Fermenter Preshaped Bottom Element Design
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Solution Overview
Problem
The construction of concrete fermentation tanks for biogas plants is challenging due to buoyant forces acting on the formwork, and existing fermenter designs lack efficient methods for maintaining the shape and contour of the inner bottom surface.
Innovation Solution
A fermenter design utilizing a preshaped bottom element with a flexible coupling element attached to a concrete wall, allowing movement and maintaining the shape under load, combined with a grouting material for support and a heater for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a concrete fermentation tank is constructed using traditional formwork methods, then the tank structure can be built, but the buoyant forces acting on the formwork make the construction difficult and complex
Solution Approach 1:
The fermenter is divided into modular components: pre-shaped bottom elements, wall sections, and coupling elements. This segmentation allows each component to be manufactured separately with simpler formwork, avoiding the complex buoyant force management required for monolithic concrete construction. The modular approach enables easier assembly while reducing overall construction complexity.
Solution Approach 2:
The bottom elements are pre-shaped and pre-manufactured before assembly into the full fermenter structure. This preliminary action allows the complex geometries to be created using simpler, smaller formworks that do not need to withstand full buoyant forces during construction. The pre-shaped elements are then easily assembled into the final structure.
2Manufacturing precision
If traditional formwork methods are used for concrete tanks, then the tank can be constructed, but maintaining a defined contour of the inner bottom surface is difficult
Solution Approach 1:
The bottom surface is defined by separate pre-shaped bottom elements rather than monolithic formwork. Each element can be precisely shaped using simple formworks, and the cumulative effect of assembling multiple elements creates the precise overall contour. This segmentation maintains manufacturing precision while simplifying the manufacturing process.
Solution Approach 2:
The approach changes the parameter of shape definition from monolithic formwork geometry to assembled pre-shaped elements. This parameter change allows precise contours to be achieved through the assembly of simpler components, maintaining both precision and ease of manufacture.
3Stability of the object's composition
If the bottom element is rigidly fixed to the wall, then structural stability is improved, but the ability to accommodate movements and maintain sealing is reduced
Solution Approach 1:
The coupling element provides a dynamic connection between the bottom element and the wall, allowing for controlled movements while maintaining structural stability. The flexible coupling adapts to thermal expansion, settlement, and other movements, preventing sealing failures while maintaining the integrity of the structure.
Solution Approach 2:
The coupling element functions as a flexible connector that bridges the bottom element and the wall. This flexible connection accommodates relative movements and thermal effects while maintaining both structural stability and sealing integrity, resolving the contradiction between rigidity and adaptability.
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 the construction of fermenters with a defined inner bottom surface contour, reducing deformation and sediment formation, while allowing for easy access and maintenance, and effectively managing hydrostatic pressures.
Implementation Method 1
The flexible part allows a movement of the preshaped bottom element relative to the wall
Implementation Method 2
effectively managing hydrostatic pressures
Data Source
Figure 1
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AI summary
It is described a fermenter (100) comprising a wall (102); and a preshaped bottom element (106) defining the contour of an inner bottom surface of the fermenter. The preshaped bottom element (106) has an outer surface portion (108), the outer surface portion (108) facing the wall (102) and being laterally spaced from a lower part of the wall (102). The fermenter (100) may be built by providing lateral walls (102), placing the preshaped bottom element (106) between the lateral walls (102) and providing a sealing element (128) between the preshaped bottom element (106) and each of the walls (102).