WO2012038560A1 - Composter of aquaculture animal byproducts not intended for human consumption (sandach) - Google Patents

Abstract

The invention relates to a composter of aquaculture animal byproducts not intended for human consumption (SANDACH). Said composter provides clean, safe and efficient treatment of small amounts of waste (up to 0.5 m³) generated by normal mortality in aquaculture facilities. The composter consists of a series of connected static elements (1, 3 and 6) and mobile elements (2, 4 and 5). A mixing shaft (4 and 8) is located along the entire length of the device and an aeration system (3) is provided. The composter further comprises controls (7) for humidity and temperature and other computer-controlled parameters of the process.

Description

 COMPOSER OF ANIMAL SUBPRODUCTS NOT INTENDED FOR HUMAN CONSUMPTION (SANDACH) FROM AQUACULTURE.

BACKGROUND.

Composting is an aerobic microbiological process that transforms putrescible organic matter into a material that can be used as a soil conditioner or fertilizer, compost. For its proper development an adequate air supply is necessary. The heat generated during the process contributes to the disinfection of the material of the possible pathogens as well as the majority of existing seeds. The objective of a composting system must be to achieve the best possible conditions in the process for the proper development of microbial activity. Its purpose is to maximize the rate of decomposition of organic matter to obtain a stabilized and easy-to-handle product in the shortest period of time. From a technological point of view, the scope of these optimal conditions of the process must be pursued within its economic viability and the possibility of energy autonomy.

The composting process requires that the following conditions be met: · Correct proportion of the carbon / nitrogen content of the materials to be composted.

 • Correct humidity of the mixture.

 • Maintenance of an adequate temperature.

 • Provide adequate air at all times to the mixture.

Maintaining aerobic conditions throughout the composting process is a very important factor that marks its efficiency. Aerobic conditions depend on the efficient passage of oxygen through composting mass. For this, most composting systems resort to different aeration and agitation systems to favor the circulation of air through the organic mass to be composted. There are different composting systems developed to be applied commercially as illustrated in the "The Practical Handbook of Compost Engineering" by Roger T. Haug. Lewis Publisher, 1993 (ISBN 0-87371-373-7) or in "Modern Composting Technologies". Chiumenti, A., et al. ByoCicle (JG Press. Inc), 2005 (ISBN 0-932424-29-5).

However, to achieve an aeration that allows an adequate development of the composting process with the consequent temperature gradient in the whole material is complex. Stirring in these systems helps to improve the passage of air through the material to be composted and the contact surface of said material due to the breakage of existing aggregates. For agitation different procedures have been used, the most commonly used are agitators and rotating drums. In the case of agitators, its effectiveness depends on the size of the mechanism. A small agitator does not mix the mixture assembly properly. On the other hand, a large mechanism that moves the entire composting mass requires motors of great power and adequate support. This last aspect, that of the necessary engine power is a term that marks the mixture using rotating drums. There are many examples of mixing systems in composters based on endless shafts, stirring vanes, rotating drums, conveyor belts, etc., among others those described in US 5744531, US 5716013, US 5766935, P 200102441, US 2005/0106715 or US 2008/0098779. They try to maximize the degree of mixing and contact with the air of the material to be composted with different success. Likewise, and linked in some way to the previous concept, the crushing or disintegration of the material to be composted is an important aspect that facilitates the development of the composting process, either previously or during the process itself. However, such crushing would imply the existence of a previous stage and additional equipment, sometimes complex, as in the case of US 5766935. The crushing process once the process has begun and the matter is partially decomposed improves the process already that the material is more easily disintegrable. For this reason, composting systems have also been described that also favor this last factor, as described in US 5744531, which implies the use of endless screws with sharp edges to favor the breakage of aggregates. Likewise, it is possible to find commercially, different designs of mixing and agitation systems in sectors such as the agri-food industry or the construction industry, such as the manufacture of concrete and construction mortars and, the production of slushies or bakery doughs, respectively. Said designs include elements that can be adapted to the particular needs of the material to be composted in the object of the invention. In the geometric description of the system object of the invention detailed below, a shaft-motor assembly design is incorporated that would favor the aeration of the material to be treated, its mixing and homogenization and the disintegration of the fish to be composted without the need for force the engine or high powers thereof.

There are composters described to treat a wide range of organic waste or designed specifically for a specific type of waste such as garden waste (US 2006/0154362 Al), plant waste from markets and restaurants with their packaging (US 5766935) or generically animal by-products (US 2005/0106715 Al). This is the case of the composter object of the invention related to the composting of fish from aquaculture facilities, a specific type of animal by-product.

