U.S. patent application number 16/502176 was filed with the patent office on 2019-10-24 for waste material processing system.
The applicant listed for this patent is Planet Found Energy Development, LLC. Invention is credited to Andrew MOSS.
Application Number | 20190322597 16/502176 |
Document ID | / |
Family ID | 58190053 |
Filed Date | 2019-10-24 |
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United States Patent
Application |
20190322597 |
Kind Code |
A1 |
MOSS; Andrew |
October 24, 2019 |
WASTE MATERIAL PROCESSING SYSTEM
Abstract
An organic waste material processing system includes a waste
material holding tank and a slurry-producing device configured to
process organic waste material into a slurry. A waste processing
section has at least one pressurizeable tank connected to the waste
material holding tank receiving slurry therefrom. The
pressurizeable tank includes a slurry temperature adjusting part
and a first hydrocarbon capturing structure configured to capture
hydrocarbon vapors produced by the slurry at a predetermined
temperature. A hydrocarbon vapor processing section collects
captured hydrocarbon vapors from the waste processing section such
that an electric power producing apparatus generates electricity
using collected hydrocarbon vapor and provides electric power to at
least the pretreatment section and the waste processing section. A
waste post-processing section is configured to receive processed
slurry produce salable organic materials, nutrient enhanced media
and recycled water.
Inventors: |
MOSS; Andrew; (Pocomoke
City, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Planet Found Energy Development, LLC |
Pocomoke City |
MD |
US |
|
|
Family ID: |
58190053 |
Appl. No.: |
16/502176 |
Filed: |
July 3, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15259859 |
Sep 8, 2016 |
10384982 |
|
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16502176 |
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62215859 |
Sep 9, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C05B 17/00 20130101;
C05F 17/10 20200101; C12M 41/40 20130101; C02F 3/28 20130101; C05F
17/20 20200101; Y02W 30/40 20150501; C05F 17/60 20200101; C12M
43/08 20130101; Y02W 30/43 20150501; C12M 21/04 20130101; C12M
41/26 20130101; C05F 17/40 20200101; Y02P 20/145 20151101; C05F
17/964 20200101; Y02W 30/47 20150501; C12M 41/12 20130101; C05F
17/50 20200101; C12M 23/58 20130101 |
International
Class: |
C05B 17/00 20060101
C05B017/00; C12M 1/107 20060101 C12M001/107; C05F 17/00 20060101
C05F017/00; C12M 1/00 20060101 C12M001/00; C12M 1/34 20060101
C12M001/34; C05F 17/02 20060101 C05F017/02 |
Claims
1. An organic waste material processing system comprising: a
pretreatment section including a waste material holding tank and a
slurry-producing device configured to process organic waste
material into a slurry; a waste processing section having a first
waste processing part having at least one pressurizeable tank
connected to the pretreatment section receiving slurry therefrom, a
slurry temperature adjusting part and a first hydrocarbon capturing
structure configured to capture hydrocarbon vapors produced by the
slurry within the at least one pressurizeable tank at a
predetermined temperature; a hydrocarbon vapor processing section
configured to collect captured hydrocarbon vapors from the waste
processing section; an electric power producing apparatus connected
to the hydrocarbon vapor processing section configured to generate
electricity using hydrocarbon vapor from the hydrocarbon vapor
processing section, the electric power producing apparatus
providing electric power to at least the pretreatment section and
the waste processing section; and a waste post-processing section
connected to the waste processing section and configured to receive
processed slurry therefrom, the waste post-processing section being
configured to produce salable organic materials, nutrient enhanced
media and recycled water that is fed to the pretreatment
section.
2. The organic waste material processing system according to claim
1, wherein the pretreatment section a second waste material holding
tank configured to receive the slurry from the waste material
holding tank and heat the slurry to the predetermined
temperature.
3. The organic waste material processing system according to claim
2, wherein the second waste material holding tank includes a
heating device and a heating manifold that at least partially
surrounds a portion of the second waste material holding tank, the
fluid heating device being configured to circulate heated fluid
through the heating manifold.
4. The organic waste material processing system according to claim
1, wherein the waste processing section has a second waste
processing part having at least one further pressurizeable tank
connected to the first waste processing part receiving slurry
therefrom, the second waste processing part including a second
hydrocarbon capturing structure configured to further capture
hydrocarbon vapors produced by the slurry within the at least the
one further tank.
5. The organic waste material processing system according to claim
1, wherein the waste post-processing section is configured to
produce salable organic materials, nutrient enhanced media in at
least two distinct particle size fractions without the use of
coagulants or flocculants.
6. The organic waste material processing system according to claim
1, wherein the slurry-producing device includes a grinding
mechanism.
7. The organic waste material processing system according to claim
1, wherein the at least one pressurizeable tank of the first waste
processing part includes a pH monitoring and pH adjusting part.
8. The organic waste material processing system according to claim
1, wherein the at least one pressurizeable tank of the first waste
processing part includes a clean-out compartment for collecting
precipitated debris.
9. A method of treating organic waste, the method comprising:
combining organic waste materials such as manure, food waste and
crop waste with water; homogenizing the organic waste material and
water producing a slurry reducing particle size of solids to no
greater than 25 mm; heating the slurry to a predetermined
temperature between 15.degree. C. and 40.degree. C.; digesting the
slurry and capturing hydrocarbon vapors given off from digested
slurry; and producing electricity from the captured hydrocarbon
vapors thereby providing power to devices that effect the
homogenizing of the organic waste material and heating of the
slurry.
10. The method of treating organic waste, according to claim 9, the
method further comprising the homogenizing of the organic waste
material includes at least one of the following operations
performed on the organic waste material: passing the organic waste
material through a grinder; passing the organic waste material
through a shredder; and passing the organic waste material through
a hammer mill.
11. The method of treating organic waste, according to claim 9,
wherein the heating of the slurry to a predetermined temperature
includes heating of the slurry to a temperature between 25.degree.
C. and 40.degree. C.;
12. The method of treating organic waste, according to claim 9,
wherein the digesting of the slurry and capturing hydrocarbon
vapors given off from the slurry includes a first anaerobic
digestion process and a second anaerobic digestion process.
13. The method of treating organic waste, according to claim 12,
wherein the first anaerobic digestion process includes feeding the
slurry into a pressurizeable tank and adjusting the slurry to the
predetermined temperature in order to promote
microbially-facilitated hydrolysis and acidogenesis to produce the
hydrocarbon vapors.
14. The method of treating organic waste, according to claim 13,
wherein the second anaerobic digestion process includes moving the
slurry from the pressurizeable tank to another pressurizeable tank
where the slurry undergoes further biological degradation at the
predetermined temperature in order to reduce total solids and odor
and mineralize nutrients and metals in the slurry.
15. The method of treating organic waste, according to claim 9, the
method further comprising a post processing process that includes
separating the digested slurry into a dewatered organic material
and produce recyclable water.
16. The method of treating organic waste, according to claim 15,
wherein the recyclable water is used in the step of combining
organic waste materials with water.
17. The method of treating organic waste, according to claim 15,
wherein a post processing process that includes subjecting the
digested slurry to a first pH adjustment in which mineral acids
such as H.sub.2SO.sub.4, HCl, or combinations of mineral and
organic acids are added to the digested slurry material in an
optionally pressurizeable and/or temperature adjusted tank or a
plurality of such tanks until the pH is at or below 6.0.
18. The method of treating organic waste, according to claim 17,
wherein after the subjecting of the digested slurry to the first pH
adjustment, the resulting slurry is further processed by a first
solids separation process in which particulate matter inherent in
the slurry and larger than about 0.5-1.5 mm is removed via sieves,
gravity screens, centrifuges, auger presses, or other dewatering
devices to produce a stable, dewatered organic material and a
filtrate.
19. The method of treating organic waste, according to claim 18,
wherein after the first solid separation process, the filtrate is
processed in a second solids separation process, optionally
facilitated by the addition of a filtration aid, in which
particulate matter smaller than about 0.5-1.5 mm is removed using a
mechanical or membrane-based dewatering device to produce a salable
organic product and a second filtrate.
