WO2013006912A1

WO2013006912A1 - Waste and organic matter conversion process

Info

Publication number: WO2013006912A1
Application number: PCT/AU2012/000835
Authority: WO
Inventors: Kenneth Michael Bellamy
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-07-12
Filing date: 2012-07-12
Publication date: 2013-01-17
Anticipated expiration: 2014-01-12
Also published as: AU2012283757A1; MY168450A; AU2012283757B2

Abstract

A method for the conversion of organic material into an output product comprising the steps of: Subjecting the organic material to a size reduction process to produce a size reduced organic material product; Inoculating the size reduced organic material product with an inoculant to form an inoculated organic material product; and Subjecting the inoculated organic material product to an incubation process to form the output product.

Description

Waste and Organic Matter Conversion Process

Field of the Invention.

The present invention relates to a waste and organic matter conversion process. In particular, the present invention relates to a process for the conversion of organic material using minimal energy input.

Background Art.

Organic material (such as food) is a significant source of waste. In Asia, and many other parts of the world, putrescent food wastes are an issue of major concern for local and national governments. For instance, it is estimated that some 6.7 million tonnes of food is discarded every year in the United Kingdom alone. In the United States, it is estimated that up to half of the food harvested in the country is never eaten. Public health issues arising from vermin or other contamination and the production of negative by-products (such as odour species) have consistently restricted the use of putrescible organic materials in conversion to a useable product. In addition, traditional methods of handling and conversion of such materials depend primarily upon the degradation of the material either naturally or in a fostered or managed process resulting in wholesale loss of nutrient content and other benefits of the material. As a result, the by-products of such conversion processes are typically low in nutrient, reactive or other value and as such have a low commercial value. Typically processes for organic conversion of putrescible materials also require or involve the incorporation or buy-in of other materials (including inert cellulose or carbon rich material, nitrogen rich elements, etc), energy in the form of mechanical manipulation, heat or other input in order to provide a balanced nutrient stock from which to allow or foster the degradation of the material concerned. This aspect of conventional processes increases the volumetric load on facilities, the cost of process and the footprint required and adds a risk of mis-management to processes which may all work to reduce the commercial viability of the conversion process. Such handling methods have also been limited by the production of various gases and other substances which are a by-product of the processes themselves.

Thus, there would be an advantage if it were possible to provide a process for the conversion of organic material (such as waste food, or putrescent organic material) to a useful product (such as fertilizer or the like) which was not dependant upon the concurrent loss of nutrients or elements of the material and was able to achieve the necessary conversion without attracting vermin or other contamination and without creating public nuisance or health risks. Further, it would be an advantage if a method existed which during the conversion process incubated or fostered the garnering of elements, beneficial characteristics or nutrients to the material which added value to the end product in calorific, or other terms rather than reducing such values in process. It would also be an advantage if a process for management and conversion of organic materials existed which did not result in the net production of harmful greenhouse gases or residues such as methane and carbon-dioxide.

In addition, there would be an advantage if it were possible to provide a process for the conversion of organic material that required the input of relatively low levels of energy to achieve the conversion, as well as reducing or eliminating the production of noxious gases and/or odours.

It would also be an advantage if a process could handle any type of concentrated material without the separate addition of carbon-based or nitrogen rich feedstocks.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

Throughout this specification, the term "comprising" and its grammatical equivalents shall be taken to have an inclusive meaning unless the context of use indicates otherwise. Summary of the Invention.

It is an object of the present invention to provide an organic material conversion process which may overcome at least some of the abovementioned disadvantages, or provide a useful or commercial choice. The process comprises a method of handling of putrescent or other organic material, as well as equipment in which the method may be carried out. The process may further comprise a set of sub-processes which favour and support photosynthetic bacterial activity incubated in putrescent organic matter. In total the process preferably provides a rapid or substantially instantaneous conversion of food and other putrescible wastes without significant artificial energy input and without significant noxious odours from hydrogen sulphide. Further, it is envisaged that the process may be completed with an extremely small carbon footprint (or even a positive carbon footprint), within a very small physical space and without attracting vermin (such as insects, including flies, or rodents etc) - allowing it to be completed at or near the source of potentially putrescent organic wastes and/or in close proximity to sensitive biological or human functions (e.g. on intensive farms or commercial food facilities). In a first aspect, the invention resides broadly in a method for the conversion of organic material into an output product comprising the steps of:

Subjecting the organic material to a size reduction process to produce a size reduced organic material product;

Inoculating the size reduced organic material product with an inoculant to form an inoculated organic material product; and

Subjecting the inoculated organic material product to an incubation process to form the output product.

