U.S. patent application number 15/493438 was filed with the patent office on 2017-08-24 for waste processing system with anaerobic mechanism and method of operation thereof.
This patent application is currently assigned to Biovessel Technologies Inc.. The applicant listed for this patent is Biovessel Technologies Inc.. Invention is credited to Jeff Brooks, Chaiyos Siripoke.
Application Number | 20170240443 15/493438 |
Document ID | / |
Family ID | 52142629 |
Filed Date | 2017-08-24 |
United States Patent
Application |
20170240443 |
Kind Code |
A1 |
Brooks; Jeff ; et
al. |
August 24, 2017 |
WASTE PROCESSING SYSTEM WITH ANAEROBIC MECHANISM AND METHOD OF
OPERATION THEREOF
Abstract
A waste processing system includes: an input module for
converting input organic waste into processed input waste; a
digester module, coupled to the input module, for generating biogas
and digester effluent from the processed input waste, including: a
digester tank; baffles affixed within the digester tank; a digester
process solution in the digester tank including, hydrolytic
bacteria, acidogenic bacteria, acetogenic bacteria, methanogenic
bacteria, or a combination thereof, for converting the processed
input waste into the biogas and the digester effluent; and an
output module, coupled to the digester module, for collecting the
biogas and digester effluent after a residence period.
Inventors: |
Brooks; Jeff; (Vancouver,
CA) ; Siripoke; Chaiyos; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Biovessel Technologies Inc. |
Vancouver |
|
CA |
|
|
Assignee: |
Biovessel Technologies Inc.
Vancouver
CA
|
Family ID: |
52142629 |
Appl. No.: |
15/493438 |
Filed: |
April 21, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14313936 |
Jun 24, 2014 |
9643867 |
|
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15493438 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y02E 50/30 20130101;
C02F 2305/06 20130101; C02F 3/006 20130101; Y02E 50/343 20130101;
C02F 2209/40 20130101; Y02W 10/20 20150501; C02F 2209/38 20130101;
C12M 27/20 20130101; C02F 3/284 20130101; C02F 3/301 20130101; C02F
3/2866 20130101; C02F 3/34 20130101; C02F 2209/03 20130101; C02F
2301/106 20130101; C12M 41/22 20130101; Y02W 10/23 20150501; C02F
2303/12 20130101; C12M 21/04 20130101; C02F 2209/005 20130101; C02F
3/348 20130101; C02F 2203/006 20130101; C02F 2103/20 20130101; C12M
45/02 20130101; C02F 2209/06 20130101; C02F 11/04 20130101; C02F
2209/42 20130101; C02F 2209/02 20130101 |
International
Class: |
C02F 3/00 20060101
C02F003/00; C02F 3/34 20060101 C02F003/34; C02F 3/28 20060101
C02F003/28; C02F 11/04 20060101 C02F011/04 |
Claims
1. An anaerobic waste processing system comprising: an input module
for converting input organic waste into processed input waste; a
digester module, coupled to the input module, for generating biogas
and digester effluent from the processed input waste, including: a
digester tank; baffles affixed within the digester tank; a digester
process solution in the digester tank including, hydrolytic
bacteria, acidogenic bacteria, acetogenic bacteria, methanogenic
bacteria, or a combination thereof, for converting the processed
input waste into the biogas and the digester effluent; an output
module, coupled to the digester module, for collecting the biogas
and digester effluent after a residence period comprising: a biogas
effluent collection module, and a digestate effluent collection
module.
2. The anaerobic waste processing system of claim 1 further
comprising: a temperature sensor for sensing the temperature inside
said tank; a pH sensor for sensing the pH inside said tank; a gas
pressure sensor for sensing the pressure of said biogas above a
surface of said digestate inside said tank; a level sensor for
sensing the level of digestate in said tank; and, an automated
control system for receiving inputs characterizing said
temperature, said pH, said pressure and said level and for
controlling operational parameters of said system.
3. The anaerobic waste processing system of claim 2 wherein said
control system is configured to evacuate biogas from said tank upon
detecting a predetermined pressure of biogas and for evacuating
digestate from said tank upon detecting a predetermined level of
said digestate.
4. The anaerobic waste processing system of claim 1 wherein said
input module comprises a weight scale for determining the weight of
said input organic waste, said weight scale providing an output to
an automated control system for controlling operational parameters
of said system.
5. The anaerobic waste processing system of claim 1 further
comprising a distillate fluid processing apparatus, coupled to the
output module, for processing the digester effluent with an
effluent enhancement solution to generate an enriched effective
microorganism solution, and further comprising a flow sensor for
sensing the flow of said distillate.
6. The anaerobic waste processing system of claim 2 further
comprising a heater within said tank, and wherein said automated
control system is configured to selectively actuate said heater to
maintain said temperature within a predetermined range and to
selectively cause the addition of acid or base to said digestate to
maintain said pH within a predetermined range.
7. The anaerobic waste processing system of claim 1 wherein said
input module comprises a grinder assembly for grinding the size of
the solids in the input organic waste to a particle size with a
diameter of about 0.25 inches to 0.75 inches.
8. The anaerobic waste processing system of claim 1 wherein the
baffles include a dynamically adjustable space for adjusting a flow
space of the baffles.
9. The anaerobic waste processing system of claim 1 further
comprising a plurality of agitators or mixers and wherein said
agitators or mixers are operable to agitate or mix at different
speeds in different areas of said digester module.
10. A method of controlling the operation of an anaerobic waste
processing system of claim 1 comprising the steps of: detecting
specific biogas constituents other than methane; and using said
detection as an input to a processor controlling the operation of
said system.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/838,546 filed Jun. 24, 2013, and the
subject matter thereof is incorporated herein by reference
thereto.
TECHNICAL FIELD
[0002] An embodiment of the present invention relates generally to
a waste processing system, and more particularly to a system for
anaerobic digestion of organic waste.
BACKGROUND
[0003] Organic waste material, such as municipal wastewater or
livestock manure, can present problems when generated on a large
scale. Organic waste material can be a health risk and a nuisance.
The disposal of Organic Food Resource Material is normally
collected from the point of generation, hauled to a landfill and
dumped without any further processing to harvest the resources
contained within the material. It is well documented that the
off-gas from this material in the forms of CO2, H25 and CH4 has
significant and harmful effects upon the environment. All waste at
a landfill is processed with vehicles that utilize some form of
fuel adding to the carbon footprint when processing. Traditional
composting is not always feasible due to the commercial locations
or sea faring vessels. Composting has been initiated at numerous
landfill facilities. It is a lengthy process requiring a strict
protocol to maintain the proper decomposition parameters without
odors and requires energy intensive specialized motor vehicles and
machines to maintain the process. Additionally, removal of off
gassing of CO2, H2S and CH4 can also poses a problem. Climate and
location can provide challenges, particularly in climates of
extreme cold and heat. With many large-scale generators of
significant quantities of food waste, on-site location for
processing the OFRM is required. Additionally, vermin and scavenger
animals and other obstacles can become an immediate problem
associated with compost storage.
[0004] Decomposing organic waste can also release greenhouse gases,
such as methane and carbon dioxide, as well as hydrogen sulfide
which is the odorous smell associated with rotting garbage and thus
can lead to a source of air and water pollution. Strategies for
dealing with organic waste in large quantities are therefore
needed. Organic waste material can be converted into useful
products or can have useful products extracted from it. This
conversion can be done within waste conversion facilities, such as,
for example, an anaerobic bio-digester. Anaerobic bio-digesters
generally process the organic material by treatment with organisms,
which can be obligate or facultative anaerobic bacteria. These
organisms can, using biochemical reactions, convert organic
material into a variety of products. Among these products are a
mixture of gases, generally referred to as biogas, and a mixture of
liquids and solids, generally referred to as biodigestate.
[0005] Biogas can include methane, carbon dioxide, and amounts of
other gases. Biogas can be burned to provide electricity locally,
and can also be transferred to utility companies or transmission
networks as natural gas. However, biogas from an anaerobic
bio-digester can contain impurities that must be removed before
transmission to utility companies. These impurities, which can
include carbon dioxide and hydrogen sulfide can be harmful to the
environment and are generally disposed of as waste products.
[0006] Concerns about overuse of fossil fuels, based in part on
environmental concerns and their substantially non-renewable
nature, have generated interest in biological sources of energy.
Biological energy sources can be desirable because the processes
used to produce or extract them are generally less damaging to the
environment. Biological energy sources can also be renewable
because they are generally derived from plant and/or animal
material.
[0007] Bio-production facilities can use biological organisms and
processes to generate useful products, including biological energy
sources, from raw materials. Examples of such bio-production
facilities include ethanol plants and bio-diesel plants, where
organisms, such as yeasts or algae use biochemical processes to
generate from a feedstock, products that can be useful, such as
ethanol or triglycerides, respectively.
[0008] However, one common problem of stand-alone waste conversion
facilities and bio-production facilities is that they use products
that must be acquired from external sources. These products include
feedstock for the bio-production facilities, and organic material
for waste conversion facilities. Importing products from external
sources can cause loss of efficiency and can incur significant
expenses on the operation of these facilities.
