U.S. patent application number 12/457209 was filed with the patent office on 2009-12-10 for modular portable micro-factory system.
Invention is credited to Richard F. Ablett.
Application Number | 20090300998 12/457209 |
Document ID | / |
Family ID | 41397447 |
Filed Date | 2009-12-10 |
United States Patent
Application |
20090300998 |
Kind Code |
A1 |
Ablett; Richard F. |
December 10, 2009 |
Modular portable micro-factory system
Abstract
A modular, portable, expandable micro-factory system is provided
herein. It includes a plurality of intact shipping containers
assembled together to provide a contiguous interior space. One such
intact shipping container provides a receiving area seamlessly
connected to a production area of a second intact shipping
container, which in turn provides a shipping area which is
seamlessly connected to the production area of a third intact
shipping container. The production area comprises a plurality of
vessels operatively interconnected to one another. The plurality of
vessels include some, but not necessarily all of a number of units,
e.g., an extractor, a press unit, a screener, at least one thin
extract tank, a foamer, a mixing valve assembly, a wash down unit,
a slurry tank, a filter plate stack, at least one clear extract
tank, an evaporator module, and a concentrator tank.
Inventors: |
Ablett; Richard F.;
(Charlottetown, CA) |
Correspondence
Address: |
THE NATH LAW GROUP
112 South West Street
Alexandria
VA
22314
US
|
Family ID: |
41397447 |
Appl. No.: |
12/457209 |
Filed: |
June 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61129075 |
Jun 3, 2008 |
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Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04H 5/02 20130101 |
Class at
Publication: |
52/79.1 |
International
Class: |
E04H 5/02 20060101
E04H005/02 |
Claims
1. A modular, portable, expandable micro-factory system comprising
a plurality of intact shipping containers assembled together to
provide a contiguous interior space, one such intact shipping
container providing a receiving area seamlessly connected to a
production area of a second intact shipping container, which in
turn provides a shipping area which is seamlessly connected to the
production area of a third intact shipping container, wherein the
production area comprises a plurality of vessels operatively
interconnected to one another, the plurality of vessels comprising
some, but not necessarily all of an extractor, a press unit, a
screener, at least one thin extract tank, a foamer, a mixing valve
assembly, a wash unit, a slurry tank, a filter plate stack, at
least one clear extract tank, an evaporator module, and a
concentrator tank.
2. A self contained modular, portable, expandable micro-factory
system comprising a plurality of intact shipping containers
assembled together to provide a contiguous interior space, one such
intact shipping container providing a receiving area seamlessly
connected to a production area of a second intact shipping
container which, in turn provides a shipping area which is
seamlessly connected to a production area of a second intact
shipping container seamlessly connected to the production area of a
third intact shipping container, wherein the first intact shipping
container provides a receiving area comprising a storage freezer, a
dry storage and thaw area, an entrance and conventional office
areas; wherein the second intact shipping container provides the
production area comprising a plurality of operatively
interconnected vessels comprising an extractor, a plurality of
reaction-supporting lines including a compressed air line, a
potable water line, a steam line and a condensate return line,
these units being operatively associated with one another; wherein
the second intact shipping container also includes a screener, a
foamer, a mixing valve assembly and a wash down station for supply
to the screener, a solids tote, a press, and a liquid tub, these
units being; wherein the second intact shipping container also
includes a first thin extract tank for reactant passing through the
screen the reactant passing operatively connected to a second thin
extract tank, these units being operatively associated with one
another; wherein the second intact shipping container also includes
a slurry tank for receiving extract from the second thin extract
tank a strainer for effluent slurry a filter plate stack for
strained effluent and a clear extract tank, theses units being
operatively associated with one another; and wherein the second
intact shipping container also includes an evaporator module
operatively connected the clear extract tank, an effluent to a
cooling tower, and a concentration tank, these units being
operatively associated with one another.
3. The modular, portable, expandable micro-factory system of claim
1, wherein the second intact shipping container is disposed at
right angles to the first intact shipping container.
4. The modular, portable, expandable micro-factory system of claim
1, wherein the third intact shipping container is disposed at right
angles to the second intact shipping container.
5. The modular, portable, expandable micro-factory system of claim
1, wherein the first intact shipping container, the second intact
shipping container and the third intact shipping container are
oriented in plan view as a "U-shape".
