Classifications

• • C—CHEMISTRY; METALLURGY
  • C05—FERTILISERS; MANUFACTURE THEREOF
  • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
  • C05F17/00—Preparation of fertilisers characterised by biological or biochemical treatment steps, e.g. composting or fermentation
  • C05F17/90—Apparatus therefor
  • C05F17/95—Devices in which the material is conveyed essentially vertically between inlet and discharge means
  • C05F17/955—Devices in which the material is conveyed essentially vertically between inlet and discharge means the material going from platform to platform
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/141—Feedstock
  • Y02P20/145—Feedstock the feedstock being materials of biological origin
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/40—Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Definitions

• the present invention relates generally to methods and apparatus for containing, composting, and reducing biodegradable waste, and more particularly to a vertical composting apparatus having discrete processing zones and a method of composting biodegradable materials using the inventive apparatus.
• thermophilic species of aerobic bacteria best suited for ' ' breaking down organic waste thrive only in limited ranges of environmental conditions.
• Those with knowledge in the art understand the importance of controlling several conditions to provide the optimal environment for a rapid decomposition process with a minimum of unpleasant odor.
• Such conditions include the porosity, temperature, oxygen level, and moisture content of the compost pile and the surrounding atmosphere.
• U.S. Pat. No. 5,190,572 to Long discloses a composter having a plurality of rectangular stackable boxes, each box having four interlocking double walled plastic panels . Each box can be secured above or below another box. so that the boxes can be stacked to any height and the stacking order can be readily changed.
• the device includes a lid to cover the uppermost box in the stack. In use, the boxes are stacked between an original bottom box and an original top box over a first region of open ground to form a first stack.
• Biodegradable matter is placed into the composter and allowed to begin decomposing. After decomposition has occurred, the stacking order of boxes is reversed, thereby mixing and aerating the material and ostensibly promoting uniform decomposition. The restacking process also provides access to the interior of the compost mass.
• the apparatus is designed only for continuous input of raw waste and for horizontal movement of the processed material through a four-process, three-week throughput cycle.
• An active contributor to the art of continuous composting is Jack Wright of Canada. His patents include: U.S. Pat. Nos. 5,846,815; 5,551,969, and 5,409,831.
• Wright teaches a continuous composter which includes an enclosed elongate horizontally- disposed tunnel having a garbage inlet end with a mixing hopper, and an outlet end for the discharge of compost.
• a raised conveyor track comprising parallel rails with rollers is situated in the tunnel floor and extends the length of the tunnel.
• a train of conveyor trays travel on the track to move processing material.
• Each tray has a shunting frame and a foramenous base for the aeration of composting material.
• a ram urges the most upstream tray to advance downstream against the train of trays preceding it, thereby moving the entire train of trays.
• Aeration means provide air into a space between the tunnel floor and conveyor trays so that air rises through the bases of the trays and the material.
• a gas exhaust is provided at the top of the tunnel. Mixing rollers with paddles extend from sides of the tunnel to mix the garbage.
• the tunnel outlet has a pressure-closed hinged door that is urged open by an
• the '969 patent discloses an improved version of the system of the '831 patent, which includes the addition of a blending trough at the garbage inlet and water input means to add water immediately after mixing by the mixing rollers.
• the apparatus of the '815 patent improves on the devices disclosed in the '969 patent and the '831 patent. While providing the same horizontally-disposed tunnel having essentially the same footprint, and while providing the same mechanical means for moving composting material, it teaches the segregation of the composting apparatus into processing zones, each having self-contained aeration units that minimize the interchange of air between the processing zones.
• the first self- contained aeration unit aerates the upstream composting zone and recirculates a portion of venting aerating gases within the upstream zone; the second self-contained aeration unit aerates the downstream composting zone and recirculates a portion of its venting aerating gases within the downstream zone.
• Multi-chamber systems may be provided, with each processing zone having a self-contained aeration unit.
• the upstream and downstream zones may be separated by intermediate zones, blending with the upstream and downstream zones but tending to minimize any interchange of air between the zones.
• Each of Wright's systems are large, complex horizontal systems that are costly to manufacture. Additionally, the aeration system in the latest system is less than optimal in that it supplies air only to the underside of the composting material, rather than injecting air into the material piles; thus, substantial portions of the waste material may receive insufficient air flow and reduced aerobic activity.
• U.S. Pat. No. 6,171,852 to Bright discloses a composting system having a horizontally-disposed composting bay with inlet and outlet ends.
