Biomass converters and processes

• US 20080134540A1
• Filed: 02/12/2008
• Published: 06/12/2008
• Est. Priority Date: 04/02/2004
• Status: Active Grant

• Current Assignee: Ecocombustion Energy Systems Corporation
• Original Assignee: Skill Associates, Inc.
• Inventors: Lasonde, Wallace R.
• Granted Patent: US 7,891,114 B2
• Time in Patent Office: Days
• US Class Current: 34/446
• CPC Class Codes: C02F 11/10 by pyrolysis
• CPC Class Codes: C02F 11/13 by heating
• CPC Class Codes: C02F 2103/20 from animal husbandry
• CPC Class Codes: C02F 2209/005 Processes using a programmable logic controller [PLC]
• CPC Class Codes: C02F 2209/02 Temperature
• CPC Class Codes: C02F 2209/38 Gas flow rate
• CPC Class Codes: C05D 9/00 Other inorganic fertilisers
• CPC Class Codes: C05F 17/939 Means for mixing or moving with predetermined or fixed paths, e.g. rails or cables
• CPC Class Codes: C05F 3/00 Fertilisers from human or animal excrements, e.g. manure
• CPC Class Codes: C05F 3/06 Apparatus for the manufacture
• CPC Class Codes: F26B 1/00 Preliminary treatment of solid materials or objects to facilitate drying , e.g. mixing or backmixing the materials to be dried with predominantly dry solids F26B5/005 takes precedence
• CPC Class Codes: F26B 2200/18 Sludges, e.g. sewage, waste, industrial processes, cooling towers
• CPC Class Codes: F26B 23/028 using solid fuel; burning the dried product
• CPC Class Codes: F26B 25/04 Agitating, stirring, or scraping devices arrangement of doctor blades F26B17/286
• CPC Class Codes: F26B 9/10 in the open air; in pans or tables in rooms; Drying stacks of loose material on floors which may be covered, e.g. by a roof ventilating means of stacks for agricultural produce A01F25/08
• CPC Class Codes: Y02A 40/20 Fertilizers of biological origin, e.g. guano or fertilizers made from animal corpses
• CPC Class Codes: Y02E 20/12 Heat utilisation in combustion or incineration of waste
• CPC Class Codes: Y02P 20/133 Renewable energy sources, e.g. sunlight
• CPC Class Codes: Y02P 20/145 the feedstock being materials of biological origin
• CPC Class Codes: Y02W 30/40 Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Abstract

This invention pertains to a bio-mass processing system, and method of processing waste bio-mass, wherein one or more mixers mixes a bed of bio-mass material such as manure at substantially any and all locations in a defined length and width portion of the bed, in a dryer. Heated air percolates upwardly through the bed. Separation apparatus separates a relatively dryer fraction of the bio-mass material from the dryer. The separated finished product from the dryer is optionally fed to a boiler where the dried bio-mass material is burned. Heat of combustion from the boiler is used as dryer heat for drying the bio-mass feed material in the dryer. Excess heat is optionally used to produce steam, which powers a turbine, which powers an electrical generator. Residual ash from the combustion process comprises about 2% by weight of the solids content of e.g. a feed stream coming into the dryer.

Claims

1-23. -23. (canceled)

24. A bio-mass processing system, comprising:

(a) a bed of bio-mass material to be processed, disposed on an underlying support, the bed of bio-mass material having a feed end and an exit end;

(b) a plurality of mixers adapted to mix the bed of bio-mass material, said plurality of mixers being mounted so as to be movable longitudinally along a length of a projected plan view area of the bed of bio-mass material so as to mix the bed of bio-mass material;

(c) air supply apparatus supplying air to the bed of bio-mass material proximate the underlying support; and

(d) separation apparatus separating a relatively dryer fraction of the bio-mass material from of the bed of bio-mass material at the exit end.

29. A bio-mass processing system as in claim 24 wherein the bed of bio-mass material has a feed end and an exit end, and wherein at least one of said plurality of mixers inclined at an angle of about 10 degrees to about 50 degrees from vertical, such that mixing activity of the respective said mixer moves such bio-mass material toward the exit end of the bed of bio-mass material.

