WO2012137064A2

WO2012137064A2 - An apparatus and method

Info

Publication number: WO2012137064A2
Application number: PCT/IB2012/000712
Authority: WO
Inventors: Adrian Patrick DALY
Original assignee: Daly Adrian Patrick
Priority date: 2011-04-08
Filing date: 2012-04-10
Publication date: 2012-10-11
Also published as: WO2012137064A3

Abstract

An extruding apparatus for extruding a blended usable product in a semi-solid form comprises a container defining a hollow interior region for receiving a material; an extruding head for extruding material into an elongated strip, the extruding head defining an extruding opening communicating with the hollow interior region of the container; a first conveying means for mixing and conveying material in the container; and a second conveying means for conveying and urging the material in the container under pressure into the extruding head. Preferably the apparatus comprises a layering apparatus detachably connected to the extruding head.

Description

"An Apparatus and Method"

Introduction

The present invention relates to an apparatus and method of producing and extruding a blended usable product in a semi-solid form from an organic material or a material comprising mainly organic waste material.

Throughout the world a lot of waste material is being produced and in many instances being disposed of in landfill or by incinerating etc. Wet organic material is being produced by industry, the food processing industry, farming and the like and the volumes of waste are considerable. A lot of work is being done to try and harvest energy and renewable resources from the waste produced.

The present invention is directed to an improved apparatus for extruding a blended material and a method of processing mainly organic waste material in the apparatus to form a usable extruded product.

Statements of Invention

According to the invention there is provided an extruding apparatus for extruding a blended usable product in a semi-solid form comprising; a container defining a hollow interior region for receiving a material; an extruding head for extruding material into an elongated strip, the extruding head defining an extruding opening communicating with the hollow interior region of the container; a first conveying means for mixing and conveying material in the container; and a second conveying means for conveying and urging the material in the container under pressure into the extruding head. l In one embodiment of the invention the extruding comprises a layering apparatus detachably connected to the extruding head.

In another embodiment of the invention the extruding apparatus comprises a harvesting device detachably connected at an end distal to the extruding head.

In one embodiment of the invention the extruding apparatus the conveying means comprises an auger. Preferably the conveying means comprise at least two augers.

In one embodiment of the invention the second conveying means comprises a tubular member at the end proximal the extruding head for conveying and urging the material in the container under pressure into the extruding head.

In one embodiment of the invention the first conveying auger comprises a plurality of extended blades for optimum blending of the material in the container.

In one embodiment of the invention the first conveying means may be positioned at an angle to the second conveying means within the container. The first conveying means may be positioned substantially perpendicular to the second conveying means.

In one embodiment of the invention the extruding apparatus comprises an additional conveying means for conveying material into the container selected from any one or more of a slatted conveyor, a conveying belt, a conveying chain, a mixer or an umbilical cord feeder system.

In one embodiment of the invention the material used in the layering apparatus comprises any one or more of an impermeable material, plastic, PVC, biodegradable and durable impermeable material or film.

In one embodiment of the invention the layering apparatus comprises means to extrude the blended product on top of a layer of material, under a layer of material and/or between layers of material.

In one embodiment of the invention the layering apparatus comprises means to lay a layer of material under the extruded product and a plurality of layers of material on top of the extruded product and means to insert a spacer between the layers of material.

In one embodiment of the invention the harvesting device comprises means to harvest product previously extruded by the extruding apparatus onto a layer of material and wherein the harvested product is separated from the layer of material during harvesting. This is important in keeping harvested treated extruded product away from any contaminated soil or material that may be underneath the layer of impermeable material.

In one embodiment of the invention the extruding apparatus comprises a chopper or cutting device detachably connected to the apparatus at an end distal to the extruding head.

In another embodiment of the invention the extruding apparatus comprises a planter and/or seeder device detachably connected to the extruding head.

In one embodiment of the invention the extruding apparatus comprises an output conveying means for conveying blended extruded material in different directions or at different heights. Preferably the output conveying means is adapted such that the blended extruded material extends along the length of the conveying means before the extrusion is tipped onto the ground or any other suitable surface.

In one embodiment of the invention the extruding apparatus is mobile. In another embodiment the apparatus is self-propelled.

In one embodiment of the invention the container comprises a trailable wagon having the extruding head located towards the rear end of the wagon and wherein the extruding head is adapted for extruding the material in a rearward direction from the trailable wagon as the trailable wagon is being trailed.

In one embodiment of the invention the extruding head comprises a single elongated extruding opening for extruding under pressure a single elongated strip of blended product in a semi-solid form. In one embodiment of the invention the material to be extruded is selected from any one or more of green waste, organic waste, soiled recyclables, non-recyclables, contaminated recyclables, food waste, paper, bagasse and/or soil.

According to the invention there is also provided a method of blending and extruding a usable product in a semi-solid form from a material on an industrial scale using the extruding apparatus.

The invention provides a method of blending and extruding a usable product of relatively high moisture content in a semi-solid form from a material comprising mainly organic waste material using the apparatus of the invention.

In one embodiment of the invention the usable product is blended and extruded from a material selected from any one or more of green waste, organic waste, soiled recyclables, non-recyclables, contaminated recyclables, food waste, paper, bagasse and/or soil using an apparatus as claimed in any preceding claim. The waste material may be selected from any one or more of the food processing industry, a by-product of an industrial process or a by-product of farming.

In one embodiment of the invention the usable product is extruded onto a layer of material selected from any one or more of an impermeable material, plastic, PVC, biodegradable and durable impermeable material or film.

In one embodiment of the invention the method provides a usable product substantially free of pathogens using the extruding apparatus of the invention wherein the blended product is extruded in a semi-solid form between layers of impermeable material and the extruded product exposed to the sun. The extruded product may be heated to a temperature of greater than 40°C or 100T.

