WO2004022508A1

WO2004022508A1 - Vertical composting apparatus including processing zones

Info

Publication number: WO2004022508A1
Application number: PCT/US2003/028284
Authority: WO
Inventors: Brian Gitt; Prakash Aswani
Original assignee: Biosystem Solutions Inc
Current assignee: Biosystem Solutions Inc
Priority date: 2002-09-09
Filing date: 2003-09-09
Publication date: 2004-03-18
Anticipated expiration: 2005-03-09
Also published as: NZ538626A; MXPA05002649A; CA2498161A1; JP2005538023A; EP1546066A1; EP1546066A4; AU2003270466A1; CN1681749A

Abstract

A vertical composting apparatus (100) having a housing (110) including at least one wall (120); an upper processing zone (150) in the housing (110); at least one lower processing zone (160) below the upper processing zone (150); at least one agitating device (190) separating the upper processing zone (150) and the at least one lower processing zone (160); a waste inlet (40) above the upper processing zonen (150); and a waste outlet (300) below the lowest of the at least one lower processing zones (160).

Description

VERTICAL COMPOSTING APPARATUS INCLUDING PROCESSING ZONES

BACKGROUND OF THE INVENTION

Technical Field

[0001] The present invention relates generally to methods and apparatus for containing, composting, and reducing biodegradable waste, and more particularly to a vertical composting apparatus having discrete processing zones and a method of composting biodegradable materials using the inventive apparatus.

Background Art

[0002] It is well known to process and systematically decompose organic waste material using composting apparatus. Under pressure from a burgeoning population with a taste for unrestrained consumption, the development and use of compositing systems and apparatus have evolved and matured rapidly; so too has the understanding of the decomposition process. It is now known that the thermophilic species of aerobic bacteria best suited for ' ' breaking down organic waste thrive only in limited ranges of environmental conditions. Those with knowledge in the art understand the importance of controlling several conditions to provide the optimal environment for a rapid decomposition process with a minimum of unpleasant odor. Such conditions include the porosity, temperature, oxygen level, and moisture content of the compost pile and the surrounding atmosphere. [0003] Curiously, the motivation compelling the development and use of composting systems, namely the reduction of organic waste, has failed to reduce the waste of physical space required by the compositing systems themselves. Thus, in the commercial setting, it is common to provide large-scale composting systems predicated on a model of moving waste

Attorney Docket No. 00221. PI PCT International Appl Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones horizontally during the decomposition process. Such systems have a large footprint and require the use of a considerable area of potentially valuable land. Generally, the systems are located in remote, rural, agricultural areas, necessitating the transportation of large amounts of biodegradable waste from urban areas, if such areas are committed to the practice of composting. There is, as yet, no known system in the art that provides a large-scale vertical composting apparatus. Known systems are exemplified by those disclosed in the patents discussed below.

[0004] An early method and apparatus is taught in U.S. Pat. No. 4,326,874, to Bϋrklin. The system entails preparing the compost material on a storage surface in which layered strips of compost material are placed side-by-side with adjacent edges and at least one additional layer of compost material is placed on the adjacent strips. Hard substances are removed and the compost material then deposited by a rake-type conveyor member which is capable of being raised and lowered. An aerating system includes aerating lances that move into and from the compost material. Material is moved through the system on a belt-type horizontal conveyor. [0005] In the residential setting, it is known to provide composting apparatus employing horizontally stacked units to improve heat containment and aeration, and to simplify manual turning and mixing of the compost pile. For instance, U.S. Pat. No. 5,190,572 to Long discloses a composter having a plurality of rectangular stackable boxes, each box having four interlocking double walled plastic panels . Each box can be secured above or below another box. so that the boxes can be stacked to any height and the stacking order can be readily changed. The device includes a lid to cover the uppermost box in the stack. In use, the boxes are stacked between an original bottom box and an original top box over a first region of open ground to form a first stack. Biodegradable matter is placed into the composter and allowed to begin decomposing. After decomposition has occurred, the stacking order of boxes is reversed, thereby mixing and aerating the material and ostensibly promoting uniform decomposition. The restacking process also provides access to the interior of the compost mass. [0006] An earlier device is taught in U.S. Pat. No. 4,683,674, to Faul, which shows a panel

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones for use in a garden compost bin. The' panel is shaped to allow horizontal and vertical nesting with like panels to create a cylindrical modular panel structure. As will be readily appreciated, neither Faul nor Long teaches an automated system suitable for large-scale, high-out composting.

