AU9418798A - Worm reactors - Google Patents

Description

P/00/008b 12/11/91 Section 29(1) Regulation 3.1(2)

AUSTRALIA

Patents Act 1990 NOTICE OF ENTITLEMENT We, MAPAS PTY. LTD., of 4 Harper Street, Mt. Gravatt, Queensland, 4122, Australia, being the Applicant in respect of the Application filed herewith, state the following:- 1. The person nominated for the grant of the patent has entitlement from the actual inventor by virtue of the entitlement of the Applicant, on the grant of a patent for the invention, to have the patent assigned to them.

2. The person nominated for the grant of the patent is the Applicant of the provisional application listed on the Patent Request form.

DATED this thirtieth day of November 1998.

Signed for and on behalf of the Applicant, MAPAS PTY. LTD., by their Patent Attorneys, FISHER ADAMS KELLY Robii KELLY Registered Patent Attorney P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE

SPECIFICATION

STANDARD

PATENT

Invention Title: "WORM REACTORS" The following statement is a full description of this invention, including the best method of performing it known to us:- 2 "WORM REACTORS" THIS INVENTION relates to worm reactors for treatment of organic wastes.

Worldwide attention is now being increasingly focused on the prevention of environmental destruction of land, waterways, sea and atmosphere and, in this regard, most responsible governments are enforcing strict regulations on the disposal of waste materials. The greater proportion of these are solid and liquid organic waste.

Worms accelerate the decomposition of organic wastes threefold, concurrently converting waste to approximately half the original volume of clean healthy fertile castings and therefore worm reactors have previously been proposed in relation to treatment of organic wastes. Such reactors, which have been previously proposed, are ground beds open to the atmosphere.

Failure or less than anticipated performances of various worm reactors have principally been caused by:lack of knowledge of the waste material; (ii) poor or inappropriate design of the operating system that was employed; (iii) lack of proper, or no control, of climatic conditions; (iv) no control of vermin or pests; excessive land area required to process the designated volume of waste; and (vi) poor management of worm beds.

3 There is a popular misconception that the problem of waste material disposed is solved by throwing a mass of worms into a heap of organic waste. This theory has resulted in a litany of failures and the consequent reluctance of some to appreciate the true potential of worms in efficient treatment of organic wastes.

Solid wastes contaminate land often by anaerobic decomposition which can continue for an indefinite period simultaneously polluting the atmosphere with greenhouse gases and contaminating land, waterways and oceans with soluble salts and heavy metals through ground, flood and surface water leaching. Some liquid waste such as liquid waste separated from agricultural wastes can be beneficially used for irrigation. This practice, however, is limited by the land area available as excessive irrigation causes run-off into waterways, rivers and eventually oceans resulting in damaging concentrations of salt, nitrogen and phosphorus in waterways and oceans.

Liquid wastes can be treated through filter beds containing worms in a casting habitat that forms part of the filter bed. In such filter beds, the excess of salts and heavy metals filtered out by the worms can be taken up by selective plants and trees, such as melaleucas and casuarinas for biological recycling.

Worldwide research carried out by highly reputable laboratories and institutions on worm feeding and breeding habits provides a wealth of information regarding worm performance in laboratory conditions. This research confirms that worms have an 4 important role to play in returning to the earth the discarded organic materials that have been harvested from it. It is therefore evident that there is a need for commercial exploitation of more efficient worm reactors for recycling organic wastes. Technology in the destruction of organic wastes by incineration, use of chemicals and other high energy means has outstripped any practical research in relation to worm reactors. The advantage of worm reactors is that they mass treat organic wastes to produce compost which may be recycled producing a valuable fertile product which is produced with minimal energy input.

