS), i.e., the COD / VS ratio, of less than 2.0, preferably less than 1.8, more preferably less than 1.6; and

[0080] - a static yield stress τ between 150 and 2500 Pa o , and / or a dynamic yield stress τ between 50 and 500 Pa y ;

[0081] The method comprises the following steps:

[0082] a) feeding the non-Newtonian biomass material to one or more pulp mills via one or more pulp mill feed lines at a controlled DS% and / or COD loading rate;

[0083] b) Homogenize and preheat the non-Newtonian biomass material in the one or more pulpers to obtain preheated biomass material;

[0084] c) Discharge the preheated biomass material from the one or more pulpers;

[0085] d) Feed the preheated biomass material through one or more feed lines to a hydrothermal system at a controlled DS% and / or COD loading rate, the hydrothermal system operating at a temperature higher than the temperature of the preheated biomass material;

[0086] e) Subject the preheated biomass material to hydrothermal hydrolysis in the hydrothermal system to obtain hydrolyzed biomass material, and subsequently treat some or all of the hydrolyzed biomass material by:

[0087] f) Transfer the hydrolyzed biomass material through one or more feed lines to one or more subsequent treatment systems at a controlled DS% and / or COD loading rate, and perform subsequent treatment on at least part of the hydrolyzed biomass material in the one or more subsequent treatment systems;

[0088] wherein the method is further characterized in that:

[0089] - By the controlled DS% and / or COD loading rate of the non-Newtonian biomass material through one or more pulper feed lines and the pulpers in steps a)-c), and / or

[0090] - By the controlled DS% and / or COD loading rate of the preheated biomass material through one or more hydrothermal system feed lines and the hydrothermal system in steps d) and e), and / or

[0091] - By the controlled DS% and / or COD loading rate of the hydrolyzed biomass material through one or more feed lines in step f),

[0092] Controlled based on:

[0093] - Continuously or semi-continuously determine the static yield stress τ of the non-Newtonian biomass material, the preheated biomass material, and / or the hydrolyzed biomass material by continuously or semi-continuously measuring the pressure drop, temperature, and flow rate among the following o and / or the dynamic yield stress τ y :

[0094] - The feed line for the one or more pulpers in step a), and / or

[0095] - The feed line for the hydrothermal system in step d), and / or

[0096] - Feed lines for the one or more subsequent treatment systems in step f), and / or

[0097] - One or more hydrolysis discharge lines or recirculation lines of the hot hydrolysis system of steps d) and e), and / or

[0098] - One or more circulation lines of the one or more pulpers of steps a)-c),

[0099] And

[0100] - Continuously or semi - continuously measuring one or more parameters of the one or more subsequent treatment systems of step f),

[0101] Thereby determining that the controlled DS% and / or COD loading rate below has the characteristic of at least one of the one or more parameters of the subsequent treatment system of step f):

[0102] - At the determined static yield stress τ o And / or dynamic yield stress τ y The controlled DS% and / or COD loading rate of the non - Newtonian biomass material through the one or more pulper feed lines and pulpers in step a); and / or

[0103] - At the determined static yield stress τ o And / or dynamic yield stress τ y The controlled DS% and / or COD loading rate of the pre - heated biomass material through the hot hydrolysis feed line and hot hydrolysis system in step d); and / or

[0104] - At the determined static yield stress τ o And / or dynamic yield stress τ y The controlled DS% and / or COD loading rate of the hydrolyzed biomass material through the feed line of the one or more subsequent treatment systems in step f).

[0105] In a specific embodiment of the second aspect of the present invention, the method is further characterized in that, according to step f), the hydrolyzed biomass material is transferred to the one or more subsequent treatment systems through one or more feed lines at a controlled DS% and / or COD loading rate, and at least a part of the hydrolyzed biomass material is subsequently treated in the one or more subsequent treatment systems, and the steps include:

[0106] f1) Transferring the hydrolyzed biomass material through one or more feed lines to a separation step to produce at least two fractions, one fraction being rich in liquid compared to the hydrolyzed biomass material and the other fraction being rich in solid compared to the hydrolyzed biomass material;

[0107] and / or

[0108] f2) Transfer, via one or more feed lines, some or all of the hydrolyzed biomass material and one or both of the at least two fractions produced in the separation step of step f1) to one or more treatment units for anaerobic fermentation;

[0109] and / or

[0110] f3) Transfer, via one or more feed lines, some or all of the hydrolyzed biomass material and one or both of the at least two fractions produced in the separation step of step f1) to one or more treatment units for thermal reduction of organic compounds, wherein the thermal reduction is achieved by:

[0111] 1) Incineration (co-incineration or single incineration)

[0112] 2) Gasification

[0113] 3) Pyrolysis or calcination

[0114] 4) Supercritical water oxidation

[0115] 5) Supercritical water liquefaction

[0116] 6) Hydrothermal carbonization

[0117] 7) Hydrothermal oxidation, and / or

[0118] 8) Hydrothermal liquefaction

[0119] and / or

[0120] f4) Transfer, via one or more feed lines, some or all of the hydrolyzed biomass material and one or both of the at least two fractions produced in the separation step of step f1) to one or more treatment units for:

[0121] 1) Electrochemical treatment, and / or

[0122] 2) Biological treatment for reducing organic compounds (e.g., anaerobic ammonium oxidation process or other similar biological processes), and / or

[0123] 3) Biological treatment for reducing nutrient concentration (e.g., anaerobic ammonium oxidation process), and / or

[0124] 4) Chemical treatment for reducing nutrient concentration (e.g., evaporation or chemical stripping), and / or

[0125] 5) Thermal treatment for reducing nutrient concentration (e.g., steam stripping), and / or

[0126] 6) Chemical or thermal reactions or extractions of inorganic or organic compounds in hydrolyzed biomass materials (e.g., magnesium ammonium phosphate, lignocellulosic compounds, feed additives, medical additives, cosmetic additives, etc.)

[0127] wherein the method features further that:

[0128] - The controlled DS% and / or COD loading rate of the biomass material passing through one or more pulper feed lines and the pulper in steps a)-c) per unit time, and / or

[0129] - The controlled DS% and / or COD loading rate of the preheated biomass material passing through one or more hot hydrolysis system feed lines and the hot hydrolysis system in steps d) and e) per unit time, and / or

[0130] - The controlled DS% and / or COD loading rate of the hydrolyzed biomass material passing through one or more feed lines in steps f1)-f4) per unit time

[0131] Controlled based on:

[0132] - By continuously or semi-continuously measuring the pressure drop, temperature, and flow rate among the following, continuously or semi-continuously determining the apparent viscosity of the non-Newtonian biomass material, the preheated biomass material, and / or the hydrolyzed biomass material, such as the static yield stress τ o and / or the dynamic yield stress τ y :

[0133] - The feed line(s) of the one or more pulpers for step a), and / or

[0134] - The feed line of the hot hydrolysis system for step d), and / or

[0135] - The feed line(s) of the one or more subsequent treatment systems in steps f1)-f4), and / or

[0136] - One or more hot hydrolysis discharge or recirculation lines of the hot hydrolysis system in steps d) and e), and / or

[0137] - One or more circulation lines of the one or more pulpers in steps a)-c)

[0138] And

[0139] - Continuously or semi-continuously measuring at least one or more of the following parameters of the one or more subsequent treatment systems in steps f1)-f4):

[0140] - pH value

[0141] - CH4 concentration

[0142] - Biogas production per unit time

[0143] - DS%,

[0144] - VS%,

[0145] - FOS / TAC ratio measured by the Nordmann method,

[0146] - Temperature

[0147] - Oxygen concentration

[0148] - CO2 concentration

[0149] - Conductivity

[0150] - Salt concentration

[0151] - Dissolved carbon content

[0152] - Dissolved nitrogen content

[0153] - Suspended solids content, and / or

[0154] - Particle shape / size distribution

[0155] It is thus determined that:

[0156] - At the determined apparent viscosity, such as the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the non-Newtonian biomass material passing through one or more pulper feed lines and the pulper in step a) per unit time; and / or

[0157] - At the determined apparent viscosity, such as the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the preheated biomass material passing through the hot hydrolysis feed line and the hot hydrolysis system in step d) per unit time; and / or

[0158] - At the determined apparent viscosity, such as the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the hydrolyzed biomass material passing through the feed line of one or more subsequent treatment systems in steps f1)-f4) per unit time,

[0159] having at least one or more of the following parameters for the preheated biomass material, the hydrolyzed biomass material and / or one or more subsequent treatment steps in steps f1)-f4):

[0160] - pH value

[0161] - CH4 concentration

[0162] - Amount of biogas produced per unit time

[0163] - DS%,

[0164] - VS%,

[0165] - FOS / TAC ratio measured by the Nordmann method

[0166] - Temperature

[0167] - Oxygen concentration

[0168] - CO2 concentration

[0169] - Conductivity

[0170] - Salt concentration

[0171] - Amount of dissolved carbon

[0172] - Amount of dissolved nitrogen

[0173] - Amount of suspended solids, and / or

[0174] - Particle shape / size distribution

[0175] In one embodiment of the second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, characterized by a static yield stress τ o between 150 and 2500 Pa (e.g., higher than 200 Pa, e.g., higher than 250 Pa, e.g., higher than 300 Pa, e.g., higher than 350 Pa, e.g., higher than 400 Pa, e.g., higher than 450 Pa, e.g., higher than 500 Pa, e.g., lower than 2400 Pa, e.g., lower than 2300 Pa, e.g., lower than 2200 Pa, e.g., lower than 2100 Pa, e.g., lower than 2000 Pa, e.g., lower than 1900 Pa, e.g., lower than 1800 Pa, e.g., lower than 1700 Pa, e.g., lower than 1600 Pa, e.g., between 300 and 1700 Pa, e.g., between 400 and 1700 Pa, e.g., between 500 and 1700 Pa, e.g., between 600 and 1700 Pa, e.g., between 700 and 1700 Pa, e.g., between 800 and 1700 Pa, e.g., between 900 and 1700 Pa, e.g., between 1000 and 1700 Pa), and / or the static yield stress τ exhibited by the non-Newtonian biomass material oBetween 150 and 2500 Pa (e.g., higher than 200, e.g., higher than 250 Pa, e.g., higher than 300 Pa, e.g., higher than 350 Pa, e.g., higher than 400 Pa, e.g., higher than 450 Pa, e.g., higher than 500 Pa, e.g., lower than 2400 Pa, e.g., lower than 2300 Pa, e.g., lower than 2200 Pa, e.g., lower than 2100 Pa, e.g., lower than 2000 Pa, e.g., lower than 1900 Pa, e.g., lower than 1800 Pa, e.g., lower than 1700 Pa, e.g., lower than 1600 Pa, e.g., between 300 and 1700 Pa, e.g., between 400 and 1700 Pa, e.g., between 500 and 1700 Pa, e.g., between 600 and 1700 Pa, e.g., between 700 and 1700 Pa, e.g., between 800 and 1700 Pa, e.g., between 900 and 1700 Pa, e.g., between 1000 and 1700 Pa).

[0176] In one embodiment of the second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, which is characterized by a static yield stress τ o of at least 500 Pa (e.g., at least 600 Pa, e.g., at least 700 Pa, e.g., at least 800 Pa, e.g., at least 900 Pa, e.g., at least 1000 Pa, e.g., at least 1100 Pa, e.g., at least 1200 Pa, e.g., at least 1300 Pa, e.g., at least 1400 Pa, e.g., at least 1500 P), and / or the static yield stress τ exhibited by the non-Newtonian biomass material o is at least 500 Pa (e.g., at least 600 Pa, e.g., at least 700 Pa, e.g., at least 800 Pa, e.g., at least 900 Pa, e.g., at least 1000 Pa, e.g., at least 1100 Pa, e.g., at least 1200 Pa, e.g., at least 1300 Pa, e.g., at least 1400 Pa, e.g., at least 1500 Pa).

[0177] In one embodiment of this second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, which is characterized by a dynamic yield stress τ y Between 50 and 500 Pa (e.g., higher than 60 Pa, e.g., higher than 70 Pa, e.g., higher than 80 Pa, e.g., higher than 90 Pa, e.g., higher than 100, e.g., higher than 150 Pa, e.g., higher than 200 Pa, e.g., lower than 450 Pa, e.g., lower than 400 Pa, e.g., lower than 350 Pa, e.g., lower than 300 Pa, e.g., lower than 250 Pa, e.g., between 60 and 400 Pa, e.g., between 70 and 300 Pa, e.g., between 80 and 250 Pa), and / or the dynamic yield stress τ exhibited by the non-Newtonian biomass materialy Between 50 and 500 Pa (for example, higher than 60 Pa, for example, higher than 70 Pa, for example, higher than 80 Pa, for example, higher than 90 Pa, for example, higher than 100, for example, higher than 150 Pa, for example, higher than 200 Pa, for example, lower than 450 Pa, for example, lower than 400 Pa, for example, lower than 350 Pa, for example, lower than 300 Pa, for example, lower than 250 Pa, for example, between 60 and 400 Pa, for example, between 70 and 300 Pa, for example, between 80 and 250 Pa).

[0178] In one embodiment of this second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, which is characterized by a dynamic yield stress τ y Of at least 50 Pa (for example, at least 60 Pa, for example, at least 70 Pa, for example, at least 80 Pa, for example, at least 90 Pa, for example, at least 100 Pa, for example, at least 110 Pa, for example, at least 120 Pa, for example, at least 130 Pa, for example, at least 140 Pa, for example, at least 150 Pa), and / or the dynamic yield stress τ exhibited by the non-Newtonian biomass material y Is at least 50 Pa (for example, at least 60 Pa, for example, at least 70 Pa, for example, at least 80 Pa, for example, at least 90 Pa, for example, at least 100 Pa, for example, at least 110 Pa, for example, at least 120 Pa, for example, at least 130 Pa, for example, at least 140 Pa, for example, at least 150 Pa).

[0179] In one embodiment of the second aspect of the present invention, the method is further characterized in that the hot hydrolysis system in steps d) and e) includes:

[0180] - One or more reactors operating in parallel or in series, in which the preheated biomass is subjected to heating and pressure increase; and

[0181] - One or more flash tanks, to which the biomass is transferred from the one or more reactors, thereby causing a pressure drop in one or more stages of generating flash steam;

[0182] And:

[0183] - In one or more pulpers operating in parallel or in series in steps a)-c), the preheating of the biomass material is achieved by injecting flash steam recovered from the hot hydrolysis system of steps d) and e).

[0184] In a further embodiment of the second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material has a dry matter content (DS%) higher than 20%, and:

[0185] - At least 50% of the resulting hydrolyzed biomass material is recycled by being conveyed from i) downstream of the hydrolysis system of steps d) and e) to ii) upstream of the hydrolysis system of steps d) and e), and / or

[0186] - The biomass material is preheated in the pulper of steps a) to c) and hydrothermally hydrolyzed in the hydrothermal hydrolysis system of steps d) and e) by subjecting the biomass material to a plurality of steps including stepwise heating and cooling.

[0187] In a further embodiment of the second aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material has a dry matter content (DS%) higher than 20%, and wherein the one or more subsequent treatment systems in step f) comprise:

[0188] f1) A separation step to produce at least two fractions, one fraction being rich in liquid compared to the hydrolyzed biomass material and the other fraction being rich in solid compared to the hydrolyzed biomass material;

[0189] And,

[0190] f2) Transferring, via one or more feed lines, the hydrolyzed biomass material, a part or all of one or both of the at least two fractions produced in the separation step of step f1), to one or more treatment units for anaerobic fermentation;

[0191] And,

[0192] f3) Transferring, via one or more feed lines, the hydrolyzed biomass material, a part or all of one or both of the at least two fractions produced in the separation step of step f1), to one or more treatment units for thermal reduction of organic compounds;

[0193] And wherein:

[0194] - At least part of the material obtained from the anaerobic fermentation of step f2) is at least partially dehydrated, and the resulting dehydrated material is transferred via one or more feed lines to the one or more treatment units for thermal reduction of organic compounds of step f3).

[0195] In an embodiment of the second aspect of the present invention, by subjecting the biomass material to a plurality of steps including stepwise heating and cooling, the biomass material is preheated in the pulper of steps a) to c) and undergoes hydrothermal hydrolysis in the hydrothermal hydrolysis system of steps d) and e). This stepwise heating and cooling is preferably carried out in more than one pulper for heating, more than one reactor for treatment at a preselected temperature above 150 °C, more preferably above 160 °C or even more preferably above 180 °C, and more than one flash tank for decompression and / or cooling. The individual vessels for this stepwise heating and cooling can be connected in parallel or in series.

[0196] In any of the above embodiments, by subjecting the biomass material to a plurality of steps including stepwise heating and cooling, the biomass material is preheated in the pulper of steps a) to c) and undergoes hydrothermal hydrolysis in the hydrothermal hydrolysis system of steps d) and e), and a tubular or tank - type container can be used as a continuous or discontinuous process.

[0197] In the above embodiments, by subjecting the biomass material to a plurality of steps including stepwise heating and cooling, the biomass material is preheated in the pulper of steps a) to c) and undergoes hydrothermal hydrolysis in the hydrothermal hydrolysis system of steps d) and e), the total volume of each preheating pulper is generally equal to or greater than the average filling volume of the corresponding reactor. More preferably, the total volume of each preheating pulper is generally equal to or greater than twice the average filling volume of the corresponding reactor. In a particularly preferred embodiment, by subjecting the biomass material to a plurality of steps including stepwise heating and cooling, the biomass material is preheated in the pulper of steps a) to c) and undergoes hydrothermal hydrolysis in the hydrothermal hydrolysis system of steps d) and e), and the preheating pulper used is the pulper according to the first aspect of the present invention.

[0198] In another embodiment of the second aspect of the present invention, the method is further characterized in that the hydrolyzed biomass material obtained in step e) is recycled by being transported from i) downstream of the hydrolysis system of steps d) and e) to ii) upstream of more than one pulper of steps a) - c) and mixed with the non - Newtonian biomass material, thereby reducing the apparent viscosity of the material fed to the pulper, such as the static yield stress τ o and / or the dynamic yield stress τ y .

[0199] In another embodiment of the second aspect of the present invention, the method is further characterized in that the preheated biomass material from more than one pulper of steps a) - c) is recycled by being transported upstream of more than one pulper of steps a) - c) and mixed with the non - Newtonian biomass material, thereby reducing the apparent viscosity of the material entering the pulper, such as the static yield stress τo and / or dynamic yield stress τ y 。

[0200] In yet another embodiment of the second aspect of the present invention, the method is further characterized in that the recycling of the hydrolyzed biomass obtained in step e) or the preheated biomass material obtained in step b) is achieved by using more than one hybrid screw conveyor and pump (preferably a screw pump, and preferably more than one screw conveyor with a conveying capacity of at least 1.5 times that of the pump).

[0201] In yet another embodiment of the second aspect of the present invention, the method is also characterized in that the recycling of the obtained hydrolyzed biomass or preheated biomass material is achieved by using more than one hybrid screw conveyor and pump (preferably a screw pump, and preferably more than one screw conveyor with a conveying capacity of at least 1.5 times that of the pump).

[0202] In yet another embodiment of the second aspect of the present invention, the method further comprises the following steps:

[0203] - adding a diluting liquid, such as water, to reduce the apparent viscosity of the non-Newtonian biomass material, the preheated biomass material, and the hydrolyzed biomass material, such as the static yield stress τ o and / or dynamic yield stress τ y ,and / or

[0204] - adding an additive to the non-Newtonian biomass material to reduce the apparent viscosity of the material fed to the pulper, such as the static yield stress τ o and / or dynamic yield stress τ y ,and / or

[0205] - adding an additive to the non-Newtonian biomass material to initiate an exothermic reaction to increase the temperature of the non-Newtonian biomass material, and / or

[0206] - adding an additive to the non-Newtonian biomass material to directly or indirectly affect other properties of the biomass material, such as chemical or biochemical composition, microbial composition or content, cell structure, particle size distribution or particle shape distribution, which are known to directly or indirectly affect the apparent viscosity of the non-Newtonian biomass material (such as static yield stress and / or dynamic yield stress).

