Modular heating device and fermentation tank

Abstract

The utility model belongs to the technical field of biological fermentation, and particularly relates to a modular heating device which comprises a hot water tank, a heating device and a heating device, the multiple united collecting pipes are arranged, the two ends of each united collecting pipe communicate with the hot water tank through a pipeline, a first control valve and a first electromagnetic valve are arranged on the pipeline, and the first control valve is located at the end close to the united collecting pipes; the plurality of heat collecting mechanisms are arranged in one-to-one correspondence with the union collecting pipes, and each heat collecting mechanism communicates with the union collecting pipes; the circulating pump is communicated with the pipeline, so that water circularly flows between the hot water tank and the heat collecting device; the multiple heating modules are arranged, and the heating modules are arranged in the axial direction of the fermentation tank at intervals; each heating module comprises a plurality of heating bodies arranged along the circumferential direction of the fermentation tank, and the heating bodies made of heat conduction materials are communicated in sequence. Therefore, the problems of low fermentation efficiency, high energy consumption and high waste gas yield of fermentation equipment in the prior art are solved.

Description

Technical Field

[0001] This utility model belongs to the field of bio-fermentation technology, specifically relating to a modular heating device and a fermenter. Background Technology

[0002] Because organic waste (such as kitchen waste and agricultural waste) varies greatly in composition and may contain high levels of lignin, cellulose, and other recalcitrant substances, microbial decomposition is slow. An imbalanced carbon-to-nitrogen ratio (C / N) (too high or too low) affects microbial activity and reduces gas production efficiency. Anaerobic fermentation is divided into mesophilic (30–45℃) and thermophilic (50–60℃) types; if the temperature fluctuates or fails to meet the target, microbial metabolic efficiency will significantly decrease. The accumulation of volatile fatty acids (VFA) during fermentation may lead to a decrease in pH, inhibiting methanogenic bacteria activity. Furthermore, insufficient mechanical stirring can cause material stratification or crusting, resulting in low mass transfer efficiency; excessive stirring may disrupt the microbial community.

[0003] Anaerobic fermentation relies on the synergistic effects of hydrolytic bacteria, acid-producing bacteria, and methanogens. If the activity of any bacterial group is insufficient (e.g., sulfides inhibit methanogens), the overall efficiency will decrease. Insufficient hydraulic retention time (HRT) or solids retention time (SRT) results in the discharge of organic matter before it is fully degraded. Maintaining a constant temperature (especially during high-temperature fermentation) requires continuous energy consumption; poor reactor insulation or low-efficiency heat recovery systems significantly increase energy consumption. Pretreatment steps such as crushing, sorting, or desalination increase energy consumption, especially for complex wastes (e.g., mixed waste). When the anaerobic environment is disrupted, facultative bacteria will undergo aerobic metabolism, producing CO2 instead of methane, leading to increased waste gas emissions. Overactive acid-producing bacteria can cause VFA and CO2 accumulation, which methanogens may fail to convert in time. The decomposition of sulfur-containing organic matter (such as proteins) produces H2S, while CO2 is a natural byproduct of anaerobic fermentation; insufficient desulfurization measures increase the pressure on waste gas treatment. Improper sealing of reactors or pipelines can lead to the release of methane (CH4), which not only reduces energy recovery rates but also increases greenhouse gas emissions.

[0004] In view of the problems of low fermentation efficiency, high energy consumption and high waste gas production in existing fermentation equipment, there is an urgent need to provide a more reasonable technical solution to optimize and improve the entire anaerobic fermentation system, thereby solving the current technical problems. Utility Model Content

[0005] The purpose of this invention is to provide a modular heating device and fermentation tank to solve the problems of low fermentation efficiency, high energy consumption and high waste gas production in existing fermentation equipment.

[0006] To achieve the above objectives, this utility model provides a modular heating device for a fermentation tank; the modular heating device includes:

[0007] Hot water tanks are used to store liquids;

[0008] Multiple manifolds are configured, and each manifold is connected to the hot water tank at both ends by pipes. A first control valve and a first solenoid valve are provided on the pipes, with the first control valve located at one end close to the manifold.

[0009] The heat collection mechanism is configured in multiple ways, each corresponding to one of the manifolds. Each heat collection mechanism is connected to the manifold and is used to heat the introduced liquid.

[0010] A circulation pump, connected to the pipes, circulates water between the hot water tank and the heat collection device; and,

[0011] Multiple heating modules are configured, with each heating module spaced apart along the axial direction of the fermentation tank. Each heating module includes multiple heating elements arranged along the circumferential direction of the fermentation tank, and the heating elements made of thermally conductive material are connected in sequence. The top area of ​​the fermentation tank is not equipped with any heating module. The hot water tank, manifold, pipeline, heat collection mechanism, and flow channel of the heating module together form a circulating water circuit.

[0012] Optionally, the heating element is embedded in both the inner and outer walls of the fermentation tank, wherein the circumference of the inner wall of the fermentation tank is F1, and the circumferential length of the heating element in the inner wall of the fermentation tank is F2, where F2 = (0.25~0.5)F1; the circumference of the outer wall of the fermentation tank is F3, and the circumferential length of the heating element in the outer wall of the fermentation tank is F4, where F4 = (0.8~0.9)F3.

[0013] Alternatively, the modular heating device may also include a heat preservation module that is detachably wrapped around the periphery of the fermenter.

[0014] Alternatively, the insulation module is connected to the fermentation tank via a clip or screws; the insulation module is equipped with a polyurethane layer.

[0015] Alternatively, the fermenter is provided with a limiting groove, and the heating element is embedded in the limiting groove.

[0016] Optionally, a sealing layer is provided in the heating element and the limiting groove.

[0017] Alternatively, the fermenter has an inlet and an outlet, and the density of the heating element in each heating module gradually decreases along the direction from the inlet to the outlet.

[0018] Optionally, each heating module is provided with a length of L1 along the axial direction of the fermentation tank, and the length of the fermentation tank is L2, where L2 = (0.5~0.8)L1.

[0019] Optionally, the modular heating device further includes a temperature detection mechanism and a pressure detection mechanism communicatively connected to the controller. The temperature detection mechanism is used to detect the current water temperature information in the heating element, and the pressure detection mechanism is used to detect the current water pressure information in the circulating water circuit. The controller is also communicatively connected to the first solenoid valve and the circulating pump to control the first solenoid valve and the circulating pump to perform corresponding actions according to the current water temperature information and the current water pressure information.

[0020] A fermenter comprising the aforementioned modular heating device.

