INNOVATIVE TECHNOLOGY by Weber Entec

DesiUS – the “turbo” for your biogas plant

Construction equipment engineering

The term “DesiUS” stands for “disintegration ultrasound system”. The disintegration process which forms the basis of DesiUS was developed by Weber Ultrasonics in collaboration with the Fraunhofer Institute, and was optimised by Weber Entec through the use of the BioPush reactor.

DesiUS (Disintegration Ultrasound System) represents energy-efficient and process-robust cell opening technology combined with exceptionally high efficiency. The robust and completely maintenance-free construction of the BioPush reactor allows a simple and uncomplicated structure. The ultrasonic reactors of the turnkey constructed plant are charged via a screw pump. The substrate is routed through the sound field at a specific speed in such a manner that the specific energy input required for treating the substrate is ideally achieved. A macerator protects the machine from foreign objects and provides coarse homogenization upstream, in order to achieve optimal coupling of the ultrasound. A PLC-supported control system enables robust and trouble-free operation. In addition, the machine is equipped with sensors that monitor temperature, pressure and volumetric flow.

Technical advantages

Very high energy efficiency – 50 % saving compared to other disintegration systems
Extremely low-maintenance plant technology
High degree of operational reliability
Long standing times
Can be ideally adapted to the respective requirements
Lower space requirement thanks to compact design, simple plug & play installation
Quick pay back

Plant control and remote access

A PLC-supported control system enables robust and trouble-free operation.

The drawing shows the simple and therefore error-free structure of DesiUS. The plant consists of a macerator, a screw pump, in this case two ultrasonic reactors, flow quantity measurement devices, and pressure and temperature sensors (two each). The control cabinet with the PLC control system may be installed in a remote location, or directly on the plant.

ADVANTAGES OF BIOPUSH

LONG LIFETIME, ZERO MAINTENANCE AND OPERATIONAL RELIABILITY

The BioPush Ultrasound reactor solves the problems of the other disintegration systems. Because biomasses with a typical solids content between 8% and max. 13% have a relatively high viscosity, more effort is usually required in traditional plants in order to ensure an effective coupling of the ultrasound to the medium. Because the cavitation performance of the ultrasound becomes more damped as the viscosity of the medium increases, the medium must therefore be passed as close as possible to the sonotrode. Although this could be achieved constructionally by means of a sufficiently small pipework cross-section, it is not possible to implement it in this way, because the sonotrodes tend to become affected by blocking and “tressing” from fibrous components, both in substrates from biogas plants using renewable raw materials and also in sewage sludges. The results are a high level of sound damping, and therefore reduced energy efficiency.

The BioPush reactor developed by Weber Entec specifically for the treatment of biomasses tackles this problem. The structure practically precludes blockages and tressing. The working life of the BioPush reactor is several times longer than with classical rod sonotrodes in the biomass area.