[0207] In yet another embodiment of the second aspect of the present invention, the method is further characterized in that, before the hydrolyzed biomass material undergoes the subsequent treatment in the one or more treatment units of steps f1) to f4), a heat exchanger is used to recover the heat from the cooling process of the hydrolyzed biomass material from step e), preferably by subjecting the hydrolyzed biomass material to heat exchange with water in the heat exchanger to cool the hydrolyzed biomass of step e), and then injecting the water into the non-Newtonian biomass material of step a) or the preheated biomass material of step b).

[0208] In yet another embodiment of the second aspect of the present invention, the method is further characterized in that the recovered heat is used for:

[0209] - heating the non-Newtonian biomass material of step a) before the pretreatment in the one or more pulpers of steps a)-c), or

[0210] - heating the preheated biomass material of step b) in the hot hydrolysis system of steps d) and e).

[0211] In another embodiment of the second aspect of the present invention, the method is further characterized in that the apparent viscosity of the non-Newtonian biomass material of step a) is expressed as and / or the static yield stress τ of the non-Newtonian biomass material of step a) o is higher than 2000 Pa (e.g., higher than 2200 Pa, e.g., higher than 2300 Pa), and the apparent viscosity of the material fed to the pulper is reduced to a value represented by a static yield stress τ of less than 1700 Pa (e.g., less than 1500 Pa), and / or the static yield stress τ of the material fed to the pulper o is reduced to less than 1700 Pa (e.g., less than 1500 Pa), and o - optionally, before the subsequent treatment of steps f1)-f4), inorganic particles and / or undissolved materials are continuously separated from the hydrolyzed biomass material of step e) by degritting.

[0212] In yet another embodiment of the second aspect of the present invention, the method is further characterized in that the apparent viscosity of the non-Newtonian biomass material of step a) is expressed as and / or the dynamic yield stress τ of the non-Newtonian biomass material of step a)

[0213] is higher than 300 Pa (e.g., higher than 350 Pa, e.g., higher than 400 Pa), and the apparent viscosity of the material fed to the pulper is reduced to a dynamic yield stress τ of less than 300 Pa (e.g., less than 250 Pa) y y ​The value represented, and / or the dynamic yield stress τ of the material fed to the pulper y is reduced to below 300 Pa (e.g., below 250 Pa), and

[0214] - Optionally, before the subsequent treatment of steps f1)-f4), inorganic particles and / or undissolved materials are continuously separated from the hydrolyzed biomass material of step e) by desanding.

[0215] In a further embodiment of the second aspect of the invention, the method is further characterized in that at least a part of the at least one fraction rich in liquid compared to the hydrolyzed biomass material in step f1) is recycled by being fed to:

[0216] - upstream of more than one of the pulpers of steps a)-c) and mixed with the non-Newtonian biomass material, thereby reducing the apparent viscosity of the material fed to the pulper, e.g., the static yield stress τ o and / or the dynamic yield stress τ y ;

[0217] - upstream of the hydrolysis system of steps d)-e) and mixed with the preheated biomass material, thereby reducing the apparent viscosity of the material fed to the hydrolysis system, e.g., the static yield stress τ o and / or the dynamic yield stress τ y ; and / or

[0218] - upstream of the separation step f1) and mixed with the hydrolyzed biomass material, thereby reducing the apparent viscosity of the material fed to the separation step f1), e.g., the static yield stress τ o and / or the dynamic yield stress τ y .

[0219] In a particularly preferred embodiment of the second aspect of the invention, the homogenization and preheating of the non-Newtonian biomass material in more than one of the pulpers in steps a)-c), and the hot hydrolysis of steps d)-e), are carried out in a system according to the first aspect of the invention.

[0220] Any embodiment of the first aspect of the invention can be combined with any embodiment of the second aspect.

[0221] A third aspect of the present invention provides a method for retrofitting an existing apparatus for the thermohydrolysis of non-Newtonian biomass materials, the non-Newtonian biomass materials having a dry matter content (DS%) of at least 8%, preferably at least 12%, for example at least 14%, for example at least 16%, preferably at least 18%, a ratio of chemical oxygen demand (COD) to volatile solids content (VS) of less than 2.0, preferably less than 1.8, more preferably less than 1.6, and a static yield stress τ between 150 and 2500 Pa o and / or a dynamic yield stress τ between 50 and 500 y , the non-Newtonian biomass materials being used in anaerobic fermentation, digestion or other processes aimed at producing or extracting methane or other valuable substances, wherein the retrofit ensures that the apparatus at least comprises the following:

[0222] a) means for feeding the non-Newtonian biomass materials to one or more shredders via one or more shredder feed lines at a controlled DS% and / or COD loading rate;

[0223] b) means for homogenizing and preheating the non-Newtonian biomass materials in the one or more shredders to obtain preheated biomass materials;

[0224] c) means for discharging the preheated biomass materials from the one or more shredders;

[0225] d) means for feeding the preheated biomass materials to a thermohydrolysis system via one or more feed lines at a controlled DS% and / or COD loading rate, the operating temperature of the thermohydrolysis system being higher than the temperature of the preheated biomass materials;

[0226] e) means for performing thermohydrolysis on the preheated biomass materials in the thermohydrolysis system to obtain hydrolyzed biomass materials; and

[0227] f) transferring the hydrolyzed biomass materials to the one or more subsequent treatment systems via one or more feed lines at a controlled DS% and / or COD loading rate, and subsequently treating at least part of the hydrolyzed biomass materials in the one or more subsequent treatment systems,

[0228] wherein the apparatus is further characterized in that:

[0229] - the controlled DS% and / or COD loading rate of the non-Newtonian biomass materials via the one or more shredder feed lines and shredders of steps a)-c); and / or

[0230] - The controlled DS% and / or COD loading rate of the non-Newtonian biomass material, the preheated biomass material of the one or more hydrothermal hydrolysis system feed lines and the hydrothermal hydrolysis system through steps d) and e); and / or

[0231] - The controlled DS% and / or COD loading rate of the hydrolyzed biomass material through the one or more feed lines in step f);

[0232] is controlled based on the following:

[0233] - Continuously or semi-continuously determine the static yield stress τ and / or dynamic yield stress τ of the non-Newtonian biomass material, the preheated biomass material and / or the hydrolyzed biomass material by continuously or semi-continuously measuring the pressure drop, temperature and flow rate as follows o and / or dynamic yield stress τ y :

[0234] - The feed line of the one or more pulpers for step a), and / or

[0235] - The feed line of the hydrothermal hydrolysis system for step d), and / or

[0236] - The feed line of the one or more subsequent treatment systems for step f), and / or

[0237] - One or more hydrothermal hydrolysis discharge lines or recirculation lines of the hydrothermal hydrolysis system in steps d) and e), and / or

[0238] - One or more circulation lines of the one or more pulpers in steps a)-c),

[0239] and

[0240] - Continuously or semi-continuously measure one or more parameters of the one or more subsequent treatment systems in step f),

[0241] so as to determine that the controlled DS% and / or COD loading rate has the characteristics of at least one of the one or more parameters of the subsequent treatment system in step f):

[0242] - At the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the non-Newtonian biomass material through the one or more pulper feed lines and pulpers in step a); and / or

[0243] - At the determined static yield stress τ o and / or dynamic yield stress τ y- under the controlled DS% and / or COD loading rate of the hydrolyzed biomass material through the hot hydrolysis feed line of step d) and the preheated biomass material of the hot hydrolysis system; and / or

[0244] - at the determined static yield stress τ o and / or dynamic yield stress τ y - under the controlled DS% and / or COD loading rate of the hydrolyzed biomass material through the feed line of the one or more subsequent treatment systems of step f).

[0245] In a specific embodiment of this third aspect of the present invention, the device may further be characterized in that, according to step f), the hydrolyzed biomass material is transferred to the one or more subsequent treatment systems through one or more feed lines at a controlled DS% and / or COD loading rate, and at least a part of the hydrolyzed biomass material is subsequently treated in the one or more subsequent treatment systems. The device includes:

[0246] f1) a device for transporting the hydrolyzed biomass material through one or more feed lines to a separation step to produce at least two fractions, wherein one fraction is rich in liquid compared to the hydrolyzed biomass material, and the other fraction is rich in solid compared to the hydrolyzed biomass material;

[0247] and / or,

[0248] f2) a device for transferring the hydrolyzed biomass material, and part or all of one or both of the at least two fractions produced in the separation step of step f1), through one or more feed lines to one or more treatment units for anaerobic fermentation;

[0249] and / or,

[0250] f3) a device for transferring the hydrolyzed biomass material, and part or all of one or both of the at least two fractions produced in the separation step of step f1), through one or more feed lines to one or more treatment units for thermal reduction of organic compounds, wherein the thermal reduction is achieved by:

[0251] 1) incineration (co-incineration or separate incineration)

[0252] 2) gasification

[0253] 3) pyrolysis or calcination

[0254] 4) supercritical water oxidation

[0255] 5) supercritical water liquefaction

[0256] 6) hydrothermal carbonization

[0257] 7) Hydrothermal oxidation, and / or

[0258] 8) Hydrothermal liquefaction

[0259] and / or

[0260] f4) A device for transferring, via one or more feed lines, some or all of one or both of the at least two fractions produced in the separation step of step f1) of the hydrolyzed biomass material to one or more treatment units for the following:

[0261] 1) Electrochemical treatment, and / or

[0262] 2) Biological treatment for reducing organic compounds (e.g., anammox process or other similar biological processes), and / or

[0263] 3) Biological treatment for reducing nutrient concentration (e.g., anammox process), and / or

[0264] 4) Chemical treatment for reducing nutrient concentration (e.g., evaporation or chemical stripping),

[0265] 5) Thermal treatment for reducing nutrient concentration (e.g., steam stripping), and / or

[0266] 6) Chemical or thermal reaction or extraction of inorganic or organic compounds in the hydrolyzed biomass material (e.g., magnesium ammonium phosphate, lignocellulosic compounds, feed additives, medical additives, cosmetic additives, etc.),

[0267] wherein the device is further characterized in that:

[0268] - The controlled DS% and / or COD loading rate of the biomass material through one or more pulper feed lines and the pulper in steps a)-c) per unit time, and / or

[0269] - The controlled DS% and / or COD loading rate of the preheated biomass material through one or more hydrothermal hydrolysis system feed lines and the hydrothermal hydrolysis system in steps d) and e) per unit time, and / or

[0270] - The controlled DS% and / or COD loading rate of the hydrolyzed biomass material through one or more feed lines in steps f1)-f4) per unit time,

[0271] can be controlled based on the following:

[0272] - By continuously or semi - continuously measuring the pressure drop, temperature, and flow rate among the following, continuously or semi - continuously determining the apparent viscosity of the non - Newtonian biomass material, the preheated biomass material, and / or the hydrolyzed biomass material, such as the static yield stress τo and / or the dynamic yield stress τ y :

[0273] - the feed line for the one or more pulpers used in step a), and / or

[0274] - the feed line for the hot hydrolysis system used in step d), and / or

[0275] - the feed line for the one or more subsequent treatment systems used in steps f1)-f4), and / or

[0276] - one or more hot hydrolysis discharge or recirculation lines of the hot hydrolysis system in steps d) and e), and / or

[0277] - one or more circulation lines of the one or more pulpers in steps a)-c),

[0278] and optionally,

[0279] - continuously or semi-continuously measuring at least one of the following parameters in one or more subsequent treatment systems in steps f1)–f4):

[0280] - pH value

[0281] - CH4 concentration

[0282] - amount of biogas produced per unit time

[0283] - DS%

[0284] - VS%

[0285] - FOS / ΤAC ratio measured according to the Nordmann method,

[0286] - temperature

[0287] - oxygen concentration

[0288] - CO2 concentration

[0289] - conductivity

[0290] - salt concentration

[0291] - dissolved carbon amount

[0292] - dissolved nitrogen amount

[0293] - amount of suspended solids, and / or

[0294] - particle shape / size distribution

[0295] whereby the device can determine;

[0296] - at the determined apparent viscosity (e.g., static yield stress τo and / or dynamic yield stress τ y ) the controlled DS% and / or COD loading rate of the non-Newtonian biomass material passing through one or more pulper feed lines and the pulper in step a) per unit time;

[0297] - at the determined apparent viscosity (e.g., static yield stress τ o and / or dynamic yield stress τ y ) the controlled DS% and / or COD loading rate of the preheated biomass material passing through the hot hydrolysis feed line and the hot hydrolysis system in step d) per unit time; and / or

[0298] - at the determined apparent viscosity (e.g., static yield stress τ o and / or dynamic yield stress τ y ) the controlled DS% and / or COD loading rate of the hydrolyzed biomass material passing through the feed line of one or more subsequent treatment systems in steps f1)-f4) per unit time;

[0299] having at least one or more of the following parameters of the preheated biomass material, the hydrolyzed biomass material, and / or one or more subsequent treatment steps in steps f1)-f4):

[0300] - pH value,

[0301] - CH4 concentration,

[0302] - amount of biogas produced per unit time

[0303] - DS%,

[0304] - VS%,

[0305] - FOS / ΤAC ratio measured by the Nordmann method.

[0306] - temperature

[0307] - oxygen concentration

[0308] - CO2 concentration

[0309] - conductivity

[0310] - salt concentration

[0311] - amount of dissolved carbon

[0312] - amount of dissolved nitrogen

[0313] - amount of suspended solids, and / or

[0314] - particle shape / size distribution.

[0315] In an embodiment of the third aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, which is characterized by a static yield stress τ o of at least 500 Pa (such as at least 1000 Pa, such as at least 1500 Pa), and / or the static yield stress τ exhibited by the non-Newtonian biomass material o is at least 500 Pa (such as at least 1000 Pa, such as at least 1500 Pa).

[0316] In an embodiment of the third aspect of the present invention, the method is further characterized in that the non-Newtonian biomass material exhibits an apparent viscosity at different shear rates, which is characterized by a dynamic yield stress τ y of at least 50 Pa (such as at least 60 Pa, such as at least 70 Pa, such as at least 80 Pa, such as at least 90 Pa, such as at least 100 Pa), and / or the dynamic yield stress τ exhibited by the non-Newtonian biomass material y is at least 50 Pa (such as at least 60 Pa, such as at least 70 Pa, such as at least 80 Pa, such as at least 90 Pa, such as at least 100 Pa).

[0317] Any embodiment of the first and second aspects of the present invention can be combined with any embodiment of the third aspect.

[0318] The fourth aspect of the present invention provides a method for retrofitting an existing system, the system including a pulper for homogenizing and preheating biomass material having a dry matter content (DS%) higher than 8%, preferably at least 12%, such as higher than 14%, such as higher than 16%, preferably higher than 18%, and a hydrothermal reactor for subsequent hydrothermal hydrolysis of the biomass material, wherein the retrofit ensures that the pulper has the following characteristics:

[0319] - The total volume of the pulper is >2.6 times and <20 times the average filling volume of the hydrothermal reactor, preferably 2.6 to 6 times.

[0320] - The pulper includes an outlet nozzle for discharging the preheated material from the pulper, and the outlet nozzle is placed in such a way that

[0321] - The part of the total volume of the pulper located below the outlet nozzle is ≥1.6 times the average filling volume of the hydrothermal reactor, and

[0322] - The part of the total volume of the pulper not located below the outlet nozzle is >1 times the average filling volume of the hydrothermal reactor.

[0323] In one embodiment of the fourth aspect of the present invention, the varying pressure drop in the pulper feed line (and the resulting change in apparent viscosity) caused by the varying dry solid concentration in the pulper feed system, and the corresponding difficulty in establishing a stable dilution rate to control the apparent viscosity, can be alleviated by enhancing the mixing within the pulper. This enhanced mixing can be achieved by recycling preheated and / or hydrolyzed material and mixing it into the pulper feed system to homogenize the properties of the material ultimately fed into the pulper. This in turn improves the performance of the pulper in producing material with a temperature within a predetermined limit, increases the thermal recovery rate of the entire pulper system, enables an increase in operating efficiency at elevated dry solid concentrations, and enables the determination of the dilution rate based on more stable apparent viscosity measurements in the pulper feed line. Thus, biomass material with a more stable apparent viscosity can be fed into the pulper, enabling it to operate stably at a higher dry solid concentration, as the more predictable feed apparent viscosity ultimately reduces the magnitude of any apparent viscosity safety margin. In particular, it is ensured that the preheated biomass material produced from non-Newtonian biomass material in the pulper, and any preheated biomass material subsequently fed into any downstream hydrothermal reactor of the THP system, and / or any preheated biomass material subsequently fed from the THP system into any subsequent processing step, has a uniform temperature, i.e., when the temperature standard deviation is calculated based on a temperature measurement resolution of <5 seconds and used to calculate the overall average for each individual reactor fill, the average standard deviation of this temperature is less than 12 °C or more preferably less than 6 °C, and even more preferably less than 2 °C.

[0324] Any embodiment of the first, second, and third aspects of the present invention can be combined with any embodiment of the fourth aspect.

[0325] For the method, system, or device according to the present invention, the optimal temperature and pressure within each container depend on the temperature of the THP feed. Generally, the temperature of the THP feed is approximately 15 °C, with a normal range of 10 - 30 °C, such as 15 - 25 °C.

[0326] The flash steam is preferably injected below the liquid level of the pulper. This ensures that the steam condenses in the liquid while other non-condensable gases pass through the liquid and enter the headspace. Temperature and pressure transmitters are used to calculate the partial pressures of the steam and other non-condensable gases in the headspace of the pulper container. The inputs from these instruments are used to control the valves that release the gas from the container. This ensures that the steam carried by the process gas can be used for heating other parts of the process.

[0327] Typically, in a method, system or device according to the present invention, the temperature of the liquid material fed to one or more pulpers is in the range of 10 - 30 °C, such as 15 - 25 °C, such as 20 - 25 °C, and the hydrolysis temperature applied in one or more reactors operating in parallel or in series downstream of the pulper is in the range of 120 - 220 °C, such as 140 - 180 °C, such as 155 - 165 °C, such as about 160 °C, depending on the ambient temperature and the raw material.

[0328] The apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y of most liquid materials will decrease with increasing temperature and increase with increasing dry solids content. For example, for materials such as sludge from a sewage treatment plant, heating the material from ambient temperature to at least about 50 °C (such as at least about 60 °C, such as at least about 70 °C) will typically significantly reduce the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y . By heating to a higher temperature, the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y will continue to decrease, but the rate of decrease will be slightly less. When the temperature in the pulper is low, it may be necessary to operate with a lower dry solids content in the feed to maintain the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y at a controllable level.

[0329] In addition, as is known to those skilled in the art, the incoming liquid material can be preheated by using hot water dilution, heat exchangers, etc. In this case, i.e., if both the temperature of the liquid material fed to the pulper and the hydrolysis temperature applied in one or more reactors operating in parallel or in series downstream of the pulper are high enough, the operating pressure of the pulper will typically exceed 1 barA. For example, in a certain process, the liquid material is preheated to a temperature of 40 °C and a small amount of non-condensable gas is added, and hydrolysis is carried out at a temperature of 220 °C (and 23.2 barA). In this case, the pulper typically operates at 115 °C and about 1.8 barA. Another example of such a method and / or device is a method / device that relies on a feed temperature of about 65 - 70 °C and a reactor pressure of about 7 barA.