[0021] Through the aforementioned technological effects, the circulating water system reduces heat loss, lowering energy consumption by more than 30% compared to direct electric heating. Thermally conductive materials (such as stainless steel or copper) enhance the heat transfer efficiency of the heating element. Axial and circumferential segmented heating avoids "cold / hot zones," maximizing microbial activity. Unheated tops reduce moisture evaporation, prevent material drying and crusting, and improve gas release. Automated temperature control via valves and sensors adapts to different fermentation stages (e.g., mesophilic / high-temperature fermentation). This allows maintaining a temperature of 35–55°C (mesophilic / high-temperature fermentation range) during fermentation, accelerating hydrolysis and methanogenesis rates, and shortening residence time. Simultaneously, precise temperature control prevents sudden pH drops caused by VFA accumulation, ensuring the activity of methanogens. This uniform heating method avoids localized anaerobic environment disruption, reducing abnormal CO2 and H2S emissions. Temperature stability improves the metabolic efficiency of methanogens, increasing the CH4 content in biogas by 10%–20%. Compared to traditional steam heating, the overall energy consumption of the circulating water system is reduced by 25%–40%. By employing a closed-loop circulation and zoned temperature control design, the problems of uneven heating and high energy consumption in traditional fermenters are solved, significantly improving the stability and energy conversion efficiency of anaerobic fermentation. Its technological advantages directly translate into higher biogas production, lower operating costs, and reduced waste gas emissions, making it suitable for large-scale organic waste treatment scenarios. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the main structure of the anaerobic fermentation equipment for organic waste provided by this utility model;

[0024] Figure 2This is a side view of the anaerobic fermentation equipment for organic waste provided by this utility model.

[0025] Figure 3 This is a schematic diagram of the arrangement of heating elements in the modular heating device provided by this utility model, wherein the density of the heating elements gradually decreases from left to right.

[0026] Figure 4 This is a perspective structural diagram of the premix processing device for fermenters provided by this utility model;

[0027] Figure 5 This is a schematic diagram of the stirring device in one embodiment of the anaerobic fermentation equipment for organic waste provided by this utility model;

[0028] Figure 6 This is a schematic diagram of the stirring device in another embodiment of the anaerobic fermentation equipment for organic waste provided by this utility model;

[0029] Figure 7 This is a schematic diagram of the stirring device in another embodiment of the anaerobic fermentation equipment for organic waste provided by this utility model.

[0030] In the above figures: 1-modular heating device, 11-heating body, 2-premixed material processing device, 21-feeding box, 211-feeding processing area, 212-secondary processing area, 213-feeding processing area, 22-mixing mechanism, 221-first positioning shaft, 222-first spiral blade, 223-first motor, 23-transporting mechanism, 231-second motor, 232-second spiral blade, 24-pushing mechanism, 25-steam mechanism, 26-weighing sensor, 27-camera, 3-fermentation tank, 4-discharge device, 5-stirring device, 51-main shaft, 52-stirring blade, 521-connecting rod, 522-lifting body, 5221-first material contact surface, 5222-last material contact surface, 6-micro-oxygen device. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that while the description of these embodiments is intended to aid in understanding the present invention, it does not constitute a limitation thereof. The specific structural and functional details disclosed herein are only for describing exemplary embodiments of the present invention. However, the present invention may be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0032] According to a first aspect of this disclosure, a modular heating device is provided for a fermenter. Wherein, Figures 1 to 7 A specific implementation example of this modular heating device is shown.

[0033] See Figures 1 to 7 As shown, the modular heating device 1 includes: a hot water tank for storing liquid; multiple manifolds, each manifold having its two ends connected to the hot water tank via pipes, with a first control valve and a first solenoid valve on the pipes, the first control valve being located near one end of the manifold; multiple heat collection mechanisms corresponding one-to-one with the manifolds, each heat collection mechanism connected to the manifold for heating the introduced liquid; a circulation pump connected to the pipes to circulate water between the hot water tank and the heat collection device; and multiple heating modules, each heating module spaced apart along the axial direction of the fermenter 3; each heating module includes multiple heating elements 11 arranged along the circumferential direction of the fermenter 3, the heating elements 11 made of thermally conductive material being connected in sequence; wherein, no heating module is provided in the top area of ​​the fermenter 3; the flow channels of the hot water tank, manifolds, pipes, heat collection mechanisms, and heating modules together form a circulating water circuit.

[0034] This modular heating device employs indirect heating via circulating hot water. A closed-loop circulating water circuit is formed by a hot water tank, manifolds, a heat collection mechanism, a circulating pump, and heating modules, achieving uniform and controllable heating of the fermenter 3. Its core principle is as follows: The heat collection mechanism (such as a solar collector, electric heater, or waste heat recovery device) heats the liquid (water or heat transfer oil) and distributes it to each heating module through the manifolds. The circulating pump drives the hot water to flow in the circulating water circuit, and the heat is transferred to the organic waste inside the fermenter 3 through the heat-conducting heating element 11. Multiple heating modules are spaced apart along the axial direction of the fermenter 3 to avoid localized overheating or uneven temperature distribution. No heating modules are installed at the top of the fermenter 3 to reduce heat loss and prevent crust formation. Precise temperature control in different areas is achieved by regulating the hot water flow in each manifold through a first control valve and a first solenoid valve.

[0035] The low-temperature liquid in the hot water tank is pumped to the heat collection mechanism, heated, and then flows into the manifold. Solenoid valves control the flow of hot water into designated heating modules based on temperature sensor signals. The hot water flows through the heat conductors of the heating modules, and heat is conducted to the fermentation material through the tank wall. The cooled liquid then flows back to the hot water tank, forming a closed-loop cycle. If the temperature in a certain area is lower than the set value (such as the hydrolysis reaction zone), the opening of the corresponding solenoid valve in the manifold increases, increasing the hot water flow. If the top temperature is too high, some valves can be closed to reduce heat input.

[0036] Through the aforementioned technological effects, the circulating water system reduces heat loss, lowering energy consumption by more than 30% compared to direct electric heating. Thermally conductive materials (such as stainless steel or copper) enhance the heat transfer efficiency of the heating element 11. Axial and circumferential segmented heating avoids "cold / hot zones," maximizing microbial activity. Unheated tops reduce moisture evaporation, prevent material drying and crusting, and improve gas release. Automated temperature control via valves and sensors adapts to different fermentation stages (e.g., mesophilic / high-temperature fermentation). This allows maintaining a temperature of 35–55°C (mesophilic / high-temperature fermentation range) during fermentation, accelerating hydrolysis and methanogenesis rates, and shortening residence time. Simultaneously, precise temperature control prevents sudden pH drops caused by VFA accumulation, ensuring the activity of methanogenic bacteria. This uniform heating method avoids localized anaerobic environment disruption, reducing abnormal CO2 and H2S emissions. Temperature stability improves the metabolic efficiency of methanogenic bacteria, increasing the CH4 content in biogas by 10%–20%. Compared to traditional steam heating, this effectively reduces the overall energy consumption of the circulating water system. By employing a closed-loop circulation and zoned temperature control design, the problems of uneven heating and high energy consumption in traditional fermenters are solved, significantly improving the stability and energy conversion efficiency of anaerobic fermentation. Its technological advantages directly translate into higher biogas production, lower operating costs, and reduced waste gas emissions, making it suitable for large-scale organic waste treatment scenarios.

[0037] In one embodiment provided in this disclosure, see [reference] Figure 2 As shown, heating elements 11 are embedded in both the inner and outer walls of the fermentation tank 3. The circumference of the inner wall of the fermentation tank 3 is F1, and the circumferential length of the heating element 11 on the inner wall of the fermentation tank 3 is F2, where F2 = (0.25~0.5)F1. That is to say, the heating element 11 only covers a portion of the inner wall circumference (25%~50%), forming an intermittent heat conduction surface to avoid overall overheating of the inner wall and material adhesion. The unheated area (low-heat zone) allows the material to settle naturally and its flowability to be adjusted, reducing stirring energy consumption. The low-heat zone of the inner wall provides operating space for mechanical scrapers or cleaning devices, avoiding maintenance difficulties caused by the heating element 11 covering the entire circumference.

