Plug Flow Fermenter for a Biogas Plant

Abstract

The invention relates to a plug flow fermenter (1) for a biogas plant, having a reactor container (2) designed as an elongated straight tube, in the reactor interior (9) of which a substrate to be fermented, preferably by dry fermentation, can be fermented as plug flow while producing biogas, wherein the reactor container (2) has at least one container inlet (10), via which the substrate to be fermented can be fed to the reactor interior (9), and at least one container outlet (12) spaced apart from the container inlet (10) in the flow direction (x) of the plug flow, via which the fermented substrate can be discharged from the reactor interior (9), and wherein a plurality of separately exchangeable agitating devices (19) is arranged spaced apart in the reactor interior (9) when seen in the longitudinal extension direction and thus in the flow direction of the plug flow.

Claims

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19. (canceled)

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26. (canceled)

27. A plug flow fermenter for a biogas plant, said plug flow fermenter comprising: a reactor vessel comprising a straight tube that defines an reactor interior for receiving a substrate to be fermented as a plug flow with biogas generation; wherein said reactor vessel includes at least one inlet for receiving said substrate to be fermented, and at least one container outlet spaced apart from said container inlet in a plug flow direction through which fermented substrate is discharged from said reactor interior; wherein a plurality of separate agitator devices are arranged in said reactor interior, said agitator devices being spaced apart in a longitudinal direction of said reactor vessel so that said substrate may be circulated locally as said substrate is conveyed in said plug flow direction during a fermenting operation; wherein at least one of said agitator devices is removable from said reactor vessel during a fermenting operation for cleaning, maintenance, or replacement with another agitator device.

28. The plug flow fermenter set forth in claim 27, wherein said agitator devices are evenly spaced from one another.

29. The plug flow fermenter set forth in claim 27, wherein said reactor vessel is positioned in a horizontal orientation, and said agitator devices are oriented in a generally vertical direction and spaced apart along said longitudinal direction of said reactor vessel.

30. The plug flow fermenter set forth in claim 27, wherein said reactor vessel includes an at least partially flat ceiling wall.

31. The plug flow fermenter set forth in claim 27, wherein said reactor vessel includes an installation opening through which said agitator devices may be introduced into said reactor interior and removed from said reactor interior, and wherein said agitator device and said installation opening form a gas-tight fit thereabout.

32. The plug flow fermenter set forth in claim 31, wherein said agitator device includes a removable cover that forms a gas-tight seal about said installation opening.

33. The plug flow fermenter set forth in claim 32, wherein at least one removable agitator device includes an agitator shaft extending from outside said reactor container through said installation opening into said reactor interior with at least one agitator blade; wherein said installation opening is dimensioned such that said agitator shaft passes therethrough, together with said at least one agitator blade arranged on said agitator shaft, so that said agitator shaft and agitator blade may be inserted into and removed from said reactor interior.

34. The plug flow fermenter set forth in claim 33, wherein said agitator shaft extends through said cover in gas-tight fashion.

35. The plug flow fermenter set forth in claim 33, wherein a bottom portion of said reactor interior includes a series of receptacles, each said receptacle receiving a bottom end of one of said agitator shafts in such a way that said connection between each said receptacle and its respective agitator shaft forms a plug-in rotary connection.

36. The plug flow fermenter set forth in claim 35, wherein a portion of said agitator shaft that is positioned outside of said reactor interior is connected to and driven by a drive motor that is selected from the group consisting of an electrically powered motor, a pneumatically powered motor and a hydraulically powered motor.

37. The plug flow fermenter set forth in claim 31, further including an apron is removably positioned within said installation opening, said apron forming a ring shape and protruding into said substrate while in a sealed position within said installation opening.

38. The plug flow fermenter set forth in claim 37, wherein said apron includes a flange that abuts said reactor vessel within said reactor interior, and further, and is secured thereto via at least one detachable screw.

39. The plug flow fermenter set forth in claim 31, wherein said installation openings form a generally slot shape, wherein each installation opening is oriented in said longitudinal direction of said reactor vessel.