The output product may be of any suitable form. However, in some embodiments of the invention, it is envisaged that the output product may comprise a fuel, fertilizer (and particularly a bio-fertilizer) or other high value organic material or incubated culture, or a collected substrate for energy generation or the like.

Any suitable organic material may be used in the method. For instance, vegetable matter (including fruits, vegetables, pulses, grains, grasses etc.) or animal matter may be used. The organic material may be fresh organic material, food scraps, waste material (including rotting food or other organic material) or the like, or a combination thereof. Any suitable size reduction technique may be used. For instance, the organic material may be crushed, ground, shredded, disintegrated, torn or the like, or any combination thereof. It is envisaged that the length of time for which the organic material is subjected to the size reduction process will vary depending on a number of factors including the type of organic material, the volume of organic material, the type of size reduction technique being used, the preferred particle size of the size reduced organic material product and so on. In some embodiments of the invention, organic material may be collected prior to the size reduction process. In this way, the method may be carried out as a batch operation, wherein the method is only conducted when sufficient organic material has been collected to make conducting the method feasible. The collected organic material may be inoculated prior to the size reduction process if desired, and inoculating the collected organic material may assist in reducing unpleasant odours generated by the organic material as it decomposes.

In an alternative embodiment of the invention, size reduced organic material may be collected prior to incubation. This means that the size reduction process may be continuous (or semi-continuous), but allows the maceration and/or incubation processes to be conducted on a batch basis once sufficient quantities of size reduced organic material have been collected.

Any suitable inoculant may be used such as, but not limited to, aerobic micro- organisms, anaerobic micro-organisms, or a combination thereof. The inoculant may include photosynthetic micro-organisms, heterotrophic bacteria, and lactic acid bacteria and the inoculant may further include a substrate. In some embodiments of the invention, more than one type of inoculant may be used in the method. In some specific embodiments of the invention, the inoculant may include purple non- sulphur producing heterotrophic photosynthetic bacteria, lactobacillus, yeasts, actinomycetes, Nocardia species, ray fungi, plankton and other chemoautotrophic bacteria. Preferably, the inoculant is of a variety that consumes certain contaminants and/or pollutants during the processing of the organic material. For instance, in a preferred embodiment of the invention, the inoculant may consume gases such as (but not limited to) hydrogen sulphide, thereby reducing the odour generated by the process of the present invention.

In a preferred embodiment of the invention, the process may include steps to maintain populations of the inoculant (and preferably, effective populations) for a suitable period of time. More preferably the process includes steps to maintain populations of the inoculant (and preferably, effective populations) substantially indefinitely.

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The process may further include one or more maceration stages. Preferably, the one or more maceration stages involve mixing the size reduced organic material with water. Preferably, the water contains an inoculant so that the facultative, fermentative or other microbial activity of the inoculant may begin. In a preferred embodiment of the invention, the process may include a two-stage maceration of the size reduced organic material. In a preferred embodiment of the invention, maceration and incubation may occur in the same vessel or chamber. Alternatively, the inoculated organic material may be transferred (for instance by pumping, under gravity etc.) from a first vessel or chamber in which maceration has occurred into a second vessel or chamber in which incubation occurs. Preferably, incubation takes place in a static chamber inoculated with and supporting photosynthetic bacterial activity.

Any suitable conditions (temperature, light, atmosphere etc.) for incubation may be used. However, in a preferred embodiment of the invention, incubation takes place in the presence of natural light. More preferably, incubation may take place in the presence of natural light without the addition of heat from an external heat source.

