U.S. patent application number 11/881145 was filed with the patent office on 2008-02-07 for biomass treatment of organic waste materials in fuel production processes to increase energy efficiency.
This patent application is currently assigned to NBE,LLC. Invention is credited to Robert E. III Clifford, Michael S. Gratz, John Mills.
Application Number | 20080028675 11/881145 |
Document ID | / |
Family ID | 39027751 |
Filed Date | 2008-02-07 |
United States Patent
Application |
20080028675 |
Kind Code |
A1 |
Clifford; Robert E. III ; et
al. |
February 7, 2008 |
Biomass treatment of organic waste materials in fuel production
processes to increase energy efficiency
Abstract
A method, system, apparatus and program extracts energy from
organic residual materials produced by the manufacturing of
biofuels. Energy is extracted from the biofuels residuals using
anaerobic bioconversion to produce a fuel for use in the
manufacturing process for producing synthetic biofuel or as an
additional energy product for sale comprises: providing at least
one bioconversion tank for conversion of organic waste material,
the bioconversion tank containing an active biomass comprising at
least one bacteria that decomposes organic material; providing at
least one inlet to the bioconversion for organic material; a
processor that receives and stores information on: the status of
chemical oxygen demand of the active biomass; and the oxygen
provision capability of any organic material that can be fed into
the bioconversion tank through an inlet; a mass flow control system
controlled by the processor which feeds at least one organic
material through an inlet at a rate based at least in part upon the
status of chemical oxygen demand in the bioconversion tank as
recognized by the processor.
Inventors: |
Clifford; Robert E. III;
(Minnetonka, MN) ; Mills; John; (Shoreview,
MN) ; Gratz; Michael S.; (Eden Prairie, MN) |
Correspondence
Address: |
Mark A. Litman & Associates, P.A.;York Business Center
Suite 205
3209 West 76th St.
Edina
MN
55435
US
|
Assignee: |
NBE,LLC
|
Family ID: |
39027751 |
Appl. No.: |
11/881145 |
Filed: |
July 25, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11126433 |
May 10, 2005 |
7163630 |
|
|
11881145 |
Jul 25, 2007 |
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60833526 |
Jul 26, 2006 |
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Current U.S.
Class: |
44/605 ; 422/119;
435/170 |
Current CPC
Class: |
C10L 3/08 20130101 |
Class at
Publication: |
044/605 ;
422/119; 435/170 |
International
Class: |
C10L 3/08 20060101
C10L003/08 |
Claims
1. A method of bioconversion of organic waste material from a
synthetic fuel manufacturing process that requires energy input in
the performance of the synthetic fuel manufacturing process, the
method comprising: providing a tank for bioconversion of organic
waste material, at least some of which organic waste material is
derived from a synthetic fuel manufacturing process, the tank
containing an active biomass comprising at least one bacteria that
decomposes organic material; providing one or more inlets to the
bioconversion tank, comprising an inlet for organic material from
the synthetic fuel manufacturing process a processor receiving and
storing information automatically or manually input to the
processor on: the status of chemical oxygen demand and/or
biological oxygen demand of the active biomass; and the oxygen
provision capability of an organic material that can be fed into
the bioconversion tank through any inlet; the processor exercising
control over a mass flow control system which feeds the at least
one organic material through an inlet, the processor directing mass
flow at a rate based at least in part upon the status of chemical
oxygen demand in the bioconversion tank as recognized by the
processor from received information; a stream carrying combustible
gases from the biomass; and the stream providing at least some of
the energy input in the performance of the synthetic fuel
manufacturing process.
2. The method of claim 1 wherein there are at least two storage
tanks for organic material, a first storage tank for the first
organic material and a second storage tank for a second organic
material, the first and second organic materials having different
chemical oxygen provision capabilities from each other; the
processor receiving and storing information on the respective
chemical oxygen provision capabilities of the first organic
material and the second organic material; and the processor feeding
feeds the first organic material and the second organic material
into the bioconversion tank at a rate based at least in part upon
the status of chemical oxygen demand in the bioconversion tank, the
chemical oxygen provision capability of the first organic material,
and the chemical oxygen provision capability of the second organic
material as recognized by the processor and a filter may be present
between the active biomass in the bioconversion tank and the
treated aqueous outlet; or wherein an energy depleted aqueous
stream is removed from the bioconversion tank through an aqueous
stream outlet and a biogas stream is removed from the bioconversion
tank through a gas venting outlet, the biogas stream comprising
primarily methane and carbon dioxide is removed from the
bioconversion tank.
3. (canceled)
4. The method of claim 2 wherein at least one of the active biomass
and energy depleted aqueous stream are automatically tested for
active biomass nutrient content and testing information is provided
to the processor or wherein when testing for pH indicates that the
pH level in the treatment tank is not within a desired range stored
in the processor, the processor directs a feed system for a pH
active material selected from the class consisting of at least one
of a base, an acid or a buffer to input pH active material into the
bioconversion tank to bring the pH level in the tank within the
desired range.
5. The method of claim 4 wherein when testing for active biomass
nutrient content indicates that the nutrient level in the
bioconversion tank is not within a desired range stored in the
processor, the processor directs a nutrient feed system to input
nutrient material into the bioconversion tank to bring nutrient
level in the tank within the desired range and wherein testing may
be performed for at least one of available nitrogen and available
phosphorous, and the results of such testing are used by the
processor to determine how much nutrient is to be added to the
bioconversion tank to specifically adjust at least one of nitrogen
and phosphorous content in the treatment tank.
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. An organic bioconversion system for providing energy to a
synthetic biofuel manufacturing process comprising: a) at least a
first organic material storage tank for a first organic material;
b) an aqueous stream input source; c) a bioconversion tank having a
controlled input connection from a) and a controlled input
connection from b), and containing an active biomass that comprises
bacteria capable of decomposing the first organic material from the
first organic material storage tank; d) a processor that controls
the input connections from a) and from b); e) a sensing system that
determines the chemical oxygen demand of the active biomass in the
bioconversion tank and controls flow of at least the first organic
material through the input connection from a) to provide oxygen
from the first organic material is provided to the active biomass
in the bioconversion tank at a rate sufficient to support health of
the bacteria in the bioconversion tank; f) an aqueous stream outlet
from the bioconversion tank; and g) a gaseous stream outlet from
the bioconversion tank that is stored and then fed or directly fed
to an oxidizing system that produces energy for the synthetic
biofuel manufacturing process having a nutrient sensing system that
detects levels of nutrients in at least one of the biomass in the
bioconversion tank and an aqueous stream passing into or through
the aqueous stream output and information from the nutrient sensing
system to the processor, and the processor determines levels of
nutrients that should be provided to the active biomass in the
bioconversion tank, and wherein the processor may contain software
that determines levels of nutrients that should be provided to the
active biomass in the bioconversion tank from sensed data from the
nutrient sensing system and controls flow of nutrients into the
bioconversion tank to provide nutrients in a quantity determined by
the software, and wherein nutrients sensed may comprise at least
one nutrient selected from the class consisting of available
nitrogen and available phosphorous and wherein the gaseous stream
outlet may be connected to a gas stream separation system that can
increase the concentration of methane in a first concentrated
stream and can increase the concentration of carbon dioxide in a
second concentrated stream.
13. (canceled)
14. (canceled)
15. (canceled)
16. The bioconversion system of claim 12 wherein there are at least
two storage tanks for organic material, a first storage tank for
the first organic material and a second storage tank for a second
organic material, the first and second organic materials having
different chemical oxygen provision capabilities from each other
and wherein the processor may control feed rates for the first
organic material and the second organic material into the
bioconversion tank, and directs feed of the first organic material
and the second organic material at a rate based at least in part
upon the status of chemical oxygen demand in the bioconversion
tank, the chemical oxygen provision capability of the first organic
material and the chemical oxygen provision capability of the second
organic material as recognized by the processor and wherein there
are sensing systems for at least one other sensible condition may
be selected from the group consisting of pH of the biomass in the
bioconversion tank, pH of the aqueous stream from the bioconversion
tank, concentration of a specific gas component in the gaseous
stream from the bioconversion tank and gas pressure within the
bioconversion tank, and the processor may contain software that
controls rate flows of materials into the bioconversion tank in
response to an indication from sensed data that the rate flows of
specific materials into the bioconversion tank, and the software
may be responsive to the sensed data in controlling mass input into
the bioconversion tank.
17. (canceled)
18. (canceled)
19. The bioconversion system of claim 16 wherein the processor
contains software that determines levels of nutrients that should
be provided to the active biomass in the bioconversion tank from
sensed data from the nutrient sensing system and controls flow of
nutrients into the bioconversion tank to provide nutrient in a
quantity determined by the software and at least one nutrient is
selected from the class consisting of available nitrogen and
available phosphorous and wherein the waste material may be
selected from the group consisting of waste material comprising at
least one of whole stillage, thin stillage and glycerin.
20. (canceled)
21. The method of claim 1 wherein mass flow through the system is
at least in part automatically controlled by sensing at least one
of a) Weight/Volume/Density/Flow; b) Viscosity/Moisture content/FOG
(Fats, Oils, and Greases); c) pH and alkalinity monitoring; d)
Temperature; e) BOD/COD/Volatile Acid concentration/Protein
concentration/FOG concentration/Carbohydrate concentration/Sugar
concentration/Methane potential; f) Particle Size; g) Detection of
contaminants and alarm; and h) General water quality parameters
such as conductivity and ORP, and automatically providing a
presumed appropriate response to the sensing according to at least
one of a lookup table, hardware response and software response, or
wherein the bioconverter system is sensed and automatically
responded to by sensing at least one of a) Contaminant alarm, b)
Solids concentration monitoring and control, c) BOD and COD
monitoring and control; d) surface tension/foam detection
monitoring and alarm; e) Fats, Oils and Grease monitoring and
alarm; f) Dissolved gas monitoring and alarm; g) Volatile acids
monitoring and alarm; h) Detection and control of specific bacteria
concentration/activity; and automatically responding thereto
22. (canceled)
23. (canceled)
24. (canceled)
25. A method of reducing total external energy requirements input
into the operation of a system requiring energy input comprising:
providing organic materials to a bioconversion process; performing
a bioconversion process on the organic materials; producing
combustible volatile organic material from the bioconversion
process; and providing input energy to the operation of the system
by oxidizing the combustible volatile organic material from the
bioconversion process, and wherein the organic material may
comprise at least 10% by weight water during the bioconversion
process and at least some water is added with the organic materials
provided to provide a total water content during the bioconversion,
and wherein water may be added with the organic material at an
average rate over time and wherein over periods of time the average
rate water added with the organic material may be decreased by
recirculation of residual water from the bioconversion process.
26. (canceled)
27. (canceled)
28. (canceled)
29. (canceled)
30. (canceled)
31. (canceled)
32. The method of claim 25 comprising at least one process selected
from the group consisting of: A) performing a process for the
manufacture of the synthetic biofuel and inputting energy to
perform the process; collecting organic waste material from the
process for manufacture of the synthetic biofuel; providing
collected waste material to a bioconversion process; providing
combustible volatile organic material from the bioconversion
process; and providing input energy to the process for the
manufacture of the synthetic biofuel by oxidizing the combustible
volatile organic material from the bioconversion process; and B) i)
at least a first organic material storage tank for a first organic
material; ii) an aqueous stream input source; iii) a bioconversion
tank having a controlled input connection from a) and a controlled
input connection from b), and containing an active biomass that
comprises bacteria capable of decomposing the first organic
material from the first organic material storage tank; iv) a
processor that controls the input connections from a) and from b);
v) a sensing system that determines the chemical oxygen demand of
the active biomass in the bioconversion tank and controls flow of
at least the first organic material through the input connection
from a) to provide oxygen from the first organic material is
provided to the active biomass in the bioconversion tank at a rate
sufficient to support health of the bacteria in the bioconversion
tank; vi) an aqueous stream outlet from the bioconversion tank; and
vii) a gaseous stream outlet from the bioconversion tank that is
stored and then fed or directly fed to an oxidizing system that
produces energy for the synthetic biofuel manufacturing process
Description
RELATED APPLICATIONS DATA
[0001] This application is a continuation-in-part of U.S.
Provisional Patent Application Ser. No. 60/833,526, filed, Jul. 16,
2006, which is in turn a continuation-in-part of U.S. patent
application Ser. No. 11/126,433, filed Aug. 18, 2006, which claims
priority from U.S. Provisional Application No. 60/709,313, filed
Aug. 18, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of material
conversion, whether original materials or wastes, particularly
organic waste streams from organic fuel synthetic procedures, such
as ethanol production or biodiesel production, and the conversion
of such waste and contaminants into an energy source (e.g.,
methane) by using processes (such as fermentation or other
bacterially induced or controlled chemical modification) involving
living organisms (Bioconversion), such as active or bacterial
biomass to convert organic biofuel processing residuals into at
least some or primarily gaseous products, and use of the gaseous
products as a fuel in the organic fuel synthetic process, or sale
of the gaseous products as fuel, or conversion of the gaseous
products to another form of energy such as electricity.
[0004] 2. Background of the Art
[0005] Many different synthetic procedures exist for the synthesis
of biofuels. Each of the various procedures for synthesis of
biofuels results in residual organic material(s) remaining after
the primary biofuel is created. Examples of primary biofuels
include ethanol and biodiesel. Examples of residuals produced by
the synthesis of biofuels include whole stillage, thin stillage and
glycerin.
[0006] Currently residuals from the synthetic procedures undergo
further processing and refinement in an attempt to create a
commercial viable product. This further processing and refinement
of residuals is energy intensive. The objective of any
commercialized biofuels process is to create a biofuel with more
energy potential than the energy required to create the biofuel. An
example would be ethanol whose published energy balance states that
it requires one unit of input energy to create ethanol which has
potential value of 1.2-1.8 energy units (depending on the reference
used). However, the energy balance figures include all of the costs
associated with the further processing and refinement of the
residuals of the biofuels synthetic procedures, such processing and
refining being energy intensive reducing the net positive gain in
energy (input versus output) substantially.
[0007] Biodiesel is an example of a renewable diesel fuel that is
used across the world today. Biodiesel can be manufactured from
vegetable oils, animal fats, waste vegetable oils (such as recycled
restaurant greases, called yellow grease), microalgae oils, or any
combination thereof, which are all renewable. These feedstocks can
be transformed into biodiesel using a variety of esterification or
transesterification technologies.
[0008] Biodiesel use is growing rapidly, increasing from about 7
million gallons in 2000 to more than 20 million gallons in 2001,
with additional production capacity available to quickly
accommodate further growth. Current U.S. biodiesel production is
based largely on soybean oil and used cooking grease, both of which
are abundant feedstocks. The most frequently used biodiesel
feedstock in Europe is rapeseed (canola) oil. No matter what the
process or the feedstock used, the produced biodiesel must meet
rigorous specifications to be used as a fuel. Fuel-grade biodiesel
must be produced to strict industry specifications, as is described
in the American Society for Testing and Materials method, ASTM
D-6751, in order to insure proper performance in diesel engines.
Technically, biodiesel is defined as a fuel comprised of mono-alkyl
esters of long chain fatty acids derived from vegetable oils or
animal fats, designated B100, and meeting the requirements of ASTM
method D-6751. Fatty-acid alkyl esters are actually long chains of
carbon molecules (8 to 22 carbons long) with an alcohol molecule
attached to one end of the chain. Biodiesel refers to the pure fuel
without blending with a diesel fuel derived from fossil fuels. The
biomass-derived ethyl or methyl esters can be blended with
conventional diesel fuel or used as a neat fuel (100% biodiesel).
Biodiesel blends are denoted as "BXX" with "XX" representing the
percentage of biodiesel contained in the blend (i.e.: B20 is 20%
biodiesel, 80% petroleum diesel; B100 is pure biodiesel). Pure
biodiesel typically requires special treatment in cold weather, due
to a high pour point. Biodiesel, as defined in ASTM D-6751, is
registered with the U.S. Environmental Protection Agency (EPA) as a
fuel and a fuel additive under Section 211(b) of the Clean Air Act.
Biodiesel is used mostly as a 20% blend (B20) with petroleum
diesel, in federal, state, and transit fleets, private truck
companies, ferries, tourist boats and launches, locomotives, power
generators, home heating furnaces, and other equipment.
