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WO2014202967A2 - An organic by-product processing plant - Google Patents

An organic by-product processing plant Download PDF

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Publication number
WO2014202967A2
WO2014202967A2 PCT/GB2014/051860 GB2014051860W WO2014202967A2 WO 2014202967 A2 WO2014202967 A2 WO 2014202967A2 GB 2014051860 W GB2014051860 W GB 2014051860W WO 2014202967 A2 WO2014202967 A2 WO 2014202967A2
Authority
WO
WIPO (PCT)
Prior art keywords
vessel
product
outer region
processing plant
processing
Prior art date
Application number
PCT/GB2014/051860
Other languages
French (fr)
Other versions
WO2014202967A3 (en
Inventor
Bruce William Palmer
Original Assignee
Elemental Digest Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Elemental Digest Limited filed Critical Elemental Digest Limited
Priority to GB1601090.2A priority Critical patent/GB2531464A/en
Publication of WO2014202967A2 publication Critical patent/WO2014202967A2/en
Publication of WO2014202967A3 publication Critical patent/WO2014202967A3/en

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F1/00—Fertilisers made from animal corpses, or parts thereof
    • C05F1/02—Apparatus for the manufacture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F11/00—Other organic fertilisers
    • C05F11/02—Other organic fertilisers from peat, brown coal, and similar vegetable deposits
    • C05F11/06—Apparatus for the manufacture
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F3/00—Fertilisers from human or animal excrements, e.g. manure
    • C05F3/06—Apparatus for the manufacture
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F5/00—Fertilisers from distillery wastes, molasses, vinasses, sugar plant or similar wastes or residues, e.g. from waste originating from industrial processing of raw material of agricultural origin or derived products thereof
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F9/00—Fertilisers from household or town refuse
    • C05F9/02—Apparatus for the manufacture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
    • Y02A40/10—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture
    • Y02A40/20—Fertilizers of biological origin, e.g. guano or fertilizers made from animal corpses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin

