Biogas Percolate Sanitization via Segmented Tank Design

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Solution Overview

Problem

Conventional biogas plants face challenges in sanitizing percolate for use as liquid fertilizer without recontamination, as the sanitized percolate becomes contaminated again when returned to the fermenter in existing systems.

Innovation Solution

A biogas plant design with a separate sanitizing tank, where excess percolate is transferred and heated to a temperature between 45° and 65°C for at least five days using thermophilic bacterial processes, preventing recontamination and allowing for continuous biogas production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If percolate is sanitized in the percolate tank as part of the percolate circuit, then sanitation is achieved, but the sanitized percolate becomes recontaminated when returned to the fermenter

Engineering Contradiction:

Improvesanitation qualityVSAvoidrecontamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The system divides the percolate handling into two separate circuits: a percolate circuit for fermentation process and a sanitation circuit for treatment. The percolate tank is split into a first portion (in percolate circuit) and a second portion (in sanitation circuit), allowing independent operation and preventing cross-contamination between sanitized and unsanitized percolate

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sanitation function is extracted from the percolate circuit by creating a separate sanitation circuit with dedicated tanks and flow paths. This extraction allows the sanitized percolate to be treated separately and prevents it from being recontaminated by returning to the fermenter through the percolate circuit

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If percolate is continuously circulated between fermenter and percolate tank, then fermentation process is maintained, but permanent sanitation cannot be achieved

Engineering Contradiction:

Improvefermentation continuityVSAvoidsanitation permanence

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The percolate tank is segmented into two separate portions with distinct functions: the first portion maintains circulation for fermentation productivity, while the second portion provides permanent sanitation by being isolated from the fermenter return path

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system maintains continuous fermentation through the percolate circuit while simultaneously achieving permanent sanitation in the separate sanitation circuit. Both processes occur continuously without interfering with each other

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If sanitized percolate is returned to fermenter for reuse, then resource efficiency is improved, but pathogen and weed seed contamination occurs

Engineering Contradiction:

Improvepercolate reuseVSAvoidpathogen contamination

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The sanitation function is extracted into a separate circuit, allowing percolate to be sanitized without being returned to the fermenter. The sanitized percolate can be used for fertilization purposes while unsanitized percolate continues circulating in the fermentation process

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary sanitation circuit that acts as a barrier between the fermenter and the final application of percolate. This intermediary system ensures that any percolate applied to fields has undergone permanent sanitation without requiring return to the fermenter

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method ensures sanitized percolate is maintained for use as a safe liquid fertilizer, preventing recontamination and reducing the need for repeated sanitization, while allowing for simultaneous biogas production.

Implementation Method 1

heating to a temperature between 45° and 65°C for at least five days using thermophilic bacterial processes

Methodology Applied

Scientific EffectThermophilic bacterial processes: Fermentation

Data Source

PatentUS9957201B2Producing liquid fertilizer in a biogas plant

Publication Date: 2018.05.01 BEKON GMBH

AI summary

A biogas plant produces both methane and liquid fertilizer by fermenting biomass. The plant includes a fermenter, a percolate tank and a sanitation tank located inside the percolate tank. Dry fermentation takes place in the fermenter and generates methane and a percolate. The percolate is circulated between the fermenter and the percolate tank. Percolate that is returned from the percolate tank to the fermenter is sprinkled over the biomass. A portion of the percolate is transferred from the percolate tank into the sanitation tank. The percolate in the sanitation tank is sanitized by heating to a Celsius temperature between 45° and 65° for a period of at least five days. The percolate in the sanitation tank is heated using both a heating device in the sanitation tank as well as heat generated from a thermophilic fermentation reaction occurring in the percolate tank. The sanitized percolate is used as liquid fertilizer.