[0038] The perimeter of the outer wall of fermenter 3 is F3, and the circumferential length of the heating element 11 on the outer wall of fermenter 3 is F4, where F4 = (0.8~0.9)F3. That is to say, the outer wall heating element 11 covers 80%~90% of the perimeter, compensating for insufficient heating of the inner wall through external main heating and maintaining the overall temperature stability of the tank. A 10%~20% non-heated area is reserved on the outer wall (such as inspection ports or sensor mounting positions) to balance functionality and thermal efficiency.

[0039] The above technical solution reduces the direct thermal contact area between the inner wall and the material, lowering the risk of instantaneous thermal shock to microorganisms in high-temperature zones (especially protecting methanogens). Radial heat diffusion through thermally conductive materials (such as stainless steel) achieves a uniform heat transfer from point heat source to surface. The outer wall, as the main heating surface, indirectly transfers heat through the thermal conductivity of the tank material (such as steel-lined PE), preventing localized overheating of the inner wall. A temperature gradient is formed between the unheated area (low-heat zone) and the heated area of ​​the inner wall, driving natural convection of the material (heat rise and cool fall), reducing reliance on mechanical stirring. High coverage of the outer wall ensures continuous heat replenishment during convection, preventing temperature stratification. Traditional full-circumference heating easily leads to rapid evaporation of moisture from materials near the inner wall, forming a hard crust. This design retains moisture in the low-heat zone, reducing the risk of crust formation. Therefore, through coordinated heating of the inner and outer walls, a temperature field distribution of "external main heat and internal auxiliary heat" is achieved, keeping the temperature difference of the material inside the tank within ±1℃, promoting balanced microbial community activity.

[0040] It should be noted that, for reference Figure 2 As shown, the areas of the inner and outer walls without heating elements 11 overlap, creating a low-heat zone that provides an escape path for bubbles (CH4 / CO2) and prevents the formation of a scum layer due to gas accumulation. A stable temperature field avoids localized acidification (VFA accumulation) and reduces abnormal emissions of H2S and CO2. Methanogens are more active in mild, warm environments, which helps increase the CH4 concentration in biogas.

[0041] To reduce heat loss, the modular heating device 1 also includes an insulation module (not shown in the figure). The insulation module is detachably wrapped around the outer periphery of the fermenter 3. The detachable design facilitates the maintenance of the heating element 11, the sensor or the tank, avoiding the problem of difficult maintenance of traditional fixed insulation layers.

[0042] The insulation module isolates the outer wall of fermenter 3 from the environment, suppressing convection and radiation heat loss and reducing overall heat loss. The heating load on the hot water tank and heat collection mechanism decreases, reducing the energy consumption of the circulating pump and improving the overall energy efficiency of the system. In low-temperature environments (such as winter), the insulation module can maintain internal temperature fluctuations of ≤±1℃, preventing a decrease in the activation of the microbial community due to temperature differences. The time for fermenter 3 to rise from room temperature to the target temperature (e.g., 35℃) is shortened, thereby accelerating the anaerobic fermentation start-up phase. During high-temperature fermentation (50–60℃), the insulation module reduces the need for additional heating; during mesophilic fermentation (30–45℃), natural heat dissipation is possible. Metal fatigue problems caused by temperature stress on the outer wall of the tank are mitigated, and the corrosion rate decreases.

[0043] Specifically, the insulation module is connected to the fermenter 3 via clips or screws. The clips (snap-on type) or screws allow for quick installation and removal of the insulation module, facilitating maintenance of the heating element 11, valves, sensors, or cleaning of the outer wall of the fermenter 3. Clips or screws ensure tight contact between the insulation module and the tank surface, reducing air gaps and preventing thermal bridging (localized heat loss) caused by loosening. Screw connections are suitable for heavy-duty or high-pressure tanks, while clips are suitable for lightweight applications or those requiring frequent maintenance.

[0044] The insulation module is equipped with a polyurethane layer. Polyurethane foam (PU) has a low thermal conductivity, effectively preventing heat loss. Compared to traditional rock wool or glass wool, polyurethane has a lower density, reducing the additional weight of the tank. The closed-cell structure of polyurethane prevents water vapor penetration, avoiding corrosion of the tank's outer wall due to condensation. Fire resistance standards can be improved by adding flame retardants to adapt to the flammable environment of biogas.

[0045] In one embodiment provided in this disclosure, the fermenter 3 is provided with a limiting groove, in which the heating element 11 is embedded. A groove (limiting groove) of a specific depth is machined into the inner / outer wall of the fermenter 3, and the heating element 11 (such as a metal heat-conducting pipe or electric heating element) is embedded therein, flush with or slightly convex to the surface of the tank. The size of the limiting groove matches the heating element 11, ensuring a tight fit and preventing loosening or displacement. The heating element 11 directly contacts the tank through the limiting groove, reducing contact thermal resistance and improving heat transfer efficiency (compared to external heating). Compared to external heating belts, the limiting groove embedding design prevents heat loss to the environment, making it particularly suitable for high-temperature fermentation (50–60°C). Under stirring or pump circulation conditions, the limiting groove fixes the heating element 11, preventing loosening or breakage due to vibration. The limiting grooves are regularly distributed along the axial / circumferential direction of the tank, making the layout of the heating element 11 more precise and eliminating local cold / hot zones.

[0046] Furthermore, a sealant layer is provided in both the heating element 11 and the limiting groove. The sealant layer uses a high-temperature resistant, high-thermal-conductivity (thermal conductivity ≥1.5W / m·K) silicone sealant or a ceramic-filled sealant. It fills the microscopic gaps between the heating element 11 and the limiting groove, reducing contact thermal resistance. It also prevents corrosive gases (such as H2S and water vapor) inside the fermenter 3 from penetrating to the joints of the heating element 11. The elastic sealant absorbs minor displacements caused by stirring or thermal deformation, preventing hard metal-to-metal contact wear. After the sealant fills the gaps, it effectively reduces the temperature difference between the tank walls, improving the activity stability of methanogenic bacteria. Under vibration conditions, the sealant also reduces the displacement of the heating element 11.

[0047] In one embodiment provided in this disclosure, see [reference] Figure 3As shown, fermenter 3 has an inlet and an outlet. Along the direction from the inlet to the outlet, the density of the heating element 11 in each heating module gradually decreases. During anaerobic fermentation, organic waste undergoes three stages sequentially along the flow direction: hydrolysis, acid production, and methanogenesis, adapting to the different temperature requirements of each stage. Intensive heating at the inlet rapidly hydrolyzes recalcitrant substances such as cellulose / lignin, shortening the residence time. Moderate heating in the middle section prevents excessive accumulation of VFAs (volatile fatty acids) and improves pH stability. For materials containing straw, manure, etc., high temperature at the front end breaks the encapsulation effect, while low temperature at the back end prevents scum caking. When the feed concentration fluctuates, the system automatically adjusts the reaction rate through temperature gradients, thereby improving gas production stability.

[0048] Specifically, the density can be reduced by 15% to 20% per meter of channel. Furthermore, temperature probes can be installed at each density change point, for example, using fiber optic temperature measurement to avoid electromagnetic interference.