Definitions

  • the present invention relates to processing plants for carrying out the processing of animal by-products, food waste, and other organic by- products, and to methods of processing such by-products, for example to produce fertilizer.
  • an organic by-product processing plant comprising a processing vessel in which the by-product can be processed, the processing vessel comprising: a vessel wall; a lifting mechanism, which may be located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member, which may extend around the lifting mechanism, and may be in an outer region of the vessel, and may be rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
  • the heat transfer member may be rotatably mounted in the vessel and may have a leading end and a trailing end.
  • the leading end may be below the trailing end such that rotation of the heat transfer member generates a lifting force acting on the by-product, which may be arranged to resist its downward movement.
  • the heat transfer member may be formed form a strip of metal.
  • the heat transfer member may be part helical.
  • the lifting mechanism may comprise a helical lifting member rotatable to lift the by-product.
  • the lifting mechanism and the heat transfer member may be mounted on a common rotatable support means.
  • the processing plant may comprise scraping means, for example one or more scrapers, arranged to scrape the inside of the vessel wall, or to scrape by-product, or other contents of the vessel, from the side wall.
  • the scraping means may be mounted on the common rotatable support means for rotation with the heat transfer member.
  • the vessel wall may be cylindrical, for example having a central axis that is vertical.
  • the vessel may further comprise heating means arranged to heat the by-product in the vessel.
  • the processing plant may further comprise a further processing vessel also comprising: a vessel wall; a lifting mechanism, which may be located in a central region of the vessel, arranged to lift the by-product within the vessel; a metal heat transfer member, which may extend around the lifting mechanism and may be in an outer region of the vessel, the heat transfer member optionally being rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and to dissipate heat through the by-product in the outer region of the vessel.
  • the vessel, or one of the vessels may have an inlet connected to a supply of water.
  • the vessel, or one of the vessels may have an inlet connected to a supply of steam.
  • the vessel, or one of the vessels may have inlet means connected to a hydrolysing composition.
  • the inlet means may be connected to: a supply of acid and hydrogen peroxide; or a strong base and hydrogen peroxide.
  • the present invention further provides a processing vessel for processing organic by-product the vessel comprising: a vessel wall; a lifting mechanism located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
  • the present invention further provides a method of processing organic by- product comprising introducing the by-product into a vessel, introducing a further product into the vessel to form a mixture, lifting the mixture upwards in a central region of the vessel by means of a lifting mechanism, resisting downward movement of the mixture in an outer region of the vessel by means of a heat transfer member, and transferring heat within the mixture using the heat transfer member.
  • the method may further comprise heating the mixture in the vessel.
  • the method may be carried out in a plant according to the invention.
  • the present invention further provides a processing plant for processing organic by-product the plant comprising a heating vessel having a product inlet arranged to receive the by-product, a water inlet arranged to receive water, and a steam inlet arranged to receive steam, and heating means arranged to heat the first heating vessel, a separator arranged to receive the contents of the first heating vessel and separate it into first and second components, and an acidification vessel having a product inlet arranged to receive the solid component, and inlet means arranged to receive a hydrolysing composition.
  • the inlet means may be arranged to receive acid, or alkali, or a strong base.
  • the inlet means may further be arranged to receive hydrogen peroxide.
  • the plant further comprises means to deliver a lime mix to the acidified by-product.
  • the plant further comprises means to deliver magnesium salts to the acidified by-product.
  • the processing plant may comprise a dryer operative to receive and dry the acidified by-product.
  • a by-product sizing apparatus may be provided operative to re-size the byproduct into pieces below a predetermined size.
  • the sizing apparatus may comprise a crusher operative to crush the raw by-product into pieces below a predetermined size.
  • the sizing apparatus may comprise a plurality of crushers arranged in sequence and operative to sequentially crush the raw by-product into smaller pieces.
  • the sizing apparatus is operative to output pieces of less than 50mm.
  • a metal detector may be provided at the inlet operative to detect any metal content in the raw animal by-product and to generate a corresponding signal that is used to prevent raw animal by-product entering the byproduct sizing apparatus if metal content is detected.
  • the plant further comprises a pre-heating vessel operative to pre-heat the sized by-product and to deliver the sized by-product to the heating vessel.
  • the plant may further comprise a supply of at least one additive and means to deliver the additive to the further heated by-product to alter the properties of the further heated by-product.
  • the plant may comprise a pellet press or granulator operative to receive dried by-product and to press or granulate the dried by-product into pellets or granules.
  • the plant may further comprise a packaging unit or bagging machine operative to receive and package or bag the pellets or granules.
  • Figure 1 is a schematic view of an organic by-product processing plant in accordance with the present invention
  • Figure 2 is a cut-away side view of a heating vessel forming part of the plant of Figure 1 ;
  • Figure 3 is a plan view of the vessel of Figure 2;
  • Figure 4 is a cut-away side view of a heating vessel of Figure 2 with further components shown;
  • Figure 5 is a plan view of the vessel of Figure 4.
  • an organic by-product processing plant comprises an inlet 10 which receives raw animal by-product.
  • a metal detector 12 is provided at the inlet 10 to detect any metal in the raw animal by-product and to generate a control signal indicative of any metal content detected.
  • the inlet 10 feeds into a particle sizing module, which in this case is a crushing module 14, arranged to reduce the raw product to pieces of a suitable size.
  • the crushing module 14 comprises a first crusher arranged to crush the raw animal by-product into pieces of less than a predetermined size, said size being 150mm in this example, and a second crusher arranged to crush the raw animal by-product into smaller pieces, of less than 50mm in this example.
