EA036349B1 - Biogas plant for anaerobic processing of organic waste - Google Patents

Abstract

The proposed device relates to the field of agriculture and food industry, namely to equipment for processing waste such as vegetable remnants, beetroot pulp and molasses, livestock breeding waste, on a commercial scale for their utilization and obtaining fertilizers and biogas, for creation of a closed biological cycle in agricultural industry. A biogas plant for anaerobic processing of organic waste comprises a receiving chopper (1), a feeding device (2), a homogenizer, a heat exchanger (5), a substrate collector (6), a bioreactor (10) with a rotary separator, dosing units (16, 23), a reducer-distributor (14), a gas reciprocating engine GRE (41), a separator (40), a biofertilizer cooler (28), a heat pump plant (30), a thermal unit (34), a gas boiler (35). The technical results consist in increasing the plant operating efficiency, minimizing the plant dimensions, increasing the substrate processing degree, reducing heat losses and primary energy consumption for operating needs, increasing the specific yield of biogas and increasing the content of methane in it, reducing crust formation, increasing the plant operation reliability.

Description

The proposed device relates to the field of agriculture and food production, namely, equipment for processing waste in the form of plant residues, beet pulp and molasses, animal waste on an industrial scale for the purpose of their utilization and obtaining fertilizers and biogas, creating a closed biological cycle in agricultural production ...

A bioreactor device (1) is known, which consists of a thermally insulated housing with a dome for collecting biogas, the inner part of the bioreactor tank is divided by partitions that are installed vertically and connected to the walls of the housing, in each section between the partitions, except for the first and the last, there are biomass flow windows from section to section. Each section is equipped with a manifold for feeding make-up, a heat exchanger, a stirring device, pH, eH, temperature and biomass level sensors.

The main disadvantages of this technical solution:

high probability of crust formation and the absence of a device for its removal, which reduces the release of biogas;

a decrease in the heat exchange of heat exchangers due to the deposition of sludge on the surface of the heat exchangers due to the low velocity of the substrate along their surface, which will lead to the need for an additional increase in the temperature in the heat exchanger and an increase in heat consumption.

The invention minimizes, but does not completely eliminate the mixing of the substrate from adjacent segments with different phases, which leads to incomplete processing of the substrate and its disinfection.

We need effective thermal insulation between the partitions due to the different substrate temperatures, and also, according to the declared stage-by-stage filling of the bioreactor, the partitions must have sufficient strength, which increases the material consumption.

The overflow of the substrate from one segment to another with different temperatures will introduce a temperature gradient of 10 ° C, which will negatively affect the work of bacteria and lead to a decrease in biogas production.

Known installation for anaerobic processing of organic waste (2), containing an anaerobic bioreactor with a main biomass heater, made in the form of a hermetically sealed container, divided by vertical partitions into sections, branch pipes for loading raw materials and unloading liquid organic fertilizer, feed system for raw materials, drainage system biogas with a compressor, a process control system made in the form of a programmable computer.

The main disadvantages of this technical solution:

the bioreactor is divided into three sections at an angle of 120 °, which forms three containers of equal volume, hydrolysis, acidogenic and methanogenic, and due to the fact that the reaction rate is different and is roughly related as 1-0.3: 5-1: 3-1 , 5 and depends on the composition of the feedstock, then in the installation these values of the fermentation time will be equal, which will either lead to incomplete completion of the reaction at one of the stages, incomplete processing of the substrate and less biogas, or to an excessive duration of the reaction time in a separate section and decrease in overall plant productivity;

mixing is realized only in the methanogenic section using a screw, which, in comparison with other methods (screw, hydraulic, etc.), requires high energy costs and does not provide a high speed of movement of the coolant along the heat transfer surface, which will eventually cause fouling of its deposits and loss of thermal conductivity with an increase in heat consumption for heating the substrate;

there is no mixing in the hydrolysis and acidogenic sections, which, due to weak convection, will cause poor mixing of the substrate and its uneven heating, which, in turn, will reduce the rate of reactions and the formation of deposits on the heat-carrying surfaces, which will reduce thermal conductivity, and over time, the consumption of biogas will increase. own needs, a crust may also form in the acidogenic section, which will block the reaction, and sludge will also form in the lower part of the reactor, which will cause the need for periodic cleaning;

the use of an electric motor is inefficient due to the fact that electricity from the network has a high cost and at the same time about 20% of the energy of the initial fuel is used;

external heating in the installation has a high degree of radiation of thermal energy into the external environment, which leads to large heat losses;

in the invention there are large heat losses with leaving biogas and processed substrate;

there is no heating of the substrate to the required temperature in the feed system, which will cause a temperature gradient when loading the reactor and a drop in the rate of the hydrolysis reaction.