It is envisaged that inoculant may be added at two or more points in the process. In one embodiment, the process may involve a three-stage inoculation of the organic material. In this embodiment, inoculation occurs in the following stages:

a. During collection and initial storage of organic matter (particularly food wastes);

b. During maceration; and

c. In a static chamber into which material is pumped/transferred following a second stage maceration

In some embodiments of the invention, inoculation may be completed by:

1. Automatic feed by use of a venturi mechanism on a water feed line which provides water as a lubricant and homogenising agent to a grinding/maceration process. During maceration, size reduced organic material is mixed with water which has been inoculated and hence organisms in the inoculant come into close proximity with both substrates of maceration (saps and juices) containing readily available nutrient and with residual organic material with a small particle size. This allows ready access for facultative, fermentative and other microbial activity.

2. ^' Automatic feed by use of a venturi mechanism on a water feed line which provides water to wash down containers used to transport organic material to the machine. In this way inoculant is carried in and adheres to the surfaces of the transport container itself and comes into contact with the organic matter prior to its being fed into the maceration process. Typically collection containers are filled over a period of up to 72 hours before being transported to the maceration mechanism. During this time, material comes into contact with organisms in the container. 3. By contact with previously inoculated organic material in the incubation chamber. Highly motile photosynthetic bacteria are fostered by initial inoculation of a static, translucent, vented but otherwise non aerated chamber typically 1 m3 in size (typically a standard IBC container). Material typically remains in this chamber for up to 21 days with material being added until the chamber is full and then once full being left to incubate for up to 28 days. In this chamber, continual fermentation is supported by the production of low level sugars and other substrates by phototrophic bacteria. Biological Nitrogen Fixation by photosynthetic bacteria is also fostered in the chamber, together with the sequestration of other substances such as carbon, phosphorus, potassium, calcium and most minerals through air transfer occurring at vents and from air entering the chamber as part of the homogenous mixture of the liquor arising during maceration.

Due to the incorporation and fostering of heterotrophic photosynthetic bacterial activity in the process and specifically in the incubation vessel or chamber, the process does not require activation, heating, additional feed-stocks, nutrient balancing or any other addition.

The benefits of the inclusion and incubation of heterotrophic purple, non-sulphur bacteria and others that are able to complete photosynthesis include:

a. The ability to use naturally occurring light frequencies other than visible light; b. The ability to use substances such as hydrogen sulphide as a feedstock; and c. A net output of water, given input of hydrogen and oxygen, provides the following benefits previously not achievable:

i. Fermentation, break-down and re-constitution of putrescent organic material may be completed without the net production of hydrogen sulphide (hence the process does not need to be sealed, does not produce obnoxious odour); ii. Fermentation, break-down and re-constitution of putrescent organic material may occur in a static chamber without external energy input other than natural light of visible or non-visible frequencies; and

Hi. Fermentation, break-down and re-constitution of mixed putrescent organic material may occur without either the input of heat or the net loss of heat.

The liquor resulting from the incubation process is preferably a chemically homogenous re-constitution of bio-mass and suspended or emulsified mineral elements making up a fully reconstituted microbial substrate. As a result a relatively consistent output material may be obtained despite significant variation in the input material.

In another aspect, the invention resides broadly in an apparatus for the production of an output product from organic material, the apparatus comprising:

A size reduction portion adapted to reduce the size of the organic material to create a size reduced organic material product;

Inoculation means for inoculating the size reduced organic material product with an inoculant to form an inoculated organic material product; and

An incubation portion in which the inoculated organic material product is incubated to form the output product.

In some embodiments of the invention, the size reduction portion of the apparatus comprises one or more size reduction means. The size reduction means may be of any suitable form, such as, but not limited to, blades, discs, impellers, wheels, grinding media, hammers, rollers or the like or any combination thereof. The size reduction means may operate continuously or may operate for a predetermined length of time. If the size reduction means are operated for a predetermined length of time, the actual length of time may be determined based on the weight of items, the volume of items, the number of items, the type of items, the type of size reduction means, the number of size reduction means, or the like or any combination thereof. The time taken for the production of the size reduced organic material may be controlled automatically (e.g. by sensors located in the size reduction portion that sense when the size reduction of the organic material has reached an optimal point) or manually (e.g. a user may be able to control the length of the size reduction step manually by actuating the size reduction means). Alternatively, the size reduction process may simply be operated for a fixed period of time, regardless of the type and quantity of organic material fed to the size reduction portion. Still further, the size reduction means may operate continuously, or may be provided with one or more sensors so that the size reduction means actuated automatically as soon as the one or more sensors sense that organic material has been fed to the size reduction means.