20. The method of treating organic waste, according to claim 19,
wherein after the second solids separation process, the second
filtrate is subjected to a second pH adjustment process in which
the pH is adjusted above pH 7 with a caustic chemical in an
optionally pressurizable and/or temperature adjustable tank or
plurality of such tanks to increase nutrient content and colloidize
the soluble nutrients in solution, and the second filtrate is then
subjected to a third solids separation process in which the
colloidal material is removed using a mechanical or membrane-based
dewatering device to produce a nutrient enhanced media and a
recyclable water, which is then either reintroduced into a waste
treatment process, used as a fertilizer, or directed towards a
further membrane filtration process in which the salinity is
reduced, resulting in recyclable water.
21. An organic material comprising: nitrogen; phosphorus;
potassium; and sulfur, an elemental ratio of nitrogen: phosphorus:
potassium: sulfur in the organic material being approximately
5:1:2:3.
22. The organic material according to claim 21, wherein a content
of sulfur in the organic material is approximately 0.5% by weight
on a dry basis.
23. An organic product comprising: nitrogen; phosphorus; potassium;
and sulfur, an elemental ratio of nitrogen: phosphorus: potassium:
sulfur in the organic product being approximately 7:1:1:3.
24. The organic product according to claim 23, wherein a content of
sulfur in the organic product is approximately 1.3% by weight on a
dry basis.
25. The organic product according to claim 24, wherein an organic
carbon content in the organic product is approximately 16.6% by
weight on a dry basis.
26. A nutrient enhanced media comprising: nitrogen; phosphorus; and
calcium, a content of calcium in the nutrient enhanced media being
at least 5.0% by weight on a dry basis, and a content of phosphorus
in the nutrient enhanced media being at least 5.0% by weight on a
dry basis.
27. The nutrient enhanced media according to claim 26, wherein an
organic carbon content in the nutrient enhanced media is
approximately 4.7% by weight on a dry basis.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional U.S. patent application claims priority
under 35 U.S.C. .sctn. 120 to U.S. patent application Ser. No.
15/259,859, filed Sep. 8, 2016, which further claims priority under
35 U.S.C. .sctn. 120 to U.S. Patent Application No. 62/215,859,
filed on Sep. 9, 2015. The entire contents of U.S. patent
application Ser. No. 15/259,859 and U.S. Patent Application No.
62/215,859 are hereby incorporated herein by reference in their
entirety.
BACKGROUND
Field of the Invention
[0002] The present invention generally relates to a process and
system for treating organic waste materials. More specifically, the
present invention relates to a process and system for treating
waste materials that captures hydrocarbon gases and produces
salable organic material and nutrient enhanced media in at least
two distinct particle size fractions while recycling a reduced
salinity water back into the system.
Background Information
[0003] Organic waste products such as chicken waste materials
include high levels of nutrients, including salts and metals.
SUMMARY
[0004] One object is to process organic waste material and produce
useful products therefrom.
[0005] In view of the state of the known technology, one aspect of
the present disclosure is to provide an organic waste material
processing system with a pretreatment section, a waste processing
section, a hydrocarbon vapor processing section, an electric power
producing apparatus and a waste post-processing section. The
pretreatment section includes a waste material holding tank and a
slurry-producing device configured to process organic waste
material into a slurry. The waste processing section has a first
waste processing part having at least one pressurizeable tank
connected to the pretreatment section receiving slurry therefrom, a
slurry temperature adjusting part and a first hydrocarbon capturing
structure configured to capture hydrocarbon vapors produced by the
slurry within the at least one pressurizeable tank at a
predetermined temperature. The hydrocarbon vapor processing section
is configured to collect captured hydrocarbon vapors from the waste
processing section. The electric power producing apparatus is
connected to the hydrocarbon vapor processing section and is
configured to generate electricity using hydrocarbon vapor from the
hydrocarbon vapor processing section. The electric power producing
apparatus provides electric power to at least the pretreatment
section and the waste processing section. The waste post-processing
section is connected to the waste processing section and is
configured to receive processed slurry therefrom. The waste
post-processing section is configured to produce salable organic
materials, nutrient enhanced media and recycled water that is fed
to the pretreatment section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Referring now to the attached drawings which form a part of
this original disclosure:
[0007] FIG. 1 is an overall schematic view of an organic waste
material processing system that includes a pretreatment section, a
waste processing section, a waste post-processing section, and a
hydrocarbon vapor processing section in accordance with a first
embodiment;
[0008] FIG. 2 is a schematic diagram showing a first part of the
pretreatment section including a holding tank and a grinding device
that produces a slurry in accordance with the first embodiment;
[0009] FIG. 3 is a schematic view of second part of the
pretreatment section including a pair of pressurize-able tanks with
heat adjusting portions and pH measuring sensors that conduct a
first phase of anaerobic digestion in accordance with the first
embodiment;
[0010] FIG. 4 is a schematic view of a first part of the waste
processing section including a pair of anaerobic digesting tanks
that each include a heat adjusting portion, a pH adjusting portion
and hydrocarbon capturing portions in accordance with the first
embodiment;
[0011] FIG. 5 is schematic view of a second part of the waste
processing section including effluent storage tanks that also
include additional hydrocarbon vapor capturing devices in
accordance with the first embodiment;
[0012] FIG. 6 is a block diagram that schematically depicts the
hydrocarbon vapor processing section showing a hydrostatic
pressurization section, a desulfurization section, a desiccation
section, an energy production section and a connection to an
external power section for disposal of excess energy produced by
the hydrocarbon vapor processing section in accordance with the
first embodiment;
[0013] FIG. 7 is a schematic diagram showing a first portion of the
waste post-processing section including acid wash tanks and a first
solid separator, the acid wash tanks being configured to adjust the
pH of the slurry, the solid separator being configured to extract
salable organic material and nutrient enhanced media from the
processed slurry in accordance with the first embodiment;
[0014] FIG. 8 is a schematic diagram showing a second portion of
the waste post-processing section including a second solid
separator, a filter membrane, a recycled water collection vessel,
and salable products produced by the system in accordance with the
first embodiment;
[0015] FIG. 9 is a schematic block diagram showing a controller
connected to various sensors, valves, temperature controllers and
control mechanisms of the organic waste material processing system
in accordance with the first embodiment;
[0016] FIG. 10 is a flowchart showing basic steps of an organic
waste treatment process performed by the organic waste material
processing system, and in particular steps performed by the first
part of the pretreatment section depicted in FIG. 2 including
organic material grinding, diluting and slurry producing related
operations in accordance with the first embodiment;
[0017] FIG. 11 is a second flowchart showing basic steps of the
organic waste treatment process including steps performed by the
waste processing section such as a first phase of anaerobic
digestion and collection of hydrocarbon vapors performed using the
pressurizeable tanks in FIG. 3 and the anaerobic digesting tanks
depicted in FIG. 4, and a second phase of anaerobic digestion and
additional collection of hydrocarbon vapors performed using the
tanks depicted in FIG. 5 in accordance with the first
embodiment;
[0018] FIG. 12 is a third flowchart showing basic steps of the
organic waste treatment process in accordance with the first
embodiment; and
[0019] FIG. 13 is a fourth flowchart showing steps performed by the
hydrocarbon vapor processing section in accordance with the first
embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
[0020] Selected embodiments will now be explained with reference to
the drawings. It will be apparent to those skilled in the art from
this disclosure that the following descriptions of the embodiments
are provided for illustration only and not for the purpose of
limiting the invention as defined by the appended claims and their
equivalents.
[0021] A description is provided below of a waste processing system
10. Thereafter, a description is provided for one combination of
processes performed to process organic waste materials M.sub.O
using the waste processing system 10. Thereafter, a description of
salable materials 22 produced from the processed organic waste
material M.sub.O is provided.
[0022] Referring initially to FIG. 1, a schematic block diagram
showing portions of the waste processing system 10 for processing
the organic waste materials M.sub.O, is illustrated in accordance
with a first embodiment.