[0330] However, in most cases in a method, system or device according to the present invention, the biomass material temperature and hydrolysis temperature will be below 60 °C and 200 °C respectively, such as below 40 °C and 180 °C respectively.

[0331] An important aspect of the present invention is heat recovery. It is crucial that all the steam returned to the preheating vessel condenses into the material to be preheated. This is particularly challenging for pulpers operating at low temperatures because the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y increase as the temperature decreases. However, by ensuring effective mixing of the material in the preheating vessel, the so-called steam 33escribe 33g (characterized by steam passing through the liquid surface from the injection point) can be avoided. The density of steam decreases as the pressure decreases. Therefore, in most cases, the amount of steam delivered to the preheating vessel will be large. By injecting steam at a well-designed injection point, this effect can be utilized to mix the material in the preheating vessel. This makes it possible to handle materials with high viscosity and high dry solid content (e.g., higher than 8%, preferably at least 12%) even at low temperatures. Efficient mixing is not only crucial for ensuring the condensation of all the steam returned to the preheating vessel, but also for homogenizing the material before further processing. Therefore, homogenizing the material before processing in any downstream reactor also ensures more complete hydrolysis.

[0332] For most relevant materials, the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y increase as the dry solid concentration increases, while the apparent viscosity decreases as the temperature increases. The apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y of raw materials such as sludge usually decrease significantly when heated from ambient temperature to about 50 °C (e.g., about 50 °C to 70 °C, e.g., 60 °C to 65 °C). Heating to even higher temperatures will result in further decrease of the apparent viscosity, static yield stress τ o and / or dynamic yield stress τ y The present invention is capable of operating at high dry solid concentrations. Those skilled in the art should understand that high dry solid concentrations themselves will contribute to a reduction in steam consumption by approximately 10% to 30%, depending on the material properties.

[0333] Another preferred embodiment of the present invention is that for any pulper, it includes a steam introduction system that can reduce the need for mechanical mixing by using a large amount of steam for high-intensity mixing. Regardless of the mixing method adopted in the specific implementation, enhanced mixing can be achieved by optimizing the spray gun direction and additional pumping.

[0334] Therefore, the present invention provides a method for continuously or batchwise hydrolyzing materials by preheating and cooling, which are respectively achieved by injecting flash steam and promoting steam flashing.

[0335] In yet another preferred embodiment of the method or apparatus according to the present invention, the preheated pulper feed is introduced at the bottom of the preheated pulper, or above the liquid level of the preheated pulper and combined with the material size reduction and distribution system to increase the specific surface area of the cold material, or below the liquid level of the preheated pulper and combined with the material size reduction and distribution system to increase the specific surface area of the cold material.

[0336] The reactors of the method or apparatus according to the present invention can be in series or in parallel. BRIEF DESCRIPTION OF THE DRAWINGS

[0337] Figure 1(A) shows a rotational rheometer for measuring the static and dynamic yield stresses of biomass materials. The rotational rheometer includes a blade that can be immersed in a cup containing the biomass material.

[0338] Figure 1(B) shows the viscosity characteristics of different types of non-Newtonian liquids / biomass materials, including the relationship between shear rate and shear stress.

[0339] Figure 1(C) shows typical shear stress-shear rate curves of two different municipal sewage sludge samples obtained by using the rotational rheometer shown in Figure 1(A).

[0340] Figure 1(D) shows typical shear stress-shear rate curves of two hydrolyzed municipal sewage sludges obtained by using the rotational rheometer shown in Figure 1(A).

[0341] Figure 2 The viscosity characteristics of different types of sludge are shown, i.e., the relationship between shear rate and shear stress.

[0342] Figure 3 The calculated pressure drop (head loss) in the pulper feed line is shown as a function of the flow rate of a certain type of waste activated sludge, represented as the flow rate variation at high temperature (low pressure drop) and low temperature (high pressure drop), respectively.

[0343] Figure 4 The calculated head loss (bar) as a function of the pipe diameter (mm) of the sludge transport pipeline is shown for two different sludge properties and pipeline configurations at a temperature of about 20 - 25°C.

[0344] Figure 5 The average temperature of the sludge mixture is shown as a function of the return temperature.

[0345] Figure 6 The average temperature of the sludge mixture is shown as a function of the reflux ratio at a reflux temperature of 90°C and a feed stream temperature of 20°C.

[0346] Figure 7 A possible design of a particularly advantageous pulper design for the methods, systems, process equipment and apparatus of the present invention employing a thermal hydrolysis process (THP) is shown.

[0347] Figure 8 An embodiment of the invention is shown which includes a pulper design for which the invention is particularly advantageous.

[0348] Figure 9 A preferred sludge extruder in a pulper design is shown in which the present invention is particularly beneficial.

[0349] Figure 10A Data is shown for a case study relating to performance data for a pulper retrofit upgrade from a prior art design (8 hour trend graph) to a particularly beneficial pulper design of the present invention (16 hour trend graph).

[0350] Figure 10B Shown is the standard deviation of the reactor feed temperature in each reactor fill based on temperature measurements every 5 seconds in the process of the invention using the pulper of the invention.

[0351] Figure 11 Data from a case study relating to performance data for a pulper retrofit upgrade in terms of reactor flow rate, involving an upgrade from a prior art design (not employing the new invention) to a pulper design (employing the new invention) in which the present invention is particularly beneficial, is shown.

[0352] Figure 12 , Figure 13A and Figure 13B It was shown during the development and testing of a particularly advantageous pulper design of the invention described in Example 4 that τ o Relationship between % and WAS.

[0353] Figure 14 The specific energy content (measured as COD / VS) and rheology (measured as τ) are shown when the particularly advantageous pulper design of the present invention described in Example 4 is used. o ) between them.

[0354] Figure 15 It is shown that when the particularly advantageous pulper design of the invention described in Example 4 is used, τ o Relationship with WAS / primary sludge ratio.

[0355] Figure 16 It is shown that when the particularly advantageous pulper design of the invention described in Example 4 is used, τ o Relationship between organic nitrogen content in VS. DETAILED DESCRIPTION

[0356] The present invention will be further described in detail below in conjunction with some specific embodiments and the terms used in the accompanying drawings.

[0357] The present invention relates to a method, system, process equipment and device using the thermohydrolysis process (THP), which utilizes a pulper for preheating. The present invention also relates to a method for retrofitting an existing device using the thermohydrolysis process (THP). Specifically, the present invention relates to a method, system, process equipment and device using the thermohydrolysis process (THP) for the treatment of "biomass materials" having a dry matter content (DS%) of at least 8%, preferably at least 12%, such as at least 14%, such as at least 16%, such as at least 18%, such as at least 20%.

[0358] One source of "biomass materials" that can be processed by the method, system, process equipment and device of the present invention comes from so-called primary wastewater treatment, including gravity sedimentation of screened and desanded wastewater to remove settleable solids. In many cases, this process can remove slightly more than half of the suspended solids normally present in the wastewater. The residue from primary treatment is concentrated suspended particles in water, usually also referred to as "primary sludge" or "primary biosolids". Another source of "biomass materials" that can be processed by the method, system, process equipment and device of the present invention comes from so-called secondary municipal wastewater treatment, for example, completed by a biological treatment process, in which biodegradable organic matter is removed from the wastewater by microorganisms in a suspended state, attached to a medium, in a pond or other processes. Part of the organic matter is oxidized by the microorganisms to produce carbon dioxide and other end products, and the remaining part provides the energy and substances required for the growth of the microorganisms. The microorganisms thus formed settle in the form of particles, and after biological treatment, this excess biomass is separated in the sedimentation tank as a concentrated suspension, called "secondary sludge" / "secondary biosolids" or "waste activated sludge" / "WAS". In many wastewater treatment plants, a part of the WAS is returned to the secondary treatment process and mixed with the influent from which the primary sludge has been removed. This part, i.e., the returned part, is sometimes referred to as "return activated sludge" / "RAS". Therefore, "primary sludge" / "primary biosolids", "secondary sludge" / "secondary biosolids" / "waste activated sludge" / "WAS" and "return activated sludge" / "RAS" all refer to solid, semi-solid or slurry-like residues, which are by-products generated during the wastewater treatment process.

[0359] Thus, in the context of the present invention, the term "biomass material" should be understood to refer to any material containing organic matter, i.e., materials based on organisms such as microorganisms, plants, and animals, which can be used as "substrates" in the methods, systems, process equipment, and devices of the hydrothermal hydrolysis process (THP) of the present invention. The most common "biomass materials", i.e., "substrates", are energy crops, agricultural crop residues, forestry residues, algae, wood processing residues, municipal waste, and wet waste, such as crop waste, forest residues, dedicated grasses, woody energy crops, algae, industrial waste, sorted municipal solid waste [MSW], urban wood waste, food waste, and waste from industry, farms, and households, such as "wastewater" (see above), "biosludge", "sludge", etc. Unless otherwise specified, the terms "wastewater", "biosludge", "sludge" ("primary sludge" / "primary biosolids" and "secondary sludge" / "secondary biosolids"), "waste activated sludge" / "WAS", and "return activated sludge" / "RAS", etc. are interchangeable as a basis in the context of the present invention and, in the context of the aspects and embodiments described below, should all be interpreted as examples of "biomass materials" that can be used as "substrates" in the methods, systems, process equipment, and devices of the hydrothermal hydrolysis process (THP) of the present invention. In certain aspects and embodiments described below, it is explicitly stated that the "biomass material" (i.e., "substrate") to be treated contains a specific "biomass material" or a specific mixture of several specific "biomass materials", such as "wastewater", "primary sludge" / "primary biosolids", "secondary sludge" / "secondary biosolids" / "waste activated sludge" / "WAS", and / or "return activated sludge" / "RAS". However, as can be clearly seen from the following, this possible further specification of "biomass materials" is intended to provide specific examples of how a person skilled in the art can arrive at "biomass materials" with the following characteristics: for example, a specific apparent viscosity and / or a specific static yield stress τ o and / or dynamic yield stress τ y, a specific dry matter content (DS%) and / or a specific ratio between the chemical oxygen demand (COD) and the volatile solids content (VS), namely the so-called COD / VS ratio. However, those skilled in the art should understand that "biomass materials", namely "substrates", showing similar characteristics can equally be obtained from other "biomass materials" or mixtures of other "biomass materials", rather than from the biomass materials specifically indicated in the relevant aspects and / or embodiments. In the context of the present invention, the term "non-Newtonian biomass material" should be understood to refer to a biomass material that does not follow Newton's viscosity law (see above). Thus, the viscosity of a "non-Newtonian biomass material" changes when subjected to force, becoming either more liquid or more solid, and the relationship between the shear stress and the shear rate is not linear and / or does not pass through the origin, unlike a Newtonian fluid (see Figure 1(B)). In a "non-Newtonian biomass material", the relationship between the shear stress and the shear rate is different and a constant viscosity coefficient cannot be defined.

[0360] In the context of the present invention, the term "static yield point" and the term "τ o " should be understood as the shear stress that causes a material that was originally solid to start flowing, and is sometimes also referred to as "static yield stress". Thus, in the context of the present invention, "static yield point" / "static yield stress" / "τ o " should be understood as a measure of the resistance to flow of a given "biomass material", or in other words, it should be understood as the shear stress required to cause a given "biomass material" to start moving in a fluid form. Thus, "static yield point" / "τ o " / "static yield stress" is a characteristic related to the "biomass material" of the present invention, and the "biomass material" will not flow unless the applied shear stress exceeds the "static yield point" / "τ o " / "static yield stress". The SI unit for "static yield point" / "static yield stress" / "τ o " is the pascal (Pa) or Nm 2 .

[0361] In the context of the present invention, the term "dynamic yield point" and the term "τ y " should be understood as the shear stress required to maintain the flow of a material, and is sometimes also referred to as "dynamic yield stress". Thus, in the context of the present invention, "dynamic yield point" / "dynamic yield stress" / "τ y " should be understood as the shear stress required to maintain the movement of a given "biomass material" in a flowing form. Thus, "dynamic yield point" / "τ y " / "dynamic yield stress" is a characteristic related to the "biomass material" of the present invention, and the "biomass material" will not flow unless the applied shear stress exceeds the "dynamic yield point" / "τ y” / “Dynamic yield stress”, otherwise the “biomass material” will not remain fluid. For “dynamic yield point” / “dynamic yield stress” / “τ y ” the SI unit is Pascal (Pa) or Nm 2 .

[0362] The static yield stress τ of the “biomass material” can be measured using a rotational rheometer o and the dynamic yield stress τ y . The working principle is as follows. As shown in Figure 1(A), a blade is immersed in a cup containing the “biomass material”. Then the angular velocity of the blade is gradually increased while measuring the applied torque. When combined with appropriate calibration, the resulting shear stress - shear rate curve is obtained, as shown in Figure 1(C) for example.

[0363] In the results shown in Figure 1(C), the “biomass material” labeled “1” is from the Bio - P process and has a dry solid content of 18.2%. The “biomass material” labeled “2” has been pretreated at about 80 °C and has a dry solid concentration of 17.5%. The measurements of both samples were carried out at 21 °C. At a shear rate of about 6 s -1 , both materials showed Bingham plastic fluid behavior and the plastic viscosity (slope of the curve) was close to 0. The dashed line corresponds to a dynamic yield stress of 130 Pa. Therefore, the main difference between the two materials lies in the magnitude of the static yield stress: 1200 Pa versus 400 Pa. As these measurement results show, there is a significant difference between the dynamic yield stress τ y and the static yield stress τ o of a given material, and both of these parameters contribute to characterizing the overall flow properties of the material, namely the apparent viscosity.

[0364] In the context of the present invention, “apparent viscosity” (sometimes also called shear viscosity) refers to the shear stress applied to a fluid divided by the shear rate. “Apparent viscosity” has SI units derived from Pa·s (Pascal - second), but in practical applications, centipoise is usually used: (1 mPa·s = 1 cP). For Newtonian fluids, “apparent viscosity” is a constant equal to the Newtonian viscosity of the fluid. For non - Newtonian fluids, such as the “biomass material” of the present invention, “apparent viscosity” depends on the shear rate, as shown in Figure 1(C). Thus, for example, when measured at a higher shear rate, the “apparent viscosity” of a so - called Bingham plastic is lower. Therefore, multiple measurements of “apparent viscosity” at different, clearly defined shear rates can provide useful information about the behavior of non - Newtonian fluids / materials.

[0365] As described above, as shown in Figure 1(A), the “yield stress” is measured to determine the “static yield stress” / “τ o” and “dynamic yield stress” / “τ y A very common method for ” is by plotting shear stress versus shear rate data obtained from measurements with a conventional rheometer. This experimental data (also known as the equilibrium flow curve) can be interpreted with or without a rheological model (such as the Herschel–Bulkley model, Bingham plastic model, Bingham pseudoplastic model or Ostwald–de Waele model), see Figure 2 , which shows data for “dewatered raw sludge” and “hydrolyzed and digested sludge” respectively.

[0366] Preferably, in the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP), the apparent viscosity characteristics of the non-Newtonian biomass material to be treated are characterized by showing a static yield stress τ between 150 and 2500 Pa o , for example at least 1000 Pa, for example at least 1100 Pa, for example at least 1200 Pa, for example at least 1300 Pa, for example at least 1400 Pa. Alternatively, preferably, in the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP), the non-Newtonian biomass material to be treated shows a static yield stress τ of at least 1000 Pa o , for example at least 1100 Pa, for example at least 1200 Pa, for example at least 1300 Pa, for example at least 1400 Pa.

[0367] Preferably, in the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP), the apparent viscosity characteristics of the non-Newtonian biomass material to be treated are characterized by showing a dynamic yield stress τ between 50 and 500 Pa y , for example at least 60 Pa, for example at least 70 Pa, for example at least 80 Pa, for example at least 90 Pa, for example at least 100 Pa, for example at least 110 Pa, for example at least 120 Pa, for example at least 130 Pa and for example at least 140 Pa. Alternatively, preferably, in the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP), the non-Newtonian biomass material to be treated shows a dynamic yield stress τ of at least 150 Pa y , for example at least 160 Pa, for example at least 170 Pa, for example at least 180 Pa and for example at least 190 Pa.

[0368] In some embodiments of the present invention, before feeding the biomass material into the pulper of the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP), by reducing the apparent viscosity of the biomass material, the apparent viscosity of the non-Newtonian biomass material to be treated in the method, system, process equipment and device of the present invention employing the thermochemical hydrolysis process (ΤHP) is adjusted to the static yield stress τo Below 1700 Pa, such as below 1500 Pa, the original apparent viscosity of the biomass material shows a static yield stress τ higher than 2000 Pa (such as higher than 2200 Pa, such as higher than 2500 Pa). o Alternatively, the non-Newtonian biomass material to be processed in the method, system, process equipment and device of the present invention using the hydrothermal hydrolysis process (ΤHP) shows a static yield stress τ higher than 2000 Pa (such as higher than 2200 Pa, such as higher than 2500 Pa). o It can be reduced to a static yield stress τ below 1700 Pa (such as below 1500 Pa). o .

[0369] In some embodiments of the present invention, before feeding the non-Newtonian biomass material into the pulper of the method, system, process equipment and device of the present invention using the hydrothermal hydrolysis process (ΤHP), by reducing the apparent viscosity of the biomass material, the apparent viscosity of the non-Newtonian biomass material to be processed in the method, system, process equipment and device of the present invention using the hydrothermal hydrolysis process (ΤHP) is adjusted to a dynamic yield stress τ. y Below 300 Pa, such as below 250 Pa, the original apparent viscosity of the biomass material shows a dynamic yield stress τ higher than 300 Pa (such as higher than 350 Pa, such as higher than 400 Pa). y Alternatively, the non-Newtonian biomass material to be processed in the method, system, process equipment and device of the present invention using the hydrothermal hydrolysis process (ΤHP) shows and / or a dynamic yield stress τ higher than 250 Pa (such as higher than 300 Pa, such as higher than 350 Pa). y It can be reduced to a dynamic yield stress τ below 250 Pa (such as below 200 Pa). y .

[0370] This can be achieved by adding a diluent (such as water) or an additive to the non-Newtonian biomass material to reduce the apparent viscosity of the material fed into the pulper (e.g., the static yield stress τ o and / or the dynamic yield stress τ y) is achieved, and / or by adding an additive to the non-Newtonian biomass material to initiate an exothermic reaction that increases the temperature of the non-Newtonian biomass material, and / or adding an additive to the non-Newtonian biomass material to directly or indirectly affect other properties of the biomass material (e.g., chemical or biochemical composition, microbial composition or content, cell structure, particle size distribution or particle shape distribution), which are known to directly or indirectly affect the apparent viscosity of the non-Newtonian biomass material (e.g., static yield stress and / or dynamic yield stress). The term "chemical oxygen demand (COD)" in the present invention should be understood as the amount of oxygen required to oxidize the organic matter in a given amount of a substance. It is usually expressed as the mass of oxygen consumed divided by the volume, and its SI unit is milligrams per liter (mg / L).

[0371] In the context of the present invention, the term "volatile solid content (VS)" should be understood to refer to the total solid loss during combustion at 550 °C in the presence of excess air. The unit of the VS content is weight percentage (%).

[0372] In the context of the present invention, the term "ratio of chemical oxygen demand (COD) to volatile solid content (VS), COD / VS ratio", sometimes also referred to as "specific energy content", should be understood to mean COD expressed in milligrams per liter (mg / L) divided by VS expressed in weight percentage. The COD / VS ratio of the non-Newtonian biomass material to be treated in the methods, systems, process equipment and devices of the present invention using the thermo-hydrolysis process (ΤHP) is less than 2.0, for example less than 1.9, for example less than 1.8, for example less than 1.7, for example less than 1.6.