Known device (3), the closest in technical essence and the achieved result, which consists of a manure receiver, an anaerobic bioreactor, a pump, a heat exchanger - condenser, connected into a single circulation loop, a fertilizer storage tank with a heat exchanger - 1 036349 heat pump evaporator. The heat exchangers are connected to each other by means of a compressor with a gas engine driven biogas to form a thermodynamic circuit of the heat pump. The heat exchanger-condenser of the heat pump is made in the form of a vertical pipe with hollow walls and is placed coaxially inside the anaerobic bioreactor, the heat exchanger-evaporator of the heat pump is made in the form of a submersible coil and is located in the lower part of the sump-storage of fertilizers. At least one additional bioreactor with a pump and a heat exchanger is provided, made similar to a heat exchanger-condenser, which uses the heat energy of the cooling liquid and exhaust gases of the gas engine drive of the heat pump.

The main disadvantages of this technical solution:

with large dimensions of the bioreactor, the use of a pipe with hollow walls as a condenser will not provide a uniform temperature around its perimeter and, accordingly, the same temperature at each point of the bioreactor, which will negatively affect the biochemical reaction process and reduce the release of biogas;

since the heat exchanger-condenser in the bioreactor has a large area, hydraulic stirring will not provide a high flow rate of the substrate along the walls of the heat exchanger, and accordingly, over time, they will be covered with deposits and heat transfer will deteriorate, which will lead to an increase in heat loss for heating;

heat removal by the heat exchanger-evaporator will have low efficiency, since it is placed in the solid fraction, where good heat exchange is not provided, which will lead to poor heat removal from the leaving solid fraction, at the same time, the liquid fraction will carry away the main amount of heat and water, which is negative will affect the efficiency of the installation;

in the proposed design, the problem of maintaining stable parameters of the substrate temperature is obvious, since the original manure, depending on the season, can have a temperature from -20 to + 30 ° C or more, depending on the climatic zone of use, which will accordingly change the load on the heat pump, its efficiency and will lead to an imbalance of temperatures in the first and second bioreactors relative to the optimal one, it will be difficult to maintain the nominal temperature, which will slow down the reaction and reduce the biogas yield;

the design does not take into account the fact that during two-phase fermentation, the ratio of the time of the first and second phases are related as 1: 6-4, depending on the raw material used, also in the first phase of fermentation, mainly hydrolysis and acidification processes take place, in which H ₂ gases are mainly released , CO ₂ and H ₂ S, which are supplied to the gas storage in the installation, thereby worsening the parameters of biogas in terms of the percentage of methane;

with a continuous cycle of operation of the installation, especially with intensive mixing, from the second bioreactor the non-fermented substrate will enter the settler, which causes a problem with incomplete deworming, and there will also be incomplete processing of the biomass, which reduces the efficiency of the installation, and additional sterilization will be required to use the fertilizer;

a high probability of crust formation and the absence of a device for its removal, which will reduce the release of biogas;

the presence of a settling tank and two bioreactors, one of which operates in a mesophilic mode, determines large losses of thermal energy of the substrate through a large enclosing surface into the environment.

When analyzing open sources, the applicant did not identify technical solutions identical to the claimed one, which allows us to conclude that the proposed invention meets the criterion of novelty.

The objective of the present invention is to create a biogas plant with high efficiency of the biogas and organic fertilizer production process, to provide improved consumer properties of the resulting products and their quality, to reduce the specific cost and payback period of the biogas plant.

The essence of the invention

The technical results of the biogas plant proposed in the invention are to increase the productivity of its operation, reduce the size of the plant, increase the degree of substrate processing, reduce heat losses and primary energy consumption for auxiliary needs, increase the specific yield of biogas and increase the content of methane in it, reduce the formation of a crust, increase reliability of the installation, which are provided by the following set of essential features:

the manure receiver has a shredder for incoming substrates and is connected to a feeding device, preferably of a screw type, the outlet of which is connected to a homogenizer, the homogenizer is located in a single heat-insulated housing with a heat exchanger and a ready-made substrate accumulator, the temperature of the finished substrate in the accumulator, regardless of the temperature of the initial substrate entering the manure receiver, is set by the software controller and is maintained by the heat exchanger stable at a level of ± 52 ° C, corresponding to the thermophilic regime, the storage volume of the input substrate is determined as

- 2 036349

VH = V6p / n, where

VH - drive volume,

V _6p is the volume of the bioreactor, n is the number of sections of the bioreactor;