[0023] The waste processing system 10 is a flexible system that can
be used to process a variety of materials using a variety of
processes. However, in the description below, one example of many
possible combinations of processes that can be conducted by the
waste processing system 10 is described. This combinations of
processes described herein below make use of the waste processing
system 10 to process and transform the organic waste materials
M.sub.O into the salable materials 22. It should be understood from
the drawings and the description herein that the waste processing
system 10 can be used to conduct any of a variety of combination of
processing steps and operations, and is not limited to usage with
the combination of processes described herein below.
[0024] As used herein below, the term "organic waste materials
M.sub.O" can include any of a variety of materials. However, for
purposes of understanding the invention, the organic waste
materials M.sub.O described below can be solid poultry or animal
wastes including any materials containing a mixture of poultry or
animal urine, feces, undigested feed, and optionally bedding
material. Additionally, the organic waste materials M.sub.O can
include: different types of poultry manure such as litter (manure
mixed with bedding material) or cake (manure with minimal bedding
material); and/or different types of animal wastes such as manure
mixed with bedding materials (such as in deep bedding systems for
pig or cow rearing) or animal wastes with minimal bedding material
(such as scraped or centrifuged manure or manure collected with
belt systems); and or different types of organic materials such as
food waste, agricultural waste, or industrial waste.
[0025] As shown in FIG. 1, the waste material processing system 10
includes a pretreatment section 14, a waste processing section 16,
a waste post processing section 18 and a hydrocarbon vapor
processing section 20, which can be configured to produce the
salable organic materials and nutrient enhanced media (salable
materials 22), as described in greater detail below.
[0026] FIGS. 2 and 3 show parts of the pretreatment section 14.
Specifically, FIG. 2 shows a first part of the pretreatment section
14 that includes a pretreatment tank 14a and a particle size
homogenization mechanism 14b. The organic waste materials M.sub.O
is fed into the pretreatment tank 14a via any of a variety of
mechanisms. For example, a hopper (not shown) can provide the
organic waste materials M.sub.O to the pretreatment tank 14a, or
delivery vehicles such as truck or tankers can directly feed the
organic waste materials M.sub.O into the pretreatment tank 14a. The
particle size homogenization mechanism 14b can be any of a variety
of pump/grinding mechanisms configured to reduce the overall size
of the organic waste materials M.sub.O by, for example, grinding,
crushing and/or pulverizing the organic waste materials M.sub.O
thereby reducing the size of particle of compositions that make up
the organic waste materials M.sub.O. The particle size
homogenization mechanism 14b can include a pump (not shown) that
further moves and/or pumps the organic waste materials M.sub.O such
that the organic waste materials M.sub.O is circulated around the
pretreatment tank 14a. Hence, the organic waste materials M.sub.O
circulates through the pretreatment tank 14a via pumping and
grinding action of the particle size homogenization mechanism 14b.
Since grinding and pulverizing mechanisms are conventional
mechanical devices, further description is omitted for the sake of
brevity.
[0027] The pretreatment tank 14a is provided with a hot water feed
W.sub.H and a recycled water feed W.sub.R that may be one and the
same. While the particle size homogenization mechanism 14b
homogenizes the organic waste materials M.sub.O thereby turning it
into the slurry S, water is added to provide workability and
flowability to the slurry S, as well as to aid in the various
downstream processing. In other words, while the organic waste
materials M.sub.O are being reduced in size by the particle size
homogenization mechanism 14b to a desired size, a slurry S is
formed with the added water. A valve V.sub.1 can be operated to
change the flow of the slurry S from recirculation within the
pretreatment tank 14a to a releasing operation in which the slurry
S is pumped via a conduit L.sub.1 to the next portion of the
pretreatment section 14, as described further below.
[0028] The hot water feed W.sub.H is a device that can raise and/or
adjust the temperature of the organic waste materials M.sub.O (and
the subsequently produced slurry S) in the pretreatment tank 14a
and dilute the organic waste materials M.sub.O. Water passing to
the hot water feed W.sub.H is heated by a heater H.sub.1 that can
be a dedicated heater or can be a water heater that heats water
provided to the various portions of the water processing system 10,
as described further below. Flow of hot water through the hot water
feed W.sub.H is controlled via a second valve V.sub.2. As is
explained in greater detail below in a description of a first
embodiment of an organic waste treatment process, the slurry S is
further processed by the downstream portions of the waste material
processing system 10. The hot water feed W.sub.H can be provided
with municipal water that is heated by the heater H.sub.1 or can be
supplied with recycled water that is also heated by the heater
H.sub.1.
[0029] In order to provide further control of the temperature and
dilution of the slurry S produced within the pretreatment tank 14a,
a separate water source can also be provided. Specifically, the
recycled water feed W.sub.R can provide additional heated or
unheated water fed directly into the pretreatment tank 14. The
recycled water feed W.sub.R is controlled via a third valve
V.sub.3. The source and production of the recycled water provided
to the hot water feed W.sub.H and the recycled water feed W.sub.R
is described in greater detail below.
[0030] As an alternative to the heater H.sub.1, it is possible to
provide the pretreatment tank 14a with a separate, independent
heating system such as a water jacket or manifold (not shown) that
surrounds the pretreatment tank 14a. The water jacket or manifold
can be provided with a temperature controlled fluid that heats
and/or cools the pretreatment tank 14a in order to achieve a
desired temperature for the slurry S being produced within the
pretreatment tank 14a from the organic waste materials M.sub.O.
[0031] FIG. 3 shows a second part of the pretreatment section 14.
The second part of the pretreatment section 14 includes a pair of
preparation tanks 14c and 14d. Each of the preparation tanks 14c
and 14d includes fluid manifolds that surround each of the tanks
14c and 14d, with heat control systems H.sub.2 and H.sub.3 pumping
temperature-controlled fluids to the manifolds. The heat control
systems H.sub.2 and H.sub.3 can be provided with dedicated heat
sources or can be provided with heat via the heater H.sub.1.
Alternatively, the heater H.sub.1 and the heater control systems
H.sub.2 and H.sub.3 can all be provided with heat from a single
central heating device configured to service the entire waste
processing system 10. Further, the heat control systems H.sub.2 and
H.sub.3 can include refrigeration portions such that the heat
control systems H.sub.2 and H.sub.3 provide heating and/or cooling
the slurry S thereby providing control for bringing and maintaining
the slurry S therein at a predetermined temperature or within a
predetermined temperature range. The preparation tanks 14c and 14d
are pressurizeable with upper portions thereof defining hydrocarbon
capturing structures connected to conduits L.sub.9 which collect
hydrocarbon vapors captured within the tanks 14c and 14d, as
described in greater detail below. Each of the preparation tanks
14c and 14d further includes aeration devices A.sub.1 and A.sub.2
that are configured to provide air to the interior of each of the
preparation tanks 14c and 14d. Each of the tanks 14c and 14d
includes respective pH sensors S.sub.1 and S.sub.2, and reagent
delivery mechanism P.sub.1 and P.sub.2. The reagent delivery
mechanisms P.sub.1 and P.sub.2 can each be connected to both acidic
and alkaline reagents for adjusting pH of the slurry S, if
necessary. The reagent delivery mechanism P.sub.1 and P.sub.2 can
also be connected to tanks (not shown) configured to retain
alternative materials and/or reagents necessary for operating the
waste processing system 10.
[0032] The slurry S is fed to each of the preparation tanks 14c and
14d by the first conduit L.sub.1 from the pretreatment tank 14a.
The preparation tanks 14c and 14d are connected to one another via
a conduit L.sub.3 allowing flow of the slurry S therebetween, if
necessary or desired. A valve V.sub.4 can be included in the
conduit L.sub.3 to open or block flow through the conduit L.sub.3.
An overflow conduit L.sub.4 can optionally be provided to one or
both of the preparation tanks 14c and 14d. In FIG. 3, only the
preparation tank 14d is shown with the overflow conduit L.sub.4,
which directs overflow slurry S back to the pretreatment tank 14a,
as shown in FIG. 2. However, it should be understood from the
drawings and the description herein that both of the preparation
tanks 14c and 14d can be provided with overflow conduits
L.sub.4.
