Rotating Disc Cell Disruption Device with Pressure Reduction
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Solution Overview
Problem
Conventional methods for disrupting cell walls of microorganisms and algae in sludge are costly and inefficient, requiring high-energy ultrasonic waves, chemical decomposition, or mechanical disruption, which are costly and inefficient, and often necessitate complex equipment for alkali treatment or heating.
Innovation Solution
A cell wall or cell membrane disrupting device with a simple construction comprising a fixed disc, rotating disc, rotating shaft, pressure reducing means, and housing, applying shearing force and reducing pressure to facilitate efficient disruption without the need for alkali treatment or heating, using a pressure reducing means such as a land or submersible pump to create a differential pressure and enhance cavitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high energy disruption methods (ultrasonic waves, chemical decomposition, mechanical disruption) are used to disrupt cell walls, then cell wall disruption is achieved, but operational costs increase and equipment complexity increases
Solution Approach 1:
The patent replaces complex mechanical disruption systems (homogenizers, mills) and high-energy systems (ultrasonic waves, chemical decomposition) with a simple rotating disc device that generates cavitation through rotational motion. The rotating disc creates low-pressure zones that induce cavitation bubbles, which then collapse to produce mechanical shock waves that disrupt cell walls, achieving effective disruption with minimal equipment complexity.
Solution Approach 2:
The patent changes the operational parameters by controlling rotational speed of the disc (500-5000 rpm) and water content of target substance (89% or higher) to optimize cavitation generation. By adjusting these parameters, the system achieves effective cell wall disruption without requiring complex equipment or high energy input, resolving the contradiction between effectiveness and simplicity.
2Reliability
If conventional mechanical disruption methods (homogenizer, mill) are used to disrupt cell walls, then cell wall disruption is achieved, but treatment efficiency is low and equipment size increases
Solution Approach 1:
The patent utilizes mechanical vibration in the form of cavitation - rapid formation and collapse of bubbles created by rotational motion of the disc. This cavitation generates intense local mechanical energy that efficiently disrupts cell walls, achieving high treatment efficiency without requiring large-scale mechanical disruption equipment, thus resolving the contradiction between effectiveness and productivity.
3Productivity
If alkali treatment or heating is used to facilitate cell wall disruption, then disruption efficiency is improved, but operational costs and equipment complexity increase
Solution Approach 1:
The patent employs a self-service mechanism where the rotating disc itself generates the energy needed for disruption through cavitation. The rotational kinetic energy of the disc directly creates low-pressure zones that form cavitation bubbles, which then collapse to provide the disruptive force. This eliminates the need for external energy input in the form of heating or chemical treatment, achieving high disruption efficiency while minimizing operational costs.
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 device significantly reduces operational costs, maintains active ingredients, and enhances the efficiency of sludge treatment, biogas fermentation, fertilizer production, and oil recovery by effectively disrupting cell walls without complex equipment, improving digestion efficiency and reducing sludge volume.
Implementation Method 1
the pressure inside the cell wall or cell membrane disrupting device is reduced to no greater than −0.08 MPa by the pressure reducing means
Implementation Method 2
shearing force generated between the rotating disc and the fixed disc is applied to a target fluid
Data Source
AI summary
Provided is a cell wall or cell membrane disrupting device whereby cell walls and/or cell membranes of microorganisms, algae and the like contained in organic sludge and the like are disrupted, the device comprising a fixed disc, a rotating disc, a rotating shaft for driving of the rotating disc, a pressure reducing means and a housing, wherein at least one pair of the fixed disc and rotating disc are disposed facing each other, the center section of the fixed disc has a hollow section that is larger than the outer diameter of the rotating shaft passing through the center section, shearing force generated between the rotating disc and the fixed disc is applied to a target fluid having a water content of 89% or higher that has been loaded into the device, and the pressure inside the cell wall or cell membrane disrupting device is reduced to no greater than −0.08 MPa by the pressure reducing means. The device can contribute to increasing biogas, reducing sludge, culturing of algae, plant cultivation and culturing of marine products, and also to separation of CH4 and CO2, for example, as resources.