Separation water containing residues of fermentation bacteria and a temperature of ± 52 ° C is supplied from the outlet of the separator of the biological installation to the inlet of the homogenizer; water and additives in the form of bacteria, microelements and pH normalizers (chalk, lime) are also supplied to the inlet of the homogenizer through the dispenser sensors pH, eH, temperature and analyzer CB (not shown in the diagram), which provides a high-quality initial preparation of raw materials, the first and partially the second phase (hydrolysis, acidogenesis) at thermophilic mode and optimal values of pH, eH and temperature, which allows to reduce the flow time reactions, depending on the raw material, up to 8-48 hours, with minimal energy consumption, the output of the finished substrate enters the bioreactor through a pipeline for methanogenesis;

the bioreactor is made of a heat-insulated casing, in the center of which there is a rotatable rotary separator separating the bioreactor, preferably into five sectors for multi-stage fermentation, on the walls of the bioreactor in each sector, except for the first one, a porous or film coating is applied to the entire height and width by 40 80% of the width of the sector with the ability to retain bacteria corresponding to the stage of fermentation, the lines for supplying and removing the substrate, the supply line is above the waterline of the substrate, the line for removing the substrate is at the level of the bottom of the bioreactor and both lines are on the same vertical line in the first sector, the bottom of the bioreactor has the slope from the center to the walls of the bioreactor, the biogas removal line and gas supply to the bubbler, the rotary separator contains a circulation column, the vertical separators are hermetically attached by the inner side to the circulation column, and the outer and lower sides have elastic ends, tightly attached running to the inner wall and bottom of the bioreactor, creating tightness between the sections with the possibility of free movement relative to the bioreactor body, horizontal separators are fixed on guides in each section with the ability to move from bottom to top, and their movement is coordinated with filling / emptying the bioreactor, horizontal separators have drainage hatches with the possibility of their automatic opening, the number of vertical and corresponding horizontal separators can be 3-8 pieces, which makes it possible to spatially divide the bioreactor, preferably into five sections, where the fermentation of the substrate in each section occurs in the optimal mode, the dosing device-2 with the possibility of feeding corrective additives to the substrate of each section under the control of a controller, pH, eH, temperature sensors, which together provide a minimum fermentation time, which, depending on the raw material used, can be from 3 to 10 days, a high degree of processing and a substrate to obtain the maximum yield of biogas with a high methane content with minimum energy consumption for own needs;

the circulation column contains a heat exchanger, each of its sections contains a flow-through heat exchanger for heating the substrate, at least one pump for hydraulic mixing and crushing of the substrate crust, inlet and outlet windows in each section, the level of the substrate waterline is located in the middle of the inlet windows, the outer casing, the sectors are made sealed in relation to each other, rotary separators are fixed to the circulation column, the rotation of the circulation column and the drive of the pumps are carried out through a gearbox from the GPE, which together allows maintaining the set temperature in the bioreactor, carrying out effective hydraulic mixing of the substrate, breaking the formed crust, using the controller to control the optimal stroke fermentation reactions and carry out loading / unloading of the bioreactor;

a heat pump unit (HPU) driven by a GPE, the first evaporator of which is built into the biogas cooler-separator, the second evaporator is built into a biofertilizer cooler, a condenser connected to a heating unit, a cooling circuit of the GPE drive, GPE HPU, GPE of a cogeneration plant (not shown), the gas boiler is connected to the input of the heating unit, to the output of which the heat exchanger of the homogenizer and the heat exchanger of the circulation column are connected with the possibility of independent temperature control in the storage and bioreactor.

The use of the GPE to drive the mechanisms of a biological plant with the utilization of the generated heat, the utilization of the residual heat of biofertilizer and biogas with the help of HPU and its summation in the heating station with subsequent separate transmission for heating the substrate in the storage tank and the bioreactor to maintain a strictly specified temperature regime allows to reduce to a minimum the consumption of biogas by own needs of the biological plant, as well as significantly improve the conditions for the reaction, which increases the specific yield of commercial gas and the content of methane in it.

The use of a thermophilic mode in combination with the technical solutions proposed in the invention makes it possible to reduce the dimensions of the bioreactor and accumulator and, at the same time, to increase the productivity of the installation with a high degree of raw material processing.

The applicant did not find any sources of information containing information about the influence of the aggregate declared distinctive features on the technical

- 3 036349 result. This, according to the applicant, indicates the compliance of this technical solution with the inventive step criterion.