[0007] Systems more suitable to commercial use include that shown in U.S. Pat. No. 6,352,855 to Kerouac, which discloses an in-vessel composting apparatus and process for continuous processing of food waste into a two component end products consisting of a bulk organic compost material and a compost-rich, liquid tea. The apparatus includes a shredder/particle sizer feeding a horizontally disposed drum having at least three chambers with connecting ports of sequentially increasing diameter, and through to a bulk collection container. Motorized drum rotation and fluid drains in the first chamber hold a batch volume at elevated temperature for a period of time, and then percolate it through the finished compost product in the third or final chamber to make a nutrient-rich liquid compost tea. The apparatus is designed only for continuous input of raw waste and for horizontal movement of the processed material through a four-process, three-week throughput cycle. [0008] An active contributor to the art of continuous composting is Jack Wright of Canada. His patents include: U.S. Pat. Nos. 5,846,815; 5,551,969, and 5,409,831. In the '831 patent, Wright teaches a continuous composter which includes an enclosed elongate horizontally- disposed tunnel having a garbage inlet end with a mixing hopper, and an outlet end for the discharge of compost. A raised conveyor track comprising parallel rails with rollers is situated in the tunnel floor and extends the length of the tunnel. A train of conveyor trays travel on the track to move processing material. Each tray has a shunting frame and a foramenous base for the aeration of composting material. A ram urges the most upstream tray to advance downstream against the train of trays preceding it, thereby moving the entire train of trays. Aeration means provide air into a space between the tunnel floor and conveyor trays so that air rises through the bases of the trays and the material. A gas exhaust is provided at the top of the tunnel. Mixing rollers with paddles extend from sides of the tunnel to mix the garbage. The tunnel outlet has a pressure-closed hinged door that is urged open by an

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones advancing conveyor tray.

[0009] The '969 patent discloses an improved version of the system of the '831 patent, which includes the addition of a blending trough at the garbage inlet and water input means to add water immediately after mixing by the mixing rollers.

[0010] The apparatus of the '815 patent improves on the devices disclosed in the '969 patent and the '831 patent. While providing the same horizontally-disposed tunnel having essentially the same footprint, and while providing the same mechanical means for moving composting material, it teaches the segregation of the composting apparatus into processing zones, each having self-contained aeration units that minimize the interchange of air between the processing zones. If the apparatus includes only two processing zones, the first self- contained aeration unit aerates the upstream composting zone and recirculates a portion of venting aerating gases within the upstream zone; the second self-contained aeration unit aerates the downstream composting zone and recirculates a portion of its venting aerating gases within the downstream zone. Multi-chamber systems may be provided, with each processing zone having a self-contained aeration unit. The upstream and downstream zones may be separated by intermediate zones, blending with the upstream and downstream zones but tending to minimize any interchange of air between the zones. Each of Wright's systems are large, complex horizontal systems that are costly to manufacture. Additionally, the aeration system in the latest system is less than optimal in that it supplies air only to the underside of the composting material, rather than injecting air into the material piles; thus, substantial portions of the waste material may receive insufficient air flow and reduced aerobic activity.

[0011] Finally, U.S. Pat. No. 6,171,852, to Bright, discloses a composting system having a horizontally-disposed composting bay with inlet and outlet ends. A transport system on the bottom of the bay receives waste material and moves the material lengthwise along the length of the bay from the inlet to the outlet end. The system also includes movable fluid distribution cells including fluid injectors which inject water and air into the waste material as the material moves through the system.

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones [0012] The foregoing patents reflect the current state of the art of which the present inventor is aware. Reference to, and discussion of, these patents is intended to aid in discharging Applicant's acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated patents disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.

Disclosure of Invention

[0013] The present invention overcomes the shortcomings of the prior art by providing a new and improved automated in-vessel vertical composting apparatus and method of decomposing waste material that utilizes a vertical arrangement of segregated processing zones for plug-flow processing of biodegradable waste.

[0014] It is therefore an object of the present invention to provide a new and improved in- vessel composting apparatus having processing zones in a stackable design. [0015] It is another object of the present invention to provide a new and improved composting apparatus that minimizes the amount of land required for a large-scale compositing system.