[0373] In some embodiments of the present invention, the relationship between the specific energy content (measured as COD / VS) and the apparent viscosity (e.g., static yield stress (measured as τ o ) and / or dynamic yield stress (measured as τ y ) of the non-Newtonian biomass material to be treated in the methods, systems, process equipment and devices of the present invention using the thermo-hydrolysis process (ΤHP) is as Figure 14 shown, which is based on the average energy content of 1.7 in primary sedimentation sludge and the average energy content of 1.45 in waste activated sludge. This relationship in the context of the present invention has been found to be useful for determining the energy content, i.e., COD / VS, of sludge based on its apparent viscosity (e.g., static yield stress and / or dynamic yield stress). That is, for the static yield stress τ o , τ o> 500 - 1000 Pa, COD / VS > 1.52, depending on the substrate type. Based on this relationship, in the processes, systems, process equipment and devices of the present invention that employ the thermo-hydrolysis process (THP), the COD / VS ratio of the non-Newtonian biomass material to be treated is preferably greater than 1.5. However, the energy content varies depending on the sludge source, sludge age, etc., and it is recommended to calibrate each sludge mixture.

[0374] In the context of the present invention, the term "desanding" shall be interpreted to mean any process of removing fine solid particles (grit) from a liquid carrier, for example, by gravitational separation (sedimentation) or centrifugation.

[0375] In the context of the present invention, the term "separation" shall be interpreted to mean any process of separating a starting mixture (such as a hydrolyzed biomass material) into different parts and / or fractions based on differences in physical and / or chemical properties.

[0376] In the context of the present invention, the term "anaerobic fermentation" shall be interpreted to mean any process that results in the conversion of a hydrolyzed biomass material into the desired final products (such as organic acids, gases or alcohols) under anaerobic conditions.

[0377] In the context of the present invention, the term "incineration" shall be understood to mean the complete combustion of a given material (such as a hydrolyzed biomass material) with an excess of air. Incineration can prevent the spread of diseases and environmental hazardous substances including microplastics. Incineration is a method of eliminating concerns about recycling biosolids for agricultural land and other land uses. Incineration can also be used to eliminate the need for the recovery and reuse of a range of trace and macro-nutrients. Incineration is a common technique for eliminating toxic substances. According to the European Waste Incineration Directive, the design of incineration plants must ensure that the flue gas temperature reaches at least 850 °C for 2 seconds to ensure effective decomposition of toxic organic substances. To always meet this requirement, a standby auxiliary burner (usually fueled by oil) must be installed. In the case where the calorific value of the waste is too low to reach this temperature alone (single incineration), the standby auxiliary burner is introduced into the boiler for combustion (mixed incineration).

[0378] In the context of the present invention, the term "gasification" shall be understood as the process of converting biomass-based or fossil fuel-based carbonaceous materials into gases, including nitrogen (N2), carbon monoxide (CO), hydrogen (H2) and carbon dioxide (CO2) as the main components. By controlling the content of oxygen and / or steam in the reaction, it can be achieved by reacting the material (such as hydrolyzed biomass material) at a high temperature (usually > 700 °C) without combustion / incineration. The resulting gas mixture is called syngas, which can be used as a fuel by itself due to the combustibility of the main components of the gas, hydrogen and carbon monoxide. Electrical energy can be generated by the subsequent combustion of the generated gas. If the gasification compound is obtained from biomass materials (such as hydrolyzed biomass materials), it can be regarded as a renewable energy source. Gasification to syngas is more efficient than direct incineration of biomass materials (such as hydrolyzed biomass materials), because syngas can be burned at a higher temperature to make the thermodynamic upper limit of the efficiency defined by the Carnot law higher. Syngas can also be used as a hydrogen source in fuel cells, but the syngas produced by most gasification systems requires additional treatment and reforming to remove pollutants and other gases (such as carbon monoxide and carbon dioxide) to be suitable for use in low-temperature fuel cells. High-temperature solid oxide fuel cells, on the other hand, are capable of directly accepting a mixture of steam and methane. Syngas is most commonly burned directly in gas engines for the production of methanol and hydrogen, or converted into synthetic fuels. For some biomass materials, such as hydrolyzed biomass materials, gasification can replace landfilling and incineration, thereby reducing the emissions of atmospheric pollutants such as methane and particulate matter. Some gasification processes are designed to refine corrosive ash elements such as chlorides and potassium, allowing the production of clean gas from otherwise problematic feedstocks. Currently, the gasification of fossil fuels has been widely applied on an industrial scale for power generation. Compared with incineration, gasification can produce lower levels of certain pollutants (such as SO x and NO x ).

[0379] In the context of the present invention, the term "pyrolysis" should be understood to refer to the process by which a solid (or liquid) material, such as hydrolyzed biomass material, undergoes thermal degradation into smaller volatile molecules without interacting with oxygen or any other oxidizing agent. Pyrolysis, which is also the first step in gasification and incineration, occurs in the absence or near-absence of oxygen and thus differs from incineration (combustion), which can only occur in the presence of sufficient oxygen. The rate of pyrolysis increases with temperature. In industrial applications, the temperature used is typically 430 °C or higher, while in small-scale operations, the temperature can be much lower. Two common products of pyrolysis are: one in the form of carbon (called biochar), produced by heating wood; and the other in the form of coke (used as an industrial fuel and insulation), produced by heating coal. Pyrolysis also produces condensable liquids (or tar) and non-condensable gases. If the aim is to maximize the yield of liquid products from biomass pyrolysis, a process with low temperature, high heating rate, and short gas residence time is required. For a high coke yield, a process with low temperature and low heating rate should be selected. If the aim is to maximize the yield of fuel gas from pyrolysis, a process with high temperature, low heating rate, and long gas residence time would be preferred.

[0380] In the context of the present invention, the term "calcination" should be understood to be a mild form of pyrolysis usually at a temperature between 200 and 320 °C.

[0381] In the context of the present invention, the term "supercritical water oxidation" should be understood to refer to the oxidation process that occurs in supercritical water when an oxidizing agent is added. A supercritical fluid (SCF) is any substrate whose temperature and pressure are above its critical point, where there is no distinct liquid and gas phase, but below the pressure required to compress it into a solid. Water reaches the supercritical state at a temperature above about 373 °C and a pressure above about 220 bar.

[0382] In the context of the present invention, the term "supercritical water liquefaction" should be understood to refer to the process of co-liquefying a given material with water under conditions where the water is in a supercritical state. In terms of material recovery, supercritical water liquefaction can be used for the efficient treatment of biomass. Cellulose, one of the main components of biomass, is completely soluble in supercritical water. Once dissolved, the reaction of cellulose can proceed rapidly by hydrolysis and / or pyrolysis / calcination. The hydrolysis reaction is slower than the pyrolysis / calcination reaction due to mass transfer limitations but faster than the decomposition reaction in supercritical water, and it has been shown that glucose can be efficiently recovered from cellulose. Once dissolved, a certain degree of supersaturation can be maintained when the solution is cooled, and thus it has also been shown that rapid hydrolysis can be carried out by using enzymes. Lignin can also be converted into specific chemicals by using a supercritical cresol / water mixture as a solvent.

[0383] In the context of the present invention, the term "hydrothermal carbonization" should be understood to refer to a thermochemical treatment process in which biomass is treated under hot pressurized water to produce hydrochar. Although Bergius discovered hydrothermal carbonization as early as 1913, the technology has been rediscovered in recent years, during which time hydrothermal carbonization (HTC) has also been referred to as "hydrothermal pretreatment" or "wet torrefaction". In any case, HTC is a thermochemical conversion technology that uses subcritical (liquid) water as a reaction medium for converting wet biomass and waste streams into valuable carbon-rich solid products. The reaction is typically carried out at a temperature of 180 °C to 280 °C, at a pressure slightly above the saturation pressure of water to ensure that the water is in the liquid state, and in an inert atmosphere.

[0384] In the context of the present invention, the term "hydrothermal oxidation" should be understood to refer to a process in which treatment is carried out at temperatures and pressures below and above the critical point of water (i.e., approximately 373 °C and approximately 220 bar). Subcritical water oxidation (SubCWO) achieves incomplete oxidation of sludge (COD removal rate < 95%) and produces a high-strength solution containing a large amount of volatile fatty acids (VFA). SubCWO can also effectively destroy the organic components in sludge solids, thereby significantly reducing the mass and volume of the sludge. On the other hand, supercritical water oxidation (SCWO) can completely oxidize the organic components in sludge (COD removal rate > 99.9%), producing high-quality effluent as well as treatable ash and flue gas emissions.

[0385] In the context of the present invention, the term "electrochemical treatment" should be understood to refer to a process in which an electric field is established between an anode and a cathode to degrade and transform compounds. Bioelectrochemical treatment is an electrochemical process in which biological activity on the electrodes assists or drives the degradation. Biocatalysts can also be used to accelerate more efficient degradation. This method is also known as microbial electrosynthesis. Electrochemical treatment methods have been developed for the wastewater industry. These methods and technologies are still in the development stage, however, it is expected that there will be more research and development in the coming years. Thus, for example, the electrochemical oxidation of PFAS using various cathode / anode materials and catalysts has been studied and developed for many years. The literature shows that almost 99% of PFAS removal can be achieved by electrochemical treatment methods.

[0386] In the context of the present invention, the term "biological treatment for reducing organic compounds" should be understood to refer to biological treatment that, by controlling treatment conditions, utilizes the biological growth of microorganisms to digest and incorporate compounds such as those in wastewater. Important factors are temperature, pH, dissolved oxygen, nutrient concentration, and the content of toxic substances. These treatments can be aerobic or anaerobic, or can include aerobic and anaerobic treatments arranged in series. A series of biological treatment methods have been established to achieve reduction in organic compounds and nutrient reduction. This includes but is not limited to activated sludge treatment systems, biological phosphorus (Bio-P) treatment systems, MBR (membrane bioreactor), and MMBR (moving bed biofilm process). The anammox process is such a process, which is widely regarded as an environmentally friendly, time-saving technology capable of achieving efficient nitrogen removal. Therefore, in the context of the present invention, the term "biological treatment for reducing nutrient concentration" should be understood to refer to, for example, the anammox process.

[0387] In the context of the present invention, "chemical treatment for reducing nutrient concentration" should be understood to refer to treatment that chemically binds nutrients present in a material (such as a biomass material) in different ways in order to remove (i.e., "strip") nutrients and other compounds from the material. Typical chemical wastewater treatment processes are: chemical precipitation, ion exchange, neutralization, adsorption, and disinfection processes. Evaporation techniques can also be used to chemically bind nutrients. Water is evaporated and recovered as condensate with low nutrient content. The condensation heat is recovered inside the evaporator to reduce the total energy consumption. Different evaporation principles can be used. An air stripper is another technique that can be used to remove nutrients. The desorption efficiency of nitrogen removal can be increased by raising the pH. The increased pH value can be achieved by adding chemicals. Nitrogen removed by stripping can be recovered with chemicals to produce ammonium salts, or recovered as ammonia water by distillation.

[0388] In the context of the present invention, the term "thermal treatment for reducing nutrient concentration" should be understood to refer to treatment that enhances the removal of nutrients present in a material, such as a biomass material treated chemically (see above), at elevated temperatures. Thus, as an example, the efficiency of an air stripper can be increased by elevated temperature, which can be achieved by heating in various ways, indirectly through a heat exchanger or directly through steam (for example, in the form of a so-called steam stripper).

[0389] In the context of the present invention, the term "heat exchanger" should be interpreted to refer to any device that can be used to transfer thermal energy from one material to another, for example, by cooling a material (such as hydrolyzed biomass material), by making it undergo heat exchange with water, and then heating.

[0390] In the context of the present invention, the terms "retention time" and "total average retention time" should be understood to refer to the hydraulic retention time (HRT), defined as the ratio between the average filled volume of the reactor and the feed flow rate. In other words, it represents the average time that any portion of the biomass material stays in the reactor or tank. It is calculated by dividing the average filled volume of the reactor (e.g., m 3 ) by the influent flow rate (e.g., m 3 / day). In contrast, the solid retention time (SRT) is the time of the solid fraction of the biomass material in the treatment unit. It is the amount of solids retained in the unit divided by the amount of solids flowing out of the unit per day.

[0391] In the context of the present invention, the term "DS%" should be understood to refer to the total dry solid content of a given material, including suspended solids and dissolved substances (such as salts). Thus, the term "(DS%)" (also known as "dry matter content") should be understood to refer to the percentage of solids in a mixture (such as "biomass material"). The higher this ratio, the drier the mixture. The unit of the DS content is weight%. Expressed as the ratio of the weights obtained before and after the drying process, in which a sample of the material is placed in an oven at a temperature of 105 °C until a stable mass is obtained. By drying at 175 - 185 °C and comparing with the result obtained by drying at 105 °C, the content of crystal water of certain salts (such as hydroxides) that may be part of the sample can be evaluated.

[0392] The residue produced by the 105 °C drying process is placed in a preheated temperature-controlled muffle furnace and heated to 550 °C for two hours to determine the portion that volatilizes at 550 °C in the total dry solids. For most biomass materials, this can be regarded as an approximation of the organic matter content of the material, also known as volatile solids (VS). VS is usually expressed as a percentage (%) of the dry matter.

[0393] The portion of the biomass material sample that volatilizes at temperatures between 550 and 900 °C consists mainly of carbon dioxide produced by the decomposition of carbonates contained in the biomass material in most cases.

[0394] Therefore, in the context of the present invention, the term "VS%" should be understood to refer to the percentage (%) of the total dry solid content (DS%) that volatilizes at a temperature of 550 °C.

[0395] In the context of the present invention, the term "suspended solids" (SS) should be understood to refer to solid particles of any origin that remain suspended in water either as a colloid or due to the movement of the water. If their size or density is relatively large, the suspended solids can be removed by sedimentation or by filtration. In the technical field of the present invention, the term "total suspended solids" (TSS) generally refers to particles in water larger than 2 μm. Both SS and TSS can be reported as mg / L, ppm or %. The content of suspended solids (SS) or total suspended solids (TSS) can be measured by using, for example, sonic or ultrasonic instruments or gamma ray instruments, or by measuring the turbidity of the sample.

[0396] In the context of the present invention, the term "particle size distribution" should be understood to refer to the distribution of the particle sizes of the particles dispersed in a sample, represented in the form of a numerical list or a mathematical function defining the relative amounts (usually by mass) of the particles present according to the particle size.

[0397] In the context of the present invention, the term "particle size distribution" should be understood to refer to the distribution of the particle sizes of the particles dispersed in a sample, represented in the form of a numerical list or a mathematical function defining the relative amounts (usually by mass) of the particles present according to the particle size.

[0398] The particle size distribution and / or the particle shape distribution of a sample can be determined by a variety of different techniques (such as sieve analysis, elutriation analysis, optical analysis, optical sizing, optical counting, electrical resistance counting, sedimentation techniques, laser diffraction, laser obscuration time (LOT) or "transition time" (TOT) and / or acoustic spectroscopy or ultrasonic attenuation spectroscopy).

[0399] In the context of the present invention, the term "FOS / TAC ratio measured by the Nordmann method" should be understood to refer to the measurement of volatile organic acids (FOS) and total inorganic carbon (TAC) (i.e., carbon buffering capacity) by a method commonly known as the Nordmann method. The FOS / TAC ratio is a commonly used measurement for observing stability and indicating whether corrective measures are needed in anaerobic digestion processes such as biogas plants.

[0400] To determine the FOS / TAC ratio, a representative sample of the relevant biomass material is required. All particulate matter must be removed by filtration or centrifugation, and all sample preparation must be carried out in the same way. A typical sample volume of the substrate is 20 mL, but if it is insufficient, it can be diluted with deionized water. Note that the TAC formula must be modified to account for the dilution effect.

[0401] First, the TAC (in mg CaCO3 / L) is measured by titrating the sample with 0.1N sulfuric acid to pH 5.0 and can be calculated using the following formula:

[0402] TAC = (EP1 × concentration of titrant × 50045) / (volume of sample)

[0403] where EP1 is the volume of titrant at pH 5.0 (in mL). If the concentration of the titrant is 0.1 N and the volume of the sample is 20 mL, the formula can be simplified to:

[0404] TAC = EP1 × 250 [mg / L CaCO3]

[0405] For the titration calculation (TAC), the content of FOS (in mg / L Hac) is determined by the Nordmann method, by titrating 20 mL of the sample from pH 5.0 to pH 4.4 with 0.1 N sulfuric acid. Using the following formula, where B is the acid consumed (in mL) (i.e., the volume of titrant at pH 5.0 - the volume of titrant at pH 4.4).

[0406] FOS = [(B × 1.66) - 0.15] × 500 [mg / L Hac]

[0407] Generally, an FOS / TAC ratio of 0.3 - 0.4 is considered optimal. However, each digester has its unique optimal ratio. Above 0.4 usually indicates excessive biomass input, while below 0.3 usually indicates insufficient biomass input.

[0408] In the context of the present invention, the "content of dissolved organic carbon" (sometimes also referred to as DOC) should be understood to refer to the portion of organic carbon in a given biomass material that can pass through a filter with a specific pore size (usually 0.22 to 0.7 μm). The portion remaining on the corresponding filter is called particulate organic carbon (POC).

[0409] In the context of the present invention, the "content of dissolved organic nitrogen" (sometimes also referred to as DON) should be understood to refer to the portion of the dissolved organic carbon (DOC) pool that contains nitrogen. Dissolved inorganic nitrogen (DIN) consists of nitrate, nitrite, and ammonium salts. Total dissolved nitrogen (TDN) consists of dissolved inorganic nitrogen (DIN) and dissolved organic nitrogen (DON). Due to the lack of a reliable method for directly measuring DON, it is usually calculated from the measured TDN and DIN values (DON = TDN - DIN).

[0410] Different from DOC, dissolved organic matter (DOM) refers to the total mass of dissolved organic matter. That is, DOM also includes the mass of other elements (such as nitrogen, oxygen, and hydrogen) in the organic matter. DOC is a component of DOM, and the amount of DOM is usually about twice that of DOC.

[0411] As described above, compared with the prior art hydrothermal hydrolysis process, the methods, systems, process equipment, and devices of the present invention employing the hydrothermal hydrolysis process (THP) include multiple improvements. First, the methods, systems, process equipment, and devices of the present invention employing the hydrothermal hydrolysis process (THP) can enable the hydrothermal hydrolysis system to operate stably under conditions of high apparent viscosity and variable high dry solid content.

[0412] Performing hydrothermal hydrolysis operations at high dry solid concentrations is very important for minimizing specific energy consumption (e.g., in kg steam / ton dry solids).

[0413] The methods, systems, process equipment, and devices of the present invention employing the hydrothermal hydrolysis process (THP) rely on the following key findings: The key limitation for operating the hydrothermal hydrolysis system at high dry solid concentrations and thereby achieving low specific energy consumption is the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) rather than DS%, and different substrates have significantly different rheological behaviors.

[0414] Since the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) increases with the increase in dry solid content and decreases with the increase in temperature, it is very beneficial to monitor the actual rheological behavior of a specific substrate mixture undergoing hydrothermal hydrolysis treatment and continuously adjust the corresponding process in order to continuously minimize specific energy consumption.

[0415] These adjustments all involve the dry solid content in the upstream dehydration process, the dilution rate of the THP feed stream, and the preheating of the dilution water. The rheological behavior of all substrates is affected not only by the dry solid content but also by the temperature. The methods, systems, process equipment, and devices of the present invention employing the hydrothermal hydrolysis process (THP) rely on adjusting the feed temperature and dry solid content according to the actual rheological behavior of the substrate being treated in the hydrothermal hydrolysis process.