31. A bio-mass processing system as in claim 24, further comprising transport structure which moves said plurality of mixers between the feed end and the exit end of the bed, and a computer controller which directs movement of said transport structure, within the bed of bio-mass material, so as to periodically mix-process the bio-mass material throughout substantially the entirety of the bed.

37. A bio-mass processing system as in claim 24, further comprising recycle loop transport structure which carries a portion of an exit stream from said bed of bio-mass material back toward the feed end of the bed and thus deposits the exit stream portion back into the bed of bio-mass material.

25-28. -28. (canceled)

30. (canceled)

32. A bio-mass processing system as in claim 30 wherein said air supply apparatus is divided into at least two substantially mutually exclusive and different supply zones, optionally at least three substantially mutually exclusive and different supply zones, along the length of the bed of bio-mass material, so as to enable feeding different air temperatures and/or different air flow rates in the respective different zones.

33-36. -36. (canceled)

38. A method of processing animal manure, comprising:

drying the animal manure to an end moisture content by

(a) collecting and containing a bed of manure to be dried, in a work location, over a floor, the bed of manure having a length and a width, an air supply system being associated with the floor and being effective to release air into the bed of manure at or adjacent the floor;

(b) supplying air through the air supply system to the bed of manure, thus to percolate the air upwardly through the bed of manure over substantial portions of both the length and the width of the bed of manure;

(c) mixing the bed of manure and;

(d) removing relatively dryer manure product of the drier first portion from the bed of manure and supplying fresh feed material to the dryer to replenish the manure in the dryer, thereby to operate a relatively continuous drying process.

39. A method as in claim 38, further comprising burning the removed product to produce heat.

40. A method as in claim 39, further comprising converting the heat to one or more other forms of energy such as mechanical energy, electrical energy, hydraulic energy, pneumatic energy, or chemical energy.

41. A method as in claim 39, further including using heat produced by the burning to supply the warmed air through the air supply system in the dryer.

42. A method as in claim 38, the dryer comprising a receptacle having upstanding walls, the method including containing the manure in the container while supplying the air, mixing the manure, and moving the manure through the dryer.

43. A method as in claim 38, the moving of the manure progressively through the dryer comprising moving the manure in a generally horizontal direction from proximate a wetter feed end of the dryer toward a relatively drier exit end of the bed of manure, thereby to produce the relatively drier manure product.

44. A method as in claim 38, further comprising recycling a portion of the relatively drier manure product to the relatively wetter feed end of the bed of manure.

45. A method as in claim 38, further comprising recycling a portion of the relatively drier manure product to a livestock barn as livestock bedding.

46. A method as in claim 38, further comprising sensing moisture level over a substantial portion of a projected area of the bed of manure, and adjusting one or more the drying process parameters, in response to the sensed moisture level.

47. A method as in claim 38, including establishing at least two different drying zones in the bed of manure, and separately adjusting at least one of temperature and mass flow rate of the heated air to at least one of the different drying zones.

48. A method as in claim 38, including establishing at least two different drying zones in the bed of manure, further comprising sensing moisture level in at least two of the drying zones, and separately adjusting at least one of temperature and mass flow rate of the heated air to at least one of the drying zones in response to the moisture sensed in at least one of the drying zones.

49. A method as in claim 43, including employing, in the mixing of the manure, at least one mixer oriented at an angle of about 10 degrees to about 50 degrees from vertical, such that operation of the mixer moves the manure being mixed, toward the exit end of the bed of manure.

50. A method as in claim 43, including employing, in the mixing of the manure, at least one mixer oriented such that operation of the mixer moves the manure being mixed, toward the exit end of the bed of manure.

51. A method as in claim 38, further comprising maintaining the bed of manure at a temperature generally of at least about 160 degrees F and maintaining sufficient air flow to the bed of manure to maintain an aerobic environment in the bed of manure.

52. A method as in claim 38, further comprising maintaining the bed of manure, in the dryer, at approximately atmospheric pressure during the process of drying the manure.

53-66. -66. (canceled)