Systems and methods for digestion of solid waste

• US 8,329,455 B2
• Filed: 09/06/2011
• Issued: 12/11/2012
• Est. Priority Date: 07/08/2011
• Status: Active Grant

• Current Assignee: Aikan North America, Inc.
• Original Assignee: Aikan North America, Inc.
• Inventors: Christensen, Christian B.
• Primary Examiner(s): HOBBS, MICHAEL L
• Application Number:
  US13/226,006
• Publication Number:
  US 20120015430A1
• Time in Patent Office: 462 Days
• Field of Search: 4352901-2904, 210/163, 210/170.08, 452/0, 465/6, 47/14, 47/656, 523/023, 405/36, 71/9, 71/10, 71/12, 71/14
• US Class Current: 435/290.4
• CPC Class Codes: C05F 17/40 Treatment of liquids or slurries
• CPC Class Codes: C05F 17/50 Treatments combining two or more different biological or biochemical treatments, e.g. anaerobic and aerobic treatment or vermicomposting and aerobic treatment
• CPC Class Codes: C05F 17/964 Constructional parts, e.g. floors, covers or doors
• CPC Class Codes: C05F 17/986 the other material being liquid
• CPC Class Codes: C05F 17/989 Flow sheets for biological or biochemical treatment
• CPC Class Codes: C12M 21/04 for producing gas, e.g. biogas digesters for manure with production of biogas A01C3/028, biological treatment of water, waste water or sewage C02F3/00, C02F11/02, preparation of natural gas or syngas C10L3/06, C10L3/10
• CPC Class Codes: C12M 29/02 Percolation
• CPC Class Codes: C12P 5/023 Methane
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• 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 relates generally to systems and methods for digestion of solid waste that simplify solids handling. In certain embodiments, anaerobic methane extraction takes place for a period of time (e.g., from 1 to 4 weeks), after which an aerobic composting process begins in the same chamber. The organic waste remains in place and oxygen (e.g., in air) is forced into the chamber for an additional period of time (e.g., from 2 to 4 weeks). At the conclusion of the aerobic phase, the process yields a rough compost product that is stable and pathogen free. The rough compost can be further processed and blended to create high value engineered soils.

Claims

1. An apparatus for decomposition of organic matter into biogas and compost, the apparatus comprising:

a waste processing tank into which solid organic waste is loaded and in which hydrolysis and composting takes place at separate times, with composting of the solid organic waste taking place during a separate stage after hydrolysis is completed, wherein the waste processing tank comprises a drain at or near its base, the drain allowing flow of percolation liquid out of the waste processing tank during the hydrolysis stage, the drain also serving as a vent through which air flows into and/or out of the solid organic waste in the waste processing tank during the composting stage;

a spraying system configured to spray percolate liquid onto the solid organic waste in the waste processing tank during the hydrolysis stage, wherein the percolate liquid comprises fatty acids leached from the solid organic waste and wherein the percolate liquid is recycled from the base of the waste processing tank during the hydrolysis stage; and

a biogas reactor tank into which the percolate liquid from the waste processing tank is pumped for generation of biogas under anaerobic conditions during a gasification stage,

wherein the drain comprises a dual-purpose drain assembly for transport of the percolation liquid from the waste processing tank during the hydrolysis stage and for ventilation of the waste processing tank during the composting stage, the drain assembly comprising;

a channel disposed below the processing tank;

one or more rails through which a plurality of conduits are drilled, wherein each of the conduits has (i) a first end facing the waste processing tank containing the solid organic waste being processed and (ii) a second end facing the channel through which the percolation liquid flows out of the waste processing tank during the hydrolysis stage and through which air flows into the waste processing tank during the composting stage, wherein the first end has a width or diameter smaller than the second end; and

a removable plate supported by the one or more rails, the plate covering the channel to prevent the solid organic waste in the waste processing tank from entering the channel.

2. The apparatus of claim 1, wherein the waste processing tank is configured to operate at ambient pressure during the hydrolysis stage, the composting stage, or both.

3. The apparatus of claim 1, wherein the waste processing tank is configured to operate under anaerobic conditions during the hydrolysis stage.

4. The apparatus of claim 1, further comprising a biofilter through which air from the waste processing tank passes prior to discharge to the atmosphere during the composting stage.

5. The apparatus of claim 1, further comprising a filter configured to separate solids from the percolate liquid.

6. The apparatus of claim 1, comprising at least two waste processing tanks connected in parallel.

7. The apparatus of claim 1, wherein the waste processing tank comprises an acid-resistant lining or coating.

8. The apparatus of claim 1, wherein the biogas reactor tank is gas-tight.

9. The apparatus of claim 1, further comprising a heater for heating the percolate liquid either in the biogas reactor tank or outside the biogas reactor tank.

10. The apparatus of claim 1, wherein the biogas reactor tank comprises a sump to separate sediment and/or particles from the percolate liquid.

11. The apparatus of claim 1, further comprising a liquid process tank into which percolate liquid from either the biogas reactor tank, the waste processing tank, or both flows prior to being pumped to the spraying system for spraying onto the solid organic waste in the waste processing tank during the hydrolysis stage.

12. The apparatus of claim 11, wherein percolate liquid from both the biogas reactor tank and the waste processing tank flows into the liquid process tank prior to being pumped to the spraying system for spraying onto the solid organic waste in the waste processing tank during the hydrolysis stage.

13. The apparatus of claim 12, further comprising a filter tank configured to separate solids from the percolate liquid before the percolate liquid enters the liquid process tank.

14. The apparatus of claim 11, comprising one liquid process tank for each waste processing tank.

15. The apparatus of claim 14, comprising at least five waste processing tanks for each of one or more biogas reactor tanks.

16. The apparatus of claim 1, wherein the first end has a diameter no greater than 90% of the diameter of the second end.

17. The apparatus of claim 1, wherein each of the one or more rails comprises a notch, thereby forming a shelf for supporting the removable plate.

18. The apparatus of claim 1, wherein the channel is formed in a concrete base below the waste processing tank.

19. The apparatus of claim 1, comprising two or more rails, wherein the two or more rails comprises at least a first rail disposed along a first edge of the channel and a second rail disposed along a second edge of the channel.

20. The apparatus of claim 1, wherein at least a portion of the percolate liquid sprayed onto the solid organic waste in the waste processing tank during the hydrolysis stage is received from the base of the waste processing tank without first passing through the biogas reactor tank.