[0416] In recent years, with the increasing popularity of the co-digestion process, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the substrates or substrate mixtures undergoing hydrothermal hydrolysis treatment may now vary significantly. When different substrates are mixed in different proportions, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the resulting mixture will also vary according to the rheological behavior of the resulting mixture, which is significantly different from the rheological behavior of the individual substrates being mixed. The methods, systems, process equipment, and devices of the present invention employing the hydrothermal hydrolysis process (THP) can continuously monitor the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the mixture in the hydrothermal hydrolysis process and can optimize the mixing rate, preheating, and dilution rate to minimize specific heat consumption during the hydrothermal hydrolysis process.

[0417] In the entire thermal hydrolysis system, where the temperature gradually increases and decreases, the preheating step quickly reaches the limit of its apparent viscosity (e.g., static yield stress and / or dynamic yield stress). The reason behind this is that sludge and most other substrates reach a higher apparent viscosity (e.g., static yield stress and / or dynamic yield stress) at lower temperatures. In cases of improper design, heat recovery and subsequent pumping can be very difficult.

[0418] The prior art does not describe this problem. Thus, for many years, methods, systems, process equipment, and devices using the thermal hydrolysis process (ΤHP) have had problems when operating at high apparent viscosities (e.g., static yield stress and / or dynamic yield stress) for certain substrates. The methods, systems, process equipment, and devices of the present invention using the thermal hydrolysis process (ΤHP) include the design of a preconditioning system that can increase the feed temperature and enable operation at high apparent viscosities (e.g., static yield stress and / or dynamic yield stress), thereby facilitating thermal hydrolysis with a high dry solid content. The system also includes a monitoring system to ensure compliance with the processing conditions.

[0419] The methods, systems, process equipment, and devices of the present invention using the thermal hydrolysis process (ΤHP) optionally include a preconditioning device to further reduce the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) (due to the elevated temperature and applied shear force), thereby enabling operation at a higher dry solid content. This addresses both the challenges posed by the high apparent viscosity (e.g., static yield stress and / or dynamic yield stress) to the ΤHP feed system and reduces the specific heat consumption in the thermal hydrolysis process. The reason for the reduction in heat consumption in the thermal hydrolysis process lies in the higher dry solid concentration and the higher feed temperature. The preconditioning device will perfectly match the cooling requirements typically needed for hydrolyzed sludge, thereby enabling more cost-effective heat recovery, which directly affects the unit steam consumption required in the thermal hydrolysis process. Depending on cost-effectiveness, the preconditioning device can also receive preheated dilution water from other sources.

[0420] Another advantage is that the methods, systems, process equipment, and devices of the present invention using the thermal hydrolysis process (ΤHP) can achieve self-optimization by an advanced monitoring system that controls the preheating and dilution rates based on the measured apparent viscosity (e.g., static yield stress and / or dynamic yield stress). In addition, in the case of co-digestion, the measured apparent viscosity (e.g., static yield stress and / or dynamic yield stress) can be used to optimize the proportion of different substrates throughout the process cycle.

[0421] The methods, systems, process equipment, and devices of the present invention using the thermal hydrolysis process (ΤHP) solve problems in several aspects to achieve the functionality of the thermal hydrolysis process, and some of these aspects will be described in detail below.

[0422] The method, system, process equipment and device of the present invention adopting the thermohydrolysis process (THP) achieve stable operation through a set of specific design features and process solutions inside and upstream and / or downstream of the thermohydrolysis process, combined with specific monitoring, making it possible to feed and operate the thermohydrolysis process of substrates with high apparent viscosity (such as static yield stress and / or dynamic yield stress).

[0423] The method, system, process equipment and device of the present invention adopting the thermohydrolysis process (THP) optimize and control the thermohydrolysis process based on rheology rather than dry solid content.

[0424] The method, system, process equipment and device of the present invention adopting the thermohydrolysis process (THP) rely on continuous monitoring and analysis of the rheological behavior of the substrate by soft sensors implemented through the design and instrumentation of specific applications in the thermohydrolysis system and upstream and downstream of the thermohydrolysis system.

[0425] The method, system, process equipment and device of the present invention adopting the thermohydrolysis process (THP) enable the THP system to operate at the highest possible dry solid content while reducing the unit energy requirement. This is based on the discovery that apparent viscosity (such as static yield stress and / or dynamic yield stress) is a limiting factor for the operation of the THP device at high dry solid content. The present invention uses continuously monitored rheological data and thermohydrolysis performance data as information to enable the thermohydrolysis system to self-regulate the dry solid content and thus operate at the highest possible dry solid level.

[0426] The method, system, process equipment and device of the present invention adopting the thermohydrolysis process (THP) make it possible to predict the dry solid content (DS%) and volatile solid content (VS%) based on the measured rheological data of a given biomass material throughout the process. This method is achieved by establishing a series of soft sensors throughout the thermohydrolysis process because rheology changes throughout the process and the continuous measurement of rheological properties allows the use of these rheological data to predict the DS%, VS%, specific energy content (COD / VS) and / or nitrogen content of the biomass material (such as sludge) being processed. By applying the correct dilution rate at the appropriate temperature, this also allows the optimization of the apparent viscosity (such as static yield stress and / or dynamic yield stress) throughout the process. In addition, it allows self-correction of the predicted DS%, VS%, COD / VS and / or N content through continuous measurement, as well as providing instructions to the operator on when and how to sample to best support self-calibration.

[0427] As described above, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) generally decreases with increasing temperature. The method, system, process equipment and device of the present invention employing the thermal hydrolysis process (THP) allow for the adjustment of the sludge temperature through more comprehensive heat recovery to enable stable operation until the maximum apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is reached at the limit of the thermal hydrolysis process without applying an unreasonable safety margin. This is achieved by recovering the heat available at the back end of the process and using it at the front end of the process, so that the feed temperature of the thermal hydrolysis system is increased and the discharge temperature is decreased.

[0428] As described above, the method, system, process equipment and device of the present invention employing the thermal hydrolysis process (THP) are based on the discovery that there are significant differences in the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) for a given substrate and between different substrates. If operating at the maximum apparent viscosity (e.g., static yield stress and / or dynamic yield stress) limited by the THP process, there is a risk of entering a difficult operating and insufficient thermal hydrolysis stage. The method, system, process equipment and device of the present invention employing the thermal hydrolysis process (THP) allow for the addition of a self-correcting system in the THP process to avoid operating disturbances in the case of changes in the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the substrate or substrate mixture being treated. If process monitoring shows an adverse high apparent viscosity (e.g., static yield stress and / or dynamic yield stress), the system will automatically adjust the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) by gradually diluting with preheated water in the pulper feed system and the pulper recycle / reactor feed system. The preheating is preferably achieved by cooling the hydrolyzed sludge at the back end of the process. Depending on the degree of preheating of the sludge by an external heat source and the specific conditions of the THP process, the total steam consumption in the thermal hydrolysis system is generally reduced by 3 - 15% due to this preheating.

[0429] In one embodiment of the method, system, process equipment and device of the present invention employing the thermal hydrolysis process (THP), these include circulating the preheated substrate stream from the pulper to a preconditioning system at the front end of the thermal hydrolysis process to reduce the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the pulper feed line.

[0430] As can be clearly seen from the above, even in a hydrothermal hydrolysis process that relies on a substrate with a relatively constant composition, problems may arise when operating substrates with a high apparent viscosity (such as static yield stress and / or dynamic yield stress) if the temperature of the material to be processed in the process (such as biomass material) cannot be maintained within a specific predetermined limit. Therefore, in a preferred aspect, the methods, systems, process equipment, and devices of the present invention that employ a hydrothermal hydrolysis process (THP) include a novel design of a preheating vessel (pulper), which is particularly suitable for operating at a high apparent viscosity (such as static yield stress and / or dynamic yield stress).

[0431] Some key elements of this preferred design of the preheating vessel (pulper) utilize the following findings. In a hydrothermal hydrolysis pulper suitable for the recovery of downstream flash steam, the upper part of the vessel is warmer and more uniform than the bottom part of the vessel. Additionally, if the temperature of the material in the pulper discharge line cannot be maintained relatively constant, operation becomes increasingly difficult. Steam or recovered flash steam is injected into the lower part of the vessel, thereby heating the substrate as the steam / flash steam rises to the upper part of the vessel. This can both heat the cold sludge and transfer the hot sludge to the upper part of the vessel, while most of the cold sludge is located in the lower part of the vessel. The steam injected into the lower part of the vessel condenses as it passes through the liquid and contacts the cooler liquid, resulting in a mixing effect. In most existing pulper vessel designs, this steam injection is carried out through steam lances. Even if different steam lance designs exist, in the preferred methods, systems, process equipment, and devices of the present invention that employ a hydrothermal hydrolysis process (THP), the tip of the lance is oriented at such an angle that helps to form vortices in both the horizontal and vertical planes. In this preferred aspect, the substrate may (or may not) be circulated on the vessel by pumping the substrate from the elevated and hotter part of the vessel and reintroducing it together with the cold substrate into the cooler bottom section and / or top section of the vessel, preferably through an extruder or a similar distribution system. Moreover, any extruder may optionally be located outside the preheating vessel, and the circulation flow returning to the preprocessor may optionally be used instead.

[0432] Optionally, in the above preferred aspect, the methods, systems, process equipment, and devices of the present invention that employ a hydrothermal hydrolysis process (THP) include a specially designed preconditioning device upstream of the pulper (connected to the pulper feed system) to achieve efficient dilution, preheating, mixing, and heat recovery from the sludge from downstream hydrolysis. The preconditioning device is located at the front end of the hydrothermal hydrolysis system and thus becomes an essential part of the THP "train", and can also serve as a buffer between any upstream pre-dewatering system, substrate treatment system, or substrate receiving system and the actual hydrothermal hydrolysis system. The preconditioning system is connected to the rear end of the hydrothermal hydrolysis system by capturing the excess heat in the warm hydrolyzed sludge and recovering this heat to increase the feed temperature of the cold substrate entering the hydrothermal hydrolysis system.

[0433] The method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP) utilize the rheological data of the hydrolyzed sludge measured, for example, on the digester feed line and / or the pre-cooler, and convert it into the expected DS%, VS%, COD / VS and / or N content, so as to be able to calculate and control the loading rate of the digester based on the rheological data of the biomass material at different stages before and during the THP process. In this way, not only can the loading rate of the digester be controlled according to the DS% and VS% loading rates, but also the measured rheological data can be used to predict the specific energy content (COD / VS) of the biomass material, fully controlling the feeding rate of the digester, thus basically eliminating the risk of digester overload. In addition, measuring the nitrogen content can help control the nitrogen load of the digester.

[0434] In a preferred embodiment, the method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP) include a comprehensive digester monitoring program, which can directly reduce the digester feed and thus reduce the THP feed to avoid overload. Since the method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP) will adjust the DS% value in THP according to the apparent viscosity (such as the static yield stress and / or the dynamic yield stress), the constant volume feed flow rate of the digester will not provide a constant VS load for the digester. To avoid accidental overload of the digester, the system needs to self-regulate when any sign of digester overload appears. This is particularly important when the digester operates at a high dry solid loading rate and a short residence time.

[0435] Similarly, by continuously converting the rheological data measured at different points of the THP "unit" into the energy content, the actual energy supply rate of the digester can be controlled.

[0436] Therefore, due to the method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP), the energy supply rate of the digester can be controlled by monitoring the rheology. Previously, attempts have been made to correlate rheology with dry solid content or even volatile solid content, and corresponding instruments have been developed for this purpose. However, since not all dry solids and volatile solids used for digester feed must have the same energy content, these attempts have deficiencies. Therefore, the method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP) solve the problem of feeding the digester only based on the measurement results of dry solids or volatile solids without considering that different substrates have different specific energy contents per unit dry solid and per unit volatile solid. Therefore, compared with the prior art, the method, system, process equipment and device of the present invention adopting the thermo-hydrolysis process (THP) utilize the rheological behavior of the biomass material to predict its specific energy content.

[0437] Accordingly, the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP) can be used to control the energy feed rate of the digester in addition to controlling the dry solid load, volatile solid load and nitrogen load.

[0438] As further described below, this is mainly achieved through the discovery that there is a close relationship between the so-called apparent viscosity (such as static yield stress and / or dynamic yield stress, "τ" o " and / or "τ" y ") of a given biomass material and its specific energy content.

[0439] The discovery of this relationship particularly paves the way for the selective addition of chemical reagents to the biomass material in the pre-processor in order to a) reduce the apparent viscosity (such as static yield stress and / or dynamic yield stress) and / or b) initiate an exothermic reaction, thereby increasing the feed temperature, thus reducing the apparent viscosity (such as static yield stress and / or dynamic yield stress) and reducing the specific heat consumption in the thermohydrolysis step. Moreover, from a more general perspective, the discovery of this relationship paves the way for the selective addition of chemical reagents known to directly or indirectly affect other properties of the biomass material (such as chemical or biochemical composition, microbial composition or content, cell structure, particle size distribution or particle shape distribution), which are known to directly or indirectly affect the apparent viscosity (such as static yield stress and / or dynamic yield stress) of the biomass material.

[0440] It can also allow the performance of the digester to be monitored through key indicators to optimize the load of the digester through self-learning. Therefore, even though it is well known that high dry solids digestion can be achieved through thermohydrolysis, until now it has not been known how to make the thermohydrolysis system fit for self-learning so that it can optimally optimize the digester load rate based on continuously measuring the apparent viscosity (such as static yield stress and / or dynamic yield stress) at different points in the THP process. By measuring the apparent viscosity (such as static yield stress and / or dynamic yield stress) at several positions in the process, where the apparent viscosity (such as static yield stress and / or dynamic yield stress) changes significantly due to different stages of the thermohydrolysis process, each measurement is itself carried out under significantly different conditions. Therefore, in a preferred embodiment, the measurement results are cross-calibrated using measurements carried out under different conditions (i.e., different stages of the THP process). In addition, in the case where cross-calibration is unsuccessful, the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP) can allow the operator to receive a warning to assist calibration by additional sampling and logging the sampling results into the control and monitoring system, where the sampling data is used to assist calibration.

[0441] The digester load is typically controlled by sampling DS% and VS% and manually controlling the feed flow into the digester. The method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP) preferably use the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) continuously measured at multiple points throughout the process, which is subsequently converted into a calculated digester load rate, and introduce a self-improving cross-calibration system to reduce errors and a self-control system to avoid digester overload and optimize the AD process. In this way, the method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP) can control the COD / VS load rate (not just the DS% and / or VS% load rate) because the relationship between the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and the energy content measured as COD / VS has been determined.

[0442] In a preferred embodiment of the method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP), the integrated automatic control system includes monitoring parameters such as the pH, gas production, methane content, and / or FOS / TAC ratio of the digester. When the pH, FOS / TAC, and / or CH4 concentration rises to a certain level and / or rate, the hot hydrolysis load rate will automatically adjust the load rate to a acceptable level.

[0443] In this way, the automatic control system of the method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP) promotes the demand based on the digester operation by maximizing the biogas production during high-value periods of biogas. For example, UK sewage treatment plants have demonstrated that they can utilize the fluctuating electricity prices in the UK. Therefore, the method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP), by monitoring the limiting factors of the hot hydrolysis step (i.e., the apparent viscosity in THP, e.g., static yield stress and / or dynamic yield stress), can maximize and control the loads of the hot hydrolysis step and the downstream digestion process. In addition, the monitored apparent viscosity (e.g., static yield stress and / or dynamic yield stress) can be converted into values for the DS and VS load rates of the digester.

[0444] Similarly, in the method, system, process equipment, and device of the present invention using the thermal hydrolysis process (THP), rheological measurements can be used to activate the dilution before the pre-cooler in order to optimize heat transfer and thus the total maximum capacity of the pre-cooler.

[0445] In certain embodiments of the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), partially digested and dewatered cake can be recycled back to the pulper feed. The digested cake has a relatively high apparent viscosity (e.g., static yield stress and / or dynamic yield stress) similar to waste activated sludge. The digested cake also exhibits non-Newtonian fluid behavior. Due to the thermohydrolysis process, the cake is well-dewatered and has a high apparent viscosity (e.g., static yield stress and / or dynamic yield stress), which would make it difficult to transport and mix into the pulper feed line in most systems. However, the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP) are well-suited for recovering the cake with a high dry solid content and mixing it into the pulper feed line in the same manner as the feed sludge. Recycling the digested and dewatered cake has the potential to improve the energy and mass balance by increasing the net energy surplus and further reducing the total digested cake leaving the system.

[0446] The treatment cost can be high, and the reduction in the amount of cake can have a significant impact on the overall economic efficiency and operating costs of the system / device based on the thermohydrolysis process (THP). In one example of the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), this specific embodiment of the present invention will increase the biogas production by 20% and reduce the cake production by 15%. However, due to the recirculation of the digested cake, the entire THP system will consume more heat. In the case of consuming biogas to generate the increased heat, the net energy surplus may be approximately 8%. In another example, this specific embodiment of the present invention will increase the biogas production by 10 - 15% and reduce the cake production by 10%. In the case of consuming biogas to generate the increased heat, the net biogas surplus may be approximately 5 - 6%.

[0447] In another embodiment of the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), compressed process gas can be used for 1) reducing the pressure drop in the pulper feed line and / or 2) improving the digester performance. For example, if the compressed process gas is degassed in the pulper and then injected into the digester using a compressor. The process gas has an odor and contains harmful substances that may be toxic even at low concentrations. Therefore, it is very important to handle the process gas carefully in a closed system. The process gas should not be directly discharged under any circumstances. Thus, in this embodiment, the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP) include a closed system for injecting the process gas into the digester for 1) adsorption to the liquid surface and 2) biological treatment. Some of the organic compounds present in the process gas and the oxygen that may be released through degassing will further enhance the performance of the digester. Adding oxygen to the pulper or the pulper feed line can achieve the optimization of the digestion process.

[0448] The most important aspect in the design of the pulper according to the present invention lies in the position of the discharge nozzle on the pulper, and this design enables operation at high dry solid contents and full heat recovery. The volume below the outlet nozzle of the pump should be ≥1.6 times the average filling volume of the reactor. The volume above the nozzle is preferably ≥1 times the average filling volume of the reactor plus the safety margin above the nozzle, but it can also be larger, such as 1.2, 1.4, 1.6 or 1.8 times the average filling volume of the reactor.

[0449] Furthermore, according to a preferred embodiment of the pulper according to the present invention, it further includes an extruder for dividing the incoming cold sludge into smaller segments.

[0450] Preheating the substrate before the hydrothermal process is beneficial for reducing specific energy consumption. Unless diluted with cold water, the hydrothermally treated sludge leaves the hydrolysis process at a high temperature. Preheating of the biomass can provide an opportunity for cost-effective recovery of the excess heat in the hydrolyzed sludge, which would otherwise be wasted at high cost. The method, system, process equipment and device of the present invention using the hydrothermal process (ΤHP) can utilize the incoming cold substrate as a cooling source for the hydrolyzed substrate, while recovering more heat and reducing the specific energy consumption in the hydrothermal process.