[0016] A further object or feature of the present invention is a new and improved composting apparatus that facilitates full control of the environmental conditions for optimal rapid decomposition of biodegradable organic waste and to ensure reliable and consistent output of high quality compost.

[0017] An even further object of the present invention is to provide a novel composting apparatus having a plurality of processing zones in a vertical arrangement, thus allowing movement from one processing zone to the next under the influence of gravity alone. [0018] Yet another object of the present invention is to provide a new and improved composting apparatus that separates processing zones with an agitating device that functions

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones to mix and delump the composing pile above the agitator, while simultaneously permitting passage of a preselected amount of compost material to move to a lower processing zone. [0019] A still further object of the present invention is to provide a new and improved non- static, plug-flow type of composting apparatus having a vertical enclosure and one or more control devices for tightly controlling the environmental conditions in which the composting process takes place.

[0020] A still further object of the present invention is to provide a composting apparatus that employs a vertically segmented composting tower to prevent increased compaction in waste material, thereby preventing odors due to a sufficient supply of oxygen in the waste mixture and the reduction of anaerobic decomposition.

[0021] Another object of the present invention is to provide a novel composting apparatus that contains and treats exhaust air through a bio-filter.

[0022] Another object of the present invention is to provide a vertical composting apparatus that collects and processes all leachate generated by the composting process to prevent ground and surface water contamination as well as odor.

[0023] Accordingly, the composting apparatus of the present invention generally comprises a vertically disposed composting enclosure having at least two physically and functionally discrete processing zones. The zones are separated by either a floor or an agitating device, or both, and each zone preferably includes apparatus for monitoring and controlling the oxygen content, moisture content, temperature of the compost pile. There is also disclosed herein a method of composting biodegradable waste utilizing the inventive apparatus. [0024] In a first preferred embodiment of the present invention, and in its most essential aspect, there is provided a vertical composting apparatus comprising: (a) a housing including a wall and having a waste inlet; (b) an upper processing zone in the housing; (c) a lower processing zone below the upper processing zone; (d) at least one device separating the upper and lower processing zones; (e) a waste inlet above the upper processing zone; and (f) an outlet below the lower processing zone. The device separating the upper processing zone from the lower processing zone preferably comprises one or more agitators.

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones [0025] More elaborate embodiments of the present invention include conveyance means for transporting waste to the waste inlet and introducing the waste into the first processing zone; environmental monitoring and control means, including water, temperature and oxygen level sensors, with corresponding hydration, aeration, and heating, cooling, and ventilation systems; programmable logic means for controlling and coordinating the environmental systems; and conveyance means for transporting waste from the vessel after composting. Additionally, larger systems may include one or more intermediate processing zones interposed between the upper and lower processing zones.

[0026] The present invention is also directed to a method for composting material utilizing the foregoing composting apparatus, the method comprising the steps of: (a) introducing biodegradable waste material through an inlet in the apparatus housing; (b) processing the compostable material in the upper processing zone; (c) moving at least one agitating device below the upper processing zone thereby delumping and mixing compost material in the upper processing zone while simultaneously allowing a predetermined amount of processed compostable material to pass into the lower processing zone; (d) processing the compostable material in the lower processing zone to form composted material; and (e) removing the composted material through an outlet below the lower processing zone. [0027] Other novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawing, in which preferred embodiments of the invention are illustrated by way of example. [0028] It is to be expressly understood, however, that the drawing is for illustration and description only and is not intended as a definition of the limits of the invention. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. The invention resides not in any one of these features taken alone, but rather in the particular combination of all of its structures for the functions specified. [0029] There has thus been broadly outlined the more important features of the invention in

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form additional subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based readily may be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

[0030] Further, the purpose of the Abstract is to enable the appropriate national patent offices and their respective public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of this application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

[0031] Certain terminology and derivations thereof may be used in the following description for convenience in reference only, and will not be limiting. For example, words such as "upward," "downward," "left," and "right" would refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as "inward" and "outward" would refer to directions toward and away from, respectively, the geometric center of a device or area and designated parts thereof. References in the singular tense include the plural, and vice versa, unless otherwise noted.