6. The modular, portable, expandable micro-factory system of claim
1, wherein the first intact shipping container, the second intact
shipping container and the third intact shipping container are
oriented in plan view as "H-shape".
7. The modular, portable, expandable micro-factory system of claim
1, wherein the modular, portable, expandable micro-factory system
also includes an ingredient scale, and/or a product scale.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a modular, expandable, portable,
micro-factory system In particular, it relates to such system which
is expandable from a pilot plan scale and finally to full
production scale, particularly in rural communities, and which is
also adaptable to dismantling and reassembling at a different
location. This application is a continuation-in-part of my
provisional application (Se. No. unknown,) filed Jun. 3, 2008, the
entire contents of which are incorporated herein by reference.
[0003] 2. Description of the Prior Art
[0004] One of the main problems in scaling-up reactions from a
laboratory scale to a mini-pilot plant scale, then to a pilot plant
scale and finally to a production scale is the cost inherent in
each step. These costs are not recoverable from step to step,
meaning that the cost of the mini-pilot plant scale cannot be
translated into a saving of costs to scale up to a pilot plant and
finally to a savings of costs to scale up to a production
scale.
[0005] One means which was conceived of achieving such end, and
which has been vaguely implied in the prior art, would be to build
the mini-pilot plant scale in a pre-designed plurality of portable,
structurally-rigid units. Such units are readily available in the
form of shipping containers The term "Shipping Containers" as used
herein refers to standard 20 foot and 40 foot ISO shipping
containers.
[0006] One patent alluded to above is U.S. Pat. No. 5,656,491
issued Aug. 12, 1997 to Snamprogettibiotechnologie S. p. A. which
allegedly provided a mobile-module plant for the development and
production of biotechnological products on a pilot scale. That
mobile-module plant included equipment for the production,
separation purification and finishing of such biotechnological
products. The plant consisted of at least two mobile modules which
could be connected together and integrated with one another for use
as biochemical plant. Each of the mobile modules comprised a
movable container. At least one of the movable containers was
provided with its pre-selected own set of the above mentioned
equipment, i.e., for the production, separation, purification and
finishing of such biotechnological products. Also, at least one of
the containers was aseptic. It was said that the plant could easily
be disassembled into its individual modules and then transported to
a different site.
[0007] Another patent alluded to above is US Patent Publication No
2002/0129566, published Sep. 19, 2002 to H. Piccolo et al, which
provided a method of converting shipping containers containing
factory equipment into a modular portable factory. The disclosed
method comprised transporting the shipping containers to the
factory site and aligning the containers in a side-by-side relation
with their facing walls, to define the walls of the factory and
floor of the factory. A roof structure spanned over the top of the
container to form a top closure for the factory. Access doors and
stairways were provided in the factory. Shipping containers forming
main storage units, and which contained building materials, were
mounted on a foundation with the supply containers placed
perpendicular, parallel or angled to the main storage units. The
supply containers were movable by a supply track. The product moved
by an assembly track. Turntables at the end of each of these tracks
were operatively connected to the tracks to move the supplies or
products in a desired direction. The portable modular factories
thus assembled were ones which were said to be able to be assembled
on one site and readily disassembled for relocation to another
site.
[0008] Notwithstanding the above prior art, the need still exists
for a method for the conversion of shipping containers into a
modular, expandable, portable, micro-factory system. In particular,
the need still exists for such system which is adaptable to pilot
plant scale which can readily be expanded to full production scale,
particularly in rural communities.
[0009] Therefore, it is a general aim of the present invention to
provide a means for satisfying the above needs.
[0010] The invention in its general form will first be described,
and then its implementation in terms of specific embodiments will
be detailed with reference to the drawings following hereafter.