[0049] In one embodiment provided in this disclosure, each heating module is provided with a length of L1 along the axial direction of the fermenter 3, and the length of the fermenter 3 is L2, where L2 = (0.5~0.8)L1. By shortening the length of the heating module (relative to the length of the fermenter), a heating zone (L1) and a non-heating transition zone (L2~L1) are formed along the axial direction of the fermenter 3. The heating zone (L1) concentrates energy to maintain efficient hydrolysis / acidification; the transition zone (L2~L1) is the suitable temperature for methane (30~38°C). The axial temperature difference promotes the natural partitioning of hydrolytic bacteria (front end) and methanogenic bacteria (back end), improving the population efficiency by more than 20%.

[0050] Compared to full-length heating, the transition zone provided in this disclosure utilizes residual heat from the material to maintain the reaction, reducing the frequency of heating module start-up and shutdown. The density difference between the heated and non-heated zones is approximately 15 kg / m³. 3 This drives material circulation, reducing stirring energy consumption. When the feed concentration changes abruptly, the transition zone acts as a buffer and effectively reduces gas production fluctuations. The non-heated zone has a higher surface humidity, preventing scum from hardening (especially for high-fat materials such as kitchen waste).

[0051] In one embodiment provided in this disclosure, the modular heating device 1 further includes a temperature detection mechanism and a pressure detection mechanism that are communicatively connected to the controller. The temperature detection mechanism is used to detect the current water temperature information in the heating body 11, and the pressure detection mechanism is used to detect the current water pressure information in the circulating water circuit. The controller is also communicatively connected to the first solenoid valve and the circulating pump to control the first solenoid valve and the circulating pump to perform corresponding actions according to the current water temperature information and the current water pressure information.

[0052] The temperature detection mechanism monitors the water temperature of the heating element 11 and feeds it back to the controller to dynamically adjust the opening of the solenoid valve and the pump speed to maintain the set temperature. By identifying the temperature differences between each heating module, the solenoid valves in abnormal areas are adjusted first (local correction) to avoid overall system fluctuations. Temperature stability improves the metabolic efficiency of methanogenic bacteria, which can increase methane concentration to some extent. Pre-adjusting the heating power according to the feed temperature (e.g., 5℃ in winter, 25℃ in summer) can reduce steam consumption.

[0053] Pressure detection systems provide high-pressure protection, reducing pump speed and simultaneously releasing pressure to lower the risk of pipe bursts. When pressure is <0.2MPa, leak detection is triggered, allowing operators to quickly locate the fault based on controller information and perform timely maintenance, minimizing waiting time. Circulation resistance is calculated using differential pressure, enabling intelligent pump speed adjustment and thus reducing energy consumption. Pressure fluctuation frequency analysis (e.g., >5Hz prompts for pipe cleaning) extends equipment lifespan.

[0054] By fusing temperature and pressure data (e.g., high temperature and low pressure indicating vaporization triggering emergency cooling), the controller can predict trends (e.g., a temperature rise rate of 0.1℃ / min indicating overheating risk). Through a closed-loop "monitoring-decision-execution" system, the heating system is upgraded from passive maintenance to intelligent pre-control, becoming the core guarantee for the efficient and stable operation of anaerobic fermentation equipment. In this way, when the water temperature exceeds the limit, the solenoid valve opening is adjusted first (local correction); when the overall temperature deviation is >2℃, the pump speed is adjusted accordingly (system-level control). For feed temperature fluctuations (e.g., low-temperature raw materials in winter), the control response delay is <30 seconds. When the pressure is >0.8MPa, the pump speed can be reduced to prevent pipe bursting; when the pressure is <0.2MPa, an alarm is triggered to detect leaks.

[0055] It should be noted that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist simultaneously.

[0056] According to a second aspect of this disclosure, a fermentation tank is provided.

[0057] The fermenter includes a modular heating device 1 as described in the first aspect, and therefore has the same technical effects as the modular heating device 1. Precise temperature control helps to maximize microbial activity and increase methane yield. Heating energy consumption is reduced through the coordinated setting of dynamic heat load distribution and insulation modules.

[0058] According to a third aspect of this disclosure, a premix processing apparatus for a fermenter is provided.

[0059] The premix processing device for the fermenter includes: a feed box 21 for containing materials, the feed box 21 having a stepped feed processing zone 211, a secondary processing zone 212, and a feeding processing zone 213, the two ends of the secondary processing zone 212 being connected to the feed processing zone 211 and the feeding processing zone 213 respectively; the feed processing zone 211, the secondary processing zone 212, and the feeding processing zone 213 are arranged in a stepped manner to allow the materials to fall; and a mixing mechanism 22, located in the feed processing zone 211, for mixing the materials and allowing the materials to flow from the feed processing zone. The material is introduced into the secondary processing zone 212 from zone 211, and the dry matter content of the feeding zone 211 is 20% to 40%; the conveying mechanism 23 is provided in the secondary processing zone 212 and the feeding zone 213, and is used to stir the material and introduce the material from the secondary processing zone 212 to the feeding zone 213; the pushing mechanism 24 is provided in the feeding zone 213, and is used to push the material into the fermentation tank 3; and the steam mechanism 25 has a plurality of nozzles, which are provided on the inner wall of the feeding zone 211 and face the material, for introducing hot steam onto the material.

[0060] The working principle of the premixed material processing device for the fermenter is as follows: the material sequentially passes through the feeding processing zone 211 → secondary processing zone 212 → feeding processing zone 213, naturally falling due to the height difference (stepped design) to reduce the energy consumption of mechanical conveying. Specifically, in the feeding processing zone 211, the dry matter content is controlled at 20%–40%; in the secondary processing zone 212, the conveying mechanism 23 performs fine mixing (breaking up agglomerates and homogenizing); in the feeding processing zone 213, the pushing mechanism 24 quantitatively pushes the material into the fermenter 3. Low-pressure saturated steam is injected through nozzles, and the steam volume is dynamically adjusted based on feedback from temperature and humidity sensors.

[0061] The premix processing unit 2 operates as follows: In the feeding zone 211, after the material enters, the mixing mechanism 22 (such as a paddle mixer) performs primary crushing, while hot steam is injected through steam nozzles. In the secondary processing zone 212, the conveying mechanism 23 (such as a screw conveyor) further mixes the material and detects the material uniformity (using a NIR sensor). In the feeding zone 213, the hydraulic pusher mechanism 24 pushes the material into the fermentation tank 3 at a constant rate to avoid feeding impact.

[0062] The above technical solutions can homogenize materials, increase the contact area with microorganisms, and shorten hydrolysis time. Furthermore, precise control of dry matter can increase CH4 production from 0.15 to 0.45 mg / L. 3 / kg VS. Steam pretreatment reduces pH fluctuations and prevents acidification collapse. Pathogen elimination reduces H2S generation. In conjunction with modular heating unit 1: the temperature of the premixed material is increased to 40℃~50℃, reducing the heating load on fermenter 3. This premixed material treatment unit 2, through an innovative combination of "physical classification and thermochemical conditioning," becomes a key pretreatment system for the efficient and stable operation of fermenter 3, especially suitable for the treatment of organic waste with complex composition and high solids content.

[0063] Furthermore, the nozzles located in the feed processing zone 211 are inclined, with the angle of inclination gradually decreasing from top to bottom relative to the horizontal direction. This facilitates the maximum diffusion of steam, ensuring sufficient contact with the material and guaranteeing the quality of material pretreatment, thereby aiding in the fermentation of the material in the fermenter.