In one embodiment of the invention the blended product is extruded between layers of different coloured impermeable material to increase or decrease the temperature as required.

In one embodiment of the invention the product is extruded onto a layer of impermeable material and covered by three layers of impermeable material, wherein the first cover layer of impermeable material is directly on top of the extruded product, a spacer is positioned between the first and second layer of impermeable material and a third layer of impermeable material supported substantially above the second layer of impermeable material.

In one embodiment of the invention an organic material selected from any one or more of animal manures, green manures or agro industrial residues, chemicals, enzymes is blended with the material in the container before the product is extruded.

In another embodiment of the invention a biological agent selected from any one or more of bacteria, fungi, enzymes, chemical agent, organic substrate or green plants is blended with the material in the container before the product is extruded. Alternatively a blended product may be extruded, heat treated and re-harvested to blend it with additives.

In one embodiment of the invention the extruded product is planted with biomass crop. Preferably the biomass crop is selected from any one or more of vetiver, sorgrum, rye, Indian grass, soybean, oats, maize, and /or corn.

In one embodiment of the invention the extruded product is irrigated with waste water. The waste water may be water from any one or more of waste water from oil-refineries, waste water from an industrial process, municipal waste water or contaminated water.

In one embodiment of the invention the biomass crop extracts and uses up the nutrients in the waste water and extruded product. Preferably after a period of time the extruded product and its biomass crop is allowed dry out.

In another embodiment of the invention the extruded product may be prepared from a soil-less waste material and after irrigation the extruded product with its biomass crop grown thereon is dried out and used as fuel.

In one embodiment of the invention a binding agent is blended with the waste material in the container of the extruding apparatus. Preferably the binding agent may be any one or more of farm manure, sewage sludge, and/or whole digestate. In one embodiment of the invention soil is harvested using the extruding apparatus of the invention, a binding agent is blended with the soil and the blended product is extruded onto a layer of impermeable material and planted with a biomass crop. The extruded product may be irrigated with waste water.

In one embodiment of the invention the initial moisture content of the waste organic material is in the range of 35% to 80%.

In another embodiment of the invention the moisture content of the extruded product is in the range of 30% to 75%.

In one embodiment of the invention the extruded product is used as a fertilizer, for growing mycelium in the ethanol or other industries, inoculated with mycelium, and/or used as a microfiltration/myco filtration bed for land remediation.

In another embodiment the blended material is mixed with larvae from the black soldier fly or other and extruded in an elongated strip wherein the black soldier fly consumes and breaks down the blended material.

In a further embodiment the blended usable product is extruded in layers alternating with layers of any one or more of cow manure, green waste, minerals or herbs to produce a stable humus material.

In one embodiment of the invention the blended material is placed in elongated strips on the ground and sown with plants using the planter or seeder apparatus attached to the extruder apparatus.

Brief Description of the Invention

The invention will be more clearly understood from the following description of some embodiments thereof, which are given by way of example only, with reference to the accompanying drawings, in which: Fig. A is a schematic showing the different waste materials that may be blended and extruded in the extruding apparatus of the invention and the various uses for the extruded product;

Fig. 1 is a side perspective view of an extruding apparatus according to one embodiment of the invention;

Fig. 2 is a top perspective view of the extruding apparatus of Fig. 1 with the cover of a portion of the container section removed showing the conveying and mixing means; Fig. 3 is a cross sectional view of the extruding apparatus of Fig. 1 showing the augers and tubular members which feed the blended material into the extruding head; Fig. 4 is a rear view of the extruding apparatus of Fig. 1 showing an elongated extruding head;

Fig. 5 is a top perspective of an extruding apparatus according to another embodiment of the invention;

Fig. 6 is a side perspective of an extruding apparatus according to further embodiment of the invention;

Fig. 7 is a side perspective view of an extruding apparatus according to another embodiment of the invention;

Fig. 8 is a side perspective view of an extruding apparatus according to another embodiment of the invention;

Fig. 9 is a rear perspective view of the extruding apparatus of Fig. 8;

Figs. 10 is a front perspective view of the extruding apparatus of Fig. 8;

Fig. 11 is a side perspective view of an extruding apparatus according to another embodiment of the invention;

Fig. 12 is a rear perspective view of the extruding apparatus of Fig. 11 ;

Figs. 13 is a front perspective view of the extruding apparatus of Fig. 11;

Fig. 14 is a schematic showing product extruded Onto a layer of impermeable material and with several impermeable layers covering the extruded product; and

Figs. 15 and 16 are schematics showing the blended material extruded by the apparatus of the invention in a water filtration bed.

Detailed description

The present invention provides an apparatus capable of receiving soil or waste material from a variety of sources and blending and extruding the material to provide a blended product which is usable in a variety of different processes. The waste material preferably has a high organic element.

The blended product is extruded in a semi-solid form. Throughout the specification the term semi-solid is taken to be material which can hold its shape. In other words the extruding apparatus of the present invention extrudes a product under pressure and where the product when extruded retains its form.

Huge volumes of waste are being produced worldwide every day and a large proportion of this waste is simply dumped or incinerated. Municipal solid waste (msw) generates huge volumes that need to be disposed of in some way. Large farms produce huge volumes of slurry. Sludge and manure are produced in vast quantities all over the world and cause huge environmental problems as the nutrients are not readily available to plants. The market for these waste products is also limited as they contain pathogens and/or harmful organisms. Waste water is a by-product of many industries and processes which is problematic and expensive to dispose of safely. The present invention provides an apparatus and method which utilises the valuable raw material that is organic waste to produce a usable product suitable for use in many different processes.