Reference may also be made to an article by J.S. Price entitled "Development of a Vermicomposting System" on pages 294-300 of the Proceedings, Volume 1, of the 4th International CIEC Symposium, Agricultural Waste Management and Environmental Protection held on May 11-14, 1987 in Braunschweig, Germany. The editors were E. Welte and I. Szabolcs. The Price reference described a mechanized system for processing agricultural livestock wastes using the earthworm Eisenia foetida. The mechanized system included an elevated reactor wherein waste material was fed to the top of the reactor and compost was discharged at the bottom of the reactor wherein temperature was controlled by variation of the depth of waste between 200-500 mm in the reactor which gave a temperature range of between 20-25 0 C. Effective drainage and aeration was provided by a mesh floor of the reactor which prevented waterlogging and anaerobicity. The reactor comprised a frame which supported the mesh floor above the ground and compost material was transferred through the mesh floor and the discharged compost was passed to one end of the reactor by a scraper. Raw waste material was applied mechanically in thin or 30 mm horizontal layers by a carriage which travelled on the top of the reactor which carriage reciprocated from end-to-end of the reactor. The reactor included an upper layer of waste material, an intermediate layer of worms and a bottom layer of compost material. The waste was scraped off the mesh floor of the reactor by a discharge mechanism which comprised a transverse breaker bar which reciprocated from one end of the mesh floor to the other end which set up a shear front causing a thin layer of compost material to be discharged.

The breaker bar which was of cruciform shape facilitated efficient discharge of waste material while worm activity continued undisturbed above. The breaker bar could be reciprocated by winches at each end of the mesh floor or alternatively, a multi-breaker frame could be reciprocated by hydraulic cylinders.

However, in relation to the worm reactor described in the Price reference, it was considered that the method of distribution or feeding of waste material to the top of the reactor using the reciprocatable carriage was bulky and cumbersome as well as being time consuming and inefficient in operation. The use of a reciprocatable carriage was also expensive. It was also noted that the Price reference did not describe how the waste was passed from the carriage to the interior of the reactor.

It therefore is an object of the invention to provide a worm 6 reactor which may alleviate at least, to some extent, the aforementioned disadvantages of the prior art.

The worm reactor of the invention includes a housing having a levelling means for maintaining a substantially uniform level of waste material within the housing as well as a discharge means for causing discharge of compost for ultimate collection.

The housing may be of any suitable shape but is preferably cuboidal having a pair of opposed ends and opposed sides to provide a fully enclosed housing. To this end, the housing may also include a frame having a plurality of uprights as well as longitudinal frame members as well as transverse frame members. There may be provided a pair of opposed side panels as well as a pair of opposed end panels wherein each of the end panels and side panels may be hingedly attached to the frame.

Preferably the housing has a top section formed of two oblique panels or gables and, in this regard, the frame may include oblique frame members and a top frame member. Hatches or panels may be incorporated in the top section which may be pivoted outwardly to facilitate access to an interior of the frame for maintenance purposes.

The housing may include a top layer of organic waste, a middle or intermediate layer of worms and a bottom layer of compost material or "vermicompost" or "worm cast".

The levelling means maintains a top surface of waste material at a substantially uniform or planar level and may, for example, include a transverse levelling bar which reciprocates along the top surface of waste material from end-to-end. The levelling bar may be operatively associated with suitable actuation means, such as a ram assembly which may be hydraulically actuated or pneumatically actuated as may be required. Alternatively, the levelling bar may be attached to chains, one of which is attached to an idler sprocket and the other of which is attached to a drive sprocket as shown in the aforementioned Price reference. Alternatively, a plurality of such levelling bars may be employed which travel along the top surface of the waste material from end-to-end.

However, more preferably there is provided a levelling conveyor which is provided with a plurality of transverse cleats which are located at spaced intervals along the conveyor. Preferably, the conveyor is provided with one or more suitably a pair of spaced chains or belts which support the plurality of cleats. Each of the chains or belts may be attached to a driving sprocket or pulley at one end and an idler sprocket or pulley at the other end. Each of the cleats may be rectangular or square in cross section or, more preferably, are L-shaped.

The levelling means may be height adjustable relative to an adjacent layer of waste material in the housing and this may be accomplished by making the levelling conveyor height adjustable as illustrated in one embodiment hereinafter. Alternatively, a top housing containing the levelling conveyor is made height adjustable relative to a bottom housing as described hereinafter in relation to another illustrated 8 embodiment by the use of pneumatically or hydraulically actuated ram assemblies.

The housing may also include a layer of mesh or perforated sheet which supports the bottom layer of compost referred to above.

The discharge means suitably comprises a bottom conveyor for transporting compost to a collection receptacle. There may also be provided harvesting means associated with the discharge means to harvest compost material from the housing into the discharge means.

