U.S. patent application number 13/351057 was filed with the patent office on 2012-06-21 for compressed straw material.
Invention is credited to Eugene Gala, Stephane Gauthier.
Application Number | 20120155972 13/351057 |
Document ID | / |
Family ID | 46234644 |
Filed Date | 2012-06-21 |
United States Patent
Application |
20120155972 |
Kind Code |
A1 |
Gauthier; Stephane ; et
al. |
June 21, 2012 |
Compressed Straw Material
Abstract
Bedding material for livestock or Hydromulch for soil treatment
is produced by extruding straw mixed with bio-char through a
conventional cubing system. The cubing process generates friction
in turn changing the properties of the straw making the straw
particles highly absorbent while binding the bio-char and any dust
into the mixture. The mixture can be used for bedding where the
bio-char acts as an absorbent. The mixture can also be used in soil
remediation by spreading over the soil in dry or Hydromulch where
the bio-char acts to filter contaminants and can act as a binder
for an fertilizer admixed into the mixture for seeding.
Inventors: |
Gauthier; Stephane; (La
Broquerie, CA) ; Gala; Eugene; (Winnipeg,
CA) |
Family ID: |
46234644 |
Appl. No.: |
13/351057 |
Filed: |
January 16, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12590562 |
Nov 10, 2009 |
7973389 |
|
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13351057 |
|
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61433331 |
Jan 17, 2011 |
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Current U.S.
Class: |
405/302.6 |
Current CPC
Class: |
A01C 1/04 20130101; C05F
11/00 20130101; C05F 11/02 20130101; C05F 11/00 20130101 |
Class at
Publication: |
405/302.6 |
International
Class: |
E02D 17/00 20060101
E02D017/00 |
Claims
1. A combination material comprising: a base material formed of
cellulosic material which is chopped to form a mass of material for
application to the ground; and particles of bio-char intermixed
with the base material and carried thereby.
2. The combination material according to claim 1 wherein the
cellulosic material is crop material.
3. The combination material according to claim 1 wherein the
cellulosic material is compressed with the bio-char admixed so that
the Bio-Char is crushed into the cellulosic material so that the
cellulosic material acts as the carrier for the Bio-Char.
4. The combination material according to claim 1 including
seeds.
5. The combination material according to claim 1 including
fertilizer.
6. The combination material according to claim 5 wherein the
fertilizer is contained in pores in the Bio-char particles.
7. The combination material according to claim 1 wherein the base
material comprises an extruded body of a compressed mass of
cellulosic material, the body having a constant cross sectional
shape along its length and containing the bio-char therein, the
body being broken transversely at spaced positions along its length
into pieces at least some of which form flakes.
8. The combination material according to claim 7 wherein at least
some of the flakes have a transverse dimension matching that of the
body.
9. The combination material according to claim 7 wherein the
cellulosic material is shredded to less than 6 inch length.
10. The combination material according to claim 7 wherein the
cellulosic material is extruded using a square die.
11. The combination material according to claim 7 wherein the
cellulosic material is shredded so as to contain at least some
pieces which are greater than 1.0 inch length
12. The combination material according to claim 7 wherein the
moisture content is below 15%.
13. The combination material according to claim 7 wherein the
flakes have a bulk density of 12-35 lbs/cu ft.
14. The combination material according to claim 7 wherein dust
particles in the cellulosic material are compacted into the
cellulosic material during the compaction.
15. The combination material according to claim 7 wherein the body
has a transverse dimension in the range from 0.25 to 2.25
inches.
16. The combination material according to claim 7 wherein the
flakes have a transverse dimension equal to or below the longest
cross section dimension of the body.
17. The combination material according to claim 1 wherein the
flakes are less than 0.5 inch in thickness.
18. The combination material according to claim 1 wherein the
cellulosic material includes crop material which is blended with
shredded paper and/or cardboard.
19. The combination material according to claim 1 wherein the
cellulosic material includes crop material which is blended with
wood shavings and/or sawdust.
20. The combination material according to claim 1 including added
salt.
21. The combination material according to claim 1 wherein the
cellulosic material comprises more than 50% switch grass.
22. The combination material according to claim 1 wherein the
Bio-Char is provided in particles having a transverse dimension
less than 0.25 inches.
23. The combination material according to claim 1 wherein the
Bio-Char forms between 10% and 25% by volume.
24-91. (canceled)
Description
[0001] This application is a continuation in part application of
application Ser. No. 12/590,562 filed Oct. 16, 2009.