The waste material intended for use with the apparatus of the invention is mainly organic waste material but may also include other organic material such as soil. The types of waste intended for use with the apparatus of the invention may be any one of more of soiled recyclables, green waste or food waste (typical constituents of municipal solid waste (msw)), manure from farms, industrial waste, glycerol, timber waste, grains from biofuel, bagasse (the fibrous matter that remains after sugarcane or sorghum stalks are crushed to extract their juice), waste paper, glycerol, sludge and whole digestate from sewerage plants and biodigesters, non-recyclables, soiled paper/plastics, metals, organic material containing contaminants that cannot be mechanically separated for recycling commercially for example plastics or debris in biodigester material. A lot of the material that may be used in the apparatus and method of the present invention includes material that cannot be separated commercially because of the number of fragments for recycling and the high costs involved in separating the waste.

The present invention provides an apparatus for processing such waste to form a usable product which has many benefits both environmentally and economically. Using the apparatus of the present invention mixed waste or contaminated soil may be blended with other waste, binding agents, organic material, additives, and/or enzymes and/or heat treated. The resulting extruded product is a valuable commodity with a large variety of uses.

The extruding apparatus of the invention is mobile and may be mounted to a driving vehicle. Alternatively the apparatus is self-propelled. The extruding apparatus may also be stationary.

The apparatus and method of the present invention provides a means of utilising waste material on a large industrial scale. The apparatus of the invention is capable of high output dealing with large volumes of waste at one time. Preferably the waste is blended with a binding agent such as farm manure, sewage sludge etc.

The waste material may be delivered to a central area where it is sorted and loaded into the extruding apparatus of the present invention. The waste material may be mixed with a binding agent. Binding agents such as manure from farms, sludge, whole digestate from sewerage plants and biodigesters and/or plant roots may be used. Preferably the waste material is mixed with an equal proportion or higher proportion of binding agent. The initial moisture content of the waste material should be in the range of 35% to 80%.

The extruding apparatus of the invention may for example be located near an oil-refinery where disposal of waste water is a big concern. Typically oil refineries are situated in areas surrounded by under-utilised arid land. Extruding a blended waste product onto a layer of impermeable material on arid land, growing a biomass crop on top of the extruded material and irrigating the crop with waste water from the oil refinery would be beneficial in many ways. Waste water would be safely disposed of and/or cleaned without the issue of large transport costs.

Where the land is arid and/or very poor in nutrients the apparatus of the invention may be used to both remediate the soil and use up waste products. Soil and sludge from sewage plants may be blended in the apparatus and extruded onto or between layers of impermeable material. After exposure from the sun the extruded heat treated product will be essentially pathogen free and may be used to grow a biomass crop. The extruded product and biomass crop may then be irrigated with waste water from a large industry. The layer of impermeable material underneath the extruded product contains any liquid and less water is thus required to irrigate the crop. The crops are fast growing and the process may be repeated again after a few weeks. This process will filter the waste water used to irrigate the crops. Alternatively waste water may be spread on top of the extruded material growing a crop of biomass. A water filtration bed may be created. The crop acts as a filter using up and collecting excess nutrients in the waste water. It also allows for the construction of a wetland where waste water can be used for irrigation.

As the product is extruded onto an impermeable layer of material the extruded product and the irrigation water is isolated from the soil beneath and the cleaned water may be easily collected and recycled.

Different types of mainly organic waste may be loaded into the apparatus of the invention, conveyed, blended and extruded under pressure onto a layer of impermeable material.

Depending on the mixture of material extruded in the extruding apparatus of the present invention the resultant product may be used in various ways.

The product is extruded onto a layer of impermeable material 81 laid down by the layering apparatus located on the extruding head on the apparatus of the invention. The height of the extruding opening on the extruding head is not very high so that the depth of the extruded semi-solid material is not too deep. Preferably the height of the extruding head is less than 50cm (approximately 20 inches), preferably between 25cm (approximately lOinches) and 38cm (approximately 15 inches). The depth of the extruded product should be sufficient to ensure that solar radiation is able to kill all pathogens and contaminants throughout all of the extruded product.

Fig. 14 shows one embodiment of the invention where, as the product is extruded several layers of impermeable material are layered on top of the extruded product 80. A first layer of impermeable material 82 is laid directly on top of the extruded product 80. A second layer 84 is laid on top of the first layer 82 and a spacer 83 positioned between the first 82 and second 84 layers. The spacer 83 may be a light weight flexible pipe which ensures an air pocket exists between the layers of the impermeable material. A third layer of impermeable material 85 is laid on top of the second layer 84 and is held above the second layer 84 in a hooped arrangement. The various layers of impermeable material prevent moisture getting in or out of the extruded product.

The different layers of impermeable material with airspaces between the layers, under exposure from the sun, trap heat and allow the extruded product to heat to high temperatures. In this way the product is heat treated. Soil-borne pathogens and nematodea are known to be susceptible to the high temperature effects. The extra layers of impermeable material provide insulation and still air chambers which add to the heat in the extruded product giving a better efficiency or heat treatment of the product. The high internal temperature and moisture in the extruded product break cell walls and kill pathogens and certain fungi. As a result of heat treatment a substantially pathogen free product is produced. The extruded product may be heated to temperatures greater than 40°C or 100°F.

A heat treated product has many uses such as a fertilizer, compost, nursery soil, use in mushroom production, or it may be inoculated with mycelium to break down lignin in the ethanol industry. Cellulosic ethanol plants need to be pretreated before being converted into ethanol. Using the apparatus and method of the present invention pre-treatment of such waste organic material maybe done in situ close to where they are required.