The essence of the invention is illustrated by drawings, which shows:

in fig. 1 - biogas plant for anaerobic processing of organic waste;

in fig. 2 - bioreactor;

in fig. 3 - the bottom of the bioreactor (top view);

in fig. 4 - section of the bottom of the bioreactor;

in fig. 5 - bioreactor circulation column;

in fig. 6 - section of the circulation column of the bioreactor;

in fig. 7 - bioreactor reducer;

in fig. 8 - bioreactor pump switch;

in fig. 9 - heat exchanger of the circulation column.

FIG. 1-9 only the fundamentally important functional elements related to the essence of the invention are shown.

A biogas plant for anaerobic processing of organic waste (Fig. 1) contains a shredder receiver 1, connected by a shredder receiver shaft 15 connected to a distributor gearbox 14, a shredder receiver 1 is connected to a feed device 2, mainly of the screw type, the outlet of which is connected to a homogenizer 3 , which contains a mixing device with a mechanical drive 4 from the GPE 41 through a distributor gearbox 14, to the second inlet of the homogenizer, a meter-1 23 is connected to the second inlet of the components 27, to the inlet of which corrective components and water are supplied through the feed hoppers 24, 25, 26 , the outlet of the separator water from the separator 21 and the condensate from the cooler of the separator 19. The homogenizer 3, the heat exchanger 5 and the accumulator 6 are placed in a single heat-insulated housing with the possibility of free movement of the substrate from the homogenizer through the heat exchanger into the accumulator, from the outlet of the accumulator is connected under By means of a pipe 9 with a bioreactor 10, a gas outlet pipe 8 connects the cover of the accumulator 7 and the inlet of the bubbler 62 (Fig. 3), dispenser-2 16 contains inputs 17 for loading corrective components and is connected by pipes 18 to the bioreactor located above the corresponding sections of the circulation column, the outlet of the bioreactor 41 is connected to the separator 21, the mechanical drive 40 of which is connected to the reducer-distributor 14, from the outlet of the separator 21 is connected to the biofertilizer cooler 28, from the outlet of which the biofertilizer goes through the line 31 for further use. From the dome of the bioreactor 10 is connected by an outlet gas line with a cooler-separator 19, from the outlet of which biogas leaves for further use 20. The biogas plant contains a heating unit 34, to the inlet of which heat sources are connected from the heat recovery system of drives GPD 41, GPD TNU 30, GPD or a fuel cell for generating electricity (not shown) through the cooling line 39 of a cogeneration plant and a gas boiler 35, a heat exchanger 5 is connected to the outputs of the heating unit separately through pipes 11 and 12 and through pipes 44 and 46 a heat exchanger 58 (Fig. 4) of the bioreactor. The first evaporator TNU 30 is mounted in the cooler-separator 19, the second heat exchanger-evaporator TNU 30 is mounted in the biofertilizer cooler 28, the condenser 32 is connected to the heating unit, the TNU 30 is driven by the HPE HPU, which operates on the generated biogas supplied through the gas supply line 29.

The operation of the biogas plant is controlled by the controller 36, the input of which receives signals from the pH, eH sensors, temperatures located in the homogenizer 3, storage tank 6, bioreactor 10, heat point, gas boiler 35, heating unit 34, TNU 30, GPD 41, cooler-separator 19, biofertilizer cooler 28, controller outputs are connected to gas boiler 35, TNU 30, heating unit 34, GPD 41, gearbox-distributor 14 with the ability to control their parameters.

The bioreactor 10 of the biogas plant (Fig. 2) has a cylindrical shape, in the center of it is installed a circulation column 50 with the possibility of rotation, to which vertical separators 42 are rigidly and hermetically attached, mainly in an amount of 5 pieces, and have an elastic end on the lower and outer side, tightly adhering to the bottom and outer wall of the bioreactor 10, the separators have a smooth, liquid-impermeable structure, to the vertical separators 42 in each section are fixed horizontal separators 45 with the possibility of free movement up and down by the drive 49 and interconnected with the filling / emptying of the section, each separator contains drainage windows 47 with the possibility of opening them in the lower position, the supply pipe of the substrate 9 is in the upper part of the bioreactor, above the level of the substrate, the lower pipe of the outlet of the substrate 54 is at the lower point of the bioreactor, both pipes 9 and 54 are in the 1st sector 51.1 ( Fig. 3) on one vertical line, in the upper part of the bioreactor at the reducer of the bioreactor 52 is installed, the biogas is released through the gas outlet pipe 8. The bottom of the bioreactor (Fig. 3) is conventionally divided mainly into 5 sections, in 2-5 sections 51.2-51.5 on the vertical wall of the bioreactor 10 from the top to the level of the substrate vertically and 40-80% along the width of the sector a porous or film coating 77 is applied with the ability to retain bacteria, in 51.4 and 51.5 sections, a bubbler 85 is mounted in the bottom of the bioreactor, the bottom of the bioreactor has a slope from the center to the walls of the bioreactor (Fig. 7).