[0009] Anaerobic digestion of biological waste to produce biofuels
is a growing area of interest as concerns about greenhouse gas
emissions grow and the use of, and demand for, alternative and
renewable energy sources increases. This form of digestion is the
process in which an environment free of oxygen allows certain
microorganisms to flourish, consuming biological solids and
creating biogas that contains a considerable amount of methane. If
not collected, the bio-gas enters the atmosphere as a greenhouse
gas with a much stronger greenhouse effect than carbon dioxide. If
captured, the biogas can be used to generate heat and/or
electricity and/or can be used to eliminate solid wastes. There are
a number of limitations in the current implementations of the
anaerobic digestion technology. In particular, anaerobic digestion
is sensitive to temperature, and if the temperature of the
biological solids is too low, then the digestion process will
either slow or even halt completely. Slower digestion times require
longer retention times that lead to higher costs due to increased
digestion tank size. Many anaerobic digestion systems utilize much
of the energy produced by the system in the form of heat just to
maintain digester temperature and digester function. These
temperature requirements normally limit the areas where anaerobic
digestion is feasible to a warmer, more temperature stable
environment.
[0010] In view of the foregoing, it would be desirable to provide a
system that reduces the need to dispose of by-products and waste
products generated in waste conversion facilities, bioproduction
facilities, and other facilities. Accordingly, there is a need for
alternatives to the traditional compositing methods to address
these issues. Solutions to these problems have been long sought but
prior developments have not taught or suggested any solutions and,
thus, solutions to these problems have long eluded those skilled in
the art.
SUMMARY
[0011] An embodiment of the present invention provides a system,
including: an input module for converting input organic waste into
processed input waste; a digester module, coupled to the input
module, for generating biogas and digestate effluent from the
processed input waste, including: a digester tank; baffles affixed
within the digester tank; a digester process solution in the
digester tank including, hydrolytic bacteria, acidogenic bacteria,
acetogenic bacteria, methanogenic bacteria, or a combination
thereof, for converting the processed input waste into the biogas
and the digestate effluent; and an output module, coupled to the
digester module, for collecting the biogas and digester effluent
after a residence time.
[0012] An embodiment of the present invention provides a system,
including: an input module for converting input organic waste into
processed input waste; a digester module, coupled to the input
module, for generating biogas and digestate effluent from the
processed input waste, including: a digester tank; baffles affixed
within the digester tank; a digester process solution in the
digester tank including, hydrolytic bacteria, acidogenic bacteria,
acetogenic bacteria, methanogenic bacteria, or a combination
thereof, for converting the processed input waste into the biogas
and the digestate effluent; an output module, coupled to the
digester module, for collecting the biogas and digester effluent
after a residence time; and an distillate fluid processing
apparatus, coupled to the output module, for processing the
digester effluent with an effluent enhancement solution to generate
an enriched effective microorganism solution
[0013] An embodiment of the present invention provides a method
including: processing input organic waste to generate processed
input waste; combining the processed input waste with a digester
process solution in a digester module to generate biogas and fluid
digestate, the digester process solution includes hydrolytic
bacteria, acidogenic bacteria, acetogenic bacteria, methanogenic
bacteria, or a combination thereof; collecting the biogas; and
generating digester effluent at a solids content of about 10% from
the fluid digestate based on a residence period.
[0014] Certain embodiments of the invention have other steps or
elements in addition to or in place of those mentioned above. The
steps or elements will become apparent to those skilled in the art
from a reading of the following detailed description when taken
with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic representation of an apparatus of A
Biovessel bio-digester.
[0016] FIGS. 2A and 2B are schematic representations of the input
module.
[0017] FIG. 3 is a schematic representation of a portion of the
input module.
[0018] FIG. 4 is an embodiment of the input module.
[0019] FIGS. 5A and 5B are further embodiments of the input
module.
[0020] FIGS. 6A and 6B are embodiments of the grinding
assembly.
[0021] FIG. 7 is a schematic representation of one embodiment of
the digester module.
[0022] FIG. 8 is a schematic representation of the output
module.
[0023] FIG. 9 is a schematic representation of an embodiment of the
distillate fluid processing apparatus.
[0024] FIG. 10 is a schematic view of an embodiment of the biogas
processing apparatus.
DETAILED DESCRIPTION
[0025] The present invention generally relates to systems, method
and apparatus, for complete conversion of organic waste to energy
or other useful biofuels. One aspect relates to an apparatus for
complete digestion of organic waste to renewable energy, the
apparatus herein referred to as a "BioVessel" which converts
biodegradable material into a biogas for a renewable energy source
and/or a fluid digestate which can be utilized as a fertilizer,
soil amendment or conditioner or for other uses, for example,
converted to a high quality micronutrient or Effective
Microorganism. The BioVessel bio-digester as disclosed herein
comprises three modular sections, including an input module, a
digester module and an output module.
[0026] The following embodiments are described in sufficient detail
to enable those skilled in the art to make and use the invention.
It is to be understood that other embodiments would be evident
based on the present disclosure, and that system, process, or
mechanical changes may be made without departing from the scope of
an embodiment of the present invention.
[0027] In the following description, numerous specific details are
given to provide a thorough understanding of the invention.
However, it will be apparent that the invention may be practiced
without these specific details. In order to avoid obscuring an
embodiment of the present invention, some well-known circuits,
system configurations, and process steps are not disclosed in
detail.
[0028] The drawings showing embodiments of the system are
semi-diagrammatic, and not to scale and, particularly, some of the
dimensions are for the clarity of presentation and are shown
exaggerated in the drawing figures. Similarly, although the views
in the drawings for case of description generally show similar
orientations, this depiction in the figures is arbitrary for the
most part. Generally, the invention can be operated in any
orientation. The embodiments have been numbered first embodiment,
second embodiment, etc. as a matter of descriptive convenience and
are not intended to have any other significance or provide
limitations for an embodiment of the present invention.
[0029] For convenience, certain terms employed in the entire
application are collected here. Unless defined otherwise, all
technical and scientific terms used herein have the same meaning as
commonly understood by one of ordinary skill in the art to which
this invention belongs.
[0030] The terms "lower", "reduced", "reduction" or "decrease" or
"inhibit" are all used herein generally to mean a decrease by a
statistically significant amount. However, for avoidance of doubt,
"lower", "reduced", "reduction" or "decrease" or "inhibit" means a
decrease by at least 10% as compared to a reference level, for
example a decrease by at least about 20%, or at least about 30%, or
at least about 40%, or at least about 50%, or at least about 60%,
or at least about 70%, or at least about 80%, or at least about 90%
or up to and including a 100% decrease, or any decrease between
10-100% as compared to a reference level.
[0031] The terms "increased", "increase" or "enhance" or "higher"
are all used herein to generally mean an increase by a statically
significant amount; for the avoidance of any doubt, the terms
"increased", "increase" or "enhance" or "higher" means an increase
of at least 10% as compared to a reference level, for example an
increase of at least about 20%, or at least about 30%, or at least
about 40%, or at least about 50%, or at least about 60%, or at
least about 70%, or at least about 80%, or at least about 90% or up
to and including a 100% increase or any increase between 10-100% as
compared to a reference level, or at least about a 2-fold, or at
least about a 3-fold, or at least about a 4-fold, or at least about
a 5-fold or at least about a 10-fold increase, or any increase
between 2-fold and 10-fold or greater as compared to a reference
level.
[0032] The term "substantially pure", with respect to a biogas,
refers to a biogas that is at least about 75%, preferably at least
about 85%, more preferably at least about 90%, and most preferably
at least about 95% pure, with respect to gas molecules making up
the biogas. Recast, the terms "substantially pure" or "essentially
purified", with regard to a biogas, refers to a biogas that contain
fewer than about 20%, more preferably fewer than about 15%, 10%,
8%, 7%, most preferably fewer than about 5%, 4%, 3%, 2%, 1%, or
less than 1%, of molecules which are not of the desired biogas.
[0033] The term "computer" can refer to any non-human apparatus
that is capable of accepting a structured input, processing the
structured input according to prescribed rules, and producing
results of the processing as output. Examples of a computer
include: a computer; a general purpose computer; a supercomputer; a
mainframe; a super mini-computer; a mini-computer; a workstation; a
micro-computer; a server; an interactive television; a hybrid
combination of a computer and an interactive television; and
application-specific hardware to emulate a computer and/or
software. A computer can have a single processor or multiple
processors, which can operate in parallel and/or not in parallel. A
computer also refers to two or more computers connected together
via a network for transmitting or receiving information between the
computers. An example of such a computer includes a distributed
computer system for processing information via computers linked by
a network.
[0034] The term "computer-readable medium" may refer to any storage
device used for storing data accessible by a computer, as well as
any other means for providing access to data by a computer.
Examples of a storage-device-type computer-readable medium include:
a magnetic hard disk; a floppy disk; an optical disk, such as a
CD-ROM and a DVD; a magnetic tape; a memory chip.
[0035] The term "software" is used interchangeably herein with
"program" and refers to prescribed rules to operate a computer.
Examples of software include: software; code segments;
instructions; computer programs; and programmed logic.
