BioCut

The universal pump system

Cost-effective pumping thanks to optimally coordinated components
Reliable conveying of a wide range of challenging media
Separation of heavy material and treatment of disruptive matter before the pump
Compact design and minimal space requirements
Service and maintenance can be performed quickly and easily on site

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Biogas

BioCut - the universal and flexible pump system for biogas plants

In biogas plants, many different kinds of liquid media need to be conveyed, possibly after first being extracted from pits and treated. These media generally contain a high proportion of solid matter and fibrous components, as well as disruptive matter such as branches, chunks of hooves etc., and they are normally viscous and laden with foreign matter. These properties and characteristics are problematic for pumping, they lead to damage and malfunctions, and they have a negative impact on the efficiency of the biogas plant.
The BioCut was developed specifically to master challenging pumping tasks. The pump system combines a rotary lobe pump from the VX series and a RotaCut in a special type of construction that makes the overall unit extremely compact in its dimensions. Taking up minimal space, the BioCut acts as the central pump system, ensuring that heavy material like stones and metal parts are reliably separated out of the liquid manure, organic suspension or other fluids. At the same time, the BioCut shreds any disruptive matter in the fluid, such as biomass, and homogenizes the medium, which can then be pumped without difficulty. In addition, this thorough treatment reduces the tendency to form a floating crust and it lowers the viscosity. Indirectly, this results in lower input energy consumption, and the improved treatment has a positive effect on the gas yield.
And the system retains the full range of QuickService functions familiar from the VX series rotary lobe pumps and the RotaCut: All wear parts can be replaced on site without dismounting the components.

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Vogelsang - Engineered to work

Vogelsang Performance Control Unit (PCU)

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Features

Separation of stones and metal parts is important for ensuring smooth operation of the cutter itself as well as of the downstream pumps and components, and also to prevent damage and blockages they may cause. Each RotaCut therefore has an integrated heavy material separator that can be individually adjusted.

The rotary lobe pump and RotaCut are combined in the pump system in a way that ensures the QuickService functions are retained in full. The wear parts can be accessed in a few easy steps. They can be replaced quickly and easily on site. The pump system is ready for use again in no time at all.

On rotary lobe pumps from Vogelsang, wear on the pump housing segments is compensated without using additional parts. This makes the most of the material and prolongs service life.

Additional information:

VX pumps from Vogelsang have sturdy, break-proof shafts with a large diameter and without cranks and recesses to weaken them. The benefit is that Vogelsang rotary lobe pumps give a minimum shaft deflection even under high pressure, very low start-up wear, and ultimately reduced operating costs and spare parts costs.

Additional information:

Vogelsang rotary lobe pumps are built according to a unique element-based design. With them, the customer isn’t forced to replace the entire body, but instead just the element that is affected. The economical replacement of individual components not only makes maintenance simpler and quicker, but simultaneously reduces the operating costs.

Additional information:

Vogelsang uses its proprietary software to develop cutting screens with optimized geometry for every size-reduction ratio. For operators, this means the best geometry at all times for smooth running, with minimal wear. The cutting screens are produced from wear-resistant special steel and offer twice the performance since they are reversible.

The Quality Cartridge mechanical seal is checked in the factory and when it is changed, all of the seal components are also replaced. This protects against sudden failures of the seal and potentially fatal damage. The complete unit is easy to change, and the replacement process takes significantly less time.

The pumps and the grinders are mounted together and optimally on a console. This result in short suction pipes, a flow which is directly pumped to the cutting screen and a very compact design. Therefore, the pumping systems required only a minimal footprint but are nevertheless easily accessible for maintenance and service.

The self-priming pump can prime media from depths as low as 9 meters up to heights as high as 9 meters.

Options

If it is necessary during priming to evacuate large quantities of air from empty pipes or if you need to prime a medium with a tendency to outgassing, the connector box is an ideal addition. It increases the suction capacity of the rotary lobe pumps in the VX series and ensures that even large volumes of air or gas are reliably evacuated or pumped.

The InjectionSystem significantly improves the foreign-matter resistance of the pump. It increases the efficiency and improves the suction capacity through optimized volumetric efficiency. Thanks to the InjectionSystem the service life of the pump is extended. Field trials prove a longer period of up to 2.5 times.

Additional information:

Radial wear plates are only available in Vogelsang rotary lobe pumps. The wear plates, made from highly wear-resistant special steel, extend maintenance intervals considerablx, simplify maintenance and minimize downtimes. Also your costs are significantly reduce during maintenance.

Additional information:

Unlike conventional lobes, Vogelsang’s HiFlo® lobes ensure pulsation-free pumping and consequently longer lifetimes for the drive and coupling. At the same time, the suction capacity is increased due to the higher number of sealing lines. The improved internal sealing enables suction from deep pits.

Additional information:

Along with the number of cuts, the hole pattern in the cutting screens is crucial to the size-reduction ratio. To be able to meet all requirements, we offer cutting screens for the RotaCut with a free passage of 4 mm to up to 50 mm, depending on the unit size. Stainless steel designs are available for aggressive media.

ACCplus further reduces the cost of maintenance and monitoring of the cutter. It monitors the cutting blade status online and displays it on an external display. This means it's no longer necessary to place the cutter out of service and open it to determine the cutting blade status. Additionally, this information can be processed and displayed by the (central) control and/or remote control.

The Auto-Reverse function detects blockages, such as those caused by coarse disruptive matter, and initiates corrective action. By periodically reversing, the function further ensures that a pair of sharp cutting edges is always used while dull ones are sharpened on the opposite site. This delivers optimal cutting performance with reduced power consumption.

The BioCut is an efficient pump system for reliable and cost-effective pumping of heterogeneous media containing heavy material and disruptive matter. It consists of a self-priming rotary lobe pump from the VX series combined with a special type of construction of the tried-and-trusted RotaCut – with both optimally coordinated and arranged to one another. The rotary lobe pump draws the medium – even out of a pit, if necessary – through the RotaCut. The RotaCut then separates out foreign matter (stones, metal parts etc.) due to their size or weight. During maintenance work, this foreign matter can then be removed through the cleaning port. Light solid matter and disruptive matter, such as fibers, wood etc., are drawn along in the flow of fluid to the cutting screen, where they are shredded and mixed with the fluid. This way, the BioCut turns a heterogeneous fluid into a pumpable, homogeneous suspension. This suspension then reaches the rotary lobe pump on as short a route as possible.

The rotary lobe pump operating principle

The pumping principle behind the non-contacting, rotating positive displacement pump is based on two counter-rotating, elastomer-coated rotary lobes whose shape ensures sealing between the suction and discharge sides in all lobe positions. On the basis of this operating principle, the rotary lobe pump can generate strong suction and the delivery rate can be regulated easily by adjusting the speed. In the BioCut pump system, the rotary lobe pump ensures cost-effective and reliable pumping of the previously treated medium.

When developing the BioCut pump system, we made sure to retain the full range of QuickService functions in the VX series rotary lobe pump and the RotaCut: The RotaCut can be opened in a few simple steps, giving you free access to the cutters. Once the adjustment unit and the blade rotor have been dismounted, you can remove the cutting screen and, if necessary, renew the gasket. Replacing parts on the VX series rotary lobe pump is just as easy. When the cover is dismounted, you have free access to the pumping chamber and you can pull the rotary lobes off the shafts.

If necessary, you can also replace the axial wear plates, the pump housing segments and the Quality Cartridge shaft seal.

The two components can both be maintained quickly on site, allowing the BioCut pump system to be put back into operation after a very short time. There is no need to dismount the pipe. This reduces downtime to a minimum.