CA2542939A1 - Method and apparatus for producing dried distiller's grain - Google Patents
Method and apparatus for producing dried distiller's grain Download PDFInfo
- Publication number
- CA2542939A1 CA2542939A1 CA002542939A CA2542939A CA2542939A1 CA 2542939 A1 CA2542939 A1 CA 2542939A1 CA 002542939 A CA002542939 A CA 002542939A CA 2542939 A CA2542939 A CA 2542939A CA 2542939 A1 CA2542939 A1 CA 2542939A1
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- Canada
- Prior art keywords
- wet material
- cyclone
- wet
- auger
- view
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B17/00—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement
- F26B17/10—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement with movement performed by fluid currents, e.g. issuing from a nozzle, e.g. pneumatic, flash, vortex or entrainment dryers
- F26B17/107—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement with movement performed by fluid currents, e.g. issuing from a nozzle, e.g. pneumatic, flash, vortex or entrainment dryers pneumatically inducing within the drying enclosure a curved flow path, e.g. circular, spiral, helical; Cyclone or Vortex dryers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B2200/00—Drying processes and machines for solid materials characterised by the specific requirements of the drying good
- F26B2200/18—Sludges, e.g. sewage, waste, industrial processes, cooling towers
Abstract
A waste treatment apparatus for the treatment and processing of wet material is provided. The apparatus comprises an inlet hopper adapted for receipt of the wet material. A
pre-conditioning unit is provided having an input and an output end wherein the wet material is received from the inlet hopper at the input end and is conveyed to the output end wherein the wet material is processed to reduce moisture and pathogen content. A
blower is provided for providing a forced air stream to direct the flow of the wet material and for directing the flow from the output end of the pre-conditioning unit. A pre-separation cyclone is provided and is operatively positioned for receiving the wet material from the output end of the pre-conditioning unit via the air stream powered by the blower, wherein the wet material is processed under the influence of cyclonic forces that further reduce the moisture content, pathogen content, and reduce the particle size of the wet material. A
separation cyclone is provided and is operatively positioned for receiving the wet material from the pre-separation cyclone via the air stream powered by the blower, wherein the wet material is processed under the influence of cyclonic forces that separate the wet material into a substantially dry portion that exits from a lower portion of the separation cyclone and a substantially liquid or vapor portion that exits from an upper portion of the separation cyclone. A wet scrubber is provided and is operatively positioned for receiving the substantially liquid portion of the wet material.
Further comprising an eductor assembly for mixing and accelerating the wet material into the cyclones.
pre-conditioning unit is provided having an input and an output end wherein the wet material is received from the inlet hopper at the input end and is conveyed to the output end wherein the wet material is processed to reduce moisture and pathogen content. A
blower is provided for providing a forced air stream to direct the flow of the wet material and for directing the flow from the output end of the pre-conditioning unit. A pre-separation cyclone is provided and is operatively positioned for receiving the wet material from the output end of the pre-conditioning unit via the air stream powered by the blower, wherein the wet material is processed under the influence of cyclonic forces that further reduce the moisture content, pathogen content, and reduce the particle size of the wet material. A
separation cyclone is provided and is operatively positioned for receiving the wet material from the pre-separation cyclone via the air stream powered by the blower, wherein the wet material is processed under the influence of cyclonic forces that separate the wet material into a substantially dry portion that exits from a lower portion of the separation cyclone and a substantially liquid or vapor portion that exits from an upper portion of the separation cyclone. A wet scrubber is provided and is operatively positioned for receiving the substantially liquid portion of the wet material.
Further comprising an eductor assembly for mixing and accelerating the wet material into the cyclones.
Description
METHOD AND~APPARATUS FOR PRODUCING DRIED DISTILLER'S GRAIN
Back,~round of the Invention 1. Field of the Invention X' ~-~
_ ~. .~ . . -..rw S The present invention relates to an apparatus and method for the processing of wet ,. '.
material. Iwparticular, to an apparatus that utilizes cyclonic.forces and a heat processing to separate and size reduce wet material.
Back,~round of the Invention 1. Field of the Invention X' ~-~
_ ~. .~ . . -..rw S The present invention relates to an apparatus and method for the processing of wet ,. '.
material. Iwparticular, to an apparatus that utilizes cyclonic.forces and a heat processing to separate and size reduce wet material.
2. Background i0 A wide range of commercial and municipal industrial operations produce wet materials.as a byproduct ofthese various industrial processes. For example, in the United States municipal- facilities that use biological processes to .treat wastewater solids create-.enormous quantities of biosolids. The Environmental Protection Agency ("EPA") estimates that such facilities generated 6.9 million. tons of biosolids in 1998, and the EPA predicts this 15 output will continue to increase far the foreseeable future. Biosolids consist of nutrient rich organic matter produced from the stabilization of sewage sludge and residential septage and under the right conditions can be reclaimed or recycled for use as a land applied fertilizer.
However, in its raw form, biosolids are a pollutant subject to strict federal regulation at the hands of the EPA, and biosolids are similarly regulated by counterpart state and municipal 20 authorities as well.
Considerable effort has been devoted to recycliing or reclaiming biosolids for beneficial uses like for use as a land applicant fertilizer. The various treatment schemes include alkaline stabilization with such substances as lime, cement, or ash;
anaerobic _.
biological digestion 'in large closed tanks to allow decomposition through introduction of #1259564 microorganisms; aerobic digestion in vessels that utilize aerobic bacteria to convert biosoiids to C02 and water; composting which regulates decomposition in a.manner that elevates the temperature of the biosolids to a level that will destroy most pathogens;
other processes include heat drying and .pelletizing thro-~.u~hTthe use of,passive or active dryers; and .~
dewatering. These efforts have met with some success but generally have been hindered by a :public opposition based on concerns about pollution, odor, risk of disease, and other .perceived .nuisance issues, and by the strict regulatory frameworks that govern the use and recovery of biosolids. Again, the EPA estimates that in 1998 only 4I% of biosolids were sufficiently reclaimed to allow for land application, another I9% were reclaimed for other beneficial uses; however, a full 3'7% of biosolids were incinerated or disposed of at landfills.
The concerns of the public with regard to the collection, reclamation, and subsequent use ofbiosolids are not totally unfounded. Untreated or minimally treated biosolids could carry,pathogens, disease-causing organisms,.which include certain bacteria, viruses, or :parasites. Furthermore, biosolids are a vector attractant for such organisms as rodents and I5 insects that can carry diseases in their own right, or become.earriers of biosolid :pathogens.
There is concern about .biosolid contamination of ground and surface water supplies. As a result, the use of biosolids is regulated to reduce these risks and set standards for the subsequent use of processed -biosolids. The EPA framework for regulation generally classifies biosolids into two groups based on the level of potential risks to society.
Class A biosolids typically undergo advanced treatment to reduce pathogen levels to 'low levels. Normahy; this is achieved through the previously discussed methods of~heat drying, composting, or high-temperature aerobic digestion. Provided that the biosolids also .
.meet the requirements for metal concentration and vector attraction reduction, Class A
.biosolids can be used freely and for the same purposes as any other fertilizer or soil amendment product.
'Class B biosolids are treated to reduce pathogens to levels protective of human .health - - and the environment, with limited ac~s.~Thus, the. use of Class B-.biosolids .require crop - -S harvesting and site restriction, which minimize the potential for human and animal contact until natural attenuation of pathogens has occurred. Class B biosolids cannot be sold or given away for use on sites such as lawns and home gardens, but can be used in bilk on agricultural lands, reclamation sites, and other controlled sites provided that certain vector, .pollutant, and management practice requirements are also met.
10. Clearly, it is highly desirable to process biosoIids into a-Class A.product, however, the prior art :methods of doing so leave much room for improvement in that these methods of treating biosolids involve lame, expensive, fixed resources. The biosolid .processing or treatment sites are usually not located. at a majority of the generation sites thereby requiring transportation ofthe.biosotids. Or, a biosolid treatment facility must be constructed adjacent 1-S to each collection facility. In addition, many ofthese processes are slaw thereby limiting tl~e efficiency of conversion of biosolids, or the processes are not cost effect given the commercial value of Class A biosolids. As a result, there is much room fox improvement in the recover of biosolids for beneficial uses.
Furthermore, the problems associated with biosolids are not unique. .Many other types 20 of wet material that result from industrial processing also fall into the category of,products -that may breakdown into products capable of beneficial use subject to the restriction of w commercially viable methods of processing the wet material': These .materials include, without limitation, calcium carbonate, calcium sulfate, mycelium, coal fines, lime sludge, i ; _ .
paper sludge, compost, saw dust, animal waste, including manure, .or any other material in need of drying and/or reduction.
. . . . . . . . _ Suit nary ~of the Invention .. . . , . .-S An object of the present invention comprises providing an improved apparatus and method for ,processing wet material.
These and other objects of the present invention will become apparent to those skilled in the art upon reference to the following specification, drawings, and claims.
The present invention intends to overcome the dil~iculties encountered heretofore. To that end, a waste treatment apparatus forthe treatment and processing ofwet material is provided. The apparatus comprises an inlet hopper adapted for receipt .of the wet :material: A
.pre-conditioning unit is provided having an input and an output end-wherein the wet material is received. from the inlet hopper at the input end .and is eorxveyed to the output end wherein .
the wet-material is .processed to reduce .moistuire and pathogen content. A
blower is provided for providing a forced air stream to direct the flow of the wet material and for directing the t'low from the output erid of the pre-conditioning unit. A pre-separation cyclone is provided and is operatively positioned for receiving the wet material from the output end of the pre-conditioning unit via the air stream-powered by the blower, wherein the wet material is processed under the influence of cyclonic forces .that further reduce the moisture content, pathogen content, and reduce the particle size of the wet material. A
separation cyclone is provided and is operatively positioned for receiving the wet material from the pre-separation - ..
cyclone via the air stream powered by the blower, wherein the wet material is processed-under the influence of cyclonic forces that separate the wet material into a substantially dry portion that exits from a lower portion of the separation cyclone and a substantially liquid or vapor portion that.exits from an upper portion of the separation cyclone. A wet scrubber is provided and is operatively positipned for receiving the substantially liquid portion of the wet material.
Further comprising an eductor assem~~formixing.md accelerating the wet material into the cyclones.
Brief Descriation of the Drawings Figure 1 is a side view of a mobile apparatus for the treatment of wet material.