[0033] In the preparation tanks 14c and 14d, the slurry S can be,
for example, aerated, heated, cooled and/or undergo pH adjustments
to achieve desired overall conditions of the slurry S, depending
upon the combination of processes being employed. However, it is
not necessary to utilize all of these capabilities of the
preparation tanks 14c and 14d. Rather, the preparation tanks 14c
and 14d are provided with the heat control systems H.sub.2 and
H.sub.3, the aeration devices A.sub.1 and A.sub.2, the pH sensors
S.sub.1 and S.sub.2, and the reagent delivery mechanism P.sub.1 and
P.sub.2 in order to allow flexible overall usage of the preparation
tanks 14c and 14d and the waste processing system 10. After all
desired processing within the preparation tanks 14c and 14d has at
least partially been accomplished, the conduits L.sub.5 and L.sub.6
and flow control valves V.sub.5 and V.sub.6 are provided to provide
selective flow out of the preparation tanks 14c and 14d to the
further downstream portions of the waste processing system 10. A
pump (not shown) can be provided to draw the slurry S from the
preparation tanks 14c and 14d through the conduits L.sub.5 and
L.sub.6 for further downstream processing. Further, each of the
tanks 14c and 14d includes a respective clean out section 14e and
14f used to routinely collect debris and clean out such debris.
[0034] FIG. 4 shows a first part of the waste processing section
16, including pressurize-able digestion tanks 16a and 16b that
receive the slurry S from the pretreatment tanks 14c and 14d via
the conduit L.sub.6. Each of the tanks 16a and 16b includes
respective heat regulating systems H.sub.4 and H.sub.5 for heating
and/or cooling the slurry S in order to bring the slurry S to, and
maintain the slurry S at a desired predetermined temperature or
within a predetermined temperature range. The heat regulating
system H.sub.4 and H.sub.5 can be supplied with stand-alone heating
and cooling devices, or can be connected to a central heating
device and a central cooling device that supplies temperature
regulating fluids to each of the various tanks as needed or
desired. Each of the tanks 16a and 16b includes a respective pH
sensor S.sub.3 and S.sub.4 and respective reagent delivery
mechanisms P.sub.3 and P.sub.4 that are supplied with acid and/or
alkaline materials as needed, and are configured to deliver such
materials to the tanks 16a and 16b in response to determining the
need for a pH adjustment. The reagent delivery mechanisms P.sub.3
and P.sub.4 can also be connected to tanks (not shown) configured
to retain bacteria, alternative materials and/or reagents necessary
for operating the waste processing system 10. Since pH sensors and
reagent delivery mechanisms, such as the respective reagent
delivery mechanisms P.sub.1, P.sub.2, P.sub.3 and P.sub.4 are
conventional mechanisms, further description is omitted for the
sake of brevity.
[0035] The tank 16a is provided with slurry S from the conduit
L.sub.6 via a valve V.sub.7 and pump 16c. The pump 16c is connected
to the tank 16a such that with the valve V.sub.7 in a first
setting, the pump 16c can recirculate the slurry S out of and back
into the tank 16a. In a second setting, the valve V.sub.7 is set so
that the pump 16c draws the slurry S from the conduit L.sub.6 and
into the tank 16a. A conduit L.sub.7 connects an upper portion of
the tank 16a to the tank 16b such that slurry S can move from the
tank 16a to the tank 16b.
[0036] The tanks 16a and 16b are further provided with a water
source via conduit L.sub.8. The conduit L.sub.8 can be provided
with recycled water, fresh water or brine that can be unheated or
heated. The tank 16b includes a pump 16d that is connected to the
tank 16b such that with the pump 16d can recirculate the slurry S
out of and back into the tank 16b.
[0037] On an upper surface of each of the digestion tanks 16a and
16b there are a plurality of hydrocarbon vapor capturing structures
20a that are also pressurize-able. The hydrocarbon vapor capturing
structures 20a are open to, or are in fluid communication with the
interior of respective ones of the tanks 16a and 16b. The water
and/or brine introduced via the conduit L.sub.8 can be configured
to provide and build up hydrostatic pressure within the tanks 16a
and 16b, as well as in the plurality of hydrocarbon vapor capturing
structures 20a. The hydrocarbon vapor capturing structures 20a are
configured to capture hydrocarbon vapors (gases) released form the
slurry S, and deliver the captured vapors to the hydrocarbon vapor
processing section 20, as is described in greater detail below. The
hydrocarbon vapor capturing structures 20a are connected to
conduits L.sub.9 that direct collected vapors to the hydrocarbon
vapor processing section 20. Each of the digestion tanks 16a and
16b can also include clean out portals 16e and 16f that are
provided for receiving precipitated material for subsequent
removal. The clean-out portals 16e and 16f are configured to with a
door (not shown) that moves between a closed orientation sealing
the clean-out portals from an interior of the corresponding one of
the tanks 16a and 16b and an open orientation allowing flow between
the tanks 16a and 16b. When in the closed orientation, the
clean-out portal can be cleaned without interfering with operation
of the waste processing system 10.
[0038] The tank 16b is also provided with a conduit L.sub.10 that
is configured to release processed slurry S for further downstream
processing, as described further below.
[0039] FIG. 5 shows a second part of the waste processing section
16. There are two effluent storage tanks 16g and 16h. The tanks 16g
and 16h both receive the digested slurry S from the pressurize-able
digestion tank 16b via the conduit L.sub.10. The effluent storage
tanks 16g and 16h also include additional hydrocarbon vapor
capturing structures 20b that capture hydrocarbon vapors released
from the slurry S in a manner similar to the hydrocarbon vapor
capturing structures 20a and feed the captured vapors the
hydrocarbon vapor processing section 20 via conduit L.sub.11. Each
of the tanks 16g and 16h includes a water feed via conduit
L.sub.12. The conduit L.sub.12 can be provided with recycled water,
fresh water or brine that is unheated or, alternatively, can be
heated and can be configured to provide and build up hydrostatic
pressure within the tanks 16a and 16b, as well as in the plurality
of hydrocarbon vapor capturing structures 20a and 20b.
[0040] Each of the tanks 16g and 16h can include a pH sensor
S.sub.5 and S.sub.6 and well as reagent delivery mechanisms P.sub.5
and P.sub.6 that are supplied with acid and/or alkaline materials
as needed, and are configured to deliver such materials to the
tanks 16g and 16h in response to determining the need for a pH
adjustment. Processed slurry S leaves the tanks 16g and 16h via
conduits L.sub.13.
[0041] A description of the hydrocarbon vapor processing section 20
is now provided with specific reference to FIG. 6. The hydrocarbon
vapor processing section 20 includes a hydrocarbon capturing part
20c, a hydrocarbon vapor treatment part 20d and an energy
production part 20e. The hydrocarbon capturing part 20c receives
captured hydrocarbon vapors from tanks 14a and 14b, the hydrocarbon
vapor capturing structures 20a and the hydrocarbon vapor capturing
structures 20b of the tanks 16a, 16b, 16g and 16h of the waste
processing section 16 via the conduits L.sub.9 and L.sub.11. The
hydrocarbon capturing part 20c can include a pump (not shown) or
compressor (not shown) and storage tanks (not shown) that are
configured to store pressurized gases in a conventional manner. The
hydrocarbon vapor treatment part 20d can include any of a variety
of vapor preparing features, such as a desulfurization apparatus
and a moisture removing apparatus (desiccation). The hydrocarbon
vapor treatment part 20d can also include a compressor (not shown)
and storage tanks (not shown) for storing processed hydrocarbon
vapors. The energy production part 20e can be an electric generator
(not shown) that is fueled by the processed hydrocarbon vapors
prepared by the hydrocarbon vapor treatment part 20d. Power
produced by the energy production part 20e is used to at least
partially power the electrical equipment 20f of the waste
processing system 10, such as pumps, heaters, valves, and other
electrically powered portions of the waste processing system 10. If
excess electricity is produced by the energy production part 20e,
it can be provided as external power 20g to a local electric grid.