40. The plug flow fermenter set forth in claim 31, wherein said installation openings form a generally slot shape, wherein each installation opening is oriented in a transverse direction that is perpendicular to said longitudinal direction of said reactor vessel.

41. The plug flow fermenter set forth in claim 33, wherein said agitator device includes a plurality of agitator blades extending away from said agitator shaft on opposite sides in a staggered, alternating arrangement.

42. The plug flow fermenter set forth in claim 27, wherein at least one of said agitator devices includes a bottom-side collecting channel, through which material to be withdrawn from said reactor interior is collected and removed by a discharge device.

43. The plug flow fermenter set forth in claim 27, further including a plurality of discharge lines are spaced apart in said longitudinal direction on said reactor vessel and are operatively connected to a collecting line, said discharge lines and said collecting line forming a discharge device, so that material may be withdrawn from said reactor vessel via said discharge device.

44. The plug flow fermenter set forth in claim 43, further including a separator, wherein said material withdrawn by means of said discharge device is fed into said separator and separated into a waste phase and a substrate phase; and wherein said substrate phase may be returned to said reactor interior via a return line as a percolate.

45. The plug flow fermenter set forth in claim 27, wherein said reactor vessel inlet is positioned on a first end of said reactor vessel, and said reactor vessel outlet is positioned on a second, opposed end of said reactor vessel.

46. The plug flow fermenter set forth in claim 27, wherein said reactor vessel is formed by four walls that form a cross-sectional shape of a rectangle.

47. The plug flow fermenter set forth in claim 27, further including a gas extraction device operatively attached to said reactor vessel for extracting biogas formed within said reactor interior.

48. The plug flow fermenter set forth in claim 27, further including a feed device for feeding substrate to be fermented into said reactor interior via said inlet, and including a discharge device for removing said fermented substrate from said reactor interior via said container outlet.

49. The plug flow fermenter set forth in claim 48, further including a control device for controlling said feed device and said discharge device, wherein said control device is regulatable in such a way that said substrate remains within said reactor vessel for a time period ranging from about 25 days to about 50 days.

50. The plug flow fermenter set forth in claim 27, wherein said substrate to be fermented has a dry matter content of 12% to 40% DM.

51. A method for generating biogas comprising the steps of: providing a reactor vessel having an inlet on a first end and an outlet on a second end, said reactor vessel forming a hollow reactor interior for receiving substrate to be fermented; providing a series of removable agitator devices that extend into said reactor interior for agitating said substrate; continuously feeding said substrate into said inlet; agitating said substrate with said removable agitator devices; providing a gas extraction device operatively connected to said reactor interior for extracting biogas from said reactor interior; extracting said biogas; and continually removing said substrate from said outlet after a predetermined period of time.

Description

[0039] In the following, the invention will be described in more detail using drawings, in which:

[0040] FIG. 1 schematically shows a perspective depiction of an exemplary embodiment of a plug flow fermenter according to the invention;

[0041] FIG. 2 is a schematic, perspective exploded view with regard to the essential components of FIG. 1;

[0042] FIG. 3 schematically shows a top view of the fermenter according to FIG. 1 with a partially omitted top wall;

[0043] FIG. 4 is a schematic side view of a portion of the exemplary fermenter according to the invention according to FIG. 1 with the sidewall omitted; and

[0044] FIG. 5 schematically shows a basic sketch with two alternative fastening options for the apron, wherein the left half of the drawing shows a first embodiment and the right half of the drawing shows an alternative, second embodiment.

[0045] FIG. 1 schematically shows a perspective depiction of an exemplary embodiment of a plug flow fermenter 1 according to the invention, which is, for example, part of a biogas plant not shown in detail. As can be seen in particular from FIG. 2, which is a schematic exploded view of the essential components of the plug flow fermenter 1 of FIG. 1, and from FIG. 3, the plug flow fermenter 1 has a reactor container 2 designed as an elongated straight tube. In this case, this reactor container 2 is designed in the form of a container or cuboid merely by way of example and has a first or front end wall 3 and a second or rear end wall 4 located opposite in the longitudinal extension direction x of the reactor container and thus in the flow direction of the plug flow. The reactor container 2 also has two sidewalls 5 and 6 opposite one another in the transverse direction y and a bottom wall 8.

