Energy-efficient mechanical disintegration
- Increases the surface of the biomass feed
- Homogenizes and reduces the viscosity of the organic suspension
- Accelerates and increases gas production
- Reduces the power consumption of mixers and pumps
- Easy to retrofit
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DisRuptor: Optimization of the gas yield and reduced internal energy consumption thanks to mechanical disintegration
The DisRuptor effectively combats problems frequently caused by switching biogas plants to low-cost, but structured biomass. In the long term, the biomass used for cost reduction reduces the gas yield, increases the internal energy consumption or formation of floating layers. The yields from the biogas plant and its overall efficiency decrease.
Mechanical disintegration of structured biomass breaks down and damages the protective and difficult to degrade components, e.g. lignin structures. At the same time, it increases the surface and thus the target for the bacteria. Treatment with DisRuptor allows agricultural by-products and substrates to be fermented that would otherwise be unprofitable to use, or would result in very limited profits. For example, this includes dung, woody grass, maintenance cuts from pastureland or landscaping material.
The viscosity of the organic suspension is reduced, the power consumption and runtimes of the mixers decrease and the specific gas yield increases, as the biomass is used and converted better thanks to the mechanical disintegration. All in all, this increases revenue, decreases costs and significantly improves the efficiency of the biogas plant in the end. The DisRuptor is easy to integrate or retrofit to existing biogas plants, and can be used in many areas, e.g. downstream of the liquid feed or as part of the digester agitation system.
Functions and effects
The organic suspension flows into the DisRuptor pot from the side and then enters the middle of the function unit from below. There, a rotor with six wings spins at a high speed. Fluid passes through openings on the casing surface of the function unit, while solids in the organic suspension like straw, grass silage etc. are shredded and ground in a small gap between the outer DisRuptor ring and the wings. Thanks to the enlarged target and breaking down of difficult to degrade structures (cellulose/lignin), the bacteria convert the biomass into biogas faster and more comprehensively, increasing the specific gas yield in the long term. In addition, the viscosity of the organic suspension is decreased, which is why the power consumption and runtimes of the mixers are reduced.
As a unique feature, the gap in the DisRuptor can be adjusted individually to the respective biomass and application using a sophisticated adjustment mechanism. For a throughput of e.g. 80 m3/h of organic suspension and a DM content of 12%, all the DisRuptor needs is an installed capacity of 15 kW. As a result, the investment in substrate treatment via DisRuptor pays off quickly thanks to the low operating costs per m3 of organic suspension treated.
Mechanical disintegration with variable function unit
The DisRuptor DR7000 offers energy-efficient mechanical disintegration thanks to its variable function unit. Handling the DisRuptor adjustment mechanism is simple. The DisRuptor head is easy to rotate upwards with hydraulic support – offering direct access to the function unit. The gap between the blades and the external ring can be adapted individually to every substrate with just a few steps and without special tools. Moreover, wear on the ring and wings can be compensated for by realignment – extending their service lives.
- Direct & indirect digester agitation
- Heat exchanger circuit
- Liquid feed with recirculated material
* Throughput depending on DS content