Conversely, if the electricity produced by the energy production
part 20e is not sufficient to power the electrically powered
equipment 20f of the waste processing system 10, external power 20g
from a local electric grid can be used to power a portion of the
waste processing system 10.
[0042] A description of the waste post processing section 18 is now
provided with specific reference to FIGS. 7 and 8. A first part of
the waste post processing section 18 is shown in FIG. 7. The first
part of the waste post processing section 18 includes acidification
tanks 18a and 18b that define a first pH adjusting section. The
tank 18a receives processed slurry S from the tanks 16g and 16h via
the conduit L.sub.13. The tank 18a includes a pH sensor S.sub.7, a
reagent delivery mechanism P.sub.7, an aeration or mixing device
A.sub.3 and an outlet that is optionally connected to a pump 18d.
The pH sensor S.sub.7 is provided to detect the current pH of the
processed slurry S. The reagent delivery mechanism P.sub.7 can
include a pH adjusting mechanism that is configured to selectively
add either acidic material(s) and/or alkaline material(s) in order
to adjust to the current pH of the slurry in the tank 18a and bring
it to a desired pH level or within a predetermined pH range. The
reagent delivery mechanism P.sub.7 can also be connected to
additional reagent delivery devices, such as an anti-foaming agent
delivery device. The aeration device A.sub.3 is provided to aerate
the slurry S in the tank 18a, if necessary. The pump 18d is
connected to a conduit L.sub.14 that feeds the slurry S into a
first solid separation device 18e.
[0043] The first solid separation device 18e is configured to
separate solid portions and liquid portions of the processed slurry
S. The first solid separation device 18e can be, for example, a
centrifuge device. However, the first solid separation device 18e
can be sieves, gravity screens, centrifuges, auger presses, or
other dewatering devices. The solid portions separated from the
processed slurry S by the first solid separation device 18e are fed
into a hopper S.sub.8 and define stable organic material 61 that is
described in greater detail below with reference to Table 1. The
remaining liquid portions of the processed slurry S are fed via
conduit L.sub.15 to the tank 18b where they are stored until fed
via a pump 18g via line L.sub.16 to downstream portions of the
waste processing system 10. Since solid separation devices such as
the first solid separation device 18e are conventional devices,
further description is omitted for the sake of brevity.
[0044] The tank 18b provided with the processed slurry S from the
first solid separation device 18e via the conduit L.sub.15. The
tank 18b includes a pH sensor S.sub.8, a reagent delivery mechanism
P.sub.8, an aeration device A.sub.4, a conduit L.sub.16 that serves
as a water feed (if necessary) and an outlet connected to a pump
18g. The pH sensor S.sub.8 is provided to detect the current pH of
the processed slurry S. The reagent delivery mechanism P.sub.8 can
include a pH adjusting mechanism configured to selectively add
either an acidic material and/or an alkaline materials in order to
adjust to the current pH of the slurry in the tank 18b and bring it
to a desired pH level or within a predetermined pH range. The
reagent delivery mechanism P.sub.8 can also be connected to
additional reagent delivery devices.
[0045] The aeration device A.sub.4 is provided to aerate the slurry
S in the tank 18b, if necessary. The pump 18g is connected to a
conduit L.sub.17 that feeds the slurry S to the second part of the
waste post processing section 18, as described further below.
[0046] The second part of the waste post processing section 18 is
shown in FIG. 8 and includes a second solid separation section 18h,
a pH adjusting section 18i and an optional water filtration section
18k. The second solid separation section 18h can include a
dewatering apparatus such as a dewatering skid or other similar
device that can extract predetermined materials from the processed
slurry S, thereby producing a salable organic product 62 and a
nutrient enhanced media 63 (in separate operations), as discussed
in greater detail below with respect to Table 1.
[0047] The second pH adjusting section 18i can include a tank
and/or a reactor provided with a pH sensor S.sub.9 and a reagent
delivery mechanism P.sub.9. The reagent delivery mechanism P.sub.9
can include a pH adjusting mechanism configured to selectively add
either acidic material(s) and/or alkaline material(s) in order to
adjust to the current pH of the slurry S bring it to a desired pH
level or within a predetermined pH range. The reagent delivery
mechanism P.sub.9 can also be connected to additional reagent
delivery devices, such as specific reagent delivery devices. The
solid portions separated from the processed slurry S by the second
solid separation section 18h in a second solid separation process
are fed into a hopper S.sub.8 and define the salable organic
product 62 that is described in greater detail below with reference
to Table 1.
[0048] The processed slurry S can optionally be recirculated back
to the second solid separation section 18h if necessary via the
conduit L.sub.17, for further liquid/solid separation in a third
solid separation process. The solid portions separated from the
processed slurry S by the second solid separation section 18h in
the third solid separation process define the nutrient enhanced
media 63 that is described in greater detail below with reference
to Table 1. Thereafter, remaining filtrate from either the second
or third solid separation processes can be fed to the optional
water filtration section 18k, which can include, for example, a
reverse osmosis apparatus (a filtration section that includes
membrane filtration). Alternatively, the optional water filtration
section 18k can be replaced with sieves, gravity screens,
centrifuges, auger presses, or other dewatering devices. The water
filtration section 18k can further include various water tanks (not
shown) for storing the filtered water produced by the water
filtration section 18k. The water produced by the water filtration
section 18k produces water that is referred to above as recycled
water to the various portions of the waste processing system 10,
including the pretreatment section 14. Solids from the water
filtration section 18k can also define the nutrient enhanced media
63, as discussed in greater detail below with respect to Table 1.
Since membrane filtration systems, such as reverse osmosis
apparatus, and water storage structures are conventional features,
further description is omitted for the sake of brevity.
[0049] A description is now provided of a control system that
monitors the various sensors and controls the various valves, and
feeds of the waste processing system 10. As shown in FIG. 9, a
controller 40 is connected to all of the electronically controlled
elements of the waste processing system 10, such as the pH sensor
S.sub.1 through S.sub.N, the mechanism P.sub.1 through P.sub.N (and
their corresponding reagent, acid and alkaline feed controls), the
temperatures controls for the heater H.sub.1 through H.sub.N and
each of the valves V.sub.1 through V.sub.N. Although not shown in
the drawings, each of the tanks 14a, 14b, 14c, 14d, 16a, 16b, 18a
and 18b can include a corresponding temperature sensor (not shown)
that are all connected to the controller 40. Thus, the controller
40 is connected to the various elements of the waste processing
system 10 and is programed to operate the waste processing system
10 to carry out any of a variety of combination of processes.
Basic Process Steps:
[0050] The organic waste treatment processing system 10 performs
the various steps outlined below.
[0051] First, in a pretreatment process, the waste materials
M.sub.O (organic matter, e.g. manure, food waste, crop waste), are
optionally homogenized with the addition of water/recycled water
with mechanisms such as grinders, shredders, hammermills and
equipment obvious to those familiar in the art. In this
pretreatment process water and/or recycled water is added to form a
slurry S which may be subsequently temperature adjusted to a
predetermined temperature or temperature range between 15.degree.
C. and 40.degree. C. and/or further homogenized with equipment such
as grinder pumps, grinders and similar engineered devices to form
the slurry S.
[0052] Next, the slurry S resulting from the pretreatment process
is treated in a waste treatment process that includes a first phase
of anaerobic digestion (AD) and a second phase of anaerobic
digestion (AD). The first phase of AD includes subjecting the
slurry S to a predetermined air pressure and predetermined
temperature using at least one pressurizeable tank or a plurality
of tanks in which the organic waste slurry S undergoes
microbially-facilitated hydrolysis and acidogenesis to produce
hydrocarbon vapors and to condition the slurry for delivery to the
second phase of AD. The second phase of AD include moving the
slurry S into one or more pressurizeable and temperature adjustable
tanks in which the slurry (the waste material) is biologically
degraded at a predetermined temperature or temperature range to
reduce total solids and odor and mineralize nutrients and metals in
the slurry as a conditioning step for a subsequent waste
post-processing process steps while producing hydrocarbon vapors
that are captured in an hydrocarbon vapor capture process using a
hydrocarbon vapor processing system.