• a transport system on the bottom of the bay receives waste material and moves the material lengthwise along the length of the bay from the inlet to the outlet end.
• the system also includes movable fluid distribution cells including fluid injectors which inject water and air into the waste material as the material moves through the system.
• the present invention overcomes the shortcomings of the prior art by providing a new and improved automated in-vessel vertical composting apparatus and method of decomposing waste material that utilizes a vertical arrangement of segregated processing zones for plug-flow processing of biodegradable waste.
• a further object or feature of the present invention is a new and improved composting apparatus that facilitates full control of the environmental conditions for optimal rapid decomposition of biodegradable organic waste and to ensure reliable and consistent output of high quality compost.
• An even further object of the present invention is to provide a novel composting apparatus having a plurality of processing zones in a vertical arrangement, thus allowing movement from one processing zone to the next under the influence of gravity alone.
• Yet another object of the present invention is to provide a new and improved composting apparatus that separates processing zones with an agitating device that functions
• a still further object of the present invention is to provide a new and improved non- static, plug-flow type of composting apparatus having a vertical enclosure and one or more control devices for tightly controlling the environmental conditions in which the composting process takes place.
• a still further object of the present invention is to provide a composting apparatus that employs a vertically segmented composting tower to prevent increased compaction in waste material, thereby preventing odors due to a sufficient supply of oxygen in the waste mixture and the reduction of anaerobic decomposition.
• Another object of the present invention is to provide a novel composting apparatus that contains and treats exhaust air through a bio-filter.
• Another object of the present invention is to provide a vertical composting apparatus that collects and processes all leachate generated by the composting process to prevent ground and surface water contamination as well as odor.
• the composting apparatus of the present invention generally comprises a vertically disposed composting enclosure having at least two physically and functionally discrete processing zones.
• the zones are separated by either a floor or an agitating device, or both, and each zone preferably includes apparatus for monitoring and controlling the oxygen content, moisture content, temperature of the compost pile.
• each zone preferably includes apparatus for monitoring and controlling the oxygen content, moisture content, temperature of the compost pile.
• a vertical composting apparatus comprising: (a) a housing including a wall and having a waste inlet; (b) an upper processing zone in the housing; (c) a lower processing zone below the upper processing zone; (d) at least one device separating the upper and lower processing zones; (e) a waste inlet above the upper processing zone; and (f) an outlet below the lower processing zone.
• the device separating the upper processing zone from the lower processing zone preferably comprises one or more agitators.
• More elaborate embodiments of the present invention include conveyance means for transporting waste to the waste inlet and introducing the waste into the first processing zone; environmental monitoring and control means, including water, temperature and oxygen level sensors, with corresponding hydration, aeration, and heating, cooling, and ventilation systems; programmable logic means for controlling and coordinating the environmental systems; and conveyance means for transporting waste from the vessel after composting. Additionally, larger systems may include one or more intermediate processing zones interposed between the upper and lower processing zones.
• the present invention is also directed to a method for composting material utilizing the foregoing composting apparatus, the method comprising the steps of: (a) introducing biodegradable waste material through an inlet in the apparatus housing; (b) processing the compostable material in the upper processing zone; (c) moving at least one agitating device below the upper processing zone thereby delumping and mixing compost material in the upper processing zone while simultaneously allowing a predetermined amount of processed compostable material to pass into the lower processing zone; (d) processing the compostable material in the lower processing zone to form composted material; and (e) removing the composted material through an outlet below the lower processing zone.
• FIG. 1 is a partial cross-sectional front-left perspective view of a first preferred embodiment of the vertical composting apparatus of the present invention:
• FIG. 2 is a cross-sectional rear view in elevation of the apparatus of FIG. 1 ;
• FIG. 3 is a cross-sectional side view in elevation of the apparatus of FIGS. 1 and 2;
• FIG. 4 is an axial, cross-sectional view of the apparatus of FIGS. 1-3, shown along the sectional line 4-4 in FIG. 2, not including the outlet screw conveyor or the waste input conveyor system;
• FIG. 5 is a cross-sectional front view in elevation of a second preferred embodiment of the vertical composting apparatus of the present invention.
• FIG. 6 is a cross-sectional side view of the apparatus of FIG. 5;
• FIG. 7 is a cross-sectional axial view of the apparatus of FIGS. 5 and 6, shown along the sectional line 7-7 shown in FIG. 5, not including the outlet screw conveyor or the waste input conveyor system;
• FIG. 8 is a perspective view of a third preferred embodiment of the vertical composting apparatus of the present invention.