[0009] Biodiesel is non-toxic and biodegradable. It is safe to
handle, transport, and store, and has a higher flash point than
petroleum diesel. Biodiesel can be stored in diesel tanks and
pumped with regular equipment except in colder weather, where tank
heaters or agitators may be required. Biodiesel mixes readily with
petroleum diesel at any blend level, making it a very flexible fuel
additive.
[0010] One of the unique benefits of biodiesel is that it
significantly reduces air pollutants that are associated with
petroleum diesel exhaust. It can help reduce greenhouse gas
emissions, as well as sulfur emissions since biodiesel contains
only trace amounts of sulfur, typically less than the new U.S. EPA
rule finalized in 2001 that required that sulfur levels in diesel
fuel be reduced from 500 ppm to 15 ppm, a 97% reduction, by
2006.
[0011] Many different synthetic procedures exist for the synthesis
of biodiesel fuels, such as the non-limiting list of Published US
Patent Applications and US Patents 20050210739 (Esen); 20050108927
(Velappan); 20040159042 (Murcia); and 20040074760 (Portnoff).
[0012] Published US Patent document 20030111410 (Branson) teaches
the use of a process and apparatus for processing agricultural
waste to make alcohol and/or biodiesel. The agricultural wastes are
subjected to anaerobic digestion which produces a biogas stream
containing methane, which is subsequently reformed to a syngas
containing carbon monoxide and hydrogen. The syngas is converted to
an alcohol which may be stored, sold, used, or fed directly to a
reactor for production of biodiesel. The solids effluent from the
anaerobic digester can be further utilized as slow release, organic
certified fertilizer. Additionally, the wastewater from the process
is acceptable for immediate reuse in agricultural operations.
[0013] Methods of treating wastewater rich in nutrients are
disclosed, for example, in U.S. Pat. No. 5,626,644 to Northrop,
U.S. Pat. No. 4,721,569 to Northrop, U.S. Pat. No. 4,183,807 to
Yoshizawa, et al., and U.S. Pat. No. 5,185,079 to Dague. Methods of
utilizing agricultural waste or biomass as fuel for electrical
generation are disclosed, for example, in U.S. Pat. No. 5,121,600
to Sanders, et al. Methods of converting methanol and fats or oils
to methyl esters and biodiesel are disclosed in, for example, U.S.
Pat. Nos. 5,713,965 to Foglia, et al., 6,015,440 to Noureddini, and
6,440,057 to Nurhan, et al. The disclosures of these patents are
incorporated by reference herein in their entirety.
[0014] Similarly, there are many synthetic procedures for the
production of ethanol from agricultural materials such as corn and
high sugar content crops. 20060019360 (Verser) teaches a process
for producing ethanol including a combination of biochemical and
synthetic conversions that result in high yield ethanol production
with concurrent production of high value coproducts. An acetic acid
intermediate is produced from carbohydrates, such as corn, using
enzymatic milling and fermentation steps, followed by conversion of
the acetic acid into ethanol using esterification and hydrogenation
reactions. Coproducts can include corn oil, and high protein animal
feed containing the biomass produced in the fermentation. Other
disclosures of synthetic ethanol production from waste or
agricultural products are shown in Published US Application Nos.
20050266540 (Offermann); 20040180971 (Inoue); 20010023034
(Verykios); and the like teach synthetic production and use of
alcohols, such as methanol and ethanol from waste products. All of
these patents are incorporated herein by reference for their
disclosures of methods of production of biofuels from waste
materials.
SUMMARY OF THE INVENTION
[0015] The disclosed technology relates to the field of renewable
energy and particularly utilization of organic residuals resulting
from the production of synthetic organic fuels. Additionally, the
present technology relates to the improvement of the overall energy
efficiency of the fuel making process so that the overall process
becomes more energy efficient. Gaseous fuels created could
additionally be sold as a product or converted to other useful
forms of energy such as electricity.
[0016] In one sense, the technology relates to any primary or
secondary synthetic, organic fuel manufacturing process that
requires energy input in the manufacturing process and produces
both a fuel stream and a residual waste stream. The residual waste
stream is subjected to a bioconversion or chemical conversion
(reaction), producing combustible gases (especially organic
compound gases) such as methane (or other C1-C10 alkanes or
combustible hydrocarbons or carbohydrates such as alcohols),
hydrogen, ammonium and the like. The combustible gases are then
used as a source of energy in the primary synthetic, organic fuel
manufacturing process. The source of energy may be used to generate
heat for any segment of the primary process, to generate
electricity for any segment of the primary or a secondary process
or for any other energy supplying purpose.
[0017] The present disclosure also includes at least software,
apparatus, processes and business methods for the implementation of
this technology. A method of conversion of biofuel residual organic
material to a source of energy to be used in the primary synthetic,
organic fuel manufacturing process or as an additional energy
product is practiced on the apparatus and using the software
described herein may, by way of non-limiting examples,
comprise:
[0018] providing one or more tanks or other containers or contained
reaction volumes (hereinafter generally referred to as "tank(s)")
for bioconversion of biofuel manufacturing organic residuals, said
tank(s) containing an active biomass comprising at least one
bacteria that bioconverts organic material in a residual waste
stream from synthetic fuel manufacturing processes (as in biodiesel
production, alcohol production, and the like);
[0019] providing one or more inlets to the bioconversion tank(s),
individual inlets may be for organic material or an aqueous stream
containing organic material;
[0020] a processor or user that receives and stores information
(either directly from sensors or from manual input or other data
entry on: [0021] the status of chemical oxygen demand of the active
biomass; and [0022] the chemical oxygen demand of a first organic
material that can be fed into the bioconversion system through the
first inlet; [0023] a mass flow control system controlled by the
processor and/or by manual control which feeds at least one organic
material through an inlet at a rate based at least in part upon the
status of chemical oxygen demand in the bioconversion tank(s) as
recognized by the processor; and/or [0024] any other data or
information that would influence intelligent control of the input
and/or output of materials, reactants, and/or energy during the
performance of the process and/or operation of the apparatus.
BRIEF DESCRIPTION OF THE FIGURES
[0025] FIG. 1 shows a schematic of a basic bioconversion system
according to teachings herein.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present technology covers a wide range of potential
commercial practices, and even where a specific field-of-use is
described as an example, or specific equipment, or specific
chemistry, or specific bacteria, or specific conditions are
described, these specific teachings are to be interpreted as
species examples within the scope of the generic concepts disclosed
herein. For example, one specific field of use method that is
contemplated within the generic scope of the technologies
originally disclosed herein is a method of bioconversion of organic
waste material from a synthetic fuel manufacturing process. The
synthetic fuel manufacturing process requires energy input in the
performance of the synthetic fuel manufacturing process. The method
itself comprises: providing a tank for bioconversion of organic
waste material, at least some of which organic waste material is
derived from a synthetic fuel manufacturing process and the tank
containing an active biomass comprising at least one bacteria that
decomposes organic material. One or more inlets is provided to the
bioconversion tank, at least one inlet comprising an inlet for
organic material from the synthetic fuel manufacturing process. A
processor receives and stores information automatically (e.g., from
sensors or gauges) or manually input (by human operators reading
gauges or observing readouts) to the processor. Among the types of
matters that could be preferred subjects for input would be data or
status of: [0027] chemical oxygen demand and/or biological oxygen
demand of the active biomass; and [0028] the oxygen provision
capability of an organic material that can be fed into the
bioconversion tank through any inlet.
[0029] The last matter (i.e., oxygen provision capability) relates
to the ability of the organic material itself or an additive or
component thereof or added therewith to provide oxygen within ot
into the reaction system. That is, as the system has an oxygen
utilization rate or requirement, desirable information would
include how much reaction useable oxygen is available in the input
organic material to determine levels of additional oxygen providing
materials may be needed. The term itself, "oxygen provision
capability," merely reflects knowledge of self-provision of oxygen
that may be used in the biodecomposition or bioconversion process
without additional introduction of additional useable
oxygen-providing materials or reagents.
[0030] The method also uses a mass flow control system controlled
by the processor which feeds at least one organic material through
an inlet at a rate based at least in part upon the status of
chemical oxygen demand in the bioconversion tank as recognized by
the processor. There is a stream for carrying combustible gases
from the biomass; and the stream providing at least some of the
energy input in the performance of the synthetic fuel manufacturing
process.
[0031] One method uses at least two storage tanks for organic
material, a first storage tank for the first organic material and a
second storage tank for a second organic material, the first and
second organic materials having different chemical oxygen provision
capabilities from each other. The processor receives and stores
information on the respective chemical oxygen provision
capabilities of the first organic material and the second organic
material; and the processor feeds the first organic material and
the second organic material into the bioconversion tank at a rate
based at least in part upon the status of chemical oxygen demand in
the bioconversion tank, the chemical oxygen provision capability of
the first organic material, and the chemical oxygen provision
capability of the second organic material as recognized by the
processor.
[0032] The method removes an energy depleted aqueous stream from
the bioconversion tank through an aqueous stream outlet and a gas
(biogas) stream is removed from the bioconversion tank through a
gas venting outlet, the gas (biogas) stream comprising primarily
methane and carbon dioxide is removed from the bioconversion tank.
The term "energy depleted" means that a significant amount of
bioconvertible material has been converted out of the original
material and that a stream subsequently removed from the system has
significantly (e.g., more than 25%) of its biofuel energy
capability removed from the stream as compared to a stream if no
bioconversion process had been performed.
[0033] It is to be noted that the bioconversion processes of the
technology described herein should be directed primarily at organic
residuals, or sources of combinations of organic and non-organic
residuals which may come from a wide variety of individual or
combined sources for the ultimate purpose of this technology in the
synthesis or organic fuels. For example, the residual may result
from the earliest stages of separation of components that are to be
introduced to the fuel synthesis stream (e.g., separating the
leaves and beans in soy plants, separating the ears and stalk from
corn, separating the beets and leaves/stems from sugar beets,
separating the pith of a sugar cane from the cane, formation of
textile fibers from agricultural products, etc.). The residual(s)
may also result from the processed mass, such as where the pulp
remains from sugar beets or soy beans, and fiber residue remains
from leaves, stems and stalks from which the primary synthetic fuel
containing ingredient has been removed.
[0034] Synthetic organic fuel manufacturing processes have their
own energy input requirements, which has been one of the main
arguments against the transition away from petroleum based fuels to
renewable sources of fuels, such as ethanol or diesel from
agricultural products. For example, many processes require drying
of the raw material and significant mass movement of materials in
the synthesis. An additional drawback has been the problem that the
residual waste stream from the synthesis, even though producing
recoverable chemical products, has produced such significant
volumes of those products that the market has become saturated and
disposal cost ineffective. One potential benefit of the present
bioconversion process and system is that these residual products
are converted to fuels that can support the primary synthetic
process, reduce or eliminate the overall external input of energy
into the system, and therefore produce a system with a much better
efficiency and potentially produce an additional energy product for
sale. As an example, if a traditional biodiesel manufacturing
system were given scholastic values of input and output of energy,
it might be considered to require an energy input (e.g.,
electricity) of 1.0 units to produce a useful energy output (e.g.,
calorie or octane output of a biodiesel or ethanol) of 1.2
equivalent energy units. It is clear on its face that by using an
extremely low energy consumption waste residuals bioconversion step
with biomass systems to convert residual waste streams to a fuel
that would then produce useful energy for the primary synthetic
process, the overall input/output efficiency would be increased,
prophetically by at least 10-30% through performance of the present
process, such that for an energy input of 1.0 units, the process of
the present technology could produce an output of 1.2 to 1.5 units,
without modifying the underlying primary synthetic process.
[0035] Because the underlying synthetic biomass-type process
described in the background of this technology is already somewhat
readily understood as to its chemical input and chemical output,
the system may operate in a manner that assists in assuring that
materials are present that are not treated by the biomass or should
not be introduced into the biomass, such as metals (even in high
concentrations in dissolved or organically tied or chelated form),
toxins (especially antibiotics, agricultural herbicides materials
that would be toxic to bacteria, such as pesticides), and
non-bioconvertible materials that would tend to collect in the
biomass without bioconversion. It is possible to provide a
venting/discharge system for such non-bioconvertible materials, but
as noted, it is preferred to avoid introduction of significant
amounts (e.g., municipal wastewater treatment plant sludges or
agricultural manures, which may be 0.05%, 1.0%. 5%, 10%, 20% or
more solids) into the system.
[0036] The technology disclosed herein has implications beyond
biofuel generation, such as in a method of reducing total external
energy requirements input into the operation of a system requiring
energy input. The steps of the process may comprise: providing
organic materials to a bioconversion process; performing a
bioconversion process on the organic materials; producing
combustible volatile organic material from the bioconversion
process; and providing input energy to the operation of the system
by oxidizing the combustible volatile organic material from the
bioconversion process. The organic material may comprise at least
10% by weight water during the bioconversion process and at least
some water is added with the organic materials provided to provide
a total water content during the bioconversion. In many commercial
processes where organic mass residues are produced with significant
water content, it has been necessary to remove water, as by
mechanical pressing, evaporation and the like. This adds a
significant energy component into the underlying process. Where
fuels are an ultimate product of the process, as in conversion of
agricultural crop(s) to biofuels, the need to eliminate water
during the fuel manufacturing process reduces the overall
efficiency of the process. This is why some fuel manufacturing
processes may produce only 1.2 units of energy as an output while
requiring 1.0 units of input. In the manufacture of synthetic
biofuels, water must be regularly introduced into the front end of
the system and sometimes subsequently removed, which adds energy
requirements in both the purification of the water and then removal
of the water. The present technology has advantages in both
providing (a) fuel(s) (biogas) without the necessity of removing
water before the bioconversion process and the ability to recycle
the discharge of the bioconverter back to the synthetic fuel
processing facility for reuse in the production of synthetic fuels.
The water input rate is often a function of water content of the
added biomass, and the dissipation of the water in the process.
Over periods of time the average rate of water added with the
organic material is decreased in the practice of the present
technology by recirculation of residual water from the
bioconversion process. This recirculated water is provided with low
energy process requirement water from the biomass, which
contributes to reduced energy input in the biofuel manufacturing
process. Thus at least part of the aqueous stream is recirculated
back into the biofuel manufacturing process.
[0037] The aqueous stream that is or can be removed from the
reactor mass may be used to provide both moisture and nutrient for
growth of agricultural products. The water effluent stream can
naturally contain nutrients remaining from unconverted biomass or
partially converted biomass.
[0038] It is desirable to understand the basic terminology and
activity within an anaerobic bioconversion system of the general
type described herein, and the immediately following discussion is
intended to assist in an appreciation of that technology. Anaerobic
conversion is the bioconversion of organic material without oxygen
present. This results in the production of gas (biogas) or low
molecular weight liquids, a valuable product containing usable
energy.
[0039] The system of bioconversion may also produce as a primary or
secondary or incidental product, carbon dioxide. The carbon dioxide
may be collected as a relatively pure or subsequently purified
product for use in refrigeration, carbonation, cleaning solvents,
dry ice manufacture and the like.
[0040] Biogas produced from the bioconversion processes described
herein usually comprises a mixture of several gases and vapors,
primarily methane and carbon dioxide, although by selection of
bacteria and particular biomass feed materials, hydrogen, ammonia,
alkanes and other useful gases and low molecular weight organic
liquids may be provided. Methane (and other alkanes) is the main
component in natural gas and contains the bulk energy value of the
biogas, with the exception of hydrogen gas, which may be useful
either for fuel cell energy production or direct combustion. Biogas
occurs naturally, hence its name, amongst others in swamps and
lakes when conditions are right. Anaerobic bioconversion within the
systems and processes described herein can be used to produce
valuable energy from organic streams. The system is generally
described as a biological system, indicating that the process is
carried out by biological organisms such as bacteria. The bacteria
in the bioconvertive or active or digestive biomass have to be kept
healthy while sustaining conditions for the bacteria. The bacteria
bioconvert or degrade or digest or decompose the organic matter fed
into the system. This means that the organic material is broken
down into component parts or converted (by bioconversion alone or
in combination with supplemental catalyzed reaction) into biogas.