The circulation column 50 (FIG. 5) has a support column 60, which is leakproof in

- 4 036349 lower part and filled up to the top with a heat carrier and into which a mixing-type heat exchanger 58 is placed with the possibility of rotation relative to the support column, to which heat-conducting fins 59, partitions and an outer casing 50 are rigidly connected, at the top of each section there are windows for the intake of the substrate, at the bottom of the window for the outlet of the substrate 56, below the windows of the intake of the substrate, pumps 57 are installed, at least one per section, above each section there is an outlet 18 of the dispenser 16 (Fig. 1). FIG. 6 shows a sectional view of the circulation column AA. The drive for rotation of the circulating column and the pumps is carried out from the circulating column reducer (Fig. 7), the gear of the worm gear 63 is rigidly fixed on the support of the column 60, which is in mesh with the worm 64, the oblique gear 62 of the pump drive is seated through bearings 65 on the support of the column 60 with the possibility of free rotation, the gear of the worm gear 67 is rigidly connected to it, with which the worm 66 is in engagement, with the oblique gear 62 in engagement is the pump drive gear 68, which, using mainly the chain drive 72, transmits the rotational movement to the pump drive shaft 73, from which through the gearbox 75 rotation is transmitted to the pump screw 76, the drive of the worms 64 and 66 is carried out from the gearbox-distributor 14 (Fig. 1). The support column through sealed bearings 69 is fixed to the overlap 70 of the bioreactor 10, the reducer is closed from above by a protective casing 71, a heat exchanger 58 is inserted into the upper open part of the support column, each pump drive gear 68 (Fig. 8) contains a clutch 81 and a clutch pusher 78, which abuts at stop 79 to disconnect the pump drive. The heat exchanger of the bioreactor (Fig. 9) contains a heat flow separator 58, nozzles for supplying a hot coolant 82 and a nozzle for intake of a cooled coolant 83.

Biogas plant operation

The initial substrate in the form of a waste mixture is loaded at the input of the receiver-grinder 1, in which the C: N: P ratios and humidity from 50 to 90% are most optimally combined, in the receiver of the grinder 1 the substrate is crushed, which allows the most rapid hydrolysis reaction, the drive of the grinder 15 connected to a gearbox-distributor 14, from the outlet of the receiver-grinder, the substrate is fed to the feeder 2, mainly of the screw type, where the substrate is compressed, freeing from voids, where air is contained and supplied under pressure to the homogenizer 3, to the homogenizer 3 also through the batcher-1 Separation and condensation water is supplied through the pipeline 22 and through the feed hoppers 24, 25, 26 components for correcting pH, eH and, if necessary, additional water. In the homogenizer under the control of the controller according to the readings of the pH, eH, temperature and humidity sensors, the substrate is brought to the technological parameters and thoroughly mixed with the help of the dispenser, under the influence of a new portion, the substrate rises through the tubes of the heat exchanger 5, where it is heated to a predetermined temperature of ± 52 ° C, corresponding to the thermophilic mode, and enters the storage tank 6, where the first phase occurs - the hydrolysis of the substrate, and also there the second phase of acid formation partially takes place, from the outlet of the storage tank 6 the hydrolysis of the substrate enters through the pipeline 9 into the bioreactor 10, in the process of hydrolysis and acidogenesis in the storage tank, gases are predominantly formed containing H ₂ , CO2 and H2S, which are fed to the bubbler 85.

After the initial loading of the bioreactor and the stabilization of the parameters, the biogas plant operates as follows: the hydrolyzed substrate under the control of the controller begins to be added to the first section of FIG. 2, at the same time, from the outlet line, the fermented substrate is pumped out into the separator 21, and the horizontal separator 45, which was initially located at the top, starts synchronously, with the help of the drive 49 and the cables 48, to go down at a speed equal to the filling / emptying of the bioreactor section, while the vertical the separators rotate and, before reaching the pipe 54, the baffle 42 stops the pumping of the substrate, thus in the section the fermented substrate is replaced with a fresh one, while the rotary separator, consisting of vertical separators 42 and a circulation column 50, rotates at a speed of one revolution per 3-10 days, depending on the input raw material used, after replacing the substrate in the first section, replacing the substrate in the second section is suitable, and the process of replacing the substrate is repeated sequentially in all sections, the newly replaced substrate is in one section, gradually passes the distance of 4 sections, where in time, acid reactions proceed sequentially otogenesis, acetogenesis and methanogenesis, reactions take place without mixing, at each phase using a dispenser-2, according to the readings of pH, eH, temperature sensors built into the bioreactor wall, the reaction conditions can be adjusted. Vertical separators 42 are rigidly and hermetically attached to the circulation column 50 with their inner side, and the lower and outer edges of the separator have an elastic end, which makes it possible to ensure a sufficiently tight fit to the inner wall and the bottom of the bioreactor 10 and, with the same substrate level in the sectors, provides sufficient hydraulic isolation of each of sections, which excludes the overflow of the substrate from one section to another.

