WO1996015661A1

WO1996015661A1 - Biomass production

Info

Publication number: WO1996015661A1
Application number: PCT/NZ1995/000120
Authority: WO
Inventors: Lon Dalton; Thomas Gosgrove Hayes; Graeme Joseph Park; Anthony John Simson; Robin Philip Morley-Smith; Grenville Morris Neville Stocker
Original assignee: Zero Grass (Nz) Limited
Priority date: 1994-11-24
Filing date: 1995-11-22
Publication date: 1996-05-30
Also published as: AU3940195A

Abstract

This invention relates to biomass production. In particular, this invention relates to a method of producing biomass (1) characterised by the steps of placing starting material on a platform (2) capable of movement, and moving the platform so that the starting material is conveyed to different treatment areas (7, 9, 12).

Description

BIOMASS PRODUCTION

TECHNICAL FIELD

This invention relates to biomass production.

Reference throughout this specification will be made to the biomass being in the form of plants having a self supporting root structure. However, it should be appreciated that this form of biomass is given by way of example only and the present invention has applications far greater than this.

Specifically, reference shall be made to use of the present invention for producing plants suitable for animal feed. Again, the present invention has applications far beyond this and for example can be used to produce feed for humans for example, bean sprouts. The biomass could also include bean sprouts, lawn grass, plants used for sporting surfaces and so forth.

BACKGROUND ART

Finding feed for various animals can be a difficult task for those in charge of the animals. In countries such as New Zealand where stock graze on pasture, winter snows can cover up the animals' normal feed supply and require the farmer to provide additional feed. In many countries the stock do not graze at all during winter, instead they are fed dried plant materials such as hay and the like.

It is important that the animals not only have an adequate feed supply, but that this feed supply is also nutritionally balanced. This is particularly so for thoroughbred and specialised animals such as race horses, deer, zoo animals and the like. It is possible to grow plants under artificial conditions. This is often done when natural conditions are not ideal, for example in winter or if there is inadequate growing area. This approach has only been economical for specimen plants, for which consumers are prepared to pay more than they would for animal feed and the like.

One of the reasons for the cost of producing plants in an artificial environment is the amount of handling that is required. Typically seeds are placed into potting mix within seed containers and are watered either by hand or with a sprinkler system. Once the seeds have germinated and grown to a particular size, the plants are pricked out and placed into individual containers. Alternatively, the plants are kept within the seed trays and sold from the seed trays themselves. As can be appreciated, neither of these methods are suitable with producing large quantities of plants for consumption by animals (or possibly humans).

There are a number of patent specifications which describe various methods of plant production in artificial environments and a few of these are discussed below.

New Zealand Patent Specification No. 77641 discloses a seed apparatus which has means for supplying fertiliser liquid to seed trays from a sprinkler system. The seed trays are arranged to allow the fertiliser to percolate through the top trays to the trays below. This system is not suitable for producing stock food and the like for a number of reasons.

Firstly, the trays need considerable handling throughout the system.

Secondly, the trickle through approach of fertiliser liquid means that the top trays would have to be saturated for the bottoms trays to receive adequate fertiliser. This can lead to various nutrient imbalances and uneven distribution of water.

New Zealand Patent Specification No. 189163 discloses an apparatus for growing bean sprouts. This has two trays of beans, one above the other. The top tray is pivotally mounted and when sufficient water has been supplied to the top tray, it tips and pours water onto the lower tray. Again, this system has disadvantages because trays are used and the distribution of liquid is inevitably uneven.

New Zealand Patent Specification No. 171830 discloses the production of a transportable grass carpet reinforced by a perforated sheet. In this invention, seed is sown on a layer of soil on a perforated water impervious sheet. While this method can be used for producing various lawn surfaces, it is obviously unusable with respect to stock food as it contains an indigestible sheet of material.

New Zealand Patent Specification No.s 166197 and 164817 both disclose methods of growing seeds on sheets of artificial material as described above. These have similar disadvantages to that described above.

It is an object of the present invention to address the above problems, or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the following description which is given by way of example only. DISCLOSURE OF INVENTION

According to one embodiment of the present invention there is provided method of producing biomass characterised by the steps of: a) placing starting material on a platform capable of movement, and b) moving the platform so that the starting material is conveyed t different treatment areas.

Reference throughout the specification shall be made to the startin material as being seeds. However it should be appreciated that any othe suitable starting material may be used, for instance spores, pieces o tissue and the like.

The term treatment area is used to indicate areas having conditions conducive to the growth or treatment of biomass from the starting material.