The system is generally operated in an anaerobic environment,
without oxygen. This means that air preferably is not allowed to
directly interact with the organic materials as they are being
bioconverted to avoid uncontrolled oxidation or other chemical
reaction with the air. To promote the production of biogas as a
valuable product of the degradation, oxygen should or must be kept
away from the environment where the biomass is bioconverting the
organic materials.
[0041] There may be a number of steps that occur in the bacterial
anaerobic conversion of the organic materials. These steps may
include at least some of the following: [0042] 1. hydrolysis: high
weight organic molecules (like proteins, carbohydrates, fat, and
cellulose) are broken down into smaller molecules like sugars,
amino acids, fatty acids and water. [0043] 2. acidogenesis: further
breakdown of these smaller molecules into organic acids, carbon
dioxide, hydrogen sulfide and ammonia occurs. [0044] 3.
acetogenesis: the products of acidogenesis are used for the
production of acetates, carbon dioxide and hydrogen. [0045] 4.
methanogenesis: methane, carbon dioxide and water are produced from
acetates, carbon dioxide and hydrogen (products of acidogenesis and
acetogenesis).
[0046] There are several groups of bacteria that may or may not
participate in each step; and, in total, ten or more and even
dozens of different species usually are needed to bioconvert an
organic stream completely.
Process Parameters
[0047] An anaerobic bioconversion process can be carried out in
quite a variety of different conditions. All of these conditions
have specific influences on the biogas production. Additionally,
from a technological viewpoint, the biological process can also be
carried out in more than one reactor (as parallel reactions and/or
serial reactions in the conversion process), which has
bioconversion efficiency and economic implications.
[0048] Thermophilic Vs. Mesophilic Bioconversion
[0049] (Bioconversion) bacteria generally have a temperature range
in which they are most productive in terms of production rates,
growth rates and substrate bioconversion performance. The several
groups of bacteria involved in anaerobic bioconversion generally
each have different temperature optimums. This results in two main
(and not necessarily overlapping, but possibly overlapping)
temperature ranges in which bioconversion usually can be performed
optimally and most economically. These ranges are: 25-38.degree. C.
called the mesophilic range, and 50-70.degree. C. called the
thermophilic range.
[0050] These ranges have different characteristics, advantages and
disadvantages of which the most important ones are: compared to the
mesophilic process, the thermophilic process usually results in a
higher bioconversion of the substrate at a faster rate. It is less
attractive from an energetic point of view since more heat is
needed for the process unless the substrate is already at or above
the thermophilic temperature range.
Batch Processes Vs Intermittent Processes Vs. Continuous
Processes
[0051] In process technology, three main types of process (models)
are used, the batch process, the intermittent process, and the
continuous process. In the batch process, the substrate is put in
the reactor(s) at the beginning of the bioconversion period after
which the reactor(s) is(are) closed for the entire period without
adding additional substrate.
[0052] As explained before, bioconversion usually consists of
several consecutive steps. In a batch reactor system, all these
reaction steps occur more or less consecutively. The production of
biogas (endproduct) is non-continuous: at the beginning only fresh
material is available and the biogas production will be low.
Half-way through the degradation period the production rate will be
highest and at the end, when only the less easily bioconvertible
material is left, production rate will drop again. In an
intermittent mode process, fresh substrate is added intermittently
or episodically in relatively uniform increments of both time and
chemical oxygen demand of the substrate. In this mode, reactions
have characteristics of both continuous and batch modes.
[0053] In a continuous process, fresh substrate is added
continuously, and therefore all reactions will occur at a fairly
constant rate resulting in a fairly constant biogas production rate
while maintaining a relatively constant concentration range of
ingredients within the reactor(s). Several combinations or
variations of these three models are developed in process
technology including the so-called plug-flow reactor and the
sequencing batch-reactor all of which try to combine the advantages
of each model.
Residence Time
[0054] The longer a substrate is kept under proper reaction
conditions, the more complete its bioconversion will become.
However, the reaction rate may decrease with increasing residence
time. The disadvantage of a longer retention time is the increased
reactor size needed for a given amount of substrate to be
bioconverted. A shorter retention time may lead to a higher
production rate per reactor volume unit, but a lower overall
bioconversion efficiency. These two effects have to be balanced in
the design of the full scale system.
Acidity or pH-Value
[0055] The groups of bacteria needed for bioconversion not only
have an optimum temperature but also an optimum acidity at which
they are most productive. Unfortunately, for the different groups
of bacteria the optimum pH-value (measure for acidity) is not the
same. The complexity of the entire system is increased by the fact
that some of the intermediate products of the bioconversion have a
tendency to lower the pH, making the later steps in the process
more difficult. This makes balancing the pH in the system an
important design and operational issue.
Organic Loading
[0056] Bacteria have a maximum bioconversion rate depending on the
type of reactor, number of reactors, substrate, temperature etc.
Organic loading is one of parameters used to describe this
production rate. It is the amount of organic material put into the
reaction medium per time unit.
[0057] The underlying area of technology may involve a water-based
input stream into the system, a biomass or organic mass input feed
stream into the system, an approximately steady or growing biomass
within the system, a gaseous output stream, a liquid output stream
(water-based), and an incidental (or optional) active biomass
control activity. Each of the streams will be discussed. The term
stream is used in the Chemical Engineering sense in that it
represents a mass input, but the term stream is not limited to a
continuous flow input, but includes an episodic/periodic or batch
input or output.
[0058] The water-based input stream (which is desirable for
ultimately sustaining a water-based output stream and assisting in
the removal of soluble, suspendable, dispersible or otherwise
carriable waste materials from the system) may be a potable input
stream (either a natural source of water, such as a stream, lake,
river, etc., or a purified supply as from a water treatment plant
or well) or may be a stream containing dissolved, suspended,
dispersed or otherwise carried organic materials, and preferably
minimal content (e.g., municipal wastewater treatment sludges or
agricultural manures) of materials that cannot be bioconverted by
bacteria in the active biomass, as indicated above. Industrial
wastewater streams may be desirable, especially where the organic
and other content of the stream can be anticipated or even
controlled, and will exclude those types of materials that are
incompatible with a bioconversion system, also as indicated above.
Such streams might be from food processing plants, pharmaceutical
plants, and the like. Streams containing animal waste products are
not preferred. By accessing such wastewater streams, a source of
low cost water containing organic material that can itself be
converted for ease of disposal can be used, as opposed to using
potable water streams. The use of the less preferred waste streams
may be more desirable in localized areas where a water stream may
be provided for local agricultural uses, especially those where
there are no consumable agricultural materials (such as lawn or
vegetation watering). The energy output of the process may be used
to move and deliver non-potable agricultural water locally, as
within a community or municipality.
[0059] The organic feed stream from the residual waste stream from
the synthetic fuel process may include organic materials that can
be bioconverted by bacteria, such as fibrous material, pulp,
organic residue compounds, glycerin, oil, alcohol, stem, leaf, and
the like. Other residual waste organic materials may even be added
to the stream as long as the environmental/habitat environment of
the biomass is maintained within the desired and essential
conditions for survival and thriving of the mass. Other such added
materials might include dated food products (e.g., cheese, cheese
by-products, processed cheese, low cellulosic content vegetable and
fruit masses (e.g., preferably excluding wood products having
significant persistent or non-bioconvertible cellulosic material)
such as rice starch, potato starch, potato mass, wheat starch,
sugars, syrups, animal waste products (excluding bone and certain
non-bioconvertible tissue, such as cartilage), synthetic organic
materials, natural organic materials, dairy products or dairy
intermediates in general (e.g., yoghurt, ice cream, milk, milk fat,
cream, egg content preferably excluding shells), baked goods,
expired food products, and the like.
[0060] Biomass content is designed to assist in bioconversion,
treatment, digestion, or decomposition of the anticipated content
of the organic biomass feed stream. Sources of such bacteria, any
required nutrients, and the like can be found commercially, as for
example, from BZT.RTM. Waste Digester cultures, enzymes and
nutrients used to improve biotreatment performance and reduce
BOD/COD (biochemical oxygen demand/chemical oxygen demand) loads in
municipal and industrial water treatment clarifiers, trickling
filters, ponds, lagoons, activated sludge systems and aerobic and
anaerobic digesters. Amnite.TM. L100 systems from Cleveland Biotech
LTD are another source of microorganisms. Other sources of biomass
and supplements include Bionetix.RTM. Canada systems, Specific
types of bacteria for such processes include, but are not limited
to Bacteria; Proteobacteria; Alphaproteobacteria; Rhizobiales;
Bradyrhizobiaceae, including such specific species as
Rhodopseudomonas cryptolactis; Rhodopseudomonasfaecalis;
Rhodopseudomonas julia; Rhodopseudomonas palustris;
Rhodopseudomonas rhenobacensis; and other Rhodopseudomonas sp. Even
though, as indicated above, wood and high cellulosic content
materials are not preferred, R. palustris has the potential to be
very useful because it can degrade and recycle several different
aromatic compounds that make up lignin, the main constituent of
wood and the second most abundant polymer on earth. Thus, this
bacterium and those like it may be useful in removing these types
of material from the environment. In addition, R. palustris
converts N.sub.2 into NH.sub.4 and H.sub.2, which can be used as a
biofuel. Chlamydomonas reinhardtii has been found to be effective
in the production of hydrogen gas from certain organic mass
sources.
[0061] The emission streams basically comprise a water-based output
stream, the gaseous fuel emission stream (e.g., methane, carbon
monoxide, hydrogen, etc.) and the potentially periodic biomass
output stream. The gaseous emission stream comprises the gaseous
bioconversion, decomposition or digestion products made by the
active or bacterial biomass on the organic mass input stream. The
primary gases (depending upon the particular bacteria and organic
mass feed provided) are likely to comprise at least some gases
selected from the group consisting of carbon dioxide, methane,
hydrogen, ammonia, hydrogen sulfide, and the like.
[0062] The water based output stream may comprise water and
dissolved, suspended, dispersed or otherwise carried organic
matter. The water output stream can be in sufficiently acceptable
form as to be sent directly to municipal waste water treatment
facilities, standard (e.g., municipal) water treatment facilities
for conversion to potable, reused by the primary synthetic biofuels
manufacturing process (with and/or without further clean
up/treatment), or at least agriculturally useful water.
Alternatively, relatively improved water effluent can be used
locally in non-potable water applications to vegetation that is not
to be ingested.
[0063] The biomass output can be little more than removal of
biomass after growth of the biomass (the microorganisms) has
exceeded a volume that is useful within the
bioconversion/digestion/treatment/decomposition environment or
tank(s) or reactor(s). The biomass is then removed and may be
treated for direct use (e.g., fertilizer) or transported to another
treatment facility to become starter, replenishment, or enhancing
biomass for another treatment facility. There are certain biomass
system bacteria that are known as non-growth bacteria that can be
useful in the present technology, which would avoid the need for
any regular removal of biomass as a stream. At the present time,
those tend to be more expensive, less active, and are therefore not
preferred. The provision of another commercial product in the
biomass solids is also a benefit to the economics of the
system.
[0064] An important additional aspect of the presently described
system is the automation of controls to the system. Automation
control may be effected by a local or central processor. Software
will be embedded in the processor that can evaluate the data and,
based upon look-up tables and/or standardized responses, make
adjustments in various levels of control that the processor can
exercise over individual elements of the system. Multiple organic
mass inputs may be provided (e.g., in batch deposits, or by more
controlled batch input from holding or storage tanks). As the
content of the organic materials can be determined in advance of
their introduction into a reaction vessel(s), and as the content or
rate of addition of various materials can and should be controlled,
and as the conditions and content of the reaction vessel(s) can be
monitored, automated controls can be provided in the present system
to provide more frequent and more reliable control over the
performance of the system. For example, even as organic input
stream material is stored, its content and characteristics can
change, so that merely providing a single input consideration of
the material into the reaction controls and stoichiometry of the
bioconversion process can lead to wide variations in system output.
As the systems are intended to produce a marketable or immediately
useful energy product (methane and/or hydrogen) and commercial gas
stream (e.g., carbon dioxide), it is essential that the system be
provided with control sufficient to assure a reliable output of the
intended gaseous products. As the energy used in the synthetic
process and the output of residuals that are converted to usable
fuel are stoichiometrically related or approximated, the balance
can be readily automated, designed and planned.
[0065] Sensing of parameters and conditions and properties within
the system (defined as any and all of including input streams,
output streams, and reaction vessels) can provide information or
data that can be interpreted by or responded to by artificial
intelligence (e.g., processors, hardware, software, field
programmable gated arrays (FPGA), ASICS, chips, and the like) to
alter mass flow, temperature, reaction times, pH, pressure,
nutrient addition, and the like. It is also desirable to have the
various components set up in a network or even a mesh network
wherein multiple receivers/transmitters are distributed throughout
the system so that if any single receiver transmitter fails,
signals can be captured and transmitted by other receivers in the
mesh network. To best effect this type of system, individual
sensing/signaling components should have specific identifying
information attached to emitted signals so that upon receipt of the
signals by the main or central control processor, the specific
source of the signal is identified by origination information from
a specific sensor as opposed to merely the path of transmission,
which may have multiple sensors sending information over the same
transmitter or line within the system. Among some of the types of
particular analysis or sensing are estimated chemical oxygen demand
(COD), estimated Biochemical Oxygen Demand (BOD), pH at various
locations within the system, temperature at various locations
within the system, pressure at various points within the system,
specific chemical content at various points within the system, mass
flow rates (including solids, liquids and gases), nutrient
requirements and estimates, and the like. The following discussions
relate to the software aspects of at least some of these areas of
the system that can and should be regulated by processed or
automated control.
[0066] The software will operate at least the active structural and
material components of an anaerobic bioconversion system. The
bioconversion system consists of multiple tanks, pumps and process
instrumentation. The process may begin with an influent raw organic
material being pumped into a storage tank for storage. From the
storage tank, the organic material is pumped to the anaerobic
bioconverter. Or, the organic material may be conveyed directly
into the bioconverter. The effluent water flows from the
bioconverter, to discharge. There is gas generated from the
bioconversion process that is discharged to other process equipment
and/or to a flare. The storage tank contents are mixed before it is
pumped into the bioconverter. There may also be chemical (base)
addition to the storage tank and/or bioconverter to adjust pH.
Multiple process instruments are associated with the storage tank
to monitor the raw organic material including liquid level, pH and
temperature. Inside the anaerobic bioconverter, there is biomass
used to convert the organic material in the stream to several gases
including carbon dioxide, and methane. In at least one of the
bioconversion tank(s), there may be an internal sand filter, used
to filter the effluent water, maintained by two rotating blades.
There are multiple process instruments associated with the
bioconversion tank(s) to monitor the liquid and gas. These include
liquid level, pH, temperature, arm position, pressure and gas
concentration.
[0067] All of the process instrumentation and equipment may be
connected to a programmable logic controller (PLC) or other logic
system (which includes distributed architecture as opposed to an
exclusively central control used with most PLC systems), which
controls the operation of the bioconversion system.