[0002] This application claims the benefit of priority under 35 USC
119(e) of Provisional Application No. 61/433,331 filed Jan. 17,
2011.
[0003] This application relates to the subject matter disclosed in
US Published Application 2009/0056208 published Mar. 5, 2009 the
disclosure of which is incorporated herein by reference.
[0004] The invention is related generally to a compressed straw
material incorporating additional components and particularly
Bio-Char for various end uses.
BACKGROUND OF THE INVENTION
[0005] Bio-Char, also known as Bio-Carbone, is also traditionally
known as charcoal and has been made for centuries for many purposes
and particularly as a high grade fuel.
[0006] Some of the major issues surrounding this material is the
lack of commercial production and the difficulty in handling the
material in an efficient manner.
[0007] Some of the issues pertaining to Bio-Char are: [0008] Hard
to deal with Fines which are considered a nuisance; [0009] Very
brittle and dusty; [0010] Very light in density; [0011] Not soluble
in water, hard to process into a slurry; [0012] Difficult to blend
into the top soil; [0013] Very difficult to apply in larger acreage
areas.
[0014] Some of the benefits of Bio-Char include: [0015] Very high
in Fixed Carbon; [0016] Very porous allowing nutrients to be stored
within the molecules; [0017] Can be used as a filtration medium;
[0018] Can sequester CO2 in larger quantities and is considered to
be stable long term; [0019] Can be produced from either wood or
agricultural residues.
[0020] Bio-char can sequester carbon in the soil for hundreds to
thousands of years, like coal. Modern bio-char is being developed
using pyrolysis to heat biomass in the absence of oxygen in
kilns.
[0021] Hydro-seeding (or hydraulic mulch seeding, hydro-mulching)
is a known planting process which utilizes a slurry of seed and
mulch. The slurry is transported in a tank, either truck- or
trailer-mounted and sprayed over prepared ground in a uniform
layer. Helicopters may be used in cases where larger areas must be
covered. Aircraft application may also be used on burned wilderness
areas after a fire, and in such uses may contain only soil
stabilizer to avoid introducing non-native plant species.
Hydro-seeding is an alternative to the traditional process of
broadcasting or sowing dry seed. It promotes quick germination and
inhibits soil erosion.
[0022] The mulch in the hydro-seed mixture helps maintain the
moisture level of the seed and seedlings. The slurry often has
other ingredients including fertilizer, tackifying agents, green
dye and other additives.
[0023] Hydro-seeding is used to seed grass on commercial sites
(highways/motorways etc.), golf courses, lawns and areas too large,
inaccessible or unsuitable for cost-effective conventional methods.
Starting a lawn by hydro-seeding is considerably cheaper than
laying sod/turf and quicker than using seed. It is also used to
spread mixtures of wildflower and tree/shrub seeds or turf grasses
for erosion control. The process is called sprigging (or
hydro-sprigging) when the slurry contains stolons or rhizomes
instead of seed.
[0024] Hydroseeding (or hydraulic mulch seeding, hydro-mulching,
hydraseeding) is a planting process which utilizes a slurry of seed
and mulch. The slurry is transported in a tank, either truck- or
trailer-mounted and sprayed over prepared ground in a uniform
layer. Helicopters may be used in cases where larger areas must be
covered. Aircraft application may also be used on burned wilderness
areas after a fire, and in such uses may contain only soil
stabilizer to avoid introducing non-native plant species.
Hydroseeding is an alternative to the traditional process of
broadcasting or sowing dry seed. It promotes quick germination and
inhibits soil erosion.
SUMMARY OF THE INVENTION
[0025] According to the invention there is provided a combination
material comprising:
[0026] a base material formed of cellulosic material which is
chopped to form a mass of material for application to the
ground;
[0027] and particles of bio-char intermixed with the base material
for application therewith.
[0028] The invention is related generally to using forms of
Bio-Char in combination with cellulose materials. The combined
product can be used as a soil amendment product by means of mixing
this material with mulches for application to the ground. The mulch
may be a Hydraulic mulch including a water carrier and may be
formed with materials such as heat treated straw and wood/paper
materials. The combined product can be used as a bedding material
for animals and can be discharged after use over the ground. The
combined product can be used as a sediment control material. It can
be added to the materials used to fill sediment socks or wattles
used for erosion control on slopes and hilly areas. The mixture
used can include a combination of cereal straws (Flax, Wheat,
Barley, Oat, grasses and others) that have been processed and/or
heat treated and bio-char at various ratios. The socks or wattles
used can be made from burlap (Jute) or other non biomass based
materials such as nylon netting.