[0064] In one embodiment provided in this disclosure, the steam mechanism 25 includes a steam generating unit, a steam distribution cylinder, and an ejector connected in sequence. The steam generating unit is used to provide steam. Multiple ejectors are arranged at intervals on the inner wall of the feeding processing area 211. Each ejector is connected to a steam distribution cylinder. A pressure reducing valve is provided between the steam distribution cylinder and the ejector. The pressure reducing valve is communicatively connected to a controller.

[0065] Working principle: High-pressure saturated steam is directly injected into the material (liquid / slurry) through nozzles or perforated pipes. The high-speed flow of steam creates turbulence, thoroughly mixing with the material. Upon contact with the low-temperature material, the steam rapidly condenses, releasing latent heat. The condensate mixes with the material, while the sensible heat of the steam (cooling down to the material temperature) also transfers some heat. Through stirring or natural convection, the heat is evenly distributed throughout the feeding and processing area 211.

[0066] The high-pressure steam generated by the steam generator is evenly distributed to multiple injectors to avoid uneven flow rates among nozzles. The controller dynamically adjusts the pressure of each branch to adapt to the dry matter requirements of different materials. High-speed steam injection into the material creates localized turbulence, which facilitates the release of latent heat from steam condensation, directly heating the material; while condensate replenishes the material's moisture content. Therefore, a pressure reducing valve prevents branch pressure from exceeding limits, avoiding the risk of pipe rupture.

[0067] Multiple ejectors cover the entire feed zone, eliminating steam dead zones and reducing the standard deviation of material moisture content. Steam instantly kills pathogens (such as E. coli), reducing the risk of spoilage within fermenter 3. The steam distributor allocates steam as needed, contributing to energy savings. The ejector design promotes complete steam condensation, reducing heat loss. For highly viscous materials (such as sludge), high-pressure injection breaks down the colloidal structure; while for fibrous materials (such as straw), low-pressure steam prevents excessive hydrolysis. The dual utilization of latent and sensible heat improves steam energy conversion efficiency. Linkage with material sensors enables millisecond-level closed-loop control of dry matter.

[0068] Furthermore, the feeding processing area 211 is equipped with a second temperature detection mechanism connected to the controller. This second temperature detection mechanism detects the current temperature information in the feeding processing area 211. Based on this current temperature information, the controller accordingly controls the operating status of the pressure reducing valve and the ejector. The second temperature detection mechanism monitors the material temperature in the feeding processing area 211 in real time, generating a feedback signal that is transmitted to the controller. This dynamically adjusts the opening of the pressure reducing valve and the start / stop of the ejector, maintaining precise control within ±1℃ (e.g., 55℃) of the set temperature, avoiding energy waste or insufficient heating caused by excessive steam. The temperature signal is coupled with parameters such as dry matter content and steam pressure for calculation (e.g., using PID algorithms in existing technologies) to achieve multi-variable coordinated control. This enables homogenized heating, reducing the difference in cellulose / starch hydrolysis rates due to temperature uniformity; simultaneously, it provides protection against pathogen inactivation, stably maintaining a temperature of 55℃~60℃ (the Salmonella inactivation threshold), thus significantly improving the sterilization rate. This allows for a leap from "extensive supply" to "precise dosing" of steam heating; the temperature signal is linked with dry matter and pressure parameters to construct an intelligent pretreatment model. This design, through a closed-loop temperature feedback system, makes the premixing treatment device an "intelligent thermostat injector" for the fermentation system, making it particularly suitable for treating high-value wastes such as temperature-sensitive kitchen waste and livestock manure.

[0069] In one embodiment provided in this disclosure, the mixing mechanism 22 includes a first positioning shaft 221, a first spiral blade 222, and a first motor 223. The first positioning shaft 221 is inserted into the feeding processing area 211 and connected to the feeding box 21 through a first bearing. The drive shaft of the first motor 223 is connected to the first positioning shaft 221. The first spiral blade 222 is spirally arranged along the first positioning shaft 221 and fixedly connected to the positioning shaft.

[0070] Through the above technical solution, the first spiral blade 222 is spirally arranged along the positioning axis and rotated by a motor, forming a two-way mixing effect of axial propulsion and radial diffusion. Along the axial direction, the inclined surface of the blade pushes the material towards the secondary processing zone 212; along the radial direction, the shear force at the blade edge breaks up clumps, achieving material tumbling. The velocity gradient generated by the spiral blade (blade tip > center) promotes interlayer friction of the material, enhancing mixing. The rotation of the spiral blade increases the contact area between steam and material by 35 times, improving heat and mass transfer efficiency. The vortex generated by the spiral blade increases the steam penetration depth, improving the utilization rate of condensation heat. Forced mixing reduces the standard deviation of dry matter distribution, meeting the feeding requirements of fermenter 3 and improving the gas production gain and operational stability of fermenter 3.

[0071] In one embodiment provided in this disclosure, the conveying mechanism 23 includes a second motor 231 and a second spiral blade 232, wherein the second spiral blade 232 is disposed in the feed box 21, and both ends of the spiral blade are rotatably connected to the feed box 21 through a second positioning shaft; the second motor 231 is drivenly connected to one of the second positioning shafts; when the second motor 231 rotates, the second positioning shaft drives the second spiral blade 232 to rotate for pushing materials.

[0072] The low-speed rotation of the second helical blade 232 achieves fine homogenization of the material, breaking up lumps that were not fully mixed in the initial stage. High-speed rotation provides stable thrust, forcing the material into fermenter 3 at a constant flow rate (e.g., 2.5 t / h). The axial arrangement of the helical blades reduces the equipment height and the lateral torque acting on the main shaft. Homogenized feeding increases the contact area between microorganisms and the microorganisms, allowing the peak methane yield to be reached earlier. The stable flow rate avoids sudden load changes in fermenter 3 and helps reduce pH fluctuations, thus ensuring stable and reliable fermentation.

[0073] In this disclosure, the pushing mechanism 24 is configured as a utility model patent entitled "Straw and Livestock Manure Pumping System" (publication number CN209456266U). This system pushes the material into the fermentation tank.

[0074] In this disclosure, the feed box 21 includes a cover and a body. The cover is formed to fit the body and is movably disposed on top of the body. The cover and body fit tightly together (optionally with a silicone sealing strip) to prevent dust (such as straw fragments) or odor (H2S, NH3) from escaping during pretreatment, thus meeting environmental emission standards.

[0075] In one specific embodiment, the lid can be connected to the box body via a hydraulic rod / hinge, thereby enabling one-button opening and closing (opening angle 70°~90°).

[0076] Furthermore, a transparent window (such as a polycarbonate panel) can be designed on the lid to monitor the material status in real time and avoid overfilling.

[0077] For ease of operation, the lid is equipped with a handle. The handle (usually U-shaped or horizontal bar design) provides a point of leverage, allowing a single person to open and close the lid.

[0078] Furthermore, a corrugated anti-slip texture or rubber coating can be used on the handle surface to maintain a grip strength of >50N when operating with wet gloves.

[0079] In this disclosure, the feed box 21 is made of metal, and at least the inner wall of the feed box 21 is corrosion-resistant. Using corrosion-resistant metal (such as 316L stainless steel) or corrosion-resistant coating (such as polytetrafluoroethylene PTFE) for the inner wall can improve the durability of the feed box 21, which is beneficial to ensuring the service life of the feed box 21, while reducing the impact on the feed box 21.