Process Systems with Related Software Routines
[0068] For each element of the bioconversion process there may be
numerous process systems. The process systems of the anaerobic
bioconversion system are each operated by a software routine. The
elements of the bioconversion process and the related process
systems are:
Storage (EQ) System
[0069] EQ Feed Pump and Valve Control [0070] EQ Tank Chemical
Addition Pump Control [0071] EQ Mixer Speed Control [0072] EQ Feed
Pump VFD Fault alarm [0073] EQ Mixer VFD Fault alarm [0074] EQ Tank
Liquid Temperature alarms [0075] EQ Tank Liquid Level alarms [0076]
EQ Tank Feed Pump Current alarms [0077] EQ Tank Mixer Current
alarms [0078] EQ Tank pH alarms Bioconverter Feed System [0079]
Bioconverter Feed Pump (or conveyer) and Valve Continuous Control
[0080] Bioconverter Feed Pump (or conveyer) and Valve Batch Control
[0081] Bioconverter Feed Pump (or conveyer) Flow totalization
[0082] Bioconverter Liquid Level alarms [0083] Bioconverter Foam
Level High alarm [0084] Bioconverter Feed Pump (or conveyer)
Current alarms [0085] Bioconverter Feed Pump (or conveyer) VFD
Fault alarm [0086] Bioconverter Liquid Level Transducer Error alarm
Bioconverter Agitation System [0087] Normal Fluidization Control
[0088] Deep Clean Fluidization Control [0089] Sludge Rake Blade
Pump Current alarms [0090] Propulsion Blade Pump Current alarms
[0091] Sand Fluidization Blade Pump Current alarms [0092] Sludge
Rake Blade Pump Pressure alarms
[0093] Propulsion Blade Pump Pressure alarms [0094] Sand
Fluidization Blade Pump Pressure alarms [0095] Sludge Rake Blade
Pump VFD Fault alarm [0096] Sand Fluidization Blade Pump VFD Fault
alarm Bioconverter Discharge Control System [0097] Bioconverter
Discharge Valve Control [0098] Bioconverter Effluent Flow
Totalization [0099] Gas Separation Tank Liquid Level High alarm Gas
Handling System [0100] Foam Lockout Control [0101] Gas Analyzer
Drain Control [0102] Gas Pressure High alarm [0103] Gas Temperature
Low alarm Bioconverter Temperature Control System [0104]
Bioconverter Liquid Temperature Control [0105] Bioconverter Liquid
Temperature High and Low alarms Chemical Addition System [0106]
Chemical Recirculation Pump Control [0107] Bioconverter Liquid pH
High and Low alarms [0108] Chemical Recirculation Pump Liquid
Pressure High and Low alarms [0109] Chemical Recirculation Pump VFD
Fault alarm [0110] Base Addition Pump Control [0111] Metal Addition
Pump Control [0112] Nutrient Addition Pump Control [0113] Sulfur
Addition Pump Control [0114] Anti-Foam Pump Control Other On-Line
Instruments may include: [0115] System Air Pressure Low alarm
[0116] Titration System TABLE-US-00001 Operator Adjustable Process
Set Points Operator Adjustable Alarm Set Points System Alarms EQ
Tank Feed Pump ON Liquid Level EQ Tank Liquid Level High-High EQ
Tank Feed Pump OFF Liquid Level EQ Tank Liquid Level Low-Low EQ
Tank Feed Pump VFD Continuous Mode Speed EQ Tank pH High EQ Tank pH
High EQ Tank Feed Pump VFD Maximum Speed EQ Tank pH Low EQ Tank pH
Low EQ Tank Feed Pump VFD Minimum Speed EQ Tank Temperature High EQ
Tank Temperature High EQ Tank Feed Pump Daily Gallons EQ Tank
Temperature Low EQ Tank Temperature Low EQ Tank Mixer VFD
Continuous Mode Speed EQ Tank Feed Pump Current High EQ Tank Feed
Pump Current High EQ Tank Mixer VFD Maximum Speed EQ Tank Feed Pump
Current Low EQ Tank Feed Pump Current Low EQ Tank Mixer VFD Minimum
Speed EQ Tank Feed Pump Pressure High EQ Tank Feed Pump Pressure
High EQ Tank Mixer VFD Maximum Speed Liquid Level EQ Tank Feed Pump
Pressure Low EQ Tank Feed Pump Pressure Low EQ Tank Mixer VFD
Minimum Speed Liquid Level EQ Tank Feed Pump Flow Low EQ Tank Feed
Pump Flow Low EQ Tank Mixer Intermittent Mode On Time EQ Tank Feed
Pump VFD Fault EQ Tank Mixer Intermittent Mode Off Time EQ Tank
Mixer Current High EQ Tank Mixer Current High EQ Tank Mixer Before
Feed On Time EQ Tank Mixer Current Low EQ Tank Mixer Current Low EQ
Tank pH EQ Tank Mixer VFD Fault EQ Tank pH Variation Bioconverter
Liquid Level High Bioconverter Liquid Level High Bioconverter Feed
Pump On Liquid Level Bioconverter Liquid Low Bioconverter Liquid
Low Bioconverter Feed Pump Off Liquid Level Bioconverter Liquid
Level High-High Bioconverter Feed Pump VFD Continuous Mode Speed
Bioconverter Liquid Low-Low Bioconverter Feed Pump VFD Maximum
Speed Bioconverter pH High Bioconverter pH High Bioconverter Feed
Pump VFD Minimum Speed Bioconverter pH Low Bioconverter pH Low
Bioconverter Feed Pump Daily Gallons Bioconverter Temperature High
Bioconverter Temperature High Bioconverter Base Addition High pH
Bioconverter Temperature Low Bioconverter Temperature Low
Bioconverter Base Addition Low pH Bioconverter Feed Pump Current
High Bioconverter Feed Pump Current High Rake Blade Pump VFD
Continuous Mode Speed (Rake Mode) Bioconverter Feed Pump Current
Low Bioconverter Feed Pump Current Low Rake Blade Pump VFD Maximum
Speed (Rake Mode) Bioconverter Feed Pump Pressure High Bioconverter
Feed Pump Pressure High Rake Blade Pump VFD Minimum Speed (Rake
Mode) Bioconverter Feed Pump Pressure Low Bioconverter Feed Pump
Pressure Low Rake Blade Pump VFD Initial Speed (Propulsion Mode -
Bioconverter Feed Pump Flow Low Bioconverter Feed Pump Flow Low
Normal Fluidize) Rake Blade Pump VFD Initial Speed (Propulsion Mode
- Bioconverter Liquid Level Transducer Bioconverter Liquid Level
Deep Clean Fluidize) Allowable Difference Transducer Error Rake
Blade Pump VFD Maximum Speed (Propulsion Mode) Bioconverter Gas
Pressure High Bioconverter Gas Pressure High Rake Blade Pump VFD
Minimum Speed (Propulsion Mode) Rake Blade Pump Current High Rake
Blade Pump Current High Rake Pump Intermittent Mode On Time Rake
Blade Pump Current Low Rake Blade Pump Current Low Rake Pump
Intermittent Mode Off Time Rake Blade Pump (Rake Mode) Pressure
Rake Blade Pump (Rake Mode) High Pressure High Rake Blade RPM Rake
Blade Pump (Rake Mode) Pressure Rake Blade Pump (Rake Mode) Low
Pressure Low Fluidization Blade (Normal Fluidize) RPM Rake Blade
Pump (Propulsion Mode) Rake Blade Pump (Propulsion Mode) Pressure
High Pressure Fluidization Blade (Deep Clean Fluidize) RPM Rake
Blade Pump (Propulsion Mode) Rake Blade Pump (Propulsion Mode)
Pressure Low Pressure Fluidization Blade Pump VFD Initial Speed
Fluidization Blade Pump Pressure High Fluidization Blade Pump
Pressure High Fluidization Blade Pump VFD Maximum Speed
Fluidization Blade Pump Pressure Low Fluidization Blade Pump
Pressure Low Fluidization Blade Pump VFD Minimum Speed Fluidization
Blade Pump Current High Fluidization Blade Pump Current High
Chemical Feed Pump VFD Initial Speed Fluidization Blade Pump
Current Low Fluidization Blade Pump Current Low Chemical Feed Pump
VFD Maximum Speed Chemical Feed Pump Pressure High Chemical Feed
Pump Pressure High Chemical Feed Pump VFD Minimum Speed Chemical
Feed Pump Pressure Low Chemical Feed Pump Pressure Low Normal
Fluidization - Time to Complete Chemical Feed Pump Current High
Chemical Feed Pump Current High Normal Fluidization - Number of
Clicks to Complete Chemical Feed Pump Current Low Chemical Feed
Pump Current Low Deep Clean Fluidization - Time to Complete Deep
Clean Fluidization - Number of Clicks to Complete Deep Clean
Fluidization - Number of failed normal fluidizes to start deep
clean Bioconverter Discharge Liquid Level Bioconverter Discharge
Liquid Level Variance Bioconverter Temperature Bioconverter
Temperature Variance Bioconverter Discharge Valve Opening Maximum
Bioconverter Discharge Valve Opening Minimum Bioconverter Sand
Filter Differential Pressure to Maintain Bioconverter Discharge
Valve Opening % in Manual Mode Bioconverter Discharge Delay Time
Prior to Opening Discharge Valve Bioconverter Feed Rate
Bioconverter Feed Interval between Feeds in Batch Mode Bioconverter
Gas Pressure to Open Gas Valve Bioconverter Gas Pressure to Close
Gas Valve Fluidization Time Between Fluidizations Fluidization Sand
Filter Differential Pressure to Trigger Fluidization Fluidization
Maximum Time to Complete One Revolution of Sand Blade Fluidization
Number of Failed Normal Fluidizes to Trigger a Deep Clean
Fluidization Sand Filter Differential Pressure after a Fluidize to
Trigger a Deep Clean Separator Tank Discharge Pump On Time
Separator Tank Discharge Pump Off Time Chemical Nutrient Pump On
Interval Time Chemical Sulfur Pump On Interval Time Chemical
Anti-Foam Pump On Interval Time Chemical Metals Pump On Interval
Time Chemical Nutrient Pump Cycle On Time Chemical Nutrient Pump
Cycle Off Time Chemical Sulfur Pump Cycle On Time Chemical Sulfur
Pump Cycle Off Time Chemical Anti-Foam Pump Cycle On Time Chemical
Anti-Foam Pump Cycle Off Time Chemical Metals Pump Cycle On Time
Chemical Metals Pump Cycle Off Time
Storage (EQ) System
[0117] Raw organic material may be pumped from a storage vessel
outside of the anaerobic bioconversion system via the EQ tank feed
pump into the EQ tank.
[0118] Raw organic material may also be mixed with water or
wastewater to reduce the solids concentration and pumped to the EQ
tank.
EQ Tank Feed Pump and Valve Control
[0119] The EQ Tank Feed Pump and EQ Tank Feed Pump Valve turn on at
the EQ Tank Feed Pump ON Liquid Level and turn off at the EQ Tank
Feed Pump OFF Liquid Level based on the liquid level measured by a
pressure transducer in the EQ Tank.
EQ Tank Chemical Addition Pump Controls
[0120] The chemical (base) addition to the EQ Tank is based on EQ
Tank pH, EQ Tank pH Variation and the measurement from the pH
sensor in the EQ Tank. The pump turns on when the measured pH in
the EQ Tank is less than EQ Tank pH-EQ Tank pH Variation and turns
off when the pH is greater than EQ Tank pH.
EQ Tank Mixer Speed Control
[0121] The EQ Tank Mixer speed is proportionally controlled based
on the liquid level in the EQ Tank. The mixer speed varies between
EQ Tank Mixer VFD Maximum Speed and EQ Tank Mixer VFD Minimum Speed
proportionally as the liquid level varies between EQ Tank Mixer VFD
Maximum Speed Liquid Level and EQ Tank Mixer VFD Minimum Speed
Liquid Level.
EQ Tank Feed Pump VFD Fault Alarm
[0122] The EQ Tank Feed Pump VFD sends an EQ Tank Feed Pump VFD
Fault alarm if a fault occurs in the VFD. The alarm will alert the
operator of the fault and shut off the VFD output to the pump.
EQ Tank Mixer VFD Fault Alarm
[0123] The EQ Tank Mixer VFD sends an EQ Tank Mixer VFD Fault alarm
if a fault occurs in the VFD. The alarm will shut off the VFD until
the fault is manually corrected. The alarm will alert the operator
of the fault and shut off the VFD output to the Mixer.
EQ Tank Liquid Temperature Alarms
[0124] The EQ Tank has a temperature transducer that measures water
temperature in the EQ Tank. There are EQ Tank High Temperature and
EQ Tank Low Temperature alarms if the temperature is out of range.
The EQ Tank has a tank heater that may or may not be controlled by
the software. Both alarms will alert the operator.
EQ Tank Liquid Level Alarms
[0125] The EQ Tank has two liquid level switches. There are EQ Tank
High-High Liquid Level and EQ Tank Low-Low Liquid Level alarms if
the liquid level is out of range. The EQ Tank High-High Liquid
Level alarm will alert the operator and shut off the EQ Tank Feed
Pump. The EQ Tank Low-Low Liquid Level alarm will alert the
operator and shut off the EQ Tank Mixer and Bioconverter Feed
Pump.
EQ Tank Feed Pump Current Alarms
[0126] The EQ Tank Feed Pump VFD outputs the EQ Tank Feed Pump
current (amps) to the PLC. There are EQ Tank Feed Pump High Current
and EQ Tank Feed Pump Low Current alarms if the current is out of
range. Both alarms will alert the operator and shut off the VFD
output to the pump.
EQ Tank Mixer Current Alarms
[0127] The EQ Tank Mixer VFD outputs the EQ Tank Mixer current
(amps) to the PLC. There are EQ Tank Mixer High Current and EQ Tank
Mixer Low Current alarms if the current is out of range. Both
alarms will alert the operator and shut off the VFD output to the
mixer.
EQ Tank pH Alarms
[0128] The EQ Tank has a pH sensor used to measure pH in the tank.
There are EQ Tank High pH and EQ Tank Low pH alarms if the pH is
out of range. The EQ Tank High pH alarm will alert the operator and
shut off the EQ Tank Chemical Addition Pump and the Bioconverter
Feed Pump. The EQ Tank Low pH alarm will alert the operator and
shut off the Bioconverter Feed Pump.
Bioconverter Feed (DF) System
[0129] Raw organic material may be pumped from the EQ tank to the
anaerobic bioconverter where organic materials are bioconverted or,
the organic material may be conveyed directly into the
bioconverter.
Bioconverter Feed Pump and/or Feed Conveyor and Valve Continuous
Control
[0130] The bioconverter feed pump (and/or feed conveyor) can run in
either of at least three modes, continuous mode or intermittent
mode or batch mode, or switched between modes at different stages
of operation. In continuous mode, the bioconverter Feed Pump
(and/or feed conveyor) VFD operates the pump continuously, varying
the speed of the pump (conveyor) to maintain a specified flow rate.
The specified flow rate is determined by calculating the
instantaneous GPM (or speed) of the pump (conveyor) required to
achieve the bioconverter Feed Pump (conveyor) Daily Gallons (mass).
The VFD speed is allowed to vary between Bioconverter Feed Pump
(conveyor) VFD Maximum Speed and Bioconverter Feed Pump (conveyor)
VFD Minimum Speed. If the VFD is required to operate above
Bioconverter Feed Pump (conveyor) VFD Maximum Speed, the system
alerts the operator that the Bioconverter Feed Pump (conveyor)
Daily Gallons (mass) must be decreased or the Bioconverter Feed
Pump (conveyor) VFD Minimum Speed must be increased. If the VFD is
required to operate below the minimum speed, the VFD runs the pump
(conveyor) at Bioconverter Feed Pump (Conveyor) VFD Minimum Speed
cycling the pump (conveyor) on and off as if it were in batch
mode.
Bioconverter Feed Pump (Conveyor) and Valve Intermittent
Control
[0131] In intermittent mode, the VFD operates the pump (conveyor)
at Bioconverter Feed Pump (conveyor) VFD Speed. The pump (conveyor)
cycles on at Bioconverter Feed Interval between Feeds in
intermittent Mode intervals. The pump (conveyor) cycles off if
either the software calculated required number of gallons (mass)
per feed interval has successfully fed or the Bioconverter Feed
Interval between Feeds in intermittent Mode period has elapsed. The
Bioconverter Feed Pump (conveyor) will operate if the liquid level
in the bioconverter is below Bioconverter Liquid Level or on an
operator selectable time schedule. There are two pressure
transducers, one being redundant, on the bioconverter to measure
the liquid level. The primary pressure transducer is used to
determine operation of the Bioconverter Feed Pump (or
conveyer).
[0132] Bioconverter Feed Pump (conveyor) Flow (mass)
Totalization
[0133] Liquid (mass) flow from the Bioconverter Feed Pump
(conveyor) passes through a liquid (mass) flow meter prior to
entering the bioconverter. There is a pulsed output from the flow
meter to the PLC. The flow meter outputs one pulse per gallon
liquid (per mass unit) through flow meter. These pulses are
totalized in the PLC and displayed as total gallons (mass) pumped
through the flow meter by the Bioconverter Feed Pump
(conveyor).
Bioconverter Liquid Level Alarms
[0134] The bioconverter has two liquid level switches. There are
Bioconverter High-High Liquid Level and Bioconverter Low-Low Liquid
Level alarms if the liquid level is out of range. The Bioconverter
High-High Liquid Level alarm will alert the operator and stop the
Bioconverter Feed Pump. The Bioconverter Low-Low Liquid Level alarm
will alert the operator and shut off the Bioconverter Discharge
Valve.