[0029] The advantage on the bio-char mixed with the other straws is
that it now becomes an erosion control system that can also filter
out micro toxins and nutrients from run off water passing though
it. The bio-char also becomes a means of CO2 sequestration.
[0030] Contrary to coal and/or petroleum charcoal, when
incorporated to the soil in stable organo-mineral aggregates,
Bio-char does not freely accumulate in an oxygen-free and abiotic
environment. This allows it to be slowly oxygenated and transformed
in physically stable but chemically reactive humus, thereby
acquiring interesting chemical properties such as cation exchange
capacity and buffering of soil acidification. Both are precious in
nutrient- and clay-poor tropical soils.
[0031] The invention also includes the method of applying to the
ground bio-char particles by admixing them in a mulch with the base
material.
[0032] The invention also includes the method of providing an
animal bedding including bio-char particles by admixing them in a
mulch with the base material.
[0033] The following invention is directed to combining the
attributes of Bio-Char with Hydro-mulch and Hydro-seeding products.
This in turn produces a very high grade Hydro-mulch and
Hydro-seeding material that can be marketed as a soil amendment or
enhancement mulch.
[0034] The Hydraulic mulch that contains quantities of Bio-Char
granules which can be of various sizes and various densities and
introduced at various concentrations.
[0035] The Bio-Char is produced using a 100% renewable biomass such
agricultural residues and/or woody biomass. The bio-char is
produced by a Torrefaction or pyrolytic process that extracts all
volatiles out from the material. The Bio-Char is relatively high
quality and has a relatively high porosity level. The Bio-Char
doesn't contain any toxic or other contaminants that are of concern
when applying to the ground.
[0036] The Bio-Char is blended with existing hydromulches in
various quantities to be used as a soil enhancement or natural
fertilizer. Therefore it can be mixed with existing wood based
hydro-mulches, mixed with existing paper mulches, mixed with
existing soil erosion control mulches or other soil amendment
mulches.
[0037] The Bio-Char is blended with straw or wood hydromulches
prior to heat treatment or processing. In many cases this involves
adding the Bio-Char to the straw prior to a densification process.
The Bio-Char is added at a certain rate, mixed and densified
together. The end product has the Bio-Char blended into the straw.
The Bio-Char is typically crushed into the straw particles so that
the straw acts as the carrier for the Bio-Char, as opposed to being
merely admixed. Thus the material has greater flowability and
viscosity than Bio-Char alone. Such a material is able to pass
through conventional Hydroseeding or Hydromulch equipment.
[0038] The Bio-Char is blended with a heat treated straw in various
quantities to be used as a soil enhancement or natural fertilizer.
This product can also be used in animal bedding application where
the bio-char mixed within will be used to absorb problematic
nutrients such as phosphorous compounds and allow a way of managing
these fertilizers.
[0039] The bio-char is preferably added to Heat Treated Straw which
comprises an extruded body of a compressed mass of crop material,
the body having a constant cross-sectional shape along its length,
the body being broken transversely at spaced positions along its
length into pieces at least some of which form flakes with the body
being compressed and heated using a densification system.
[0040] The crop material can comprise one or more of wheat straw,
barley straw, oat straw, timothy straw and various forage straws
and/or any cereal, grain or forage straws. Other agricultural crop
residues found in large quantities include; Wheat Straw, Barley
Straw, Corn Stover, Kentucky Blue Grass Screenings, Switch grass
and Bagasse.
[0041] The body is compressed and heated using a cubing system or
similar compression machine such as a briquetter or screw
extruder.
[0042] Preferably at least some of the flakes have a transverse
dimension matching that of the body.
[0043] Preferably the straw is shredded to less than 6 inch
length.
[0044] Preferably the straw is cubed using a substantially square
die to form an extruded body of square cross-section and square
flakes. However the die could be also round or any other shape.
[0045] Preferably the straw cubes and or flakes are cooled.
[0046] Preferably the straw is shredded so as to contain at least
some pieces which are greater than 1.0 inch length
[0047] Preferably the cubing process exerts extreme pressure and
friction on the straw particles causing the internal cell walls of
the straw to collapse and expel any moisture locked within. This
refining action is due to the nature of the cuber. The press wheel
exerts a slip action that causes the hemi-cellulose to break down
maintaining a long straw fibre ideal for erosion control mulches.