Reference throughout the specification shall be made to the biomass as being barley grass. It should be appreciated however, that other types o biomass may be used, for example lawn, bean sprouts, dichondra and the like.

The seed may be placed directly on the platform, or in trays or on other support media on the platform depending on the nature of the crop to be grown. In preferred embodiments of the present invention the seed is placed directly onto a conveyor belt at a sufficient density that the root formations of the growing seed intertwine and provide a self supporting mat.

This preferred embodiment has a number of advantages over the prior art. One advantage is that less handling is required than with previous systems as there are no trays from which the plants have to be removed.

Another advantage is that the crop can be taken directly from the platform and transferred to stock for eating as there is no indigestible support structure unlike many prior art systems.

The platform may come in a variety of forms. In preferred embodiments, the platform is a moving conveyor. One of the main advantages of having a conveyor system over the prior art is that there may be provided a continuous process of plant production,

According to another aspect of the present invention there is provided a method of producing biomass characterised by the steps of: a) placing starting material on a platform capable of movement, and b) moving the platform so that the starting material is conveyed to different treatment areas, and c) removing the increased or treated biomass from the downstream end of the conveyor, and d) repeating steps a) to c) as required.

Use of a conveyor in this manner removes the requirement to handle the plants during the various phases of treatment.

Another advantage is that if there is manual movement of plants from one treatment area to another, it is quite possible for the plants to be subjected to an undesirable environment during the transfer, for example, if the plants are carried from one room to another. The entire conveyor can be housed within an insulated room or building and provisions made to ensure that the movement from one treatment area to another area is within a desirable environment.

One of the problems with artificial environments is ensuring that the plants have the appropriate amount of water. A major problem is that it is possible for pooling of water to occur in various places on the surface on which the plant material is placed.

According to another aspect of the present invention there is provided a method of biomass production characterised by the step of growing the biomass on a platform wherein the platform is angled with respect to the horizontal.

Reference throughout the specification shall be made to the platform as being a conveyor although other platforms (even stationary ones) may be used. The inclined surface of the conveyor is raised in its centre so that fluid sprayed onto the belt will tend to drain out to the sides of the conveyor. In this configuration, liquid sprayed substantially in the centre of the conveyor (although in most cases it will be sprayed over the whole belt) will flow past all the plant material on the conveyor as a consequence of gravity. Further, this configuration ensures that pooling does not occur.

The angled of part of the conveyor may be achieved by a variety of means. In one embodiment, the conveyor may have a number of individual rollers which are configured to ensure that the conveyor surface has the appropriate configuration. In other embodiments full length rollers, or any other suitable structure may be used. In further embodiments, the conveyor is a continuous platform having an upper part and a lower part wherein the starting material is placed on the upper part, characterised in that the lower part is angled with respect to the horizontal. This allows water to flow off the conveyor belt when it is underneath the conveyor. This overcomes the problem of spilt water stagnating on the conveyor belt when the belt is underneath the body of the conveyor.

At the edge of the conveyor there may be provided a collection system to collect water and nutrients flowing off the conveyor. This excess flow of fluid can be recycled.

In one embodiment, gutters are used to collect the water and nutrients flowing off the conveyor.

In a preferred embodiment, the floor is angled, and the water runs down the floor slope to be collected and recirculated. This overcomes the problem of the gutters blocking or being overwhelmed by the amount of water. This also overcomes the problem of mould growing in the gutters.

Preferably the platform is constructed so as to discourage the biomass from attaching to the platform.

An example of plant production in accordance with one embodiment of the present invention is discussed below.

Firstly, there may be provided a conveyor system inside an insulated building with all operations including sprays, salinity, temperature, air conditioning, light, humidity and nutrient supply being controlled by a computer. Some manual control may also be possible. Using barley grass as an example, the seeds may be loaded onto th conveyor at a suitable density so that the roots of the barley grass, onc sprouted, will mesh together to form an integral mat. The total amoun of seed placed on the conveyor depends on how fast the particular cro grows as well as the speed, length and width of the conveyor.

The seeds may be then presoaked with a systems of nozzles that are time to keep the seeds damp at all times. During this process, the conveyo may be stopped for approximately 24 hours.

On the second day, the conveyor may move the presoaked seeds under a system of misting nozzles which apply water and nutrients to the now sprouting seeds. At the same time, a new batch of seeds may be spread on the conveyor in the now empty presoaked area. This continual replenishment of the conveyor with new seeds as the conveyor moves on may occur throughout the growing process.

The spray areas of the nozzles may be overlapped. In this way, the malfunction of a nozzle does not cause the barley grass to cease growing as the other nozzles keep the plants watered.