[0036] The term a "computer system" may refer to a system having a
computer, where the computer comprises a computer-readable medium
embodying software to operate the computer.
[0037] As used herein the term "comprising" or "comprises" is used
in reference to compositions, methods, and respective component(s)
thereof, that are essential to the invention, yet open to the
inclusion of unspecified elements, whether essential or not. By way
of further example, a composition that comprises elements A and B
also encompasses a composition consisting of A, B and C. The terms
"comprising" means "including principally, but not necessary
solely". Furthermore, variation of the word "comprising", such as
"comprise" and "comprises", have correspondingly varied meanings.
The term "consisting essentially" means "including principally, but
not necessary solely at least one", and as such, is intended to
mean a "selection of one or more, and in any combination." In the
context of the specification, the term "comprising" means
"including principally, but not necessary solely". Furthermore,
variation of the word "comprising", such as "comprise" and
"comprises", have correspondingly varied meanings.
[0038] As used herein the term "consisting essentially of" refers
to those elements required for a given embodiment. The term permits
the presence of additional elements that do not materially affect
the basic and novel or functional characteristic(s) of that
embodiment of the invention.
[0039] The term "consisting of" refers to compositions, methods,
and respective components thereof as described herein, which are
exclusive of any element not recited in that description of the
embodiment.
[0040] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural references
unless the context clearly dictates otherwise. Thus for example,
references to "the method" includes one or more methods, and/or
steps of the type described herein and/or which will become
apparent to those persons skilled in the art upon reading this
disclosure and so forth.
[0041] Other than in the operating examples, or where otherwise
indicated, all numbers expressing quantities of ingredients or
reaction conditions used herein should be understood as modified in
all instances by the term "about." The term "about" when used in
connection with percentages can mean.+-.1%. The present invention
is further explained in detail by the following, including the
Examples, but the scope of the invention should not be limited
thereto.
[0042] It is understood that the foregoing detailed description and
the following examples arc illustrative only and arc not to be
taken as limitations upon the scope of the invention. Various
changes and modifications to the disclosed embodiments, which will
be apparent to those of skill in the art, may be made without
departing from the spirit and scope of the present invention.
Further, all patents, patent applications, and publications
identified are expressly incorporated herein by reference for the
purpose of describing and disclosing, for example, the
methodologies described in such publications that might be used in
connection with the present invention. These publications are
provided solely for their disclosure prior to the filing date of
the present application. Nothing in this regard should be construed
as an admission that the inventors are not entitled to antedate
such disclosure by virtue of prior invention or for any other
reason. All statements as to the date or representation as to the
contents of these documents are based on the information available
to the applicants and do not constitute any admission as to the
correctness of the dates or contents of these documents.
[0043] This invention is further illustrated by the following
examples which should not be construed as limiting. The contents of
all references cited throughout this application, as well as the
figures and tables are incorporated herein by reference.
[0044] It should be understood that this invention is not limited
to the particular methodology, protocols, and reagents, etc.,
described herein and as such can vary. The terminology used herein
is for the purpose of describing particular embodiments only, and
is not intended to limit the scope of the present invention, which
is defined solely by the claims.
[0045] Referring now to FIG. 1, therein is shown a schematic
representation of an apparatus of A Biovessel bio-digester 10. The
Biovessel 10 can include three modular sections for anaerobic
digestion of input organic waste 21, such as Organic Food Resource
Material, an input module 20, Digester module 30, and an output
module 50. It is understood that "Organic Food Resource Material"
can be used interchangeably with the input organic waste 21 unless
otherwise specified below.
[0046] The Biovessel 10 can be a complete standalone anaerobic
digester system. The Biovessel 10 can include a number of features,
which are briefly mentioned herein and discussed in greater detail
below. As an example, the Biovessel 10 can include a firewalled
enclosure and electronic thermal controls to maintain consistent
temperature in all climates. In some embodiments, the Biovessel 10
can be wrapped in steel cladding allowing for indoor and outdoor
installations.
[0047] In some embodiments, the Biovessel 10 can utilize an array
of sensors to monitor all processes throughout the machine. For
example, the types of data collected range from the input organic
waste 21, output of biogas to the health of the microbes inside the
digester module 30. Data is recorded and processed by an onboard
CPU and made available for secure download via Ethernet or
WiFi.
[0048] As described in greater detail below, the present invention
is tailored to comprise a specific microbiom. The BioVessel 10 is
an alternative to traditional composting and addresses problems
such as need to remove waste byproducts from the composting, e.g.,
gasses such as CO2 and H4S as well as the end digested product.
While similar appearing technologies have been developed to meet
the problems of organic food wastes, these systems, unlike the
BioVessel 10 technology as disclosed herein, do not close the loop
completely and do not extract the maximal amount of value from the
OFRM.
[0049] For example, other systems or digesters discard the effluent
down the sewer line which can lead to pollution and/or are dealt
with by the municipalities, while other systems and digesters
require additional time for the composing of the OFRM. In some
cases, other available systems and digesters use the semi-processed
effluent material as a soil amendment, which poses a hazard of mold
growth. Accordingly, none of the current systems or digesters are
able to capture the gas for cleaning and utilization as a clean
fuel source.
[0050] In contrast, the BioVessel 10 as disclosed herein digests
the OFRM into useful biogases, e.g., methane, a solid and a fluid
digestate liquid, which are used as beneficial and marketable soil
products. Accordingly, the present bio-digester as disclosed herein
provides a significant advantage over other bio-digesters in that
it extracts all the value from the OFRM and closes the loop, and
does not result in any unusable waste.
[0051] Additionally, the advantages of the BioVessel 10 system and
processes as disclosed herein are not limited to energy output of
the system. The system provides a significant reduction of volume
in the waste solids thereby reducing the costs associated with
disposal and/or distribution. For example, the biogas, e.g.,
methane produced from the anaerobic digestion of the OFRM using the
systems, methods and devices as disclosed herein can be readily
compressed to produce an enriched compressed natural gas having 95%
less emissions per Gallon Gasoline Equivalent than diesel fuel or
alternatively can be sold to a gas pipeline utility or for use in
the transportation industry or other uses. The digester effluent
produced from the anaerobic digestion of the OFRM using the
systems, methods and devices as disclosed herein can be used as a
pathogen free digestate which can be utilized as a fertilizer, soil
amendment or conditioner or for other uses, for example, it can be
converted in proprietary manor to a high quality micronutrient or
Effective Microorganism. An additional advantage is that the
BioVessel 10 system as disclosed herein is a small unit, which can
be scaled appropriately to the space available, and does not
require the large space requirements of other digesters.
[0052] Alternatively, the biogases and/or fluid digestate created
by the BioVessel 10 system can be used in conjunction with an
electricity generator such as a fuel cell or internal combustion
engine, combustion turbine or the like connected to an electrical
generator to produce electricity that can be fed to the grid. The
flexibility of the output of the process of the present invention
allows the system to offset electricity and heating costs for the
digestion or other operations in the facility while simultaneously
producing a product as disclosed herein) which can be sold to
further offset costs and/or generate profit.
[0053] The BioVessel 10 system as disclosed herein are suitable for
use in any business, municipal or school campus with cafeterias,
food processing facilities of any size, supermarkets, restaurants,
hospitals, hotels, seasonal open-air markets, sporting events,
cruise ships or other ships, and anywhere there is an abundance of
organic food waste can effectively utilize the BioVessel 10 system
technology.
[0054] Accordingly, the BioVessel 10 system as disclosed herein
closes-the-loop of OFRM, in a quiet and efficient manner. It
eliminates odor and vermin problems, uses minimal power and water
and eliminates harmful greenhouse gases. The bio-digester of the
BioVessel 10 system as disclosed herein digests organic waste into
an energy source and delivers a pathogen free digestate that is
utilized as a fertilizer, soil amendment or conditioner.
Accordingly, the biodigester as disclosed herein eliminates the
need to process or dispose of the organic waste further by
closing-the-loop in the ideal and most healthful organic waste
management system available to date. All other fees associated with
dealing with the removal of the organic waste or the nuisance
involved with onsite storage of waste products and their removal
are therefore eliminated.
[0055] Further, the present invention relates to a device,
apparatus and method for a high-moisture fermentation process using
a microbial ecological selection signature process utilizing a
specific bacterial component comprising methanogenic bacteria
within the BioVessel 10 system that releases the nutritional and
energy elements of the OFRM.
[0056] Referring now to FIG. 2A and FIG. 2B, therein is shown
schematic representations of the input module 20. The input module
10 can include an auger 27 or a pump/injector 45 to deliver
processed input waste 23 to the digester module 30 of FIG. 1. The
processed input waste 23 is input waste, such as the OFRM of the
input organic waste 21, that has been processed to reduce the
particle size of the solid components, contaminants, impurities, or
a combination thereof in the input waste. The removal of
contaminants and impurities will from the input organic waste 21 to
generate the processed input waste 23 will be discussed in greater
detail below. The input module 20 allows input of the input organic
waste 21 from a waste collection container 22.