Pellets produced using a conventional pellet mill will not have
this characteristic and will not produce long fibres.
[0048] Preferably the cubed straw becomes 10-40% more absorbent
than untreated straws making it comparable to wood or paper fibre
mulches.
[0049] Preferably the cubed straw is exposed to temperature above
110.degree. F. for a minimum of 3 seconds so as to become
pasteurized.
[0050] Preferably the shredded straw and Bio-Char is compacted with
a minimal force of 1000 PSIG.
[0051] Preferably the final product moisture content is below
15%.
[0052] Preferably any seed in the straw is made sterile by the heat
generated in the compression during which the process destroys the
germ of any seed.
[0053] Preferably the straw cubes and/or flakes have a bulk density
of 15-25 lbs/cu ft.
[0054] Preferably dust particles in the shredded straw and found in
the Bio-Char are compacted together during the compaction thus
minimizing dust in the flakes.
[0055] Preferably the shredded raw materials product has moisture
content of 30% or lower.
[0056] Preferably material is extruded through an orifice having a
transverse dimension in the range from 0.25 to 2.25 inches.
[0057] Preferably the densified straw is broken up into smaller
pieces, flakes and fines allowing the material to breakdown
relatively fast when submerged in water.
[0058] Preferably the particle length of the final product is equal
or below the longest cross section dimension of the die.
[0059] Preferably the straw is blended with shredded paper or
cardboard.
[0060] Preferably the flakes are less than 0.5 inch in
thickness.
[0061] Typically where readily and widely available the cellulosic
material can comprise primarily wheat straw. However in other
locations it can comprise primarily, that is more than 50% and
often as much as 100%, switch grass.
[0062] Preferably the Bio-Char is provided in particles having a
transverse dimension less than 0.25 inches. Larger particles are
difficult to bind into the cellulose material in the compression
action.
[0063] Preferably the Bio-Char forms between 10% and 25% by volume.
Any less than 10% provides an insufficient effect and any greater
than 25% causes difficulties in providing the binding without
adding additional unwanted binding materials.
[0064] This invention is intended to offer an alternative to straw
based hydromulches and dry mulches being offered in the market that
can also provide a soil amendment product and a means of carbon
dioxide sequestration. Some of the markets being targeted are
Hydromulch or Hydroseeding companies that are looking for
alternatives to wood or paper based mulches that can perform as
good or better and offer other benefits such as soils enhancement
and CO2 sequestration.
[0065] The intent is to be able to provide a product that can be
bagged, has a relatively high bulk density, and that can perform as
well if not better than wood or paper products. Through having
conducted extensive research and trials, the straw & Bio-Char
flakes have proven to be a more than suitable alternative. The
product can be packaged in various size and types of bags to
accommodate many markets including the Hydromulch and Hydroseeding
to large scale farms that could take bulk deliveries to be applied
on larger acreages.
[0066] In the central plains of Canada, many new laws are being
implemented to restrict stubble burning of straw in fields after
harvest. This has created abundance straw residues that become a
nuisance to the farmer. This invention would help create a new
market opportunity for farmers wishing to bale the straw and create
a value added product.
[0067] The flaked product can be used to absorb various chemicals
including alcohols and hydrocarbons as a replacement of clay based
absorbent. The flakes have a natural tendency to wick oils and lock
them into the internal wall structures of the straw particles. This
minimizes the leaching effect when land filled. The flakes offer a
lighter, less dusty and easier spreading alternative to clay based
materials.
[0068] Another use for the bio-char and straw mixture is to be used
as a sediment control material. It can be added to the materials
used to fill sediment socks or wattles used for erosion control on
slopes and hilly areas. The mixture used can include a combination
of cereal straws (Flax, Wheat, Barley, Oat, grasses and others)
that have been processed and/or heat treated and bio-char at
various ratios. The socks or wattles used can be made from burlap
(Jute) or other non biomass based materials such as nylon
netting.
[0069] The advantage on the bio-char mixed with the other straws is
that it now becomes an erosion control system that can also filter
out micro toxins and nutrients from run off water passing though
it. The bio-char also becomes a means of CO2 sequestration.
[0070] Another use for the bio-char and cellulose material mixture
is to be used as a sediment control material. It can be added to
the materials used to fill sediment socks or wattles used for
erosion control on slopes and hilly areas. Socks, sometimes called
"wattles" are elongate tubular containers using a porous or
permeable outer covering typically of a fabric material which hold
the material into a body which can be laid across the water flow.