In one form, such harvesting means may comprise a plurality of cleats which scrape or contact the bottom layer of compost to fall onto the conveyor through the mesh sheet described above whereinafter such conveyor may transport the compost to a receptacle adjacent the housing.

In another form, the housing means may comprise a scraper blade which, in one embodiment, reciprocates to and fro along the length of the mesh sheet. Such scraper blade may be actuated by a hydraulic ram assembly or pneumatic ram assembly or, alternatively, be attached to one or more conveyor chains or belts.

Alternatively, such harvesting means may comprise a plurality of valves which, in a closed position, form part of a bottom support sheet of the compost material and which may open when required by suitable control means to allow compost material to fall or be discharged onto the bottom conveyor. In one embodiment, there may be provided a plurality of rotors or pivotally mounted members having plates 9 attached thereto which form the abovementioned bottom support sheet but when each of the rotors are pivoted may cause upward or downward movement of the plates to provide discharge openings for the compost material.

Reference may be made to a preferred embodiment of the invention as shown in the attached drawings, wherein:- FIG. 1 is an exploded perspective view of a worm reactor constructed in accordance with the invention; FIG. 2 is a detailed view of the water sprayers located at a top location of the worm reactor shown in FIG. 1; FIG. 3 is an end view of the worm reactor shown in FIG. 1; FIG. 4 is a side view of the worm reactor shown in FIG. 1; FIG. 5 is a detailed view of one end of the worm reactor shown in FIG. 4; FIG. 6 is a plan view of the worm reactor shown in FIG. 1; FIG. 7 is a detailed perspective view of support rails which support a bottom flight of the levelling conveyor; FIG. 8 is a perspective view of another type of worm reactor constructed in accordance with the present invention; FIG. 9 is a side view of the worm reactor shown in FIG. 8; FIG. 10 is a view of one side of the worm reactor shown in FIG. 8 illustrating the drive means for the top and bottom conveyors; FIG. 11 is a perspective view of a distribution member for use in the distribution means for feeding waste material into the top conveyor;and FIG. 12 is a perspective view of a rotor member for use with the harvesting means for harvesting worm cast onto the bottom conveyor.

In the drawings, there is shown worm reactor 10 which includes housing 11 which has a housing frame 12 having posts 13, longitudinal frame members 14A and 14B transverse frame members and oblique frame members 16A interconnecting longitudinal frame member 14B and top frame member 16. The frame 11 may also include side panels 17 and end panels 18.

The worm reactor 10 also includes a feed hopper 19 for feeding waste material into housing 11. There is also provided an upper conveyor 20 which is provided with L-shaped cleats or scrapers 21 on chains 22 which are each attached to chain sprockets 23 located at each end of housing 11 as shown in FIG. 1. There is also provided an axle or shaft 24 interconnecting each chain sprocket 23. As is also shown in FIG. 1, upper conveyor 20 also includes a drive sprocket 25 which is connected to an appropriate drive means such as an output shaft of a motor (not shown). There may also be provided a reduction gear box (not shown) intermediate the drive motor and the drive sprocket. There is also included a lower conveyor 26 of similar structure to upper conveyor which is provided with opposed chains 27 interconnected by cleats 28.

Conveyor 26 is also provided with chain sprockets 28A interconnected by axle 26A as well as a drive sprocket 29 and bearings 30 as shown in FIG.

1. Similar bearings 30A are used in upper conveyor 11 There is also provided hatches or covers 31 which are mounted within each of the apertures 32 of frame 12 which are bounded by frame members 14B, 16 and 16A or end panel 18 as shown in FIG. 1.

In FIG. 1, only one hatch 31 is shown for the sake of convenience. There is also shown a network 33 of transverse pipes 34 having apertures or jets 35 which are interconnected by longitudinal pipes 36 to provide a continuous circulation of air within housing 11 which may be emitted from jets 35. Each of transverse pipes 34 may extend through holes 37A located in side panels 17. There is also provided elbow joints 35A and T joints 35B for screw-threadedly connecting pipes 35 and 36. There is also provided a mesh sheet 37 located within housing 11. The housing 11 also contains a top layer 38 of waste material, an intermediate layer 39 of worms through which may extend pipes 34, and a bottom layer 40 of worm castings. There is also provided a plurality of nozzles 41 located at spaced intervals along top frame member 16.