Figure 2 is a perspective view of the apparatus with the outer paneling removed.
I 0 Figure 3 is a top view of the apparatus shown in Figure 2.
Figure 4a is an end view of an 'inlet hopper, augers; and auger drive of the apparatus, Figure 4b is a side view of the components of the apparatus shown in Figure 4a.
Figure.4c is an opposite end view of the components of the apparatus shown in Figure 4a.
Figure 5 is a perspective view of the inlet hopper augers.-Figure 6a is a top view of a pre-conditioning unit of the apparatus.
F.igure.6 b is a side view of the pre-conditioning unit.
Figure 6c is an end view of the pre-conditioning unit.
Figure 6d is bottom view of the pre-conditioning unit.
Figure 7a is a side cross-sectional view of the pre-conditioning unit.
Figure 7b is an end cross-sectional view of the pre-conditioning unit taken along the line b-b shown in Figure 'la.
However, in its raw form, biosolids are a pollutant subject to strict federal regulation at the hands of the EPA, and biosolids are similarly regulated by counterpart state and municipal 20 authorities as well.
Considerable effort has been devoted to recycliing or reclaiming biosolids for beneficial uses like for use as a land applicant fertilizer. The various treatment schemes include alkaline stabilization with such substances as lime, cement, or ash;
anaerobic _.
biological digestion 'in large closed tanks to allow decomposition through introduction of #1259564 microorganisms; aerobic digestion in vessels that utilize aerobic bacteria to convert biosoiids to C02 and water; composting which regulates decomposition in a.manner that elevates the temperature of the biosolids to a level that will destroy most pathogens;
other processes include heat drying and .pelletizing thro-~.u~hTthe use of,passive or active dryers; and .~
dewatering. These efforts have met with some success but generally have been hindered by a :public opposition based on concerns about pollution, odor, risk of disease, and other .perceived .nuisance issues, and by the strict regulatory frameworks that govern the use and recovery of biosolids. Again, the EPA estimates that in 1998 only 4I% of biosolids were sufficiently reclaimed to allow for land application, another I9% were reclaimed for other beneficial uses; however, a full 3'7% of biosolids were incinerated or disposed of at landfills.
The concerns of the public with regard to the collection, reclamation, and subsequent use ofbiosolids are not totally unfounded. Untreated or minimally treated biosolids could carry,pathogens, disease-causing organisms,.which include certain bacteria, viruses, or :parasites. Furthermore, biosolids are a vector attractant for such organisms as rodents and I5 insects that can carry diseases in their own right, or become.earriers of biosolid :pathogens.
There is concern about .biosolid contamination of ground and surface water supplies. As a result, the use of biosolids is regulated to reduce these risks and set standards for the subsequent use of processed -biosolids. The EPA framework for regulation generally classifies biosolids into two groups based on the level of potential risks to society.
Class A biosolids typically undergo advanced treatment to reduce pathogen levels to 'low levels. Normahy; this is achieved through the previously discussed methods of~heat drying, composting, or high-temperature aerobic digestion. Provided that the biosolids also .
.meet the requirements for metal concentration and vector attraction reduction, Class A
.biosolids can be used freely and for the same purposes as any other fertilizer or soil amendment product.
'Class B biosolids are treated to reduce pathogens to levels protective of human .health - - and the environment, with limited ac~s.~Thus, the. use of Class B-.biosolids .require crop - -S harvesting and site restriction, which minimize the potential for human and animal contact until natural attenuation of pathogens has occurred. Class B biosolids cannot be sold or given away for use on sites such as lawns and home gardens, but can be used in bilk on agricultural lands, reclamation sites, and other controlled sites provided that certain vector, .pollutant, and management practice requirements are also met.
10. Clearly, it is highly desirable to process biosoIids into a-Class A.product, however, the prior art :methods of doing so leave much room for improvement in that these methods of treating biosolids involve lame, expensive, fixed resources. The biosolid .processing or treatment sites are usually not located. at a majority of the generation sites thereby requiring transportation ofthe.biosotids. Or, a biosolid treatment facility must be constructed adjacent 1-S to each collection facility. In addition, many ofthese processes are slaw thereby limiting tl~e efficiency of conversion of biosolids, or the processes are not cost effect given the commercial value of Class A biosolids. As a result, there is much room fox improvement in the recover of biosolids for beneficial uses.
Furthermore, the problems associated with biosolids are not unique. .Many other types 20 of wet material that result from industrial processing also fall into the category of,products -that may breakdown into products capable of beneficial use subject to the restriction of w commercially viable methods of processing the wet material': These .materials include, without limitation, calcium carbonate, calcium sulfate, mycelium, coal fines, lime sludge, i ; _ .
paper sludge, compost, saw dust, animal waste, including manure, .or any other material in need of drying and/or reduction.
. . . . . . . . _ Suit nary ~of the Invention .. . . , . .-S An object of the present invention comprises providing an improved apparatus and method for ,processing wet material.
These and other objects of the present invention will become apparent to those skilled in the art upon reference to the following specification, drawings, and claims.
The present invention intends to overcome the dil~iculties encountered heretofore. To that end, a waste treatment apparatus forthe treatment and processing ofwet material is provided. The apparatus comprises an inlet hopper adapted for receipt .of the wet :material: A
.pre-conditioning unit is provided having an input and an output end-wherein the wet material is received. from the inlet hopper at the input end .and is eorxveyed to the output end wherein .
the wet-material is .processed to reduce .moistuire and pathogen content. A
blower is provided for providing a forced air stream to direct the flow of the wet material and for directing the t'low from the output erid of the pre-conditioning unit. A pre-separation cyclone is provided and is operatively positioned for receiving the wet material from the output end of the pre-conditioning unit via the air stream-powered by the blower, wherein the wet material is processed under the influence of cyclonic forces .that further reduce the moisture content, pathogen content, and reduce the particle size of the wet material. A
separation cyclone is provided and is operatively positioned for receiving the wet material from the pre-separation - ..
cyclone via the air stream powered by the blower, wherein the wet material is processed-under the influence of cyclonic forces that separate the wet material into a substantially dry portion that exits from a lower portion of the separation cyclone and a substantially liquid or vapor portion that.exits from an upper portion of the separation cyclone. A wet scrubber is provided and is operatively positipned for receiving the substantially liquid portion of the wet material.
Further comprising an eductor assem~~formixing.md accelerating the wet material into the cyclones.
Brief Descriation of the Drawings Figure 1 is a side view of a mobile apparatus for the treatment of wet material.
Figure 2 is a perspective view of the apparatus with the outer paneling removed.
I 0 Figure 3 is a top view of the apparatus shown in Figure 2.
Figure 4a is an end view of an 'inlet hopper, augers; and auger drive of the apparatus, Figure 4b is a side view of the components of the apparatus shown in Figure 4a.
Figure.4c is an opposite end view of the components of the apparatus shown in Figure 4a.
Figure 5 is a perspective view of the inlet hopper augers.-Figure 6a is a top view of a pre-conditioning unit of the apparatus.
F.igure.6 b is a side view of the pre-conditioning unit.
Figure 6c is an end view of the pre-conditioning unit.
Figure 6d is bottom view of the pre-conditioning unit.
Figure 7a is a side cross-sectional view of the pre-conditioning unit.
Figure 7b is an end cross-sectional view of the pre-conditioning unit taken along the line b-b shown in Figure 'la.
i i Figure 8 is a side view of a diesel coolant inlet into a first end of the.pre-conditioning unit shown in Figure 6c.
Figure 9 is a perspective view of an intake hopper of the pre-conditioning unit.
Figure 10 is a perspective. viey~~,f, ~~portion of the pre-conditioning unit adjacent to . . .
the -intake hopper.
Figure 11 is a perspective view of an auger drive motor and diesel coolant outlet located at a second end of the pre-conditioning unit: _ Figure 12 is a.perspective view of a.grinder/air lock for receiving material from the pre-conditioning unit.
Figure 13 is a perspective view of an alternative grinder/air lock Figure 14 is a perspective view of a first and second cyclone of the apparatus, Figure 15 is a perspective view of the first and second cyclone taken from the opposite .
side of the cyclones as depicted in Figure ~14.
Figure 16a is a top view of the first cyclone.
Figure 16b is a perspective view of the first cyclone.
Figure 16c is a side view of the f trst cyclone.
Figure 16d is a side view of the first.cyclone rotated 90 degrees in a clockwise direction from the view of the.first cyclone as depicted in Figure 16c.
Figure 17 is a perspective view of a lower portion of the first cyclone.
Figure 18a is a top view,of the second cyclone.
Figure 18b is a perspective view of the second cyclone.
Figure 18c is a side view of the second cyclone.
Figure 9 is a perspective view of an intake hopper of the pre-conditioning unit.
Figure 10 is a perspective. viey~~,f, ~~portion of the pre-conditioning unit adjacent to . . .
the -intake hopper.
Figure 11 is a perspective view of an auger drive motor and diesel coolant outlet located at a second end of the pre-conditioning unit: _ Figure 12 is a.perspective view of a.grinder/air lock for receiving material from the pre-conditioning unit.
Figure 13 is a perspective view of an alternative grinder/air lock Figure 14 is a perspective view of a first and second cyclone of the apparatus, Figure 15 is a perspective view of the first and second cyclone taken from the opposite .
side of the cyclones as depicted in Figure ~14.
Figure 16a is a top view of the first cyclone.
Figure 16b is a perspective view of the first cyclone.
Figure 16c is a side view of the f trst cyclone.
Figure 16d is a side view of the first.cyclone rotated 90 degrees in a clockwise direction from the view of the.first cyclone as depicted in Figure 16c.
Figure 17 is a perspective view of a lower portion of the first cyclone.
Figure 18a is a top view,of the second cyclone.
Figure 18b is a perspective view of the second cyclone.
Figure 18c is a side view of the second cyclone.
i i Figure 18d is a side view ofthe second cyclone rotated 90 degrees in a clockwise direction from the view of the second cyclone as depicted in Figure 18c.
Figure 19 is a perspective view of a shear plate and blades of the second cyclone shown from :the inside ~of the second cyclone: . . w ~ ~ ~ ~ - . - .
_.. ,~
Figure 20 is a top view of a discharge auger shown from inside the second cyclone.
Figure 21 is a side view of the discharge auger and a lower portion of the second cyclone.
Figure 22a is a top view of a hydraulic reservoir and d iesel fuel tank of the apparatus.