The regulatory framework for animal waste generated in aquaculture facilities is contained in Regulation 1774/2002 of the European Parliament and of the Council of October 3, 2002, which establishes the sanitary standards applicable to animal by-products not intended for human consumption introduced the classification of animal by-products into three categories depending on the degree of risk. Aquaculture facilities operators may consider reusing those categories that do not pose a significant risk to public and animal health. In the aforementioned regulation, dead animals were considered type 2 and had to be removed from the place of their generation through a system of withdrawal and transport to authorized plants. Both this Regulation and the one that replaces it (EC 1069/2009) allow the use of alternative disposal methods, carried out on the farms themselves, that prevent the transfer of by-products and, therefore, the biosecurity and environmental hazards that may arise . The transformation of this type of waste into a product, the compost, with agronomic quality and absence of physical-chemical contaminants marks an alternative management route.

It should be noted that these types of farms are usually installed in isolated areas and, sometimes, with a certain degree of environmental protection, such as natural parks. This circumstance may condition the operation of facilities dedicated to the treatment of their waste. This fact may mark the need for its possible operation with alternative energy sources, an aspect also included in patents such as US 2008/0098779. However, in the aforementioned reference, a series of particularities associated with energy autonomy are not suggested, such as the storage of renewable energy demanded by the composter for normal operation or, the participation of elements that favor the natural extraction of gases inside of the composter, element that could be perfectly adapted in the configuration object of the invention, notably saving the energy consumed in forced extraction.

Returning to the particular case of the waste to be treated in the composter that is presented, it is necessary to ensure a maintenance at an adequate temperature and for a certain time for the correct elimination of the components that affect the biological risk of the material so that it can be declassified as such. In the bibliographic references inventions have been found that although they allow the composting of a wide range of waste, in a generic way, they are not specifically adapted to the characteristics of the waste to be composted or to the particular scenarios of generating them in the aquaculture sector as the alternative that involves the use of the object of the invention.

DESCRIPTION OF THE INVENTION In general, the composter of animal by-products not intended for human consumption (SANDACH) from aquaculture, which is the subject of the invention, has a device for treating small amounts of waste (up to 0.5 m ³ ) from ordinary fish deaths in the facilities, although the model allows scalability to adapt to different volumes of waste. The conception of the composter is configured, in general lines, by means of a coated envelope where the mixture is stirred and a mechanism specially designed for its agitation composed of, a shaft-motor assembly to which a series of lightened blades have been incorporated, arranged so suitable along the entire length of the shaft. In addition, the special configuration of the shaft-blade assembly of low weight together with the particular characteristics of the dough to be mixed, favor the use of low power motor elements and, this results in low energy consumption. This last feature greatly facilitates the incorporation into isolated facilities through the application of a mixed system of renewable energy sources such as wind, photo voltaic and / or tidal and the participation of the energy storage system demanded. The elementary characteristics of the composter configuration presented are, among others, the following:

1. Suggest a combination of fixed and mobile parts.

 2. It incorporates a type of shaft that, due to its geometry, allows this type of waste to be mixed and aerated properly, favoring composting with low energy requirements and without prejudice to the possibility of compacting the mixture.

 3. Add an automatic control and registration system of the most relevant parameters such as: humidity and indoor temperature.

 4. Proposes an isolation and oxygenation system for the mixture to be composted specially designed to achieve the objective of aerobic fermentation.

5. The loading system is manual or automatic by pipe, screw or tipper and the unloading is done by tilting the envelope.

 6. The process is carried out in a discontinuous regime and the compost obtained inside the envelope matures outside it.

Next and, in order to clarify the concepts indicated in the previous description, several figures will be accompanied that include illustrations with the most outstanding geometric details.

BRIEF DESCRIPTION OF THE FIGURES. Figure 1: Front view of the closed composter, in normal operating position and, where the following component parts are collected:

 the. Bottom enclosure composed of straight semi-cylindrical ferrule.

 Ib. Upper envelope composed of straight iron.

 2. Rectangular prismatic lid that closes the enclosure by means of a watertight joint in the normal operating position and allows loading and unloading by rotating 90 ° on the axis of the lower enclosure and, by means of the guides, or some other similar mechanism.

 3 a. Evacuation duct of accumulated gases inside the envelope as a result of the process.

 3b Fan box provided with forced air intake grilles by means of the indoor ventilation device.

 4. Motor-reducer assembly provided with a protection box and its fixation to the floor to neutralize noise and vibration levels.

5. Guides carved on the envelope that allow the rotation of all the same for loading and unloading tasks by means of wheels or similar Slip through the inner groove, provided, in turn, with limit switches and emergency brakes.

 6. Metal structure set to support the weight of the dough to be composted and the composter's own weight. In addition, it is provided with wheels to allow easy transport and safety brakes.

8. Control panel and automatic register of signals that indicate the humidity and temperature values of the process, this allows the connections between PC equipment and programmable controllers and, in its feeding regime by means of renewable energies, it allows to connect the necessary inverters for its correct operation and, energy storage.

Figure 2: Exploded view of the component parts that have already been collected in Figure 1 but, in this case, with the top cover open which allows to visualize the inside of the envelope. Inside it is located the component part named with No. 7 which comprises the cylindrical longitudinal axis element provided with blades specially located thereon, respecting an angular range of between 55 ° -65 ° with respect to the axis itself, and whose number of blades will depend on the production of compost to be generated in each case but, you should always sweep the entire interior of the dough in a homogeneous way, without compaction.

