Bioreactor Mist for Explosion Prevention
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Solution Overview
Problem
Bioreactors face a risk of explosion due to the presence of flammable gases and oxygen in the gaseous sky, which can lead to significant safety and economic challenges in biogas production.
Innovation Solution
A misting device generates a non-flammable liquid mist with droplets less than 1 mm in diameter, capable of absorbing heat radiation, trapping oxygen, and reducing the oxygen content, thereby reducing or eliminating the risk of explosion by maintaining high humidity and preventing energy transfer during potential ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bioreactor is designed to withstand thermal explosion, then safety is improved, but economic profitability deteriorates due to considerable costs
Solution Approach 1:
The system performs preliminary action by injecting a non-flammable gas (nitrogen or carbon dioxide) into the bioreactor before the explosive conditions can develop. This proactive measure prevents the formation of an explosive atmosphere by displacing oxygen, thereby avoiding the need for expensive explosion-resistant reactor designs while maintaining safety
Solution Approach 2:
A non-flammable gas acts as an intermediary substance between the flammable biogas and the oxygen in the air. This intermediary gas creates a physical barrier that prevents the ignition and propagation of explosions, protecting the bioreactor without requiring it to be built with expensive explosion-resistant materials
2Reliability
If the bioreactor is designed to withstand thermal explosion, then safety is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary action by injecting a non-flammable gas (nitrogen or carbon dioxide) into the bioreactor before the explosive conditions can develop. This proactive measure prevents the formation of an explosive atmosphere by displacing oxygen, thereby avoiding the need for expensive explosion-resistant reactor designs while maintaining safety
Solution Approach 2:
A non-flammable gas acts as an intermediary substance between the flammable biogas and the oxygen in the air. This intermediary gas creates a physical barrier that prevents the ignition and propagation of explosions, protecting the bioreactor without requiring it to be built with expensive explosion-resistant materials
3Reliability
If liquid mist is generated to reduce explosion risk, then safety is improved, but liquid consumption increases
Solution Approach 1:
The system changes the parameter of droplet size by using ultrasonic vibration to generate extremely fine mist with droplet diameters of 1 micrometer or less. This parameter change dramatically increases the surface area to volume ratio, allowing much lower liquid consumption (0.01-10 mL/m³) while maintaining effective explosion prevention through enhanced heat absorption and oxygen displacement
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
The liquid mist effectively reduces the risk of explosion by absorbing thermal radiation, maintaining high humidity, and lowering oxygen levels, allowing for safe biogas production with minimal liquid consumption, even in aerobic fermentations, thus enhancing operational safety and economic viability.
Implementation Method 1
The absorption of thermal radiation by the liquid mist reduces the risk of ignition of the gaseous sky by heating
Implementation Method 2
The liquid mist allows cooling of the internal walls of the bioreactor in its upper part. This reduces the risk of mechanical bursting due to gas compression
Implementation Method 3
The liquid mist makes it possible to lower the oxygen content of the gaseous sky by dissolving in droplets of this liquid at least a part of the residual oxygen contained in the gas leaving the reaction medium
Data Source
Figure 1
AI summary
Biogas is produced using a bioreactor (5) comprising a reaction medium and a gaseous headspace (4) above the reaction medium. A misting device (2, 3, 9) generates a mist of non-flammable liquid in the gaseous headspace (4) of the bioreactor (5) by misting. The non-flammable liquid mist comprises droplets with a nominal diameter of less than 1 mm, so that the non-flammable liquid mist is capable of absorbing thermal radiation and trapping oxygen. This reduces, or even eliminates, the risk of explosion in the bioreactor (5).