  • a conveyor 16, which may be a screw conveyor, is arranged to transfer the crushed product from the outlet of the crushing module 14 to the first 18 of three heating vessels 18, 20, 22.
  • the first heating vessel 18 comprises an enclosed steel container having an inlet 24 at the top through which the crushed product can be introduced, a further inlet 26, also at the top, which is connected to a water supply via a pump 28 so that water can be added to the product in the vessel 18, a further inlet 29 connected to a supply of steam, and an outlet 3 1 at the bottom.
  • Flow control valves are provided in the water and steam inlets 26, 29, and the outlet 3 1.
  • a heater 30 is provided around the wall of the vessel, and a temperature gauge 32 is arranged to measure the temperature in the vessel 18.
  • a controller 34 is arranged to control the operation of the whole plant, including all the conveyors, pumps and heaters, and the inlet and outlet valves, as will be described in more detail below.
  • a first separation vessel 36 is arranged to receive the product from the outlet 3 1 from the first heating vessel, and is arranged to hold the solid product and allow liquid to drain into a collection tank 38 situated below it.
  • a second conveyor 40 is arranged to transport the solid product from the separation vessel 36 to the inlet 42 of the second heating vessel 20.
  • the second heating vessel 20 is pressurized, and has a pressure vent controlled by a vent valve 43 so that the pressure in the vessel 20 can be controlled. It also has a further inlet 44 for water, a further inlet 45 for steam, and an outlet 46 at its bottom end, each with a flow control valve controlled by the controller 34. It also has a heater 48 around its side walls, and a temperature gauge 50 and pressure gauge 52 arranged to measure the temperature and pressure of the contents of the second vessel 20. These are connected to the controller 34 which is arranged to control the temperature and pressure, as well as the quantities of water, steam, and product, in the second vessel 20 as required.
  • a second separation vessel 56 is arranged to receive the product from the outlet 46 from the second heating vessel 20, and is arranged to hold the solid product and allow liquid to drain into a collection tank 58 situated below it.
  • a third conveyor 60 is arranged to transport the solid product from the separation vessel 56 to a second crusher unit 62.
  • the second crusher unit 62 is arranged to break down the solid product into pieces no larger than 2mm.
  • the outlet from the crusher unit 62 is arranged to output the product into a pan 64, which may be arranged to pre-heat the product prior to it being received in the third heating vessel 22.
  • a further conveyor 66 is arranged to transport the product from the pan 64 to the inlet 68 of the third heating vessel 22.
  • the third vessel 68 also has a further inlet 70 at its top end connected to a source 72 of acid via a pump 74, and a further inlet 76 connected to a source 78 of hydrogen peroxide, via pump 80. These are controlled by the controller 34 so that acid and hydrogen peroxide can be added into the vessel 22 in the required amounts and rates and at the required time.
  • the third vessel also has a heater 82 and a temperature gauge 84 connected to the controller 34.
  • An outlet 84 at the bottom end of the vessel 22 is connected to a neutralization vessel 86 which is arranged to receive the product from the third heating vessel 22, and also arranged to receive an alkaline additive, in this embodiment a lime mix, via a conveyor 88, from an alkaline additive source 90, under the control of the controller 34.
  • an alkaline additive in this embodiment a lime mix, via a conveyor 88, from an alkaline additive source 90, under the control of the controller 34.
  • the lime mix is 70% calcium carbonate, 20% calcium hydroxide and 10% calcium oxide.
  • hydrolysing composition or compositions supplied to this container will depend on the product being processed.
  • other types of acid can be used, or a strong base or alkali can be used instead of an acid
  • the final neutralized product is in the form of a paste and an extruder 92 is arranged to receive this product from the neutralization vessel 86 and extrude it into pellets, and a packaging module 94 is arranged to receive the extruded pellets and package them for transport away from the plant.
  • Each of the liquid collection vessels 38, 58 has an outlet that is connected to a separator in the form of a centrifuge 96 which is arranged to separate out the lighter and heavier components of the liquid.
  • the lighter components will generally comprise fats, and the heavier components generally comprise gelatine, and these components are collected in separate collection vessels 98, 100.
  • Raw bone is introduced into the crusher module 14 where it is crushed into pieces no larger than 50mm. From there it is transferred into the first vessel 18.
  • the controller 34 is arranged to monitor the amount of product entering the vessel 18, for example using a load cell to measure its weight, and to stop the transfer of product when a specified amount has entered the vessel.
  • the controller 34 is also arranged to control the introduction of water and steam into the vessel 18, and to heat the vessel 18 to the required temperature. The bone and water mixture is heated to approximately 95°C to form a solid and liquid mix which is then transferred to the separation vessel 36.
  • the drier mix is then transferred via the conveyor 40 to the second heating vessel 20.
  • the amount of mix introduced into the second vessel 20 is controlled by the controller, for example using weighing cells to weigh the amount added, and then controlled amounts of water and steam are added by controlled operation of the inlet valves.
  • the second vessel 20 is then heated up to about 135°C, and the vent valve 43 closed so that the pressure increases to about 3.5bar. This temperature and pressure is maintained for about twenty minutes.
  • the vent valve 43 is opened to reduce the pressure in the vessel, and the outlet 46 is opened to allow the product, which is still in the form of a mix, to empty into the second separation vessel 56.
  • the solid product is transferred via conveyor 66 into the third heating vessel 22 via the conveyor 66 and the inlet 68. Again the amount of product introduced is controlled, and also sulphuric acid and hydrogen peroxide are added in controlled amounts via the inlets 70, 76.
  • the reaction in the vessel 22 is exothermic and the temperature rises to about 95°C, and then falls off when the reaction is complete. This heat and the acid and hydrogen peroxide kills any disease or bacteria in the product, and also oxidises any carbon in the product resulting in an inorganic product which is suitable for use as a fertiliser.