In this way previously contaminated soil may be remediated. This may be carried out in situ. Soil is harvested using the harvester located on the front end of the apparatus, conveyed into the container, mixed, conveyed and extruded under pressure through the extruding head as a compact semi-solid block. The product is extruded onto a layer of impermeable material laid down by the layering apparatus or between layers of material and heat treated. The extruded material undergoes chemical, physical and biological changes after heat treatment. The impermeable layer ensures that the product extruded on top of the impermeable material is not in contact with the soil underneath. The extruded soil may be blended in the container with additives to improve the soil quality before extruding and/or after heat treatment the extruded product may be re-harvested and additional additives added.

The layer of impermeable material under the extruded material prevents the heat treated extruded product, especially where the waste raw material is soil, of being re-infested with soil-borne pests, pathogens, nematodes, insects, fungi or bacteria which may have been present in the soil. Alternatively a waste material may be mixed with the soil in the container of the extruding apparatus. The waste material may be sludge from sewerage or large farms. Having the impermeable layer underneath the extruded product prevents any harmful effluent from the extruded product penetrating into the ground beneath and entering the water table. It contains any run-off. Under exposure from the sun and with layers of impermeable material on top of the extruded product the high temperatures reduce pathogens and other contaminants in the extruded product yet leaves nutrients intact and more readily available for plant growth.

After heat treatment the apparatus of the invention may be used to harvest the heat treated product. The product is harvested in such a way that the impermeable layer of plastic underneath the extruded product is kept separate from the pathogen free product to ensure the pathogen free product does not come into contact with any of the untreated soil beneath the impermeable layer of plastic.

Combining heat treatment with various organic material which have pesticidal activity when incoporated into soil is known as biofumigation of soil. Studies have shown that combining heat treatment with composted animal manures, provide disease management via enhanced release of toxic volatile compounds from the residues in heated soil.

Soil may be harvetsed and a biofumigant may be added to the container of the apparatus and mixed with the soil. Biofumigant material such as manure /green manure sludge may be pumped using an umbilical sludge system in over the side of the container of the apparatus and blended with the soil. The product is then extruded under pressure as described above and exposed to the sun to heat to high temperatures.

Where a soil-less waste material is blended and heat treated, the heat treated product may be dried and used as fuel. In addition a biomass crop may be grown on top of the extruded product, waste water used to irrigate the crop. The crop and extruded product may be dried and used as a valuable fuel source.

The apparatus of the invention can utilise many forms of organic waste, msw and extrude them in a way that the extruded product is dried over time by exposure to the sun and wind. The dried extruded product is a valuable biomass. The dried material may be harvested, broken up into blocks and used as fuel biomass for gasification, pyrolysis or it may be ground into a powder or granulated form for spreading on land as a fertilizer.

The extruded blended product may be extruded under pressure in a number of different ways including extruded onto a layer of impermeable material, onto a layer of impermeable material and under a layer of impermeable material and allowed dry; onto a layer of impermeable material and under several layers of impermeable material and heat treated; extruded onto a layer of impermeable material, covered with another layer of impermeable material and planted with a crop; extruded onto a layer of impermeable material, covered with water for filtration beds; extruded onto a layer of impermeable material and flooded to make fish ponds; and/or extruded in layers to form a compost bed. The extruded product may also be extruded directly on to the land and/or planted and allowed dry naturally.

Extruding the material onto an impermeable material such as plastic or PVC has a number of advantages in that the material does not mix with the soil or other material on the ground; it stops moisture getting in or out of the extruded product or reducing it. Extruding onto a layer of impermeable layer and covering it with another layer of impermeable material keeps the extruded product together and prevents it from spreading with the wind or other elements; keeping the mix together also keeps smells down to a minimum; it prevents vermin or pests interfering with the material. It is essential to prevent water run-off from some extruded waste products away from the water table and having a layer of impermeable material underneath diverts the waste water to a drain or pond where it can be used for irrigation or other uses. The use of plastic or PVC also allows for a modular system so different crops can be differentiated from others (times, dates, type and product can be monitored).

The blended product may be extruded onto a layer of impermeable material which is biodegradable and disintegrates over time. Over time the extruded treated product may be incorporated into the soil.

The product may be extruded onto a layer of impermeable material and covered with another layer of impermeable material. A crop may then be planted on top of the extruded material. Crops such as vetiver, sorgrum, rye, Indian grass, soybean, oats, maize, corn are suitable crops for growing on top of the extruded product. Sowing a crop has a number of advantages. It creates cover. It looks better to have acres of green area than to have acres of drying biomass and it is better for wildlife and the environment. Other advantages of growing a crop on top of the extruded blended product include controlling pests, helping with soil erosion, reducing odours, retaining moisture, keeping the mix together; creating an extra biomass yield from the roots and from the crop itself; the roots of the crop may be used as a binder for the blended material. For soil-less waste in particular the roots of a biomass crop bind the extruded product together and when dried out the product may be easily harvested for example by simply rolling up the elongated extrusion and transported for storage and/or used for fuel. Growing a crop on top of the extruded product keeps dust down and other debris. The crop use up nitrates and other minerals that create problems in the ground water using them up in the growing of the material, moisture can be used up by the crop and the crop will be easier to harvest as it will form into a mat. The biomass may also be used for different technologies as the nitrates and other minerals limit the technologies that certain products can be used for.

The roots of the crop help dry out the extruded blended material out more. After it rains the product will dry quicker. It will extend the growing season as the crops will dry quicker and with less heat. As a result it will open the process up to it being used in more countries. It will add to the yield of biomass crop that can be harvested per acre.

The extruded blended material may also be extruded in such a way as to result in filtration bed. Figs. 15 and 16 show a schematic of a wetland or filtration bed where the extruded material is irrigated by waste water. The extruded material 80 is irrigated with waste water 82. The extruded material 80 may have a biomass crop 85 grown on it. The spreading, growing/filtration area 83 is irrigated. The direction of flow of the irrigation water is indicated by the arrows. The waste water is cleaned and after a period of time the area may be drained and the extruded product and biomass dried and used as fuel. The extruded blended material may also be extruded in such a way as to result a floating mass or pontoon.