In the 51.4 and 51.5 sections of the bioreactor, the tubes of the bubbator 85 are mounted in the bottom part, into which the hydrolysis gas containing H ₂ , CO2 and H2S is supplied through the gas outlet pipe 8, which allows due to bioreaction

CO2 + H2 = CH4 + H2O to obtain biogas enrichment with methane, also porous or film material 77 attached in sectors 51.2-51.5 on the inner wall of the bioreactor, located along the entire height of the bioreactor

- 5 036349 from the bottom to the waterline and in width from 40 to 80% along the perimeter of the segment (Fig. 3), allows bacteria to be absorbed into the pores during operation and, when a new substrate approaches, serve as a source of their intensive reproduction, which reduces the reaction time. The bottom of the bioreactor is made with a slope from the center to the walls of the bioreactor (Fig. 4), which ensures the drainage of the sediment and its washing out through the outlet line 54 into the separator, also thanks to the elastic end of the vertical separator, which runs along the bottom and walls, the latter constantly cleans them like a scraper from possible deposits, horizontal separators 45 have drainage hatches, which are open in the lower position, which allows gases to escape into the bioreactor dome, and the rest of the time are closed, the remainder of the substrate after replacement, located below the horizontal separator 45 (Fig. 4), contains the necessary for the reaction bacteria and, when the pump is turned on, is spread throughout the volume of the section, which quickly starts the bioreaction process.

The circulation column 50 (Fig. 5) is designed to rotate the separators inside the bioreactor, hydraulic stirring of the substrate and heating it, the substrate through the middle of the upper window 56 enters the intake area of the pump 57, which sucks in the substrate and squeezes it out through the lower window 56, if in the process bioreaction, a crust will form, then it will be sucked into the pump 57 and grinded by the blades of the pump 57, the substrate, passing along the heat exchanger, will be heated, and the heated substrate when leaving the lower window 56 will mix the substrate in the sections, which ensures a uniform temperature throughout the volume, which will ensure the uniformity of the bioreaction, the rotation speed of the pump screw is in the range of 150-300 rpm, a sufficiently high speed of the substrate movement along the surface of the heat exchanger 59 does not allow the formation of deposits on the surface of the heat exchanger 59, the heat exchangers 59 receive heat through the walls of the support column from the coolant filling the internal etc The space of the support column 60, inside which the mixing heat exchanger is inserted (Fig. 9), containing a flow separator 58, between the wall of which and the wall of the support column hot water is supplied by nozzles 82, which, passing between the walls, gives off heat to heat exchangers 59, cools and returns through the return pipe 11, the heat exchanger 58 is rigidly fixed to the bioreactor body and does not have rigid connection with the support column 60, which allows it to rotate freely relative to the heat exchanger, on top of the circulation column above each section, there are outlets 18 of the dispenser 16, through which, if necessary, automatically at the command of the controller based on the readings of the pH and eH sensors in each section (not shown) the necessary components that adjust the substrate for the optimal course of bioreaction, the components enter the region of the substrate entry, and they are mixed by the pump 57, through the outlet window 56 the components mixed with the substrate are distributed throughout the volume of the substrate in the section, which provides a quick adjustment of the bioreaction parameters in each phase aze.

The drive for rotation of the column and pumps is made from the GPE 41, through the gearbox 14 rotates the shaft with the worm 64 mounted on it (Fig. 7), which drives the gear of the worm gear 63, rigidly connected to the support column 60, the transmission ratio is selected in such a way that the circulation column rotates at a speed of one revolution in 3-10 days and can be adjusted by the transfer ratio depending on the raw material used, the rotation speed of the circulation column determines the duration of the cycle of complete fermentation of the substrate in the bioreactor, a second worm pair is used to drive the pump, the worm 66 is connected to a gearbox -distributor 14, the worm 66 drives the worm gear 67, which is rigidly connected to the cylindrical, oblique gear 62, which is fixed through bearings 65 on the housing of the support column 60, from the oblique gear 65, the torque is transmitted to the pump drive gear 68, which is preferably through chain drive 72 drives in rotation the pump drive shaft 73, which rotates the pump screw 76 through the pump drive gear reducer 75, the transmission ratio of all gearboxes is chosen such that the pump screw rotates in the range of 150-300 rpm and is determined by the technological mode, the gearbox is covered with a protective casing 71 on top, the support column fixed to the housing of the bioreactor 70 through the bearing 69.