Bioconverter Foam Level Alarm
[0135] The bioconverter has one liquid level switch used for
high-level foam detection. There is a Bioconverter High Foam Level
alarm if the foam level is over range. The Bioconverter High Foam
Level alarm will alert the operator and shut off the Bioconverter
Feed Pump.
Bioconverter Feed Pump Current Alarms
[0136] The Bioconverter Feed Pump VFD outputs the Bioconverter Feed
Pump current (amps) to the PLC. There are EQ Tank Feed Pump High
Current and EQ Tank Feed Pump Low Current alarms if the current is
out of range. Both alarms will alert the operator and shut off the
VFD output to the pump.
Bioconverter Feed Pump VFD Fault Alarm
[0137] The Bioconverter Feed Pump VFD sends a Bioconverter Feed
Pump VFD Fault alarm if a fault occurs in the VFD. The alarm will
alert the operator and shut off the VFD output to the pump.
Bioconverter Feed Conveyor Current Alarms
[0138] The Bioconverter Feed Conveyor VFD outputs the Bioconverter
Feed Conveyor current (amps) to the PLC. There are Feed conveyor
High Current and Feed Conveyor Low Current alarms if the current is
out of range. Both alarms will alert the operator and shut off the
VFD output to the pump.
Bioconverter Feed Conveyor VFD Fault Alarm
[0139] The Bioconverter Feed Conveyor VFD sends a Bioconverter Feed
Conveyor VFD Fault alarm if a fault occurs in the VFD. The alarm
will alert the operator and shut off the VFD output to the
conveyor.
Bioconverter Liquid Level Transducer Error Alarm
[0140] The liquid level measurement from the primary pressure
transducer and liquid level measurement from the redundant pressure
transducer varying by more than Bioconverter Liquid Level
Transducer Allowable Difference will cause a Bioconverter Liquid
Level Transducer Error alarm. The alarm will alert the
operator.
Bioconverter Agitator System
[0141] There may be, for example, one, two or more rotating blades
in the anaerobic bioconverter used to maintain the bioconverter
sand bed filter as well as aid in the mixing of the bioconverter
contents. Two examples of blades are the Sand Fluidization Blade
and the Propulsion Blade. Any blade may be operated mechanically
(e.g., gear, planetary gear, shaft, belt, magnetic drive, piston or
any other mechanically transmitted power drive) or pneumatically
hydraulically, fluid pressure or air pressure) driven for purposes
of this technology.
Sludge Rake Blade Control
[0142] The Sludge Rake Blade is used to "rake" the sludge/biomass
layer directly on top of the sand bed filter in the anaerobic
bioconverter. This raking effect aids in increasing the effluent
discharge flow from the bioconverter. If operated hydraulically,
the sludge rake blade pump can run in either of two modes,
continuous mode or intermittent mode. In continuous mode, the VFD
that controls the rake blade pump runs continuously, varying the
speed of the Rake Blade Pump between Rake Blade Pump VFD Maximum
Speed (Rake Mode) and Rake Blade Pump VFD Minimum Speed (Rake Mode)
to control the rotational speed of the rake blade. In intermittent
mode, the VFD turns on and off for Rake Blade Pump Intermittent
Mode On Time and Rake Blade Pump Intermittent Mode Off Time periods
while still varying the speed of the rake blade pump to control the
rotational speed of the rake blade. The rake blade may be
mechanically (e.g., gear, planetary gear, shaft, belt, magnetic
drive, piston or any other mechanically transmitted power drive) or
pneumatically (hydraulically, fluid pressure or air pressure)
driven for purposes of this technology.
[0143] Magnetic switches that actuate as the blade rotates
determine the rotational speed of the Rake Blade. The time between
switch actuations (clicks) is measured by the PLC. The Rake Blade
RPM is calculated from the time between clicks. The Rake Blade VFD
output is adjusted up or down based on the current RPM compared to
the Rake Blade RPM. If the time between clicks is too long (i.e.
the blade is moving too slow) the VFD output is increased
incrementally speeding up the Rake Blade, if the time between
clicks is too short (i.e. the blade is moving too fast) the VFD
output is decreased incrementally slowing down the Rake Blade.
Normal Fluidization Control
[0144] The sand fluidization blade is used to "fluidize" the sand
bed filter in the anaerobic bioconverter to prevent the sand bed
from getting "packed" and restricting effluent flow. A fluidization
cycle is started in either of two ways. If the Fluidization Time
between Fluidizes period elapses without a fluidize cycle, one will
begin. A fluidize cycle will also begin based on the differential
pressure measured across the sand filer bed. When the bioconverter
is discharging and the differential pressure across the sand filter
bed becomes greater than Fluidization Sand Filter Differential
Pressure to Trigger Fluidize, the discharge will stop and a
fluidize cycle will begin. It is also contemplated in the practice
of the present technology to use one or more blades to effect this
function, either during continuous operation of the process, or as
a separate intermediate step while this section of the system is
not active in the bioconversion process. A blade may be
mechanically (e.g., gear, planetary gear, shaft, belt, magnetic
drive, piston or any other mechanically transmitted power drive) or
pneumatically (hydraulically, fluid pressure or air pressure)
driven for purposes of this technology.
[0145] The Propulsion Pump is used to hydraulically propel the
Fluidization Blade through the sand filter during a fluidize cycle
during operation. The Sand Fluidization Pump is used to "fluidize"
the sand in front of the rotating blade, allowing it to be
propelled through the sand bed. The Propulsion Pump VFD initially
starts at Propulsion Pump Initial VFD Speed and varies the speed
between the Propulsion Pump Maximum VFD Speed and Propulsion Pump
Minimum VFD based on the rotational speed of the sand blade. The
Sand Fluidization Blade VFD initially starts at Sand Fluidization
Pump Initial VFD Speed and is capable of varying the speed between
the Sand Fluidization Pump Maximum VFD Speed and Sand Fluidization
Pump Minimum VFD Speed.
[0146] Magnetic switches that are actuated as the blade rotates
determine the rotational speed of the Fluidization Blade. The time
between switch actuations (clicks) is measured by the PLC. The
Fluidization Blade RPM is calculated from the time between clicks.
The Sand Blade Pump VFD speed is adjusted up or down based on the
calculated RPM compared to the Fluidization Blade (Normal Fluidize)
RPM. If the time between clicks is too long (i.e. the Fluidization
Blade is moving too slow) the VFD output is increased incrementally
speeding up the Fluidization Blade, if the time between clicks is
too short (i.e. the Fluidization Blade is moving too fast) the VFD
output is decreased incrementally slowing down the Fluidization
Blade.
[0147] A successful fluidize cycle is recorded when a set number of
clicks are recorded during a fluidize cycle. An unsuccessful
fluidize cycle is recorded when Normal Fluidization--Time to
Complete elapses before a successful fluidize. If the number of
unsuccessful fluidizes exceeds Deep Clean Fluidization--Number of
Failed Normal Fluidizes to Start Deep Clean a Deep Clean Fluidize
cycle will start.
[0148] Deep Clean Fluidization Control by Automated or Manual
Control
[0149] A Deep Clean Fluidize is a fluidize cycle where the
Propulsion Pump runs at a slower speed than in the Normal Fluidize
Cycle to more thoroughly fluidize the sand bed compared to a Normal
Fluidize. It is also contemplated in the practice of the present
technology to use one or more blades to effect this function,
either during continuous operation of the process, or as a separate
intermediate step while this section of the system is not active in
the bioconversion process. A blade may be mechanically (e.g., gear,
planetary gear, shaft, belt, magnetic drive, piston or any other
mechanically transmitted power drive) or pneumatically
(hydraulically, fluid pressure or air pressure) driven for purposes
of this technology.
[0150] A Deep Clean Fluidize step is initiated when the time to
perform a successful normal fluidize is less than Normal
Fluidization--Time to Complete, a successful normal fluidize has
not occurred during Deep Clean Fluidization--Number of Failed
Normal Fluidizes to Start Deep Clean or after a successful Normal
Fluidize, the differential pressure across the Sand Filter Bed
exceeds Fluidization Sand Filter Differential Pressure after a
Fluidize to Trigger a Deep Clean. The Sand Blade Pump VFD speed is
controlled the same way it is in a Normal Fluidize. The Propulsion
Pump VFD speed is adjusted up or down based on the calculated RPM
compared to the Fluidization Blade (Deep Clean) RPM.
Sludge Rake Blade Pump Current Alarms
[0151] The Sludge Rake Blade Pump VFD outputs the Sludge Rake Blade
Pump current (amps) to the PLC. There are Sludge Rake Blade Pump
High Current and Sludge Rake Blade Pump Low Current alarms if the
current is out of range. Both alarms will alert the operator and
shut off the VFD output to the pump.
Propulsion Blade Pump Current Alarms
[0152] The Propulsion Blade Pump VFD outputs the Propulsion Blade
Pump current (amps) to the PLC. There are Propulsion Blade Pump
High Current and Propulsion Blade Pump Low Current alarms if the
current is out of range. Both alarms will alert the operator and
shut off the VFD output to the pump.
Sand Fluidization Blade Pump Current Alarms
[0153] The Sand Fluidization Blade Pump VFD outputs the Sand
Fluidization Blade Pump current (amps) to the PLC. There are Sand
Fluidization Blade Pump High Current and Sand Fluidization Blade
Pump Low Current alarms if the current is out of range. Both alarms
will alert the operator and shut off the VFD output to the
pump.
Sludge Rake Blade Pump Pressure Alarms
[0154] The Sludge Rake Blade Pump has a pressure transducer on its
effluent side. There are Sludge Rake Blade Pump High Pressure and
Sludge Rake Blade Pump Low Pressure alarms if the pressure is out
of range. Both alarms will alert the operator and shut off the VFD
output to the pump.
Propulsion Blade Pump Pressure Alarms
[0155] The Propulsion Blade Pump has a pressure transducer on its
effluent side. There are Propulsion Blade Pump High Pressure and
Propulsion Blade Pump Low Pressure alarms if the pressure is out of
range. Both alarms will alert the operator and shut off the VFD
output to the pump.
Sand Fluidization Blade Pump Pressure Alarms
[0156] The Sand Fluidization Blade Pump has a pressure transducer
on its effluent side. There are Sand Fluidization Blade Pump High
Pressure and Sand Fluidization Blade Pump Low Pressure alarms if
the pressure is out of range. Both alarms will alert the operator
and shut off the VFD output to the pump.
Sludge Rake Blade Pump VFD Fault Alarm
[0157] The Sludge Rake Blade Pump VFD sends a Sludge Rake Blade
Pump VFD Fault alarm if a fault occurs in the VFD. The alarm will
alert the operator and shut off the VFD output to the pump.
Propulsion Blade Pump VFD Fault Alarm
[0158] The Propulsion Blade Pump VFD sends a Propulsion Blade Pump
VFD Fault alarm if a fault occurs in the VFD. The alarm will alert
the operator and shut off the VFD output to the pump.
Sand Fluidization Blade Pump VFD Fault Alarm
[0159] The Sand Fluidization Blade Pump VFD sends a Sand
Fluidization Blade Pump VFD Fault alarm if a fault occurs in the
VFD. The alarm will alert the operator and shut off the VFD output
to the pump.
Bioconverter Discharge Control
[0160] The anaerobic bioconverter discharges water in order to
maintain a liquid level in the tank(s).
Bioconverter Discharge Valve Control
[0161] The anaerobic bioconverter has an actuated valve on the
discharge that is adjusted based on the differential pressure
across the Sand Filter Bed when the bioconverter is discharging.
The discharge valve's percentage open is adjusted between
Bioconverter Discharge Valve Opening Maximum and Bioconverter
Discharge Valve Opening Minimum to maintain Bioconverter Sand
Filter Differential Pressure to Maintain. The bioconverter will
begin to discharge water when the liquid level in the bioconverter
is greater than Bioconverter Liquid Level. When the bioconverter is
discharging and the Sand Filter Bed is becoming "packed", the
differential pressure across the Sand Filter Bed will become
greater than Fluidization Sand Filter Differential Pressure to
Trigger Fluidize and a Normal Fluidize cycle will start. When the
fluidize cycle is finished, if the liquid level in the bioconverter
is still above Bioconverter Liquid Level minus Bioconverter Liquid
Level Variance the bioconverter discharge valve will begin the
discharge-fluidize cycle again until the liquid level is below
Bioconverter Liquid Level minus Bioconverter Liquid Level
Variance.
Bioconverter Effluent Flow Totalization
[0162] Discharge liquid flow from the bioconverter passes through a
liquid flow meter. There is a pulsed output from the flow meter to
the PLC. The flow meter outputs one pulse per gallon liquid through
flow meter. These pulses are totalized in the PLC and displayed as
total gallons discharged from the bioconverter. The flow may then
enter a gas separation tank or may be discharged directly from the
bioconverter.
Biogas Separation Tank Liquid Level Alarm
[0163] The Biogas Separation Tank has one liquid level switch used
for high liquid level detection. There is a Biogas Separation Tank
Liquid Level alarm if the liquid level is over range. The Biogas
Separation Tank Liquid Level alarm will alert the operator and
close the bioconverter valve.
Foam Lockout Control
[0164] Biogas handling is required as biogas generated inside the
bioconverter, passes to the biogas separation tank. This biogas is
combined with the separated biogas from the discharge water. A
sample of this combined biogas is pumped through a biogas analyzer.
The remaining biogas passes through a flow meter and is discharged
to a flare or other biogas processing equipment.
Biogas Analyzer Drain Control
[0165] The biogas that passes to the biogas analyzer contains
moisture. This moisture is collected and the biogas analyzer drain
pump is activated to drain the condensate collector.
Biogas Pressure Alarm
[0166] A pressure transducer continuously monitors bioconverter
headspace pressure. When the biogas pressure reaches Bioconverter
Biogas Pressure to Open Biogas Valve, a solenoid valve opens and
biogas is released through the flow meter and subsequently to the
flare. This valve stays open until the pressure measured reaches
Bioconverter Biogas Pressure to Close Valve. To prevent any liquid
from entering the biogas process piping a solenoid valve is located
at the beginning of the biogas piping. If a Bioconverter High Foam
Level or a Biogas Separation Tank Liquid Level alarm is detected,
this valve will close until the alarm is cleared.
[0167] The Bioconverter Biogas Discharge has a pressure transducer
on its effluent side. There is a Bioconverter Biogas Discharge High
Pressure alarm if the pressure is out of range. The alarm will
alert the operator and cause a Foam Lockout Alarm.
Bioconverter Temperature Control
[0168] A bioconverter heater maintains a constant temperature in
the bioconverter.
Bioconverter Liquid Temperature Control
[0169] The bioconverter heater is turned on and off based on
Bioconverter Temperature and Bioconverter Temperature Variance. The
bioconverter heater turns on when the temperature is less than
Bioconverter Temperature--Bioconverter Temperature Variance and
turns off when the temperature is above Bioconverter
Temperature.
Bioconverter Liquid Temperature Alarms
[0170] There are Bioconverter Temperature High and Bioconverter
Temperature Low alarms if the bioconverter temperature is out of
range. Both alarms will alert the operator.
Chemical Addition System
[0171] There may be multiple metering pumps used to supply
supplemental chemicals to the bioconverter. They include but are
not limited to a Base Pump, Nutrients Pump, Sulfur Pump, and Metals
Pump.
Bioconverter Chemical and Solids Recirculation Pump Control
[0172] The Bioconverter Chemical and Solids Recirculation Pump is
used to provide recirculation of bioconverter contents within an
individual bioconversion tank or between multiple bioconversion
tanks within the bioconverter system and allow for chemical
addition to the bioconversion tank(s). No alarms cause the
Recirculation Pump to shut off.
Bioconverter Liquid pH Alarms
[0173] The bioconverter has pH sensors used to measure pH in the
tank. There are Bioconverter High pH and Bioconverter Low pH alarms
if the pH is out of range. The Bioconverter High pH alarm and Low
pH alarm will alert the operator and may turn on or off any of the
chemical addition metering pumps.
Bioconverter Chemical and Solids Recirculation Pump Liquid Pressure
Alarms
[0174] The Chemical and Solids Recirculation Pump has a pressure
transducer on its effluent side. There are Chemical and Solids
Recirculation Pump High Pressure and Chemical and Solids
Recirculation Pump Low Pressure alarms if the pressure is out of
range. Both alarms will alert the operator.