Figure 3: View of the composter in loading and unloading regime in full dump position.

Figure 4: Front and top orthogonal views of the shaft-and-blade assembly, in detail of one of the blades. This last view illustrates the geometric peculiarities that make up this special element.

DESCRIPTION OF THE PREFERRED EMBODIMENT FORM.

The composter of animal by-products not intended for human consumption (SANDACH) from aquaculture consists of an enclosure housing with adequate thickness coating, of sufficient capacity for volumes up to 0.5m ³ , of semi-cylindrical geometry in its lower part (the) and its upper part (Ib), disposed of metallic material, has closures through an upper cover (2) and, on the left and right side, by plates of the same geometry and material described for the envelope. In these covers the removable elements that make up the aeration-extraction system are inserted, which allows the composting process to be aerobic, it is located on both sides of the enclosure as follows: on the right side cover; gas evacuation duct (3 a) and engine with protection box and floor support (4) and; on the left side cover, it has a fan box (3b). The assembly formed by enclosure and covers, including the elements described above, are supported by a structure composed of standardized metal profiles finished on two of its legs by means of wheels with brake, to facilitate its transport (6). The support structure admits an effective dump either by means of guides (5) or, by means of a mechanism based on elements meshed on a pipion-crown assembly, optionally. In addition, as an especially innovative element, an axle-motor system is installed with blades of ellipsoidal exterior geometry and inclusions of holes evenly distributed throughout its surface to lighten weight and facilitate the passage of mass avoiding compactions that affect its correct aeration (7 ). The blades joined to the axis by its center, are located at full length oriented in the angular range of 55-65 ° with respect to it, in this way the movement of the entire mass to be composted is covered, with the minimum area required for it. Thanks to the ellipse-shaped geometry of the blades, it is possible to sweep more travel in the direction of its major axis, achieving zero interference of the blade with the envelope, in the direction of the minor axis. The entire mechanical subsystem incorporates a control automation subsystem (8), based on sensors and recording of the signals corresponding to the basic process parameters such as humidity, temperature, motor rotation and ventilation. Additionally, the gas extraction system can be suitably conducted towards the atmospheric environment or towards some type of device intended for the treatment of odors such as a biofilter. Finally, it is possible to adapt the composter to renewable energy sources and the incorporation of wind extractors operating in a depression regime that favor the evacuation of gases operating in isolated situations where conventional energy supplies are not possible.

Claims

1.- Composter of animal by-products not intended for human consumption (SANDACH) from aquaculture comprising:  a) An envelope of semi-cylindrical geometry in its lower part (the) and terminated in its upper part by a suitable cover (2).  b) The shaft-motor assembly located inside the enclosure arranged with ellipsoidal geometry blades, which have been made holes evenly distributed throughout its surface, to lighten weight and facilitate the passage of mass avoiding compactions that affect correct aeration (7)  c) A crossed gas renewal system composed of a forced ventilation element (3b) and a gas extraction element.  d) A loading and unloading system composed of guides fixed to the enclosure (5) or by a gear mechanism of the crown-pinion type.  e) A support of the set consisting of a metal structure that allows the rotation of the envelope and its easy transport by means of wheels provided with brake (6).  f) A system for capturing, controlling and recording process parameters (8) such as temperature, humidity of the air mass inside the composter, as well as, speed and frequency of rotation of the mixing shaft and, the mass temperature that is Compost, all of this, suitable for the composter object of the invention. 2. Composer of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claim 1, characterized by having the following elements: closure caps, in its upper part (2) and; on its left and right sides, composed of two plates of the same geometry and material described for the envelope, in which the removable elements that make up the aeration-extraction system are inserted, which allows the composting process to be aerobic. 3. Composer of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claim 1, characterized by a shaft-motor assembly in which the blades attached to the shaft at its center, are located along its entire length oriented in the angular range of 55-65 ° with respect to it. 4. - Composter of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claim 1, characterized in that it contains a crossed gas renewal system composed, on one side, of a forced ventilation element (3b) and, in front of the first one, another one of gas extraction (3 a) where, optionally, the connection of a conveniently controlled natural wind extraction is allowed. 5. - Composter of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claim 1, characterized in that the support structure allows an effective dump well, by means of guides (5) or, by means of a crown-pinion type gear mechanism. 6. - Composter of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claims 1 and 5, characterized in that the assembly formed by enclosure and covers are supported by a structure composed of standardized metal profiles finished in two of its legs by wheels with brake, for easy transport (6). 7. - Composter of animal by-products not intended for human consumption (SANDACH) from aquaculture, according to claim 1, characterized in that it has a system for capturing, controlling and recording process parameters (8) such as temperature, humidity of the mass of air inside the composter and, the mass temperature that is composted, as well as measuring the speed and frequency of rotation of the mixing shaft (7) and the ventilation-extraction system (3a and 3b).