[0053] The waste post-processing process includes a first pH
adjustment step in which mineral acids such as H.sub.2SO.sub.4,
HCl, or combinations of mineral and organic acids are added to the
digested slurry material in an optionally pressurizeable and/or
temperature adjusted tank or a plurality of such tanks until the pH
is at or below 6.0 in order to reduce pathogens, solubilize
nutrients and metals, and destroy reserve alkalinity in the
slurry.
[0054] A subsequent step in the waste post-processing process
includes a first solids separation process in which particulate
matter inherent in the slurry S larger than about 0.5-1.5 mm is
removed via sieves, gravity screens, centrifuges, auger presses, or
other dewatering devices to produce a stable, dewatered organic
material 61 (described further below) and a filtrate. Production of
the filtrate effectively removes approximately 95% of the
water/liquid from slurry S (and the dewatered organic material
61).
[0055] Another subsequent step in the waste post-processing process
includes a second solids separation process, optionally facilitated
by the addition of a filtration aid such as, for example,
diatomaceous earth, in which the filtrate from the first solids
separation process is further processed by removing particulate
matter smaller than about 0.5-1.5 mm using a mechanical or
membrane-based dewatering device to produce a salable organic
product 62 and a second filtrate made up of approximately 95% of
water removed from the salable organic product 62.
[0056] In yet another subsequent step in the waste post-processing
process, a second pH adjustment process 54 in which the pH of the
filtrate resulting from the second solids separation process is
adjusted above pH 7 using a caustic chemical (NaOH, KOH,
Mg(OH).sub.2, NH.sub.3 or similar) in an optionally pressurizeable
and/or temperature adjustable tank or plurality of such tanks to
increase the nutrient content of the filtrate and colloidize the
soluble nutrients in solution.
[0057] In an optional subsequent step in the waste post-processing
process, a third solids separation process in which the colloidal
material from the second pH adjustment process is removed using a
mechanical or membrane-based dewatering device to produce a
nutrient enhanced media 63 that is discussed further below, and a
recyclable water that can be reintroduced into the organic waste
treatment processing system 10.
Example of Specific Process Steps
[0058] In accordance with a first embodiment, a specific
combination of processes conducted by the waste processing system
10 is now described with specific reference to FIGS. 10-13.
[0059] As shown in FIG. 10, an organic waste treatment process
begins at step S10 with the delivery of organic waste materials
M.sub.O to pretreatment tank 14a of the pretreatment section 14. As
stated above, the organic waste materials M.sub.O can be delivered
via a conveyor, a conduit, or delivered by vehicles delivering the
organic waste materials M.sub.O to the pretreatment tank 14a. As
shown at steps S11a and S11b, two inter-related operations can
occur in either order (step S11a first, then step S11b or, step
S11b followed by step S11a), or can occur simultaneously depending
upon, for example, the condition of the organic waste materials
M.sub.O. Specifically, at step S11a, the organic waste materials
M.sub.O the organic waste materials M.sub.O is pulverized, mashed
or ground up by, for example, the particle size homogenization
mechanism 14b. In step S11b, water is added to the pretreatment
tank 14a in order to dilute and help liquefy and further homogenize
the organic waste materials M.sub.O in the pretreatment tank 14a.
The water added to the pretreatment tank 14a can be hot water,
recycled water, brine, as well as mixtures thereof. Next at step
S12, the organic waste materials M.sub.O continues to be mixed and
pulverized, mashed or ground up by the particle size homogenization
mechanism 14b and mixed with water such that the mixture of the
water and the organic waste materials M.sub.O is pre-processed into
the slurry S.
[0060] The addition of heated water at step S11b can begin a
process of raising the overall temperature of the subsequently
produced slurry S to a desired or predetermined temperature. The
maximum particle size is variable depending upon the nature of the
original organic waste material M.sub.O. However, in the
embodiments described herein, the maximum particle size within the
slurry S can range from between 5 mm and 25 mm in overall
diameter.
[0061] At step S13, the slurry S is pumped by, for example, the
particle size homogenization mechanism 14b, which can include a
pumping capability, or by a separate pump (not shown) from the tank
14a to the preparation tanks 14c and 14d (FIG. 3). In the tanks 14c
and 14d, the homogenized slurry S undergoes temperature adjustment
to predetermined temperature. In the embodiments described herein,
the predetermined temperature can be between 15.degree. C. and
40.degree. C., but is more preferably between 25.degree. C. and
35.degree. C. At the bottom of FIG. 10, the flow of processes moves
to the depictions in FIG. 11.
[0062] As shown in FIG. 11, at step S14, the organic waste
treatment process proceeds with a first phase of anaerobic
digestion of the slurry S. Specifically, as the slurry S is heated
within the tanks 14c and 14d, the slurry S is put into a state
where microbial facilitated hydrolysis (anaerobic digestion) can
begin, or the progress of such anaerobic digestion is initiated. At
step S14, the heated slurry S within the tanks 14c and 14d is
digested and hydrocarbon vapors begin to form, as indicated at step
S15 in FIG. 11. The hydrocarbon vapors such as methane can
initially be collected from the tanks 14c and 14d. Since the slurry
S is heated within the tanks 14c and 14d, the first phase of
anaerobic digestion of the slurry S continues in the tanks 14c and
14d. The anaerobic action within the tanks 14c and 14d can result
in a decreased pH to between 6.0 and 8.0 pH, which can be monitored
using the pH sensors S.sub.3 and S.sub.4. The anaerobic digestion
results in the production and release from the slurry S of
hydrocarbon vapors such as methane, which can initially be
collected from the tanks 14c and 14d. However, as the anaerobic
digestion of the slurry S continues, the heated slurry S is moved
to the tanks 16a and 16b for further capture of the released
hydrocarbon vapors and to move to a second phase of anaerobic
digestion, as indicated at step S16 in FIG. 11.
[0063] Within the tanks 16a and 16b, the slurry S undergoes the
second phase of anaerobic digestion (step S16), which can proceed
naturally after an initial inoculation, since microbes and bacteria
are present in the organic waste materials M.sub.O. However, if the
anaerobic digestion of the slurry S needs microbial or bacterial
assistance in proceeding, various agents can be introduced into the
slurry, such as Streptococcus sp., Enterobacterium sp., Pseudomonas
sp., Bacillus sp., etc. Optionally, microbial organisms as
mentioned above can be introduced along with optional
micronutrients and elements such as B, Ni, Co, or pH adjusting
chemicals such as Ca(CO.sub.3).sub.2, NaCO.sub.3.
[0064] At step S17 in FIG. 11, hydrocarbon vapors are collected in
the tanks 16a and 16b via the hydrocarbon vapor capturing
structures 20a. During the second phase of anaerobic digestion
within the tanks 16a and 16b, the pressure within the tanks 16a and
16b can have a gas pressure within a range of between 5 kpa to
approximately 20 kpa. Since the tanks 16a and 16b are provided with
the heat regulating system H.sub.4 and H.sub.5, the temperatures
within the tanks 16a and 16b can be achieved and maintained at a
predetermined temperature or within a predetermined temperature
range of, for example, between 25.degree. C. and 40.degree. C. The
anaerobic action within the tanks 16a and 16b can result in a
further decreased pH, which can be monitored using the pH sensors
S.sub.3 and S.sub.4. During the first and second phases of
anaerobic digestion (steps S14 through S17), the hydrocarbon vapors
captured by the hydrocarbon vapor capturing structures 20a and 20b
are fed to the hydrocarbon vapor processing section 20, as is
described in greater detail below. The hydrocarbon vapors produced
in the anaerobic digestion mainly include methane gas, but can also
include small amounts of more complex hydrocarbon gases, including
ethane and propane.
[0065] As mentioned above, the microbial facilitated hydrolysis can
proceed without addition of a bacterial agent, depending upon the
nature of the organic waste 12. Specifically, organic waste 12,
such as poultry or other animal related waste, naturally has
various microbial agents in it. Therefore, the anaerobic digestion
proceeds naturally, in particular, once the temperature of the
slurry S has been raised to the above-mentioned predetermined
temperature range. However, if an agent is needed, Streptococcus
sp., Enterobacterium sp., Pseudomonas sp., Bacillus sp., etc. can
be introduced. However, since this is a self-organized biological
process only a small quantity of any bacterial agent need be
introduced, if at all.