[0046] As can be seen from FIGS. 1 to 4, the reactor container 2 also has an upper, preferably accessible and flat, top wall 7 that is opposite the bottom wall 8 in the vertical axis direction z. In this case, the reactor container 2 is thus designed, by way of example, as an elongated straight-line cuboid that is delimited by six rectangles forming the reactor container walls 3, 4, 5, 6, 7, and 8 and thus has six side surfaces that are at right angles to one another, wherein the end walls 3, 4 opposite one another in the longitudinal extension direction x or linear direction are as parallel as the sidewalls 5, 6 opposite one another in the transverse direction y and the top wall 7 and the bottom wall 8 opposite one another in the vertical axis direction z. The walls 5, 6, 7, and 8 of the reactor container 2 also form a rectangular reactor interior 9 based on the cross section (sectional plane y-z) through the reactor container 2, but this is only to be understood as an example. The reactor container can naturally also have other internal and also other external geometries, for example, be designed to be at least partially rounded at the internal and/or external corners in order to form, for example, a more circular or oval cross section. Semicircular cross sections are also conceivable, to name just one further example.

[0047] Herein, the reactor container 2 is shown in a horizontal position which also corresponds to its most common use and which is why such fermenters are also called horizontal fermenters. The walls of the fermenter can be made of any suitable material, for example, concrete or stainless steel.

[0048] By way of example, the reactor container 2 herein has a container inlet 10 in the region of the first end wall 3, via which a substrate to be fermented can be fed continuously or at specific times in an interval-like manner by means of a feed device which in this case is designed as a feed screw 11 by way of example. By pressing in the substrate, a feed force for the plug flow is generated preferably simultaneously in its flow direction, which corresponds to the longitudinal extension direction x of the reactor container 2.

[0049] Furthermore, a container outlet 12 is provided on the opposite second end wall 3 of the reactor container 2, via which the fermented substrate can be discharged from the reactor interior 9 by means of a discharge device designed, for example, as a discharge pump.

[0050] Furthermore, a plurality of agitating devices 19 spaced apart when seen in the flow direction x of the plug flow is arranged in the reactor interior 9, by means of which the substrate to be fermented can be locally circulated and/or by means of which the substrate can be conveyed in the flow direction x of the plug flow.

[0051] The agitating devices 19 are preferably designed to be essentially identical and, in addition, are preferably evenly spaced apart from one another.

[0052] The agitating devices 19 are also aligned vertically with respect to the horizontal reactor container 2, i.e., in the vertical axis direction z, and in this case, each have, for example, an agitator shaft 20 guided from outside the reactor container 2 through the top wall 7 with a plurality of agitator blades 21 spaced apart from one another in the longitudinal direction of the agitator shaft.

[0053] In this case, the agitating device 19 specifically has, for example, a plurality of agitator blades 21 extending away from the agitator shaft 20 on opposite sides and lying in a vertical plane (see in particular FIGS. 2 and 4), wherein, on a first side of the agitator shaft 20, a plurality of agitator blades 21, one above the other and spaced apart from one another when seen in the vertical axis direction, protrudes from the agitator shaft 20, and wherein, on an opposite side of the agitator shaft 20 spaced apart by 180°, a plurality of agitator blades 21, one above the other and spaced apart from one another when seen in the vertical axis direction, also protrudes from the agitator shaft 20. As can also be seen here, the agitator blades 21 on the second side are offset by way of example in the vertical axis direction z with respect to the agitator blades 21 on the first side.

