Process and system for drying and heat treating materials

• US 7,685,737 B2
• Filed: 07/18/2005
• Issued: 03/30/2010
• Est. Priority Date: 07/19/2004
• Status: Expired due to Fees

• Current Assignee: Earthrenew Inc.
• Original Assignee: Earthrenew Inc.
• Inventors: Fedkenheuer, Alvin W., Gorbell, Brian N., Starosud, Alexander, Jonasson, John S., Carin, legal representative
• Primary Examiner(s): GRAVINI, STEPHEN MICHAEL
• Application Number:
  US11/184,738
• Publication Number:
  US 20060101665A1
• Time in Patent Office: 1,716 Days
• Field of Search: 34/86, 345/78, 341/61, 607/80, 712/18, 210/788
• US Class Current: 34/86
• CPC Class Codes: F26B 19/005 Self-contained mobile devices, e.g. for agricultural produce movable devices with radiation means F26B3/28; small self-contained devices for drying objects at rest F26B9/003
• CPC Class Codes: F26B 2200/18 Sludges, e.g. sewage, waste, industrial processes, cooling towers
• CPC Class Codes: F26B 23/001 using waste heat
• CPC Class Codes: Y02P 70/10 Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Abstract

This invention discloses systems and methods for conversion of high moisture waste materials to dry or low moisture products for recycle or reuse. The equipment systems comprise a gas turbine generator unit (preferred heat source), a dryer vessel and a processing unit, wherein the connection between the gas turbine and the dryer vessel directs substantially all the gas turbine exhaust into the dryer vessel and substantially precludes the introduction of air into the dryer vessel and wherein the processing unit forms the dried material from the dryer vessel into granules, pellets or other desired form for the final product. Optionally, the systems and methods further provide for processing ventilation air from manufacturing facilities to reduce emissions therefrom.

Claims

1. A converted material for use as a fertilizer or soil builder, the converted material comprising:

a waste material feedstock that has not been exposed to significant composting or digestion that is thermally treated at a temperature of at least 700 degrees F., without significant oxidation and significant pyrolysis and for a sufficient period of time to destroy at least one undesired component present in the waste material feedstock, wherein the at least one undesired component includes at least one of organisms, microorganisms, viable seeds, pesticides, antibiotics, hormones, prions and viruses and for a sufficient period of time to render the waste material feedstock self-binding without the addition of non-water agglomerating additives or binders to the waste material feedstock, wherein after the waste material feedstock has been thermally treated, liquid water is added to the waste material feedstock to re-moisturize the waste material feedstock, wherein after the waste material feedstock has been re-moisturized through the addition of liquid water, the waste material feedstock is passed through a pelletizer where the waste material feedstock is re-heated during an extrusion process and portions of the waste material feedstock are bound together to form granules, pellets or prill suitable for conventional dry product handling, transport or use, and wherein the waste material feedstock contains at least one of NOx, SOx, and COx components absorbed or complexed therein as a result of the treatment of the waste material feedstock in the absence of significant oxidation.

2. A converted material according to claim 1, wherein the waste material feedstock includes manure feedstock.

3. A converted material according to claim 1, wherein the at least one undesired component includes organisms.

4. A converted material according to claim 1, wherein the at least one undesired component includes microorganisms.

5. A converted material according to claim 1, wherein the at least one undesired component includes viable seeds.

6. A converted material according to claim 1, wherein the at least one undesired component includes pesticides.

7. A converted material according to claim 1, wherein the at least one undesired component includes antibiotics.

8. A converted material according to claim 1, wherein the at least one undesired component includes hormones.

9. A converted material according to claim 1, wherein the at least one undesired component includes prions.

10. A converted material according to claim 1, wherein the at least one undesired component includes viruses.

11. A converted material according to claim 1, wherein the at least one undesired component includes organisms, microorganisms, and viable seeds.

12. A converted material according to claim 1, wherein the at least one undesired component includes pesticides, antibiotics, and hormones.

13. A converted material according to claim 1, wherein the at least one undesired component includes prions and viruses.

14. A converted material according to claim 1, wherein the at least one undesired component includes organisms, microorganisms, viable seeds, pesticides, antibiotics, hormones, prions and viruses.