• FIGS. 1-8 The elements in FIGS. 1-8 are as follows:
• FIG. 1 is a partial cross-sectional front-left perspective view of a first preferred embodiment of the vertical composting apparatus of the present
• FIGS. 2, 3 and 4 are, respectively, a cross-sectional rear view and cross- sectional side view, and an axial, cross-sectional view thereof. These views show the inventive apparatus 100 in its most essential aspect comprises a vessel housing 110 having at least one housing wall 120.
• the vessel is preferably either generally cylindrical, in which event the wall is singular and contiguous, or cuboid, in which event the housing has four walls comprising sides.
• the vessel housing is cuboid and is supported on a frame 130. Vessel dimensions will vary according to the scale of the composting operation, though heights ranging from approximately nine to eighteen meters (thirty to sixty feet) have proven most serviceable and work best for materials processed for a typical resonance time in a plug-flow system.
• a waste inlet 140 is located at the top of the housing above an upper processing zone 150.
• the inlet may be either directly above the upper processing zone or to the side, depending upon the means provided for distributing and spreading the waste before introduction into the first processing zone.
• a lower processing zone 160 Positioned below the first processing zone is a lower processing zone 160.
• Leveling means 170 preferably comprising at least one auger screw having either continuous solid or ribbon flights.
• leveling means 170 preferably comprising at least one auger screw having either continuous solid or ribbon flights.
• a rotary leveler as illustrated in FIG. 8
• the at least one auger screw is driven by a reversible motor 180, which permits periodic and systematic movement of the waste material in each direction along the length of the auger screw.
• At least one upper agitating device 190 is interposed between the upper processing zone 150 and the lower processing zone 160.
• the agitating device comprises a first set of side-by-side rollers 200, 210, each of which include a plurality of surface paddles or bars 220.
• the rollers are actuated by one or more reversible motors, 230. When operated, the rollers are preferably rotated in opposite directions such that when viewed from either end,
• the agitating device may be replaced by a different, non-agitating device such as a stationary grid, bars, a moving floor, slide gate, or a hatch.
• the device which separates the different zones in the apparatus, keeps the weight of compost material in the upper region of the composting apparatus from compressing compositing material at the lower region of the composting apparatus.
• the fundamental concept of processing the compost in vertically disposed but discrete processing zones is nonetheless preserved in such embodiments.
• a lower agitation device 250 is positioned at the base of the lower processing zone 160.
• the agitation device comprises a second set of side-by-side rollers 260, 270 that operate in the manner as described above.
• the second set of rollers is actuated by at least one second motor 280.
• the agitation means are operated at predetermined intervals.
• the agitators mix, delump, aerate, and turn over the compost material inside vessel.
• the agitation means also support the compost material above them so that the full weight of compost pile does not compact the compost material below it, thereby limiting oxygen supply to material deep within the pile.
• Effective agitation can be enhanced by the provision of one or more baffle plates 240 positioned on the interior surface(s) of the vessel housing.
• the vessel housing itself include inwardly tapering walls 290, in the fashion of a hopper, to direct the material flow into the agitators and through the opening at the lower portion of the processing zone.
• a discharge outlet 300 is positioned directly below the lower agitation device. This portion of the vessel housing is configured to direct finished compost into a discharge conveyor system 310, preferably a screw auger, which transports nutrient rich plant growth media from the apparatus to holding bins or other containers to await use.
• a discharge conveyor system 310 preferably a screw auger
• the inventive system For large scale processing of biodegradable waste, it is preferable for the inventive system to include a waste input conveyor system 320, preferably a vertically disposed bucket conveyor.
• a waste input conveyor system 320 preferably a vertically disposed bucket conveyor.
• the preference of conveyor type is driven by the angle or orientation of the system, and the orientation is directed to advancing the space-saving purpose of the inventive apparatus, though it is not critical to its effective function.
• alternative systems could be employed if the conveyor were more horizontally disposed.
• the waste input conveyor system includes a waste loading inlet 330, a vertically disposed tube 340, a motor driven bucket conveyor cable 350, and a material outlet 360, all of which are well known in the art.
• Misting nozzles 380 may be positioned in any processing zone to increase the humidity of the atmosphere and to increase the water content of the compost pile. Optimally added water will not be required in the upper processing zone.