[0054] As can also be seen in particular from the figures, the agitating devices 19 also each have an actuating device, for example, a drive motor 22, which is arranged outside the reactor container 2 and supported and mounted on the top wall 7 by means of a support device 15. The agitator shaft 20 can be rotationally driven by means of the drive motor 22. In this case, the support device 15 is formed by way of example by a frame carrying the drive motor 22 with a plurality of support legs 14 which are arranged around the agitator shaft 20 and fan out towards the bottom.

[0055] As can be seen in particular from FIG. 1 in conjunction with FIGS. 2, 3, and 4, the top wall 7 has an installation opening 24 in the region of the agitator shaft lead-through, which can be closed in a gas-tight manner by means of a cover 23 preferably made of stainless steel, wherein the agitator shaft 20 extends through the cover 23 in a gas-tight manner. The installation openings 24 are also dimensioned such that the agitator shaft 20, together with the agitator blades 21, can be introduced into and removed from the reactor interior 9 through said installation openings. For this reason, the installation openings 24 extend in this case, by way of example, in a slot-like manner essentially over the entire width of the top wall 7, i.e., in the transverse direction y between the sidewalls 5 and 6. In addition, the installation openings 24 also lie spaced apart and one behind the other in a straight line or in straight alignment when seen in the longitudinal extension direction x, and are preferably all designed to be identical and/or aligned parallel to one another. In this case, the same also applies to the covers 23 in their installed state.

[0056] On the side of the installation opening 24 facing the reactor interior 9, an apron 25 is arranged, preferably made of stainless steel, which protrudes from the installation opening 24 in the direction of the reactor interior 9 and surrounds the installation opening 24 in an annular manner and dips into the substrate 16 when in the sealing position (see in particular FIG. 4). This apron 25 is preferably formed by a separate component and, for example, as shown in the left half of FIG. 5, can be immobilized from below on the opening edge region around the installation opening 24. However, alternatively (the right half of FIG. 5), the apron 25 can also be hooked into the installation opening 24 from above and supported or mounted on the opening edge region around the installation opening 24. For immobilizing the apron 25, it has in both alternative embodiments preferably a flange region 25a which bears against the opening edge region (from below in the first alternative of the left half of the drawing and from above in the second alternative of the right half of the drawing). In this case, by way of example and specifically, the apron 25 is immobilized via its flange region 25a in each case preferably via releasable screw connections 13, so that the apron can also be exchanged if necessary and replaced with a new apron.

[0057] As is shown in FIG. 1 only by way of example and schematically and with dashed lines, at least some of the agitating devices 19 are assigned a bottom-side collecting channel 26 in which, in particular when the agitating devices 19 are actuated, material 17 (see FIG. 4), in particular a substrate-sand mixture, to be removed from the reactor interior 9 accumulates. The collecting channels 26 are each arranged spaced apart between two agitating devices 19 merely by way of example, wherein the collecting channels 26 in this case extend further, for example, in the transverse direction y between the sidewalls 5 and 6. The collecting channels 26 can be designed, for example, as trough-shaped depressions, into each of which a removal line 27 opens, which in turn is part of a removal device, by means of which the material 17 accumulating in the respective collecting channel 26 can be removed from the collecting channel 26.

[0058] In this case, the removal lines 27 open, for example, into a collecting line 28, via which the removed material is fed to a separator 29 of the removal device, in which the removed material, preferably a substrate-sand mixture, is separated into a substrate phase and a waste phase, preferably a sand phase.

[0059] A return line 30 of a return device then leads from the separator 29 back to the reactor container 2, so that the substrate phase separated in the separator 29 can be fed to the reactor interior as percolate, preferably fed as percolate to the substrate from above when seen in the vertical axis direction z. This is shown in FIG. 1 merely by way of example and schematically by means of a plurality of percolate lines 18 branching off from the return line 30. It goes without saying that only a single percolate line or a different number of percolate lines can also be provided.

