Biogas Substrate Viscosity Reduction for Heavy Component Separation
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Solution Overview
Problem
High viscosity of substrates in biogas plants hinders efficient separation of heavy components like sand, grit, and stones by gravity, and diluting the substrates would compromise the anaerobic process's economics, leading to sediment buildup and operational inefficiencies.
Innovation Solution
A method and device that utilize the natural reduction in viscosity within the fermenter by mixing fresh substrates with low-viscosity contents, promoting sedimentation through pneumatic circulation and targeted mixing, allowing for effective separation of heavy components without disrupting the anaerobic process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gravity separation methods are used to separate heavy components, then separation of sand, grit and stones is attempted, but the high viscosity of the starting substrate prevents efficient separation
Solution Approach 1:
The patent changes the viscosity parameter of the substrate by mixing the highly viscous starting substrate with low-viscosity fermenter contents. This parameter change enables gravity-based separation methods to work effectively, as the reduced viscosity allows sand, grit and stones to settle properly in the sedimentation chamber.
Solution Approach 2:
The fermenter contents act as an intermediary medium that facilitates separation. By introducing this intermediate substance with different viscosity properties into the starting substrate, the patent creates a mixed medium that enables efficient gravity separation while maintaining process economics.
2Productivity
If the substrate is diluted by adding media to reduce viscosity, then separation efficiency improves, but the economics of the anaerobic process is significantly jeopardized
Solution Approach 1:
The system uses its own fermenter contents (which are already present in the biogas plant) to dilute and reduce the viscosity of the starting substrate. This self-service approach avoids the need to add external media, thereby maintaining substrate concentration within economically acceptable ranges while still achieving effective separation.
Solution Approach 2:
The fermenter contents serve multiple functions: they act as a diluting agent to reduce viscosity, provide a medium for gravity separation, and maintain the anaerobic process economics by avoiding external additive costs. This multi-functionality resolves the contradiction between separation efficiency and economic viability.
3Productivity
If sediment layers build up in anaerobic reactors, then separation has not been effective, but mechanical removal requires considerable effort and causes business interruption
Solution Approach 1:
The patent performs separation action preliminarily, before the substrate enters the main anaerobic reactor. By removing sand, grit and stones in advance in the sedimentation chamber, the patent prevents sediment buildup in the reactor, eliminating the need for subsequent mechanical removal operations and ensuring continuous operation.
Solution Approach 2:
The invention extracts heavy components (sand, grit, stones) from the starting substrate before it enters the anaerobic reactor. This extraction prevents these components from accumulating in the reactor, thereby avoiding the need for complex mechanical removal systems and maintaining continuous operation without business interruption.
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
Enables efficient separation of sand, grit, and stones at the inlet of the fermenter, reducing mechanical effort and costs associated with sediment removal, while maintaining the economic viability of the biogas plant operations.
Implementation Method 1
by pneumatic circulation such as blowing in/injecting gas
Implementation Method 2
a rotating flow and thus a turbulence of fresh starting substrate with the fermenter contents
Implementation Method 3
heavy components such as sand, grit and stones sinking, the sediments are collected
Implementation Method 4
The tube apparatus is inclined enough to allow sediments to slide down by gravity
Implementation Method 5
An injector flow is generated by the inflowing fresh starting substrate, which draws the contents of the fermenter into the jacket tube 9
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method and device for separating heavy components such as sand, grit, and stones from a high viscosity starting substrate of biogas plants. In order to promote sedimentation, the starting substrate is diluted to reduce the viscosity thereof by mixing it with fermenter content the viscosity of which is reduced as a result of decomposition processes.