A bio digester and other technologies may fit in with the process for producing the usable blended product of the invention. Because of the fact that a bio digester collects only the gas, the process of the present invention can use up the liquids and the solids after the bio gas has been collected.

Different waste material may be blended together depending on the intended use of the extruded product. The apparatus of the present invention is capable of taking waste material on a large scale, currently not utilised to its optimum potential, to produce a usable product which is environmentally beneficial. By extruding waste in the different ways as described herein, contaminants in the waste material are reduced if not eliminated. Extruding the blended product between impermeable layers of material and with the help of solar radiation the product undergoes chemical, biological and physical changes. This results in a substantially pathogen free product being produced. The substantially pathogen free product is suitable for use as a fertiliser or compost. Extruding the blended product and growing a biomass crop thereon is beneficial in creating a further valuable fuel source. The biomass may be used as fuel in a biogdigester or other technologies.

Extruding the blended product and using the extruded product to make filtration beds is environmentally beneficial. The extruding apparatus of the present invention may be used to extrude a mass or semi-solid block of material from a blend of manure, plant roots and/or timber waste. The extruded material is allowed to dry. A crop is grown on the mass which helps to dry the extruded material and bind the extruded mass. The mass or block of dried extruded material may then be floated in water. The crop creates a biomass. The crop may be used to filter waste water. The crop helps reduce the level of nutrients getting into the ground water. Fish ponds may be created, the fish providing a food source and providing a source of rich fish manure. An enriched biomass may be harvested after a period of weeks depending on the climate.

Referring to the drawings and initially to Figs. 1 to 5 thereof, there is illustrated an extruding apparatus 50 according to the invention for extruding blended product under pressure onto land for drying. The extruding apparatus 50 of the invention may be a trailable apparatus which is suitable for trailing an agricultural tractor or any other suitable prime mover. The apparatus has a container section 51 resting on a chassis and having a pair of ground engaging wheels 52. The apparatus 50 may be hitched to a tractor or other such prime mover. Alternatively the apparatus may be self-propelled. The container section of the apparatus is ideally located low to the ground.

The container 51 comprises a pair of side walls 53 which are inclined inwardly towards each other to a central conveying means, which in this embodiment of the invention comprises a plurality of parallel conveying augers 54. The container 51 comprises a base, a pair of spaced apart opposite side walls 53, a front end wall 58 and a rear end wall 59. The base, side walls 53 and front and rear end walls 58 and 59 define a hollow interior region for receiving the blended waste material.

The conveying and mixing augers 54 extend the length of the container 51 into tubular members 55, and are operated to convey the blended material in the container 51 from the front end thereof into the tubular members 55, and through the tubular members 55 directly to the extruding mechanism 56. The extruding mechanism 56 is mounted on the rear end wall 59 and communicates with the hollow interior region through an opening formed in the rear end wall 59. The extruding mechanism 56 comprises an extruding head 57.

The apparatus 50 comprises a material layering device (not shown) mounted onto the extruding mechanism 56. The product is extruded onto a layer of material as described hereinbefore. Alternatively or additionally a plastic bag fitter 58a may be detachably mounted onto the extruding head 57 so that the extruded product may be bagged for ease of transport.

The extruding mechanism 56 may comprise a plurality of parallel augers in the extruding head 57 which receive the material from the conveying augers 54 further mixing the material and forcing the blended product out under pressure through the elongated extruding opening 57. The tubular members 55 are connected directly into the extruding head 57, and the conveying or urging augers 54 by extending into the tubular members 55 pressurise the blended material as it is being urged through the tubular members 55 into the extruding head 57.

The blended material or product is extruded onto a layer of impermeable material onto the ground behind the apparatus as it moves forward.

A slatted loading conveyor 60 may be mounted on the front of the container 51 for conveying and delivering waste material into the container 51. The loading conveyor 60 comprises a main framework within which a slatted conveyor is operable. However the extruding apparatus also operates without a loading conveyor. A loading vehicle may simply offload their load straight into the container 51. Referring now to Fig. 5 there is illustrated an extruding apparatus 70 according to another embodiment of the invention. The extruding apparatus 70 is substantially similar to the extruding apparatus 50 which has been described with reference to Figs. 1 to 4, and similar components are identified by the same reference numerals.

The container 51 of extruding apparatus 70 in this embodiment rests on a chassis comprising a scissors axel 71. The scissors axel 71 allows the extruding apparatus 70 to be heightened and lowered as required. This may be required when the blended material is to be loaded onto conveyors of different heights for filling growing tunnels, when creating layered compost beds or pits or when the apparatus needs to be raised to clear a ditch or raised earth.

As shown in Fig. 5 the apparatus 70 may comprise a material layering device 72. Fig. 6 shows apparatus 70 with a planter or seeder device 73 mounted onto the extruding mechanism 56 in addition to the material layering device 72. In this way the extruded material may be extruded onto a layer of impermeable material such as plastic or PVC and at the same time planted or seeded with a crop.

Fig. 7 shows a further embodiment of the invention where apparatus 70 additionally comprises an output conveying means 74 for conveying blended extruded material in different directions. The output conveying means 74 is adapted such that the blended material is extruded and extends along the length of the conveying means before the extrusion is tipped onto the ground or any other suitable surface.

Apparatus 70 may comprise a harvesting head (not shown) at the front of the apparatus so that soil may be harvested, conveyed to the container and blended with different additives. The additives are added to the container with the help of an umbilical sludge system or any other conveyor means. The blended product is extruded under pressure from the extruding head. In this way soil may be remediated. The soil may be harvested and extruded in situ. Any extruded product may also be re-harvested to add additional additives.