These embodiments are intended to demonstrate the principle of the
invention, and the manner of its implementation. the invention in
its broadest sense and more specific forms will then be further
described, and defined, in each of the individual claims which
conclude this specification
SUMMARY OF THE INVENTION
Statement of Invention
[0011] One broad aspect of the present invention provides a
modular, portable, expandable micro-factory system. Such system
includes a plurality of intact shipping containers assembled
together to provide a contiguous interior space. One such intact
shipping container provides a receiving area seamlessly connected
to a production area of a second intact shipping container, which
in turn provides a shipping area which is seamlessly connected to
the production area of a third intact shipping container. The
production area comprises a plurality of vessels operatively
interconnected to one another. The plurality of vessels includes a
plurality of interconnected apparatus units, namely some, but not
necessarily all of an extractor, a press unit, a screener, at least
one extract tank, a foamer, a mixing valve assembly, a wash down
unit, a slurry tank, a filter plate stack, at least one clear
extract tank, an evaporator module, and a concentrator tank.
[0012] A second broad aspect of the present invention provides a
self contained modular, portable, expandable, micro-factory system.
Such system includes a plurality of intact shipping containers
assembled together to provide a contiguous interior space. One such
intact shipping container provides a receiving area seamlessly
connected to a production area of a second intact shipping
container, which, in turn provides a shipping area which is
seamlessly connected to the production area of a third intact
shipping container. The first intact shipping container provides a
receiving area comprising a storage freezer, a dry storage and thaw
area, an entrance and conventional office areas. The second intact
shipping container provides the production area comprising a
plurality of operatively interconnected apparatus units including
an extractor, a plurality of reaction-supporting lines including a
compressed air line, a potable water line, a steam line and a
condensate return line, these units being operatively associated
with one another; a screener, a foamer, a mixing valve assembly and
a wash down station for supply to the screener, a solids tote, a
press, and a liquid tub, these units being operatively associated
with one another; a first thin extract tank for reactant passing
through the screen and being operatively connected to a second thin
extract tank, these units being operatively associated with one
another; a slurry tank for receiving extract from the second thin
extract tank, a strainer for effluent slurry, a filter plate stack
for strained effluent and a clear extract tank, these units being
operatively associated with one another; an evaporator module
operatively connected to the clear extract tank, an effluent to a
cooling tower, and a concentration tank, these units being
operatively associated with one another
OTHER FEATURES OF THE INVENTION
[0013] According to one variant of the first and second aspects of
the present invention, the second intact shipping container is
disposed at right angles to the first intact shipping container
[0014] According to another variant of the first and second aspects
of the present invention, the third intact shipping container is
disposed at right angles to the second intact shipping
container
[0015] According to another variant of the first and second aspects
of the present invention, the first intact shipping container, the
second intact shipping container and the third intact shipping
container are oriented in plan view as a "U-shape"
[0016] According to another variant of the first and second aspects
of the present invention, the first intact shipping container, the
second intact shipping container and the third intact shipping
container are oriented in plan view as a "H-shape"
[0017] According to another variant of the first and second aspects
of the present invention, the modular, portable, expandable
micro-factory system also includes an ingredient scale, and/or a
product scale
[0018] The foregoing summarizes the principal features of the
invention and some of its optional aspects. the invention may be
further understood by the description of the preferred embodiments,
in conjunction with the drawings, which now follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of a novel modular, expandable,
portable micro-factory system according to the one aspect of the
present invention;
[0020] FIG. 2 is a schematic representation of the interior of one
novel modular, expandable, portable micro-factory system of FIG. 1,
but of another aspect of the present invention; and
[0021] FIG. 3 divided into FIG. 3A, FIG. 3B, FIGS. 3 C and 3D for
convenience shows the piping instrumentation and processing units
layout of a main processing module of a novel modular, expandable,
portable micro-factory system according to the another aspect of
the present invention
DESCRIPTION OF PREFERRED EMBODIMENTS
Detailed Description of FIG. 1
[0022] FIG. 1 shows a perspective view of a novel modular,
expandable, portable micro-factory system (10) according to one
embodiment of the present invention. It shows six modules, each of
which is an intact shipping container.
[0023] Module # 1 (100) is a shipping container providing office
and employee facilities and is shown being lowered into position by
a sky crane (not seen) Module # 1 (100) is labeled "Lab &
Office" and "Change Room"
[0024] Module # 2 (200) is a shipping container providing
downstream processing and shows a freezer/dryer.
[0025] Module # 3 (300) is a shipping container providing
extraction and concentration facilities and shows a pressure filter
and a product scale.
[0026] Module # 4 (400) is a storage container providing raw
material storage and flammable material storage.