When emptying / filling the section, the operation of the pump 57 is stopped by disabling the clutch 77 by the pusher 78, which is pressed when entering the emptying / filling section against the stop 79 (Fig. 8), the sector in which the pump 80 is turned off is larger than the sector 51 separated by separators so that the movement of the substrate can be damped.

In the thermal circuit of a biogas plant, a heating unit is used, which sums up the thermal power received from the heat recovery system GPE 41, GPE TNU 30, along line 39 from the cogeneration unit (if any), from the gas boiler 35 and from the condenser TNU 32, which cools the outgoing biogas in the cooler-separator, the substrate in the biofertilizer cooler, from the outlet of the heating unit, the thermal power is used to heat the incoming substrate to a process temperature of ± 52 ° C, corresponding to the thermophilic mode, and the substrate in the bioreactor to the same temperature, depending on the operating mode, the outside temperature, the degree of thermal insulation of the bioreactor and the storage, the controller regulates the outlet temperature from the heating unit, if the heat power is insufficient, the gas boiler 35 is automatically turned on, and in case of excess heat power can be supplied to consumers or discharged in a dry cooler (not shown). Such implementation of the thermal scheme allows minimizing energy losses in the biogas plant and increasing the output of commercial biogas, the use of GPE in the drive of the biogas plant and HPU allows up to 90% use of biogas energy, which in general reduces the specific consumption of biogas for own needs.

The controller of the biogas plant 36 (Fig. 1) allows automatic control of all technological modes.

Industrial applicability

Thus, in the proposed biogas plant, organic waste gradually passes through all phases of anaerobic digestion (hydrolysis, acidogenesis, acetogenesis and methanogenesis) in optimal modes, with their hydraulic separation.

Using the proposed invention will allow the following.

1. Get biogas in the maximum possible volume and with the maximum percentage of methane.

2. Get high-quality organic fertilizers that do not require further sterilization.

3. Eliminate the slowdown or blockage of the fermentation reaction due to crust formation.

4. To obtain a high specific productivity per bioreactor volume in a continuous process.

5. Reduce the water consumption of the biogas plant to a minimum.

6. Reduce energy consumption for auxiliary needs (heat and electricity) to less than 10% based on the consumption of biogas due to the use of GPE and HPU and reduce the use of water.

7. Reduce the time of the bioreaction, adjust it depending on the raw material used.

8. Ensure high reliability of the biogas plant

9. To reduce the size of the plant due to the use of thermophilic regime and the proposed design of the biogas plant, to reduce the land area occupied by the biogas plant.

10. Reduce the payback period of the biogas plant.

It is advisable to build the proposed biogas plant from a bioreactor volume of 500 m ³ at enterprises with animal waste, fat and oil production, sugar factories, grain waste and other sources of organic raw materials.

In temperate and cool climates, it is advisable to bury the bioreactor in the ground, which will reduce temperature fluctuations and reduce the temperature difference, which will further reduce energy consumption for own needs and reduce the occupied area. A biogas plant can contain one or more bioreactors combined in a cluster, which will increase production and reduce heat losses. When placed in the ground, it is most preferable to make the bioreactor from concrete, the rest of the equipment used is known in the industry and does not cause problems when used in the proposed biogas plant.

List of sources of information.

1. RF patent No. 2491330 C1, 09.12.2011

2. RF patent No. 2370457 C1, 14.07.2008

3. RF patent No. 2414443 C2, 04.06.2009

Claims (18)