[0057] In some embodiments, the input module 20 can include a
pump/injector to transfer the ground organic waste to the input of
the AD tank. In alternative embodiments, the input assembly
comprises an auger to transfer the processed input waste 23 to the
input of the digester module 30. In some embodiments, the input
assembly further includes a grinder hopper which is coupled to the
grinder, and a means to lift the container to deposit the organic
waste in the container into the grinder hopper, wherein the grinder
hopper feeds the input organic waste 21 to the grinder. In some
embodiments, the input module 20 further comprises a scale to
measure the input of the organic waste from the container into the
grinder hopper. Each of the above embodiments will be discussed in
greater detail below.
[0058] Referring now to FIG. 3, therein is shown a schematic
representation of a portion of the input module 20. The input
module 20 can include a weight scale 24 to track and control the
daily input of the input organic waste 21 into the digester module
30. By tracking the input on a daily, monthly and annual basis, the
end user will know exactly how much waste has been diverted from
landfill. In some embodiments, the weight scale 24 measures nominal
pressure and is a measure of collection of daily input into the
digester module 30 by weight.
[0059] Reference is made to FIG. 4 showing an embodiment of the
input module 20. The input module can include a lifting mechanism
26, e.g., a motorized lift mechanism is configured to deliver or
transfer the input organic waste 21 of FIG. 1, including the OFRM,
from a container into the Delivery Hopper 28. Accordingly, the
motorized lift 26 provides the user with an effortless, hands free
loading system to deliver the OFRM into the Delivery Hopper 18. The
Delivery Hopper 28 funnels the waste continuously to the Grinder
Assembly 29.
[0060] Reference is made to FIGS. 5A and 5B showing further
embodiments of the input module 10. The embodiments of the input
module 10 can include a Delivery hopper 28 and Grinder Assembly 29,
where the outlet of the Delivery Hopper 28, which is connected to
the input of the Grinder Assembly 29, holds or store the input
organic waste 21 of FIG. 1, including the OFRM, before it enters
into the grinder 29. Once the OFRM enters the Hopper 28, it is
gravity fed towards a grinder 29, where the grinder 29 comprises
cutting or grinding blades. The grinder 29, similar to grinders
known in the art, is configured to reduce the size of the OFRM to
be digested by the anaerobic microorganisms in the digester module
30 of FIG. 1 to generate the processed input waste 23 of FIG.
2.
[0061] In some embodiments, the grinder 29 comprises cutting or
grinding blades to reduce the OFRM to a specific particle size for
efficient introduction into the digester module 30 and optimum
interaction with the anaerobic microbial organisms. By reducing the
size of OFRM, the hydrolysis process is optimized by providing more
surface area for the microbes to breakdown. In some embodiments,
the cutting or grinding blades are custom cutting blades. In some
embodiments, the cutting or grinding blades reduce the OFRM to
between a range of about 3/4 inch to about 1/4 inch. The grinder 29
can be configures to have a range of settings available to grind
the OFRM to an appropriate size depending on the incoming
material.
[0062] In some embodiments, the grinder 29 is an in-line macerator.
A macerator can breaks up the OFRM, particularly the
lignin-containing materials contained therein, so as to facilitate
digestion of the OFRM, and to prevent interference with subsequent
bio-digestion processes. A macerator encompassed for use in the
apparatus, systems and devices herein can be any commercially
available macerator. For example, a macerator may use
counter-rotating blades that can grind the OFRM. Macerating the
OFRM can also be advantageous because breaking up the
lignin-containing materials can promote anaerobic digestion of
these lignin-containing materials which, prior to maceration, are
substantially undigested. Maceration can thereby increase overall
biogas output. Such embodiments where the grinder assembly 29
comprises a macerator can be advantageous because the OFRM may
contain lignin-containing materials, which can interfere with
pumping and subsequent anaerobic bio-digestion processes.
[0063] In some embodiments, the Grinding Assembly 29 houses two
sets of grinding blades keyed on separate axles with controls to
regulate direction and speed. In some embodiments, the cutting or
grinding blades in the Grinding Assembly 29 arc chain-driven or
directly driven by motor. In some embodiments, the motor for
driving the grinding blades of the grinding assembly are user
controlled, where the operator switches on the motor controlling
the grinding assembly at each cycle of the introduction of the
OFRM.
[0064] The grinder Assembly 29 is designed with a built in safety
feature. For example, the safety features will only allow the
Grinding Assembly, as well as the cutting or grinding blades, to
turn on when the hopper door is completely closed.
[0065] As shown in FIG. 5A, in some embodiments, the grinding can
be a double stage grinding processes, where located below the
Grinding Assembly 29 is an inlet for a pump/injector 45, allowing
the processed input waste 23, including ground OFRM, from the
grinder 29 to be processed by the pump/injector 45 which is
configured to inject the ground OFRM into the input of the Digester
module 30. Any pump/injector 45 can be used to force the ground
OFRM from the grinder 29 into the inlet of the Digester module 30.
A pump/injector 45 encompassed for use herein include any
pump/injectors which are known by one of ordinary skill in the art,
such as for example, those frequently used in septic systems, which
can be configured to directly inject the ground OFRM from the
bottom of the grinder assembly into the Digester module 30 under
pumped pressure.
[0066] Referring now to FIGS. 6A and 6B, therein is shown
embodiments of the grinding assembly 29. As shown in FIG. 6A, the
pump/injector 45 to pump the processed input waste 23, including
processed or ground OFRM, from a collection area located below the
Grinder Assembly 29 to the digester module 30 of FIG. 1. In some
embodiments, an inlet of the pump/injector 45 located within the
collection area located below the Grinder Assembly 29 to pump the
ground OFRM through a pipe and to a pump/injector outlet which is
connected to the input of the digester module 30. Located along the
pipe is a tap 46 to control the flow of the ground OFRM from the
outlet of the pump/injector to the digester module 30. Using a
pump/injector 45 to directly feed the ground OFRM into the digester
module 30 provides the additional benefit of reducing the retention
and/or processing time of the ground OFRM in the digester module 30
due to increased surface area of the OFRM which the anaerobic
bacteria can digest.
[0067] An alternative implementation of the grinding assembly 29 is
shown in FIG. 6B. The grinding assembly 29 can be connected to an
Auger Assembly 27. In some embodiments, the processed input waste
23, including the processed or ground OFRM, from the Grinder
Assembly 29 drops to a collection area at the bottom of the
Grinding Assembly 29 where the proximal end of an Auger Assembly 27
is located. The auger 27, similar to other augers known in the art,
can be a closed or open auger, and is configured to convey the
ground OFRM from the proximal end to the distal end upon
appropriate rotation of the auger along its longitudinal axis,
where the distal end is elevated relative to the proximal end. In
some embodiments, the auger 27 can be at an angle, e.g., at least
about a 45.degree. angle, and in some embodiments, the auger 27 can
be vertical. As a result, ground OFRM is generally conveyed out of
the grinder assembly 29 and into the input of the tank hopper 25.
In some embodiments, the auger 27 works under pressure.
[0068] The auger assembly 27 raises ground OFRM from the outlet at
the bottom of the Grinder 29 Assembly to the top of the Auger
Assembly 27, where the output of the Auger Assembly is connected to
the inlet of the Tank Hopper 25. The OFRM exits the Auger assembly
27 from the outlet of the Auger Assembly 27 into the inlet of the
tank hopper and to drops into the Tank Hopper 25 by gravity. The
bottom of the tank hopper 25 is sloped to a tank hopper outlet
which delivers the ground OFRM to an inlet on the digester module
30 below the fluid level present of the digester module 30.
[0069] In some embodiments, the grinder assembly 29 is configured
to segregate the ground OFRM for additional grinding based on a
pre-determined minimum size. For example, segregation can be
performed by a segregator which segregated the ground OFRM from
large or hard particles. For example, a segregator can comprise a
suitably-sized sieve used to retain large or hard particles from
the OFRM of a given size while allowing smaller ground OFRM to pass
into the next stage of the digestion process, e.g., into the
digester module 30.
[0070] In other embodiments, segregation by size exclusion can
occur by subjecting the ground OFRM to size-limiting aperture or
entrance, such that only the smaller-sized or ground OFRM is able
to pass into the digester module 30. Larger, released hard
particulates of OFRM are not able to pass through, and thus can be
deflected or diverted from the OFRM to be digested to another
location, thereby segregating the particulates from the OFRM. In
some embodiments, ground OFRM can be impelled or otherwise urged
towards to the size exclusion structure so that the non-ground OFRM
can be re-ground with the grinder 29 or discarded. An exemplary
suitable device for such a segregation can use a sieve, or any
other structure having one or more size-excluding openings or gaps.
Such a structure may have openings that are sized to retain hard
particulates having a minimum mean diameter. A suitable mean
diameter of the retained particulates can be, for example, greater
than 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 4, 5, 8, or 10 centimeters. A
preferred mean diameter is about 0.5 centimeters. The desired gap
or opening size is also configured not to retain the disrupted
waste, thereby allowing the disrupted waste to be passed through
the size-excluding structure. Thus the separator may provide a
solution to reduce, if not minimize, any problems caused by
contaminants, such as non-ground OFRM or hard particles from the
OFRM. Contaminant can include, for example, bedding straw, rocks
and dirt from the ground, garbage, and other debris.