[0080] In one embodiment provided in this disclosure, a weighing sensor 26 is provided on the bottom wall of the feeding processing area 211 to weigh the current weight information of the material in the feeding processing area 211; the weighing sensor 26 is communicatively connected to a controller, and the controller is communicatively connected to the mixing mechanism 22, the conveying mechanism 23, the pushing mechanism 24 and the steam mechanism 25, so as to control the mixing mechanism 22, the conveying mechanism 23, the pushing mechanism 24 and the steam mechanism 25 to perform corresponding actions according to the current weight information of the material.

[0081] Weighing sensor 26 can monitor the weight of materials in the feeding processing area 211 in real time, replacing the traditional batch metering method and realizing continuous dynamic weighing. The weighing data is fed back to the controller, and when the weight is exceeded (e.g., the weighing data > 120% of the design value), an audible and visual alarm is triggered, and the feeding rate is automatically reduced. By precisely controlling the feeding amount, the fluctuation of the organic load rate (OLR) of the fermenter 3 is reduced, increasing the stability of methane yield. The steam injection volume is linearly adjusted according to the weight of the material, avoiding waste of "small material, large steam" and saving steam costs.

[0082] In this disclosure, the feeding processing area 211 is equipped with a camera 27, which is communicatively connected to the controller. Based on the camera 27, the status of the material can be captured in real time using a high-definition camera (such as a 2-megapixel industrial camera). This includes observing the material's moisture content (through surface reflection analysis), the size of material clumps (image segmentation algorithms detect clumps >5cm), and the presence of foreign objects (alarms for abnormal objects such as metal and plastic). This records the entire pre-processing process and supports playback analysis of fault causes. Image analysis of dry matter distribution allows for dynamic optimization of steam injection volume, reducing energy consumption and improving efficiency. Detection of metal foreign objects prevents damage to subsequent equipment (such as spiral blades), reducing maintenance costs.

[0083] According to a fourth aspect of this disclosure, an anaerobic fermentation device for organic waste is provided.

[0084] The anaerobic fermentation equipment for organic waste includes: a fermentation tank 3, mounted on a substrate, having a feed end and a discharge end positioned opposite each other, wherein the feed end is equipped with a premixing device 2 and the discharge end is equipped with a discharge device 4; a stirring device 5, used to stir the material in the fermentation tank 3, the stirring device 5 including a main shaft 51 and stirring blades 52 mounted on the main shaft 51, wherein the main shaft 51 is eccentrically positioned relative to the fermentation tank 3 such that the distance between the stirring blades 52 and the top wall of the fermentation tank 3 is greater than the distance between the stirring blades 52 and the bottom wall of the fermentation tank 3; a micro-oxygen device 6, connected to the fermentation tank 3, used to supply oxygen to the fermentation tank 3; and a modular heating device 1, mounted on the fermentation tank 3, used to heat the material.

[0085] The working principle of the anaerobic fermentation equipment for organic waste is as follows: In the pretreatment stage, the premix treatment device 2 homogenizes and conditions the raw materials (controlling the dry matter content to 20%–40%) and kills pathogens. In the main fermentation stage, the eccentric stirring and modular heating device 1 maintains the anaerobic environment and promotes the microbial chain reaction of hydrolysis → acid production → methanogenesis. In the post-treatment stage, the discharge device 4 stably discharges the residue, avoiding disturbance to the activated sludge layer.

[0086] The eccentric setting of the main shaft 51 causes it to deviate from the center of the tank, forming an asymmetric flow field (large gap at the top and small gap at the bottom). This causes the large bubbles at the top to break up (enhancing gas-liquid mass transfer), while the strong shear force at the bottom prevents sedimentation. Furthermore, the precise injection of trace amounts of oxygen (DO < 0.1 mg / L) through the micro-oxygen device 6 can stimulate the activity of facultative bacteria and accelerate hydrolysis.

[0087] During fermentation, the large gap at the top prevents the scum layer from clogging the stirring shaft and promotes biogas release; while the small gap at the bottom prevents sand and gravel deposition due to high shear force, reducing wear rate. Pulsed oxygen supply improves hydrolysis efficiency without disrupting the anaerobic environment. Modular heating device 1 (such as a hot water jacket) is linked to the stirring mechanism to improve temperature uniformity. Eccentric stirring increases the cellulose contact area, reducing hydrolysis time; microaerobic stimulation enhances the activity of methanogens, increasing the CH4 content. Coordinated temperature and stirring control reduces pH fluctuations, which is beneficial for fermentation.

[0088] In one embodiment provided in this disclosure, the stirring device 5 includes: a drive motor for providing driving force; a main shaft 51 disposed in a fermentation tank 3, with both ends rotatably connected to the fermentation tank 3 via second bearings; and a plurality of stirring blades 52, each stirring blade 52 including a connecting rod 521 and a lifting body 522, wherein the connecting rod 521 is spirally arranged along the axial direction of the main shaft 51, and both ends of the connecting rod 521 are respectively fixedly connected to the main shaft 51 and the lifting body 522.

[0089] The working principle of the mixing device 5 is as follows: the spirally arranged connecting rod 521 pushes the material along the main shaft 51, forming a longitudinal circulation (speed 0.3-0.6 m / s). The rotating lifting body 522 generates centrifugal force, causing the material to disperse radially towards the tank wall. The bowl-shaped structure of the lifting body 522 scoops up bottom sediment on the rising side, achieving material exchange between the bottom and top. The continuous curved surface of the spiral connecting rod 521 disrupts the laminar boundary layer, allowing high-solids materials to still be effectively mixed. When the lifting body 522 rotates, a low-pressure zone is formed on its back, promoting the release of biogas bubbles.

[0090] The drive motor starts at low speed to avoid sudden torque increases that could damage the bearings. The lifting body 522 scrapes the bottom of the tank, raising the settled sludge to the upper middle part; the spiral connecting rod 521 pushes the material axially; and the edges of the lifting body 522 break up large air bubbles.

[0091] In practical applications, the material can be periodically reversed (5 rpm, 30 seconds) to clean the tangled fibers from the back side of the lifting body 522, thereby ensuring its performance.

[0092] The bowl-shaped structure (its diameter is typically 1 / 3 the length of the main shaft 51) has a 10-15mm gap with the bottom of the tank, creating a forced scraping effect to prevent anaerobic caking of the bottom material (common in livestock and poultry manure fermentation). The rotating material body 522 generates Taylor vortices, increasing the contact area between biogas and liquid.

[0093] Furthermore, serrations can be provided on the rim of the lifting body 522 to break up the foam layer and prevent scum from accumulating.

[0094] Furthermore, along the rotation direction of the main shaft 51, the lifting body 522 has a material-contacting surface 5221 and a material-contacting surface 5222, wherein the extension length of the material-contacting surface 5222 is greater than the extension length of the material-contacting surface 5221. The asymmetrical structure of the lifting body 522 allows the material-contacting surface (short side) to quickly cut into the material, reducing starting resistance; while the material-contacting surface (long side) can prolong the action time, forming continuous lift (similar to the Bernoulli effect of an airfoil).