Referring now to Figs.8 to 10 there is illustrated an extruding apparatus 90 according to another embodiment of the invention. The extruding apparatus 90 is substantially similar to the extruding apparatus 50 and 70 which has been described with reference to Figs. 1 to 7, and similar components are identified by the same reference numerals.

The container 51 of extruding apparatus 90 in this embodiment rests on a chassis comprising tracks 96 for ease of movement. The container is at an angle with the front wall 58 of the container closer to ground level than the rear wall 59 of the container. The angled container makes it easier for loading of waste material into the hollow interior of the container. The angled container ensures good mixing and urging of the waste material along the base of the container and into the extruding head section 56.

The container 51 comprises sidewalls 53 which may or not be inclined inwardly toward one another. The container 51 comprises a base, a pair of spaced apart opposite side wall 53, a front end wall 58 and a rear end wall 59. A central conveying, mixing and urging means comprises a plurality of augers 54. The conveying mixing and urging augers 54 extend the length of the container into tubular members and communicate with the extruding head section 56 through an opening in the rear end wall 59.

Apparatus 90 has a mixing auger 98 located at an angle in this instance at a substantially perpendicular angle to the conveying, mixing and urging augers 54 at the rear end wall 59 of the container. As material is conveyed along the container by the conveying, mixing and urging augers 54 the mixing auger 98 ensures that any material which gathers at the end of the container is pushed back onto conveying, mixing and urging augers 54 and urged through to the extruding head.

On the front of the apparatus 90 is a harvesting head 91. Soil or previously extruded material may be harvested into the container 51 through openings in the front end wall 59 of the container. To the rear of the container and in an elevated position there is a cab 97 for the operator to sit and control the apparatus. From the elevated position the operator is able to observe both the container area and the extruding head area. The extruding head in this embodiment comprises a single elongated extruding opening 57. Surrounding the extruding opening is a material layering device 72. Rollers 93 are located on either side of extruding head section for mounting rolls of impermeable material.

Hydraulic arms 94 and 95 raise the height of the extruding head section and the front harvesting end of the apparatus respectively as required. When not in use or for transporting the harvesting head may be raised. In a similar manner the extruding head may be raised or lowered.

Referring now to Figs. 11 to 13 there is illustrated an extruding apparatus 100 according to another embodiment of the invention. The extruding apparatus 100 is substantially the same as extruding apparatus 90 and similar components are identified by the same reference numerals.

Apparatus 100 has a conveyor 101 at the front 58 of the container 51 for conveying waste material into the hollow interior of the container 51. Waste material may be brought in large transporters and loaded onto the conveyor 101.

A pipe or hose reel 102 is mounted at the side of the cab 97 to deliver flexible piping 103 between the layers of impermeable material laid on top of the extruded product as shown in Fig. 14. Rollers 93 on the top of the extruding head section unwind rolls of impermeable material as the product is extruded therein between. Curved edging 104 around the extruding opening 57 ensure a layer of impermeable material under the extruded product is brought up or folded up along the sides and over the top edge of the extruded product. The edging 104 also ensures that the top layers of impermeable material are brought down along the sides and under the extruded product. In this way the product is extruded between the layers of impermeable material and under the weight of the extruded product the layers of impermeable material are held securely in position.

During towing or driving of an apparatus of the invention along a road or other access ways, the extruding head is in a raised position. On reaching the field over which the blended material is to be extruded for drying, the extruding head is lowered so that the extruding opening is located at a level just above ground level. The conveyor and mixing and urging augers are then operated so that as the apparatus is being trailed or drives over the field, the waste material is conveyed and mixed in the hollow interior region of the container towards the rear of the container where the tubular members of the urging augers urge the blended material through bores in the rear wall of the container and in turn to the extruding head and onto the field. At the same time the material layering apparatus is laying out the layers of impermeable material as required. Thus, as the apparatus moves in the forward direction over the field elongated extruded strips of blended material are extruded over the field.

The apparatus of the invention may be used for producing fuel blocks. The method comprises blending organic material with farm manure in the apparatus of the invention. The waste material is of a moisture content in the range of 35% to 80%, and is transported to a suitable blending site, where it is blended with farm manure of a moisture content typically in the range of 35% to 90%. Typically, the blending would take place on a farm, which typically would be a relatively large farm which would have a relatively high output of animal manure. The waste organic material is then blended with the manure in any suitable mixing apparatus to produce a relatively homogeneous blend of the waste organic material and the manure.

On being blended the blend of waste organic food material and manure is then loaded into the container of an apparatus of the invention. The blended material may be extruded in elongated extruded strips on land with or without a layer of impermeable material beneath.

The elongated extruded strips of the blended material are left in the field exposed to sunlight, typically for two weeks to five weeks, until the moisture content of the extruded strips is in the order of 18%. At that stage, the extruded strips are dried to a satisfactory moisture content, and are then broken along transverse indents in the elongated strips into blocks which are suitable for use as biomass fuel blocks for burning in an open fire, a stove or a furnace or any other suitable burning equipment. Alternatively, it is envisaged that the blocks may be ground into powder or granulated form to be suitable for spreading on land as a fertiliser. It is also envisaged that the blocks may be used as adobe bricks. The extruded material may be covered with a thin layer of soil, compost material or an odour reducing agent which would minimise foul odours emanating from the elongated extruded strips during drying thereof. Additionally or alternatively, the extruded material may be covered with a sheet of material, for example PVC to collect gases emitted by the extruded material.