[0066] The second phase of anaerobic digestion proceeds within the
pressurizeable tanks 16a and 16b. Specifically, at step S16, the
slurry S is moved from the tanks 14c and 14d to the tanks 16a and
16b. The tanks 16a and 16a are pressurizeable up to approximately
20 kpa. The tanks 16a and 16b can also optionally include the heat
regulating systems H.sub.4 and H.sub.5.
[0067] The second phase of anaerobic digestion facilitates
anaerobic digestion of the organic waste material M.sub.O and also
proceeds at the above mentioned predetermined temperature or
temperature range of between 25-40.degree. C., and more preferably
between 35-40.degree. C. The organic waste material M.sub.O in the
partially digested slurry S can be further biologically degraded
via the presence of or introduction of Pseudomonas sp., Bacillus
sp., Syntrophomonas sp., Syntrophobacter sp., Methanobacterium sp.,
Methanosarcina sp., Methanococcus sp., Methanobacterium sp., etc.
The further anaerobic digestion within the tanks 16a and 16b (step
S16) reduces total solids in the slurry S, reduces odor and
mineralizes nutrients and metals in the slurry S while producing
additional hydrocarbon vapors that are captured by the hydrocarbon
vapor capturing structure 20b (step S17 in FIG. 11). The captured
hydrocarbon vapors are then processed by the hydrocarbon vapor
processing section 20.
[0068] In steps S14 through S16 when the slurry S is moved into the
tanks 14a and 14b, the slurry S preferably has a total solids
content of 5-15% by weight and preferably approximately 10% by
weight. Upon exiting the tanks 16a and 16b, the slurry S preferably
has 2-12% by weight of solid material, and ideally approximately 6%
by weight of solids. However, hydrocarbon vapors are released and
captured in this portion of the process. It should be understood
that the reduction in solids content during Steps S14 through S16
are the result of microbial degradation and the associated
production of hydrocarbon vapors.
[0069] As shown at the bottom of FIG. 11, the organic waste
treatment process continues in the steps depicted in FIG. 12. After
capturing further amounts of hydrocarbon vapors in step S17 in FIG.
11, the processed slurry S is moved to the waste post processing
section 18 of the waste processing system 10. Specifically, the
slurry S is moved to the effluent/acidification tanks 16g and 18a
where it undergoes a first pH adjustment, as represented at step
S18 in FIG. 12. At step S18, the processed slurry S is optionally
heated and the tank 18a can be pressurized to between 0.0 kpa and
14.0 kpa (0.0-2.0 psi). Further, within the tank 18a, the pH of the
processed slurry S is adjusted in the first pH adjustment step to a
pH of between 3.5 and 4.5.
[0070] At step S19, after the processed slurry S has undergone the
first pH adjustment, the slurry S is moved to the first solids
separation device 18e (for example, a centrifuge) where a solid
portion of the slurry S is separated from a liquid filtrate portion
of the slurry S to produce a coarse but stable reduced-pathogen
organic material 61 in a first solids separation process. The
organic material 61 is described in greater detail below with
reference to Table 1.
[0071] The first solids separation device 18e removes particles
larger than about 0.5 mm to 1.5 mm from the slurry S and allows all
particles smaller than about 0.5 mm to pass through the first solid
separation device 18e as a first liquid filtrate. The first solids
separation device 18e includes one or more of a sieve, a gravity
screen, a centrifuge, an auger press, or any other suitable
dewatering device that removes particles larger than about 0.5 mm
to 1.5 mm, or any combination thereof. The liquid filtrate portion
of the slurry S that leaves the first solids separation device 18e
can include fine particulate organic matter suspended in the liquid
filtrate.
[0072] This first liquid filtrate then proceeds to a second solids
separation process at step S20. In step S20, the first liquid
filtrate from the first solids separation process is further
processed in the second solids separation device 18h to remove
particles smaller than about 0.5 mm to 1.5 mm to produce a salable
organic product 62 and a second liquid filtrate. The salable
organic product 62 is described in greater detail below with
reference to Table 1.
[0073] The second filtrate then undergoes, a second pH adjustment
process in step S21 in the second pH adjustment section 18i. In the
second pH adjustment step S21, the pH of the second filtrate is
raised to a pH of between 8.5 and 11 to colloidize the soluble
nutrients contained in the second filtrate in solution. For
example, a caustic chemical (NaOH, KOH, Mg(OH).sub.2, NH.sub.3 or
similar) can be added to raise the pH of the second filtrate to
suitable level to colloidize the soluble nutrients.
[0074] After the second pH adjustment step, the colloidal material
of the second filtrate is removed in a third solids separation
process S22. In the third solids separation process (water
filtration process), a second solids separation device 18h is used
again but this time to remove the colloidal material produced in
step S21 to produce a nutrient enhanced media 63 and a third
filtrate. The nutrient enhanced media 63 is described in greater
detail below with reference to Table 1.
[0075] In an optional subsequent step S23 in the waste
post-processing section, the membrane filtration process using the
optional water filtration section 18k. can reduce the salinity of
the third filtrate, resulting in a recyclable water 11 that is
reintroduced into the organic waste treatment processing system
10.
[0076] A description is now provided of the operations carried out
by the hydrocarbon vapor processing section 20 with reference to
FIG. 13. At step S24, the hydrocarbon vapors are captured and
pressurized. At step S25, the hydrocarbon vapors undergo
desulfurization. At step S26 the hydrocarbon vapors undergo
desiccation to remove moisture. At step S27 the hydrocarbon vapors
(compressed) are fed to electric generators (not shown) that
produce electric power. The electric power can be used to power
some or all of the electronic elements of the waste processing
system 10. If sufficient electric power is produced at step S27 to
run the entire waste processing system 10, any extra electricity
can be sold and used to power external devices or can be supplied
to a local electrical grid. Conversely, if insufficient electric
power is produced at step S27 to run the entire waste processing
system 10, electricity can be drawn from the local electrical
grid.
Optional Processes
[0077] The first solid separation device 18e of the waste post
processing section 18 can be configured to extract specific
compounds and elements therefrom such as phosphorus, nitrogen,
and/or other predetermined materials from the slurry using the
methodology set forth in Applicant's U.S. Patent Application No.
62/215,859, which is hereby incorporated herein by reference in its
entirety. Further, the second solid separation device 18h of the
waste post processing section 18 can be configured to extract water
from phosphorus-depleted slurry. The waste post processing section
18 can include a reactor and a reverse osmosis water extracting
system that extracts water, nutrients, salts, metals, and
organic/inorganic material from the remaining slurry materials.
Products
[0078] As mentioned above there are at least three categories of
products that can be produced using the above. Applicants have
compiled the data listed in Table 1 (below) that outlines the
products.