[0095] When the lifting body 522 rotates, it generates an asymmetric vortex. On the short side, a high-speed zone is formed to break up clumps; while on the long side, a low-pressure zone (suction effect) is formed to lift the bottom material. The short side's initial contact surface reduces direct impact with the sediment, lowering the wear rate, while the long side's rear contact surface scoops up the sediment in a "bucket" shape, improving conveying efficiency. Thus, the dual function of the short side acting as a shearing agent and the long side lifting the material facilitates the tail vortex generated at the end of the long side, promoting biogas release and shortening bubble residue time.

[0096] Furthermore, along the radial direction away from the main shaft 51, the opening size of the lifting body 522 gradually increases. The gradually expanding opening forms a diffusion channel, which reduces the flow velocity of the material as it leaves the main shaft 51; the flow direction changes from radial to axial to dominant. For the near-axial region (small opening), high shear breaks up the fiber clumps; while for the far-axial region (large opening), low shear protects the methanogenic flocs.

[0097] The gradually expanding structure reduces fluid separation losses and provides better energy savings compared to straight-blade designs. The small opening end creates strong disturbances, thus renewing the boundary layer material; while the large opening end creates a wide flow field, covering the distant dead zone. High-density materials such as sand and gravel aggregate and break down due to centrifugal force in the small opening area; lightweight fibers are uniformly dispersed along the large opening channel.

[0098] In one embodiment provided in this disclosure, the distance between the stirring blade 52 and the bottom wall of the fermentation tank 3 is at least 1 meter, and the distance between the stirring blade 52 and the top wall of the fermentation tank 3 is at least 1.5 meters.

[0099] The large gap at the bottom (≥1m) provides sufficient space to accommodate the sediment layer (such as sand, gravel, and non-biodegradable solids), preventing the mixing blades from directly scraping the bottom. This reduces wear and extends blade life. A low-speed circulation zone (0.1–0.3 m / s) is created at the bottom of the blades, allowing heavy particles to settle naturally while lighter materials are entrained and lifted. The large gap at the top (≥1.5m) provides space for gas-liquid separation, creating an expansion zone for biogas bubbles, increasing their diameter and rising speed. In the crushing zone, the rotating blades shear large bubbles, improving the release rate. This design prevents blade disturbance from breaking up the scum layer and reduces foam entrainment.

[0100] Dividing the vertical space of the tank into a sedimentation zone (bottom), a reaction zone (middle), and a separation zone (top) helps the material ferment efficiently; the spacing setting can better match the sedimentation characteristics of microorganisms; and the bottom gap serves as a "safety buffer" to prevent the agitator from overloading and touching the bottom.

[0101] In one embodiment provided in this disclosure, the anaerobic fermentation equipment for organic waste further includes a limiting device, which includes a support frame and a third bearing. The support frame is fixedly installed in the fermentation tank 3. The third bearing is coaxially arranged with respect to the main shaft 51 and connected to the support frame. The main shaft 51 is inserted into the inner ring of the third bearing.

[0102] The limiting device provides dynamic support. Specifically, when the main shaft 51 rotates, the inner ring of the third bearing rotates with the main shaft 51, while the outer ring is fixed to the tank body by the support frame, constraining the radial runout of the main shaft 51. Simultaneously, the bearing end face engages with the shoulder of the main shaft 51 to prevent axial movement of the stirring blades 52. The bending moment generated by the stirring torque is distributed to the tank wall through the support frame, avoiding stress concentration at the root of the main shaft 51. When the material suddenly thickens (e.g., due to fiber entanglement), causing a surge in torque, the bearing temperature sensor triggers an alarm. This limits the oscillation of the main shaft 51, making the stirring flow field more stable, and the support frame controls the deflection of the main shaft 51 within a certain range, reducing mechanical vibration.

[0103] In one embodiment provided in this disclosure, the inclination angle of the fermenter 3 is 1‰ to 3‰ of the total length of the fermenter body. This inclination angle allows bottom sediments (such as sand and gravel, and non-degradable solids) to slide along the slope towards the lower sludge collection area, preventing accumulation across the entire bottom of the tank and reducing the sediment layer thickness from 30-50 cm to 10-15 cm. The light liquid phase flows upwards under the influence of gravity, forming a continuous microcirculation, promoting contact between the material and microorganisms, and reducing dead zones in the mixing process.

[0104] In one embodiment provided in this disclosure, the micro-oxygen device 6 is configured as two sets and both are located at the feed end of the fermenter 3. The air nozzle of the micro-oxygen device 6 is located in the lower region of the fermenter 3 and is spaced apart from the stirring blade 52.

[0105] The micro-oxygen device 6 injects trace amounts of oxygen (DO 0.05–0.1 mg / L) during the organic matter hydrolysis stage (feed end), stimulating the activity of facultative bacteria (such as Bacillus) and increasing the cellulose decomposition rate. Simultaneously, it improves the conversion efficiency of volatile fatty acids (VFA). The micro-oxygen device 6 is spaced apart from the stirring blades 52 to prevent the airflow from being directly sheared away by the blades. The oxygen supply design, through "precise positioning, micro-control, and biosynergy," decouples the hydrolysis and methanation stages, improving overall efficiency.

[0106] In one embodiment provided in this disclosure, the discharge device 4 includes a third motor and a third spiral blade. The third spiral blade is disposed in the fermentation tank 3, and one end of the spiral blade is connected to the fermentation tank 3 through a third positioning shaft. The third motor is driven to the third positioning shaft. When the third motor rotates, the third positioning shaft drives the third spiral blade to rotate, so as to push the material out of the fermentation tank 3.

[0107] The discharge device 4 adopts a variable pitch design (large pitch at the feed end and small pitch at the discharge end). During rotation, the large pitch rapidly collects materials (flow rate 0.4–0.6 m / s); while the gradually narrowing pitch increases the pushing pressure (up to 0.15 MPa), overcoming the liquid level resistance inside the fermenter 3. The gap between the blades and the tank wall is ≤3 mm to prevent material backflow. The third motor starts at low speed (15 rpm) to avoid hydraulic shock. The spiral blades push the fermentation residue from the bottom of the tank to the discharge port. At the same time, the squeezing action causes the free liquid to flow back to the reaction zone; the low-pressure area on the back of the blades promotes the desorption of residual biogas.

[0108] In this disclosure, the anaerobic fermentation equipment for organic waste also includes a detection device communicatively connected to the controller. The detection device includes one or more of a pressure sensor, a liquid level detector, a temperature sensor, and a torque sensor. The pressure sensor is used to detect the current pressure information in the fermenter 3, the liquid level detector is used to detect the current liquid level height in the fermenter 3, the temperature sensor is used to detect the current temperature information in the fermenter 3, and the torque sensor is disposed on the main shaft 51 and / or the stirring blade 52 to detect the current torque information. The detection device also includes one or more of a methane sensor, a pH sensor, a hydrogen sulfide sensor, and a CO2 / O2 concentration analyzer.

[0109] When the temperature sensor detects an abnormal temperature rise (e.g., >60℃), the modular heating device 1 is automatically adjusted and pressure is released to avoid a chain reaction of "overheating, sudden increase in gas production, and overpressure". When pH <6.2 and ORP >200mV, the alkali addition system is triggered to prevent acidification collapse.

[0110] The torque sensor detects an increase in viscosity (such as fiber accumulation) and automatically increases the stirring speed (by 10%) to prevent localized sedimentation.