[0060] Alternatively to this above-described solution with the collecting channels, it can also be provided that possibly no collecting channels 26 are provided and instead only a plurality of removal lines 27 spaced apart from one another along or around the reactor container 2 is provided. These removal lines 27 then form a removal device and in this case are guided, for example, through the sidewall 5 of the reactor container 2 into the bottom-side lower region of the reactor interior 9, so that a material 17 to be removed, in particular a substrate-sand mixture, can be removed from the reactor container 2 via said removal lines and fed to the collecting line 28. Via said collecting lines, the removed material is fed to the separator 29 analogously to the above description, in which the removed material, preferably a substrate-sand mixture, is separated into a substrate phase and a waste phase, preferably a sand phase. If necessary, the above-described solution and the solution with collecting channels can also be realized together, so that two types of removal lines 27 are thus provided, namely removal lines 27 guided to the collecting channels 26 and removal lines 27 not guided to the collecting channels 26. In the latter case, one collecting line 28 can then be provided for all of the removal lines 27 or two collecting lines 28 can be provided, i.e., one collecting line 28 for each of the different types of removal lines 27.

[0061] The dosing of the biomass, the discharge of the biomass, the actuation of the agitating devices, the removal of the material from the collecting channels 26 (if present) and the return of the substrate to the reactor container 2 are in this case all carried out in a controlled manner by means of a control device (not depicted). By means of said control device, in particular the feed into and the discharge from the reactor container 2 and thus the retention time of the substrate in the reactor container 2 are controlled in an open-loop and closed-loop manner. The open-loop or closed-loop control is preferably carried out such that the retention time in the reactor container 2 is between 25 to 50 days and/or that the substrate in the reactor container 2 has a dry matter content of 12 to 40% DM, preferably 19 to 30% DM.

[0062] Furthermore, a gas extraction device 31 is provided, by means of which the generated biogas (methane gas) can be extracted from the reactor container 2.

[0063] If an agitating device 19 or a plurality of agitating devices 19 is to be replaced while the plug flow fermenter 1 is in operation, i.e., when the reactor container 2 is full or filled, it can be achieved in a simple manner with the present invention such that the agitating device 19 designated for replacement, as shown schematically and by way of example in FIG. 4 using the second agitating device 19 from the right, is simply lifted out through the installation opening 24. For this purpose, as shown by way of example in FIG. 4, it is particularly advantageous (but not mandatory) if the substrate 16 in the reactor interior 9 has such a filling height in the vertical axis direction z that the apron 25 dips into the substrate 16, since an essentially gas-tight state is then established in the region of the installation opening 24, which allows for the cover 23 to be opened and the agitating device 19 to be lifted out or removed without any significant gas escaping from the installation opening 24 or from the reactor container 2. The same applies, of course, in an analogous manner to a reinsertion of the or a new agitating device 19.

[0064] As can also be seen from FIG. 4, the removed agitating device 19 has in this case been rotated with respect to the agitator blades 21 spaced apart by 180° such that the agitator blades 21 are aligned in the direction of the slot-shaped installation opening 24 and the agitator shaft 20 together with the agitator blades 21 can thus be introduced into, as well as removed from, the reactor interior 9 in the simplest manner.

[0065] In this case, the agitator shafts 20 are assigned on the bottom side in the reactor container 2, i.e., on the inner side of the bottom wall 8, a bearing seat 20a, preferably made of steel, in particular stainless steel, which herein is raised by way of example and optionally also widens upward into a funnel shape (not depicted), in which the free agitator shaft end 20b is rotatably received in the installed state, wherein it is preferably provided that the connection is designed as a plug-in rotary connection.

[0066] The cover 23 with a single piece or multipiece design can, as shown in the figures, be part of the agitating device 19 and, when the agitating device 19 is in the inserted, installed state, can close the associated installation opening 24, preferably close it in a gas-tight manner. Alternatively hereto, the cover 23 can in principle also be formed by a separate component that can be handled independently of the agitating device 19. In this case, the cover has then, for example, a multipiece design in order to be able to arrange it around the agitator shaft 20 in a simple and gas-tight manner.

[0067] In both above-described variants, the cover 23 can be arranged in the region of the installation opening 24, for example, resting on the edge region, such that the cover 23 can also be immobilized on the surrounding reactor container wall region by means of releasable fastening means.