[0071] It is understood that some or all of the metal contaminants
may have already been removed from the OFRM during the segregation
step, as metal contaminants may share certain properties with hard
particulates that would permit their selection and segregation from
the disrupted waste. In some embodiments, a magnet may be used to
extract ferromagnetic metal contaminants. In some embodiments, the
magnet may guide or deflect the metal, so that the metal is
retained when the diluted waste is conveyed out or removed from
this step, thereby segregating them from the diluted waste.
[0072] In some embodiments, the bottom of the Tank Hopper 25
comprises an outlet through which the ground OFRM enters the inlet
of the digester module 30. In some embodiments, the Tank Hopper
outlet is configured to be connected to a trap, e.g., a U-, S- or
J-shaped pipe located below the outlet, such that there always
remains a small amount of fluid just after the outlet to create a
seal that prevents biogas from the digester module 30 from passing
back into the Tank Hopper 25 or the Injector/Grinder Assembly. In
some embodiments, the Tank Hopper outlet is connected to a p-trap,
which are known by persons of ordinary skill in the art, which
comprises an addition of a 90 degree fitting on the outlet side of
a U-bend, thereby creating a P-like shape, which are commonly used
in plumbing to prevent sewer gasses from backing up. The trap
connected to the Tank Hopper outlet is configured to preserve the
integrity of the anaerobic environment in the digester module
30.
[0073] In some embodiments, the input organic waste 21, including
the OFRM, can be diluted in the Tank Hopper 25 to a solid content
of about 5%, about 6%, about 7%, about 8%, about 9%, about 10%,
about 11%, 12% about 13%, about 15%, about 17%, about 20%, about
25%, about 50%, or any other suitable amount to generate the
processed input waste 23. In some embodiments, a solid content is
about 12% to 13%. The liquid diluent may be any suitable liquid,
such as water. In some embodiments, other liquids, such as complex
liquids derived from other processes may be used, or fed back, to
act as a diluent. Use of such complex liquids may act as a source
of supplemental components or co-substrates to be mixed with the
waste. For example, water or fluid digestate from digester assembly
30 can be used as the diluent, or the diluent may be composed in
part of the fluid biodigestate. In some embodiments, the addition
of the fluid biodigestate to the waste may enhance the subsequent
bio-digestion of the ORFM, and may also improve the mixing
characteristics of the waste.
[0074] Referring now to FIG. 7, therein is shown a schematic view
of one embodiment of the digester module 30. The single stage
anaerobic digester 30 can include a single tank, referred herein to
an digester tank 31, which enables anaerobic digestion of the
processed input waste 23 to biogas 70 and to a fluid digestate 72,
which can be removed as digester effluent 78 to be converted on
premises, or off premises to a high quality micronutrient or
Effective Microorganism fertilizer.
[0075] Accordingly, the present invention comprises a modular
system, wherein in some embodiments, the digester module 30
receives the processed input waste 23 from the input module 20, and
outputs biogas and fluid digestate to the output module 50, both of
FIG. 1.
[0076] In some embodiments, the digester module 30 outputs biogas
and fluid digestate to output assembly module 50, where the output
assembly can be located as part of the facility, e.g., an output
assembly can be located underneath, or as part of, the facility. In
some embodiments, where the output assembly is part of, or
integrated into, the facility, it permits the biogas and fluid
digestate to be utilizes by the facility as an energy source for
the normal operation of the facility.
[0077] In alternative embodiments, the input module 20, digester
module 30 and output module 50 are a self-contained system, such
the three modules can be installed as a single system at location
in a facility, and provided power and water are provided to the
system, the system can function independent of other modules at the
facility. In such embodiments, the biogas and fluid digestate can
also be utilized as an energy source by the facility for the normal
operation of the facility.
[0078] The digester module 30 can be configured to maintain the
temperature and pH at the desired conditions for digestion of the
processed input waste 23 by the anaerobic microorganisms, and can
include both agitator blades 34 and baffles 33, and heating units
32 for distribution of the processed input waste 23 at a constant
temperature and around the digester tank 31. The digester tank 31
can be thermally insulated by a thermal wall 35 for optimal low
cost temperature maintained. Both the biogas 70 and the fluid
digestate 72 is collected from the digester tank 31 and processed
accordingly, where the biogas 70 is filtered clean of contaminating
gasses to collect at least about 90% methane gas and the fluid
digestate 72 is collected and converted in proprietary manor to a
high quality micronutrient or Effective Microorganism (EM),
described in further detail below.
[0079] Accordingly, one aspect of the present invention relates to
a biodigester comprising an anaerobic digestion tank configured to
receive ground organic waste, the AD tank comprising: a floor,
walls and a ceiling; an inlet for receiving ground organic waste; a
plurality of heating units; a plurality of mixers dispersed
throughout the AD tank to mix the suspension of solid waste; a
plurality of baffles; at least one of or a combination of the
following: a plurality of pH sensors, a plurality of temperature
sensors, a plurality of pressure sensors, at least one level
sensor; at least one biogas outlet for removal of the biogas
produced in the AD tank; and at least one fluid digestate outlet
for removal of the fluid digestate produced in the AD tank. It is
understood that the term "AD tank" and the term "digester tank 31"
can be used interchangeably. For example, the Digester tank 31
comprises at least one or a combination of heating units 32,
baffles 33 and agitator blades 34 to optimize the anaerobic
digestion by a range of microbial organisms present within the
tank. As an example, two instances of the baffles 33 can be placed
in the digester tank 31 separate the interior of the digester tank
31 into three separate instances of a residence chamber 90.
[0080] In some embodiments, the exterior of the digester tank 31 is
surrounded by a thermal wall, e.g., a thermal wall that has an
insulation value of between R40 and R60, or about R55. In some
embodiments, a leak sensor is located between the exterior of the
digester tank 31 and the interior of the thermal wall.
[0081] In some embodiments, the heating units and/or pressure
sensors of the digester tank 31 are embedded within the floors
and/or walls of the interior of the digester tank 31. In some
embodiments the AD tank temperature sensors, heat units, pressure
sensors, leak sensors, agitator blades etc. of the digester tank 31
are connected to a control system which is connected to a computer,
the control system couples to the temperature sensors and heating
units to provide continuous regulated temperature to the digester
tank 31, which are described in greater detail below.
[0082] In some embodiments, the plurality of mixers in the digester
tank 31 are a plurality of agitator blades. In some embodiments,
the digester tank 31 further comprises a plurality of inlets to
inject one or more biological additives or a composition comprising
anaerobic microorganisms at desired locations in the digester tank
31, which are described in greater detail below.
[0083] In some embodiments, the biogas outlet of the AD tank is
located near the ceiling of the AD tank to collect biogas produced
in the AD tank. In some embodiments, the pressure sensors of the AD
tank are located in the top quarter of the AD tank, e.g., in some
embodiments, a pressure sensor is located in close proximity to the
biogas outlet.
[0084] In some embodiments, the floor of the AD tank is sloped
towards the fluid digestate outlet, and in some embodiments, the
floor of the AD tank further comprises a drain, which can be in
close proximity or adjacent to the fluid digestate outlet.
[0085] The Digester module 30 as disclosed herein can include a
single tank and utilizes a predefined range of microbial organisms
operating under mesophilic conditions for complete digestion of the
processed input waste 23 in a single stage or process. The
anaerobic digestion process occurs in the Digester tank 31 which is
located within a thermally insulated and sealed system, and
comprises; a single OFRM inlet which is connected to the outlet of
the tank hopper, an outlet for biogas and an outlet for fluid
digestate. The Digester module 30 comprises a single self-contained
Digester tank 31, where the AD tank inlet is connected to and
receives processed input waste 23 from the air/water outlet of the
Tank Hopper 25 of FIG. 2.
[0086] The heating units 32 can heat and maintain the fluid
digestate 72 to a desired digestion temperature. A variety of
different heater unit configurations can be used including, but not
limited to, a sleeve heater, an in-line heater or a heater provided
within the internal walls of the AD tank. In some embodiments, the
heater unit 32 may be integral or separate from the AD Tank. In
some embodiments, a heater unit 32 heats the fluid digestate 72 to
a temperature in the range from about 30.degree. C. to about
4.degree. C. In some embodiments, the heater unit 32 heats the
temperature to about 37.degree. C. In some embodiments, the heating
units are located at the bottom of the Digester tank 31, however,
they can be positioned elsewhere in the interior of the Digester
tank 31 such that they provide a constant heat source for the
function of the microbial organisms. In some embodiments, the
Digester tank 31 can include heating elements or the heating units
32 embedded within the floor, walls, and optionally ceiling. The
heating elements or units 32 may be designed to heat specific zones
or regions of the digester. A plurality of temperature sensors 36
may be dispersed throughout the Digester tank 31.
[0087] A control system connected to a computer may be coupled to
the temperature sensors 36 and the heating elements 32 to provide
continuous, regulated heating of the Digester tank 31. In some
embodiments, the heating units 32 enable constant temperature of
the interior of the Digester tank 31, and are controlled by a
feed-back mechanism based on temperature sensors 36 in the interior
of the AD tank to ensure that the Digester tank 31 is maintained at
a desired and/or constant temperature.
