Possible integration of the BIOSONATOR compact into biogas plants

The biomass is disintegrated, resulting in increased microbiological activity within the digester.
This intensified process leads to a significant increase in biogas production (typically 10 to 15%), achieved with only minimal energy input.
The payback period for the investment is 3 to 5 years and is therefore correspondingly short.
Connecting the container to the biogas plant is straightforward.
Connections for the inflow and outflow of substrate and rinse water are provided on the outside.
Only an electrical connection (400 V, 32 A, TN-S network) is required.

Equipment and technical configuration

At the heart of the BIOSONATOR are four units, arranged in the following technological sequence:

- Wet grinder with helical gear motor (2.2 kW drive power)
- Modified eccentric screw pump with helical gear motor (1.5 kW drive power) and frequency converter
- High-performance ultrasonic system with 5 kW connected load
- Flow meter

Flowchart of the BIOSONATOR

The individual components are connected using stainless steel pipes (DN 100 and DN 65).
All fittings are made from the same grade of stainless steel.
The following parameters are recorded and processed within the BIOSONATOR:

- Flow rate
- Temperature
- Pressure
- Sound power in per cent (output parameter of the ultrasonic control unit)
- Operating time

Automation is provided by a SIMATIC S7-300 module from Siemens.
The process flow diagram and the recorded measurement values are displayed on a touchscreen multi-panel.
The BIOSONATOR’s control system can be integrated into the biogas plant’s control system via a data interface.
The power supply, power circuits and I&C technology are housed in a wall-mounted control cabinet.

Optimised operation – Increased plant efficiency

The BIOSONATOR can be operated in either automatic (standard mode) or manual mode.

The eccentric screw pump first draws the biosuspension through the wet shredder.

Here, long-fibred solid particles are shredded to ensure stable pump operation.

The PALMINCO ultrasonic system is located on the discharge side of the pump.

The pressure fluctuations caused by the ultrasound generate enormous cavitation forces that break down the biomass structure.

This breakdown makes the biomass more readily available, intensifies the digestion process and produces more biogas.

Alternatively, the operator can reduce the feed rate whilst maintaining a constant biogas output.

In addition, the methane content is increased, thereby improving the quality of the biogas.

The simultaneous reduction in viscosity induced by the application of ultrasound also leads to savings in the plant’s own electricity consumption.

A time-controlled flushing system is built in to ensure stable, uninterrupted operation of the BIOSONATOR.

This guarantees a long service life for the ultrasonic system.

Through the continuous recording and monitoring of the process-specific key parameters,

the plant operator is thus constantly able to operate the BIOSONATOR optimally.

Operating parameters

Flow rate:                                                 10 to 33 l/min or 0.6 to 2 m³/h biomass suspension
Medium:                                                   Biomass suspension with approx. 5 to approx. 10% dry matter content
Medium temperature:                                  33 to 55°C
Operating pressure of the ultrasonic system:   max. 2.5 bar during ultrasonic operation
Annual operating time:                                Continuous operation over 8,760 h/a, excluding maintenance/servicing