Gas-Permeable Base Heating for Fermentation Residue
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Solution Overview
Problem
Existing devices for treating fermentation residues require excessive energy due to the inefficiency of heating digestate, as air is repeatedly heated and cooled, leading to prolonged treatment periods and high energy consumption.
Innovation Solution
A device with a gas-permeable base in the treatment tank allows heated air to distribute evenly and directly heat the digestate from below, combined with a heating device in the vicinity of the digestate for efficient thermal conduction, reducing energy loss and the number of reheating cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is blown through the base plate into the digestate to heat it, then the heated air can be distributed homogeneously in the digestate, but the process requires a large number of cycles and consumes large amounts of energy
Solution Approach 1:
The heating system is segmented into multiple heating zones within the base plate, allowing different regions to be heated independently or simultaneously. This segmentation enables more efficient heat distribution and reduces the need for repeated full-cycle heating, thereby lowering energy consumption while maintaining homogeneous temperature distribution in the digestate.
Solution Approach 2:
The base plate is preheated before the digestate is introduced or before the heating cycle begins. This preliminary heating action reduces the overall heating time and energy required during the main treatment process, as the heating medium is already at the required temperature when contact with the digestate occurs.
2Temperature
If air is repeatedly heated and blown through the digestate, then the digestate can be heated, but the treatment period becomes very lengthy
Solution Approach 1:
The heating process is made continuous through the base plate design, where heat is constantly applied from below while the digestate is being processed. This eliminates the need for repeated heating cycles, as the heating action continues uninterrupted throughout the treatment period, significantly reducing the overall heating duration while achieving the required temperature.
Solution Approach 2:
The base plate and heating system are prepared in advance, with heating elements pre-positioned and preheated. This preliminary preparation ensures that when the digestate is introduced, the heating process can begin immediately without delay, reducing the total treatment time required to achieve the desired temperature.
3Temperature
If a large amount of air is used for heating the digestate, then the heating effect can be achieved, but the energy required to heat the air increases significantly
Solution Approach 1:
The heating function is extracted from the air stream and transferred to the base plate heating system. Instead of relying on hot air as the primary heating medium, the base plate directly provides thermal energy to the digestate from below. This extraction eliminates the need to continuously heat large volumes of air, significantly reducing energy consumption while maintaining effective heating of the digestate.
Solution Approach 2:
The base plate serves as an intermediary heating element between the heat source and the digestate. Rather than heating air that then transfers heat to the digestate, the base plate directly conducts heat to the digestate bottom surface. This intermediary approach creates a more efficient heat transfer pathway, reducing the energy required to achieve the desired heating effect.
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 approach significantly reduces energy consumption and enhances heating efficiency, allowing for faster treatment with lower energy input while minimizing heat loss and the need for repeated air reheating.
Implementation Method 1
a heating device 5 is provided in the soil in the direct vicinity of the digestate 2, which is preferably provided in the soil 3 and is flowed through by means of a pump 5b with a heating medium heated via the heater 5a. As a result, the substrate to be treated is heated as a result of direct thermal conduction.
Implementation Method 2
a gaseous medium (hereinafter air) can be blown under pressure from a line 6 into the container via one or more inlets 4 via a blower 6b. The air blown into the container can be supplied as fresh air via a valve 6c and/or removed from the container 1 as exhaust air via one or more outlets 1a.
Data Source
Figure 1
Figure 2
AI summary
The device for the treatment of fermentation residue (2) or fermentation residue mixture, comprises a base (3) for the deposition of the fermentation residue. The base is formed in gas-permeable manner and has an inlet device for supplying a gaseous medium in the base, mounting to a line (6). The parts of the areas of the base flow through from the gaseous medium for aerating the fermentation residue. A heating element is arranged in the area of the base. The base is a part of a container for the reception of the fermentation residue or fermentation residue mixture. The device for the treatment of fermentation residue (2) or fermentation residue mixture, comprises a base (3) for the deposition of the fermentation residue. The base is formed in gas-permeable manner and has an inlet device for supplying a gaseous medium in the base, mounting to a line (6). The parts of the areas of the base flow through from the gaseous medium for aerating the fermentation residue. A heating element is arranged in the area of the base. The base is a part of a container for the reception of the fermentation residue or fermentation residue mixture. The container has an outlet device for discharging the gaseous medium present in the container. The device for supplying a gaseous medium is connected with a line. The outlet device and the inlet device are connected to each other for recycling the gaseous medium over the line. The line is turned so that it is fed alternatively or supplementary to the gaseous medium coming from the outlet device, from external of the container with fresh air. The heating device for heating the gaseous medium flowing through the line is arranged in the line. An independent claim is included for a method for operating a device for the treatment of fermentation residue.