Brief Description of the Drawings

[0032] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones thereof. Such description of the best mode of making and using the invention makes reference to the annexed drawings wherein:

[0033] FIG. 1 is a partial cross-sectional front-left perspective view of a first preferred embodiment of the vertical composting apparatus of the present invention:

[0034] FIG. 2 is a cross-sectional rear view in elevation of the apparatus of FIG. 1 ;

[0035] FIG. 3 is a cross-sectional side view in elevation of the apparatus of FIGS. 1 and 2;

[0036] FIG. 4 is an axial, cross-sectional view of the apparatus of FIGS. 1-3, shown along the sectional line 4-4 in FIG. 2, not including the outlet screw conveyor or the waste input conveyor system;

[0037] FIG. 5 is a cross-sectional front view in elevation of a second preferred embodiment of the vertical composting apparatus of the present invention;

[0038] FIG. 6 is a cross-sectional side view of the apparatus of FIG. 5;

[0039] FIG. 7 is a cross-sectional axial view of the apparatus of FIGS. 5 and 6, shown along the sectional line 7-7 shown in FIG. 5, not including the outlet screw conveyor or the waste input conveyor system; and

[0040] FIG. 8 is a perspective view of a third preferred embodiment of the vertical composting apparatus of the present invention.

[0041] Reference Numeral Legend

The elements in FIGS. 1-8 are as follows:

100 first embodiment of inventive apparatus

110 vessel housing

120 housing wall

130 frame

140 waste inlet

150 upper processing zone

160 lower processing zone

170 leveling means/auger screw(s)

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones 180 motor

190 upper agitating device

200 roller

210 roller

220 roller paddles

230 motor

240 baffle plates

250 lower agitation device

260 roller

270 roller

280 motor

290 inwardly tapering walls

300 discharge outlet

310 discharge conveyor system/screw auger

320 waste input conveyor system/vertically disposed belt conveyor

330 waste loading inlet

340 vertically disposed tube

350 motor driven bucket conveyor cable

360 material outlet

370 misting nozzles

400 second preferred embodiment of present invention

410 intermediate processing zone

420 intermediate agitation device

430 roller

440 roller

450 third motor system

460 gas outlet duct

470 bio-filter

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones 480 air inlet

490 air heating and cooling unit

500 programmable logic means/PLC 500 or computer.

600 third preferred embodiment of the present invention

610 cylindrical housing

620 upper processing zone

630 lower processing zone 630

640 waste inlet

650 waste conveyor system

660 discharge outlets

670 discharge conveyor system

680 bio-filter

690 air inlet duct

700 and outlet duct

710 floor

710a-b floor openings

720 floor

720a-b floor openings

730 slide gate

740 slide gate

750 gate actuating means/hydraulic or pneumatic cylinder

760 gate actuating means/hydraulic or pneumatic cylinder

Best Mode for Carrying Out the Invention

[0042] Referring to Figs. 1 through 8, wherein like reference numerals refer to like components in the various views, FIG. 1 is a partial cross-sectional front-left perspective view of a first preferred embodiment of the vertical composting apparatus of the present

Attorney Docket No. 0022 J. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones invention, while FIGS. 2, 3 and 4 are, respectively, a cross-sectional rear view and cross- sectional side view, and an axial, cross-sectional view thereof. These views show the inventive apparatus 100 in its most essential aspect comprises a vessel housing 110 having at least one housing wall 120. For purposes of composting waste according to the present invention, the vessel is preferably either generally cylindrical, in which event the wall is singular and contiguous, or cuboid, in which event the housing has four walls comprising sides. However, in the first preferred embodiment the vessel housing is cuboid and is supported on a frame 130. Vessel dimensions will vary according to the scale of the composting operation, though heights ranging from approximately nine to eighteen meters (thirty to sixty feet) have proven most serviceable and work best for materials processed for a typical resonance time in a plug-flow system.

[0043] A waste inlet 140 is located at the top of the housing above an upper processing zone 150. The inlet may be either directly above the upper processing zone or to the side, depending upon the means provided for distributing and spreading the waste before introduction into the first processing zone. Positioned below the first processing zone is a lower processing zone 160.

[0044] Waste introduced into the housing through the waste inlet is leveled and evenly distributed over the upper processing zone by leveling means 170, preferably comprising at least one auger screw having either continuous solid or ribbon flights. It will be appreciated, however, that numerous suitable alternative means may be employed, including, for instance, a rotary leveler (as illustrated in FIG. 8). The at least one auger screw is driven by a reversible motor 180, which permits periodic and systematic movement of the waste material in each direction along the length of the auger screw.