  • the outlet 22 from the third vessel 22 is opened and the product transferred to the neutralization vessel 86, to which lime mix is added in controlled quantities in order to increase the pH of the mixture to neutralize the product.
  • the lime mix may comprise a mixture of chalk and lime, or quick lime for example.
  • the lime mix may also comprise additives to alter the properties of the mix, such additives for example comprising selected macro/micro nutrients.
  • the lime mix, and/or the additives can be varied as required to deliver the required fertilizer properties.
  • the lime mix causes an exothermic reaction. This serves to at least partially dry the acidified animal by-product.
  • the increased pH mixture which is typically in the form of a paste, is then dried if necessary, and passed into the extruder 92, from which it is extruded as pellets or granules, and packaged at packaging module 94 for transport.
  • the liquid from the collection vessels 38, 58 is separated in the centrifuge 96, with fat being transferred to fat storage tank 98 and gelatine to the gelatine storage tank 100.
  • the third heating vessel 22 may also comprise additive inlets arranged to deliver further additives to the mix.
  • additives can be of any suitable ingredient to adjust the mineral or nutritional content of the solid particles of the mix to suit a particular use or location of use.
  • the additives can be controlled to alter the macro/micro nutrient bases of the solid slurry particles to suit different soil or ground conditions for example, or to provide optimum nutrition for a particular type of crop.
  • the first heating vessel 18 comprises a cylindrical steel body 200, about 1.25m high and 750mm in diameter, arranged so that its central axis 202 and curved side walls 204 extend vertically.
  • a pair of part-helical heat transfer blades 206 are mounted by means of cross members 208 on a central rotatable shaft 210 which is located on the central axis 202.
  • Each of the heat transfer blades 206 is formed of a strip of sheet metal 209 about 80mm wide, which is formed into a part-helix shape extending around the outer part of the vessel close to the side wall 204 but spaced slightly from it.
  • the blades each extend from a point about two thirds of the way up the side of the vessel, down to close to the bottom of the vessel, and through half a turn around the central axis.
  • the two blades 206 are diametrically opposite each other, so that they extend around opposite sides of the vessel.
  • a pair of scrapers 212 are also supported on the cross members 208.
  • Each scraper 212 comprises a flat scraper blade 214 extending vertically down the side wall 204 of the vessel with an outer scraping edge 216 just clear of the side wall 204.
  • Each of the scraper blades 214 is supported on a set of support brackets 218, which in turn are supported on a vertical support pole 220 which extends vertically between the cross members 208 near their outer ends.
  • a baffle plate 221 extends around the bottom end of the shaft 210 and is of conical shape tapering towards its top end.
  • the conical volume below the baffle plate 221 is connected to the supply of steam, and the baffle plate 221 has holes through it to allow the steam into the bottom of the vessel.
  • an inner helical lifting flight 222 is also mounted on the shaft 210.
  • the lifting flight 222 is formed of a flat strip of metal 224 about 80mm wide, formed into a helix centred on the shaft 210, and turning through about seven turns.
  • the top of the lifting flight 222 is about level with the top of the heat transfer blades 206 and the bottom of the lifting flight 222 is slightly above the bottom of the heat transfer blades 206.
  • the turning sense of the lifting flight 222 is the same as both of the heat transfer blades 206.
  • the lifting flight 222 has holes 227 through it so as to allow steam, entering the vessel at the bottom, to rise up through the flight 222 as it rotates.
  • a motor 225 is arranged to rotate the shaft 210, so that the lower end of the lifting flight forms a leading end and the upper end of the lifting flight forms a trailing end, and the lifting flight provides lift in the central part of the vessel 18 close to the central axis 202.
  • the lower ends of the heat transfer blades 206 form leading ends and the upper ends of the heat transfer blades form trailing ends, and the heat transfer blades also provide a small amount of lift, or in fact resistance to downward flow, in the outer part of the vessel closer to the outer wall 204.
  • the scrapers 212 move around the wall 204 of the vessel, scraping from the wall any of the by-product or other contents of the vessel that may have accumulated on the wall.
  • the central shaft 210 is rotated as the product is introduced into the vessel 18 through the inlet 24, the water is introduced through the inlet 26, this forms a mixture, and the steam is introduced through the inlet 29 via the baffle plate 221 which helps to heat the mixture.
  • the central lifting flight 222 causes a general upward flow of the mixture in the central area of the vessel.
  • the mixture then moves outwards at the top of the vessel 18 and cascades downwards in the outer region of the vessel 18 close to the wall 204.
  • the rotating heat transfer blades 206 provide some resistance to the downward flow, and therefore mix the mixture, but also help to conduct heat through the mixture quickly allowing it to be heated quickly to the required temperature. This helps to reduce the time required for the heating step carried out in the first heating vessel 18.
  • the second vessel 20 has the same mixing and heat exchange mechanism as the first vessel 18 as shown in Figures 2 to 5.
  • the heating process is similar to the first vessel, though at increased pressure, and the heat exchange coils and the lifting flight serve to distribute heat from the heater and steam throughout the vessel in a similar way.
  • the third vessel 22 also has the same mixing and heat exchange mechanisms as shown in Figures 2 to 5. In this case the heat is generated by the exothermic reaction in the vessel. However, rapid heat dissipation is still helpful to ensure that the temperature remains approximately equal throughout the vessel, and that the reaction proceeds at about the same rate throughout the vessel.
  • the two heat transfer blades could be replaced by one continuous helical coil, or more than two blades.
  • the blades may not be strictly part-helical.
  • the angle of the blade or blades to the vertical may vary along its length.
  • the lifting flight may be of a different shape, or may be rotated independently of the heat transfer coils. Indeed a different type of lifting mechanism may be provided which is not a helical flight.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Botany (AREA)
  • Container, Conveyance, Adherence, Positioning, Of Wafer (AREA)
  • Photosensitive Polymer And Photoresist Processing (AREA)
  • Exposure Of Semiconductors, Excluding Electron Or Ion Beam Exposure (AREA)
  • Processing Of Solid Wastes (AREA)
  • Fertilizers (AREA)