The mixture used can include a combination of cereal straws (Flax,
Wheat, Barley, Oat, grasses and others) that have been processed
and/or heat treated in the cubing process described herein and
bio-char at various ratios. The socks or wattles used can be made
from burlap (Jute) or other non biomass based materials such as
nylon netting.
[0071] The socks will also act as a filter media as the bio-char
particles will have very porous microstructures that will capture
very fine particles including heavy metals such as cadmium.
[0072] The advantage on the bio-char mixed with the other straws is
that it now becomes an erosion control system that can also filter
out micro toxins and nutrients from run off water passing though
it. The bio-char also becomes a means of CO2 sequestration.
[0073] The material can add in other feedstock to be used for
Hydromulch production such as Switch Grass, Canary Reed Grass
[0074] When used in animal bedding the added bio-char provides the
advantages that it:
[0075] aids in odor control
[0076] acts as an additional absorbent
[0077] provides increased traction for animals
[0078] When used in Hydro-Mulch the added bio-char provides the
advantages that it:
[0079] adds water retention due to the increased surface area of
the bio-char particles. This helps establish a better plant roots
system that will enhance growth.
[0080] Acts to sequester CO2 (Carbon sink).
[0081] aids to stabilize soil PH.
[0082] helps in reducing amounts used of traditional fertilizers
(NPK) in large scale farming.
[0083] The material can be applied in loose flakes in a dry form
with use of a manure spreader machine rather than a hydraulic
mulch.
[0084] The material can be used as a potting soil mix or garden
mulch to replace woody based products such as bark and chips
[0085] The material can be used as a soil remediation product for
areas like tar sands in Alberta
[0086] The material can be used as a filter medium in waste water
treatment plants or as a binder in their screw pressing
operations.
[0087] The material can be used as a biomass renewable fuel in
large commercial boilers or power plants.
[0088] The material can capture very fine particles including heavy
metals such as cadmium.
[0089] One particular advantage of the use of the bio-char in the
combination applied to the soil is that the porous bio-char is used
to contain or store fertilizer which is absorbed into the pores.
Thus mixing the material with a liquid fertilizer binds the
fertilizer into the pores. In the pores the fertilizer is held
against washing away into the soil, where it is lost from the
plants. In the pores the fertilizer is held at the surface of the
soil for the root structure of the newly germinated plant to
penetrate the pores and extract the retained fertilizer. Thus the
soil remediation material which can be applied to the ground
includes the combined material described above carrying the
fertilizer. Typically this will be applied in dry form as a mat
over the ground with the longer fibers obtained by the process
described herein acting to interlock to hold the mat as an integral
structure to protect the soil until the plants and the plant root
structures commence their binding action. The combination therefore
provides a synergistic action generating all of the above
advantages and leading to significantly increased plant growth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
[0091] FIG. 1 is an isometric view of a cubed material according to
the present invention.
[0092] FIG. 2 is an exploded view of a cuber for manufacturing the
product of FIG. 1.
[0093] FIG. 3 is a vertical cross-sectional view of the cuber of
FIG. 2.
[0094] FIG. 4 is an isometric view of the cuber of FIG. 2.
[0095] FIG. 5 is a schematic illustration of a hydromulching system
using the method of the present invention where the admixed
material of the present invention is spread over ground to be
remediated or seeded.
[0096] FIG. 6 is a cross-sectional view of a ditch or other run off
area where soil erosion can occur and including socks containing
the material of the present invention for erosion control.
[0097] FIG. 7 is a schematic illustration of the material of the
present invention when applied to the ground and forming a
filtration mat.
DETAILED DESCRIPTION OF THE EMBODIMENTS AS SHOWN
[0098] The preferred technique for compression of materials to form
a compressed or densified product known as "cubing" is well
established and widely used. The design of the Cuber has been
available for 40 years and has changed little in that time. Such a
Cuber is available from Cooper Cubing Systems of Burley, Id. USA.
The Cuber of this type is robust and relatively inexpensive. Such
Cubers have however been used for the compression of forage crops
such as alfalfa. The alfalfa is introduced into the cubing system
and the high compression up to 6,000 psi of the material as it
enters the series of dies creates an effective product which is
extruded through the dies. The Cuber is particularly designed and
arranged to provide and effective cubing action of the alfalfa to
maintain an attractive green appearance of the product so that it
is attractive to the animals to be fed and to the handlers of those
animals.