Figure 22b is a perspective view of the hydraulic reservoir and diesel fuel tank.
Figure 22c is a side view of the hydraulic reservoir and diesel fuel tank.
Figure 22d is an end view of the hydraulic reservoir and diesel fuel tank.-Figure 23 is a perspective view of a diesel engine, 9U degree drive, blower, and a portion of the pz-econditioning unit of the apparatus.
higure 24 is a perspective view of a fan and a radiator of the apparatus. , 1 S Figure 2S is a perspective view.of a hydraulic pump of the apparatus.
Figure 26 is a side view of a hydraulic manifold of the apparatus:
Figure, 27 is ati end view of the discharge auger.
Figure 28 is a perspective view of an alternative embodiment ofthe invention that utilizes an eductor.
Figure 29 is a perspective cut away view of a portion of the eductor.
Figure ~0 is a perspective view of a recycle loop utilized by an alternative embodimentofthe invention.
Figure 31 is a perspective view of a slide gate and a first auger of the recycle loop.
Figure 19 is a perspective view of a shear plate and blades of the second cyclone shown from :the inside ~of the second cyclone: . . w ~ ~ ~ ~ - . - .
_.. ,~
Figure 20 is a top view of a discharge auger shown from inside the second cyclone.
Figure 21 is a side view of the discharge auger and a lower portion of the second cyclone.
Figure 22a is a top view of a hydraulic reservoir and d iesel fuel tank of the apparatus.
Figure 22b is a perspective view of the hydraulic reservoir and diesel fuel tank.
Figure 22c is a side view of the hydraulic reservoir and diesel fuel tank.
Figure 22d is an end view of the hydraulic reservoir and diesel fuel tank.-Figure 23 is a perspective view of a diesel engine, 9U degree drive, blower, and a portion of the pz-econditioning unit of the apparatus.
higure 24 is a perspective view of a fan and a radiator of the apparatus. , 1 S Figure 2S is a perspective view.of a hydraulic pump of the apparatus.
Figure 26 is a side view of a hydraulic manifold of the apparatus:
Figure, 27 is ati end view of the discharge auger.
Figure 28 is a perspective view of an alternative embodiment ofthe invention that utilizes an eductor.
Figure 29 is a perspective cut away view of a portion of the eductor.
Figure ~0 is a perspective view of a recycle loop utilized by an alternative embodimentofthe invention.
Figure 31 is a perspective view of a slide gate and a first auger of the recycle loop.
i. . . .. . .... .
Figure 32 is a perspective view of the junction of the first auger and a'second auger of the recycle loop.
Figure 33 is a perspective view of the second auger and a discharge chute of the . . recycle loop: ~ ~ - ... . , .. . . . . .. . .
. m~;fi.. _.
Figure 34 is a perspective view: of the second cyclone of the waste treatment apparatus, the slide gate of the recycle loop, and the first auger of the recycle loop.
Figure 35 is a perspective view of the-output end of the second cyclone of the waste treatment apparatus, the slide gate of the recycle loop, and the first auger of the recycle loop.
Figure 36 is a perspective view of the output end of the waste treatment apparatus, the first auger ofthe recycle loop, and the second auger of~the recycle loop.
T'igure 37 is a.perspect~ve view ofthe junctiom ofthe first auger and the second auger of.the recycle loop.
Figure 38 is a ;perspective view of the junction. of the first auger and the second auger ofthe recycle loop.
1 S Figure 39 .is a -perspective view of the second auger and the chute of the recycle loop and the inlet hopper of the waste treatment apparatus.
rigure 40 is a side view of an improved eductor assembly.
Detailed Description of the Invention Describe hereinbelow is one embodiment ofthe present invention; however, those of ordinary skill in the art will understand that the invention is not so limited.. In particular, variations on the present invention are described in United States Fatent Nos.
6,790,349, and 6,50b,311, which are incorporated herein by-reference. The present invention could be carried out on the apparatus disclosed in these patents as well, and on variations therefrom as will be apparent to those of ordinary skill in the art.
In the Figures, Figure 1 shows a mobile apparatus 10 for the treatment of wet material.
The apparatus 10 is adapted for treatr,ent~of a wide variety of wet material including, ..
without limitation, ethanol waste such~as distillers .grain, brewery waste, dairy waste, turkey waste, poultry waste, .beef waste, swine waste; grape residue from wineries, calcium carbonate; calcium sulfate, mycelium, coal fines, lime sludge, paper sludge, compost, saw dust, animal waste, including manure, or any material in need of drying and/or reduction. The apparatus 10 is also adapted for processing ofbiosolids, and preferably for converting biosolids into a-Class A product, but also into a Class B product.
As shown in Figure 1, the apparatus 10 is fully-.enelosed behind a piuralityofpanels secured to a. frame 12, and is built upon a wheeled trailer bed to allow for connection of the apparatus 10 to a semi-tractor (not shown) or other similar device for remote transportation to a working site. As shown in Figures 2-3, the apparatus includes a plurality of main 1 S processing components that will be described in detail hereinbelow, these -include an inlet hopper 14 for receipt of the wet -material (not shown), a diesel fuel tank 1 G
that provides.fuel to a.diesel engine 24 that powers the apparatus 10, a hydraulic reservoir 18 for use with the various hydraulic systems of the apparatus 10, a preconditioning unit 20 for initial treatment (orvprocessing) of the wet material, an air inlet plenum 22 for drawing air.
into -the apparatus I O for use .in treatment of the wet material and forcooling some of the components of the apparatus 10, a radiator 38 for transferring heat from an engine 24 to_ the incoming air stream, w ..
a grinder/air lock 2G for receipt of~the wet material from the pre-conditioning unit 20, a feed-through housing 28 that receives the wet. material from the grinder/air lock 26 and through which the wet material is transferred to a fcrst cyclone 30 for pre-separation treatment, a second cyclone 32 -for separation of the wet material into a substantially dry portion and a substantially liquid (or vapor} portion, an air-discharge housing 34 for.transferring the substantially liquid component ofthevet.material-to a wet scrubber 36, a discharge_auger 132 S for output of the substantially dry portion of the wet material, and a blower 40 that provides air flow to move the wet material through the apparatus 10 and to provide the cyclonic air flow used in the first and second cyclones 30, 32.
>~igures 4a-c and S show in detail the inlet hopper 14 that is designed fox a running capacity of about 3.5 cubic yards of wet material. Of course, those of ordinary skill in the art will understand that the exact amount of wet material fed into the apparatus 10 can and will vary depending on the nature of the wet material and the desired consistency of the output.
The .inlet hopper 14 includes a dual axle auger-comprised of an auger drive .42 and a first and second -flighted auger shafts 44, 46 (see Figure S) that can rapidly move the;wet material fed into the inlet hopper 14 into the apparatus 10, and in particular into the pre-conditioning unit 20.
Figures 6a-d, 7a-b, and 8-11 show in detail the pre-conditioning unit 20. The ,pre-conditioning unit 20 rests upon support feet 50 and is oriented at an angle to conserve space and to accommodate the loading and unloading of the wet material. The pre-conditioning unit 20 includes an intake hopper 48, located at an inlet end of the pre-conditioning unit 20, for receipt of the wet material -from the auger driven inlet hopper 14. The wet material exits the-pre-conditioning unit 20 through outlet 51 located at the bottom of the unit 20 and at an w ..
outlet end thereof. A flighted .pre-conditioning auger 66 moves the wet material through the pre-conditioning unit 20 under the power of an auger.drive motor.58 .located at an output end of the pre-conditioning unit 20. The pre-conditioning auger 66 is contained within an auger shell 52, which is subject to various heat sources designed to raise the temperature of the wet material inside the auger shell 52 to a sufficient level to begin 'killing pathogens in the wet material. In particular, the pre-eondit~o~ning.auger 66 has a.hollow core designed to_accept .
diesel coolant from the engine 24. Tha coolant enters the core of the pre-conditioning auger 66 through coolant hose 76 (see Figure 11 ) and coolant inlet fixture 60 located at the output end of the pre-conditioning unit 20. The coolant exits the core of the pre-conditioning auger 66 at the input end of the pre-conditioning unit 20 through coolant output fixture 62 and ~traveIs through coolant hose 74 back to the diesel engine 24 (see Figure 8).
In this manner, engine waste heat is captured and transferred to the coolant and is in turn transferred to the pre-conditioning auger 66, and in particular to the flights of the auger 66, and then'to the wet material, in the preferred embodiment of the invention, the pre-conditioning auger 66 has over'75 ft. of exposed fin surface area for direct transfer of heat to the wet material. The heat from the coolant is transferred .to the wet material and begins the process of pathogen reduction, aids in drying .the wet material, and helps to soften the wet material fo facilitate further processing by the cyclones 30; 32. Under normal operating conditions, the coolant enters the pre-conditioning unit 20 in excess of 195° F and exits at less than 170° F thereby transferring to the wet material a delta.heat exchange of at least 25°
F.
Further waste heat from the diesel engine 24 is captured by channeling the exhaust from the diesel engine 24 to the pre-conditioning auger 20. Shown best in Figures 7 and 10, the auger shell 52 is surrounded by a helical shell 54 that contains a helix 68. Exhaust from the diesel engine 24 flows into the helical shell 54 through an inlet 70, and exits the helical shell 54 at an outlet 72 at the opposite end of the helical shell 54 from the inlet 70. The heat r from the diesel engine 24 exhaust is channeled through the coils ofthe helix GS wherein the helix.b8 assists in absorbing the heat and subsequent transfer of the heat to the wet material within the auger shell 52. To further facilitate heat transfer the exhaust flows through the pre-conditioning auger 20 in.a direction oosiYte to the direction of flow ~of the wet material. In :~,.
the preferred embodiment of the invention, the diesel exhaust enters. the helical shell 54 at a temperature of about 500° F, and exits at a temperature of about 190° F.