[0045] At least one upper agitating device 190 is interposed between the upper processing zone 150 and the lower processing zone 160. Preferably the agitating device comprises a first set of side-by-side rollers 200, 210, each of which include a plurality of surface paddles or bars 220. The rollers are actuated by one or more reversible motors, 230. When operated, the rollers are preferably rotated in opposite directions such that when viewed from either end,

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus . Express Mail No: EV 272824339 US Including Processing Zones the left hand roller rotates clockwise and toward the right hand roller, and the right hand roller rotates counterclockwise and toward the left hand roller. However, each roller may also be rotated in the opposite direction, as long as both rollers are not simultaneously rotated in the same direction.

[0046] In alternative embodiments, the agitating device may be replaced by a different, non-agitating device such as a stationary grid, bars, a moving floor, slide gate, or a hatch. In these embodiments, the device, which separates the different zones in the apparatus, keeps the weight of compost material in the upper region of the composting apparatus from compressing compositing material at the lower region of the composting apparatus. The fundamental concept of processing the compost in vertically disposed but discrete processing zones is nonetheless preserved in such embodiments.

[0047] In the preferred embodiments of the present in invention, a lower agitation device 250 is positioned at the base of the lower processing zone 160. Preferably the agitation device comprises a second set of side-by-side rollers 260, 270 that operate in the manner as described above. The second set of rollers is actuated by at least one second motor 280. [0048] Throughout the composting cycle, the agitation means are operated at predetermined intervals. The agitators mix, delump, aerate, and turn over the compost material inside vessel. The agitation means also support the compost material above them so that the full weight of compost pile does not compact the compost material below it, thereby limiting oxygen supply to material deep within the pile. Effective agitation can be enhanced by the provision of one or more baffle plates 240 positioned on the interior surface(s) of the vessel housing. Alternatively, the vessel housing itself include inwardly tapering walls 290, in the fashion of a hopper, to direct the material flow into the agitators and through the opening at the lower portion of the processing zone.

[0049] A discharge outlet 300 is positioned directly below the lower agitation device. This portion of the vessel housing is configured to direct finished compost into a discharge conveyor system 310, preferably a screw auger, which transports nutrient rich plant growth media from the apparatus to holding bins or other containers to await use.

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones [0050] For large scale processing of biodegradable waste, it is preferable for the inventive system to include a waste input conveyor system 320, preferably a vertically disposed bucket conveyor. The preference of conveyor type is driven by the angle or orientation of the system, and the orientation is directed to advancing the space-saving purpose of the inventive apparatus, though it is not critical to its effective function. Thus, alternative systems could be employed if the conveyor were more horizontally disposed. The waste input conveyor system includes a waste loading inlet 330, a vertically disposed tube 340, a motor driven bucket conveyor cable 350, and a material outlet 360, all of which are well known in the art. [0051] Misting nozzles 380 may be positioned in any processing zone to increase the humidity of the atmosphere and to increase the water content of the compost pile. Optimally added water will not be required in the upper processing zone.

[0052] FIGS. 5 through 7 illustrate a second preferred embodiment 400 of the present invention. Reference numerals in these views indicate identical elements to those in FIGS. 1- 4. These views show the inventive apparatus as having an additional, intermediate processing zone 410, interposed between the upper processing zone 150 and the lower processing zone 160. Provision of one or more intermediate processing zones requires the concomitant provision of one or more intermediate agitation devices 420, preferably a third set of rollers 430, 440, as well as a third motor system 450.

[0053] Environmental control systems may be provided to tightly regulate the conditions under which the material is processed during the resonance period. As noted, misting nozzles can be provided to add water to selected processing zones. Additionally, temperature, oxygen level, and moisture level sensors may be installed in one or more of the processing zones so that adverse conditions can be corrected promptly. The sensors are not shown as they are common and well known in the art. The system may further include gas outlet duct 460 for venting and removing exhaust gasses produced by the composting process. The air removed from the system may be processed in a bio-filter 470, released directly into the atmosphere (if appropriate and permitted), or directed into a ground berm. Either fresh or recycled air may be directed into the vessel housing via air inlet 480, and such may be heated or cooled by a

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones heating and cooling unit 490. All of the environmental systems are preferably coordinated with one another, as well as with the agitation systems, through programmable logic means, either a PLC 500 or a computer.