Abstract

An organic by-product processing plant comprises a processing vessel (200) in which the by-product can be processed, the processing vessel comprising: a vessel wall (204); a lifting mechanism (222) located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member (209) extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.

Description

AN ORGANIC BY-PRODUCT PROCESSING PLANT Field of the Invention
The present invention relates to processing plants for carrying out the processing of animal by-products, food waste, and other organic by- products, and to methods of processing such by-products, for example to produce fertilizer.
Background to the Invention
During the processing of animals for meat production or otherwise, relatively large amounts of the animal are removed, discarded and not sold on to an end user. Such discarded by-products include bone, blood, wool and feathers for example. This represents a significant waste of the animal resource. There is also a cost involved in storing and disposing of such waste. Other organic waste is also produced in agriculture and the food and catering industries, such as chicken litter, pig slurry, and food waste. Various processes are known for treating animal by-products, and many of these involve heating and mixing large quantities of product, and it is important that this heating can be carried out quickly and uniformly.
Summary of the Invention
According to a first aspect of the invention there is provided an organic by-product processing plant comprising a processing vessel in which the by-product can be processed, the processing vessel comprising: a vessel wall; a lifting mechanism, which may be located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member, which may extend around the lifting mechanism, and may be in an outer region of the vessel, and may be rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
The heat transfer member may be rotatably mounted in the vessel and may have a leading end and a trailing end. The leading end may be below the trailing end such that rotation of the heat transfer member generates a lifting force acting on the by-product, which may be arranged to resist its downward movement.
The heat transfer member may be formed form a strip of metal. The heat transfer member may be part helical.
The lifting mechanism may comprise a helical lifting member rotatable to lift the by-product. The lifting mechanism and the heat transfer member may be mounted on a common rotatable support means.
The processing plant may comprise scraping means, for example one or more scrapers, arranged to scrape the inside of the vessel wall, or to scrape by-product, or other contents of the vessel, from the side wall. The scraping means may be mounted on the common rotatable support means for rotation with the heat transfer member.
The vessel wall may be cylindrical, for example having a central axis that is vertical. The vessel may further comprise heating means arranged to heat the by-product in the vessel.
The processing plant may further comprise a further processing vessel also comprising: a vessel wall; a lifting mechanism, which may be located in a central region of the vessel, arranged to lift the by-product within the vessel; a metal heat transfer member, which may extend around the lifting mechanism and may be in an outer region of the vessel, the heat transfer member optionally being rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and to dissipate heat through the by-product in the outer region of the vessel. The vessel, or one of the vessels, may have an inlet connected to a supply of water. The vessel, or one of the vessels, may have an inlet connected to a supply of steam. The vessel, or one of the vessels, may have inlet means connected to a hydrolysing composition. For example the inlet means may be connected to: a supply of acid and hydrogen peroxide; or a strong base and hydrogen peroxide.
The present invention further provides a processing vessel for processing organic by-product the vessel comprising: a vessel wall; a lifting mechanism located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
The present invention further provides a method of processing organic by- product comprising introducing the by-product into a vessel, introducing a further product into the vessel to form a mixture, lifting the mixture upwards in a central region of the vessel by means of a lifting mechanism, resisting downward movement of the mixture in an outer region of the vessel by means of a heat transfer member, and transferring heat within the mixture using the heat transfer member.
The method may further comprise heating the mixture in the vessel.
The method may be carried out in a plant according to the invention. The present invention further provides a processing plant for processing organic by-product the plant comprising a heating vessel having a product inlet arranged to receive the by-product, a water inlet arranged to receive water, and a steam inlet arranged to receive steam, and heating means arranged to heat the first heating vessel, a separator arranged to receive the contents of the first heating vessel and separate it into first and second components, and an acidification vessel having a product inlet arranged to receive the solid component, and inlet means arranged to receive a hydrolysing composition. The inlet means may be arranged to receive acid, or alkali, or a strong base. The inlet means may further be arranged to receive hydrogen peroxide.
Preferably the plant further comprises means to deliver a lime mix to the acidified by-product.
Preferably the plant further comprises means to deliver magnesium salts to the acidified by-product.
The processing plant may comprise a dryer operative to receive and dry the acidified by-product.
A by-product sizing apparatus may be provided operative to re-size the byproduct into pieces below a predetermined size. The sizing apparatus may comprise a crusher operative to crush the raw by-product into pieces below a predetermined size.
The sizing apparatus may comprise a plurality of crushers arranged in sequence and operative to sequentially crush the raw by-product into smaller pieces. Preferably the sizing apparatus is operative to output pieces of less than 50mm.
A metal detector may be provided at the inlet operative to detect any metal content in the raw animal by-product and to generate a corresponding signal that is used to prevent raw animal by-product entering the byproduct sizing apparatus if metal content is detected.
Preferably the plant further comprises a pre-heating vessel operative to pre-heat the sized by-product and to deliver the sized by-product to the heating vessel. The plant may further comprise a supply of at least one additive and means to deliver the additive to the further heated by-product to alter the properties of the further heated by-product.
The plant may comprise a pellet press or granulator operative to receive dried by-product and to press or granulate the dried by-product into pellets or granules.
The plant may further comprise a packaging unit or bagging machine operative to receive and package or bag the pellets or granules.
The plant, or method, or vessel may further comprise, in any combination, any one or more features or steps of the preferred embodiments of the invention which will now be described by way of example only with reference to the accompanying drawings in which:
Figure 1 is a schematic view of an organic by-product processing plant in accordance with the present invention; and Figure 2 is a cut-away side view of a heating vessel forming part of the plant of Figure 1 ;
Figure 3 is a plan view of the vessel of Figure 2;