• FIGS. 5 through 7 illustrate a second preferred embodiment 400 of the present invention. Reference numerals in these views indicate identical elements to those in FIGS. 1- 4. These views show the inventive apparatus as having an additional, intermediate processing zone 410, interposed between the upper processing zone 150 and the lower processing zone 160. Provision of one or more intermediate processing zones requires the concomitant provision of one or more intermediate agitation devices 420, preferably a third set of rollers 430, 440, as well as a third motor system 450.
• Environmental control systems may be provided to tightly regulate the conditions under which the material is processed during the resonance period.
• misting nozzles can be provided to add water to selected processing zones.
• temperature, oxygen level, and moisture level sensors may be installed in one or more of the processing zones so that adverse conditions can be corrected promptly. The sensors are not shown as they are common and well known in the art.
• the system may further include gas outlet duct 460 for venting and removing exhaust gasses produced by the composting process.
• the air removed from the system may be processed in a bio-filter 470, released directly into the atmosphere (if appropriate and permitted), or directed into a ground berm. Either fresh or recycled air may be directed into the vessel housing via air inlet 480, and such may be heated or cooled by a
• FIG. 8 is a perspective view of a third preferred embodiment 600 of the vertical composting apparatus of the present invention.
• This view shows a system having a cylindrical housing 610, an upper processing zone 620 and a lower processing zone 630, a waste inlet 640 through which biodegradable waste is conveyed into the upper processing zone by a waste conveyor system 650, and one or more discharge outlets 660 through which compost is directed to a discharge conveyor system 670.
• the system may include hydration means (not shown), temperature control and regulation means (not shown), and exhaust and air conditioning means, preferably a bio-filter 680 in fluid communication with the vessel interior through air inlet and outlet ducts 690, 700, respectively.
• the third preferred embodiment separates the upper and lower processing zones, and the lower processing zone and the discharge outlets, with floors 710, 720, having openings 710a, 710b, 720a, 720b, selectively exposed or closed by slide gates 730, 740.
• the slide gates are actuated by gate actuating means, 750, 760, preferably hydraulic or pneumatic cylinders, as are well known in the art.
• Agitation means are provided, preferably comprising a shaft 770 vertically disposed in the processing zones, the shaft having a plurality of arms 780 extending radially from the shaft to engage and project into the compost pile in each processing zone, and to break up, delump, and aerate the pile when operated. Actuation of the shaft is by a motor (not shown) coupled to the shaft at one end 790.
• Method Steps comprise the essential processing sequence in employing the vertical composting apparatus of the present invention: [0057] (1) Organic waste (biodegradable waste) is combined with a bulking agent (wood chips, sawdust, etc.) to achieve a proper carbon to nitrogen ration and a correct porosity in waste material mixture. [0058] (2) The organic waste and bulking agent are mixed thoroughly (typically in a
• Plant growth media is discharged from the bottom of the composting apparatus via screw conveyor or an equivalent method for further post processing (such as curing, drying, screening, bagging, etc.).
• the bio-filter may include a specific mixture of stabilized mature compost, woodchips and other filtering media to clean exhaust air in order to prevent odor from being emitted into the surrounding environment.
• Other air filtration devices can be utilized to scrub or clean the air instead of a bio-filter.
• Moisture sensors can be positioned throughout the composting mass to give continuous feedback to the control panel which activates irrigation emitters to control moisture content of the composting material.
• the moisture level of the composting mass can be maintained at approximately 60% to optimize the composting process.
• All leachate (waste liquid) generated during the composting process can be contained and diverted for appropriate handling. Leachate can be recycled and used for irrigation purposes or can be diverted to a drain or container for disposal.

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• 2003
  • 2003-09-09 CA CA 2498161 patent/CA2498161A1/en not_active Abandoned
  • 2003-09-09 AU AU2003270466A patent/AU2003270466A1/en not_active Abandoned
  • 2003-09-09 NZ NZ538626A patent/NZ538626A/en unknown
  • 2003-09-09 WO PCT/US2003/028284 patent/WO2004022508A1/en active Application Filing
  • 2003-09-09 JP JP2004534796A patent/JP2005538023A/ja active Pending
  • 2003-09-09 CN CNA038213923A patent/CN1681749A/zh active Pending
  • 2003-09-09 MX MXPA05002649A patent/MXPA05002649A/es unknown
  • 2003-09-09 EP EP03752159A patent/EP1546066A4/de not_active Withdrawn

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