[0054] FIG. 8 is a perspective view of a third preferred embodiment 600 of the vertical composting apparatus of the present invention. This view shows a system having a cylindrical housing 610, an upper processing zone 620 and a lower processing zone 630, a waste inlet 640 through which biodegradable waste is conveyed into the upper processing zone by a waste conveyor system 650, and one or more discharge outlets 660 through which compost is directed to a discharge conveyor system 670. The system may include hydration means (not shown), temperature control and regulation means (not shown), and exhaust and air conditioning means, preferably a bio-filter 680 in fluid communication with the vessel interior through air inlet and outlet ducts 690, 700, respectively. [0055] Unlike the first and second embodiments discussed above, the third preferred embodiment separates the upper and lower processing zones, and the lower processing zone and the discharge outlets, with floors 710, 720, having openings 710a, 710b, 720a, 720b, selectively exposed or closed by slide gates 730, 740. The slide gates are actuated by gate actuating means, 750, 760, preferably hydraulic or pneumatic cylinders, as are well known in the art. Agitation means are provided, preferably comprising a shaft 770 vertically disposed in the processing zones, the shaft having a plurality of arms 780 extending radially from the shaft to engage and project into the compost pile in each processing zone, and to break up, delump, and aerate the pile when operated. Actuation of the shaft is by a motor (not shown) coupled to the shaft at one end 790.

[0056] Method Steps: The following steps comprise the essential processing sequence in employing the vertical composting apparatus of the present invention: [0057] (1) Organic waste (biodegradable waste) is combined with a bulking agent (wood chips, sawdust, etc.) to achieve a proper carbon to nitrogen ration and a correct porosity in waste material mixture. [0058] (2) The organic waste and bulking agent are mixed thoroughly (typically in a

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones automated four auger mixer, though this can also be accomplished with a front loader or an equivalent method).

[0059] (3) The mixed organic waste and bulking agent are loaded into a bucket elevator receiving hopper. This is typically accomplished with a conveyer, though it can also be done with a front loader or an equivalent method.

[0060] (4) The waste mixture is vertically conveyed by bucket elevator to the top of the composting apparatus.

[0061] (5) The waste mixture is deposited into the top of the composting apparatus.

[0062] (6) The waste mixture is distributed evenly in the horizontal plane by leveling screws into the upper processing zone in the composting apparatus.

[0063] (7) The waste mixture is retained in the upper processing zone for approximately seven days. Each day the waste mixture is moving down as compost is unloaded and new waste is added).

[0064] (8) The waste mixture reaches the agitation system rollers on approximately the seventh day.

[0065] (9) The waste mixture is turned, agitated, de-lumped and forced into the lower processing zone by the agitation system rollers.

[0066] (10) Water is added to the waste mixture if needed to maintain adequate moisture content after the waste mixture passes through the agitation system rollers.

[0067] (11) The waste mixture is retained in the lower processing zone for approximately seven additional days. Each day the waste mixture progressively moves down as compost is unloaded and new waste is added.

[0068] (12) After approximately the fourteenth day, retention in the composting apparatus waste mixture has been stabilized to meet pathogen destruction and vector attraction regulations and now comprises a nutrient rich plant growth media.

[0069] (13) Plant growth media is discharged from the bottom of the composting apparatus via screw conveyor or an equivalent method for further post processing (such as curing, drying, screening, bagging, etc.).

Attorney Docket No. 00221. P1PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones [0070] Monitoring/Controls : The following controls and monitoring systems may be employed to ensure the maintenance of optimum composting conditions: [0071] (1) Vertically oriented temperature probes may be permanently fixed in the center of the composting mass to give continuous feedback to the control panel which activates fans or blowers to effectively regulate temperature and oxygen within the composting mass. The temperature may be controlled so as not to exceed 71 C (160 degrees Fahrenheit) and not to go below 54 C (131 degrees Fahrenheit). Positive air may be pushed by blowers into the bottom of the composting mass and negative air pressure is exerted on top of the composting mass to pull air from the top of the composting mass to a bio-filter. The bio-filter may include a specific mixture of stabilized mature compost, woodchips and other filtering media to clean exhaust air in order to prevent odor from being emitted into the surrounding environment. Other air filtration devices can be utilized to scrub or clean the air instead of a bio-filter.