[0099] An example of a Cuber of this type is shown in a brochure of
the above company and such Cubers include an exterior housing with
a longitudinal axis where the housing is held stationary with the
axis horizontal. A feed duct is provided at the top of the housing
for feeding the material to be cubed into the interior of the
housing. The housing defines a cylindrical inner surface at the
feed section where a web of the material to be compressed enters
through the feed opening.
[0100] At one end of the cylindrical feed section is provided a
pair of clamping disks with the disks lying in parallel radial
planes of the axis. One of the disks at the feed section has a
central opening through which the material feeds to be located
between the two disks.
[0101] The disks act to clamp an array of radially extending,
axially located dies with the array surrounding the axis and
located between the clamping disks. The clamping disks clamp the
dies between them using bolts passing through holes in the dies to
squeeze the disks together and hold the dies at a fixed position
surround the axis. The dies thus define a radially inwardly facing
inlet mouth with a duct of the die extending radially outwardly
toward an outlet. Each die therefore forms an extrusion tube with
the material being compressed into the inner end of the die.
[0102] Within the outer housing is provided an inner rotor with a
generally cylindrical outer surface at the inner surface of the
feed housing of the outer housing. The inner rotor also caries a
press wheel lying in the radial plane of the dies so that the press
wheel rolls in the radial plane on the dies at the inlet mouth with
the press wheel being mounted such so that as an axis of rotation
of the press wheel rotates around the axis of the outer housing.
Thus as the press wheel rotates it squeezes the material outwardly
into the mouth of the die to be compressed and extruded through the
die. The outer housing carries on its inner surface a plurality of
upstanding flights extending from the outer surface inwardly toward
the axis. The outer surface of the inner rotor also carries one or
more flights which rotate with the rotor so as to sweep the
material from the feed opening to the inlet of the dies where the
material is engaged by the press wheel.
[0103] Outside the mouth of the dies where the material exits there
is provided an angled plate so that the material as it exits
engages the plate and is diverted to one side of its normal
direction of movement thus causing breakage of the extruded solid
stream of the material into individual pieces giving the name
"Cuber", even though the length of the broken pieces may vary and
differ from the transverse dimension so that the product produced
is not literally a "cube".
[0104] As shown in FIG. 1, the material is formed by extrusion in
the cubing machine to form an extruded body 10 of a compressed mass
of crop material or other cellulose material 11 as previously
described. The cellulose material 11 selected is blended with
Bio-Char particles 12 simply by adding the particles in the
required sizes as an additional element blended into the feed stock
of the cubing machine described as shown in FIG. 2. As formed the
body 10 shown in FIG. 1 has a constant cross-sectional shape along
its length which is shown as a square, which is typical for the
cubing machine but other dies of different shape can be used.
[0105] The Bio-Char is typically provided in particles having a
transverse dimension less than 0.25 inches. Larger particles are
difficult to bind into the cellulose material in the compression
action.
[0106] The Bio-Char typically forms between 10% and 25% by volume.
Any less than 10% provides an insufficient effect and any greater
than 25% causes difficulties in providing the binding without
adding additional unwanted binding materials.
[0107] The body is broken transversely at spaced positions along
its length into pieces at least some of which have a length in a
direction along the body less than 0.5 inches and typically of the
order of 1/8 inch to 1/4 inch to form flakes 13. Some flakes or
broken pieces retain a longer length of greater than 0.5 inches to
form cubes. Thus at least some of the flakes as shown in FIG. 1
have a transverse dimension matching that of the body.
[0108] The straw is shredded prior to cubing to less than 6 inch
length and so as to contain at least some pieces which are greater
than 1.0 inch length.
[0109] As shown in the apparatus of FIGS. 2, 3 and 4, the straw is
cubed using a square die to form square cubes and flakes which are
naturally broken to length after cooling.
[0110] The cubing process exerts extreme pressure and friction on
the straw particles causing the internal cell walls of the straw to
collapse and expel any moisture locked within. The rough surface of
the press wheel and the action applied on the straw causes the
straw pieces to split length wise in effect refining the straw
while compressing the material through the die. The cubed straw
becomes 10-40% more absorbent than dry wood shaving or sawdust (6%
Moisture Content). The cubed straw is exposed to temperature above
110.degree. F. for a minimum of 3 seconds so as to become
pasteurized. The shredded straw is compacted with a minimal force
of 1000 PSIG. The final product moisture content is below 15%. Any
seed in the straw is made sterile by the heat generated in the
compression during which the process destroys the germ of any seed.