Bioconverter Chemical and Solids Recirculation Pump VFD Fault
Alarm
[0175] The Chemical and Solids Recirculation Pump VFD sends a
Chemical and Solids Recirculation Pump VFD Fault alarm if a fault
occurs in the VFD. The alarm will alert the operator and shut off
the VFD output to the pump.
Base Pump
[0176] One or more chemical feed pumps are used to add base to the
system. One of the pumps may add base to EQ tank and another pump
may add base to the bioconverter. Base pumps operate the same way.
The EQ Tank Base pump turns on when the measured pH in the EQ Tank
is less than EQ Tank pH--EQ Tank pH Variation and turns off when
the pH is greater than EQ Tank pH The bioconverter Base pump turns
on when the measured pH in the bioconverter is less than
Bioconverter pH-Bioconverter pH Variation and turns off when the pH
is greater than Bioconverter pH
Nutrient Pump
[0177] The Nutrient Pump is a metering pump that adds nutrients to
the bioconverter. The Nutrient Pump has adjustable settings. They
may include Nutrient Pump Capacity (GPD), Nutrient Pump Flow (GPD)
and Nutrient Pump Pumping Interval. Nutrient Pump Flow is divided
by Nutrient Pump Capacity to calculate the amount of time during
the day the pump has to run. The required daily run time of the
pump is divided into intervals based on Nutrient Pump Pumping
Interval and the pump on and off times per interval are
calculated.
Sulfur Pump
[0178] The Sulfur Pump is a metering pump that adds sulfur to the
bioconverter. The Sulfur Pump has adjustable settings. They may
include Sulfur Pump Capacity (GPD), Sulfur Pump Flow (GPD) and
Sulfur Pump Pumping Interval. Sulfur Pump Flow is divided by Sulfur
Pump Capacity to calculate the amount of time during the day the
pump has to run. The required time is divided into equal intervals
based on Sulfur Pump Pumping Interval and the pump on and off times
are calculated.
Metals Pump
[0179] The Metals Pump is a metering pump that adds metals to the
bioconverter. The Metals Pump has adjustable settings. They may
include Metals Pump Capacity (GPD), Metals Pump Flow (GPD) and
Metals Pump Pumping Interval. Metals Pump Flow is divided by Metals
Pump Capacity to calculate the amount of time during the day the
pump has to run. The required time is divided into equal intervals
based on Metals Pump Pumping Interval and the pump on and off times
are calculated.
Anti-Foam Pump
[0180] The Anti-Foam Pump is a metering pump that adds anti-foam to
the bioconverter. The Anti-Foam Pump has adjustable settings. They
may include Anti-Foam Pump Capacity (GPD), Anti-Foam Pump Flow
(GPD) and Anti-Foam Pump Pumping Interval Anti-Foam Pump Flow is
divided by Anti-Foam Pump Capacity to calculate the amount of time
during the day the pump has to run. The required time is divided
into equal intervals based on Anti-Foam Pump Pumping Interval and
the pump on and off times are calculated.
Other On-Line Instruments
System Air Pressure Alarm
[0181] The System Air Pressure has a pressure switch associated
with it. There is a System Air Pressure Low alarm if the pressure
is out of range. The alarm will alert the operator.
[0182] Additional considerations and controls applied in the
Bioconverter System may include one or more of the following
Additional parameters involving the bioconverter:
[0183] 1. Intermediate degradation component detection and control
[0184] a. Intermediate degradation components can be monitored and
information sent to the PLC. System variables such as pH, feed rate
and alkalinity can be adjusted to maintain the process.
[0185] 2. Contaminant alarm [0186] a. The process can be monitored
for the presence of contaminants (such as quaternary ammonium) with
information being sent to the PLC to cause alarm conditions.
[0187] 3. Solids concentration monitoring and control [0188] a.
Detection of the solids concentration in the bioconverter is sent
to the PLC to allow the system to adjust system parameters such as
feed rate to maintain the process.
[0189] 4. BOD and COD monitoring and control [0190] a. Real time or
near real-time monitoring of COD and/or BOD allowing the PLC to
adjust system parameters such as feed rate and pH to maintain the
process.
[0191] 5. Surface tension/foam detection monitoring and alarm
[0192] a. Surface tension is monitored sending information to the
PLC to cause an alarm condition if the surface tension is outside
of acceptable user selectable parameters.
[0193] 6. Fats, Oils, and Grease (FOG) monitoring and alarm [0194]
a. FOG is monitored sending information to the PLC allowing system
parameters such as feed rate and feed type to be adjusted to
maintain the process. An alarm condition is triggered when FOG
levels are outside of user selectable parameters.
[0195] 7. Dissolved biogas monitoring and alarm [0196] a. Dissolved
biogas is monitored sending information to the PLC allowing system
parameters such as feed rate and feed type to be adjusted to
maintain the process. An alarm condition is triggered when
dissolved biogas levels are outside of user selectable
parameters.
[0197] 8. Volatile acids monitoring and alarm [0198] a. Volatile
acids concentration is monitored sending information to the PLC
allowing system parameters such as feed rate and feed type to be
adjusted to maintain the process. An alarm condition is triggered
when volatile acids concentration levels are outside of user
selectable parameters.
[0199] 9. Detection and control of specific bacteria
concentration/activity [0200] a. The activity of specific bacteria
may be monitored and other system parameters such as feed rate may
be adjusted to maintain desired activity level and/or concentration
Titration
[0201] A titrator may be incorporated in the system for checking
critical data. This titrator consists of instrumentation and
control valves that are controlled via the PLC. The titrator
consists of independent, dedicated solenoid valves that are
connected to multiple sample points within the bioconversion
process including influent, effluent and various locations on the
bioconverter tank:
The titrator also may have the following:
[0202] 1. DI water [0203] 2. CDA (Clean Dry Air) [0204] 3. Drain
solenoid valve [0205] 4. Feed pump [0206] 5. Sample bottle [0207]
6. Sample stirrer [0208] 7. pH probe [0209] 8. Metering pump [0210]
9. Purge Solenoid valve [0211] 10. Drain Solenoid Valve
[0212] The titrator is used to run two pre-programmed routines. The
first routine only checks for initial pH. The second routine tests
for the following: pH, Alkalinity, Volatile Acids. The
pre-programmed routines proceed in a stepwise fashion through the
following steps: [0213] 1. Sample Preparation [0214] 2. Initial pH
[0215] 3. Initial Volatile Acids Step [0216] 4. Alkalinity
Determination [0217] 5. Final Volatile Acids Step [0218] 6.
Equipment Cleaning.
[0219] For each test, samples may be automatically taken from the
above listed sample points at user selectable sampling intervals
(intervals for each sampling point will be different).
[0220] The Acid Metering pump may operate by dispensing a known
volume of Acid each time it receives a discrete signal to initiate
pumping. The PLC shall operate the pump by making an 110V contact
closure signal. The pump shall then dispense a known quantity of
acid (typically 20 microliters) into the titration vessel. There
shall be a time delay between discrete signals, settable by the HMI
(typically 3 seconds), to allow time for the mixer to disperse the
acid, and obtain a valid pH reading.
[0221] The mixer should be always on.
Sample Preparation
[0222] At the beginning of each cycle, clean water is in the
Titration Vessel (as the last step in the Equipment cleaning
process). In addition, prior to collecting the sample to be
analyzed, sample material shall be purged directly to drain, to
assure that a valid sample is being tested. Since the physical
distance to the sample port is different for each port, the
quantity of sample to be purged is different for each selected
sample. This shall be controlled by the quantity of time that the
purge valve is open, and shall be individually changeable via the
HMI. Sample preparation shall proceed as follows: [0223] 1. Open
drain solenoid valve to empty titration vessel, for a time
adjustable via the HMI. [0224] 2. Close drain valve [0225] 3. Open
Purge valve, and selected sample port valve, for a quantity of time
settable via the HMI. The specific sample port valve shall be
selected via the HMI. At the same time turn on feed pump (p-10).
[0226] 4. At the end of the purge cycle, close the sample port
valve, turn off the feed pump and close the purge valve. [0227] 5.
Open the CDA Valve to push the sample into the titration vessel.
The quantity of time that the CDA valve will be open shall be
settable via the HMI (typically 20 seconds). [0228] 6. Close the
CDA Valve [0229] 7. Sample preparation is complete. pH
[0230] Collecting an accurate initial pH is generally the first
step in all of the pre-programmed routines. To test for pH, the
titrator shall do the following: [0231] 1. Wait a predetermined
quantity of time to allow sample stabilization prior to recording
the initial pH (typically 20 seconds). This time delay shall be
settable via the HMI. [0232] 2. Take pH reading. When the pH varies
by less than 0.02 pH units in a 5-second period, store the data in
a form usable to the HMI interface. [0233] 3. If the pH is the only
item requested by the HMI, proceed to the Equipment Cleaning
procedure. Alkalinity and Volatile Acids [0234] 1. Collect an
initial pH (per above procedure). [0235] 2. Add in acid, using
discrete pulses to the Acid metering pump (as described above), and
record the number of pulses required to reduce the initial pH to pH
5.00. [0236] 3. Continue to add acid, using discrete pulses to the
Acid metering pump (as described above), and record the number of
pulses required to reduce the initial pH to pH 4.30. [0237] 4.
Continue to add acid, using discrete pulses to the Acid metering
pump (as described above), and record the number of pulses required
to reduce the initial pH to pH 4.00. [0238] 5. If the pH of 4.00
cannot be reached within a maximum number of acid additions
settable by the operator (typically 200 cycles), end the procedure
and set an alarm for the HMI. [0239] 6. Calculation of the
Alkalinity and Volatile Acids shall be performed in the HMI and
shall use the recorded values. Equipment Cleaning [0240] 1. After
the sample analysis is complete, open the Titrator vessel drain
valve, the DI valve and the purge valve, for a time settable by the
HMI (typically 20 seconds). [0241] 2. Close the valves. [0242] 3.
Open the DI valve for a time settable by the HMI to put excess DI
water into the titrator vessel. [0243] 4. Close the DI valve.
[0244] 5. Open the CDA valve for a time settable by the HMI to push
DI water into the vessel. [0245] 6. Open the drain valve to drain
the titrator vessel. [0246] 7. Close the titrator drain valve.
[0247] 8. Open the purge valve and the DI water valve, for a time
settable by the HMI. [0248] 9. Close the valves. [0249] 10. Repeat
steps 3-8 for a number of repetitions settable by the HMI
(typically 2). [0250] 11. For the final rinse cycle repeat steps
3-5. [0251] 12. Equipment cleaning step is now complete. Software
Content
[0252] The software (where used) can be provided in any operative
language or code useful for operation of the system. Examples of
actual software used in a typical operation of a sense and response
system are provided below and in Appendices of the ladder step
details of the procedures filed with this application and
incorporated herein by reference for the:
Bioconverter Discharge
XIO I:7.0/11 NXB XIC T4:29/DN BND XIO B3:0/1 BST TON T4:29 1.0 5 0
NXB XIC T4:29/DN OTE N9:17/11 BND
1. XIC I:6.0/11 XIO N9:21/2 XIO N9:21/3 XIC I:7.0/10 XIC I:7.0/11
XIC I:7.0/9 XIC N9:21/11 BST XIC T4:73/DN OTE B3:1/0 NXB OTE
N9:21/14 BND
2. BST CPT F8:7 N9:2-((N9:5-5000.0)*0.12042) NXB MOV F8:7 N9:112
BND
3. BST SUB N10:66 N10:13 N9:109 NXB BST GRT N9:112 N10:66 NXB XIC
N9:21/11 BND GRT N9:112 N9:109 OTE N9:21/11 BND
4. BST MOV N10:100 T4:73.PRE NXB XIC N9:21/14 TON T4:73 1.0 60 0
BND
5. BST SUB N9:2 N9:64 N9:47 NXB LES N9:47 0 MOV 0N9:47 NXB GRT
N9:47 N10:33 OTE B3:I/1 NXB LES N9:47 N10:33 OTE B3:1/2 NXB GRT
N9:47 N10:44 TON T4:47 1.0 5 0 BND
6. XIC B3:1/0 BST XIC T4:12/DN BST XIC B3:1/1 SUB N9:81 50 N9:81
NXB XIC B3:1/2 ADD N9:81 50N9:81 BND NXB LES N9:81 N10:45 MOV
N10:45 N9:81 NXB GRT N9:81 N10:46 MOV N10:46 N9:81 NXB LES N10:46
N10:45 MOV 10000 N10:46 BND
7. XIC I:6.0/10 XIO N9:21/2 XIO N9:21/3 XIC I:7.0/9 MOV N10:71
N9:81
8. BST XIO I:6.0/11 XIO I:6.0/10 NXB XIC N9:21/2 NXB XIC N9:21/3
NXB XIC I:6.0/11 XIO B3:1/0 BND MOV 0 N9:81
9. GRT N9:81 0 OTE O:1.0/13
10. BST XIC I:6.0/11 BST XIC B3: I/O OTE N9:94/1 NXB XIO B3:1/0 OTE
N9:94/2 BND NXB XIO 1:6.0/11 XIO I:6.0/10 OTE N9:94/3 NXB XIC
I:6.0/10 OTE N9:94/4 BND
11. XIC N9:17/11 OTE N9:94/5
12. BST BST BST XIC I:8.0/2 NXB XIC O:3.0/3 BND XIC I:7.0/14 XIC
I:6.0/13 XIC I:7.0/11 NXB XIC 1:6.0/12 BND BST OTE O:3.0/3 NXB OTE
O:1.0/14 BND NXB XIC O:3.0/3 MOV N10:123 N9:161 NXB XIO O:3.0/3 MOV
0 N9:161 BND
13. BST XIC I:6.0/13 BST XIC O:3.0/3 OTE N9:94/6 NXB XIO O:3.0/3
OTE N9:94/7 BND NXB XIO I:6.0/13 XIO I:6.0/12 OTE N9:94/8 NXB XIC
I:6.0/12 OTEN9:94/9 BND
14. XIC B3:0/0 OTE N9:94/10
15. BST BST BST XIC I:8.0/0 NXB XIC O:2.0/13 BND XIC I:8.0/1 XIC
I:6.0/15 XIC I:7.0/11 NXB XIC 1:6.0/14 BND BST OTE O:2.0/13 NXB OTE