In embodiments of the invention in which the size reduction means is operated manually, it is envisaged that a user may actuate the size reduction means using any suitable actuator. For instance, the actuator may comprise buttons, pedals, switches or the like, or a combination thereof. In some embodiments of the invention, the actuator may be actuated remotely, such as through a wireless device (remote control or the like), using a computer program or application or the like.

The size reduction means may be operated using any suitable power source, such as mains power, one or more batteries, one or more photovoltaic cells, generators or the like, or any suitable combination thereof. However, it is envisaged that the size reduction means will typically be operated using a mains power source.

In a preferred embodiment of the invention, the apparatus may further comprise a maceration portion. The maceration portion may be separate to the incubation portion, or the maceration portion and the incubation portion may be the same portion of the apparatus used for separate steps in the processing of the inoculated organic material.

Preferably, the maceration portion and the incubation portion comprise one or more chambers or vessels in which the inoculated organic material is processed. The one or more chambers or vessels may be of any suitable size, shape or volume. In a preferred embodiment, the interior of the incubation portion may be exposed to light. This may be achieved by fabricating the incubation portion from a clear or semi-opaque- material, or by providing the incubation portion with one or more apertures (and, preferably, closed apertures such as windows or the like) through which light can enter the incubation portion. In this way, photosynthesis can be achieved in the incubation portion.

It is envisaged that the size reduced organic material leaving the size reduction portion will be transferred to the incubation portion of the apparatus (or the maceration portion, if present). The transfer of the size reduced organic material may be achieved using any suitable technique. For instance, the size reduced organic material may be fed under gravity to the inoculation portion or maceration portion. Alternatively, the size reduced organic material may be transferred using mechanical means, such as a pump or the like. Still further, the size reduced organic material may be transferred using a Venturi or the like.

The inoculation means may be of any suitable form. For instance, the inoculant may be added manually to the apparatus. Alternatively, the inoculant may be added automatically to the apparatus. In some embodiments of the invention, the inoculation means may comprise a storage vessel for the inoculant, the storage vessel being associated with one or more outlets in the form of a nozzle, hose, pipe, valve or the like, or any suitable combination thereof. It is envisaged that the storage vessel will require periodic re-filling by a user.

The inoculation means may operate continuously, so that inoculant is continuously added to the apparatus. Alternatively, the inoculation means may be actuated only when, for instance, the size reduction portion is actuated. Still further, the inoculation means may be controlled such that inoculant is automatically added to the apparatus at intervals at time, including at regular intervals of time. Preferably, however, inoculant is added to the apparatus only when required.

It is envisaged that more than one inoculant may be added to the apparatus. The inoculants may be stored and added together, or may be stored in separate storage vessels and added independently of one another. When more than one inoculant is used, the inoculants may be added to different parts of the apparatus (for instance, a first inoculant may be added to the size reduced organic material, while a second inoculant may be added once the inoculated organic material has been transferred to the maceration portion or the incubation portion.

The maceration portion may further include agitation means. For instance, one or more pumps, impellers or other suitable form of agitator may be used to agitate the size reduced material. This may be done to ensure that sufficient contact between the inoculant and the size reduced organic material is achieved.

The apparatus may comprise a single unit in which each portion of the apparatus is housed. Alternatively, one or more portions of the apparatus may be housed in separate housings to one another. For instance, the size reduction portion (and optionally the maceration portion) may be housed in a first housing, while the incubation portion (and optionally the maceration portion) may be housed in a second housing in fluid communication with the first housing. In other embodiments, the size reduction portion may be housed in a first housing, the maceration portion may be housed in a second housing and the incubation portion may be housed in a third housing. If desired, the inoculant storage vessel or chamber may also be housed in a separate housing.