In FIG. 2, there is shown an individual nozzle 41 which provides a spray of water 42, which nozzle is connected to water conduit 43 for conveying water under pressure to nozzles 41. Water conduit 43 is suitably a hollow interior of top frame member 16. There is also shown hinges 44 which interconnect each of hatches 31 to frame member 16 so that hatches 31 may be pivoted upwardly as required for inspection or maintenance purposes as well as handles 44A.

In FIG. 3, there is shown a bottom layer of worm castings which is collected in housing 11 after passage through mesh sheet 37 by 12 the action of lower conveyor 26 as hereinafter described. Layer 45 is collected on collector tray 46.

In FIGS. 4-5, there is shown housing 11 in side view wherein waste material is deposited on feed hopper 19 which includes an entrance portion 19A together with a guide portion 19B whereby waste material is guided to fall between each of the spaces 48 located between cleats 21 of upper conveyor 20 and thus form the top layer 38 which is supported by mesh sheet 37.

In FIG. 5, there is shown a more detailed view of one end 49 of housing 11 remote from feed hopper. In FIG. 5, there is shown guide and top flight 51 of upper conveyor 20 which has a lower flight 52.

There is also provided a lower guide 53 for supporting top flight 54 of lower conveyor 26 which also has a lower flight It will also be appreciated that when cleats 28 on top flight 54 are in the position shown in FIG. 4 that they may harvest or scrape castings from the top surface 63 of mesh sheet 37 into collection tray 46.

It will also be noted that cleats 21 on lower flight 52 of conveyor scrape the top surface 64 of waste material 38 to ensure that top surface 64 is substantially level.

FIG. 6 shows a plan view of reactor 10 wherein only four hatches 31 are shown for convenience with the remainder of such hatches having been omitted for convenience. It will also be appreciated that the reactor 10 has an axis of bilateral symmetry.

FIG. 7 also shows a detailed view of support rails 68 which 13 are L-shaped in cross section as shown for supporting lower flight 52 of top conveyor 20. Such rails 68 are height adjustable and this is shown by adjustment belts 72 engaging in slots 69 in side panels 17 with the use of washers 70 and nuts 71.

In FIG. 8, there is shown a modified worm reactor 75 that incorporates a feed hopper 76 having a cover 77 wherein waste material 78 is fed into hopper 76 wherein the waste is subjected to the action of feed rollers 79 which function not only in forcing the waste material into a top or auxiliary housing 80 which contains top conveyor 81, best shown in FIG. 9, but also breaking up the waste material into smaller particles.

The feed rollers 79 are driven by gears 82 which mesh together as shown in FIG. 8. It will be appreciated that gears 82 may be driven by any suitable form of drive means such as an electric motor (not shown).

The worm reactor 75 also includes a control panel 83 mounted to control box 84. The conveyor housing 80 also has covers and also may be provided with strengthening ribs 86. The top conveyor 81 has a drive shaft 88 and is supported on hydraulic or pneumatic ram assemblies 89 for the purpose of controlling the height of top conveyor 87 above a bottom housing 90 which contains a top layer of waste material 91, an intermediate layer of worms 92 and a bottom layer of worm cast 93 as best shown in FIG. 9.

There is also provided opposed support frames 94 which also house a bottom conveyor 95 which is preferably formed from mesh 14 material. Bottom conveyor 95 is provided with drive roller 95A. Also indicated is control mechanism 94A for harvesting members 96 best shown in FIG. 9. Harvesting members 96 harvest worm cast from level 93 onto bottom conveyor 95 as best shown in FIG. 9. Also shown is an air manifold 97 connected to a source of pressurized air (not shown) for aerating a top flight 98 of bottom conveyor 95. Connected to air manifold 97 are supply conduits 99. Also shown at each end of reactor 75 are water tanks 100 each having a water inlet 101 and cap 102 for replenishing each tank 100 when required.

As best shown in FIG. 9, the action of feed rollers 79 is shown in forcing waste material 78 into top housing 80 through chute 103.

There is also provided water sprays or jets 104 each connected to a common manifold 105 for moistening the top bed or layer 91 of waste material when required. Elevation of top housing 80 by pistons 89A is indicated by the double headed arrow in full outline. Pistons 89A are supported in cylinders 89B bolted to frames 94 at 106. Also shown is inlet 107 for fluid for entering cylinders 105 when required.