O:1.0/15 BND NXB XIC O:2.0/13 MOV N10:122 N9:160 NXB XIO O:2.0/13
MOV 0 N9:160 BND
16. BST XIC I:6.0/15 BST XIC O:2.0/13 OTE N9:95/0 NXB XIO O:2.0/13
OTE N9:95/1 BND NXB XIO I:6.0/15 XIO I:6.0/14 OTE N9:95/2 NXB XIC
I:6.0/14 OTE N9:95/3 BND
17. XIC B3:0/0 OTE N9:95/4
18. BST XIC B3:2/3 OSR B3:2/4 ADD F8:6 1.0 F8:6 NXB XIO I:8.0/13
TON T4:78 1.0 0 0 NXB BST XIC I:8.0/13 NXB XIC B3:2/3 BND XIO
T4:78/DN OTE B3:2/3 BND
[0253] 19. BST BST XIC I:8.0/8 NXB XIC I:8.0/9 XIO N9:21/12 LEQ
N9:113 N10:117 BND BST OTE O:3.0/14 NXB OTE O:2.0/0 BND NXB BST XIO
I:8.0/9 NXB XIC N9:21/12 NXB LEQ N9:113 0 BND ADD N10:117N10:118
N9:113 NXB XIC I:8.0/9 XIO N9:21/12 XIC T4:14/DN SUB N9:113 1
N9:113 NXB XIC O:3.0/14 MOV N10:124 N9:72 NXB XIO O:3.0/14 MOV 0
N9:72 BND
20. BST XIC I:8.0/9 BST XIC O:3.0/14 OTE N9:94/11 NXB XIO O:3.0/14
OTE N9:94/12 BND NXB XIO I:8.0/9 XIO I:8.0/8 OTE N9:94/13 NXB XIC
I:8.0/8 OTE N9:94/14 BND 0. BST
Titration Tester/Sensor
[0254] 0. GRT N10:60 0 BST BST MOV N9:24 N9:86 NXB MOV N10:60 N9:87
NXB MOV 0 N9:34 NXB MOV 0 N9:35 NXB MOV 0 N9:36 NXB MOV 0 N9:37 NXB
MOV 0 N9:88 BND NXB LES N10:60 20 EQU N9:32 0 MOV 1 N9:32 NXB EQU
N10:60 20 MOV 0 N9:32 NXB EQU N10:60 21 MOV 21 N9:32 NXB MOV 0
N10:60 BND
1. BST MOV N10:84 T4:53.PRE NXB EQU N9:32 1 BST OTE N9:33/0 NXB TON
T4:53 1.0 90 0 NXB XIC T4:53/DN MOV 2 N9:32 BND BND
2. BST MOV N10:93 T4:54.PRE NXB EQU N9:32 2 BST OTE N9:33/1 NXB TON
T4:54 1.0 40 0 NXB XIC T4:54/DN MOV 3 N9:32 BND BND
3. BST MOV N10:85 T4:55.PRE NXB EQU N9:32 3 BST OTE N9:33/2 NXB TON
T4:55 1.0 7 0 NXB XIC T4:55/DN MOV 4 N9:32 BND BND
[0255] 4. BST MOV N10:86 T4:56.PRE NXB EQU N9:32 4 BST OTE N9:33/3
NXB TON T4:56 1.0 10 0 NXB CPT F8:3
((((N9:100+N9:101)+N9:102)+N9:103)+N9:104)|5.0 NXB MOV F8:3 N9:105
NXB SUB N9:105 N9:53 N9:106 NXB ABS N9:106 N9:106 NXB XIC T4:56/DN
LEQ N9:106 N10:94 OTE B3:1/12 NXB XIC T4:12/DN BST MOV N9:103
N9:104 NXB MOV N9:102 N9:103 NXB MOV N9:101 N9:102 NXB MOV N9:100
N9:101 NXB MOV N9:53 N9:100 BND NXB XIC T4:56/DN XIC B3:1/12 BST
TON T4:68 1.0 5 0 NXB XIC T4:68/DN BST MOV N9:53 N9:34 NXB GRT
N9:87 10 MOV 10 N9:32 NXB LES N9:87 10 MOV 21 N9:32 BND BND BND
BND
5. EQU N9:32 10 BST OTE N9:33/4 NXB LEQ N9:53 N10:99 BST MOV N9:88
N9:108 NXB MOV 11 N9:32 BND BND
6. EQU N9:32 11 BST OTE N9:33/4 NXB LEQ N9:53 N10:95 BST MOV N9:88
N9:35 NXB MOV 12 N9:32 BND BND
7. EQU N9:32 12 BST OTE N9:33/5 NXB LEQ N9:53 N10:96 BST MOV N9:88
N9:36 NXB MOV 13 N9:32 BND BND
8. EQU N9:32 13 BST OTE N9:33/6 NXB LEQ N9:53 N10:97 BST MOV N9:88
N9:37 NXB MOV 21 N9:32 BND BND
9. BST MOV N10:88 T4:57.PRE NXB EQU N9:32 21 BST OTE N9:33/7 NXB
MOV N10:92 N9:89 NXB TON T4:57 1.0 90 0 NXB XIC T4:57/DN MOV 22
N9:32 BND BND
10. EQU N9:32 22 BST OTE N9:33/8 NXB TON T4:63 0.01 50 0 NXB XIC
T4:63/DN MOV 23N9:32 BND
11. BST MOV N10:89 T4:58.PRE NXB EQU N9:32 23 BST OTE N9:33/9 NXB
TON T4:58 1.0 7 0 NXB XIC T4:58/DN MOV 24 N9:32 BND BND
[0256] 12. EQU N9:32 24 BST OTE N9:33/10 NXB TON T4:67 0.01 10 0
NXB XIC T4:67/DN MOV 25 N9:32 BND 13. BST MOV N10:90 T4:59.PRE NXB
EQU N9:32 25 BST OTE N9:33/11 NXB TON T4:59 1.0 5 0 NXB XIC
T4:59/DN BST GRT N9:89 0 MOV 26 N9:32 NXB EQU N9:89 0 MOV 0 N9:32
BND BND BND
14. BST MOV N10:98 T4:64.PRE NXB EQU N9:32 26 BST OTE N9:33/12 NXB
TON T4:64 1.0 90 0 NXB XIC T4:64/DN MOV 27 N9:32 BND BND
15. EQU N9:32 27 BST OTE N9:33/13 NXB TON T4:65 0.01 50 0 NXB XIC
T4:65/DN MOV 28 N9:32 BND
16. BST MOV N10:91 T4:60.PRE NXB EQU N9:32 28 BST OTE N9:33/14 NXB
TON T4:60 1.0 7 0 NXB XIC T4:60/DN MOV 29 N9:32 BND BND
17. EQU N9:32 29 BST OTE N9:33/15 NXB TON T4:66 0.01 50 0 NXB XIC
T4:66/DN BST GRT N9:89 0 SUB N9:89 1 N9:89 NXB MOV 23 N9:32 BND
BND
18. BST XIC N9:33/1 NXB XIC N9:33/9 NXB XIC N9:33/14 BND OTE
O:4.0/0
19. XIC N9:33/1 OTE O:4.0/1
20. BST XIC N9:33/2 NXB XIC N9:33/11 NXB XIC N9:33/14 BND OTE
O:4.0/2
21. XIC N9:33/9 OTE O:4.0/3
22. XIC N9:33/1 BST EQU N9:87 7 NXB EQU N9:87 17 BND OTE
O:4.0/4
23. XIC N9:33/1 BST EQU N9:87 6 NXB EQU N9:87 16 BND OTE
O:4.0/5
24. XIC N9:33/1 BST EQU N9:87 5 NXB EQU N9:87 15 BND OTE
O:4.0/6
25. XIC N9:33/1 BST EQU N9:87 4 NXB EQU N9:87 14 BND OTE
O:4.0/7
26. XIC N9:33/1 BST EQU N9:87 3 NXB EQU N9:87 13 BND OTE
O:4.0/8
27. XIC N9:33/1 BST EQU N9:87 2 NXB EQU N9:87 12 BND OTE
O:4.0/9
28. XIC N9:33/1 BST EQU N9:87 I NXB EQU N9:87 11 BND OTE
O:4.0/10
29. BST XIC N9:33/0 NXB XIC N9:33/7 NXB XIC N9:33/12 BND OTE
O:4.0/11
30. BST XIC O:4.0/2 NXB XIC O:4.0/3 BND OTE O:4.0/13
31. BST BST XIC N9:33/4 NXB XIC N9:33/5 NXB XIC N9:33/6 BND BST XIO
T4:62/DN BST OTE O:3.0/10 NXB OSR B3:1/13 ADD N9:88 1 N9:88 BND NXB
XIO T4:61/DN TON T4:62 0.01 50 0 NXB XIC T4:62/DN TON T4:61 1.0 3 0
BND NXB MOV N10:83 T4:61.PRE BND
32. BST BST XIC N9:33/4 NXB XIC N9:33/5 NXB XIC N9:33/6 BND GRT
N9:88 N10:87 NXB XIC N9:18/6 BND XIO B3:0/1 BST OTE N9:18/6 NXB OSR
B3:1/14 MOV 21 N9:32 BND
Bioconverter Fluidizer
1. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND GRT N9:65
N10:14 NXB XIC T4:16/DN BND XIO B3:0/1 BST TON T4:16 1.0 5 0 NXB
XIC T4:16/DN OTE N9:16/11 BND
2. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND XIC O:2.0/15
LES N9:65 N10:15 NXB XIC T4:17/DN BND XIO B3:0/1 BST TON T4:17 1.0
5 0 NXB XIC T4:17/DN OTE N9:16/12 BND
3. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND GRT N9:15
N10:68 NXB XIC T4:18/DN BND XIO B3:0/1 BST TON T4:18 1.0 5 0 NXB
XIC T4:18/DN OTE N9:16/13 BND
4. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND XIC O:2.0/14
LES N9:15 N10:69 NXB XIC T4:19/DN BND XIO B3:0/1 BST TON T4:19 1.0
5 0 NXB XIC T4:19/DN OTE N9:16/14 BND
5. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND GRT N9:52
N10:20 NXB XIC T4:20/DN BND XIO B3:0/1 BST TON T4:20 1.0 5 0 NXB
XIC T4:20/DN OTE N9:17/3 BND
6. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND LES N9:52
N10:21 NXB XIC T4:21/DN BND XIO B3:0/1 BST TON T4:21 1.0 5 0 NXB
XIC T4:21/DN OTE N9:17/4 BND
7. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND GRT N9:51
N10:22 NXB XIC T4:22/DN BND XIO B3:0/1 BST TON T4:22 1.0 5 0 NXB
XIC T4:22/DN OTE N9:17/5 BND
8. XIC B3:0/0 BST BST XIC N9:21/2 NXB XIC N9:21/3 BND LES N9:51
N10:23 NXB XIC T4:23/DN BND XIO B3:0/1 BST TON T4:23 1.0 5 0 NXB
XIC T4:23/DN OTE N9:17/6 BND
9. XIC N9:21/2 GRT N9:26 8 BST OTE B3:0/6 NXB MOV N9:44 N9:45
BND
10. XIC N9:21/3 GRT N9:26 N10:36 OTE B3:0/12
11. BST XIC N9:21/2 NXB XIC N9:21/3 BND MOV N10:32 N9:29
12. XIC I:5.0/11 BST XIO N9:21/2 XIO N9:21/3 XIC T4:14/DN GRT N9:29
0 SUB N9:29 1 N9:29 NXB LEQ N9:29 0 OTE N9:21/4 BND
13. BST XIC N9:21/2 NXB XIC N9:21/3 BND BST XIC T4:12/DN LES N9:44
30000 ADD N9:44 1 N9:44 NXB OSR B3:1/11 MOV 0 N9:44 BND
[0257] 14. BST XIO N9:21/3 XIC N9:21/4 NXB XIO N9:21/3 XIC T4:47/DN
NXB XIO N9:21/3 XIC N10:0/0 NXB XIC N9:21/2 BND XIO B3:0/5 XIO
B3:0/6 XIC I:5.0/11 XIC I:5.0/13 BST OTE N9:21/2 NXB BST OTU
N10:0/0 NXB OSR B3:0 .mu.l MOV N9:24 N9:30 BND BND BST XIO N9:21/2
XIC B3:0/0 LES N9:45 N10:28 NXB XIO N9:21/2 GEQ N9:38 N10:30 NXB
XIO N9:21/2 XIC N10:0/1 NXB XIC N9:21/3 BND XIO B3:0/5 XIO B3:0/12
XIC I:5.0/11 XIC I:5.0/13 BST OTE N9:21/3 NXB OTU N10:0/1 NXB MOV
N10:28N9:45 NXB MOV0N9:38 BND
15. XIO N9:17/4 XIO N9:17/3 XIO N9:17/6 XIO N9:17/5 XIO N9:16/12
XIO N9:16/14 LES N9:43 N10:29 OTE B3:0/7
16. XIO B3:0/7 BST OTE B3:0/5 NXB XIC N9:21/2 OSR B3:1/9 ADD N9:38
1 N9:38 BND
17. BST XIC N9:21/2 NXB XIC N9:21/3 BND OSR B3:0/8 BST MOV 0 N9:26
NXB MOV 0 N9:27 NXB MOV 0 N9:40 BND
18. XIC I:7.0/6 OSR B3:0/9 OTE B3:1/6
19. XIC I:7.0/13 OSR B3:0/10 OTE B3:1/7
20. XIC B3:1/6 ADD N9:26 1 N9:26
21.XIC B3:1/7 ADD N9:27 1 N9:27
22. XIC I:5.0/10 MOV N10:34 N9:73
23. BST XIC N9:21/3 LES N9:26 2 OSR B3:1/15 MOV N10:35 N9:73 NXB
XIC N9:21/2 LES N9:26 2 OSR B3:2/0 MOV N10:110 N9:73 NXB XIC
N9:21/2 MOV N10:109 N10:39 NXB XIC N9:21/3 M4V N10:108 N10:39
BND
24. BST XIC N9:21/3 NXB XIC N9:21/2 BND XIC T4:13/DN ADD N9:43 1
N9:43
25. XIO N9:21/3 XIO N9:21/2 MOV 0 N9:43
[0258] 26. XIC N9:21/10 GRT N9:43 N10:39 BST XIO T4:71/DN TON T4:71
1.0 5 0 NXB XIC T4:71/DN BST ADD N9:73 200 N9:73 NXB GRT N9:73
10000 MOV 10000 N9:73 BND NXB BST EQU N9:107 10000 NXB XIC N9:18/8
BND XIO B3:0/1 BST TON T4:72 1.0 300 0 NXB XIC T4:72/DN OTE N9:18/8
BND BND
27. EQU N10:39 0 MOV 25 N10:39
[0259] 28. NEQ N9:26 N9:40 BST XIC N9:21/3 GEQ N9:26 2 BST CPT F8:1
(((N9:43*N9:73)|N10:39)*0.25)+(N9:73*0.75) NXB LIM 0.0 F8:1 10000.0
MOV F8:1 N9:73 NXB GRT F8:1 10000.0 MOV 10000 N9:73 BND NXB BST MOV
N9:43 N9:46 NXB MOV N9:43 N9:84 NXB MOV 0 N9:43 NXB MOV N9:26 N9:40
BND BND
29. BST LES N9:73 N10:40 MOV N10:40 N9:73 NXB GRT N9:73 N10:41 MOV
N10:41 N9:73 BND
30. XIO N9:21/2 XIO N9:21/3 XIO I:5.0/10 MOV 0 N9:73
[0260] 31. BST BST XIC N9:21/2 NXB XIC N9:21/3 NXB XIC I:5.0/10 BND
BST TON T4:24 1.0 5 0 NXB BST XIC N9:21/2 NXB XIC N9:21/3 XIC S:4/5
BND OTE O:1.0/5 NXB XIC T4:24/DN OTE N9:21/10 BND NXB BST XIC
N9:21/10 NXB XIC N9:21/9 BND XIC I:8.0/7 OTE O:2.0/14 NXB BST XIC
T4:24/EN NXB XIC O:3.0/5 BND XIO T4:52/DN BST OTE O:3.0/5 NXB OTE
N9:21/5 BND NXB XIO T4:24/EN TON T4:52 1.0 5 5 BND
32. BST XIC I:5.0/11 BST XIC O:2.0/14 OTE N9:91/9 NXB XIO O:2.0/14
OTE N9:91/10 BND NXB BST XIO I:5.0/10 XIO I:5.0/11 OTE N9:91/11 NXB
XIC I:5.0/10 OTE N9:91/12 BND BND
33. BST XIC N9:16/11 NXB XIC N9:16/12 NXB XIC N9:17/4 NXB XIC
N9:17/5 BND OTE N9:91/13
[0261] 34. BST BST XIC N9:21/2 NXB XIC N9:21/3 NXB XIC I:5.0/12 BND
BST OTE O:1.0/6 NXB TON T4:46 1.0 5 0 NXB XIC T4:46/DN XIC I:8.0/7
OTE O:2.0/15 BND NXB BST XIC O:1.0/6 NXB XIC O:3.0/6 BND XIO
T4:51/DN BST OTE O:3.0/6 NXB OTE N9:21/7 BND NXB XIO O:1.0/6 TON
T4:51 1.0 5 5 BND
35. BST XIC O:2.0/15 BST MOV N10:70 N9:80 NXB LES N9:80 N10:42 MOV
N10:42 N9:80 NXB GRT N9:80 N10:43 MOV N10:43 N9:80 BND NXB XIO
O:2.0/15 MOV 0 N9:80 BND
36. BST XIC I:5.0/13 BST XIC O:2.0/15 OTE N9:91/14 NXB XIO O:2.0/15
OTE N9:91/15 BND NXB BST XIO I:5.0/12 XIO I:5.0/13 OTE N9:92/0 NXB
XIC I:5.0/12 OTE N9:92/1 BND BND
37. BST XIC N9:16/11 NXB XIC N9:16/12 NXB XIC N9:17/4 NXB XIC
N9:17/5 BND OTE N9:92/2
38. BST XIC I:7.0/7 NXB XIO I:7.0/7 XIC B3:0/0 BND OSR B3:0/13 BST
ADD N9:66 2 N9:66 NXB DIV N9:66 6 N9:67 BND
39. BST XIC I:5.0/8 NXB XIC I:5.0/9 LES N9:66 2 BND XIO N9:21/2 XIO
N9:21/3 XIC N9:21/9 MOV N10:47 N9:107
40. GRT N9:107 0 XIC T4:13/DN ADD N9:68 1 N9:68
[0262] 41. XIC N9:21/9 GRT N9:81 0 GRT N9:68 N10:37 BST XIO
T4:69/DN TON T4:69 1.0 5 0 NXB XIC T4:69/DN BST ADD N9:107 200
N9:107 NXB GRT N9:107 10000 MOV 10000 N9:107 BND NXB BST EQU N9:107
10000 NXB XIC N9:18/7 BND XIO B3:0/1 BST TON T4:70 1.0 300 0 NXB
XIC T4:70/DN OTE N9:18/7 BND BND
42. EQU N10:37 0 MOV 50 N10:37
[0263] 43. XIC I:5.0/9 XIO N9:21/2 XIO N9:21/3 NEQ N9:66 N9:79 BST
GEQ N9:66 2 BST CPT
F8:2(((N9:68*N9:107)|N10:37)*0.05)+(N9:107*0.95) NXB LIM 0.0 F8:2
10000.0 MOV F8:2 N9107 NXB GRT F8:2 10000.0 MOV 10000 N9:107 BND
NXB BST MOV N9:66 N9:79 NXB MOV N9:68 N9:85 NXB MOV 0 N9:68 BND
BND
44. XIO N9:17/0 OTE B3:0/15
45. BST LES N9:107 N10:101 MOV N10:101 N9:107 NXB GRT N9:107
N10:102 MOV N10:102 N9:107 BND
46. BST XIC N9:21/2 NXB XIC N9:21/3 NXB XIO I:5.0/8 XIO I:5.0/9 NXB
XIO B3:0/15 BND BST MOV 0 N9:107 NXB MOV 0 N9:66 BND
[0264] 47. BST BST XIC I:5.0/8 NXB XIC I:5.0/9 BND XIO N9:21/2 XIO
N9:21/3 XIO N9:91/13 XIO N9:21/10 BST BST XIC I:5.0/9 XIO N10:0/6
NXB XIC I:5.0/8 NXB XIC I:5.0/9 XIC N10:0/6 XIO T4:79/DN BND BST
OTE O:1.0/4 NXB OTE N9:21/9 BND NXB XIC I:5.0/9 XIC N10:0/6 XIO
T4:80/DN TON T4:79 1.0 119 0 NXB XIC T4:79/DN TON T4:80 1.0 1680 0
BND NXB MOV N10:113 T4:79.PRE NXB MOV N10:114 T4:80.PRE BND
[0265] 48. BST BST XIC I:5.0/8 NXB XIC I:5.0/9 BND XIO N9:21/2 XIO
N9:21/3 XIO N9:91/13 XIO N9:21/10 BST BST XIC I:5.0/9 XIC N9:21/14
NXB XIC I:5.0/9 XIO N9:21/14 XIC N10:0/6 XIO T4:79/DN NXB XIC
I:5.0/9 XIO N9:21/14 XIO N10:0/6 NXB XIC I:5.0/8 BND BST OTE
O:1.0/4 NXB OTE N9:21/9 BND NXB XIC I:5.0/9 XIC N10:0/6 XIO
T4:80/DN TON T4:79 1.0 119 0 NXB XIC T4:79/DN TON T4:80 1.0 1680 0
BND NXB MOV N10:113 T4:79.PRE NXB MOV N10:1 14 T4:80.PRE BND
49. XIC N9:21/9 BST GRT N9:81 0 MOV N9:107 N9:73 NXB EQU N9:81 0
MOV N10:105 N9:73 NXB OTE O:3.0/4 BND
50. BST XIC I:5.0/9 BST XIC N9:21/9 OTE N9:91/4 NXB XIO N9:21/9 OTE
N9:91/5 BND NXB BST XIO I:5.0/8 XIO I:5.0/9 OTE N9:91/6 NXB XIC
I:5.0/8 OTE N9:91/7 BND BND
51. XIC N9:18/7 OTE N9:91/8
Organic Biomass Input Feed Stream
[0266] An estimated minimum scope of patent protection that could
be reasonably sought for a generic treatment process might be
couched as follows: [0267] a) Liquid, solid or dry material storage
equipment; [0268] b) feed from liquid, solid or dry storage to an
EQ tank and/or directly to an anaerobic bioconverter; [0269] c)
flow from the bioconverter; and [0270] d) discharge of energy
depleted water from the system [0271] e) discharge of energy rich
biogas [0272] wherein {specific parameters} are sensed in the
anaerobic bioconverter to provide signals to a processor that
controls influx of i) nutrients, ii) oxidizing agents [inclusive of
sulfur and oxygen], iii) antifoam agents and iv) metal additives,
wherein with respect to at least two of i), ii), iii) and iv), at
least one different condition is sensed to provide sensed data for
controlling introduction rates for each of the at least two of i),
ii), iii) and iv).
[0273] Upon further review, the process may be broadened so as not
to require all four additions, with otherwise similar limitations
on process control.
[0274] The system may also monitor and control all elements of
material handling within the and out of the system. Material
handling is another potentially important independent step in the
process of converting waste food materials to energy. Prior to the