The present invention provides a number of significant benefits and advantages. Firstly, the process of the present invention has a very small (or even positive) carbon footprint. Given that putrescent organic material is a significant source of methane and other so-called greenhouse emissions, this is a major advantage. In addition, alternative treatment of organic materials (such as composting) has a relatively large carbon footprint. Processing of organic material in this invention differs from either conventional composting or anaerobic digestion processes in that the process sequesters some atmospheric carbon during processing rather than primarily precipitating the wholesale release of organic carbon as carbon dioxide during the fermentation/reconstitution of organic matter. Hence, photosynthetic activity is at its core.

Furthermore, the physical footprint of the present invention is much smaller than that for alternative methods of processing organic waste. This is achieved through the effective compression of the waste by the reduction of particle size. Further, the process is self-sufficient (or makes up for deficiencies) in nutrient, such that it is not necessary to add large volumes of other "carrier" materials (soil, green waste, other organic matter etc) as required in other processes to balance and maintain microbial activity.

Further advantages include the fact that the present invention has a significantly reduced energy signature in comparison to alternative processes. This is due to the use of bacterial photosynthesis which captures light energy rather than having to use inputs of electrical and/or other energy which characterize organics processing in many alternative processes. In addition, the cost of the present process is significantly reduced in comparison to alternative processes due to the preceding advantages and the fact that processing may take place close to the source of the waste so as to reduce materials handling costs.

Finally, the present invention provides a reduced exposure to odours than alternative processes due to the inclusion of and ability to maintain populations of organisms that consume hydrogen sulphide during photosynthesis.

Brief Description of the Drawings.

An embodiment of the invention will be described with reference to the following, drawings in which:

Figure 1 illustrates a flow diagram of a waste conversion process according to an embodiment of the present invention; and

Figure 2 illustrates an exploded view of a waste conversion apparatus according to an embodiment of the present invention; and

Figure 3 illustrates a schematic view of a waste conversion apparatus according to an embodiment of the present invention.

In Figure 1 there is illustrated a flow diagram of a waste conversion process according to an embodiment of the present invention. Illustrated in this Figure are a number of containers 10 in the form of buckets for the collection and transportation of organic material to a waste conversion apparatus. In the embodiment of the invention shown in Figure 1, the containers 10 whose contents have already been dispensed into the apparatus are washed in a washing facility 1 1. In the washing facility 1 1 , inoculant is added to the water, meaning that the organic material collected in the containers 10 is pre-inoculated. This is done in part to suppress odours arising from the organic material, and also to enhance the production of the output product 12.

Organic material is fed into a size reduction process 13 and is mixed with water 14 and inoculant 15. Once the size of the organic material has been reduced to the desired size, the size reduced and inoculated organic material is fed to a maceration and mixing process 16. Once maceration is completed, the inoculated organic material is transferred to an incubation process 17. The incubation process 17 is conducted in a static (i.e. non- agitated), vented vessel or chamber. If necessary or desired, gases 18 may be extracted from the incubation process for use, for instance in the generation of electricity.

After a suitable period of time (and the length of time will depend on the type of inoculant used, the type and amount of organic material used, the size of the size reduced organic material, the ambient conditions and so on) the output product 12 is removed from the incubation process 17 and used for fertilizer, fuel, as a collected substrate for energy generation and so on.

In Figure 2 there is shown an exploded view of a waste conversion apparatus 19 according to an embodiment of the present invention. The apparatus 19 comprises a size reduction portion 20 comprising a grinding unit 21 that is housed within a first housing 22. Organic material is fed into the grinding unit 21 through an aperture 23 in an upper surface 31 of the first housing 22, with the aperture 23 being in communication with the grinding unit 21. Tools such as a plunger 24 and tongs 25 are provided to assist in forcing organic material into and through the grinding unit 21 , for instance if the organic material becomes stuck in the grinding unit 21. It is also envisaged that, in commercial or domestic applications, the apparatus 19 will be provided with a poster 25 or instruction sheet that sets out details of how to use the apparatus 19 and/or the types of matter that should and should not be placed in the grinding unit 21. It is envisaged that the poster 25 will be displayed on a wall or other surface adjacent the apparatus 19.

