Waste Milling Machine with Blunt Tools for Biogas Substrate
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Solution Overview
Problem
Existing biogas substrate manufacturing processes face challenges in achieving high dry solids content and efficient separation of foreign objects like plastics, metals, and glass, often requiring multiple steps, liquid addition, and energy input, with potential for machine breakdowns and high operational costs.
Innovation Solution
A multi-functional machine that integrates sorting, washing, and milling capabilities, using a rotating shaft with blunt tools and a stationary counter-tool to process organic waste into suitable particle size without liquid addition or heating, while separating and washing foreign bodies, allowing for handling various packaging types without preliminary sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pulping technique is used to handle heavily polluted waste, then the ability to process mixed waste is improved, but the dry solids value decreases due to liquid addition
Solution Approach 1:
The process is divided into separate stages: first mechanical sorting and separation of foreign objects, then milling of organic material, and finally washing of separated components. This segmentation allows each stage to optimize for its specific function without compromising the overall dry solids content.
Solution Approach 2:
Foreign objects (plastics, metals, glass) are extracted and separated from the organic waste stream before processing. This extraction prevents contamination of the biogas substrate while allowing the organic material to be processed at high dry solids content without dilution.
2Manufacturing precision
If conventional milling machine is used, then particle size control is improved, but the risk of machine breakdown increases due to foreign objects
Solution Approach 1:
Foreign objects are separated and removed from the waste stream before the milling process. This preliminary action prevents foreign objects from entering the mill, eliminating the risk of machine breakdown while maintaining precise particle size control during milling.
Solution Approach 2:
Metal detectors and sorting mechanisms extract and remove foreign objects (metals, plastics, glass) from the waste stream before it enters the milling stage, protecting the milling machinery from damage while ensuring consistent particle size output.
3Measurement precision
If multiple processing stations are used, then the separation efficiency is improved, but the device complexity increases
Solution Approach 1:
Multiple functions (sorting, separating foreign objects, milling, and washing) are merged into a single integrated machine. The machine combines mechanical sorting, metal detection, milling, and washing capabilities in one unit, reducing the number of separate processing stations while maintaining high separation efficiency.
Solution Approach 2:
The machine is designed with multi-functionality, capable of handling various types of waste (food waste, green waste, etc.) and performing multiple operations (sorting, separating, milling, washing) within a single device, thereby reducing overall system complexity.
4Ease of operation
If liquid is added during processing, then the processing ability is improved, but the transport cost increases due to low dry solids value
Solution Approach 1:
Washing is applied selectively and partially - only to the separated foreign objects and not to the entire organic waste stream. This partial washing provides sufficient cleaning capability while minimizing liquid addition, thereby maintaining high dry solids content and reducing transport 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 machine produces biogas substrate with high dry solids content, efficiently separates and washes foreign objects, reducing operational costs and energy consumption, and maintains the integrity of soft packaging materials like plastics and netting, enabling direct processing of mixed waste without preliminary sorting or liquid addition.
Implementation Method 1
A rotating shaft (4) with at least one tool (5) attached to its circumference and a stationary counter-tool (6) are mounted in the interior chamber (3)... the tools (5) and the counter-tool (6) are adjusted in such a manner that a distance exists between them... solid parts of the waste are milled into smaller particles
Implementation Method 2
The tools (5) and the counter-tool (6) are adjusted in such a manner that a distance exists between them which is adapted so as to achieve a milling effect on the solid parts of the waste for grinding into smaller particles when they pass between the tool (5) and the counter-tool (6)
Implementation Method 3
Hot steam is introduced into the interior chamber (3) through nozzles (7)... the steam breaks up the adhering organic waste and washes the foreign bodies clean
Implementation Method 4
Hot steam is introduced into the interior chamber (3) through nozzles (7)... the steam breaks up the adhering organic waste and washes the foreign bodies clean
Data Source
Figure 1
Figure 2
AI summary
A machine for providing organic particles preferably substrate for use in manufacturing biogas, the machine comprising; an intake for input of moist and dry organic waste to the machine's interior chamber, where the organic waste may contain foreign bodies such as soft packaging, preferably plastics, netting and binding twine, as well as metal and glass, etc.; a rotating shaft located in the chamber and provided with at least one tool which is positioned at the circumference of the shaft, the tool/tools having a blunt shape; a stationary part mounted in the chamber, where the stationary part acts as the tool's counter-tool; an outlet for milled particles; an ejector for foreign bodies, the distance between the tool and the stationary part being of such a size that a milling effect is achieved on the waste's solid parts for grinding up into smaller pieces, while the extent of the distance prevents a grinding effect from being exerted on the waste's softer parts such as plastics. The application further comprises a method for providing organic particles, preferably substrate for use in manufacturing biogas.