Mechanical disintegration system DisRuptor by Vogelsang

More efficiency through 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


Functions and effects of mechanical disintegration
How the Vogelsang DisRuptor works

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. Even with high throughput and a high DM content, the DisRuptor only needs a low drive power. 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.

Optimization of the gas yield and reduced internal energy consumption thanks to mechanical disintegration
Why you need to use 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. in front downstream of the liquid feeding system or as part of the digester recirculation system.

Digitalize your product!
Control technology for Vogelsang technology

Investing in our progressive and smart control technology significantly boosts the performance and efficiency of Vogelsang machines and systems. It captures and continuously monitors key parameters like the capacity or throughput rate, rpm, pressure and power consumption. The control detects malfunctions early, and rectifies them by intervening appropriately. The integrated communication interfaces like ProfiNet and OPC UA can exchange data with other systems or a superordinate control in real time.

At the same time, the web-based user interface displays all key data clearly in all major browsers. Optionally, the data can be accessed on mobile devices for remote monitoring.

Our experts’ experience from hundreds of applications in various areas constantly inspires our software development and lays the foundation for the major benefits for the users: low operating costs, maximum availability and efficiency.

Our range of controls offers the right solution for all machine requirements and all customers’ needs. From ready-to-use, factory-tested and commissioned system solutions for end users, to basic versions for experts who want to put the finishing touches to the control technology themselves.

Options in control technology for the DisRuptor

Features of the DisRuptor

The variable function unit is the DisRuptor’s outstanding feature. It allows the DisRuptor to be adjusted individually for the biomass and the application. The gap between the DisRuptor ring and the wing is infinitely adjustable. In this way, wear can be compensated quickly and simply, without having to replace parts.
The sophisticated design of the function unit makes intensive disintegration possible at a high throughput and low drive power. With just 15 kW of installed capacity, up to 200 m3/h of organic suspension can be treated. This combination is what makes mechanical disintegration viable.
Thanks to the QuickService design, service and maintenance are quick and easy in the DisRuptor: Swivel up the DisRuptor head provides optimal access to the function unit. Maintenance, adjusting the function unit or replacing parts are simple and can be done in just a few steps.
All DisRuptor units have a hydraulic support for swivel the DisRuptor head upwards. That allows the DisRuptor to be opened effortlessly, e.g. for service and maintenance.
Both parts of the DisRuptor ring are hardened with a special process, and have a wear-resistant surface. The DisRuptor wings are made of hardened special steel. In addition, the sophisticated geometry and layout of the parts ensure a long service life.

Options of the DisRuptor

For individual adjustment of the DisRuptor to the local situation and the medium, there are two different types of DisRuptor pot on offer. Customers can choose from the Inline pot with a permissible pressure up to 2 bar. It is very easy to retrofit, as the inlet and outlet are opposite one another. As an alternative, the Compact XL pot facilitates pressures up to 4 bar.
For simple installation and a firm stand, the DisRuptor is available fully installed on a steel base. It has forklift pockets to allow the unit to be easily transported and positioned.
All components of the DisRuptor are made of steel. The housing is completely galvanized. A stainless steel variant is available for applications with particularly aggressive media. In this version, all wetted parts are made of stainless steel, including the DisRuptor ring and DisRuptor wings.

  • Variable mechanical disintegration system[br]DR7000

Mechanical disintegration with variable function unit
Mechanical disintegration system DisRuptor DR7000

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 swivel 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.

Get in contact with Vogelsang India!

We will find the right solution for you