The upper surface 31 of the first housing 22 is sloped downwards towards the aperture 23 in order to assist in ensuring the organic material flows towards the aperture 23. In addition, the sloped upper surface 31 allows for the upper surface 31 to be washed down easily after use.

The outlet 26 of the grinding unit 21 is connected to a pump 27 via hose 28 that passes through an aperture 30 in the wall of the first housing 22 as well as a corresponding aperture in the wall of a second housing 29. The pump 27 is housed within the second housing 29 which, in the embodiment of the invention illustrated in Figure 2, is separate to the first housing 22.

The pump 27 pumps the size reduced and inoculated organic material to either a maceration portion (not shown) or an incubation portion (not shown) via hose 32 that exits the second housing 29 through an aperture 33 in the wall thereof. The upper surface 34 of the second housing 29 is provided with a substantially flat region in which a container 10 for the collection of organic material may be stored when not in use or prior to emptying its contents into the grinding unit 21.

In Figure 3 there is shown a schematic view of a waste conversion apparatus 19 according to an embodiment of the present invention. In this Figure it may be more clearly seen that the outlet 26 of the grinding unit 21 is connected to the pump 27 by hose 28. A series of controls 37 are provided on the first housing 21 for switching the apparatus on and off, operating the grinding unit 21 and/or the pump 27 and so on. The outlet of the pump 27 is connected to the incubation portion 35 (in the form of a clear or semi-opaque tank) via hose 32. In the embodiment of the invention shown in Figure 3, a fitting 36 is inserted into an upper region of the incubation portion 35 to allow a flow of organic material through the hose 32 and into the incubation portion 35.

It is envisaged that the incubation portion 35 will include a tap, stopcock, valve or the like (not shown) through which the output material may be removed from the incubation portion 35 for use. Those skilled in the art will appreciate that the present invention may be susceptible to variations and modifications other than those specifically described. It will be understood that the present invention encompasses all such variations and modifications that fall within its spirit and scope.

Claims

1. A method for the conversion of organic material into an output product comprising the steps of:

2. A method according to claim 1 wherein the organic material comprises vegetable matter or animal matter.

3. A method according to claim 1 or claim 2 wherein the size reduction process involves crushing, grinding, shredding, disintegrating or tearing the organic material.

4. A method according to any one of the preceding claims wherein the inoculant comprises aerobic micro-organisms, anaerobic micro-organisms or a combination thereof.

5. A method according to any one of the preceding claims wherein the inoculant includes photosynthetic micro-organisms.

6. A method according to any one of the preceding claims wherein the method further includes one or more maceration stages between the size reduction process and the incubation process.

7. A method according to any one of the preceding claims wherein inoculant is added at two or more points in the process.

8. A method according to any one of the preceding claims wherein the incubation process is conducted without the addition of heat from an external heat source.

9. An apparatus for the production of an output product from organic material, the apparatus comprising:

10. An apparatus according to claim 9 wherein the size reduction portion comprises one or more size reduction means in the form of blades, discs, impellers, wheels, grinding media, hammers, rollers, or a combination thereof.

11. An apparatus according to claim 9 or claim 10 wherein the apparatus further comprises a maceration portion.

12. An apparatus according to claim 1 1 wherein the maceration portion includes agitation means.

13. An apparatus according to any one of claims 9 to 12 wherein the incubation portion is fabricated from a clear or semi-opaque material, or is provided with one or more apertures through which light can enter the incubation portion.

14. An apparatus according to any one of claims 9 to 13 wherein the inoculation means comprises a storage vessel for the inoculant, the storage vessel being associated with one or more outlets.

15. An apparatus according to any one of claims 9 to 14 wherein the size reduction portion and the incubation portion are housed in separate housings to one another.

16. An apparatus according to any one of claims 9 to 15 wherein power is supplied to the size reduction portion by mains power.

17. A method according to any one of the preceding claims wherein the output product comprises a fuel, fertilizer or other high value organic material or incubated culture, or a collected substrate for energy generation.