In a further embodiment, two rows of spray nozzles are provided. This also allows for nozzle malfunction.

In one embodiment, water is sprayed on the barley grass for at least 10 minutes of every hour. This amount of water promotes growth. The large amount of water also penetrates the root mat, preventing stagnation and rotting. With the present invention, it takes just seven days for the barley seeds to be sown, germinated and grow to suitable height (say 15 cm) for consumption by stock.

In one embodiment, the air flow may be controlled and in one embodiment fresh air may be pumped in at a rate of six changes per hour. This prevents the build up of mould that can occur in still, damp conditions. This also ensures that the growing plants have sufficient access to carbon dioxide to continue the growing process.

It should be appreciated that there may be other controls in addition to those already described. For example, in some embodiments there may be provided an ozone machine which can be used to purify the water supplied to the growing plants with the action of the ozone killing mould spores.

The crop, once fully grown, can be removed from the conveyor by a variety of methods. For example, if the crop is to be used for sporting surfaces or lawn then it may be fed from the conveyor and rolled in a continuous sheet.

If the crop is to be used for stock feed, then in preferred embodiments it is cut into strips. This has a number of advantages over previous methods of preparing stock feed.

Typically stock feed is present in blocks (such as hay bales), in which case, cattle and the like tend to walk on it. With strips of feed, the cattle can eat the strips in a similar manner to spaghetti. Therefore the feed does not get trampled on and is fully consumed. There may be various means by which the plant material can be cut int strips or mats.

One embodiment by the applicant used a shear type blade. However thi blade had problems in that the grass tended to separate from the roo system which was its main support.

A further trial used a sliding blade. However this blade tended to brea up the mat and could pull the crop off the side of the growing conveyo belt.

The preferred embodiment of the present invention has a round blad (made of stainless steel or other suitable material) that rotates as it move across the width of the crop. Preferably the root system is cut from left t right with the blade rotating in a clockwise direction, and from right t left with the blade rotating in an anticlockwise direction. The best result have been achieved with the blade cutting the root mat from underneat rather than from the top.

The blade may be driven by any number of means. However, preferably hydraulic motor is used to drive the blade as electrical motors ar susceptible to the moist environment. The motor may be mounted on trolley fitted within a box section track. The trolley may be chain or wir driven from the end of the track by a second hydraulic motor. The track may be lifted to or lowered from the conveyor belt by a hydraulic cylinde as the crop is cut.

In one embodiment, the components of the cutting blade apparatus tha fit are positioned inside the box section track. This helps to prevent th components corroding and increases safety as the moving parts canno be directly contacted. Also, being inside the helps the box section track helps the cleaning process as high pressure water can be safely sprayed onto the box section, and thereby remove stray seeds, without damage to the cutting equipment.

It should be appreciated that the present invention is not just limited to the use of a single conveyor belt. In preferred embodiments, there may be a number of conveyor belts for example situated above each other or beside each other contained within the one insulated room or building. If this is the case, then each conveyor belt may have separate spray nozzles and cutters. Alternatively, a single system which can be moved from level to level may be used. For example, it would be relatively easy to have the cutting blade or sprayers moved from one conveyor level to another.

In one embodiment, each conveyor belt is provided with spray nozzles on the underside to supply fluid to the conveyor belt below it.

It should be appreciated that in addition to all of the advantages discussed above, the present invention provides a high yield, high quality animal fodder which can be produced in any season and in any climate. Further, this fodder can be modified to suit the animals needs by changing the nutrient levels.

BRIEF DESCRIPTION OF DRAWINGS

Aspects of the present invention will now be described by way of example only with reference to the accompanying drawings in which

Figure 1 is a side view of a conveyor system in accordance with one embodiment of the present invention, and Figure 2 is a cross-sectional view of a conveyor in accordance with one embodiment of the present invention, and

Figure 3 is a diagrammatic view of a cutting system in accordance with one embodiment of the present invention.

BEST MODES FOR CARRYING OUT THE INVENTION

With respect to Figure 1 there is provided a plant production system generally indicated by arrow 1.

The plant production system 1 has a conveyor 2 which is driven by drive rollers 3 and guided by guide rollers 4.

The length of the conveyor 2 and the rate at which it moves is dictated by the growing rate of the crop and the desired length at which it is to be removed from the conveyor system.

At one end of the conveyor 2 is a seed spreader hopper 5 which deposits seeds on to the conveyor 2.

The conveyor then moves the seed 6 to a first treatment area generally indicated by arrow 7. The first treatment area 7 consists of presoak sprays 8 which soak the seeds with water only. The seeds stay in this treatment area for 24 hours and are sprayed with tap water for two minutes every ten minutes. The temperature of the water is 20-23°C.