Still further waste heat from the diesel engine 24 is captured for subsequent transfer to the wet material by directing waste heat from the diesel engine 24 into a heater box 56, or exhaust plenum extension, which surrounds the pre-conditioning auger 20 (see Figures 6 a-d, . and 11). Inlet air is introduced into the mobile apparatus 10 through an air plenum 22 (see lrigures 2-3). The air is then exposed to a radiator 38 that is in operative communication with the diesel engine 24. The inlet air is used to cool the diesel engine 24 as it is forced through the .radiator 3 8. The heated air is then channeled through a pre-heater duct 39 and into the heater 'box S6 that surrounds the helical 5he1154. The pre-heated inlet air enters the heater I S box 56 through a pre-heated aix opening 64 in the top of the heater box 56 located near the inlet end ofthe pre-conditioning auger 20. A series of helical fns (not shown) that conforzii to the shape ofthe heater box S6 surround the helical shell 54 and channel the air from the .pre-heated air opening 54 to the pre-heated air outlet 65 located at the bottom of the heater box 56 near the outlet end ofthe pre-conditioning auger 20. The pre-heated air then enters a feed through tube 27 from opening bS, and under the power of a blower 40 is further heat compressed to a temperature in the preferred-embodiment of 140° F. The helical fns in the ~ ..
heater box 56 also assist in the transfer of heat from the pre-heated air into the helical shell 54 and ultimately to the wet material'. Also located inside the air plenurn 22 is a fan 140 used to i .
cool the diesel engine 24. The fan 140 is triggered based on the temperature of the diesel engine 24 and channels a portion of the inlet air from the air :plenum 22 to cool the.engine 24.
After the wet material passes through the. pre-conditioning unit 20'it enters the ~grinder/air lock assembly 26 (see Figure 1a~:1.3)~. The assembly 26 provides for additional :~..
reduction of the particle size of the wet material and for isolation ofthe high velocity heated air moving from the feed through housing 28 under the power of the blower 40 and into the first cyclone 30. Figures 12-13 show two embodiments of the grinder/air lock assembly 26.
In both embodiments, the grinder 82 consists of a plurality of beater 'bars 76 mounted to two a -pair of beater 'bar shafts 80. The shafts 80 rotate under the power of a motor 86 in opposite directions to funnel -the wet material into the center of the grinder 86. The impingement of the wet material on the 'beater bars 76 facilitates particle reduction and thereby reducing bridg~ing.of the material that could clog the grinder 82 and otherwise reduce the efficiency of operation ofthe apparatus 10. The embodiment ofthe grinder/air lock assembly 26 shown in .
Figure 13 utilizes a plurality of gears 88 and a chain 90 driven by the motor 86 to rotate the l 5 beater bar shafts 80. I~owever, those of ordinary skill in the art will understand that the motor can drive the shafts directly, 'or other similar drive means could be uses as well-. In this manner, .the grinder 82 uses .counter-rotating intersection blades to shear or grind fihe wet material into small sized particles in the range of a half inch in size to facilitate acceleration of the wet material upon introduction into the high velocity air stream after the wet material passes through the air Lock 84. The air lock 84 is conventional and is also powered by the motor 86 to move the material from the grinder 82 into the high velocity air stream enclosed ' .
in the feed through 28.
i After the wet material exits the air lock 84 it enters the feed through housing 28 and .is exposed to pre-heated high velocity airflow that moves. the wet material into the first cyclone 30, or pre-separation cyclone. In the preferred embodiment of the invention, the airflow in . . . . the feed through housing_28 reaches to first~cyelone inlet 114 at 325 feetJsecond. Fi~ures~. ~, .. ~ ~ .~ . . , .
. 14-17 show the first cyclone 30. The l<nst cyclone 30 includes a cyclone inlet 114 where the wet material enters the top of the cyclone 30. Inside the first cyclone 30, the wet material is further desiccated and separated under cyclonic forces of the heated blower air moving through~the apparatus. The cyclonic action~moves the wet material in a descending spiral about the exterior of the inside of the first cyclone 30, a column of air rises through the center of the exterior spiral from the bottom .to the top of the first cyclone 30 and moves the wet material out of the f rst cyclone exit port 116. As the wet material circulates inside the first cyclone 30 it is size reduced by collision with the other circulating wet.
material iri the cyclone, and the density .of the material is reduced through desiccation from exposure to the .heated air. Also, exposure to the Seated air reduces pathogens. As the particle size of the wet material -is reduced by separation and the weight of the mateiial is reduced by desiccation, the wet material descends to the bottom of the first cyclone 30 and eventually reaches a size and density that allows it to be carried up and out of the first cyclone 30 as it is captured in the upward center draft of the cyclone.
The first cyclone 30 is constructed in two segments that are bolted together;
the shape ofthe segments facilitates the eyclonic flow or aitthrough the first cyclone 30. Thewpper segment 106 of the first cyclone 30 is cylindrical in shape with a fixed diameter. The lower segment 108 is a frustum, or truncated cone. The upper and lower segments 106, 108 both include matingly aligned flanges where the segments 106, 108 are bolted together. A core i -i :finder 118 is centrally located in the interior ofthe first cyclone 30, and terminates at its upper end at the exit port 116. The core finder 118 serves two purposes. First, the core f nder 118 prevents the wet material from traveling straight from the .inlet 114 to the exit port 116 - - -, without entering in the cyclonic flow. In other words, the core. finder 1-18 extends downward --.~,~~... _.
from the top of the first cyclone to prevent a short circuit of the path of the wet material in the first cyclone 30. Additionally, the core finder 118 is vertically adjustable to affect the cyclonie flow inside the first cyclone 30, and in particular to prevent the accumulation of material at the bottom of the first cyclone 30. The vertical position of the core 'finder 118 will affect haw far toward the bottom of the fzrst cyclone 30 the outward spiral of air descends. If the core finder 118 is not positioned close enough to the bottom of the first cyclone 30 the wet material may not -reach a density and size to allow it to move upward into the rising central column of air that takes the wet material out of the first cyclone 30.
The correct ;position of the core finder I 18 will vary depending on processing requirements and the nature of the wet material, and can be determined through experimentation. The first.cyclone 30 , .. also includes a hatch 98 to allow for maintenance and clearing as necessary. The first cyclone 30 rests on three support feet 102 that secure to the floor of the apparatus 10.
The partially processed wet material leaves the first cyclone 30 through the flop of the first cyclone 30 and enters a material feed tube 92 where the wet material moves to the second cyclone 32 {see Figures 18-21). The second cyclone 32 is generally similar to the. first . cyclone 30 in that it includes an upper cylindrical segment 110 and a lower segment 112 that is a frustum. The upper and lower segments 110, 112 both include-matingly aligned flanges where the segments 110, 112 are bolted together. In the preferred embodiment, the upper segment 110 of the second cyclone 32 is comprised of two individual segments joined at a r matingly aligned flange. Of course, those of ordinary skill in the art will understand that the specific orientation of the segments of cyclones 30, 32 can and will vary depending on processing requirements.
. . ~ In a manner similar to the first~cy~elone 30, the~wet material enters the second cyclone . .
.~ca 32 tangentially through inlet,pipe 120 and then enters the cyclonic flow within the~second cyclone 32. In the preferred embodiment of the invention, the inlet velocity into the second cyclone 32 is in excess of 300 feet per second. The upper segment 110 of the second cyclone 32- includes a plurality of shear panels 96 located about the circumference of the upper segment 110.. The inside of the shear panels 96 include a.plurality of blades 130 that project inward into the cycionic flow of the wet material and mechanically shear the~wet material to further size reduce the material. . The second .cyclone 32 also includes a core finder 128 that ~.tnctionally operates in the same manner as the core finder 118 of the .first cyclone 30. The core ~fnder 128 is hydraulically adjusted through pistons 126. This allows the core finder 128 to-'be~asily and precisely located in order to achieve the desired separation between a substantially dry and a substantially liquid portion of the wet material .in the second cyclone 32. As opposed to the first cyclone 30, which is focused on desiccation and particle size reduction, the second cyclone 32 is a separation cyclone whereby the wet material under the influence of eyclonic forces is separated into a substantially dry and a substantially liquid portion through specific gravity separation. Pathogen reduction also takes place therein. The substantially dry portion leaves the second cyclone 32 through~a lower exit 124, while the substantially liquid portion leaves the second cyclone 32 through an upper exit 122. The w degree ofseparation is influenced to a-large degree by the amount of time the material is exposed to the cyclonic forces within the second'cyclone 32. Manipulation of the position of j I
the core finder 1.28 affects this processing parameter, as .well as other variables. Of course, those of ord inary skill in the art will understand that the exact position of the core finder 128 can and will vary depending on the type of wet material and the desired consistency of the .._. . ~,~. ~ .'~.~. ...
final :processed product. The second c clone 32. includes a support frame 104 that.terminates . - . ~ .
in three legs that secure to the floor of~the apparatus 10. The second cyclone 32 also includes a :hatch 100 for inside access and for .clean out purposes if necessary.
As noted above, the substantially dry portion of the wet material exits that second cyclone through the lower exit 124 where it enters a discharge auger 132 that is surrounded by an auger shell 94 (Figures 1, 20, 21, and 27). The discharge auger 132 conveys the substantially dry portion of the processed wet material from the bottom of the. second cyclone .
32 to any convenient receptacle that is. placed at the output erid of the discharge auger and shell 132, 94 (seen best in Figure 1). A discharge auger hatch 134 is,provided at the input end ofthe auger and shell 132, 94 for clean out purposes. Additionally, the casing around the input end of the auger and.shell 132, 94 and the bottom of the second cyclone 32 forms a vortex dissipater that maximizes the size ofthe second cyclone 32 and minimizes the overall height of the second cyclone 32. Alternatively, a remote feed tube (not shown) can be attached to the output end of the discharge auger and shell 132, 94 to extend the reach of the output of the substantially dry portion of the processed wet material.
Hydraulic hook ups are provided to power the remote feed tube as needed.
The substantially liquid, or vapor, portion of the processed wet material exits the second cyclone, 22 hrough the upper exit 122 of the second cyclone 32 and then enters a discharge plenum 34. The discharge plenum 34 transports the wet material to the wet scrubber 36 for additional processing. The wet scrubber 36 is of a type that is commercially available. Preferably, the wet scrubber 36 includes a blower capacity of 10,000 CFM, is hydraulically driven, and has a capacity on the order of 280 gallons of liquid. The wet scrubber 3G uses a fine mistlspray at the junction of the discharge plenum 34 and wet scrubber 36 inlet to remove any.resid-u~al dust partioies. .The wetacrubber_ 36 also feat~uresw S continual water re-circulation and effluent filtration.
The apparatus 10 is completely powered by a diesel engine 24, which in the preferred embodiment of the invention is provided by Caterpillar Inc., namely a model diesel engine (shown best in Figuxe 23). A 90-degree drive 136 is attached to one end of the diesel engine 24 and to the blower 40 at the other end, and allows the diesel engine to power the .blower 40. The 90-degree drive 136 is commercially available from Hub City Drive.