[0088] In some embodiments, the temperature of the heating units
are controlled by the input to the temperature sensors 36, which
measures the internal temperature of the AD tank and controls the
heat of the heating units 32 so that the temperature in the
internal of the AD tank maintains at a temperature of between about
92.degree. F. to 95.degree. F. In some non-limiting embodiments,
the temperature of the interior of Digester tank 31 is regulated to
a temperature in the range from about 90.degree. F. to 145.degree.
F. In other non-limiting embodiments, the temperature of the AD
tank is regulated to a temperature in the range from about
90.degree. F. to 110.degree. F. In still other non-limiting
embodiments, the temperature of the AD Tank is regulated to a
temperature in the range from about 120.degree. F. to 145.degree.
F. In some embodiments, due to the mesophilic nature of the
anaerobic microbes used in the digestion as disclosed herein, the
heating units are used to maintain a constant temperature of
35.degree. C. to 40.degree. C. A temperature sensor 36 is used to
monitor and maintain optimum temperature within the Digester tank
31. In some embodiments, the temperature sensors 36 decrease the
temperature of the heating units due to an increase in the internal
temperature of the AD tank due to heat derived from an exothermic
biological or chemical process of the digestion of the fluid
digestate 72.
[0089] In some embodiments, the Digester tank 31 comprises at least
one heat unit 32, or at least 2, or at least 3, or at least 4 or at
least 5 or more heating units. The heating units 32 can be
configured to be any conformation and size and can be configured to
completely cover at least one surface of the AD tank, or only
partially cover a surface of the AD tank. In some embodiments, the
Digester tank 31 is surrounded with a thermal wall 35 to maintain
the constant temperature of the interior of the Digester tank 31.
In some embodiments, the thermal wall 35 has an insulation value of
about R55, or an insulation value of between about R40 and R60.
[0090] In some embodiments, the Digester tank 31 comprises a
plurality of mixers dispersed throughout the AD Tank to mix the
suspension of the fluid digestate 72 and digested product. In some
embodiments, the mixers are agitator blades 34. In alternative
embodiments, non-limiting examples of mixers encompassed for use
include peristaltic hose pumps and variable speed mixers. In some
embodiments within the scope of the invention, the mixing is slow
near the inlet and progressively becomes faster near the outlet.
Thus, mixers disposed closest to the AD tank inlet may operate at a
slower speed than the mixers disposed closest to the AD tank
outlet.
[0091] The Digester tank 31 is configured to include elements to
mix the fluid digestate 72 within the AD tank. The mixing can take
place for a pre-determined amount of time, or until a desired
consistency of the fluid digestate 72, or continuously throughout
the anaerobic digestion process. In some embodiments, the mixing
can occur during the dilution of the fluid digestate 72 or addition
of the anaerobic bacteria and microorganisms to the fluid digestate
72 and/or during the addition of other chemical or biological
additives as disclosed herein. In some embodiments, the fluid
digestate 72 is mixed in the AD tank using agitator blades 34,
where the agitator blades rotate about the axis and thereby mix the
fluid digestate 72 in the Digester tank 31. In some embodiments, a
series of agitator blades 34 in the AD tank are located above the
heat source to mix and distribute the fluid and the fluid digestate
72 in the AD tank.
[0092] In some embodiments, the Digester tank 31 comprises at least
one agitator blade 34, comprising at least one blade, and in some
embodiments, the AD tank comprises at least 1, or at least 2, or at
least 3, or at least 4, or at least 5, or at least 6 or more
agitator blades, each comprising at least 1 blade. In some
embodiments, each agitator blade comprises at least 1, or at least
2 or at least 3 or more blades. Each agitator blade is connected to
an agitator blade motor 36, which is configured to rotate each
agitator blade 34 in Digester tank 31.
[0093] In some embodiments, the agitator blade motor 36 is located
external to the thermal wall 36 of the AD tank. The agitator blades
34 can rotate in the same direction or in opposite directions with
respect to each other. In some embodiments, the agitator blades 34
rotate at the same speed with respect to each other, and in some
embodiments, they rotate at different speeds with respect to each
other. In some embodiments, the agitator blades rotate at about
2-10 RPM, or about 2-4 RPM, or about 4-6 RPM, or about 6-8 RPM, or
about 8-10 RPM or in the range of about 10-20 RPM or faster than 20
RPM. In some embodiments, the agitator blades 34 rotate at about 6
RPM.
[0094] The digester module 30 can include baffles 33 affixed within
the digester tank 31. In some embodiments, to improve mixing of the
fluid digestate 72 in the AD tank, the AD tanks comprise a
plurality of deflecting plates or baffles 33 disposed within and/or
along the walls of the AD tank. In some embodiments, the deflecting
plates and/or baffles 33 have a surface that provide points of
attachment for the anaerobic bacteria and microorganisms. In some
embodiments, the AD tank comprises at least one baffle 33, where
the baffle 33 is configured to regulate the flow of a fluid in the
AD tank. In some embodiments, the baffle 33 includes at least one
baffle board or baffle plate. In some embodiments, a series of
baffles 33 in the AD tank are located between the agitator blades
to regulate and distribute the flow of the OFRM in the AD tank. In
some embodiments, the Digester tank 31 comprises at least one
baffle 33, comprising at least one baffle board, and in some
embodiments, the AD tank comprises at least 1, or at least 2, or at
least 3, or at least 4, or at least 5, or at least 6 or more
baffles, each comprising at least 1 baffle board. In some
embodiments, each baffle comprises at least 1, or at least 2 or at
least 3 or more baffle boards.
[0095] In some embodiments, the baffle 3 can be oriented
vertically, spanning from the top of the digester tank 31 to the
bottom 31 of the digester tank 31. For illustrative purposes, FIG.
7 depicts the digester tank 31 with the baffle 33 without a flow
space, which is a space between the top of the digester tank 31 to
the bottom 31 of the digester tank 31, although it is understood
that the baffle 33 can be configured within the digester tank 31
differently. For example, the baffle 33 can include the flow space
in the portion of adjacent the top or ceiling of the digester tank
31, the bottom or floor of the digester tank 31, or a combination
thereof. The flow space in the baffle 33 can allow the fluid
digestate 72 and solids to flow through the digester tank 31.
[0096] As a further example, the gap or space in the baffle 33 can
vary relatively from one instance of the baffle 33 to then next
instance of the baffle 33. As a specific example, the flow space in
the baffle 33 closest to the inlet of the digest tank 31 can be
greater than the flow space in the baffle 33 closest to the fluid
digestate outlet 44.
[0097] In yet a further example, the flow space in the baffle 33
can be dynamically adjusted. More specifically, mechanical means,
such as hydraulically actuated gates integrated with or attached to
the baffle 33 or along the walls, top, or bottom of the digester
tank 33 can adjust the dimensions of the flow space.
[0098] The AD tank may comprise a plurality of chemical inlets 41
to inject one or more chemical or biological additives at desired
locations within the AD tank. Non-limiting examples of such
additives include acids or bases for pH control, microbial
inoculum, nutrients to support microbial growth, defoaming and/or
antifoaming agents, water, and so forth. Some non-limiting examples
of nutrients which support microbial growth include free amino acid
nitrogen, surfactants, metals cations such as calcium, zinc,
copper, and so forth. Certain metal cations may also be added to
facilitate enzyme activity and to provide "food", along with the
amino acids, for microbial growth. In some embodiments, an additive
is a carbon-rich waste product, or a nitrogen-rich waste product,
or one or more enzymes to increase digestion of poorly-digestible
components, such enzymes including but are not limited to,
cellulase, hemicellulase, and lipase, proteinases, liginases,
laccases, ureases. In some embodiments, the chemical inlets may be
configured as a liquid spray system disposed at the ceiling.
[0099] The apparatus for the AD tank within the scope of the
present invention may include other features to improve the yield,
efficiency, and performance of the AD tank to digest the fluid
digestate 72. As disclosed herein, the AD Tank comprises a
combination of sensors for monitoring and control of the AD
process. In some embodiments, the AD tank comprises a range of
sensors, including for example, at least one pH sensor 37, at least
one gas leak sensor 38, at least one level sensor 39, at least one
temperature sensor 36, at least one biogas pressure sensor 40.
[0100] The temperature sensor 36 measures the internal temperature
of the AD tank and maintains the temperature to between 92.degree.
F. to 95.degree. F. The pH sensor 37 monitors the pH in the
interior of the AD tank, in particular the fluid being digested,
and maintains a pH level of 6-7. The level sensors 39 detect the
level of the fluid digestate 72 in the AD tank and once the
material reaches the level sensor, a pump 53 and gate valve is
activated and the fluid digestate evacuated to the reservoir tank
51 for a predetermined time period. The pressure sensor 40 measures
the pressure of the biogas 70 in the AD tank, and once the level of
gas reaches to about 3 PSI, the gas compressor 59 is activated and
the biogas is evacuated via the biogas outlet 42 to the biogas line
43 for a predetermined time period. The gas leak detector 38,
detects abnormally high levels of gases outside the Digester tank
31 and between the thermal wall 35 or immediately surrounding the
thermal wall 35 of the AD tank assembly 30.