While the method in this embodiment has been described as being used for producing fuel or fertiliser from waste organic material from the food industry, it is envisaged that the method may be used for producing a usable product, which may be a fuel or a fertiliser from any waste material with a high organic element, be it waste material or otherwise from any industry, and in which case, the waste organic material would be blended with farm manure or sewage sludge as already described and extruded by the extruding apparatus 1 for drying thereof.

It is also envisaged that as well as the blend comprising waste organic material and manure or sewage sludge whereby the manure or sewage sludge acts as a binder for binding the blend together, it is also envisaged that a binding material may be blended with the waste organic material and/or the manure or sewage sludge to further bind the blend together. Such a binding material may be clay-mud or whole digestate from an anaerobic digester or roots from biomass produced from previously extruded material.

It is envisaged that the organic material, be it waste organic material or otherwise may be derived from many industries, for example, the agricultural industry, the forestry industry. Additionally, the organic material, be it waste or otherwise, may be sourced from abattoirs, the brewing industry, the spirits-making industry, the wine- making industry, the bio-fuels production industry. Where the blended material includes sewage or sewage sludge, the sewage or sewage sludge may be included in the blended material instead of or as well as manure, and the sewage or sewage sludge may be sourced from municipal sewage treatment plants, the organic material may also be sourced from industries involved in algae production, and may also be sourced from anaerobic digesters. The organic material, be it waste material or otherwise, may be straw, sugar cane, paper pulp, wood waste, bark peelings, glycerol, brewer's grain, and any other suitable organic material, be it waste organic material or otherwise.

While the apparatus 50, 70, 90 and 100 have been illustrated as comprising a single elongated extruding opening, it will be readily apparent to those skilled in the art that any number of extruding nozzle outlets may be provided.

It is also envisaged that the extruding apparatus may be adapted to be a stationary apparatus, and in which case, a plurality of output conveyors would be provided extending from corresponding ones of the extruding nozzle outlets, and each conveyor would be adapted so that when a blended material extrusion extends the length of the conveyor, the conveyor would tip the extrusion onto the ground or any other suitable surface on which the blended extrusion would be exposed to dry. Alternatively the blended extrusion may be extruded in the different ways already described, for example between sheets of impermeable material and/or flooded to form filtration beds or extrude in layers for compost. The conveyors would be operated at the same speed as the speed at which the blended extrusion is being extruded through the extruding nozzle outlets.

It is also envisaged that the extruding nozzle outlets may be directed to discharge the blended extrusion transversely of the direction of motion of the extruding apparatus where the extruding apparatus is a mobile apparatus, and in which case, the extruded blended material would be extruded onto a conveyor from each extruding nozzle outlet as just described, and when the blended extrusion from each extruding nozzle outlet extended the length of the corresponding conveyor, the blended extrusion would be tipped onto the ground.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail. It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof.

Claims

1. An extruding apparatus for extruding a blended usable product in a semisolid form comprising; a container defining a hollow interior region for receiving a material; an extruding head for extruding material into an elongated strip, the extruding head defining an extruding opening communicating with the hollow interior region of the container; a first conveying means for mixing and conveying material in the container; and a second conveying means for conveying and urging the material in the container under pressure into the extruding head.

2. An extruding apparatus as claimed in claim 1 comprising a layering apparatus detachably connected to the extruding head.

3. An extruding apparatus as claimed in claim 1 or 2 comprising a harvesting device detachably connected at an end distal to the extruding head.

4. An extruding apparatus as claimed in any preceding claim wherein the conveying means comprises an auger.

5. An extruding apparatus as claimed in any preceding claim wherein the conveying means comprises at least two augers.

6. An extruding apparatus as claimed in any preceding claim wherein the second conveying means comprises a tubular member at the end proximal the extruding head for conveying and urging the material in the container under pressure into the extruding head.

7. An extruding apparatus as claimed in claim 4 or 5 wherein the first conveying means is positioned at an angle to the second conveying means within the container.

8. An extruding apparatus as claimed in any preceding claim comprising an additional conveying means for conveying material into the container selected from any one or more of a slatted conveyor, a conveying belt, a conveying chain, a mixer or an umbilical cord feeder system for conveying material into the container.

9. An extruding apparatus as claimed in any of claims 2 to 8 wherein the material used in the layering apparatus comprises any one or more of an impermeable material, plastic, PVC, biodegradable and durable impermeable material or film.

10. An extruding apparatus as claimed in any of claims 2 to 9 wherein the layering apparatus comprises means to extrude the blended product on top of a layer of material, under a layer of material and/or between layers of material.

1 1. An extruding apparatus as claimed in claim 9 wherein the layering apparatus comprises means to lay a layer of material under the extruded product and a plurality of layers of material on top of the extruded product and means to insert a spacer between the layers of material.

12. An extruding apparatus as claimed in any of claims 3 to 10 wherein the harvesting device comprises means to harvest product previously extruded by the extruding apparatus onto a layer of material and wherein the harvested product is separated from the layer of material during harvesting.

13. An extruding apparatus as claimed in any preceding claim comprising a chopper or cutting device detachably connected to the apparatus at an end distal to the extruding head.

14. An extruding apparatus as claimed in any preceding claim comprising a planter and/or seeder device detachably connected to the extruding head.

15. An extruding apparatus as claimed in any of preceding claim comprising an output conveying means for conveying blended extruded material in different directions or at different heights.

16. An extruding apparatus as claimed in claim 15 wherein the output conveying means is adapted such that the blended extruded material extends along the length of the conveying means before the extrusion is tipped onto the ground or any other suitable surface.

17. An extruding apparatus as claimed in any preceding claim which is mobile.

18. An extruding apparatus as claimed in claim 17 wherein the apparatus is self-propelled.

19. An extruding apparatus as claimed in claim 17 or 18 wherein the container comprises a trailable wagon having the extruding head located towards the rear end of the wagon and wherein the extruding head is adapted for extruding the material in a rearward direction from the trailable wagon as the trailable wagon is being trailed.