Also connected to the diesel engine 24 is a radiator 38 and fan 140 to provide a means to control the temperature of the .diesel engine 24 (see Figure 24). A hydraulic :pump 144 is attached o the diesel engine.24 at the end opposite to the 90 degree drive 136, and below the radiator 38 and fan 140 (see Figure 25). The hydraulic pump 144 °is :powered by the diesel , I 5 engine 24 and drives the various hydraulic systems in the apparatus 10. In the preferred embodiment ofthe invention, the hydraulic pump 144 is a commercially available pump of the type provided by Vickers Hydraulic. Figure 26 shoves a hydraulic manifold 146 for connection of the various hydraulic lines between the hydraulic pump 144 and the various hydraulic systems of the apparatus 10.
In this regard, the apparatus 10 includes the following hydraulically powered systems and/or components: (1) the core finder 118 ofthe second cyclone 32; (2) the intake hopper 14 w auger drive 42; (3) the pre-conditioning auger 66; {4) the discharge auger 132; (S) a fan located internal to the wet scrubber 36; (6) a circulating pump located internal to the wet 1$
i , __ scrubber 36; (7) the grinder/air lock 26; and (8) a roof vent or skylight {not shown).
Additionally, the apparatus 10 includes hydraulic hook ups to allow for a hydraulically driven extension to the discharge auger 132, in the case where such extensions are necessary to reach ~. ~ . -- . . . ._ ..
a sp~ific disposalwlocation.~ _ .. . r;,:. . .. . . . . , . .
Figures 22a-d shows various vieiws of a fuel tank 16 used to store diesel fuel for the diesel engine 24, and a hydraulic fluid reservoir 18 used in connection with the various hydraulic systems and hydraulic pump 144: The fuel tank includes a plurality of internal baffles 148 to reduce the movement of the fizel in the tank when the apparatus 10 is in motion.
~ The.,present invention also includes an alternative embodiment wherein the grinder/air lock 26 is replaced with an eductor 150 {shown generally in Figure 28, and operatively in Figure 29). 1n the referred embodiment of the invention, the eductor 150 is a 4 inch :L48E~TAR Mixing Eductor with a urethane insert nozzle sold by Votex Ventures Inc. of FIouston Texas, which is of.a type disclosed in United States Patent Nos.
5,664,733 and 1 S 5,775466 (which are incorporated herein by reference). A tube 152 connects. the outlet 51 'of the :pre-conditioning, unit 20 to the feed-through housing 28~ and to the eductor 150. Thus, the wet material exiting the pre-conditioning unit 20 enters the eductor 150 through tube 152.
The eductor 150 is powered by a centrifugal or gear pump .(not shown) that creates a pressurized fluid stream that enters the eductor 150 through a primary liquid feed 153. A
nozzle 154 generates an axial and radial flow stream directed toward a mixing chamber 160.
The pressurized fluid stream is converted from pressure-energy to high velocity as the fluid enters the nozzle 154 and exits in the radial and axial flow stream, which increases turbulence in -the mixing chamber 160. The high velocity jet stream exiting the nozzle 154 produces a strong suction in the mixing chamber 160 that draws a secondary fluid such as the wet material through an inletlsuction port I 58 and into the mixing chamber I60.
An exchange of momentum occurs when the primary and secondary fluids interact. The turbulence between the two fluids~;produces a~ uniformly m~ix~ed.stream traveling at.a velocity intermediate ~ . _. _ between the motive and suction velocities through a narrowed fixed diameter throat 159 where the mixing is completed. The mix enters a diffuser 156 that is shaped to reduce velocity gradually and to convert velocity back into pressure at the discharge end of the diffuser 156 with a minimum loss of energy. At this point, the mixture/wet material exits the eductor 158 and is moved by the air stream within the feed-through housing 28 fox processing in the manner described hereinabove.
In a further embodiment of this invention, a recycle loop 200 having an input end 202.
and.an output end 204 carries a portion of the processed material from the output end of the second cyclone 32 of the apparatus 10 fio the inlet hopper 14 for re-treatment (Figs. 30-39}.
Processed material exits the second cyclone 32.and may fall into a first auger.surrounded by IS an auger shell 208 (Figs. 31; 34, 35}. The first auger directs the processed material away from the input end 202 of the recycle .loop 200 of the apparatus 10. As shown in Figures 32, 37;
and 38, the.material then exits the first auger through an open portion 210 of the frst auger shell 208 and falls onto a second auger surrounded by a shell 214. The second auger carries the.processed material to the output end 204 ofthe recycle loop 200 for reintroduction into the inlet hopper 14 of the waste treatment apparatus 10 (Figs. 33 and 39).
When the material reaches the output end 20f, the material falls out of the second auger shell 214 into a chute - ..
216 that directs the material into the inlet hopper 14. The material is then re-processed through the apparatus 10 and acts as a scouring agent to clean the insides of the apparatus 10 of polymer and residue that builds up during operation. The two augers in the recycle loop 200 are .hydraulically powered by a first drive :box 220 and a second drive 'box 222 and are made from mild or stainless steel, or PVC pipe. 1n the preferred embodiment, two 4-inch augers are.used, although tha augers ~odbe 6-inch,-7-inch, or-8-inch augers.
The.,~shape of.
the recycle loop 200 is dictated by space considerations. One skilled in the art would recognize that the recycle loop 200 could use one auger or more.
In this embodiment, the output end of the second cyclone 32 of the apparatus 10 and the input end 202 ofthe recycle loop 200 are separated by a slide gate 218 (Figs. 31, 34, 35~.
The slide gate 218 controls the amount of processed material allowed to enter the recycle loop 200. The slide gate 218, however, is not required, as the flow of processed material into the recycle loop 200 can also be controlled by the speed of.the first auger. In this embodiment, :the slide. gate 21'8 can be USed as an on/off device for the recycle loop 200.
L;eaving.at least some.processed material in the second cyclone 32 may be desirable, as it allows for some material to be available for reprocessing when the waste treatment apparatus 10 is used again. A user then does not have to wait for an initial cycle of processing through the waste treatment apparatus 10 to be completed in order for the recycle loop 200 to be used.
in addition, the recycle loop 200 can be used with other waste treatment apparatus designs than the one shown and described above.
Figure 40 shows an improved eductor assembly 300. The assembly 300 uses, preferably, the same eductor 158 disclosed in reference to Figures 28, 29. As shown in Figure 40, the material to be processed enters the asserribly 300 from the preconditioning unit 20. In this embodiment, the grinder/air (ock 26 may be omitted and replaced.with a funnel 302 i extending from the .preconditioning unit 20. The .material enters a tube 304 at the entry end of the eductor 158. A hose clamp 306 secures the tube 304 and funnel 302. A
pressurized air source (indicated by arrow 308), enters the eductor 158. The air stream is between preferably - between about 100 to about 120 psi, wv p :to 500 ef/m: _The air stream to the eduotor 15'8 is ..~>
essentially the same, and the eductor 1S8 operates in essentially the same manner as disclosed hereinabove in reference to Figures 28, 29. The material and air exiting in the eductot 158 as described hereinabove, and exit the eductor throat 310 of the eductor 158 as a combined stream. The combined stream then enters an eductor tube 312.
An air stream (indicated by arrow 314) .is also provided. The air stream 314 enters through a blower pipe 316, and is the same air stream indicated hereinabove as provided by the blower 40. The air stream 314 is .preferably at about 3. psi. The blower pipe 316 surrounds the eductor tube 312, and includes flange clamps 318, 320 that secure the various pieces afthe.blowerpipe 316. The blower pipe 316 terminates with a tube extension 322 welded ~in place. The tube extension 322 brings the end of the blower pipe 316 about to the 1 S end of the eductor tube 312. At this junction, the eductor 158, blower pipe 316 meet the feed through housing 28, which Leads to the .first cyclone 30..
A neck down cover 324 attaches to the tube extension 332, and is located in side the feed through .housing 28. The shape of the cover 324 provides acceleration of the air stream 314 at the point where the air stream 308 containing the material mixes together with air stream 314. This creates a venturi into the feed through housing 28, and prevents biowback of material toward the 'blower 40. Without correctly dimensioning and controlling the acceleration ofthe additional air stream a vacuum can be created in the feed through housing 28, which can lead' material away from the first cyclone 30. This arrangement,greatly i increases the rate of flow of material out of .the preconditioning unit 20 and into the first cyclone 30, and reduces a potential throughput bottleneck at this juncture.
The blower pipe 3 i G, extension tube 322, and the cover 324, can be constructed of . . one piece, or welded together as shown inaFigure 40.--The-preferred material~is.carbon~steel, .~". ._ .
or PVC, however, any suitable simi.lar:material is sufficient.
As stated, the construction of the assembly 300 provides far efficient mixing of the material, and for.acceleration of the material into the feed through housing 28, thereby avoiding a potential bottleneck at the juncture of the feed though housing 28 and the preconditioning unit 20. The use of two venturis accomplishes both proper mixing and I0 acceleration of material; and prevents the problem of blow back.
Accordingly, the design of the assembly 300 is a substantial .improvement on prior designs, and substantially eliminates the drawbacks thereof In the preferred embodiment, the assetribly utilizes the following dimensions.
The tube 304 is between about 4-G inches in diameter. The eductor throat 3 i0 is between about 4-6 inches .in diameter. The eductor tube 312 is between about 4-7 inches in diameter. The neck down cover 324 is between about 6-9 inches in diameter at it narrowest :point, and is between about '7-I O inches at the point the cover 324 joins the end of the blower pipe 3I G.
The inside diameter of the feed through housing. is between about 9-12 inches.
Those of ordinary skill in :the art will understand that the dimensions can and will vary from these preferred ranges, without departing from the scope of the present invention.
The foregoing description and drawings comprise illustrative emboditiients of the present inventions. The foregoing embodiments and the methods described herein may vary based on the ability, experience, and preference of those skilled in the art.
Merely listing the i . _ steps ofthe method in a certain order does not constitute any limitation on the order ofthe steps of the method. The foregoing description and drawings merely explain and illustrate the invention; and the invention is not limited thereto, except insofar as the claims are so limited.
-- ~ . Those skilled in the art that have the..~~~hisure before them will be able-to make.-..~;,~. . .
modifications and variations therein wl'tt~out departing from the scope of the invention.