[0101] Accordingly, various gas, temperature, pH, fluid levels,
pressure and flow sensors arc attached in numerous strategic places
in the Digester tank 31 and other regions of the BioVessel 10
system as disclosed herein to gather continual data and regulate
processes. Systems and methods for gathering and aggregating data
about the process interact with all processes of this
invention.
[0102] In some embodiments, the plurality of pH sensors in the
digester tank 31 are coupled to a control system, wherein the
control system is connected to a computer, the pH sensors detecting
the pH of the suspension of organic waste in the digester tank 31.
In some embodiments, the pH sensors maintain the pH of the organic
waste or the processed input waste 23 being converted to the fluid
digestate 72 in the digester tank 31 to between pH of 6-7.
[0103] In some embodiments, a plurality of chemical inlets 41 are
preferably coupled to the control system and introduce acid or base
to the suspension of organic waste to control the pH based upon pH
measurements from the pH sensors. In a typical AD tank digestion
process, the pH is preferably maintained in the range from about pH
5 to pH 9. In some embodiments, a pH sensor is used to maintain the
optimum pH level of 6.5 to 7. The actual pH may vary depending upon
the source of waste solid and the type of OFRM. As an example,
animal waste digestion may operate at a pH range from about 7.1 to
7.6, for corn ethanol solids, the pH may range around 5.2, and for
cane solids the pH may range around 6 or slightly higher. An
important benefit of this pH control system is the ability to
monitor and control pH within various regions of the AD tank in
real time. Prior art pH control techniques require days and
sometimes weeks to control pH conditions within the AD tank.
[0104] Other sensors may be dispersed throughout the AD tank as
needed and coupled to the control system to monitor the AD tank
operation and make appropriate changes to AD tank operation, such
as addition of appropriate chemical or biological additives,
including increased addition of a range of different anaerobic
microorganisms as disclosed herein.
[0105] The size of the Digester tank 31 is crucial to insure
complete digestion of the fluid digestate 72. The daily input
capacity is directly correlated to the size of the Digester tank
31. The ratio of AD tank size to daily input is 30:1. Inside the
Digester tank 31, fluid digestate 72 is acted upon by a microbial
signature, without manure or fecal matter, which creates biogas and
promotes microbial degradation of the fluid digestate 72 into the
digester effluent 78 and the biogas 70.
[0106] Accordingly, the Digester tank 31 as disclosed herein allows
for scalability of daily inputs from a range of about 100 lbs. to
about 10000 lbs. In some embodiments, the volume of input into the
AD tank is between about 100-200 lb, or about 200-300 lb, or about
300-500 lb, or about 500-750 lb, or about 750-1000 lb, or about
1000-2000 lb, or about 2000-3000 lb, or about 3000-4000 lb, or
about 4000-5000 lb, or about 5000-6000 lb, or about 6000-7000 lb,
or about 70008000 lb or about 8000-9000 lb, or about 9000-10000 lb
or more than about 10000 lb. Additionally, the type of the
processed input waste 23 into the Digester tank 31 can also range
from 5% to 100% moisture content while maintaining peak methane
production capabilities. In some embodiments, optimized feedstock
for the machine consists of food scraps known as Organic Food
Resource Material. In some embodiments, the interior of the AD tank
is sized to provide adequate anaerobic digestion and time of the
OFRM. The Digester tank 31 may have a volume equivalent selected to
provide a retention time in a range of about approx. 8 hours to
about 48 hours based on the flow rate of the ground OFRM into the
Digester tank 31.
[0107] In some embodiments, the Digester tank 31 comprises a
plurality of pressure sensors 40 located in the upper fourth, or
near the top of the AD tank. These pressure sensors 40 can be
located on the sides of the interior of the AD tank and/or on the
ceiling of the Digester tank 31. As biogas is produced from the
digestion of the OFRM continuously flows upward within the Digester
tank 31, once the pressure builds to a desired and pre-defined set
point, a pressure sensor 40 triggers the opening of a biogas outlet
42 located at, or near the top of the Digester tank 31 to efflux
the biogas to an inlet of a biogas line 43 which is connected to
the output assembly 50 to deliver the biogas to the output assembly
50 for filtration. In some embodiments, the biogas line 43
comprises at least one gas flow sensor and/or gas analyzer to
measure the flow and quality of the effluxed biogas from the AD
tank for levels of a variety of gasses, including but not limited
to, CH4, H2S, CO2 and 02. The data collected is sent to the on
board CPU for processing.
[0108] The digestate fluid can be removed from the Digester tank 31
to the output assembly by a number of ways. In some embodiments,
the Digester tank 31 also comprises a digestate fluid outlet 44. In
some embodiments, the digestate fluid outlet 44 is located in the
floor of the AD tank to drain the digestate fluid from the Digester
tank 31. In some embodiments, the floor of the AD tank is
preferably sloped towards the digestate fluid outlet 44 to
facilitate drainage out of the digestate fluid outlet 44. The slope
may be from 1% to 2%, front to back along the entire AD tank floor,
or to the middle of the floor of the AD tank. In some embodiments,
the digestate fluid outlet 44 is connected to a reservoir storage
tank 51 in the output assembly 50 for storage of the digestate
fluid. The digestate is conveyed to the reservoir storage tank 51
by any device which is configured or suitable for conveying
liquidified or semi-solid material. In some embodiments, the fluid
digestate is conveyed through pipes using a passive conveyance or
by active conveyance, or any suitable combination thereof In some
embodiments, the fluid digestate is conveyed to the reservoir
storage tank 51 using a pump 53.
[0109] In some embodiments, floor of the Digester tank 31 also
comprises a drain located adjacent or next to the fluid digestate
outlet 44, where the drain is coupled with the ability to a
drainage system, where the AD tank has the ability to introduce
clean water into the AD tank, thus enabling the entire AD tank to
be flushed and drained. A suitable valve plugs the drain when not
in use. In some embodiments, clean water can be flushed through the
AD tank using a spray system, all water directed to the areas in
the Digester tank 31 that require cleaning and flushing. This is
important in circumstances where the entire content of the AD tank
needs to be flushed and replaced. In some embodiments, the AD tank
can be cleaned out in less than 12 hours, beginning to end. This is
a huge advantage than removing the top of the AD tank to clean. If
the digester is providing either electricity or has, the entire
down time can be limited to 24 hours and therefore saves money from
penalties for down time due to cleaning due to non-production of
gas or electricity.
[0110] In some embodiments, the fluid digestate 72 can be removed
from the Digester tank 31 continuously, which can reduce down time,
and in some embodiments the fluid digestate 72 is removed from the
AD tank in batched after a pre-defined period of anaerobic
digestion in the Digester tank 31, which can allow for more
thorough digestion and/or complete mixing of the processed input
waste 23.
[0111] The digester unit 30 can include a digester process solution
74. The digester process solution 74 can be mixed or combine with
the processed input waste 23 in the digester tank 31. The digester
process solution 74 is a specific bacterial component that includes
a combination of at least one species each of a hydrolytic
bacteria, acidogenic bacteria, acetogenic bacteria, methanogenic
bacteria, or a combination thereof. The digester process solution
74 can be introduced to the digester tank 31 to releases the
nutritional and energy elements of the processed input waste
23.
[0112] The Digester tank 31 may be seeded with the microorganisms,
or the microorganisms may be carried into the Digester tank 31 as a
component of the processed input waste 23. The microorganisms
convert solids in the processed input waste 23 into, among other
things, the biogas 70 and the fluid digestate 72 which is collected
and removed from the Digester tank 31.
[0113] Although a preferred embodiment of the present invention
utilizes anaerobic digestion in the digester tank 31 and it will be
described in this context, it is also applicable to aerobic
digestion or a combination in sequence of aerobic and anaerobic
digestion. In some embodiments, the digester tank 31 can include a
solution with numerous psychrophilic, mesophilic and thermophilic
bacteria families of the Archaea general, which are useful in
anaerobic digestion.
[0114] In some embodiments, an anaerobic microorganism encompassed
for use in the present invention is a fermentative bacteria in the
processing of thermophilic waste sludge is the
Thermoanaerobacterium genus. An example is the species aotearoense
of the Clostridia class. For aerobic digestion major bacterial
groups in the beginning of the composting process are mesophilic
organic acid producing bacteria such as Lactobacillus spp. and
Acetobacter spp. Later, at the thermophilic stage, Gram-positive
bacteria such as Bacillus spp. and Actinobacteria, become dominant.
The processed input waste 23 and other feedstock commonly contains
biological solids that are both digested through anaerobic and
aerobic digestion as well as solids that require extensive
treatment and retention times or even cannot be successfully
processed.
[0115] Methanogenesis or biomethanation is the formation of methane
by microbes known as methanogens. Organisms capable of producing
methane have been identified only from the domain Archaea, a group
phylogenetically distinct from both eukaryotes and bacteria,
although many live in close association with anaerobic bacteria.
Methanogens are microorganisms that produce methane as a metabolic
byproduct in anoxic conditions. They are classified as archaea, a
domain quite distinct from bacteria.