EQ tank, material must be received and qualitative and quantitative
information obtained to allow the system to process the material
into a suitable feed substrate (feedstock) to the bioconverter.
[0275] Waste fuel production by-products and any supplemental
additives such as food materials may be dry, a slurry, or aqueous
in nature. Materials can be stored in segregated fashion, such as
individual tanks, or multiple materials can be combined in a single
container. Once the material is received and stored, the system can
monitor multiple parameters from each storage vessel for each type
of waste. While several parameters are common to all types of
wastes, some parameters are more appropriate for specific types of
wastes. For example, weight is a more appropriate quantitative
measure of a dry material while gallons is a more appropriate
quantitative measure of an aqueous material. COD is an example of a
parameter common to all food wastes and biofuel production residual
or by-products.
[0276] To maintain the bioconversion process as close to a
theoretical optimal level as possible requires quantitative and
qualitative characteristics of the waste materials to be sent to
the PLC allowing the PLC to determine the appropriate next step(s)
in the process.
[0277] Maintaining a relatively stable and consistent organic
loading to the bioconversion step of the process is a critical
factor. Waste biofuel residuals and/or food material must be
processed in various ways depending of the characteristics of the
material to form a feedstock. Multiple steps may be required. For
example, dry material may be required to be ground into smaller
particles size and combined with aqueous and/or slurried materials
in a proportional manner that creates a feed substrate matching the
parameters required by the bioconversion step of the process.
Another example would be that various aqueous materials need to be
combined in proportion based on their COD concentrations to result
in a COD of the combined material equal or near equal to the
desired COD concentration the bioconverter expects to process. A
third example would be that the materials lack specific compounds
or chemicals such as nitrogen and phosphorous which must be added
to the waste material to properly condition the material for
bioconversion. The PLC software can obtain quantitative and
qualitative information regarding each type of waste food material
and direct the subsequent process steps required to create the
desired feed substrate to the bioconverter.
[0278] Multiple quantitative and qualitative characteristics are
incorporated into the material handing process including:
[0279] 1. Weight/Volume/Density/Flow [0280] a. There are many
examples of quantitative information that may be used to determine
amount of materials available to be processed or being processed.
They may be measured at various points along the system, correlated
with known or expected results, and the system designed (e.g.,
programmed or set to provide an alarm or notice) according to past
measurements.
[0281] 2. Viscosity/Moisture content/FOG (Fats, Oils, and Greases)
[0282] a. These are used to determine additional processing
requirements such as dilution, from which established needs of the
system can be responded to. [0283] b. These may also be used to
determine what type of conveyance device is used to transport the
material through additional processing steps.
[0284] 3. pH and alkalinity monitoring and control [0285] a. Used
to determine if the pH must be adjusted. The bioconversion step in
the process operates around neutral pH. For example, the pH of two
distinct stored organic material sources will have been measured,
and the balance of the materials may be shifted to reflect the
needs of pH adjustment suggested by the readings.
[0286] 4. Temperature [0287] a. The bioconversion step requires
operating temperatures between 77- and 100 degrees F. for
mesophilic operation and between 122 and 158 degrees F. for
thermophilic operation. The temperature may be automatically
adjusted in response to the measurement of shifting or undesirable
temperatures.
[0288] 5. BOD/COD/Volatile Acid concentration/Protein
concentration/FOG concentration/Carbohydrate concentration/Sugar
concentration/Methane potential [0289] a. These all are examples of
parameters which may be used by the PLC to determine proportional
amounts of each waste food material required to create the desired
feedstock for the bioconversion step [0290] b. These are all are
examples of parameters which may be used by the PLC in determining
if additional compounds or chemicals such as traces metals (nickel,
iron, cobalt, etc) are required to be added.
[0291] 6. Particle Size [0292] a. Used to determine if waste
material should be processed differently through grinding and
crushing operations to create the desired particle size/shape in
the feedstock for the bioconversion step. Upon determination of
required size change, the operating parameters of material sizing
equipment may be altered.
[0293] 7. Detection of contaminants and alarm [0294] a. Detection
in the raw waste food material of contaminants which would disrupt
and/or destroy the biological bioconversion activity can be
essential, and rapid response is desirable. Examples of
contaminants include high chlorine levels and quaternary ammonium.
The PLC would not use the contaminated material when creating
feedstock for the bioconversion step of the process. Materials can
be available that are known antagonistic vectors against such
contaminants and which might leach, absorb, chelate or otherwise
restrain or remove such contaminants.
[0295] 8. General water quality parameters such as conductivity and
ORP may also be usefully measured and automatically adjusted in the
system.
[0296] Energy control, energy output and energy conservation
considerations may also be effected and maintained in the operation
of the present system. For example, Connections to Energy
Production equipment require monitoring and control of equipment.
Monitoring and control is done both to optimize energy production
and to accurately count the units being sold to the end user.
[0297] Parameters controlled by the PLC to optimize energy
production may include gas input flow maintenance including control
valves to supplement with pipeline natural gas as needed to
supplement bioconverter gas output; maintenance of gas blowers to
maintain a constant gas pressure; control of equipment for moisture
reduction; control of equipment for sulfur dioxide reduction;
connections to the end-user require connections to, control and
measurement of the output electrical power; connections to, control
and measurement of hot water piping flows, pressure and hot water
heat output; connections to, control and measurement of steam
piping, pressure, flow, steam quality and steam heat output.
[0298] A view of the Figures will assist in an additional
appreciation of the scope of the present technology. FIG. 1 shows a
schematic of a basic biomass bioconversion system 2 according to
general teachings herein. The system 2 shown in FIG. 1 has a
biomass bioconversion tank 4 containing the mixture 6 of biomass
and liquid and a gas containing space 8 over the mixture 6. The
bioconversion tank 4 is shown with three outlet systems 10, 12 and
14 for the gas outlet (10), the liquid and dissolved, dispersed,
suspended solids outlet (12), and an optional mass outlet (14)
which may be used for the infrequent removal of excess biomass from
the bioconversion tank 4. The gas outlet 10 is in mass transfer
communication with a gas separation system 16, which is shown with
three venting outlets 18 (e.g., for CO.sub.2), 20 (e.g., for
CH.sub.4, H.sub.2) and residual gas outlet 22 for any other gases
emitted. There may be additional vents if H.sub.2 is a significant
gaseous component of the stream initially vented through outlet 10
from the bioconversion tank 4.
[0299] The configuration of the system 2 in FIG. 1 shows an
adjacent organic waste producing commercial biofuel production
facility 26 (e.g., a biodiesel or ethanol synthesizing plant, etc.)
that may produce a solids waste stream 28 and/or an aqueous waste
stream 30 that may each be fed into the bioconversion tank 4 as at
least one source of both organic solids and aqueous material (which
may also contain dissolved, suspended or dispersed solids). The
system 2 is also shown with a nutrient storage tank 24 and feed
stream 24a to the bioconversion tank 4, and three separate organic
solids material storage tanks 32, 34 and 36 with their individual
feed streams 32a, 34a and 36a to the bioconversion tank 4. There
may be, and preferably is, a separate aqueous supply stream that
can be fed either directly into the bioconversion tank 4 or into
the individual organic solids storage tanks 32, 34 and 36 or into
their individual feed streams 32a, 34a and 36a to the bioconversion
tank 4. A central data processing system 40 is shown with various
communication links (which may be hard wire or wireless) 52, 42,
44, 46, 48 and 50 to other components (e.g., distal node, FPGA,
ASIC, subprocessor, or signal router 72; organic solid material
storage tanks 32, 34 and 36; commercial plant 26; and nutrient
storage tank 24, respectively). Each feed stream (including at the
site of the storage tank or originating facility) would preferably
have an automatically controlled rate flow system in communication
link with the central processor 40. A filter bed 90 is shown
between the biomass and the liquid outlet 12 to assure retention of
larger size particles and other solids. Liquid outlet 12 may flow
to a liquid/gas separation tank 92 prior to discharge.
[0300] As indicated more thoroughly in the discussion above, the
sensors may be (in the gas volume 8 for gas pressure, gas
temperature, gas content (e.g., methane, carbon dioxide, volatile
acid and/or hydrogen content), gas acidity, gas conductivity (as an
indication of gas content) and the like, and in the biomass volume
6 for pH, nutrient content, temperature, density, temperature,
specific component or by-product content, water content, chemical
oxygen concentration or requirements, flow rates through the filter
90 or into the liquid outlet 12, and the like, as described
above.
[0301] Inside and/or at flow inlets and outlets to the
bioconversion tank 4 may be sensors as indicated in the discussion
above. In FIG. 1 are shown two sensors 62 and 64 in the gas volume
8 in the bioconversion tank 4 and three sensors 66, 68 and 70 in
the biomass volume 6 in the bioconversion tank 4. These sensors 62,
64, 66, 68 and 70 may be in direct communication with the processor
40 or may be linked to the processor 40 through a router or other
intermediary device 72. In order to reduce computing power needed
and to simplify repair and replacement of parts, the sensors may
communicate as nodes in a distributed architecture format, using
linking element 72 to properly format, translate or encode signals
to be sent to processor 40 for reading, storage and analysis,
followed by commands or state change signals from the processor or
responsive or controlled elements, such as the flow control or rate
of flow control in the various sources of materials (and energy) to
the bioconversion tank 4, as explained above.
[0302] Attached and incorporated into this application is Appendix
I, which contains three distinct software ladders for use in
various individual and separate component sequences in the practice
of technology that is described herein. LAD 6 represents a sequence
that may be used with the bioconverter discharge controls and
constitutes copyrighted code and material of the assignee.
[0303] LAD 5 represents a sequence that may be used with the
bioconverter agitator controls and constitutes copyrighted code and
material of the assignee.
[0304] LAD 11 represents a sequence that may be used with the
Titrator Sequence controls and constitutes copyrighted code and
material of the assignee.
[0305] Other software for other individual performance steps
identified in this disclosure may be similarly structured as taught
by the technology. One of ordinary skill in the art, upon reading
this disclosure will become readily aware of variations,
alternatives and orientations that are not specifically identified
in this disclosure, but which are within the scope of the
technology disclosed. These variations and equivalents are intended
to be included within this disclosure and the discussion of
specific structures, materials, software and line code is not
intended to limit the scope of protection afforded by the following
claims to this technology.
[0306] In its simplest embodiment, the technology of the present
invention may be associated with any biofuel synthesizing or
manufacturing plant that produces organic waste. The organic waste
residuals are then processed in a bioconverter to generate
combustible gaseous or volatile fuel (such as methane, hydrogen and
the like). The combustible fuel is then, sold as an energy product,
oxidized or burned to generate energy (either directly as heat, or
secondarily as an electrical generation system) to provide energy
to the biofuels synthesizing or manufacturing plant, and/or as a
saleable energy product.
[0307] All references to other publications made herein incorporate
each and every reference in their entirety herein to provide
additional information according to this disclosure.
* * * * *