[0111] The methane sensor regulates the micro-oxygen device 6 in real time, stabilizing the DO concentration during the hydrolysis stage at 0.05–0.1 mg / L and increasing the hydrolysis rate. When the CO2 / O2 analyzer detects CO2 > 40%, it automatically adjusts the feed rate or pH to increase the CH4 content to > 60%.

[0112] If the pressure sensor detects a sudden drop in air pressure (such as a pipeline leak), it can quickly shut off the intake valve and trigger an alarm.

[0113] The level detector identified an abnormal rise in foam. Torque trend analysis predicted wear on the spindle bearing 51, allowing for advance scheduling of maintenance.

[0114] In one embodiment provided in this disclosure, the micro-oxygen device 6 and the discharge device 4 are each configured as two sets, and are respectively arranged in the lower area of ​​the fermenter 3.

[0115] Two sets of air nozzles for the micro-oxygenation device 6 are diagonally distributed at the bottom of the fermenter 3, covering 80% of the cross-sectional area and forming a cross-flow. The double-helix discharge shafts are arranged in parallel, enabling bidirectional material delivery and improving residue discharge efficiency. When one set of micro-oxygenation devices 6 fails, the other set can still maintain 50% of its processing capacity, thus ensuring the reliability of the system during operation. The two sets of air nozzles work together to optimize the dissolved oxygen (DO) gradient from 0.05–0.3 mg / L (single set) to 0.08–0.15 mg / L (dual sets), thereby enhancing the activity of facultative bacteria.

[0116] It should be noted that the pressure sensor, level detector, temperature sensor, torque sensor, methane sensor, pH sensor, hydrogen sulfide sensor, and CO2 / O2 concentration analyzer disclosed herein are all equipped with existing detection instruments. Those skilled in the art can select any suitable detection instrument according to actual needs.

[0117] According to the fifth aspect of this disclosure, a process method for an anaerobic fermentation device for organic waste is provided.

[0118] The process of the anaerobic fermentation equipment for organic waste includes the following steps: conveying materials into the fermentation tank 3; acquiring first material information in the fermentation tank 3, the first material information including current gas composition information, gas temperature information, gas humidity information, and gas pressure information; acquiring second material information in the fermentation tank 3, the second material information including material temperature information and material solid-liquid ratio information; and controlling the premix processing device 2, stirring device 5, micro-oxygen device 6, modular heating device 1, and discharge device 4 to perform corresponding actions based on the first material information and the second material information.

[0119] The specific process flow of the anaerobic fermentation equipment for organic waste is as follows:

[0120] The material enters through the premixing device 2 (stepped feed box 21), and is then subjected to steam conditioning (controlling dry matter content to 20%–40%) and crushing and homogenization by the mixing mechanism 22 (spiral blades).

[0121] The steam volume is dynamically adjusted based on feedback from the weighing sensor 26; the mixing speed (20-60 rpm) is automatically adjusted based on the material viscosity (torque sensor).

[0122] Two sets of micro-oxygen devices 6 inject a small amount of oxygen (DO 0.05~0.1mg / L) into the lower part of the feed end to stimulate the activity of facultative bacteria.

[0123] After the material enters the fermenter 3, the eccentric stirring device 5 (main shaft 51 and spiral blades) operates, forming a three-dimensional flow field. At the top (gap 1.5m), there is a degassing zone, which can break up large bubbles; while at the bottom (gap 1m), a strong shear zone is formed to prevent sedimentation.

[0124] The double-screw discharge device 4 squeezes the residue, and the free liquid flows back to the reaction zone.

[0125] Torque sensor for overload protection, level detector for overflow protection.

[0126] Through the aforementioned technological methods, the entire process can be optimized through "precise pretreatment, intelligent fermentation, and efficient recovery," and closed-loop control based on multi-sensor feedback can adapt to complex raw material fluctuations. This improves biogas quality and residue calorific value, opening up new pathways for energy utilization, and is particularly suitable for the large-scale treatment of organic waste with high solids content, high sulfur, and high fiber content.

[0127] Finally, it should be noted that this utility model is not limited to the above-described optional embodiments, and anyone can derive other various forms of products under the guidance of this utility model. The above specific embodiments should not be construed as limiting the scope of protection of this utility model, which should be determined by the claims, and the description can be used to interpret the claims.

Claims

1. A modular heating device for a fermenter, characterized in that, include: Hot water tanks are used to store liquids; Multiple manifolds are configured, and each manifold is connected to the hot water tank at both ends by pipes. A first control valve and a first solenoid valve are provided on the pipes, with the first control valve located at one end close to the manifold. The heat collection mechanism is configured in multiple ways, each corresponding to one of the manifolds. Each heat collection mechanism is connected to the manifold and is used to heat the introduced liquid. A circulation pump, connected to the pipe, allows water to circulate between the hot water tank and the heat collection device. In addition, there are multiple heating modules, each spaced apart along the axial direction of the fermentation tank; each heating module includes multiple heating elements arranged along the circumferential direction of the fermentation tank, and the heating elements made of thermally conductive material are connected in sequence; wherein, the top area of ​​the fermentation tank is not equipped with the heating modules; the hot water tank, manifold, pipe, heat collection mechanism and the flow channel of the heating module together form a circulating water circuit.

2. The modular heating device according to claim 1, characterized in that, The heating element is embedded in both the inner and outer walls of the fermentation tank. The circumference of the inner wall of the fermentation tank is F1, and the length of the heating element in the circumferential direction of the inner wall of the fermentation tank is F2, where F2 = (0.25~0.5)F1. The circumference of the outer wall of the fermentation tank is F3, and the length of the heating element in the circumferential direction of the outer wall of the fermentation tank is F4, where F4 = (0.8~0.9)F3.

3. The modular heating device according to claim 2, characterized in that, The modular heating device also includes a heat preservation module, which is detachably wrapped around the outer periphery of the fermenter.

4. The modular heating device according to claim 3, characterized in that, The insulation module is connected to the fermentation tank via a clamp or screws; the insulation module is equipped with a polyurethane layer.

5. The modular heating device according to claim 1, characterized in that, The fermenter is provided with a limiting groove, and the heating element is embedded in the limiting groove.

6. The modular heating device according to claim 5, characterized in that, The heating element and the limiting groove are provided with a sealing layer.

7. The modular heating device according to claim 1, characterized in that, The fermenter has an inlet and an outlet. Along the direction from the inlet to the outlet, the density of the heating element in each heating module gradually decreases.

8. The modular heating device according to claim 1, characterized in that, Each heating module is provided with a length of L1 along the axial direction of the fermentation tank, and the length of the fermentation tank is L2, where L2 = (0.5~0.8)L1.

9. The modular heating device according to any one of claims 1 to 8, characterized in that, The modular heating device also includes a temperature detection mechanism and a pressure detection mechanism that are communicatively connected to the controller. The temperature detection mechanism is used to detect the current water temperature information in the heating element, and the pressure detection mechanism is used to detect the current water pressure information in the circulating water circuit. The controller is also communicatively connected to the first solenoid valve and the circulating pump to control the first solenoid valve and the circulating pump to perform corresponding actions according to the current water temperature information and the current water pressure information.

10. A fermentation tank, characterized in that, Includes the modular heating device as described in any one of claims 1 to 9.

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