TABLE-US-00001 TABLE 1 Product 61 Product 62 Product 63 Avg StDev
Avg StDev Avg StDev As Sampled Total Solids 25.4% 1.2% 36.1% 3.0%
34.9% 2.5% Fixed Solids 14.1% 2.4% 68.0% 7.4% 91.9% 0.0% (% of TS)
Organic 49.8% 1.4% 16.6% 4.1% 4.7% 0.0% Carbon Soluble Salts 2.5 --
3.1 1.0 2.9 0.0 (ds/m) C:N Ratio 20.9 -- 6.3 0.7 7.0 0.0 Elemental
N:P 3.3 1.9 9.4 4.8 0.1 0.0 Ratio Fertilizer N:P 1.5 0.8 4.1 2.1
0.1 0.0 Ratio By Dry Weight Total Nitrogen 0.9% 1.3% 2.9% 0.5% 0.7%
0.1% (TKN) Total 0.2% 0.2% 0.4% 0.2% 5.0% 0.7% Phosphorus Total
0.3% 0.3% 0.6% 0.3% 0.4% 0.1% Potassium Sulfur 0.5% 0.6% 1.3% 0.6%
0.4% 0.1% Calcium 0.3% 0.4% 1.0% 0.6% 5.3% 0.6% Magnesium 0.1% 0.1%
0.2% 0.1% 1.8% 0.4% Sodium 0.1% 0.1% 0.4% 0.1% 0.5% 0.1% Zinc 0.0%
0.0% 0.1% 0.0% 0.0% 0.0% Iron 0.0% 0.1% 0.2% 0.1% 0.2% 0.1%
Manganese 0.0% 0.0% 0.0% 0.0% 0.2% 0.1% Copper 0.0% 0.0% 0.1% 0.0%
0.0% 0.0% Aluminum 0.0% 0.0% 0.1% 0.0% 0.0% 0.0% Boron 0.0% 0.0%
0.0% 0.0% 0.0% 0.0%
[0079] As shown in Table 1 above, the stable organic material 61
produced in step S19 has a an Elemental nitrogen to phosphorus
ratio (Elemental N:P Ratio) of 3.3:1.+-.1.9 and a fertilizer ratio
of nitrogen to phosphorus (Fertilizer N:P Ratio) of 1.5:1.+-.0.8.
The organic material 61 also contains approximately 0.5% by weight
of sulfur on a dry basis and has an Elemental N:P:K:S ratio of
5:1:2:3.
[0080] Table 1 also shows that the salable organic product 62
produced in step S20 has an elemental ratio of nitrogen to
phosphorus (Elemental N:P Ratio) of 9.4:1.+-.4.8 and a fertilizer
ratio of nitrogen to phosphorus (Fertilizer N:P Ratio) of
4.1:1.+-.2.1. The salable organic product 62 also contains
approximately 1.3% by weight of sulfur on a dry basis and has an
Elemental N:P:K:S ratio of 7:1:1:3, while retaining organic carbon
levels of 16.6%.+-.4.1%.
[0081] As shown in Table 1 above, the nutrient enhanced media 63
produced in step S22 has an elevated level of phosphorus and
calcium (5.0%.+-.0.7% and 5.3%.+-.0.6% on a dry weight basis,
respectively) and an Elemental N:P:K:S ratio of 2:12:1:1, with a
very low organic carbon composition of 4.7%.
Other Literature
[0082] Van Slyke (U.S. Pat. No. 6,916,426) discloses to extract
ammonium, phosphorus and potassium from an animal waste slurry to
form ureates of potassium and ammonium in crystalline form. Van
Slyke further discloses that a substantial amount of potassium is
extracted as ureates of potassium using flocculation before they
degrade. Therefore, the solid material disclosed by Van Slyke
contains substantial amounts of the potassium, nitrogen and
phosphorus that were contained in the original animal waste sludge.
Our fertilizer phosphorus product material is low in potassium
(e.g., potassium content of less than 1%) and low in nitrogen
(e.g., nitrogen content of less than 4) because the acid treatment
that we apply with our process would solubilize and destroy the
potassium ureates, and the potassium remains in solution in the
liquid extract. Our subsequent alkaline addition to the liquid
extract reaching a pH between 8 and 11 does not recover significant
amounts of the solubilized potassium that resulted from the
destruction of the potassium ureates at acid pH. Therefore, our
phosphorus fertilizer product contains low concentrations of
potassium. In contrast, our process does not involve ureates; there
is also no flocculation of our initial animal wastes prior to or
during our acid addition and/or lime addition.
[0083] The acidification of organic waste according to Szogi et al.
(U.S. Pat. No. 8,673,046) is a three-part process that involves 1)
phosphorus extraction, 2) phosphorus recovery, and 3) phosphorus
recovery enhancement. These steps include the acidification of
organic waste to a pH from 3.0-5.0, the settling of phosphorus
depleted solids for removal from the waste stream, the
precipitation of phosphorus by adjusting pH to between pH 8.0-11.0
using an alkaline earth based, and the removal of the precipitated
phosphorus via settling and the addition of a flocculent. Our
process differs in that it teaches the pretreatment and anaerobic
digestion of organic material as a means of solubilizing nutrient
and reducing pathogens in the original waste material. It further
differs through the use of staged dewatering systems that, contrary
to Szogi et al., seek to retain organic material beyond the first
dewatering step in two distinct particle size fractions, and
strictly avoids the use of coagulants or flocculants in any
later-stage dewatering step. Critically, our process teaches the
recycling of water from post-treatment to pretreatment.
[0084] Thus, in view of the above, the process of the present
application concerns (in part) the following:
[0085] The various elements of the waste processing system 10 can
be automated with electronically controlled valves, metering valves
for accurately adding, for instance, acid, alkaline materials
and/or water to the waste materials M.sub.O and slurry, sensors for
detecting, for example, temperature and pH, pumps, grinders, and
other slurry and waste processing equipment. The automated control
of the portions of the waste processing system 10 can be operated
by a controller (not show). The controller preferably includes a
microcomputer with a control program that controls the various
sections of the waste processing system 10, as discussed below. The
controller can also include other conventional components such as
an input interface circuit, an output interface circuit, and
storage devices such as a ROM (Read Only Memory) device and a RAM
(Random Access Memory) device. The microcomputer of the controller
is programmed to control the waste processing system 10. The memory
circuit stores processing results and control programs such as ones
for waste processing system operation that are run by the processor
circuit. The controller is operatively coupled to the various
elements of the waste processing system 10 in a conventional
manner. The controller is capable of selectively controlling any of
the components of the waste processing system 10 in accordance with
the control program. It will be apparent to those skilled in the
art from this disclosure that the precise structure and algorithms
for the controller can be any combination of hardware and software
that will carry out the functions of the present invention.
General Interpretation of Terms
[0086] In understanding the scope of the present invention, the
term "comprising" and its derivatives, as used herein, are intended
to be open ended terms that specify the presence of the stated
features, elements, components, groups, integers, and/or steps, but
do not exclude the presence of other unstated features, elements,
components, groups, integers and/or steps. The foregoing also
applies to words having similar meanings such as the terms,
"including", "having" and their derivatives. Also, the terms
"part," "section," "portion," "member" or "element" when used in
the singular can have the dual meaning of a single part or a
plurality of parts. Also as used herein to describe the above
embodiment(s), the following directional terms "forward",
"rearward", "above", "downward", "vertical", "horizontal", "below"
and "transverse" as well as any other similar directional terms
refer to those directions of a vehicle equipped with the waste
processing system. Accordingly, these terms, as utilized to
describe the present invention should be interpreted relative to a
vehicle equipped with the waste processing system.
[0087] The term "detect" as used herein to describe an operation or
function carried out by a component, a section, a device or the
like includes a component, a section, a device or the like that
does not require physical detection, but rather includes
determining, measuring, modeling, predicting or computing or the
like to carry out the operation or function.
[0088] The term "configured" as used herein to describe a
component, section or part of a device includes hardware and/or
software that is constructed and/or programmed to carry out the
desired function.
[0089] The terms of degree such as "substantially", "about" and
"approximately" as used herein mean a reasonable amount of
deviation of the modified term such that the end result is not
significantly changed.
[0090] While only selected embodiments have been chosen to
illustrate the present invention, it will be apparent to those
skilled in the art from this disclosure that various changes and
modifications can be made herein without departing from the scope
of the invention as defined in the appended claims. For example,
the size, shape, location or orientation of the various components
can be changed as needed and/or desired. Components that are shown
directly connected or contacting each other can have intermediate
structures disposed between them. The functions of one element can
be performed by two, and vice versa. The structures and functions
of one embodiment can be adopted in another embodiment. It is not
necessary for all advantages to be present in a particular
embodiment at the same time. Every feature that is unique from the
prior art, alone or in combination with other features, also should
be considered a separate description of further inventions by the
applicant, including the structural and/or functional concepts
embodied by such features. Thus, the foregoing descriptions of the
embodiments according to the present invention are provided for
illustration only, and not for the purpose of limiting the
invention as defined by the appended claims and their
equivalents.
* * * * *