Figure 4 is a cut-away side view of a heating vessel of Figure 2 with further components shown; and
Figure 5 is a plan view of the vessel of Figure 4.
Description of the Preferred Embodiments
Referring to Figure 1 , an organic by-product processing plant comprises an inlet 10 which receives raw animal by-product. A metal detector 12 is provided at the inlet 10 to detect any metal in the raw animal by-product and to generate a control signal indicative of any metal content detected. The inlet 10 feeds into a particle sizing module, which in this case is a crushing module 14, arranged to reduce the raw product to pieces of a suitable size. In this embodiment the crushing module 14 comprises a first crusher arranged to crush the raw animal by-product into pieces of less than a predetermined size, said size being 150mm in this example, and a second crusher arranged to crush the raw animal by-product into smaller pieces, of less than 50mm in this example. A conveyor 16, which may be a screw conveyor, is arranged to transfer the crushed product from the outlet of the crushing module 14 to the first 18 of three heating vessels 18, 20, 22.
The first heating vessel 18 comprises an enclosed steel container having an inlet 24 at the top through which the crushed product can be introduced, a further inlet 26, also at the top, which is connected to a water supply via a pump 28 so that water can be added to the product in the vessel 18, a further inlet 29 connected to a supply of steam, and an outlet 3 1 at the bottom. Flow control valves are provided in the water and steam inlets 26, 29, and the outlet 3 1. A heater 30 is provided around the wall of the vessel, and a temperature gauge 32 is arranged to measure the temperature in the vessel 18. A controller 34 is arranged to control the operation of the whole plant, including all the conveyors, pumps and heaters, and the inlet and outlet valves, as will be described in more detail below.
A first separation vessel 36 is arranged to receive the product from the outlet 3 1 from the first heating vessel, and is arranged to hold the solid product and allow liquid to drain into a collection tank 38 situated below it. A second conveyor 40 is arranged to transport the solid product from the separation vessel 36 to the inlet 42 of the second heating vessel 20.
The second heating vessel 20 is pressurized, and has a pressure vent controlled by a vent valve 43 so that the pressure in the vessel 20 can be controlled. It also has a further inlet 44 for water, a further inlet 45 for steam, and an outlet 46 at its bottom end, each with a flow control valve controlled by the controller 34. It also has a heater 48 around its side walls, and a temperature gauge 50 and pressure gauge 52 arranged to measure the temperature and pressure of the contents of the second vessel 20. These are connected to the controller 34 which is arranged to control the temperature and pressure, as well as the quantities of water, steam, and product, in the second vessel 20 as required.
A second separation vessel 56 is arranged to receive the product from the outlet 46 from the second heating vessel 20, and is arranged to hold the solid product and allow liquid to drain into a collection tank 58 situated below it. A third conveyor 60 is arranged to transport the solid product from the separation vessel 56 to a second crusher unit 62. The second crusher unit 62 is arranged to break down the solid product into pieces no larger than 2mm.
The outlet from the crusher unit 62 is arranged to output the product into a pan 64, which may be arranged to pre-heat the product prior to it being received in the third heating vessel 22. A further conveyor 66 is arranged to transport the product from the pan 64 to the inlet 68 of the third heating vessel 22.
The third vessel 68 also has a further inlet 70 at its top end connected to a source 72 of acid via a pump 74, and a further inlet 76 connected to a source 78 of hydrogen peroxide, via pump 80. These are controlled by the controller 34 so that acid and hydrogen peroxide can be added into the vessel 22 in the required amounts and rates and at the required time. The third vessel also has a heater 82 and a temperature gauge 84 connected to the controller 34. An outlet 84 at the bottom end of the vessel 22 is connected to a neutralization vessel 86 which is arranged to receive the product from the third heating vessel 22, and also arranged to receive an alkaline additive, in this embodiment a lime mix, via a conveyor 88, from an alkaline additive source 90, under the control of the controller 34. In this example the lime mix is 70% calcium carbonate, 20% calcium hydroxide and 10% calcium oxide.
It will be appreciated that the hydrolysing composition or compositions supplied to this container will depend on the product being processed. For example other types of acid can be used, or a strong base or alkali can be used instead of an acid The final neutralized product is in the form of a paste and an extruder 92 is arranged to receive this product from the neutralization vessel 86 and extrude it into pellets, and a packaging module 94 is arranged to receive the extruded pellets and package them for transport away from the plant.
Each of the liquid collection vessels 38, 58 has an outlet that is connected to a separator in the form of a centrifuge 96 which is arranged to separate out the lighter and heavier components of the liquid. The lighter components will generally comprise fats, and the heavier components generally comprise gelatine, and these components are collected in separate collection vessels 98, 100.
Operation of the plant will now be described with particular reference to the treatment of bone, although it will be appreciated that it can be used for a wide variety of other waste products.
Raw bone is introduced into the crusher module 14 where it is crushed into pieces no larger than 50mm. From there it is transferred into the first vessel 18. The controller 34 is arranged to monitor the amount of product entering the vessel 18, for example using a load cell to measure its weight, and to stop the transfer of product when a specified amount has entered the vessel. The controller 34 is also arranged to control the introduction of water and steam into the vessel 18, and to heat the vessel 18 to the required temperature. The bone and water mixture is heated to approximately 95°C to form a solid and liquid mix which is then transferred to the separation vessel 36.
In the separation vessel 36, liquid drains from the mix into the collection tank 38 while the mix is transferred along the vessel. The drier mix is then transferred via the conveyor 40 to the second heating vessel 20. The amount of mix introduced into the second vessel 20 is controlled by the controller, for example using weighing cells to weigh the amount added, and then controlled amounts of water and steam are added by controlled operation of the inlet valves. The second vessel 20 is then heated up to about 135°C, and the vent valve 43 closed so that the pressure increases to about 3.5bar. This temperature and pressure is maintained for about twenty minutes. At the end of the treatment in the second vessel 20, the vent valve 43 is opened to reduce the pressure in the vessel, and the outlet 46 is opened to allow the product, which is still in the form of a mix, to empty into the second separation vessel 56. From that vessel 56, liquid drains into the second collection vessel 58, and the solid component of the mix is transferred via conveyor 60 into the second crusher unit 62, where it is crushed to a particle size of about 2mm and transferred to the pre-heating vessel 64, where it is pre-heated.