Figure 32 is a perspective view of the junction of the first auger and a'second auger of the recycle loop.
Figure 33 is a perspective view of the second auger and a discharge chute of the . . recycle loop: ~ ~ - ... . , .. . . . . .. . .
. m~;fi.. _.
Figure 34 is a perspective view: of the second cyclone of the waste treatment apparatus, the slide gate of the recycle loop, and the first auger of the recycle loop.
Figure 35 is a perspective view of the-output end of the second cyclone of the waste treatment apparatus, the slide gate of the recycle loop, and the first auger of the recycle loop.
Figure 36 is a perspective view of the output end of the waste treatment apparatus, the first auger ofthe recycle loop, and the second auger of~the recycle loop.
T'igure 37 is a.perspect~ve view ofthe junctiom ofthe first auger and the second auger of.the recycle loop.
Figure 38 is a ;perspective view of the junction. of the first auger and the second auger ofthe recycle loop.
1 S Figure 39 .is a -perspective view of the second auger and the chute of the recycle loop and the inlet hopper of the waste treatment apparatus.
rigure 40 is a side view of an improved eductor assembly.
Detailed Description of the Invention Describe hereinbelow is one embodiment ofthe present invention; however, those of ordinary skill in the art will understand that the invention is not so limited.. In particular, variations on the present invention are described in United States Fatent Nos.
6,790,349, and 6,50b,311, which are incorporated herein by-reference. The present invention could be carried out on the apparatus disclosed in these patents as well, and on variations therefrom as will be apparent to those of ordinary skill in the art.
In the Figures, Figure 1 shows a mobile apparatus 10 for the treatment of wet material.
The apparatus 10 is adapted for treatr,ent~of a wide variety of wet material including, ..
without limitation, ethanol waste such~as distillers .grain, brewery waste, dairy waste, turkey waste, poultry waste, .beef waste, swine waste; grape residue from wineries, calcium carbonate; calcium sulfate, mycelium, coal fines, lime sludge, paper sludge, compost, saw dust, animal waste, including manure, or any material in need of drying and/or reduction. The apparatus 10 is also adapted for processing ofbiosolids, and preferably for converting biosolids into a-Class A product, but also into a Class B product.
As shown in Figure 1, the apparatus 10 is fully-.enelosed behind a piuralityofpanels secured to a. frame 12, and is built upon a wheeled trailer bed to allow for connection of the apparatus 10 to a semi-tractor (not shown) or other similar device for remote transportation to a working site. As shown in Figures 2-3, the apparatus includes a plurality of main 1 S processing components that will be described in detail hereinbelow, these -include an inlet hopper 14 for receipt of the wet -material (not shown), a diesel fuel tank 1 G
that provides.fuel to a.diesel engine 24 that powers the apparatus 10, a hydraulic reservoir 18 for use with the various hydraulic systems of the apparatus 10, a preconditioning unit 20 for initial treatment (orvprocessing) of the wet material, an air inlet plenum 22 for drawing air.
into -the apparatus I O for use .in treatment of the wet material and forcooling some of the components of the apparatus 10, a radiator 38 for transferring heat from an engine 24 to_ the incoming air stream, w ..
a grinder/air lock 2G for receipt of~the wet material from the pre-conditioning unit 20, a feed-through housing 28 that receives the wet. material from the grinder/air lock 26 and through which the wet material is transferred to a fcrst cyclone 30 for pre-separation treatment, a second cyclone 32 -for separation of the wet material into a substantially dry portion and a substantially liquid (or vapor} portion, an air-discharge housing 34 for.transferring the substantially liquid component ofthevet.material-to a wet scrubber 36, a discharge_auger 132 S for output of the substantially dry portion of the wet material, and a blower 40 that provides air flow to move the wet material through the apparatus 10 and to provide the cyclonic air flow used in the first and second cyclones 30, 32.
>~igures 4a-c and S show in detail the inlet hopper 14 that is designed fox a running capacity of about 3.5 cubic yards of wet material. Of course, those of ordinary skill in the art will understand that the exact amount of wet material fed into the apparatus 10 can and will vary depending on the nature of the wet material and the desired consistency of the output.
The .inlet hopper 14 includes a dual axle auger-comprised of an auger drive .42 and a first and second -flighted auger shafts 44, 46 (see Figure S) that can rapidly move the;wet material fed into the inlet hopper 14 into the apparatus 10, and in particular into the pre-conditioning unit 20.
Figures 6a-d, 7a-b, and 8-11 show in detail the pre-conditioning unit 20. The ,pre-conditioning unit 20 rests upon support feet 50 and is oriented at an angle to conserve space and to accommodate the loading and unloading of the wet material. The pre-conditioning unit 20 includes an intake hopper 48, located at an inlet end of the pre-conditioning unit 20, for receipt of the wet material -from the auger driven inlet hopper 14. The wet material exits the-pre-conditioning unit 20 through outlet 51 located at the bottom of the unit 20 and at an w ..
outlet end thereof. A flighted .pre-conditioning auger 66 moves the wet material through the pre-conditioning unit 20 under the power of an auger.drive motor.58 .located at an output end of the pre-conditioning unit 20. The pre-conditioning auger 66 is contained within an auger shell 52, which is subject to various heat sources designed to raise the temperature of the wet material inside the auger shell 52 to a sufficient level to begin 'killing pathogens in the wet material. In particular, the pre-eondit~o~ning.auger 66 has a.hollow core designed to_accept .
diesel coolant from the engine 24. Tha coolant enters the core of the pre-conditioning auger 66 through coolant hose 76 (see Figure 11 ) and coolant inlet fixture 60 located at the output end of the pre-conditioning unit 20. The coolant exits the core of the pre-conditioning auger 66 at the input end of the pre-conditioning unit 20 through coolant output fixture 62 and ~traveIs through coolant hose 74 back to the diesel engine 24 (see Figure 8).
In this manner, engine waste heat is captured and transferred to the coolant and is in turn transferred to the pre-conditioning auger 66, and in particular to the flights of the auger 66, and then'to the wet material, in the preferred embodiment of the invention, the pre-conditioning auger 66 has over'75 ft. of exposed fin surface area for direct transfer of heat to the wet material. The heat from the coolant is transferred .to the wet material and begins the process of pathogen reduction, aids in drying .the wet material, and helps to soften the wet material fo facilitate further processing by the cyclones 30; 32. Under normal operating conditions, the coolant enters the pre-conditioning unit 20 in excess of 195° F and exits at less than 170° F thereby transferring to the wet material a delta.heat exchange of at least 25°
F.
Further waste heat from the diesel engine 24 is captured by channeling the exhaust from the diesel engine 24 to the pre-conditioning auger 20. Shown best in Figures 7 and 10, the auger shell 52 is surrounded by a helical shell 54 that contains a helix 68. Exhaust from the diesel engine 24 flows into the helical shell 54 through an inlet 70, and exits the helical shell 54 at an outlet 72 at the opposite end of the helical shell 54 from the inlet 70. The heat r from the diesel engine 24 exhaust is channeled through the coils ofthe helix GS wherein the helix.b8 assists in absorbing the heat and subsequent transfer of the heat to the wet material within the auger shell 52. To further facilitate heat transfer the exhaust flows through the pre-conditioning auger 20 in.a direction oosiYte to the direction of flow ~of the wet material. In :~,.
the preferred embodiment of the invention, the diesel exhaust enters. the helical shell 54 at a temperature of about 500° F, and exits at a temperature of about 190° F.
Still further waste heat from the diesel engine 24 is captured for subsequent transfer to the wet material by directing waste heat from the diesel engine 24 into a heater box 56, or exhaust plenum extension, which surrounds the pre-conditioning auger 20 (see Figures 6 a-d, . and 11). Inlet air is introduced into the mobile apparatus 10 through an air plenum 22 (see lrigures 2-3). The air is then exposed to a radiator 38 that is in operative communication with the diesel engine 24. The inlet air is used to cool the diesel engine 24 as it is forced through the .radiator 3 8. The heated air is then channeled through a pre-heater duct 39 and into the heater 'box S6 that surrounds the helical 5he1154. The pre-heated inlet air enters the heater I S box 56 through a pre-heated aix opening 64 in the top of the heater box 56 located near the inlet end ofthe pre-conditioning auger 20. A series of helical fns (not shown) that conforzii to the shape ofthe heater box S6 surround the helical shell 54 and channel the air from the .pre-heated air opening 54 to the pre-heated air outlet 65 located at the bottom of the heater box 56 near the outlet end ofthe pre-conditioning auger 20. The pre-heated air then enters a feed through tube 27 from opening bS, and under the power of a blower 40 is further heat compressed to a temperature in the preferred-embodiment of 140° F. The helical fns in the ~ ..
heater box 56 also assist in the transfer of heat from the pre-heated air into the helical shell 54 and ultimately to the wet material'. Also located inside the air plenurn 22 is a fan 140 used to i .
cool the diesel engine 24. The fan 140 is triggered based on the temperature of the diesel engine 24 and channels a portion of the inlet air from the air :plenum 22 to cool the.engine 24.
After the wet material passes through the. pre-conditioning unit 20'it enters the ~grinder/air lock assembly 26 (see Figure 1a~:1.3)~. The assembly 26 provides for additional :~..
reduction of the particle size of the wet material and for isolation ofthe high velocity heated air moving from the feed through housing 28 under the power of the blower 40 and into the first cyclone 30. Figures 12-13 show two embodiments of the grinder/air lock assembly 26.
In both embodiments, the grinder 82 consists of a plurality of beater 'bars 76 mounted to two a -pair of beater 'bar shafts 80. The shafts 80 rotate under the power of a motor 86 in opposite directions to funnel -the wet material into the center of the grinder 86. The impingement of the wet material on the 'beater bars 76 facilitates particle reduction and thereby reducing bridg~ing.of the material that could clog the grinder 82 and otherwise reduce the efficiency of operation ofthe apparatus 10. The embodiment ofthe grinder/air lock assembly 26 shown in .