The top conveyor 81 is provided with cleats 108 for levelling the top layer 91 of waste material in similar manner as described in the first embodiment shown in FIGS. 1-8.

There is also provided harvesting members or rotors 96 for harvesting worm cast from layer 93 onto bottom conveyor 95 and, as such, cleats 28 are replaced by harvesting rotors 96. As shown in FIG.

12, each rotor is star-shaped'in cross section having a plurality of plates 110 and opposed ends comprising pipes 111. Each rotor 96 is connected to one end of an associated link 112. Each link 112 is attached at its other end to a control rod 113 so that upon linear or reciprocatable movement of threaded control rod 113, each link will pivot from an upright position as shown in FIG. 10 to an oblique position as shown in FIG. 9. To facilitate this, each link 112 also includes an actuating block 112A engageable in an associated slot 112B. Also, each link 112 has an aperture 112C for engaging an associated pipe 111.

FIG. 10 illustrates an open position for each rotor 96 which allows worm cast or compost 93 to fall through spaces or gaps 115 onto the top flight 98 of conveyor 95 as shown. On the other hand, FIG. 9 illustrates a closed position for each rotor 96.

It will also be appreciated that links 112 when in either an oblique position shown in full outline in FIG. 9 or another oblique position as shown in phantom in FIG. 9 will retain each rotor in a closed position.

Thus, a full cycle will comprise movement of each link 112 from a closed position as shown in FIG. 9 to an open position having either oblique position as shown in FIG. 10 and back to the original upright position shown in FIG. 9.

When worm cast 93 has been deposited upon flight 98 of conveyor 95, such cast may then be deposited into collection receptacle 116 as shown in FIG. 10. Movement of the conveyor 95 is also shown by the arrows in full outline. There is also provided air supply conduits 99 which directs a flow of air upwardly onto the cast supported on flight 98 of

I

16 conveyor 95. There is also provided air conduits 117 shown in phantom for aeration of worms 92.

In FIG. 11, there is shown the drive means 118 for each conveyor 81 and 95 and such drive means includes a drive motor 119 mounted on mounting frame 120 and gear box 121 which is coupled to drive pulley 122. The drive pulley 122 is coupled to another pulley 123 attached to drive shaft 114 of bottom conveyor 95. There is also provided belt clutch 124.

There is also provided belt 125 attached to drive pulley 122 which also engages with pulley 126 coupled to drive shaft 88 of top conveyor 81, pulley 128 and pulley 129. Each of pulleys 128 and 129 are attached to control lever 130 which is provided with counterweight 131 at its other end as shown. Pulley 128 is also attached to housing 80 while pulley 129 is only attached to control lever 130. This enables control lever 130 to pivot from a position shown in full outline to a position shown in phantom and thus the assembly of lever 130 and counterweight 131 together with pulleys 128 and 129 functions as a suitable belt tensioner to belt 125.

In FIG. 12, the feed rollers 79 are illustrated in more detail comprising star-shaped gear 82, axle 132 and tines 133 oriented at different angles to the longitudinal axis of axle 132 as shown to facilitate breaking up of waste material and also forcing the waste material down chute The rotors 96 are also illustrated in greater detail comprising 17 opposed end conduits 111 and plates 110.

It is also believed that the worm reactor of the invention will provide an inexpensive and efficient method of disposal of organic waste which, at present, can only be disposed of by methods which are not environmentally acceptable, such as incineration and chemical means described above or by landfill.

Another advantage of the worm reactor of the invention is that it enables organic waste to be disposed of at the source of such waste and thus waste which emanates from restaurants, hotels, shopping centres and institutions does not require to be transported to an incinerator or landfill site.

It will also be appreciated that, in the near future, waste from abattoirs, dairy farms, piggeries will have to be disposed of by methods which are far more environmentally friendly than the present methods as described above and thus the worm reactor of the invention will become an increasingly commercial proposition. Such worm reactors can dispose of organic wastes with minimal labour.

The organic wastes which are subject to treatment by the worm reactor of the invention include:domestic and kitchen waste from small scale operations; agriculture and abattoir waste; and the filtrate of waste liquids.