The straw cubes have a bulk density of 12-35 lbs/cu ft. Dust
particles in the shredded straw and found in the Bio-Char are
compacted together during the compaction thus minimizing dust in
the cubes.
[0111] The material is extruded through an orifice having a
transverse dimension in the range from 0.25 to 2.25 inches and the
straw cubes are broken up into smaller pieces, flakes and fines by
allowing the cubes to free fall and hit a deflection plate.
[0112] The straw and bio-char blends may be mixed with other woody
fibres including paper products to produce a variety of
Hydromulches.
[0113] The plant materials are selected such that they are shredded
to a length of the pieces when extended which is greater than 1
inch. Thus the pieces when compressed may crumple into small
elements or maybe laid into the structure as pieces as indicated at
20 where the pieces are laid through the structure and provide
continuous connection through the structure. This selection of a
shredding action which provides materials having a length greater
that 1 inch and commonly greater than 2 inch or 4 inch reduces the
amount of dust or fines within the structure so that the pieces
when they break during the forming action or at any later time do
not crumble to dust but instead break along fault lines generated
by the elongate pieces such as the piece 20 first to break into
larger chunks rather than mere dust or fines.
[0114] The shredding action as described above is carried out so
that the amount of small components or comminuted components within
the structures is maintained relatively low. Thus the proportion of
components having a dimension of less than 0.5 inch is less than
40%.
[0115] One of the cubing machines is shown is FIGS. 2, 3 and 4.
This comprises an outer housing 40 in the form of a cylindrical
drum 41 with an inlet duct 39 supplying the feed material from the
conveyor into the interior of the drum. The drum has a cylindrical
inside surface 42. At the end of the drum is provided a first
clamping disk 43 which is welded to the end of the tube forming the
drum and extends outwardly there from to form an annular disk shape
as indicated at 44. The disk has a circular interior 45 matching
the end of the drum 41. Thus material passing along the inside
surface of the drum can pass through the hole 45 in the disk and
enter the area on the outside face of the disk 43 and adjacent to
the second end disk 46. The disks lay in common radial planes of an
axis 47 of the drum. The disks are generally coextensive. The disks
act as clamping disks and have a series of mounting holes 48 in
cooperating patterns for receiving axially extending bolts between
the disks. The disks thus can be used to clamp a series of dies 50
so that the dies are arranged angularly around the axis 47 with
each die providing a duct through which the material from the
interior of the drum can be extruded. The dies thus are arranged
around the axis with an inside face of the die facing toward the
interior and located just outside the inner edge 45 of the disk 43.
Each die thus forms a tube extending radially outwardly from the
inner end at the edge 45 to an outer end extended beyond the outer
edge of the disk.
[0116] The inner rotor 55 mounted within the outer housing 40
comprises a shaft 56 extending along the axis 47. The shaft 47 is
mounted in end bearings with one bearing be located in an end cap
57 of the disk 46 and the second bearing being located in the end
plate 53. Thus the shaft is carried on the axis 47 and can rotate
around the axis 47 driven by a motor 58.
[0117] The inner rotor 55 carries a feed drum 59 which is located
axially aligned with the inside surface of the casing 41 so that
the feed drum acts to carry the feed material along the inside
surface of the casing 41 to the circular opening 45 in the disk 43
so that the material can be presented through that opening to the
dies.
[0118] The inner rotor 55 further includes a press wheel 60 carried
on a support 61. The press wheel 60 is mounted with a wheel axis 63
offset from the shaft 56 and the axis 47. Thus the axis of the
press wheel can be rotated around the axis 47 so that the wheel
rolls around the inside surfaces of the dies moving from each die
to the next as the shaft rotates. Support 61 is suitably designed
to carry the press wheel to apply onto the inside surfaces of the
dies a significant force providing compression of the material
within the dies.
[0119] The drum 59 has an outer surface 63 which is located at a
position spaced from the inside surface 42 of the outer casing 41.
This defines therefore an annular chamber between these two
surfaces. On the outside surface of the drum 59 is provided a
flight 64 which extends diagonally along the outside surface 63 so
as to form a helix defining an auger which rotates around the axis
47 and thus acts to carry material axially along the outside
surface 63 of the drum toward the end 66 of the drum at the press
wheel 60. It will be appreciated that the end 66 is located at the
opening 45 in the disk 43 so that the action of the flight 64 is to
carry the material into the area between the two disks and through
the opening 45 to feed into the compression zone defined between
the inside surfaces of the dies and the press wheel.
