Hygienisation Unit for High Solids Biogas Feedstock
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Solution Overview
Problem
Existing hygienization units are poorly suited for processing high solids content raw materials due to challenges in supply and removal from batch processing containers, and they lack efficiency in achieving the required thermal treatment for biogas production as per European regulations.
Innovation Solution
A continuously operating hygienization unit with a pressure-resistant tortuous pipe, utilizing a piston pump for feeding and pressurizing raw material, and heat transfer through the pipe for heating, along with control systems to maintain temperature and pressure for effective hygienization without chemical reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batch processing hygienisation unit is used, then hygienisation can be performed, but processing of high solids content raw material is difficult due to supply and removal challenges
Solution Approach 1:
The patent implements continuous hygienisation through a horizontal reactor where raw material is continuously fed, heated, and discharged. This eliminates the batch processing steps that cause operational difficulties with high solids content materials, allowing continuous flow while maintaining effective hygienisation temperatures and residence times.
Solution Approach 2:
Instead of vertically feeding material into a batch container as in conventional designs, the patent uses horizontal feeding with a screw conveyor system. This inversion of the feeding approach allows high solids content material to be easily supplied and removed horizontally, solving the operational difficulty while maintaining hygienisation effectiveness.
2Temperature
If conventional heating methods are used, then heating can be achieved, but energy efficiency is low and thermal treatment requirements may not be met
Solution Approach 1:
The continuous heating process ensures that material is constantly exposed to hygienisation temperatures without interruption. The screw conveyor maintains continuous movement through the heated zone, ensuring all material receives adequate thermal treatment while minimizing energy loss from heating and cooling cycles associated with batch processing.
Solution Approach 2:
The patent replaces conventional external heating methods with internal friction heating generated by the screw conveyor mechanism. The mechanical energy of the screw is converted to thermal energy through friction between material particles and between material and the screw flights, achieving hygienisation temperatures without external fuel consumption.
3Reliability
If batch processing is used, then hygienisation can be performed, but processing time and productivity are reduced
Solution Approach 1:
The continuous operation allows uninterrupted processing of high solids content raw material through the hygienisation reactor. Material flows continuously through the heated zone with controlled residence time, maintaining reliable hygienisation while achieving high processing throughput compared to batch methods that require loading, heating, holding, and unloading cycles.
Solution Approach 2:
The screw conveyor speed and rotation are dynamically adjusted to control material residence time in the heated zone. This dynamic control ensures adequate hygienisation time is provided for all material while optimizing throughput, allowing the system to adapt to different material types and hygienisation requirements.
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 hygienization of high solids content raw materials with controlled dwell time and temperature, preventing pathogen kill and nitrogen separation, improving biogas production efficiency while reducing energy waste and space requirements.
Implementation Method 1
piston pump arranged to feed the raw material into the tortuous pipe in a solids content of at least 15% - 35%
Implementation Method 2
heating equipment arranged outside the pipe for heating raw material inside the pipe by the effect of heat transferred through the pipe
Implementation Method 3
gate valve arranged between the pump and the space for preventing the return flow of raw material
Implementation Method 4
second gate valve arranged at the end of the delimited space in the direction of motion of raw material for closing the delimited space to increase pressure
Implementation Method 5
hygienisation temperature sufficient in terms of the duration of hygienisation or pressure sterilisation for hygienising raw material
Data Source
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AI summary
The invention relates to a hygienisation unit for hygienising or pressure sterilising raw material fed to a biogas reactor, the hygienisation unit being continuously operating and the hygienisation unit (10) including - a delimited space (12) for a high solids content raw material, the delimited space (12) being a pressure resistant tortuous continuous pipe (20), - feed equipment (14) for feeding the suppliable raw material to the space (12), the feed equipment (14) including a piston pump (22) for feeding raw material, - heating equipment (16) arranged outside the pipe (20) for heating raw material in said space (12), - measuring equipment (18) for measuring the temperature and pressure of the raw material existing in the space (12), - control equipment (40) arranged to control said feed equipment (14) and heating equipment (16) for adjusting the raw material dwell time and the hygienisation temperature sufficient in terms of the duration of hygienisation or pressure sterilisation for hygienising raw material based on the measurement of the measuring equipment (18). The invention is also related to a method.