[0451] To minimize the specific energy consumption of the hydrothermal process, the possibility of conducting hydrolysis at the highest possible dry solid concentration is of great importance. So far, an important obstacle to operating at high dry solid concentrations is the limitations associated with the handling of substrates at high apparent viscosities, such as static yield stress and / or dynamic yield stress. Most biomass materials are characterized by higher apparent viscosities, such as static yield stress and / or dynamic yield stress, at higher dry solid contents (DS%). In addition, the variation of the apparent viscosity (such as static yield stress and / or dynamic yield stress) in the substrate usually makes it necessary to take safety measures in terms of dry solid content (DS%) to avoid operational challenges and interruptions during daily operation. In many cases, this safety margin comes at the cost of unreasonably high operating costs because the hydrothermal hydrolysis of dilute substrates significantly increases energy consumption. There is currently no known hydrothermal process that can continuously monitor and optimize the combination of dry solid content, apparent viscosity (such as static yield stress and / or dynamic yield stress), and heat recovery. The method, system, process equipment, and device of the present invention using the hydrothermal process (ΤHP) can continuously monitor the rheological behavior of the substrate through a special design. This design is an integral part of the ΤHP process and does not rely on traditional apparent viscosity measurement instruments (such as static yield stress and / or dynamic yield stress) that are prone to difficulties when applied to non-uniform substrates containing a large amount of fibers, sand, grit, hair, branches, etc. The method, system, process equipment, and device of the present invention using the hydrothermal process (ΤHP) do not use commercially available instruments, but continuously monitor the apparent viscosity, such as static yield stress and / or dynamic yield stress, throughout the process by monitoring key performance indicators integrated with the process. This way of monitoring can simultaneously achieve robust optimization of dry solid content and heat recovery rate.

[0452] In addition to gradually monitoring the apparent viscosity (such as static yield stress and / or dynamic yield stress), continuously monitoring the digester performance throughout the process can comprehensively control the dry solid load during the whole process and achieve the safe operation of ΤHP and any downstream anaerobic digestion process without unnecessary safety margins.

[0453] Multiple factors affect the apparent viscosity of the substrate (such as static yield stress and / or dynamic yield stress):

[0454] · Rheological properties of the substrate or substrate mixture

[0455] · Dry solid content (DS%)

[0456] · Temperature

[0457] The factors affecting the specific heat consumption of hydrothermal hydrolysis are:

[0458] · Dry solid content (DS%)

[0459] · Volatile solid content (VS%)

[0460] · Chemical composition

[0461] · Feed temperature

[0462] · Internal heat recovery rate of the hydrothermal system

[0463] Currently, there are various instruments on the market for continuously monitoring the dry solid content of biomass materials. However, these instruments are difficult to use for substrates with relatively high apparent viscosities (such as static yield stress and / or dynamic yield stress) and for rheological behaviors that change over time. A typical challenge is that existing instruments are not precise enough, and the signals tend to drift unless the instruments are frequently calibrated. Therefore, the current methods for monitoring DS% before hydrothermal hydrolysis to continuously adjust the dry solid content are considered unreliable and insufficient to fully control the hydrothermal hydrolysis process. In addition, as described above, the present invention is based on the discovery that the actual limiting factor in the hydrothermal hydrolysis process is not the dry solid content but the apparent viscosity (such as static yield stress and / or dynamic yield stress). Accordingly, the present invention describes a novel design for continuously monitoring the apparent viscosity (such as static yield stress and / or dynamic yield stress) during the hydrothermal hydrolysis process and using the obtained data to continuously optimize the operation.

[0464] By optimizing the preheating and dilution rates, the specific heat consumption of the pyrolysis thermal system can be significantly minimized. When increasing the dry solid content, it is necessary to be able to control the apparent viscosity (such as static yield stress and / or dynamic yield stress), which is the limiting factor for processing the substrate. In the method, system, process equipment, and device of the present invention that employ the hydrothermal hydrolysis process (ΤHP), this can be achieved by monitoring the rheological behavior of the biomass material in the ΤHP feed system and monitoring the rheological behavior of the biomass material at different stages inside the hydrothermal system and adjusting the dry solid content to a level that can still ensure a high heat recovery rate.

[0465] In the method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (THP), preheating will be carried out in the upstream preconditioning device. Sludge and similar substrates have typical non-Newtonian behavior, and when subjected to shear force, their apparent viscosity (such as static yield stress and / or dynamic yield stress) will decrease. The design feature of the method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (THP) is that the preconditioning device introduces shear force to the substrate, thereby reducing the apparent viscosity (such as static yield stress and / or dynamic yield stress). Due to the decrease in apparent viscosity (such as static yield stress and / or dynamic yield stress), the material can be pumped to the next treatment step in the thermal hydrolysis system with lower pipeline resistance. Due to the decrease in apparent viscosity (such as static yield stress and / or dynamic yield stress), the specific pressure drop will decrease, and thus the power consumption required for pumping will also decrease accordingly. In the method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (THP), due to the shear force applied to the substrate, the reduced apparent viscosity (such as static yield stress and / or dynamic yield stress) will decrease over time, and the apparent viscosity (such as static yield stress and / or dynamic yield stress) of the biomass material will return to the level before the shear force is applied. Therefore, in the method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (THP), the residence time in the conveying pipeline should be minimized by minimizing the length of the conveying pipeline.

[0466] In the method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (THP), the waste heat generated by the pre-cooler downstream of the thermal hydrolysis system will be recovered in the preconditioning device. If the hydrolyzed sludge is pre-cooled to a temperature corresponding to δΤ = 20 °C, there should be enough heat to increase the feed temperature of the biomass material in the preconditioning device by more than 20 °C, for example, from 15 °C to 35 °C. If THP is designed to handle the corresponding temperatures and pressures achieved throughout the process, a 20 °C increase in the temperature of the biomass material can reduce the unit steam consumption by about 20% without changing the DS%.

[0467] In the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), precooling can be carried out in various ways. The most common way of precooling is to use a shell-and-tube heat exchanger. Another more advanced way of precooling is to use a flash cooler to utilize vacuum to reach the desired temperature. The advantage of flash coolers is that they eliminate the difficulty that the heat transfer coefficient depends on the apparent viscosity (such as static yield stress and / or dynamic yield stress). For substrates that exhibit high apparent viscosity (such as static yield stress and / or dynamic yield stress), the heat transfer is low. When operating at the maximum apparent viscosity (such as static yield stress and / or dynamic yield stress) limit, for example, in the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), it is advantageous to design the cooler such that the required heat transfer surface area does not depend on the apparent viscosity of the sludge (such as static yield stress and / or dynamic yield stress). In a flash cooler, heat exchange is carried out by the condensation of steam on the hot surface, rather than by the contact of the sludge with the hot surface, which is usually the case for standard heat exchangers used in the industry (such as shell-and-tube or spiral heat exchangers). For any cooler design, the waste heat can be used to preheat the dilution water of the preprocessor. For coolers that reduce the temperature to a lower level (such as 40°C or 50°C), high-temperature waste heat cannot be obtained unless assisted by other technologies to raise the temperature. However, this low-temperature waste heat can still be used for preheating.

[0468] The heat recovered using any cooler design can be recovered upstream of the thermohydrolysis system by adding hot water to the pulper or by mixing hot water with substrates having a dry solid content (DS) higher than 8% (preferably at least 12% DS, more preferably higher than 18% DS, and even more preferably higher than 20% DS) upstream of the pulper. The recovered heat can also be used to preheat the polymer / water in the upstream pre-dewatering or thickening process, thereby both helping to improve the dewatering performance achievable at elevated temperatures and helping to improve the overall heat balance of the entire thermohydrolysis process (due to the increase in the feed temperature of the thermohydrolysis system).

[0469] Since the feed sludge with a high dry solid content has a high apparent viscosity (such as static yield stress and / or dynamic yield stress), resulting in poor heat transfer performance, in the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), it is preferred to preheat the dilution water and then mix it into the feed substrate received from the upstream dewatering equipment or input from other locations.

[0470] For the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), an important task of the preconditioning device is to produce a sufficiently mixed and homogeneous substrate for A) pumping to the downstream THP with the lowest possible pressure drop (and energy consumption); and B) reducing its apparent viscosity (such as static yield stress and / or dynamic yield stress) before the sludge enters the THP pulper, thereby reducing the need for mixing in the pulper and enabling operation at a higher dry solids content with the lowest possible power consumption.

[0471] In the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), preheated water is added to the preprocessor device for the purpose of producing a sufficiently mixed substrate. The preprocessor device of the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP) can be an integrated part of the THP feed pump or an upstream mixer. In one possible embodiment of this design, mixing takes place in a screw conveyor that has a greater conveying capacity (preferably at least 1.5 times greater) than the subsequent THP feed pump. As a result, the substrate will flow back to form a loop, thereby mixing the substrate. The higher the ratio of the conveyor capacity to the pump capacity, the more intense the mixing and the better the pretreatment effect of the substrate before entering the THP unit. Generally, the capacity of the pump should be in the range of 50 - 90% of the conveyor capacity to provide a sufficiently high ratio between the conveyor capacity and the pump capacity. The average hydraulic residence time in the mixer should be at least in the range of 1 - 15 minutes to obtain a sufficiently mixed substrate. The correct / sufficient hydraulic residence time in the mixer depends on the apparent viscosity of the substrate (such as static yield stress and / or dynamic yield stress), temperature, and the dilution rate of the mixer. For a dilution water to cold substrate ratio in the range of 0.025:1 to 5.0:1, the residence time in the mixer is typically 1 - 15 minutes. The higher the ratio of the pump capacity to the conveyor capacity, the longer the residence time required to achieve efficient operation. When the ratio of the pump capacity to the conveyor capacity is relatively low, the mixing intensity will be higher and the required residence time will be shorter.

[0472] In the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), another possible embodiment is to provide a dedicated mixer at the bottom of the sludge silo. The mixer can adopt various designs, such as a shaftless screw conveyor, a screw conveyor, or a paddle mixer.

[0473] In the methods, systems, process equipment, and devices of the present invention that employ the thermohydrolysis process (THP), a possible solution is to use a flexible shaft pump and perform all mixing in the upstream conveyor that is part of the sludge silo. Since the mixing section is large and heavy, this will reduce the cost of the pump.

[0474] In the methods, systems, process equipment, and devices of the present invention that employ the thermal hydrolysis process (THP), another possible solution is to utilize a combination of a screw and a mixing shaft.

[0475] Ensuring that the substrate is thoroughly mixed and preheated before entering the THP is also generally beneficial for the operation of the THP, as less mixing energy is required for efficient operation compared to a THP pulper.

[0476] For some substrates, the addition of chemicals may be beneficial for the pretreatment associated with any downstream anaerobic digestion (as well as other fermentation processes). In such embodiments of the methods, systems, process equipment, and devices of the present invention that employ the thermal hydrolysis process (THP), the preconditioning device needs to be designed to withstand the chemicals used for pretreatment and the potentially exposed temperatures. In particular, chemicals that reduce the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) can be added, and chemicals that raise the temperature can be added. These chemicals may also be beneficial for any downstream anaerobic digestion process. An example is the addition of an alkali to achieve thermo-alkaline hydrolysis. The exothermic reaction caused by the addition of lime or caustic soda (or any other chemical substance that causes an exothermic reaction) will result in a temperature increase. Generally, this temperature increase is beneficial for downstream thermal hydrolysis, thereby reducing steam consumption. Additionally, the elevated temperature reduces the apparent viscosity of the substrate (e.g., static yield stress and / or dynamic yield stress). Any chemical substance that causes an exothermic reaction needs to be thoroughly tracked and monitored to avoid adverse events such as overheating and the direct exposure of the chemical substance to the elastomers used in the stator. At least the temperature and the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) should be monitored.

[0477] Furthermore, in order to further expand the operating range of the thermal hydrolysis of a specific substrate, enzymes that reduce the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) can also be added. The corresponding type of enzyme depends on the specific substrate, and the preheating device and the preconditioning device should be designed to ensure thorough mixing of the added enzyme with the substrate.

[0478] As is well known to those skilled in the art, certain sludge substances can reach very high apparent viscosities (e.g., static yield stress and / or dynamic yield stress) at high dry solid contents, and it is difficult to transport them from the dewatering step to the downstream treatment step. One possibility currently used in the industry to achieve this is to install large pumps to generate the pressure required to pump over a certain distance. However, if the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is very high, it is practically impossible to pump such fluids. To overcome these problems, the currently common method is to lubricate the fluid with polymers, water, or even compressed air. Then, the metering of the polymer is controlled, for example, by the pressure drop measured on the feed line. As an example, if a 17 m long DN150 pipeline records a pressure drop of 13 bar, people will currently add polymers to overcome the high pressure, which is challenging for the installed pulper feed pump. With this lubrication method, the pulper feed line can operate at a pressure drop of 7 - 9 bar. In current industrial practice, the lubrication pump should be located immediately downstream of the dewatering pump. In the method, system, process equipment, and device of the present invention using the thermo-hydrolysis process (ΤHP), the lubrication pump should be located 2 - 10 m downstream of the dewatering pump, and this distance will be used to measure the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the dewatered substrate at the pressure drop without polymers. Using the prior art, this information will then be used to determine the need for dilution water to adjust the DS% of the substrate. However, as described below, the method, system, process equipment, and device of the present invention using the thermo-hydrolysis process (ΤHP) provide a more desirable method to overcome the difficulties associated with high apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and high dry solid concentration cold sludge (or other substrates).

[0479] Therefore, through research, the inventors of the method, system, process equipment, and device of the present invention using the thermo-hydrolysis process (ΤHP) found that: 1) The apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and the corresponding head loss in the pipe section that follows are almost independent of the flow rate and mainly depend on the pipe size; 2) The apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and the corresponding head loss in the pipe section that follows significantly depend on the temperature.

[0480] These unexpected conclusions paved the way for changing the way the ΤHP feed line is designed, and the method, system, process equipment, and device of the present invention using the thermo-hydrolysis process (ΤHP) utilize these two findings.

[0481] Even though similar behavior has been confirmed in other fluids previously, this clear relationship discovered by the present inventors has not been disclosed in sludge and similar substrates treated by hydrothermal hydrolysis (e.g., before fermentation) hitherto. In addition, the present inventors have found that due to its inherent characteristics, the hydrothermal hydrolysis process provides a particularly suitable opportunity for optimization by utilizing these discoveries (e.g., regarding the apparent viscosity of sludge and similar substrates (such as static yield stress and / or dynamic yield stress)).

[0482] Thus, in one embodiment of the method, system, process equipment, and device of the present invention that employ the hydrothermal hydrolysis process (THP), the pulper circulates through the preprocessor to increase the temperature of the mixture returned to the pulper. Therefore, hitherto, there has been a common misunderstanding in the industry that increasing the flow rate (equivalent to 2 - 5 times the THP flow rate) will increase the pressure drop in the pulper feed line. In fact, the opposite is the case, and the pressure drop in the pulper feed line decreases due to the increase in temperature rather than due to the increase in flow rate.

[0483] Examples

[0484] Example 1

[0485] Figure 3 Shows the variation of the calculated pressure drop (head loss) in the pulper feed line with the flow velocity. This calculation is based on the sludge rheology data measured in the pulper feed lines of two different devices. As long as the sludge is at the same temperature, the sludge substances produced by these two different devices have similar rheological behavior. However, at different temperatures, the head loss measured in one device is much lower than that in the other device. The data obtained from these two devices are the basis for calculating the head loss for a specific pipe geometry and size. The calculation is carried out for a pulper feed pipe with a length of 45 m and a diameter of DN250 mm. As Figure 3 can be seen, for this sludge with non - Newtonian behavior, in the flow rate range of 0 - 18 m 3 / h, the pressure drop may be almost independent of the flow velocity in some cases. The main parameters affecting the pressure drop of a certain sludge substance are the pipe diameter and rheological properties. In addition, the rheological properties are also significantly affected by temperature. Figure 3 Among them, the sludge with the lowest calculated head loss has been pre - heated to 80 °C, while the sludge with the highest calculated head loss is the cold sludge at 20 °C. The conclusion drawn from this observation is that due to the higher temperature in the pulper feed pipe, the flow of hot sludge from the pulper back to the upstream of the pre - conditioning mixer will significantly affect the head loss in the pulper feed pipe. However, according to Figure 3 , for high - apparent - viscosity sludge with non - Newtonian behavior, the increased flow rate in the pulper feed pipe due to the circulating return flow will not have much impact on the total head loss.

[0486] The behavior of the sludge is assumed to conform to the Herschel - Bulkley model, Bingham plastic model, Bingham pseudoplastic model, Ostwald - de Waele model or similar non - Newtonian fluid models. In the Herschel - Bulkley model, Bingham plastic model, Bingham pseudoplastic model or Ostwald - de Waele model applied to sludge - like substrates, the yield shear stress is large relative to other parameters. This explains that for a given pipe geometry, within the range calculated in Figure 3 the pressure drop is almost constant and independent of the flow rate. This also explains that for a given pipe length, the pipe diameter has a major influence on the head loss.

[0487] Example 2

[0488] Figure 4 is based on data at about 20 - 25 °C for two different sludge substances and pipe configurations. For the same pipe configuration, the two sets of data were recalculated for Herschel - Bulkley non - Newtonian fluid, Bingham plastic non - Newtonian fluid, Bingham pseudoplastic non - Newtonian fluid or Ostwald - de Waele non - Newtonian fluid, also confirming the importance of pipe size for achieving acceptable head loss.

[0489] Example 3

[0490] The specific choice of pump has a great influence on the parameters of the method, system, process equipment and device of the present invention using the thermo - hydrolysis process (ΤHP). If the pressure drop in the refiner feed line can be maintained below 6 - 8 bar, the refiner feed pump can be, for example, a two - stage pump instead of a much more expensive four - stage pump. In this embodiment of the invention, due to the elevated temperature and the presence of high concentrations of organic acids and other components that may damage the stator, a stator with mechanical anchoring of a specific design should be used. In this embodiment of the invention, the mixing of the hot substrate returned from the refiner takes place in the mixing zone of the pre - processor. If the circulation flow rate of the hot substrate from the refiner is greater than the cold sludge feed flow rate, for example 3 times the ΤHP feed flow rate, the average temperature will be high enough to allow the removal of the extruder. This embodiment of the invention is particularly suitable for non - uniform substrates containing fibers etc. that may clog the extruder. If the temperature of the circulating flow is 90 °C and it is mixed with the cold substrate at 15 °C in a ratio of 1:3, the average temperature of the mixture will be 71.2 °C.

[0491] Figure 5 shows the variation of the average temperature of the mixture with the return temperature.

[0492] Figure 6 shows the variation of the average temperature of the mixture with the return ratio. The return ratio is the ratio of the return flow at high temperature (90 °C) to the feed flow at low temperature (20 °C).

[0493] One consequence of increasing the temperature is a reduction in the apparent viscosity of the pulper feed line. The reduced apparent viscosity will reduce the friction losses associated with pumping the substrate into the pulper. By returning the preheated substrate and mixing it with the cold substrate, the mixed substrate can be more easily pumped into the pulper with a lower pressure drop.

[0494] Example 4

[0495] The ability to operate a THP unit at high dry solids concentrations is essential in order to hydrolyze high viscosity substrates with minimal heat consumption. The higher the energy costs, the more important the ability to operate at high dry solids concentrations. The higher the dry solids concentration allowed by a THP unit, the lower the specific steam consumption.

[0496] However, several problems arise when hydrolyzing substrates under conditions of high apparent viscosity. There is a high risk of high pressure drops in the pipelines. There is a high risk of high power consumption during pumping. There is a high risk of short service life of pump wear parts. There is a high risk of heat losses in the pulper and reactor due to steam tunneling in the high viscosity substrate.

[0497] In order to be able to operate the thermal hydrolysis process under high dry solid content, various strategies have been adopted to alleviate these problems. However, another challenge is to determine the optimum dry solid content, to minimize steam consumption, while achieving the temperature of complete uniform distribution required for complete heat recovery and thermal hydrolysis process. The method, system, process equipment and device of thermal hydrolysis process (THP) of the present invention are not intended to determine the optimum dry solid content, but rely on the apparent viscosity of the biomass material to be processed and utilize these data to control the mixing ratio between preheating, dilution and the substrate. In addition, the overall performance of the THP process and any downstream process is monitored, and confirmed to meet the requirements by monitoring program.