Next the conveyor moves the now germinating seed 6 to a second treatment area generally indicated by arrow 9. This second treatment area 9 consists of a number of misting sprays 10 which spray water and nutrients on to the now growing plants 11. The water/nutrient mixture is sprayed for two minutes every twenty minutes. The fluid is at the same temperature as above.

The supply water first passes through a molecular water treatment unit. These units work on the basis of magnetically influencing chemicals and other matter within the supply water.

The third treatment area generally indicted by arrow 12 is where the crop is cut by a blade 13. In the treatment area 12, the conveyor 2 moves the plants 11 (which have now grown together in a solid mat) onto a rigid surface 14 along which a blade 13 travels to cut the crop 11 from underneath.

To prevent pooling of fluid on the conveyor, it is raised in its middle section. This is shown in greater detail in Figure 2.

The conveyor 2 is comprised essentially of three sections, two side sections 15 and 16 and a middle section 17. These sections are comprised of a number of rollers 18 positioned on a moulded plastics frame. The surface web (not shown here) of the conveyor 2 is passed over the rollers 18.

As the rollers 18 are not positioned at the outside ends of the frame, the angle of the surface web is more vertical near the ends, helping the fluid to run off the web. This prevents the water stagnating in the root mat, causing rot . The fluid running off the conveyor 2 flows onto a sloped floor from where it can be collected and recirculated.

Figure 3 illustrates in greater detail the cutting system. This comprised blade 13 which is attached to a hydraulic motor 19. The motor 19 fits onto a trolley 20 which runs inside a track 21. A second hydraulic motor 22 drives the trolley from one end of the track to the other.

If there are a number of conveyors used in plant production (which is most likely) then there may be provided a lifting system for the cutting system generally indicated by arrow 23. The lifting system may comprise further track guides 24 into which the track 21 fits. The track 21 may be lifted by a lifting chain 25 powered by a hydraulic cylinder 26.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the appended claims.

Claims

THE CLAIMS DEFINING THE INVENTION ARE:

1. A method of producing biomass characterised by the steps of: a) placing starting material on a platform capable of movement, and b) moving the platform so that the starting material is conveyed through different treatment areas.

2. A method of producing biomass as claimed in claim 1 wherein the starting material is seeds.

3. A method of producing biomass as claimed in either claim 1 or claim 2 wherein each treatment area has conditions conducive to the growth or treatment of biomass from the starting material.

4. A method of producing biomass as claimed in any one of claims 1 to 3 characterised by the step of placing starting material directly on the platform.

5. A method of producing biomass characterised by the further steps of: a) removing the increased or treated biomass from the downstream end of the conveyor, and b) repeating step a) as required.

6. A method of producing biomass as claimed in claim 5 characterised by the further step of rolling the biomass in a continuous sheet when removed from the platform.

7. A method of producing biomass as claimed in either claim 5 or claim 6 characterised by the further step of cutting the removed biomass into strips.

8. A method of producing biomass as claimed in claim 7 characterised by the step of cutting biomass from underneath.

9. A method of biomass production characterised by the step of growing the biomass on a platform wherein the platform is angled with respect to the horizontal.

10. A method of biomass production as claimed in claim 9 characterised by the further step of collecting any water and nutrients flowing off the platform.

11. A method of biomass production as claimed in claim 9 or claim 10 characterised by the step of moving the platform.

12. A method of biomass production as claimed in any one of claims 1 to 11 wherein the platform is constructed so as to discouraged the biomass from attaching to the platform.

13. A method of biomass production as claimed in any one of claims 7 to 12 characterised by the further step of cutting the biomass with a round blade.

14. A method of producing biomass as claimed in claim 13 characterised by the steps of:

a) rotating the round blade in a clockwise direction when it is cutting from left to right, and

b) rotating the round the round blade in an anti-clockwise direction when it is cutting from right to left.

15. A method of producing biomass as claimed in any one of claims 1 through 14 wherein the platform is a continuous platform having an upper part and a lower part wherein the starting material is placed on the upper part, characterised in that the lower part is angled with respect to the horizontal.

16. A method of producing biomass as claimed in any one of claims 1 to 15 characterised by the step of using more than one platform.

17. An apparatus capable of producing biomass in accordance with the method as claimed in any of claims 1 to 16.

18. A method of producing biomass substantially as herein described with reference to and as illustrated by the accompanying drawings.

19. An apparatus for the production of biomass substantially as herein described with reference to and as illustrated by the accompanying drawings.