From the pre-heating vessel 64 the solid product is transferred via conveyor 66 into the third heating vessel 22 via the conveyor 66 and the inlet 68. Again the amount of product introduced is controlled, and also sulphuric acid and hydrogen peroxide are added in controlled amounts via the inlets 70, 76. The reaction in the vessel 22 is exothermic and the temperature rises to about 95°C, and then falls off when the reaction is complete. This heat and the acid and hydrogen peroxide kills any disease or bacteria in the product, and also oxidises any carbon in the product resulting in an inorganic product which is suitable for use as a fertiliser.
When the acidification step is complete, the outlet 22 from the third vessel 22 is opened and the product transferred to the neutralization vessel 86, to which lime mix is added in controlled quantities in order to increase the pH of the mixture to neutralize the product. The lime mix may comprise a mixture of chalk and lime, or quick lime for example. The lime mix may also comprise additives to alter the properties of the mix, such additives for example comprising selected macro/micro nutrients. The lime mix, and/or the additives, can be varied as required to deliver the required fertilizer properties. The lime mix causes an exothermic reaction. This serves to at least partially dry the acidified animal by-product.
The increased pH mixture, which is typically in the form of a paste, is then dried if necessary, and passed into the extruder 92, from which it is extruded as pellets or granules, and packaged at packaging module 94 for transport.
The liquid from the collection vessels 38, 58 is separated in the centrifuge 96, with fat being transferred to fat storage tank 98 and gelatine to the gelatine storage tank 100.
The third heating vessel 22 may also comprise additive inlets arranged to deliver further additives to the mix. These additives can be of any suitable ingredient to adjust the mineral or nutritional content of the solid particles of the mix to suit a particular use or location of use. Thus the additives can be controlled to alter the macro/micro nutrient bases of the solid slurry particles to suit different soil or ground conditions for example, or to provide optimum nutrition for a particular type of crop.
Referring to Figures 2 and 3, the first heating vessel 18 comprises a cylindrical steel body 200, about 1.25m high and 750mm in diameter, arranged so that its central axis 202 and curved side walls 204 extend vertically. A pair of part-helical heat transfer blades 206 are mounted by means of cross members 208 on a central rotatable shaft 210 which is located on the central axis 202. Each of the heat transfer blades 206 is formed of a strip of sheet metal 209 about 80mm wide, which is formed into a part-helix shape extending around the outer part of the vessel close to the side wall 204 but spaced slightly from it. The blades each extend from a point about two thirds of the way up the side of the vessel, down to close to the bottom of the vessel, and through half a turn around the central axis. The two blades 206 are diametrically opposite each other, so that they extend around opposite sides of the vessel.
A pair of scrapers 212 are also supported on the cross members 208. Each scraper 212 comprises a flat scraper blade 214 extending vertically down the side wall 204 of the vessel with an outer scraping edge 216 just clear of the side wall 204. Each of the scraper blades 214 is supported on a set of support brackets 218, which in turn are supported on a vertical support pole 220 which extends vertically between the cross members 208 near their outer ends.
A baffle plate 221 extends around the bottom end of the shaft 210 and is of conical shape tapering towards its top end. The conical volume below the baffle plate 221 is connected to the supply of steam, and the baffle plate 221 has holes through it to allow the steam into the bottom of the vessel.
Referring to Figures 4 and 5, an inner helical lifting flight 222 is also mounted on the shaft 210. The lifting flight 222 is formed of a flat strip of metal 224 about 80mm wide, formed into a helix centred on the shaft 210, and turning through about seven turns. The top of the lifting flight 222 is about level with the top of the heat transfer blades 206 and the bottom of the lifting flight 222 is slightly above the bottom of the heat transfer blades 206. The turning sense of the lifting flight 222 is the same as both of the heat transfer blades 206. The lifting flight 222 has holes 227 through it so as to allow steam, entering the vessel at the bottom, to rise up through the flight 222 as it rotates. A motor 225 is arranged to rotate the shaft 210, so that the lower end of the lifting flight forms a leading end and the upper end of the lifting flight forms a trailing end, and the lifting flight provides lift in the central part of the vessel 18 close to the central axis 202. At the same time, the lower ends of the heat transfer blades 206 form leading ends and the upper ends of the heat transfer blades form trailing ends, and the heat transfer blades also provide a small amount of lift, or in fact resistance to downward flow, in the outer part of the vessel closer to the outer wall 204. As the shaft rotates, the scrapers 212 move around the wall 204 of the vessel, scraping from the wall any of the by-product or other contents of the vessel that may have accumulated on the wall.
The central shaft 210 is rotated as the product is introduced into the vessel 18 through the inlet 24, the water is introduced through the inlet 26, this forms a mixture, and the steam is introduced through the inlet 29 via the baffle plate 221 which helps to heat the mixture. As the heater 30 heats up the contents of the vessel 18 and the steam is inj ected into it, the central lifting flight 222 causes a general upward flow of the mixture in the central area of the vessel. The mixture then moves outwards at the top of the vessel 18 and cascades downwards in the outer region of the vessel 18 close to the wall 204. The rotating heat transfer blades 206 provide some resistance to the downward flow, and therefore mix the mixture, but also help to conduct heat through the mixture quickly allowing it to be heated quickly to the required temperature. This helps to reduce the time required for the heating step carried out in the first heating vessel 18.
The second vessel 20 has the same mixing and heat exchange mechanism as the first vessel 18 as shown in Figures 2 to 5. In this vessel the heating process is similar to the first vessel, though at increased pressure, and the heat exchange coils and the lifting flight serve to distribute heat from the heater and steam throughout the vessel in a similar way. Similarly the third vessel 22 also has the same mixing and heat exchange mechanisms as shown in Figures 2 to 5. In this case the heat is generated by the exothermic reaction in the vessel. However, rapid heat dissipation is still helpful to ensure that the temperature remains approximately equal throughout the vessel, and that the reaction proceeds at about the same rate throughout the vessel.
It will be appreciated that various modifications can be made to the embodiment described above, and that the design of the heating vessel or vessels can be varied as appropriate for the process and products to be treated. For example, the two heat transfer blades could be replaced by one continuous helical coil, or more than two blades. Also the blades may not be strictly part-helical. For example the angle of the blade or blades to the vertical may vary along its length. Similarly the lifting flight may be of a different shape, or may be rotated independently of the heat transfer coils. Indeed a different type of lifting mechanism may be provided which is not a helical flight.