[0072] (2) Moisture sensors can be positioned throughout the composting mass to give continuous feedback to the control panel which activates irrigation emitters to control moisture content of the composting material. The moisture level of the composting mass can be maintained at approximately 60% to optimize the composting process. [0073] (3) All leachate (waste liquid) generated during the composting process can be contained and diverted for appropriate handling. Leachate can be recycled and used for irrigation purposes or can be diverted to a drain or container for disposal. [0074] The foregoing disclosure is sufficient to enable one having skill in the art to practice the invention without undue experimentation, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not intended to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.

[0075] Accordingly, the proper scope of the present invention should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications as well as all relationships equivalent to those illustrated in the drawings and described in the specification.

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones

Claims

CLAIMS What is claimed as invention is:

1. A vertical composting apparatus comprising: a housing including at least one Wall; an upper processing zone in the housing; at least one lower processing zone below said upper processing zone; at least one dividing means selectively separating said upper processing zone and said at least one lower processing zone; a waste inlet above said upper processing zone; and a waste outlet below the lowest of said at least one lower processing zones.

2. The vertical composting apparatus of claim 1, wherein said at least one dividing means comprises at least one agitating device which selectively allows composting material to pass from said upper processing zone to said lower processing zone while simultaneously agitating the composting material in said upper processing zone.

3. The vertical composting apparatus of claim 2, wherein said at least one agitating device comprises two or more agitating devices, each agitating device comprising a motor and a rotating member driven by the motor.

4. The vertical composting apparatus of claim 3 wherein said rotating member comprises a roller having surface paddles.

5. The vertical composting apparatus of claim 1 further comprising at least one baffle plate angling inwardly from said at least One wall.

6. The vertical composting apparatus of claim 1 further comprising a conveyor

Attorney Docket No. 00221. PI PCT International Appl. Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones system to deliver compostable material to said waste inlet.

7. The vertical composting system of claim 1, further including a conveyor system to convey compost material from said waste outlet.

8. The vertical composting apparatus of claim 1, wherein said at least one processing zone below said upper processing zone includes an intermediate processing zone positioned immediately below said upper processing zone, and a lower processing zone positioned immediately below said intermediate processing zone.

9. The vertical composting apparatus of claim 8, wherein said at least one dividing means comprises at least two agitating devices.

10. The vertical composting apparatus of claim 9, wherein said at least two agitating device comprises two or more agitating devices comprising a motor and a rotating member driven by the motor.

11. A method for composting material comprising:

(a) introducing a biodegradable material through a waste inlet in a composting apparatus comprising a housing;

(b) processing the compostable material in an upper processing zone positioned above a processing zone in the housing positioned below the upper processing zone;

(c) moving at least one agitating device below the upper processing zone thereby allowing the processed biodegradable material to pass into the lower processing zone;

(d) processing the compostable material in the lower processing zone to form composted material; and

(e) removing the composted material through an outlet below the lower processing zone.

12. The method of claim 11 wherein (e) comprises automatically discharging the composted material through a discharge outlet.

13. The method of claim 11 wherein step (c) involves moving an agitating device including a rotating member and a motor, wherein the rotating member is driven by the motor.

14. The method of claim 11 wherein step (c) involves moving an agitating device comprising two or more agitating devices that are spaced apart from each other.

15. A vertical composting apparatus comprising: a vertically oriented housing including a wall; an upper processing zone in the housing; at least one lower processing zone positioned below the first processing zone; at least one device separating the upper processing zone from the second processing zone; an inlet above the upper processing zone; and an outlet below the at least one lower processing zone.

16. The vertical composting apparatus of claim 15 wherein said at least one device separating the upper processing zone from the at least one lower processing zone is a device selected from the group consisting of: a stationary grid, bars, a moving floor, slide gates, agitating device, and a hatch.

17. The vertical composting apparatus of claim 15, wherein said wall is substantially cylindrical.

18. The vertical composting apparatus of claim 15, further including agitation means.

19. The vertical composting apparatus of claim 18, wherein said agitation means comprises a shaft vertically disposed in said upper processing zone and said at least one lower processing zone, said shaft having a plurality of arms extending radially from said shaft, and further including shaft actuation means operatively coupled to said shaft.

Attorney Docket No. 00221. PI PCT International Appl Filing Date: 09/09/2003 (9 Sept. 2003) PCT Patent Application Priority Date: 09/09/2002 (9 Sept. 2002) For: Vertical Composting Apparatus Express Mail No: EV 272824339 US Including Processing Zones