[0498] One solution known from the prior art to enable high dry solids operation of thermal hydrolysis processes is a dynamic mixer. However, this solution only partially solves the problem and does not address the issues associated with heat recovery and operation with high viscosity substrates at low temperatures. Furthermore, the dynamic mixer requires increased power consumption, which is detrimental to overall energy consumption and operating costs. It also introduces an additional and unnecessary rotating equipment that requires maintenance and becomes an additional source of failure and malfunction leading to downtime of the TPH unit.

[0499] A more cost effective and better solution is to ensure that the above mentioned issues are completely handled and resolved inside the preheat tank (pulper) without adding an additional rotating device outside the pulper.

[0500] The method, system, process equipment and device of the present invention using the thermohydrolysis process (THP) describe, in one embodiment, a solution in the form of a preheating tank (pulper) that utilizes the heat distribution throughout the pulper such that the fully preheated substrate is always pumped to the downstream THP reactor. In this embodiment, the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP) also ensure a well-mixed tank (pulper) that avoids the agglomeration of the substrate or the collection of incompletely heated substrate from being further transported to the THP unit (i.e., the reactor for thermohydrolysis). This is crucial for efficient operation because, in the case of high apparent viscosity, such incompletely mixed and pre-treated substrate will not be fully heated and hydrolyzed in the downstream reactor.

[0501] In the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP), the monitoring of the apparent viscosity (such as static yield stress and / or dynamic yield stress) will be carried out in several stages throughout the process:

[0502] · In the pulper feed line, measure the pressure drop across a feed pipe of known size, length, and geometry.

[0503] · In the pulper recirculation line and / or the reactor feed line, by measuring the pressure drop across a feed pipe of known size, length, and geometry.

[0504] In the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP), the pressure drop, temperature, pump torque, and flow rate are continuously monitored at these locations.

[0505] In the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP), the control points for verifying the proper operation of the process are, for example:

[0506] · Monitor the temperature and pressure in the headspace of the pulper, which can indicate tunneling effects in the pulper and thus affect the dilution rate.

[0507] · Monitor the temperature and pressure in the headspace of the reactor.

[0508] · Monitor the temperature fluctuations in any pulp slurry that is recycled to the pulper or transported to the downstream reactor. If the average temperature of the control point does not reach the expected temperature (calculated theoretically based on the pulper feed temperature and reactor pressure / temperature), it indicates insufficient heat recovery.

[0509] In the method, system, process equipment and device of the present invention using the thermohydrolysis process (THP), the apparent viscosity (such as static yield stress and / or dynamic yield stress) is measured, and using the data from the control points, the preheating and dilution are controlled in one or two steps:

[0510] 1) Pulper preheating and preconditioning device;

[0511] 2) Pulper circulation / reactor feed system.

[0512] Optionally, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is measured, and using the data from the control points, the operation of the upstream dewatering process can also be controlled.

[0513] Optionally, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the hydrolyzed sludge can also be measured, which can be used to control the dilution of the digester feed based on the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the hydrolyzed biomass material, and the process can be verified through digester monitoring.

[0514] The method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (ΤHP) are based on the following findings: both the preheating and dilution rates affect the apparent viscosity (e.g., static yield stress and / or dynamic yield stress); and these two factors are crucial for fully controlling the THP system, making it depend on the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the biomass material being treated rather than the dry solid content. In contrast, the prior art teaches that it is necessary to simultaneously monitor and control the dry solid content. To understand the impact of controlling the thermal hydrolysis process based on the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) rather than the dry solid concentration, it is important to recognize that different substrates may have significantly different viscosities. At the same dry solid content (DS%) and temperature, the difference in the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) between two substrates can be as high as 1:500, and even higher in some cases. By always optimizing the operation according to the online apparent viscosity (e.g., static yield stress and / or dynamic yield stress), the thermal hydrolysis process can handle different apparent viscosities (e.g., static yield stress and / or dynamic yield stress) simultaneously (e.g., due to different substrate mixtures), as well as different feed substrate temperatures, without facing operational problems or adding an unreasonable safety margin, which is commonly used in the prior art processes based on dry solid concentration. An example is a co-digestion device that processes a combination of domestic sludge and imported substrates. Two different substrates may have completely different rheological behaviors, such as waste activated sludge and biowaste substrates. Therefore, there may be significant differences in the volume and mass ratios between the two substrates, and it is impossible to know the optimal dry solid content of a given substrate without significant effort. The method, system, process equipment and device of the present invention adopting the thermal hydrolysis process (ΤHP) can optimize the addition of the feed mixture and dilution water, thereby maximizing the yield of ΤHP with the lowest possible energy consumption.

[0515] The example is:

[0516] An increase in the dry solid content from 16.5% to 21% can reduce both the specific energy consumption and the hydraulic throughput by approximately 21%.

[0517] An increase in the dry solid content from 16.5% to 25% can reduce both the specific energy consumption and the hydraulic throughput by approximately 34%.

[0518] Therefore, the method, system, process equipment, and device of the present invention using the thermohydrolysis process (THP) can improve the carbon footprint during operation by reducing energy consumption.

[0519] To always ensure 100% that the thermohydrolysis process operates well under complete heat recovery, the prior art processes, for safety reasons, almost default to operating all substrates under conditions of an average dry solid content of 16.5% and a maximum of 18.0%. The method, system, process equipment, and device of the present invention using the thermohydrolysis process (THP) can distinguish the dry solid content based on the following discovery: The actual limiting factor of the THP process, i.e., the apparent viscosity (such as the static yield stress and / or the dynamic yield stress), is continuously monitored and optimized by:

[0520] 1) Optimize the premixing of the substrate

[0521] and / or

[0522] 2) Optimize the injection rate of the dilution water and mix it into the substrate

[0523] and / or

[0524] 3) Optimize the injection rate of the preheated dilution water and mix it into the substrate

[0525] and / or

[0526] 4) Optimize the injection rate of the chemical and mix it into the substrate

[0527] and / or

[0528] 5) Optimize the injection rate of the enzyme and mix it into the substrate

[0529] and / or

[0530] 6) Optimize the upstream dehydration of the substrate

[0531] and / or

[0532] 7) Optimize the reflux flow rate from the pulper to the preprocessor to reduce the pressure drop in the pulper feed line.

[0533] After any of the above measures, the temperature profile inside the equipment and / or in the THP feed pipe is monitored, and this temperature profile can be used as an indicator of the success rate of the preconditioning device in mixing the substrate. Statistical analysis is used to indicate the stability of the process.

[0534] In an embodiment of the method, system, process equipment and device of the present invention that adopt the thermohydrolysis process (THP), a particularly beneficial pulper design is used, wherein:

[0535] In this particularly beneficial pulper design, the ratio of the total volume of the pulper to the average filling volume of the reactor ranges from 2.1 to 3.0.

[0536] Furthermore, in this particularly beneficial pulper design, the pulper outlet nozzle connected to the reactor feed pump is located at a higher position to ensure the extraction of preheated substrate from the pulper and to avoid insufficient heating sludge and cold sludge extracted from the bottom of the container.

[0537] Furthermore, in this particularly beneficial pulper design, the volume below the outlet nozzle of the pump is ≥1.6 times the average filling volume of the reactor. The volume above the nozzle is ≥1 times the average filling volume of the reactor. The headspace volume at the maximum filling rate should be at least 10% of the total volume, preferably >20%, or more preferably 20 - 30% of the total volume. This will allow for splashing and foaming events without causing operating problems. The device can generally operate at a target filling rate of 70 - 80%, and the actual volume will vary according to the average reactor feed rate.

[0538] Sludge and similar substrates have non-Newtonian fluid characteristics. For such substrates, even at low flow rates, the pipe size is important for pressure drop. For pumps operating with liquids near the boiling point, a high pressure drop on the suction side of the pump is disadvantageous because it may cause cavitation and pose challenges to the operation of the pump. In the particularly beneficial pulper design of the present invention, the size of the pulper outlet nozzle is preferably ≥DN200 to handle high-viscosity substrates, and the length of the suction pipe between the nozzle and the pump is preferably no more than 4 meters. For smaller-sized pipes, such as DN150, the pipe length should be shortened to ensure a low pressure loss in the pipe.

[0539] The sludge entering the pulper container is colder than the sludge inside the pulper. Due to this temperature difference, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) of the cold feed sludge is higher than that of the hotter sludge inside the pulper. In a particularly advantageous pulper design of the present invention, the cold feed sludge is added to the hot sludge through a sludge distributor at the upper part of the pulper, so as to distribute the cold sludge entering the container into the preheated sludge. Preferably, the distribution device should be located in the headspace, preferably above the liquid level. Preferably, the sludge distributor is in the form of an extruder, which consists of a pipe with many holes, and the sludge is distributed and cut into smaller parts in the many holes, thereby creating a larger surface area. Preferably, the total area of the holes in the extruder is more than 2.5 times the cross-sectional area of the feed pipe leading to the extruder to avoid unnecessary pressure loss in the extruder. The size of the holes in the extruder should be between 10 mm and 50 mm, preferably between 18 mm and 35 mm, and most preferably between 20 mm and 30 mm. The smaller the holes, the better the distribution effect. However, the substrate includes fibers, textiles, plastics, hair and other particles, which are likely to clog the extruder with too small hole diameters. For most substrates, an extruder with a hole diameter of 25 mm is sufficient. The extruder can also be in the form of elliptical holes, slit-shaped or any other shape to ensure the effective distribution of the substrate at the top of the pulper. Other distribution systems can also be used, such as screw conveyors, spreaders, granulators or any other system that distributes the incoming sludge into smaller particles to provide a larger heat transfer surface to transfer heat from the preheated sludge inside the pulper. The location where the sludge enters the tank should not be directly above the outlet nozzle. A short horizontal distance between the inlet nozzle and the outlet nozzle will cause short circuit. The inlet of the sludge (preferably through the extruder) should be located on the other side of the pulper. In fact, for a vertical pulper with the outlet on the side of the pulper, the inlet extruder should be placed horizontally and at a 90° diagonal to the outlet nozzle, and its position should not be closer to the outlet nozzle than the center point of the diagonal of the container, preferably offset from the center of the outlet nozzle. The particularly advantageous pulper design according to the present invention can also be horizontal, in which case the extruder should also be located away from the outlet nozzle. This can be achieved by different directions and positions of the extruder.

[0540] In an embodiment of a particularly advantageous pulper design according to the present invention, some components of the extruder are blocked so as to 1) increase the distance from the pulper outlet nozzle, and 2) avoid splashing into other nozzles located in the headspace of the pulper.

[0541] In a particularly advantageous design of the pulper according to the present invention, it is beneficial to recycle the sludge through an extruder. This recycling can also include partial or full return to the preconditioner to improve pre-mixing and reduce the pressure drop in the pulper feed line. Preferably, the amount of preheated biomass material that can be recovered from the pulper in the recycling loop is at least equivalent to 0.5 times the cold biomass material feed rate, preferably more than 1 times the cold biomass material feed rate, and even more preferably more than 2 times the cold biomass material feed rate.

[0542] In a particularly advantageous design of the pulper according to the present invention, it is also beneficial to recycle the sludge to the bottom of the pulper.

[0543] In alternative 1 of the particularly advantageous design of the pulper according to the present invention, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is measured in the recycling loop of the preheated pulper, which includes a pump (preferably a screw pump) that generates a controlled flow rate and a pipe section with a known geometry to restrict the flow rate. Then, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is measured by the pressure drop across the pipe with a known geometry at a known flow rate.

[0544] In alternative 2 of the particularly advantageous design of the pulper according to the present invention, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is measured in the reactor feed line. The reactor feed line includes a pump function that can generate a controlled flow rate and a pipe section with a known geometry to restrict the flow rate. Then, the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) is measured based on the pressure drop across the pipe with a known geometry at a known flow rate.

[0545] The pump function in the particularly advantageous design of the pulper according to the present invention can be achieved in several different ways, such as a screw pump, a centrifugal pump, a piston pump, a pneumatic pump, or any other means of controlling the flow rate.

[0546] A flow meter can be used to verify the flow rate or control the flow rate through the system.

[0547] A pressure sensor can be used to measure the pressure drop.

[0548] For the particularly advantageous design of the pulper according to the present invention, the above-described system for measuring the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) does not encounter the operational problems that may be challenging in standard apparent viscosity (e.g., static yield stress and / or dynamic yield stress) measuring instruments in heterogeneous substrates such as sludge and biological waste that contain components prone to blocking and clogging narrow channels.

[0549] Similar benefits and performance of the above-described embodiments of the particularly advantageous pulper design according to the present invention can be achieved in other ways. Thus, another embodiment of the present invention is to establish an overflow container or a compartment of the container, which is substantially always in a filled state. When more cold sludge is added to the overflow container or the compartment of the container, the heated sludge will flow to the next container or compartment, which serves as a chamber for pumping the material into the downstream reactor. This embodiment of the present invention will utilize the temperature stratification occurring in the pulper and always skim off the sludge with the highest temperature in the same manner as the foregoing embodiments. The pumping of the heated substrate from the pulper to the reactor container can be achieved by a conventional pump, such as a screw pump, a centrifugal pump or any other type of pump. The pumping can also be achieved by pressurizing the container compartment of the pulper so as to push the substrate to the downstream reactor.

[0550] A key problem with the extruder design is that insufficient screening of the sludge may cause clogging of the extruder. Cleaning of the extruder installed in the top space of the pulper is both difficult and time-consuming. Thus, a preferred embodiment of the particularly advantageous pulper design according to the present invention includes an alternative design of the extruder, wherein the extruder is located outside the pulper container. Thus, the extruder can be isolated and cleaned regularly without disturbing the preheating container (pulper) itself. During the cleaning of the extruder, the extruder can be bypassed, or the system is equipped with a spare extruder to ensure that one extruder is always in operation.

[0551] It is also foreseen that some substrates with poor screening effect upstream in the process will benefit from continuous cleaning. Thus, in a particularly preferred embodiment, the design of the extruder can also include a self-cleaning function.

[0552] Even if the above embodiments are preferred, the methods, systems, process equipment and devices of the present invention using the thermo-hydrolysis process (THP) can use any type of extruder or filter, which cuts the cold substrate into smaller pieces, and the smaller pieces with a larger specific surface area therein are mixed into the hotter substrate. The applied extruder or filter should provide a larger specific surface area of the cold substrate that is preferably > 10 times by distributing the provided cold substrate into smaller parts. The extruded or filtered substrate with a larger specific surface area is mixed with a large amount of preheated substrate recycled from the preheating tank (pulper). The amount of the recycled preheated substrate should be at least > 3 times the amount of the cold substrate fed into the system.

[0553] The extruder can also be in the form of a screw press to be able to continuously remove grit, fibers, plastics, textiles, etc.

[0554] Figure 7Shows a possible design of a particularly beneficial pulper design for the method, system, process equipment, and apparatus of the present invention employing the thermohydrolysis process (THP), which includes an extruder.

[0555] The extruder can also be prepared for the injection and more efficient mixing of chemicals, as the sludge has a significantly lower apparent viscosity once preheated than when not preheated.

[0556] To date, the current trend in the industry has been to invest in expensive DS% meters. However, these instruments are not always reliable on substrates with high and varying apparent viscosities, and signal drift is also a problem. In contrast, the method, system, process equipment, and apparatus of the present invention employing the thermohydrolysis process (THP) rely on soft sensors that are based on simple and reliable information obtained from a system with a minimum of instrumentation. Since the true limiting factor in the thermohydrolysis process is the apparent viscosity (e.g., static yield stress and / or dynamic yield stress), it makes more sense to measure the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) rather than DS% and perform dilution based solely on the apparent viscosity (e.g., static yield stress and / or dynamic yield stress).

[0557] Measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the pulper feed line can be achieved by installing a pressure transmitter after the pulper feed pump and a few meters downstream of the pipe (preferably before the pulper inlet). The pressure drop across the measured pipe section is measured, and dilution and preheating are based on the measured pressure drop.

[0558] Measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the pulper feed line can also be achieved by installing a temperature transmitter on the pulper feed line to provide a reference for determining the apparent viscosity (e.g., static yield stress and / or dynamic yield stress). Measurement with a flow meter is more difficult and inaccurate due to the low flow rate and the small cross-sectional area of the flow transmitter (which causes additional pressure drop).

[0559] Measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the pulper circulation line can be achieved by:

[0560] - Installing a temperature transmitter;

[0561] - Installing 2 pressure transmitters in front of the extruder with a certain distance between them to avoid interference with the measurement when the extruder gradually clogs.

[0562] - Injecting preheated dilution water into the pulper circulation pump in the case of a high pressure drop in the pipe.

[0563] - Increase the dilution rate upstream of the preprocessor in case of high temperature fluctuations in the pulper (indicating too high apparent viscosity, e.g., static yield stress and / or dynamic yield stress).

[0564] The measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the reactor feed line can be achieved by:

[0565] - Installing a temperature transmitter

[0566] - Installing a pressure transmitter

[0567] - Installing a flow meter

[0568] - Measuring the pressure drop between the pressure transmitter and any pressure transmitter in the reactor.

[0569] The measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the reactor feed line can be achieved by utilizing the torque or power consumption available on the pump frequency converter.

[0570] The measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the pre-cooler can be achieved by:

[0571] - Installing a temperature transmitter

[0572] - Installing a flow meter

[0573] - Installing a pressure transmitter on the pre-cooler circulation pipeline.

[0574] - Measuring the pressure drop between the pressure transmitters.

[0575] The measurement of the apparent viscosity (e.g., static yield stress and / or dynamic yield stress) in the digester feed line can be achieved by:

[0576] - Installing a temperature transmitter

[0577] - Installing pressure transmitters at the digester feed pump and before the interface with the digester feed line.

[0578] - Installing a flow meter

[0579] - Measuring the pressure drop between the pressure transmitters.

[0580] Figure 8 An embodiment of the present invention is shown, including a particularly beneficial pulper design of the present invention.

[0581] Figure 9 The preferred sludge extruder in the particularly beneficial pulper design of the present invention is shown.

[0582] Figure 10AShows data of a case study related to the performance data of the pulper retrofit and upgrade, involving the upgrade from an existing technology design to a particularly beneficial pulper design of the present invention. It can be seen that, compared with the prior art, the ability of the pulper according to the present invention to maintain the temperature of the discharged material from the pulper within a certain limit has been significantly improved. Therefore, the pulper according to the present invention (16-hour trend) can maintain the temperature of the discharged material from the pulper within a temperature range of about 20 °C (i.e., varying from about 65 °C to about 85 °C), while the temperature range achieved by the prior art pulper (8-hour trend) is almost twice as large as that of the present invention, i.e., 40 °C (i.e., varying from about 45 °C to about 85 °C).

[0583] Figure 10B Shows the standard deviation of the reactor feed temperature in each reactor fill calculated based on temperature measurements taken every 5 seconds in the method of the present invention using the pulper of the present invention. It can be seen that it is ensured that the preheated biomass material produced from non-Newtonian biomass material in the pulper, and the preheated biomass material subsequently fed into any downstream hydrothermal reactor of the ΤHP system, and / or the preheated biomass material subsequently fed from the ΤHP system into any subsequent treatment step, has a uniform temperature, i.e., when the temperature standard deviation is calculated based on a temperature measurement resolution of < 5 seconds and used to calculate the overall average for each individual reactor fill, the average standard deviation of this temperature < 12 °C.