Claims

1. An organic by-product processing plant comprising a processing vessel in which the by-product can be processed, the processing vessel comprising: a vessel wall; a lifting mechanism located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
2. A processing plant according to claim 1 wherein the heat transfer member is rotatably mounted in the vessel and has a leading end and a trailing end, the leading end being below the trailing end such that rotation of the heat transfer member generates a lifting force acting on the by- product to resist its downward movement.
3. A processing plant according to claim 1 or claim 2 wherein the heat transfer member is formed form a strip of metal.
4. A processing plant according to any foregoing claim wherein the heat transfer member is part helical.
5. A processing plant according to any foregoing claim wherein the lifting mechanism comprises a helical lifting member rotatable to lift the by-product.
6. A processing plant according to any foregoing claim wherein the lifting mechanism and the heat transfer member are mounted on a common rotatable support means.
7. A processing plant according to claim 6 further comprising scraping means arranged to scrape the inside of the vessel wall.
8. A processing plant according to claim 7 wherein the scraping means is mounted on the common rotatable support means for rotation with the heat transfer member.
9. A processing plant according to any foregoing claim wherein the vessel wall is cylindrical having a central axis that is vertical.
10. A processing plant according to any foregoing claim wherein the vessel further comprises heating means arranged to heat the by-product in the vessel.
1 1. A processing plant according to any foregoing claim further comprising a further processing vessel also comprising: a vessel wall; a lifting mechanism located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
12. A processing plant according to claim 1 1 wherein one of the vessels has an inlet connected to a supply of water.
13. A processing plant according to claim 1 1 or claim 12 wherein one of the vessels has an inlet connected to a supply of steam.
14. A processing plant according to any of claims 1 1 to 13 wherein one of the vessels has inlet means connected to a supply of acid and hydrogen peroxide.
15. A processing vessel for processing organic by-product the vessel comprising: a vessel wall; a lifting mechanism located in a central region of the vessel and arranged to lift the by-product within the vessel; a metal heat transfer member extending around the lifting mechanism in an outer region of the vessel and rotatable around the outer region of the vessel to resist downward movement of the by-product in the outer region of the vessel and dissipate heat through the by-product in the outer region of the vessel.
16. A method of processing organic by-product comprising introducing the by-product into a vessel, introducing a further product into the vessel to form a mixture, lifting the mixture upwards in a central region of the vessel by means of a lifting mechanism, resisting downward movement of the mixture in an outer region of the vessel by means of a heat transfer member, and transferring heat within the mixture using the heat transfer member.
17. A method according to claim 16 further comprising heating the mixture in the vessel.
18. A method according to claim 16 or claim 17 wherein the method is carried out in a plant according to any of claims 1 to 14.
19. A processing plant for processing organic by-product the plant comprising a heating vessel having a product inlet arranged to receive the by-product, a water inlet arranged to receive water, and a steam inlet arranged to receive steam, and heating means arranged to heat the first heating vessel, a separator arranged to receive the contents of the first heating vessel and separate it into first and second components, and an acidification vessel having a product inlet arranged to receive the solid component, and acid inlet means arranged to receive acid.
20. A processing plant substantially as described herein with reference to any one or more of the accompanying drawings.
21. A processing vessel substantially as described herein with reference to Figures 2 to 5.
PCT/GB2014/051860 2013-06-21 2014-06-17 An organic by-product processing plant WO2014202967A2 (en)

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DE102019104189B3 (en) 2019-02-19 2020-06-10 TMM Petfood GmbH Process for the thermal treatment of animal by-products and sterilization device
DE102020119041A1 (en) 2020-07-17 2022-01-20 TEC Austria GmbH Device and method for producing a fertilizer and/or animal feed

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DE102019104189B3 (en) 2019-02-19 2020-06-10 TMM Petfood GmbH Process for the thermal treatment of animal by-products and sterilization device
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DE102020119041A1 (en) 2020-07-17 2022-01-20 TEC Austria GmbH Device and method for producing a fertilizer and/or animal feed

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WO2014202967A3 (en) 2015-02-19
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GB201311115D0 (en) 2013-08-07

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