[0116] Exemplary examples of methogens, or methanogenic bacteria
included in the digester process solution 74, which can be used in
the anaerobic digestion process in the methods, systems and
apparatus as disclosed herein include, but are not limited to:
Methanobacterium bryantii, Methanobacterium formicium,
Methanobrevibacterium arboriphilus, Methanobrevibacter
gottschalkii, Methanobrevibacterium ruminantium, Methanobrevibacter
smithii, Methanocalculus chunghsingensis, Methanococcoides
burtonii, Methanococcus aeolicus, Methanococcus deltae,
Methanococcus jannaschii, Methanococcus maripaludis, Methanococcus
vannielli, Methanocorpusculum labreanum, Methanoculleus bourgensis,
Methanoculleus marisnigri, Methanofollis liminatans, Methanogenium
cariaci, Methanogenium frigidum, Methanogenium organophilum,
Methanogenium wolfei, Methanomicrobium mobile, Methanopyrus
kandleri, Methanoregula boonei, Methanotrix concilli, Methanosaeta
thermophile, Methanosarcina acetivorans, Methanosarcina barkeri,
Methanosarcina mazei, Methanosphaera stadtmanae, Methanospirillium
hungatei, Methanothermobacter defluvii, Methanothermobacter
thermautotrophicus, Methanothermobacter thermoflexus,
Methanothermobacter wolfei, Methanothrix sochngenii.
[0117] In some embodiments, the digester process solution 74 can
include composition comprising a combination of methogenic bacteria
and anaerobic bacteria are used in the anaerobic digestion of the
processed input waste 23 according to the methods and systems as
disclosed herein. In some embodiments, the digester process
solution 74 can include at least about 3, or at least about 4, or
at least about 5, or at least about 6, or at least about 7, or at
least about 8, or at least about 9, or at least about 10, or at
least about 10-12, or at least about 12-15, or at least about 15-20
or more than 20 methogenic bacteria in the anaerobic digestion of
the digester process solution 74 in the digester tank 31 according
to the methods and systems as disclosed herein. As a specific
example, the digester process solution 74 can preferably include
methanogenic bacteria of methanotrix concilli, methanosarcinar
barkeri, methanosarcinar mazei, methanospirillum hungatei,
mehtanococcus vannielli, methanobacterium formicium,
methanobrevibacterium ruminantium, methanobacterium arboriphilus,
or a combination thereof.
[0118] The fluid digestate 72 in the digester tank 31 can be
removed as digester effluent 78 after a residence period 76. The
residence period 76 is a predetermined period sufficient for
conversion of the processed input waste 23 into the biogas 70 and
raw material for a high quality micronutrient or effective
microorganism solution. For example, the residence period 76 can be
a period of time ranging from about 10 days to 60 days. In another
example, the residence period 76 can be a period ranging from 20 to
40 days. In a further example, the residence period 76 can be a
period ranging from 25 to 30 days.
[0119] Referring now to FIG. 8, therein is shown a schematic
representation of the output module 50. In some embodiments, the
output module 50 can include a distillate fluid processing
apparatus 52 and a biogas processing apparatus 55. In some
embodiments, the biogas 70 can be filtered by the biogas processing
apparatus 55 to remove H2O, CO2 and H2S, and where the filtered
biogas 70 as methane and can be stored in a gas storage tank. In
some embodiments, the residence period 76 can be the time for the
digested organic waste to reach a pre-defined level in the
air-tight chamber.
[0120] Referring now to FIG. 9, therein is shown a schematic
representation of an embodiment of the distillate fluid processing
apparatus 52. The distillate fluid processing apparatus 52 can
include a reservoir tank 51, a pump 53, and a liquid flow sensor
54. The fluid distillate outlet 44 in the digester tank 31 of FIG.
7 is connected to the reservoir tank 51 via a series of tubes or
other connectors, and located in the connection between the fluid
distillate outlet 44 and the reservoir tank 51 is at least one pump
53 to pump the digester effluent 78 into the reservoir tank 51, and
at least one liquid flow sensor 54 to monitor the flow rate and the
amount of the digester effluent 78 pumped into the reservoir tank
51. The liquid flow sensor 54 measures the amount of digester
effluent 78 evacuated from Digester tank 31 to reservoir storage
tank 51.
[0121] The pump 53 can be any mechanical pump, and in some
embodiments is a filtered pump system which can be electronically
activated and monitored to pump digester effluent 78 from the
digester tank 31 into the reservoir tank 51. The reservoir tank 51
stores the digester effluent 78 so it can be used as a pathogen
free digestate which can be utilized as a fertilizer, soil
amendment or conditioner or for other uses.
[0122] In some embodiments, the digester effluent 78 is converted
in proprietary manor to an enriched effective microorganism
solution 80, which is a high quality micronutrient or effective
microorganism solution, with an effluent enhancement solution 82.
The effluent enhancement solution 82 is a combination of
microorganisms for removing pathogens and refining the digestate
effluent. For example, the effluent enhancement solution 82 can
include hydrolytic bacteria, lactic acid bacteria, yeast,
phototropic bacteria, or a combination thereof.
[0123] In some embodiments, the reservoir tank 51 is a 100-gallon
NSF approved tank. Through a series of valves the same pump 53 can
be used to evacuate this reservoir tank. In some embodiments, there
is an outlet in the reservoir tank 51 which for efflux or
collection of any of the biogas 70 released from the digester
effluent 78, which is connected to the biogas line 44 prior to the
biogas filters 56 to be processed by the biogas processing
apparatus 55.
[0124] Upon anaerobic digestion of the OFRM, the biogas 70 and a
portion of the fluid digestatc 72 is also produced. The fluid
digestatc 72 can include at least partially nutrient-depleted media
resulting from anaerobic bacterial growth, as well as the bacteria.
The fluid digestate 72 can include other volatile and non-volatile
metabolites from bacteria growth. The solid content of fluid
digestate 72 can vary, depending on the extent of digestion, the
initial moisture/solid content of the waste, and the amount of
water added to or removed from the Digester tank 31 during the
digestion.
[0125] Referring now to FIG. 10, therein is shown a schematic view
of an embodiment of the biogas processing apparatus 55. The biogas
processing apparatus 55 can include a plurality of biogas filters
56, at least one gas flow sensor 57, at least one gas flow analyzer
58, at least one gas compressor 59, and at least one gas storage
tank 60 tank). The biogas line 43 transports the biogas 70 from the
biogas outlet 42 in the Digester tank 31 to the biogas storage
tanks 60. Located along the biogas line 43, between the biogas
outlet 42 and the biogas storage tanks 60, are at least one biogas
filter 56, at least one gas flow sensor 57, at least one gas flow
analyzer 58, and at least one gas compressor 59.
[0126] The biogas filter 56 removes contaminating biogases e.g.,
filters the biogas free of specific gasses types, e.g., but not
limited to H2O, CO2 and H2S. Any gas filters can be used as the
biogas filters 56, for example, but not limited to commercially
available filters such as Shelco Filters.
[0127] The biogas 70 can include one or more inert gases, or gases
produced by anaerobic digestion such as methane, carbon dioxide, or
nitrogen. For example, waste gases left after enriching the biogas
70, primarily carbon dioxide, can be used for bubble scouring in
the biogas filters 56. Preferably, the biogas filters 56 are
operated in a sealed tank with gases used for scouring bubbles
captured in a head space of the tank and recycled to the aerators.
In some embodiments, the biogas filters 56 can capture certain
gasses, e.g., CO2 for reuse, and in such embodiments, the collected
CO2 biogas is delivered via gas lines to a CO2 storage tank and/or
to be used directly on site.
[0128] The gas flow sensor 57 detects the rate of flow of the
biogas in the biogas line 43, and the gas flow analyzer 58 detects
the purity and quality of the biogas 70 remaining, in particular,
the quality of the methane gas and removal of contaminant gasses
CO2, H2S and 02. Also present in the biogas line is a gas totalizer
which measures the total volume of gas produced.
[0129] The biogas 70 remaining after processing, typically at least
90% methane is compressed with the gas compressor 59 to, for
example, at least about 3600 psi and is stored in a plurality of
biogas storage tanks 60. In some embodiments, the biogas processing
apparatus 55 can include at least three compressed natural gas or
alternatively four Gallon gasoline equivalent tanks as the biogas
storage tanks 60. Alternatively, the biogas can be diverted from
being stored in the storage tanks and used directly on site as a
natural gas supplement.
[0130] The resulting method, process, apparatus, device, product,
and/or system is straightforward, cost-effective, uncomplicated,
highly versatile, accurate, sensitive, and effective, and can be
implemented by adapting known components for ready, efficient, and
economical manufacturing, application, and utilization. Another
important aspect of an embodiment of the present invention is that
it valuably supports and services the historical trend of reducing
costs, simplifying systems, and increasing performance.
[0131] These and other valuable aspects of an embodiment of the
present invention consequently further the state of the technology
to at least the next level.
[0132] While the invention has been described in conjunction with a
specific best mode, it is to be understood that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the aforegoing description. Accordingly, it is
intended to embrace all such alternatives, modifications, and
variations that fall within the scope of the included claims. All
matters set forth herein or shown in the accompanying drawings are
to be interpreted in an illustrative and non-limiting sense.
* * * * *