20. An extruding apparatus as claimed in any preceding claim wherein the extruding head comprises a single elongated extruding opening for extruding under pressure a single elongated strip of blended product in a semi-solid form.

21. An extruding apparatus as claimed in any preceding claim wherein the material to be extruded is selected from any one or more of green waste, organic waste, soiled recyclables, non-recyclables, contaminated recyclables, food waste, paper, bagasse and/or soil.

22. An extruding apparatus substantially as hereinbefore described with reference to the drawings.

23. A method of blending and extruding a usable product in a semi-solid form from a material on an industrial scale using an apparatus as claimed in any preceding claim.

24. A method of blending and extruding a usable product of relatively high moisture content in a semi-solid form from a material comprising mainly organic waste material using an apparatus as claimed in any preceding claim.

25. A method of blending and extruding a usable product from a material selected from any one or more of green waste, organic waste, soiled recyclables, non-recyclables, contaminated recyclables, food waste, paper, bagasse and/or soil using an apparatus as claimed in any preceding claim.

26. A method as claimed in any of claims 23 to 25 wherein the material is waste material is selected from any one or more of the food processing industry, a by-product of an industrial process or a by-product of farming.

27. A method as claimed in any of claims 23 to 26 wherein the usable product is extruded onto a layer of material selected from any one or more of an impermeable material, plastic, PVC, biodegradable and durable impermeable material or film.

28. A method of producing a usable product substantially free of pathogens using an apparatus as claimed in any of claims 1 to 22 wherein the blended product is extruded in a semi-solid form between layers of impermeable material and the extruded product exposed to the sun and heated to a high temperature.

29. A method as claimed in claim 28 wherein the extruded product is heated to a temperature of greater than 40°C or 100°F.

30. A method as claimed in claim 28 or 29 wherein the product is extruded onto a layer of impermeable material and covered by three layers of impermeable material, wherein the first cover layer of impermeable material is directly on top of the extruded product, a spacer is positioned between the first and second layer of impermeable material and a third layer of impermeable material supported substantially above the second layer of impermeable material.

31. A method as claimed in any of claims 27 to 30 wherein an organic material selected from any one or more of animal manures, green manures and/or agro industrial residues is blended with the material in the container before the product is extruded.

32. A method as claimed in any of claims 27 to 31 wherein an additive selected from any one or more of a biological agent, bacteria fungi, enzymes, chemical agent, organic agent, enzymes or green plants is added to the extruded heat treated material.

33. A method as claimed in any of claims 27 to 32 wherein the extruded product is re-harvested using the apparatus as claimed in any of claims 1 to 23 and additives added before extruding the product onto a layer of impermeable material.

34. A method as claimed in any of claims 28 to 33 wherein the upper layers of impermeable material on top of the extruded material are removed and/or aerated after heat treatment.

35. A method as claimed in any of claims 27 to 34 wherein the extruded product is planted with biomass crop.

36. A method as claimed in claim 35 wherein the biomass crop is selected from any one or more of vetiver, sorgrum, rye, Indian grass, soybean, oats, maize, and /or corn.

37. A method as claimed in claim 35 or 36 wherein the extruded product is irrigated with waste water.

38. A method as claimed in claim 37 wherein the waste water is water from any one or more of waste water from oil-refineries, waste water from an industrial process, municipal waste water or contaminated water.

39. A method as claimed in any of claims 35 to 38 wherein the biomass crop extracts and/or uses up the nutrients in the waste water and extruded product.

40. A method as claimed in claim 39 wherein after a period of time the extruded product and its biomass crop is allowed dry out.

41. A method as claimed in any of claims 35 to 39 wherein the extruded product is prepared from a soil-less waste material and after irrigation the extruded product with its biomass crop grown thereon is dried out and used as fuel.

42. A method as claimed in any of claims 35 to 41 wherein the roots of the biomass crop bind the extruded product together making the extruded product easy to dry and harvest.

43. A method as claimed in any of claims 23 to 27 wherein a binding agent is blended with the waste material in the container of the extruding apparatus.

44. A method as claimed in claim 43 wherein the binding agent may be any one or more of farm manure, sewage sludge, and/or whole digestate.

45. A method as claimed in claim 43 or 44 wherein soil is harvested using an apparatus as claimed in any of claims 1 to 22 a binding agent blended with the soil and the blended product extruded onto a layer of impermeable material and planted with a biomass crop.

46. A method as claimed in claim 45 wherein the extruded product is irrigated with waste water.

47. A method as claimed in any of claims 23 to 46 wherein the initial moisture content of the wet organic waste material is in the range of 35% to 80%.

48. A method as claimed in any of claims 23 to 46 wherein the moisture content of the extruded product is in the range of 30% to 75%.

49. A method as claimed in any of claims 23 to 48 wherein the extruded product is used as a fertilizer, compost, for growing mycelium in the ethanol or other industries, inoculated with mycelium, and/or used as a microfiltration/myco filtration bed for land remediation.

50. A method as claimed in any of claims 23 to 48 wherein the blended material is mixed with larvae from the black soldier fly or other and extruded in an elongated strip wherein the black soldier fly consumes and breaks down the blended material.

51. A method as claimed in any of claims 23 to 48 to wherein the blended usable product is extruded in layers alternating with layers of any one or more of cow manure, green waste, minerals or herbs to produce a stable humus material.

52. A method as claimed in any of claims 23 to 48 to wherein the blended material is placed in elongated strips on the ground and sown with plants using the planter or seeder apparatus attached to the extruder apparatus.