[0120] The dies 50 are held in place in an annular array
surrounding the compression zone with each die extending radially
outwardly from the axis 47. In practice the dies are formed in two
halves so that each die piece has on each side one half of the
tubular opening forming the die. Thus when the pieces are clamped
together the two halves of the duct forming the die are closed.
[0121] Target moisture content for the materials supplied to the
cubers is of the order of 17%. However for operation to occur, the
moisture content can lie in the range 10% to 30%.
[0122] The materials selected for the container 23 are preferably
arranged to provide a moisture content of the order of 6% to
15%.
[0123] Turning now to FIG. 5, the material described above is used
on the ground as a soil remediation or seeding process.
[0124] Thus the extruded and broken flakes 13 are supplied in a
supply 13A into a mixer 14 which merely tumbles or mixes the flakes
with seeds from a supply 15 and fertilizer from a supply 16.
[0125] In some cases, the seeds can be omitted and the ground
seeded as a separate process from application of the mulch.
[0126] In some cases the fertilizer can be omitted and applied as a
separate process.
[0127] In some cases the seeds and fertilizer are omitted where
only a ground cover is required without cultivation of plants over
the ground.
[0128] The mixed material is typically supplied to a bagger 16 or
other packaging system which allows the material when mixed to be
transported in a convenient manner.
[0129] For dry application of the material, the bags are supplied
to a dry applicator 17 such as a conventional fertilizer spreader
where they are applied to the ground as a dry layer of a required
rate on the ground. This acts to apply the mixed material onto the
ground as a layer which forms a mat containing the admixed
materials of the cellulose material, bio-char and optionally the
seeds and optionally the fertilizer.
[0130] For application of the material as a Hydromulch, the bags
are supplied from a supply feed 19 to a mixing tank 18 where they
are mixed with water from a supply 20. From the tank they are
supplied to a spreader 21 by a pump 22 where they are applied to
the ground 23 as a layer of a required rate on the ground. This
acts to apply the mixed material onto the ground as a layer which
forms a mat containing the admixed materials of the cellulose
material, bio-char and optionally the seeds and optionally the
fertilizer. The water will remain to some extent in the layer to
aid seed germination. Much of the water will drain into the soil
and acts merely as a carrier.
[0131] One particular advantage of the use of the bio-char in the
combination applied to the soil is that the porous bio-char is used
to contain or store fertilizer which is absorbed into the pores.
Thus the liquid fertilizer is bound into the pores where it is held
at the surface for the root structure to penetrate the pores and
extract the retained fertilizer. The bio-char held in the mat thus
acts to remediate the soil as previously described and also acts to
hold the fertilizer and make it more available to the plants. This
can reduce the amount of fertilizer required and wasted and of
course reduces fertilizer run off into adjacent areas.
[0132] The arrangement thus provides a method of treating soil
wherein the base material of cellulosic material is chopped to form
a mass of material into which particles of bio-char are intermixed
for application therewith and the admixed material is spread over
ground including the soil to be treated.
[0133] As shown at spreader 21 the admixed material can be spread
over the ground by spraying in a water carrier or as shown art 17
the admixed material is spread over the ground in a dry
condition.
[0134] To provide the best advantage, the bio-char material is
formed using methods which create the highest possible porosity.
This acts to hold the most amount of the fertilizer, to provide the
best filtration system and to allow the best penetration of the
root system into the particles.
[0135] Turning now to FIGS. 6 and 7, there is shown a method of
controlling soil erosion caused by water flow. Thus in FIG. 6, the
admixed material described above is contained in a container or
sock 25 formed by a surrounding permeable layer 26 to form a
tubular body 27 of the admixed material. The sock 25 is elongate
and is laid across a direction D of the water flow so that the
water flow passes through the body. Thus as shown for example in
FIG. 6, an inclined ditch or gulley with running water W has a
plurality of the socks 25 at spaced positions along the ditch with
each sock extending wholly or partly across the ditch to intercept
the running water. This acts as a flow and sediment control system
so that the water builds up behind each sock and the body of
material therein and then the material acts as a filter medium
requiring the water to pass through. This holds back the flow and
filters the flow to extract contaminants. Thus the bio-char acts to
filter the water of contaminants.
[0136] In FIG. 7 the admixed material is placed as a mat 30 on the
soil for example using the spreading systems of FIG. 5 so that the
water or liquid L passes through the mat and is filtered as
described above.
* * * * *