The bioCrack is a state-of-art high voltage lysing system that prepares the liquid for maximized biogas yield and reduces solid contents in the sludge. The overall system uses mechanical maceration combined with an electrokinetic process that produces a liquid with the highest potential for making biogas and reducing solids compared to conventional slurry handling and reduction methods.

The bioCrack provides the bacteria easier access to the nutrients in the bio-suspension. A high voltage field is generated by the elelctrokinetic disintegration process within the module. Exposure to the field degrades and breaks the cell walls of the organic matter. As a result, the nutrients within the cells are released to the fermenting bacteria. The result: Increased gas yield, better utilisation of the substrates and less residual solids to dispose of.

High Voltage Sludge Lysing

high voltage sludge lysing

The BioCrack Product Line

The BioCrack is a highly configurable device that can be worked into countless configurations to maximize space savings and minimize retrofitting. The BioCrack can be installed on a frame as shown below or mounted
to an existing structure.

Typical results

Adding a BioCrack affects each plant differently
depending on the properties of the sludge or slurry.

Average Results include:

•Increased Biogas yields up to 18%.
•Increased energy production.
•Enhanced digestion with less material consumption.
•Reduced process energy consumed by mixing.
•Shorter and more stable digestion cycles.
•Reduced dry solids content with better
dewatering up to 21%.
•Reduced polymer consumption up to 18%.

The Biocrack Product Line

How Biocrack works?

The sludge flows through a pipe system with an internal electrical high voltage field. The electric force creates a pulsing effect on the cells causing them to deform and finally rupture. As a result, the raw material inside the cell is exposed to the bacteria. The enhanced exposure produces more methane gas. The process also stimulates the bacteria which allows it to perform at higher efficiency.

Where to add a BioCrack?

The BioCrack is primarily designed to enhance the digestion process. It is typically placed between the digester and the heat exchanger or on a digester feed line.
Sludge is cycled through the BioCrack at predetermined intervals depending the characteristics of the sludge as well as the digester and related components.

Feeding the biocrack

Feeding the BioCrack

The BioCrack must be fed the sludge by means of a pump. The sludge must also be mechanically conditioned to remove or separate hard solids while also homogenizing the liquid. For best results, we require a Vogelsang VX Rotary Lobe pump and a RotaCut Inline Grinder to feed sludge into the BioCrack system. This ensures the system is fed at the optimum flow rate and damaging solids are reduced or removed from the liquid.

The BioCrack is made up of three major components. The Internal electrode disperses the electric field within the tube housing. The tube housing contains the electric field while also containing and feeding the liquid throughout the processes. The electrodes are controlled either by individual panels or can be wired together into a common control panel. The panel can also be configured to control the RotaCut and Pump as well.
The BioCrack requires a feed pump and a RotaCut inline grinder. Solids must be reduced in order for the process to work effectively.

Components of Biocrack

Model Diamensions Power Required Max Solids Flange Size Max Pressure Material Stainless Capacity*
l/w in l/w mm Watts Voltage % in mm psi bar gpm m3/h
U-Style Pipe 81×13 2053×326 35 110% 60hz 8 6 125 73 5 316 352 80
S-Style Pipe 81×20 2053×492 35 110% 60hz 8 6 125 73 5 316 352 80
90° Left Flange Pipe 81×20 2053×326 35 110% 60hz 8 6 125 73 5 316 352 80
270° Right Flange Pipe 81×20 2053×326 35 110% 60hz 8 6 125 73 5 316 352 80

BioCrack Configurations:

The BioCrack can be set up in a variety of ways. Using our assembly frame, up to six pipes can be mounted together. The number of pipes is determined by the characteristics of the sludge and digestion process. Each plant is different thus, many options are available to achieve the best results.