It is therefore considered that the worm reactor of the 18 invention will provide a ready solution to efficient disposal of the waste referred to above and, in particular, domestic and kitchen waste because, at present, this waste is extremely variable in nature and subject to fly and vermin infestation which occurs in areas of high population and human habitation.

The worm reactor of the invention is not only vermin pest free but can operate with minimum unskilled labour.

In the worm reactor of the invention, the waste is totally enclosed and operates in a controlled artificial climate, thereby enabling the worms to work at optimum capacity 24 hours a day. The worm reactor of the invention may also incorporate a milling/grinding mixing operation at the feed end of the reactor. It is anticipated that these reactors will be located close to habitation and therefore will be completely odourless.

The worm reactor of the invention can also provide appropriate control of such variables as temperature, oxygen content, moisture content, pH, aeration and humidity to facilitate the best conditions for propagation of the worms which may be automatically adjusted as may be required by automatic sensors. In this regard, the aeration pipes 34 and 117 may not only provide the worms in levels 39 and 92 with oxygen but also heated air if the worm reactor is located in a cold climate.

It will also be appreciated that the bottom layer of pipes 34 underneath layer 40 are used for drying the worm castings collected in layer 45 in the FIGS. 1-7 embodiment.

Claims (17)

1. A worm reactor including a housing having a levelling means for maintaining a substantially uniform level of waste material within the housing as well as a discharge means for causing discharge of compost for ultimate collection.

2. A worm reactor as claimed in Claim 1 wherein the housing includes a top layer of waste material, an intermediate layer of worms and a bottom layer of compost.

3. A worm reactor as claimed in Claim 2 wherein the levelling means comprises a transverse levelling bar which reciprocates along a top surface of the layer of waste material from end-to-end.

4. A worm reactor as claimed in Claim 2 wherein the levelling means comprises a plurality of levelling bars or cleats which travel along a top surface of the layer of waste material from end-to-end.

5. A worm reactor as claimed in Claim 4 wherein the levelling cleats are attached to a conveyor.

6. A worm reactor as claimed in any preceding claim wherein the levelling means is height adjustable to vary the distance or clearance between the levelling means and waste material in the housing.

7. A worm reactor as claimed in any one of Claims 1-5 wherein there is provided an auxiliary housing containing the levelling means which is located above the housing characterized in that the auxiliary housing is height adjustable to vary the clearance between the levelling means and waste material in the housing.

8. A worm reactor as claimed in Claim 7 wherein there is provided hydraulic or pneumatic ram assemblies between the auxiliary housing and the housing containing the waste material.

9. A worm reactor as claimed in any one of Claims 2-9 wherein there is provided harvesting means for harvesting compost material from the housing into the discharge means. A worm reactor as claimed in Claim 9 wherein the harvesting means comprises one or more transverse cleats which move from one end of the housing to the other and which scrape or harvest compost from the housing into the discharge means.

11. A worm reactor as claimed in Claim 10 wherein the compost is suspended on a mesh or perforate sheet which is contacted by the transverse cleat(s).

12. A worm reactor as claimed in Claim 10 or 11 wherein the transverse cleats are attached to a bottom conveyor which transports compost to a collection receptacle.

13. A worm reactor as claimed in Claim 9 wherein the harvesting means comprises a plurality of valves in the form of pivot members which, in the closed position, form a bottom sheet of the housing and, in the open position, provide a plurality of openings for transfer of compost into the discharge means.

14. A worm reactor as claimed in Claim 13 wherein the pivot members are each controlled by a control rod which moves in a reciprocatable manner. 21 A worm reactor as claimed in Claim 14 wherein each pivot member is pivotally attached to an associated link which is pivotally attached to the control rod.

16. A worm reactor as claimed in any one of Claims 1-11 and 13-15 wherein the discharge means is a bottom conveyor which transports compost from the housing to a colloidal receptacle.

17. A worm reactor as claimed in Claim 16 wherein the bottom conveyor is provided with aeration means for aerating compost located on an upper flight of the bottom conveyor.

18. A worm reactor as claimed in any one of Claims 2-17 wherein the housing is provided with aeration means to aerate a layer of worms in the housing.

19. A worm reactor substantially as herein described with reference to the accompanying drawings. DATED this thirtieth day of November 1998. LTD-, 4- urck by their Patent Attorneys, FISHER ADAMS KELLY.