Horizontal Fermentation Propeller for Continuous Biogas Production
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Solution Overview
Problem
Traditional biogas fermentation devices face challenges such as batch-type continuous production, large dry fermentation compartment volumes, incomplete fermentation due to back mixing, difficulty in homogeneous inoculation, and low reaction efficiency due to high solid content agitation and material displacement issues.
Innovation Solution
A large-type horizontal device and method for continuous methane fermentation using two-phase anaerobic techniques, with a U-shaped fermentation compartment design, spiral material transportation, counter-rotating material propellers, and air agitation to facilitate homogeneous inoculation and agitation, separating hydrolytic acidification and methanogenesis processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large-scale batch-type fermentation devices are used, then fermentation capacity is increased, but continuous production cannot be achieved and fermentation time becomes too long
Solution Approach 1:
The fermentation system is divided into multiple independent fermentation tanks (first fermentation tank, second fermentation tank, third fermentation tank, fourth fermentation tank) that operate in parallel. This segmentation allows continuous production by while one tank is being fermented, another can be prepared or discharged, maintaining continuous output while using manageable tank sizes
Solution Approach 2:
The system implements continuous operation through multiple tanks working in sequence and parallel. Materials are continuously fed into available tanks, and fermented materials are continuously discharged from completed tanks, eliminating idle time and achieving continuous production without requiring excessively large single-tank capacity
2Productivity
If large volume fermentation compartment is used, then fermentation capacity is increased, but material agitation becomes non-homogeneous and displacement is difficult
Solution Approach 1:
Instead of using one large fermentation compartment, the system uses multiple smaller fermentation tanks (each 100-200m³). These smaller volumes allow effective material agitation and homogeneous mixing while the overall system capacity is maintained through parallel operation of multiple tanks
Solution Approach 2:
The system transitions from a single large-volume approach to a multi-tank parallel arrangement, effectively adding a dimensional aspect to the fermentation capacity. The total capacity is achieved through the sum of multiple smaller units rather than one large unit, solving the agitation problem while maintaining productivity
3Productivity
If high solid content materials are used, then dry fermentation efficiency is improved, but material displacement and agitation become difficult
Solution Approach 1:
The system divides the fermentation process into multiple smaller tanks, each handling manageable volumes of high solid content materials. This segmentation makes material displacement feasible through localized agitation devices in each tank while maintaining the high solid content necessary for dry fermentation efficiency
Solution Approach 2:
The system replaces traditional mechanical agitation methods with gas-phase agitation (using air or nitrogen bubbles) to mix high solid content materials. This substitution avoids the mechanical complexity and difficulty of agitating viscous, high-solid materials while maintaining effective mixing and displacement
4Device complexity
If mesotherm fermentation is used, then process simplicity is maintained, but reaction efficiency is low due to inability to separate hydrolytic acidification and methanogenesis
Solution Approach 1:
The fermentation process is segmented into two separate stages occurring in different tanks: hydrolytic acidification stage (in first and second fermentation tanks at 35°C) and methanogenesis stage (in third and fourth fermentation tanks at 55°C). This segmentation enables optimized reaction efficiency for each stage while maintaining overall process simplicity through standardized tank designs and operations
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 continuous, complete fermentation with reduced fermentation time, uniform agitation, and efficient material displacement without mixing, achieving higher biogas production and lower operational costs through the use of a reinforced concrete compartment design and gas agitation.
Implementation Method 1
a material propeller which is arranged at the bottom of the fermentation compartment and rotates in spiral along the fermentation direction
Implementation Method 2
The fermentation bacteria are propagated in the fermented materials, and the fermented materials are used for inoculating the materials to be fermented
Implementation Method 3
utilize biomass resource and control the pollutant emission by biomass efficiently
Implementation Method 4
agitation approach for a lot of materials
Data Source
AI summary
A large-type horizontal device and a method for continuous methane fermentation. The whole distribution of a fermentation compartment uses a U-shape plane layout, which is a snap-back type and uses a material propeller. The material propeller has two axes and two blades and is constantly occluded with counter rotation. The irreversible propulsion of materials can be realized through counter rotation of two occluded blades. The propeller is set at the bottom of the main partition of the fermentation compartment. The propel ability of propeller can be changed through changing of rotation speed. Counter rotation of two occluded blades can realize material propeller without material reverting. The inlet and outlet entrances of the reactor in the disclosure are near to the ground and can be operated conveniently. The homogeneous output of materials and entire plug-flow can be realized at the same time without material mixing in the whole process.