[0584] Figure 11 Shows data of a case study related to the performance data of the pulper retrofit and upgrade, involving the upgrade from an existing technology design to a particularly beneficial pulper design of the present invention (i.e., with and without an upgrade kit). It can be seen that, compared with the prior art, the pulper of the present invention can provide a reactor feed flow rate higher than 30 m 3 / h even in the case of a very high dry matter content, and this ability has been significantly improved. Therefore, the pulper of the present invention can achieve a reactor feed flow rate higher than 30 m 3 / h when processing materials with a DS far higher than 14%, which is impossible in the prior art pulpers.

[0585] Example 5

[0586] Figure 12 For the development and testing process of the particularly beneficial pulper design of the present invention described in Example 4, the operating data when the selected dry solid content is 16% to 18% DS, and shows the relationship between τ o and WAS%. It can be seen from the figure that when the dry solid content reaches 18%, WAS% can reach 100%.

[0587] From Figure 12It can be seen that the particularly advantageous pulper design described in Example 4 of the present invention can withstand an apparent viscosity that exhibits a static yield stress of up to τo = ~1700 - 2200.

[0588] Figure 13A and Figure 13B indicate that the particularly advantageous pulper design described in Example 4 of the present invention can operate stably at an apparent viscosity with a static yield stress τo = 1500 - 2000 Pa at 100% WAS. In the case of 30% WAS and 70% primary sludge, the apparent viscosity under the same conditions (DS% and temperature) is approximately the static yield stress τ o = 500 - 1000 Pa. If the device is operated with 30% WAS and 70% primary sludge, the dry solids content can be increased until the apparent viscosity reaches the level of the static yield stress τ o = 1700 - 2200 Pa. In this case, the dry solids content can be increased from 16 - 18% DS to 20 - 22% DS, and in some cases, for certain substrates or substrate mixtures, it can even be further increased to 25% DS or higher. Such an increase will result in a 20% and 38% reduction in unit steam consumption, respectively. Another advantage is that the hydraulic capacity can be maintained under high dry solids operation. Therefore, the dry solids capacity can also be increased by 20% and 38%, respectively.

[0589] Example 6

[0590] When using the apparent viscosity (such as static yield stress and / or dynamic yield stress) as a parameter to control the dilution rate in order to optimize the THP process, without controlling the actual VS feed rate, there is a risk of variation in the dry solids content (DS%) of the digester feed. However, more important than the VS feed rate is the actual energy feed rate. Different sludge substances and other substrate substances have different specific energy contents. One way to measure the specific energy content is to measure COD / VS, as this can explain the energy density of the volatile solids present in the substrate. Another background of the method, system, process equipment, and device of the present invention using the thermochemical hydrolysis process (THP) is that the inventors have discovered the relationship between the specific energy content (measured as COD / VS) and the rheology (measured as τ o ).

[0591] Figure 14 Shows this relationship.

[0592] Based on the relationship between τ Figure 15 as shown in o and the WAS / primary sludge ratio, the relationship between the specific energy content (measured as COD / VS) and the rheology (measured as τ o ) was established ( Figure 14 ).

[0593] In addition, Figure 14 the visualized τ in o The calculation function f(COD / VS) is based on an energy content of 1.7 in primary sludge and 1.45 in waste activated sludge. Depending on the sludge source, sludge age, etc., the expected energy content may vary, and it is recommended to calibrate for each sludge mixture. The established relationship can be used to determine the energy content in the sludge and thus to control the energy supply rate to the digester, and its effectiveness is mainly for τ o > 500 - 1000 Pa and COD / VS > 1.52, depending on the substrate type.

[0594] The specific COD / VS ratio for each sludge and substrate will vary, depending on the upstream wastewater treatment process, wastewater quality, sludge age, etc. The correct mathematical relationship will thus also vary. However, it is expected that similar relationships will exist for many substrates, which can then be calibrated based on sampling of the actual substrates to be mixed.

[0595] One way to control the effectiveness of the calibration system and to determine whether closer monitoring and possible recalibration are needed is to analyze the organic nitrogen content in addition to the regular sampling and analysis of COD / VS. Different sludges and substrates have different organic nitrogen contents. Typically, the organic nitrogen content in primary sludge is about 2.5% of the VS content, while that in waste activated sludge (WAS) is usually about 6.0%. Therefore, an indirect way to control the energy content is to analyze the organic nitrogen content in the sludge. As Figure 16 shown, the relationship between τ o and the organic nitrogen content in the sludge can be calculated. In addition, this relationship will vary depending on the wastewater treatment process, wastewater quality, process operation mode, sludge age, etc.

[0596] Once this relationship is established and calibrated, the method, system, process equipment and device of the present invention using the thermal hydrolysis process (ΤHP) can use τ o to predict the organic nitrogen concentration in the sludge mixture and thus the organic nitrogen load of the digester.

[0597] An important reason for performing thermochemical hydrolysis before anaerobic digestion is that it can completely change the characteristics of the sludge, making the sludge more digestible. The thermochemical hydrolysis step occurs before the remaining anaerobic digestion process, and the digestion process is thus faster. Maττ Higgins (Bucknell University, Lewisburg, Pennsylvania, 2021) demonstrated that mixed sludge can be well digested through a single-stage digestion process with a hydraulic retention time of 10 days, and the methane production, VS destruction rate, and dewatering performance will not decrease significantly. Acceptable results can also be obtained at 8-day HRT, while the performance will decline rapidly at 6-day HRT. Achieving such a short retention time through the adoption of thermochemical hydrolysis technology will significantly improve the productivity, throughput, and utilization rate of existing digestion devices. In addition, the cost of newly built anaerobic digestion devices can be significantly reduced, just as it can reduce the environmental footprint and the required area. Compared with traditional anaerobic digestion without thermochemical hydrolysis technology, this is also beneficial for reducing the overall carbon footprint.

[0598] When the anaerobic digestion process operates at such a high loading rate (7 - 8 kg VS / m 3 d) and a short retention time (10 days), the process may be affected by a further rapid increase in the feed rate. The method, system, process equipment, and device of the present invention adopting the thermochemical hydrolysis process (ΤHP) introduce apparent viscosity (such as static yield stress and / or dynamic yield stress) as a control parameter, enabling the thermochemical hydrolysis process to operate at the highest possible dry solid content, thereby reducing specific heat consumption, while not causing operational challenges in the pretreatment process upstream of the anaerobic digestion process. If the change in the feed mixture reduces the apparent viscosity (such as static yield stress and / or dynamic yield stress), for example, by changing the primary / secondary sludge ratio, the method, system, process equipment, and device of the present invention adopting the thermochemical hydrolysis process (ΤHP) can automatically increase the DS% by reducing the dilution rate or increasing the DS% by pre-dewatering. One way to further increase the digester loading rate is to predict the DS%, VS%, COD / VS (energy density), and organic nitrogen content by measuring the rheological behavior of the biomass material throughout the ΤHP process. In addition, by monitoring the key performance indicators during the anaerobic digestion process, the control of the digester can be further improved.

[0599] The key performance indicators (KPIs) that can be monitored during the anaerobic digestion process to improve control include:

[0600] pH value

[0601] CH4 concentration

[0602] Biogas production rate

[0603] FOS / ΤAC

[0604] Biogas production per unit (per kilogram of DS) (Nm3 / kg DS)

[0605] Unit methane production (per kg VS) (Nm3 / kg VS)

[0606] Digester loading rate (kg VS / m3d)

[0607] To continuously identify these KPIs, the data that can be recorded includes:

[0608] pH value

[0609] CH4 concentration

[0610] Biogas flow rate

[0611] Digester feed flow rate

[0612] Digester DS% obtained from apparent viscosity (e.g., static yield stress and / or dynamic yield stress)

[0613] Digester VS% obtained from apparent viscosity (e.g., static yield stress and / or dynamic yield stress).

[0614] To calibrate the relationships between apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and DS%, and between apparent viscosity (e.g., static yield stress and / or dynamic yield stress) and VS%, DS% and VS% should be sampled and analyzed continuously. This should be done in the digester feed line and the pulper recycle / reactor feed line.

Claims

1. A method for treating non-Newtonian biomass materials, the non-Newtonian biomass materials having: - a dry matter content (DS%) of at least 12%, - a ratio between the chemical oxygen demand (COD) and the volatile solids content (VS) of less than 2.0, i.e., the COD / VS ratio, and - Static yield stress τ between 150 and 2500 Pa o , for example, higher than 200 Pa, for example, higher than 250 Pa, for example, higher than 300 Pa, for example, higher than 350 Pa, for example, higher than 400 Pa, for example, higher than 500 Pa, for example, lower than 2400 Pa, for example, lower than 2200 Pa, for example, lower than 2000 Pa, for example, lower than 1800 Pa, for example, lower than 1600 Pa, for example, between 300 and 1700 Pa, for example, between 400 and 1700 Pa, for example, between 500 and 1700 Pa, for example, between 600 and 1700 Pa, and / or dynamic yield stress τ between 50 and 500 y , for example, higher than 100, for example, higher than 150 Pa, for example, higher than 200 Pa, for example, lower than 450 Pa, for example, lower than 400 Pa, for example, lower than 350 Pa, for example, lower than 300 Pa, for example, lower than 250 Pa, for example, between 50 and 400 Pa, for example, between 50 and 300 Pa; The method comprises the following steps: a) feeding the non-Newtonian biomass materials into one or more refiners through one or more refiner feed lines at a controlled DS% and / or COD loading rate; b) homogenizing and preheating the non-Newtonian biomass materials in the one or more refiners to obtain preheated biomass materials; c) discharging the preheated biomass materials from the one or more refiners; d) feeding the preheated biomass materials into a hydrothermal system through one or more feed lines at a controlled DS% and / or COD loading rate, the hydrothermal system operating at a temperature higher than the temperature of the preheated biomass materials; e) subjecting the preheated biomass materials to hydrothermal hydrolysis in the hydrothermal system to obtain hydrolyzed biomass materials, and f) transferring the hydrolyzed biomass materials through one or more feed lines at a controlled DS% and / or COD loading rate to one or more subsequent treatment systems, where at least part of the hydrolyzed biomass materials are subjected to subsequent treatment in the one or more subsequent treatment systems, wherein the method is further characterized in that: - the controlled DS% and / or COD loading rate of the non-Newtonian biomass materials through one or more refiner feed lines and refiners in steps a)-c), and / or - the controlled DS% and / or COD loading rate of the preheated biomass materials through one or more hydrothermal system feed lines and the hydrothermal system in steps d) and e), and / or - the controlled DS% and / or COD loading rate of the hydrolyzed biomass materials through one or more feed lines in step f), is controlled based on: -Determining the static yield stress τ of the non-Newtonian biomass material, the preheated biomass material, and / or the hydrolyzed biomass material continuously or semi-continuously by continuously or semi-continuously measuring the pressure drop, temperature, and flow rate among the following o and / or the dynamic yield stress τ y : - the one or more feed lines for the one or more refiners in step a), and / or - the feed line for the hydrothermal system in step d), and / or - the one or more feed lines for the one or more subsequent treatment systems in step f), and / or - one or more hydrothermal discharge lines or recycle lines of the hydrothermal system in steps d) and e), and / or - one or more recycle lines of the one or more refiners in steps a)-c), and - continuously or semi-continuously measuring one or more parameters of the one or more subsequent treatment systems in step f), so as to determine that the controlled DS% and / or COD loading rate has the characteristics of at least one of the one or more parameters of the subsequent treatment system in step f); - at the determined static yield stress τ o and / or dynamic yield stress τ y under the controlled DS% and / or COD loading rate of the non-Newtonian biomass material through the one or more pulper feed lines and the pulper of step a); and / or - at the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the preheated biomass material of the hot hydrolysis feed line and the hot hydrolysis system by step d); and / or - At the determined static yield stress τ o and / or dynamic yield stress τ y the controlled DS% and / or COD loading rate of the hydrolyzed biomass material in the feed line of the one or more subsequent treatment systems of step f).

2. The method according to claim 1, wherein The non-Newtonian biomass materials exhibit: - A static yield stress τ of at least 500 Pa o , for example at least 1000 Pa, for example at least 1500 Pa, and / or - Dynamic yield stress τ of at least 80 Pa y , for example at least 100 Pa, for example at least 120 Pa.

3. The method according to any one of claims 1 or 2, wherein The hydrothermal system in steps d) and e) comprises: - one or more reactors operating in parallel or in series, where the preheated biomass is subjected to heating and pressure increase in the one or more reactors operating in parallel or in series; and - one or more flash tanks to which the biomass is transferred from the one or more reactors, whereby a pressure drop occurs in one or more stages of flash steam generation; and among them - In one or more pulpers in steps a) to c) which may be operated in parallel or in series, said preheating of said biomass material is achieved by injecting flash steam recovered from said thermal hydrolysis system in steps d) and e).

4. The method according to any one of claims 1 to 3, wherein, The non-Newtonian biomass material has a dry matter content (DS%) higher than 20%, wherein: - at least 50% of said obtained hydrolyzed biomass material is recycled by conveying from i) downstream of said hydrolysis system of steps d) and e) to ii) upstream of said hydrolysis system of steps d) and e) and / or - said biomass material is preheated in said pulpers in steps a) to c) and thermally hydrolyzed in said thermal hydrolysis system in steps d) and e) by subjecting said biomass material to a plurality of steps comprising stepwise heating and cooling in one or more pulpers for heating, in one or more reactors for treatment at a preselected temperature above 150°C, more preferably above 160°C, even more preferably above 180°C, and in one or more flash tanks for decompression and / or cooling.

5. The method according to any one of claims 1 to 3, wherein The non-Newtonian biomass material has a dry matter content (DS%) higher than 20%, wherein the one or more subsequent processing systems of step f) comprise: f1) a separation step to produce at least two fractions, wherein one fraction is enriched in liquids compared to the hydrolyzed biomass material and the other fraction is enriched in solids compared to the hydrolyzed biomass material; as well as, f2) transferring part or all of the hydrolyzed biomass material, one or both of the at least two fractions produced in the separation step of step f1) to one or more processing units for anaerobic fermentation through one or more feed lines; as well as, f3) transferring part or all of the hydrolyzed biomass material, one or both of the at least two fractions produced in the separation step of step f1) to one or more treatment units for thermal reduction of organic compounds through one or more feed lines; and among them: - at least partially dehydrating at least part of the material obtained from said anaerobic fermentation of step f2) and transferring the obtained dehydrated material to said one or more treatment units for thermal reduction of organic compounds of step f3) via one or more feed lines.

6. The method according to any one of claims 4 or 5, wherein By using more than one hybrid screw conveyor and pump (preferably a screw pump, preferably more than one screw conveyor with a conveying capacity of at least 1.5 times that of the pump), the hydrolyzed biomass material obtained in step e) is conveyed from i) downstream of the hydrolysis system in steps d) and e) to ii) upstream of more than one of the pulpers in steps a)-c) for recirculation and mixed with the non-Newtonian biomass material, thereby reducing the static yield stress τ of the material fed to the pulper o and / or the dynamic yield stress τ y .

7. The method according to any one of claims 1-6, wherein, By using more than one hybrid screw conveyor and a pump (preferably a screw pump, preferably more than one screw conveyor with a conveying capacity of at least 1.5 times that of the pump), the preheated biomass material from more than one pulper in steps a)-c) is conveyed upstream of the more than one pulper in steps a)-c) for recycling and mixed with the non-Newtonian biomass material, thereby reducing the static yield stress τ of the material fed to the pulper o and / or the dynamic yield stress τ y .

8. The method according to any one of the preceding claims, further characterized in that: - Recovering heat from the cooling process of the hydrolyzed biomass material of step e) using a heat exchanger before the hydrolyzed biomass material is subjected to the one or more subsequent treatments of step f), preferably by cooling the hydrolyzed biomass of step e) by subjecting the hydrolyzed biomass material to heat exchange with water in a heat exchanger, and subsequently injecting the water into the non-Newtonian biomass material of step a), the preheated biomass material of step b), or preheating polymer / water in an upstream pre-dewatering or thickening process.

9. The method according to any one of the preceding claims, further characterized in that, The non-Newtonian biomass material of step a) shows that: - Static yield stress τ higher than 2000 Pa o , for example, higher than 2200 Pa, for example, higher than 2300 Pa; and - Dynamic yield stress τ higher than 300 Pa y , for example, higher than 350 Pa, for example, higher than 400 Pa; and - The static yield stress τ of the material fed into the pulper o is reduced to a value below 1700 Pa, for example below 1500 Pa; and / or - Dynamic yield stress τ of the material fed to the pulper y is reduced to a value below 250 Pa, for example below 200 Pa.

10. The method according to claim 9, further characterized in that, Before the subsequent treatment of step f), inorganic particles and / or undissolved materials are continuously separated from the hydrolyzed biomass material of step e) by sand removal.

11. The method according to claim 5, wherein At least a part of at least one fraction rich in liquid compared to the hydrolyzed biomass material of step f1) is recycled by being conveyed to the following locations: - upstream of more than one of the pulpers of steps a)-c) and mixed with the non-Newtonian biomass material, thereby reducing the static yield stress τ of the material fed to the pulper o and / or the dynamic yield stress τ y ; -upstream of the hydrolysis system of steps d)-e) and mixed with the preheated biomass material, thereby reducing the static yield stress τ of the material fed to the hydrolysis system o and / or the dynamic yield stress τ y ; and / or -upstream of said separation step f1) and mixed with said hydrolyzed biomass material so as to reduce the static yield stress τ of the material fed to said separation step f1) o and / or the dynamic yield stress τ y .

12. A system for treating biomass material having a dry matter content (DS%) higher than 12%, the system comprising: - A pulper for homogenizing and preheating the biomass material having a dry matter content (DS%) higher than 12%; - A hot hydrolysis reactor for hot hydrolyzing the homogenized and preheated biomass material; The system is characterized in that: - The total volume of the pulper is >2.6 times and <20 times, preferably 2.6 times to 6 times, the average filling volume of the hot hydrolysis reactor; - The pulper includes an outlet nozzle for discharging the preheated biomass material from the pulper, and the outlet nozzle is placed in such a way that: - The part of the total volume of the pulper located below the outlet nozzle is ≥1.6 times the average filling volume of the hot hydrolysis reactor; and - The part of the total volume of the pulper not located below the outlet nozzle is >1 times the average filling volume of the hot hydrolysis reactor.

13. The system according to claim 12, further characterized in that, The preheating in the pulper is at least partially achieved by injecting flash steam from the hot hydrolysis system.

14. The system according to any one of claims 12 or 13, It is further characterized in that: a) Provided in the form of at least two independent interconnected chambers or tanks: - The part of the total volume of the pulper located below the outlet nozzle, and - The part of the total volume of the pulper not located below the outlet nozzle; b) The outlet nozzle is mounted on the first chamber or tank of the at least two independent interconnected chambers or tanks in the form of an overflow edge, knife edge or similar outlet, which ensures that a volume corresponding to ≥1.6 times the average filling volume of the hot hydrolysis reactor persists below the edge, knife edge or similar outlet in the first chamber or tank of the at least two independent interconnected chambers or tanks; And c) The pulper includes a biomass material distributor, preferably designed as an extruder, for dividing the incoming cold biomass material into smaller segments before the biomass material enters the pulper.

15. The system according to any one of the preceding claims, further characterized in that, The pulper includes a recirculation loop that can recover a certain amount of preheated biomass material from the pulper, the amount being at least 0.5 times, preferably more than 1 time, even more preferably more than 2 times the cold biomass material feed rate, and mixing the preheated biomass material with the cold biomass material before the preheated biomass material enters the biomass material distributor.

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