[0027] Module # 5 (500) is a shipping container providing a tank
module, and includes preliminary evaporator facilities and second
stage evaporator facilities.
[0028] Module # 6 (600) is a shipping container providing services,
namely electrical facilities, boiler and chiller shop areas and
finished storage.
Detailed Description of FIG. 2
[0029] FIG. 2 is a schematic representation of the interior of one
novel modular, expandable, portable micro-factory system but of
another aspect of the present invention in which the intact
shipping containers are arranged in an "H" plan orientation
(3000).
[0030] In a receiving area provided by the right-hand vertical arm
of the "H", there is a freezer (2022) for storing frozen waste
bio-active material and therefore also a freeze/thaw area (400) and
refrigerated storage (3002) and dry storage (3004) areas That
right-hand vertical arm of the "H" also provides space for an
office (100) and washrooms (3006).
[0031] The contiguous space provided by the horizontal arm includes
the interconnected reaction apparatus units. They may consist of a
weigh scale (2042), a screen (2040), a filter (2034), an evaporator
(2036) other condensers (2032) and packaging weighing and labeling
machines (2032, 2028)
[0032] The contiguous space provided by the left-hand vertical arm
of the "H" includes the shipping area (2024) and a utility room
(600). The shipping area (2024) includes a freezer/refrigerator
(200) and a shipping dock (2044) Also shown, but not numbered, are
the various pipelines carrying water, compressed air and various
reactants, waste bio-products and final processed bio-products.
Detailed Description of FIG. 3A, FIG. 3B, FIG. 3C and FIG. 3D
[0033] Composite FIG. 3 shows the piping instrumentation and
processing units layout of a main processing module of a novel
modular, expandable, portable micro-factory system according to the
another aspect of the present invention The interconnected units
are labeled and so the drawing is believed to be self-explanatory.
However it is to be noted that there are main processing lines for
incoming and outgoing compressed air, potable water, steam and
steam condensate, the latter leading to a condensate return.
[0034] In composite FIG. 3, FIG. 3A shows an ingredient scale
(4012), and an extractor (4018) A pump (4016) feeds water to a
condenser return (4014) which leads by associated lines to a
condensate return line and a bleed line to a surrounding heat
exchanger to cool the extractor (4018) The extractor (4018)
includes the necessary lines for the various reagents and
reactants.
[0035] In composite FIG. 3, the continuation in FIG. 3B shows a
screener, (4022) where liquid leads to a holding tank (4023). The
solids are captured in a solids tote (4040) which feeds a press
(4024--so that expressed liquid in liquid tub 4026) is fed to the
holding tank (4023) Interconnecting feeder lines are connected to,
and between, a pair of thin extract tanks 4028)
[0036] In composite FIG. 3, the continuation in FIG. 3C shows a
slurry tank (4034) which is connected to a filter plate stack
(4038). A strainer (4036) from the slurry tank (4034) also feeds
the filter plate stack (4038) The clear extract from the thin
extractor tanks (4928 see FIG. 4B) is fed to a clear extract tank
(4080). From the clear extract tank (4080) clear effluent is led to
its associated line. Other lines, namely the main processing lines
which are continuations of lines in FIG. 4A and FIG. 4B are
provided for incoming and outgoing compressed air, potable water,
steam and steam condensate provide a mixing valve assembly (4030)
leading to a washroom station (4031) The generated foam feeds a
foamer (4032) or to a filter previously mentioned
[0037] In composite FIG. 4, the continuation in FIG. 4D shows an
evaporation module (2034). This consists of plate evaporator (4042)
and cyclone evaporator (4044), with their attendant connecting
lines. The cyclone evaporator (4044) has an effluent leading to
another condenser (4045) which drains to a cooling tower The
bottoms for cyclone evaporator (40440 feeds a concentrate tank
(4046) The final unit is a product scale (4048).
CONCLUSION
[0038] The foregoing has constituted a description of specific
embodiments showing how the invention may be applied and put into
use. These embodiments are only exemplary. The invention in its
broadest, and more specific aspects is further described and
defined in the claims which follow. These claims, and the language
used therein are to be understood in terms of the variants of the
invention which have been described. They are not to be restricted
to such variants, but are to be read as covering the full scope of
the invention as is implicit within the invention and the
disclosure that has been provided herein.
* * * * *