CLAIM 1. Biogas plant for the anaerobic processing of organic waste, consisting of a manure receiver, an anaerobic bioreactor, a pump, a heat exchanger-condenser, an evaporator heat exchanger, heat exchangers are connected to each other by means of a compressor with a gas motor drive on biogas to form a thermodynamic circuit of a heat pump, heat energy is used to heat the bioreactor cooling liquid, exhaust gases of the gas engine drive of the heat pump and the thermal energy of the processed substrate, characterized in that the manure receiver (1) has a grinder of incoming substrates, is connected to a feed device, preferably of a screw type, the outlet of which is connected to a homogenizer (3) located in a single heat-insulated housing with a heat exchanger (5) and a ready-made substrate accumulator (6), which is connected by a pipeline (9) to the bioreactor (10), the gas outlet pipe (8) from the accumulator cover (7) is connected to the inlet of the barbatator (85) of the bioreactor, the bioreactor is made and from a heat-insulated body, in the center of which there is a rotatable rotary separator separating the bioreactor, preferably into five sectors for multi-stage fermentation, a line for supplying (9) and removing a substrate (54), a biogas discharge pipe (20) and gas supply to a bubbling device (85 ), a rotary separator contains a circulation column (50), vertical separators (42) and horizontal separators (45), a drive reducer (52), a circulation column (50) contains a heat exchanger (58), each section contains a flow-through heat exchanger for heating the substrate (59 ), a pump (57) for hydraulic mixing of the substrate, inlet and outlet windows (56) in each sector, an outer casing (50), the sectors are sealed against each other, contains a dosing device-1 (23) and a dosing device-2 (16) with the possibility of supplying corrective additives to the substrate under the control of the controller (36), contains a gas piston engine (GPE) (41) for driving a biogas plant ki mechanically connected to - 7 036349 by a reducer-distributor (14), from which a bioreactor, a manure receiver, a homogenizer and a separator are driven, contains a heat pump unit (HPU) driven by a GPE (30), the first evaporator of which is mounted in the biogas cooler-separator (19), the second the evaporator is mounted in the biofertilizer cooler (28), the condenser (32) is connected to the heating unit (34), the cooling circuits of the GPE drive (41), the GPE HPU (30), the GPE of the cogeneration unit (39), the gas boiler (35) are connected to the input the heat exchanger (5) of the storage unit and the heat exchanger of the bioreactor (58) with the possibility of independent regulation of heat transfer by the controller (36), the separator (21) is connected to the outlet of the bioreactor, to the outlet of which a fertilizer cooler is connected and to it the biofertilizer outlet line, to the separator is connected to a line for supplying separation water (22) and condensate (43) to dispenser-1 (23), contains a bioinstallation control controller (36), inputs (37) receive information from yes sensors pH, eH, level, temperature (not indicated) installed in the manure receiver, homogenizer, accumulator, in the middle of the walls of each section of the bioreactor, the controller outputs are connected to the heating unit (34), dispensers (23, 16), HPU, GPD. 2. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the temperature of the finished substrate in the storage tank (6), regardless of the temperature of the original substrate entering the manure receiver (1), is set by the software controller (36) and is maintained stable at the level is mainly ± 52 ° C, corresponding to the thermophilic regime. 3. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the volume of the storage of the input substrate is defined as Where VH - storage volume; V _6p is the volume of the bioreactor; N is the number of bioreactor sections. 4. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the vertical separators are hermetically attached with the inner side to the circulation column (50), and the outer and lower sides have elastic ends, tightly adhering to the inner wall and bottom of the bioreactor, creating tightness between sections with the possibility of free movement relative to the bioreactor body. 5. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the horizontal separators are fixed on guides in each section with the ability to move from bottom to top in coordination with filling / emptying the bioreactor and have elastic seals around the perimeter. 6. Biogas plant for the anaerobic processing of organic waste according to claim 1, characterized in that the horizontal separators have drainage windows (47) that are automatically closed in the first sector when filling / emptying the bioreactor. 7. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the number of vertical and corresponding horizontal separators can be 3-8 pieces. 8. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that at least one pump is installed in each section of the circulation column. 9. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the middle of the entrance windows (56) is at the level of the substrate waterline. 10. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the bioreactor drive, heat pump and boiler (35) are powered by the biogas engine from the biogas produced by the bio-plant through the line (29). 11. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the walls of the bioreactor in each sector, except for the first (81), are coated with a porous coating (77) over the entire height and width of 40-80% of the width of the sector with the ability to retain bacteria. 12. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the bottom of the bioreactor has a bottom with a slope from the center to the wall of the bioreactor. 13. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that a switch of the pump (57) for hydraulic stirring is installed in the first section. 14. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the rotational speed of the rotary separator is one revolution in 3-10 days and is programmed. 15. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the inlet line is above the substrate waterline, the lower line is at the bottom of the bioreactor and both lines are on the same vertical line in the first sector. 16. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that any known separator can be used as a biogas cooler-separator - 8 036349 gases with cooling, including a hydrate cooler-separator. 17. Biogas plant for anaerobic processing of organic waste according to claim 1, characterized in that the reaction time can be adjusted using the biogas plant control controller by changing the gear ratio of the reducer and / or the speed of rotation of the GPE drive. 18. Biogas plant for the anaerobic processing of organic waste according to claim 1, characterized in that the biogas plant may contain more than one bioreactor combined into a cluster.