Figure 13 utilizes a plurality of gears 88 and a chain 90 driven by the motor 86 to rotate the l 5 beater bar shafts 80. I~owever, those of ordinary skill in the art will understand that the motor can drive the shafts directly, 'or other similar drive means could be uses as well-. In this manner, .the grinder 82 uses .counter-rotating intersection blades to shear or grind fihe wet material into small sized particles in the range of a half inch in size to facilitate acceleration of the wet material upon introduction into the high velocity air stream after the wet material passes through the air Lock 84. The air lock 84 is conventional and is also powered by the motor 86 to move the material from the grinder 82 into the high velocity air stream enclosed ' .
in the feed through 28.
i After the wet material exits the air lock 84 it enters the feed through housing 28 and .is exposed to pre-heated high velocity airflow that moves. the wet material into the first cyclone 30, or pre-separation cyclone. In the preferred embodiment of the invention, the airflow in . . . . the feed through housing_28 reaches to first~cyelone inlet 114 at 325 feetJsecond. Fi~ures~. ~, .. ~ ~ .~ . . , .
. 14-17 show the first cyclone 30. The l<nst cyclone 30 includes a cyclone inlet 114 where the wet material enters the top of the cyclone 30. Inside the first cyclone 30, the wet material is further desiccated and separated under cyclonic forces of the heated blower air moving through~the apparatus. The cyclonic action~moves the wet material in a descending spiral about the exterior of the inside of the first cyclone 30, a column of air rises through the center of the exterior spiral from the bottom .to the top of the first cyclone 30 and moves the wet material out of the f rst cyclone exit port 116. As the wet material circulates inside the first cyclone 30 it is size reduced by collision with the other circulating wet.
material iri the cyclone, and the density .of the material is reduced through desiccation from exposure to the .heated air. Also, exposure to the Seated air reduces pathogens. As the particle size of the wet material -is reduced by separation and the weight of the mateiial is reduced by desiccation, the wet material descends to the bottom of the first cyclone 30 and eventually reaches a size and density that allows it to be carried up and out of the first cyclone 30 as it is captured in the upward center draft of the cyclone.
The first cyclone 30 is constructed in two segments that are bolted together;
the shape ofthe segments facilitates the eyclonic flow or aitthrough the first cyclone 30. Thewpper segment 106 of the first cyclone 30 is cylindrical in shape with a fixed diameter. The lower segment 108 is a frustum, or truncated cone. The upper and lower segments 106, 108 both include matingly aligned flanges where the segments 106, 108 are bolted together. A core i -i :finder 118 is centrally located in the interior ofthe first cyclone 30, and terminates at its upper end at the exit port 116. The core finder 118 serves two purposes. First, the core f nder 118 prevents the wet material from traveling straight from the .inlet 114 to the exit port 116 - - -, without entering in the cyclonic flow. In other words, the core. finder 1-18 extends downward --.~,~~... _.
from the top of the first cyclone to prevent a short circuit of the path of the wet material in the first cyclone 30. Additionally, the core finder 118 is vertically adjustable to affect the cyclonie flow inside the first cyclone 30, and in particular to prevent the accumulation of material at the bottom of the first cyclone 30. The vertical position of the core 'finder 118 will affect haw far toward the bottom of the fzrst cyclone 30 the outward spiral of air descends. If the core finder 118 is not positioned close enough to the bottom of the first cyclone 30 the wet material may not -reach a density and size to allow it to move upward into the rising central column of air that takes the wet material out of the first cyclone 30.
The correct ;position of the core finder I 18 will vary depending on processing requirements and the nature of the wet material, and can be determined through experimentation. The first.cyclone 30 , .. also includes a hatch 98 to allow for maintenance and clearing as necessary. The first cyclone 30 rests on three support feet 102 that secure to the floor of the apparatus 10.
The partially processed wet material leaves the first cyclone 30 through the flop of the first cyclone 30 and enters a material feed tube 92 where the wet material moves to the second cyclone 32 {see Figures 18-21). The second cyclone 32 is generally similar to the. first . cyclone 30 in that it includes an upper cylindrical segment 110 and a lower segment 112 that is a frustum. The upper and lower segments 110, 112 both include-matingly aligned flanges where the segments 110, 112 are bolted together. In the preferred embodiment, the upper segment 110 of the second cyclone 32 is comprised of two individual segments joined at a r matingly aligned flange. Of course, those of ordinary skill in the art will understand that the specific orientation of the segments of cyclones 30, 32 can and will vary depending on processing requirements.
. . ~ In a manner similar to the first~cy~elone 30, the~wet material enters the second cyclone . .
.~ca 32 tangentially through inlet,pipe 120 and then enters the cyclonic flow within the~second cyclone 32. In the preferred embodiment of the invention, the inlet velocity into the second cyclone 32 is in excess of 300 feet per second. The upper segment 110 of the second cyclone 32- includes a plurality of shear panels 96 located about the circumference of the upper segment 110.. The inside of the shear panels 96 include a.plurality of blades 130 that project inward into the cycionic flow of the wet material and mechanically shear the~wet material to further size reduce the material. . The second .cyclone 32 also includes a core finder 128 that ~.tnctionally operates in the same manner as the core finder 118 of the .first cyclone 30. The core ~fnder 128 is hydraulically adjusted through pistons 126. This allows the core finder 128 to-'be~asily and precisely located in order to achieve the desired separation between a substantially dry and a substantially liquid portion of the wet material .in the second cyclone 32. As opposed to the first cyclone 30, which is focused on desiccation and particle size reduction, the second cyclone 32 is a separation cyclone whereby the wet material under the influence of eyclonic forces is separated into a substantially dry and a substantially liquid portion through specific gravity separation. Pathogen reduction also takes place therein. The substantially dry portion leaves the second cyclone 32 through~a lower exit 124, while the substantially liquid portion leaves the second cyclone 32 through an upper exit 122. The w degree ofseparation is influenced to a-large degree by the amount of time the material is exposed to the cyclonic forces within the second'cyclone 32. Manipulation of the position of j I
the core finder 1.28 affects this processing parameter, as .well as other variables. Of course, those of ord inary skill in the art will understand that the exact position of the core finder 128 can and will vary depending on the type of wet material and the desired consistency of the .._. . ~,~. ~ .'~.~. ...
final :processed product. The second c clone 32. includes a support frame 104 that.terminates . - . ~ .
in three legs that secure to the floor of~the apparatus 10. The second cyclone 32 also includes a :hatch 100 for inside access and for .clean out purposes if necessary.
As noted above, the substantially dry portion of the wet material exits that second cyclone through the lower exit 124 where it enters a discharge auger 132 that is surrounded by an auger shell 94 (Figures 1, 20, 21, and 27). The discharge auger 132 conveys the substantially dry portion of the processed wet material from the bottom of the. second cyclone .
32 to any convenient receptacle that is. placed at the output erid of the discharge auger and shell 132, 94 (seen best in Figure 1). A discharge auger hatch 134 is,provided at the input end ofthe auger and shell 132, 94 for clean out purposes. Additionally, the casing around the input end of the auger and.shell 132, 94 and the bottom of the second cyclone 32 forms a vortex dissipater that maximizes the size ofthe second cyclone 32 and minimizes the overall height of the second cyclone 32. Alternatively, a remote feed tube (not shown) can be attached to the output end of the discharge auger and shell 132, 94 to extend the reach of the output of the substantially dry portion of the processed wet material.
Hydraulic hook ups are provided to power the remote feed tube as needed.
The substantially liquid, or vapor, portion of the processed wet material exits the second cyclone, 22 hrough the upper exit 122 of the second cyclone 32 and then enters a discharge plenum 34. The discharge plenum 34 transports the wet material to the wet scrubber 36 for additional processing. The wet scrubber 36 is of a type that is commercially available. Preferably, the wet scrubber 36 includes a blower capacity of 10,000 CFM, is hydraulically driven, and has a capacity on the order of 280 gallons of liquid. The wet scrubber 3G uses a fine mistlspray at the junction of the discharge plenum 34 and wet scrubber 36 inlet to remove any.resid-u~al dust partioies. .The wetacrubber_ 36 also feat~uresw S continual water re-circulation and effluent filtration.
The apparatus 10 is completely powered by a diesel engine 24, which in the preferred embodiment of the invention is provided by Caterpillar Inc., namely a model diesel engine (shown best in Figuxe 23). A 90-degree drive 136 is attached to one end of the diesel engine 24 and to the blower 40 at the other end, and allows the diesel engine to power the .blower 40. The 90-degree drive 136 is commercially available from Hub City Drive.
Also connected to the diesel engine 24 is a radiator 38 and fan 140 to provide a means to control the temperature of the .diesel engine 24 (see Figure 24). A hydraulic :pump 144 is attached o the diesel engine.24 at the end opposite to the 90 degree drive 136, and below the radiator 38 and fan 140 (see Figure 25). The hydraulic pump 144 °is :powered by the diesel , I 5 engine 24 and drives the various hydraulic systems in the apparatus 10. In the preferred embodiment ofthe invention, the hydraulic pump 144 is a commercially available pump of the type provided by Vickers Hydraulic. Figure 26 shoves a hydraulic manifold 146 for connection of the various hydraulic lines between the hydraulic pump 144 and the various hydraulic systems of the apparatus 10.
In this regard, the apparatus 10 includes the following hydraulically powered systems and/or components: (1) the core finder 118 ofthe second cyclone 32; (2) the intake hopper 14 w auger drive 42; (3) the pre-conditioning auger 66; {4) the discharge auger 132; (S) a fan located internal to the wet scrubber 36; (6) a circulating pump located internal to the wet 1$
i , __ scrubber 36; (7) the grinder/air lock 26; and (8) a roof vent or skylight {not shown).
Additionally, the apparatus 10 includes hydraulic hook ups to allow for a hydraulically driven extension to the discharge auger 132, in the case where such extensions are necessary to reach ~. ~ . -- . . . ._ ..
a sp~ific disposalwlocation.~ _ .. . r;,:. . .. . . . . , . .
Figures 22a-d shows various vieiws of a fuel tank 16 used to store diesel fuel for the diesel engine 24, and a hydraulic fluid reservoir 18 used in connection with the various hydraulic systems and hydraulic pump 144: The fuel tank includes a plurality of internal baffles 148 to reduce the movement of the fizel in the tank when the apparatus 10 is in motion.
~ The.,present invention also includes an alternative embodiment wherein the grinder/air lock 26 is replaced with an eductor 150 {shown generally in Figure 28, and operatively in Figure 29). 1n the referred embodiment of the invention, the eductor 150 is a 4 inch :L48E~TAR Mixing Eductor with a urethane insert nozzle sold by Votex Ventures Inc. of FIouston Texas, which is of.a type disclosed in United States Patent Nos.
5,664,733 and 1 S 5,775466 (which are incorporated herein by reference). A tube 152 connects. the outlet 51 'of the :pre-conditioning, unit 20 to the feed-through housing 28~ and to the eductor 150. Thus, the wet material exiting the pre-conditioning unit 20 enters the eductor 150 through tube 152.
The eductor 150 is powered by a centrifugal or gear pump .(not shown) that creates a pressurized fluid stream that enters the eductor 150 through a primary liquid feed 153. A
nozzle 154 generates an axial and radial flow stream directed toward a mixing chamber 160.
The pressurized fluid stream is converted from pressure-energy to high velocity as the fluid enters the nozzle 154 and exits in the radial and axial flow stream, which increases turbulence in -the mixing chamber 160. The high velocity jet stream exiting the nozzle 154 produces a strong suction in the mixing chamber 160 that draws a secondary fluid such as the wet material through an inletlsuction port I 58 and into the mixing chamber I60.
An exchange of momentum occurs when the primary and secondary fluids interact. The turbulence between the two fluids~;produces a~ uniformly m~ix~ed.stream traveling at.a velocity intermediate ~ . _. _ between the motive and suction velocities through a narrowed fixed diameter throat 159 where the mixing is completed. The mix enters a diffuser 156 that is shaped to reduce velocity gradually and to convert velocity back into pressure at the discharge end of the diffuser 156 with a minimum loss of energy. At this point, the mixture/wet material exits the eductor 158 and is moved by the air stream within the feed-through housing 28 fox processing in the manner described hereinabove.
In a further embodiment of this invention, a recycle loop 200 having an input end 202.
and.an output end 204 carries a portion of the processed material from the output end of the second cyclone 32 of the apparatus 10 fio the inlet hopper 14 for re-treatment (Figs. 30-39}.
Processed material exits the second cyclone 32.and may fall into a first auger.surrounded by IS an auger shell 208 (Figs. 31; 34, 35}. The first auger directs the processed material away from the input end 202 of the recycle .loop 200 of the apparatus 10. As shown in Figures 32, 37;
and 38, the.material then exits the first auger through an open portion 210 of the frst auger shell 208 and falls onto a second auger surrounded by a shell 214. The second auger carries the.processed material to the output end 204 ofthe recycle loop 200 for reintroduction into the inlet hopper 14 of the waste treatment apparatus 10 (Figs. 33 and 39).
When the material reaches the output end 20f, the material falls out of the second auger shell 214 into a chute - ..
216 that directs the material into the inlet hopper 14. The material is then re-processed through the apparatus 10 and acts as a scouring agent to clean the insides of the apparatus 10 of polymer and residue that builds up during operation. The two augers in the recycle loop 200 are .hydraulically powered by a first drive :box 220 and a second drive 'box 222 and are made from mild or stainless steel, or PVC pipe. 1n the preferred embodiment, two 4-inch augers are.used, although tha augers ~odbe 6-inch,-7-inch, or-8-inch augers.
The.,~shape of.
the recycle loop 200 is dictated by space considerations. One skilled in the art would recognize that the recycle loop 200 could use one auger or more.
In this embodiment, the output end of the second cyclone 32 of the apparatus 10 and the input end 202 ofthe recycle loop 200 are separated by a slide gate 218 (Figs. 31, 34, 35~.
The slide gate 218 controls the amount of processed material allowed to enter the recycle loop 200. The slide gate 218, however, is not required, as the flow of processed material into the recycle loop 200 can also be controlled by the speed of.the first auger. In this embodiment, :the slide. gate 21'8 can be USed as an on/off device for the recycle loop 200.
L;eaving.at least some.processed material in the second cyclone 32 may be desirable, as it allows for some material to be available for reprocessing when the waste treatment apparatus 10 is used again. A user then does not have to wait for an initial cycle of processing through the waste treatment apparatus 10 to be completed in order for the recycle loop 200 to be used.
in addition, the recycle loop 200 can be used with other waste treatment apparatus designs than the one shown and described above.
Figure 40 shows an improved eductor assembly 300. The assembly 300 uses, preferably, the same eductor 158 disclosed in reference to Figures 28, 29. As shown in Figure 40, the material to be processed enters the asserribly 300 from the preconditioning unit 20. In this embodiment, the grinder/air (ock 26 may be omitted and replaced.with a funnel 302 i extending from the .preconditioning unit 20. The .material enters a tube 304 at the entry end of the eductor 158. A hose clamp 306 secures the tube 304 and funnel 302. A
pressurized air source (indicated by arrow 308), enters the eductor 158. The air stream is between preferably - between about 100 to about 120 psi, wv p :to 500 ef/m: _The air stream to the eduotor 15'8 is ..~>
essentially the same, and the eductor 1S8 operates in essentially the same manner as disclosed hereinabove in reference to Figures 28, 29. The material and air exiting in the eductot 158 as described hereinabove, and exit the eductor throat 310 of the eductor 158 as a combined stream. The combined stream then enters an eductor tube 312.
An air stream (indicated by arrow 314) .is also provided. The air stream 314 enters through a blower pipe 316, and is the same air stream indicated hereinabove as provided by the blower 40. The air stream 314 is .preferably at about 3. psi. The blower pipe 316 surrounds the eductor tube 312, and includes flange clamps 318, 320 that secure the various pieces afthe.blowerpipe 316. The blower pipe 316 terminates with a tube extension 322 welded ~in place. The tube extension 322 brings the end of the blower pipe 316 about to the 1 S end of the eductor tube 312. At this junction, the eductor 158, blower pipe 316 meet the feed through housing 28, which Leads to the .first cyclone 30..
A neck down cover 324 attaches to the tube extension 332, and is located in side the feed through .housing 28. The shape of the cover 324 provides acceleration of the air stream 314 at the point where the air stream 308 containing the material mixes together with air stream 314. This creates a venturi into the feed through housing 28, and prevents biowback of material toward the 'blower 40. Without correctly dimensioning and controlling the acceleration ofthe additional air stream a vacuum can be created in the feed through housing 28, which can lead' material away from the first cyclone 30. This arrangement,greatly i increases the rate of flow of material out of .the preconditioning unit 20 and into the first cyclone 30, and reduces a potential throughput bottleneck at this juncture.
The blower pipe 3 i G, extension tube 322, and the cover 324, can be constructed of . . one piece, or welded together as shown inaFigure 40.--The-preferred material~is.carbon~steel, .~". ._ .
or PVC, however, any suitable simi.lar:material is sufficient.
As stated, the construction of the assembly 300 provides far efficient mixing of the material, and for.acceleration of the material into the feed through housing 28, thereby avoiding a potential bottleneck at the juncture of the feed though housing 28 and the preconditioning unit 20. The use of two venturis accomplishes both proper mixing and I0 acceleration of material; and prevents the problem of blow back.
Accordingly, the design of the assembly 300 is a substantial .improvement on prior designs, and substantially eliminates the drawbacks thereof In the preferred embodiment, the assetribly utilizes the following dimensions.
The tube 304 is between about 4-G inches in diameter. The eductor throat 3 i0 is between about 4-6 inches .in diameter. The eductor tube 312 is between about 4-7 inches in diameter. The neck down cover 324 is between about 6-9 inches in diameter at it narrowest :point, and is between about '7-I O inches at the point the cover 324 joins the end of the blower pipe 3I G.
The inside diameter of the feed through housing. is between about 9-12 inches.
Those of ordinary skill in :the art will understand that the dimensions can and will vary from these preferred ranges, without departing from the scope of the present invention.
The foregoing description and drawings comprise illustrative emboditiients of the present inventions. The foregoing embodiments and the methods described herein may vary based on the ability, experience, and preference of those skilled in the art.
Merely listing the i . _ steps ofthe method in a certain order does not constitute any limitation on the order ofthe steps of the method. The foregoing description and drawings merely explain and illustrate the invention; and the invention is not limited thereto, except insofar as the claims are so limited.
-- ~ . Those skilled in the art that have the..~~~hisure before them will be able-to make.-..~;,~. . .
modifications and variations therein wl'tt~out departing from the scope of the invention.
Claims (4)
1. An eductor assembly for use in mixing and moving wet material inside an apparatus for processing wet material, said assembly comprising:
an input housing for the introduction of wet material into said assembly;
an eductor for mixing wet material with an air stream; and a housing operatively engaged with at least a portion of said eductor for introducing a second air stream into said assembly.
an input housing for the introduction of wet material into said assembly;
an eductor for mixing wet material with an air stream; and a housing operatively engaged with at least a portion of said eductor for introducing a second air stream into said assembly.
2. The assembly of claim 1, further comprising a restrictive cover secured to said housing for accelerating said second air stream.
3. An apparatus for processing wet material, said apparatus comprising:
an eductor assembly for processing wet material, said assembly comprising:
an input housing for the introduction of wet material into said assembly;
an eductor for mixing wet material with an air stream; and a housing operatively engaged with at least a portion of said eductor for introducing a second air stream into said assembly; and a cyclone for processing the wet material received from said assembly;
an eductor assembly for processing wet material, said assembly comprising:
an input housing for the introduction of wet material into said assembly;
an eductor for mixing wet material with an air stream; and a housing operatively engaged with at least a portion of said eductor for introducing a second air stream into said assembly; and a cyclone for processing the wet material received from said assembly;
4. The apparatus of claim 3, further comprising a restrictive cover secured to said housing for accelerating said second air stream.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/176,980 US20070007198A1 (en) | 2005-07-07 | 2005-07-07 | Method and apparatus for producing dried distiller's grain |
| US11/176,980 | 2005-07-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2542939A1 true CA2542939A1 (en) | 2007-01-07 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002542939A Abandoned CA2542939A1 (en) | 2005-07-07 | 2006-04-12 | Method and apparatus for producing dried distiller's grain |
Country Status (3)
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|---|---|
| US (1) | US20070007198A1 (en) |
| CA (1) | CA2542939A1 (en) |
| WO (1) | WO2007008266A2 (en) |
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-
2005
- 2005-07-07 US US11/176,980 patent/US20070007198A1/en not_active Abandoned
-
2006
- 2006-04-12 WO PCT/US2006/013538 patent/WO2007008266A2/en active Application Filing
- 2006-04-12 CA CA002542939A patent/CA2542939A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20070007198A1 (en) | 2007-01-11 |
| WO2007008266A3 (en) | 2007-03-08 |
| WO2007008266A2 (en) | 2007-01-18 |
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