Variable system for waste processing, handling and use

Abstract

A variable system for waste processing, handling and use, where sorting, mechanical handling, separation and processing of waste can take place. The system comprises a waste container (1) with at least one waste quantity sensor (2) and at least one waste movement sensor (3). A waste shredder (5) with load sensor (6) is connected to the waste container (1) via a meter (4). The waste quantity sensor (2), the other waste movement sensor (3) and the load sensor (6) are interconnected with a control unit (7). The control unit (7) is also connected to a number of conveyor belt drive controllers in the waste container (1), the meter (4) and the shredder (5), respectively. Behind the shredder (5) a treatment plant is arranged for mechanical handling, cleaning, drying, separation and granulation. The treatment plant is followed by a biogas plant, a sorter and a thermochemical unit (8). The biogas plant is used for processing and handling of organic material for energy recovery and subsequent use as compost. The sorter is used for separating the produced granules according to their plastic type for recycling. The thermochemical unit (8) can produce energy fuel in the form of gas, oil and carbon, and it is followed by at least one liquid gas tank (9).

Description

TECHNICAL FIELD

[0001] The present invention relates to a variable system for waste processing, handling and use, including sorting, mechanical handling, separation and processing of waste. BACKGROUND

[0002] The first step in current waste management is household waste collection, and there is a basic sorting basis for plastics, glass, paper, bio-waste and municipal waste in the existing waste collection system. Although the public is actively engaged in waste sorting, it is difficult to ensure that sorted waste does not end up in a landfill and is used or ultimately processed through a heat plant for energy production. If it is disposed of in a landfill, the opportunity to be reused through complete recycling and thus save mineral resources such as crude oil is lost. Heat treatment in a heat plant not only increases waste gas emissions, damaging air quality, but also completely prevents reuse of waste, and only 30% of waste is recovered in this way. Therefore, the current system is outdated and inappropriate from both an environmental and economic point of view, and indeed needs to be revolutionized.

[0003] Waste sorting is designed for large collective municipalities and low population density areas. In urban areas, garbage sorting containers are about 100 meters from residential areas. Small villages use large-capacity garbage bins, or set up waste recycling centers to collect waste. The waste recycling center system is also used for sorting large amounts of garbage, especially waste electrical appliances and tires.

[0004] The main disadvantage of the current solution is the high cost of building a municipal waste incinerator and poor energy efficiency. SUMMARY

[0005] The present invention substantially solves the above mentioned problems. The variable system for waste processing, treatment and use according to the present invention covers sorting, mechanical treatment, separation and processing of waste. The system mainly comprises at least one waste container provided with a waste quantity sensor and at least one other waste movement sensor, which waste container is connected through a meter to a waste shredder provided with a load sensor. The waste quantity sensor, the other waste movement sensor and the load sensor are interconnected to a control unit, which control unit is also connected to a conveyor belt drive controller provided in the waste container, the meter and the shredder, respectively. Behind the shredder there are provided a waste treatment device, a sorter and a thermochemical unit. The waste treatment device is used for mechanical treatment, cleaning, drying, separation and pelletizing, after which a biogas plant is provided for processing and treatment of organic material for energy recovery and subsequent use as compost. The sorter is used for separating the pellets according to their plastic type for recycling. The thermochemical unit produces energy fuel in the form of gas, oil and carbon, and is followed by at least one liquefied gas tank provided with mixing means.

[0006] The shredder is preferably a slow-running shredder with a press sieve, which achieves a uniform material particle size for subsequent classification and processing.

[0007] The thermochemical unit is preferably provided with an air-excluding metering feeder, at least three heat sources interconnected to the control unit and a heat sensor in the distiller of the thermochemical unit.

[0008] The thermochemical unit is preferably provided with means for dosing the pelletized material and / or an extruder which compresses the input plastic to its melting point to homogenize the plastic. The extruder ensures airtightness at the inlet without the need for additional sealing measures. Furthermore, the use of the system according to the present invention allows dosing of the plastic without kneading, which results in a significant saving of energy consumption in the plastic processing procedure. Another advantage of using an extruder is that the temperature of the input material is close to the thermal decomposition temperature, which accelerates the time for starting the thermal decomposition and thus increases the efficiency of the entire procedure.

[0009] The variable system for waste processing, treatment and use according to the present invention preferably comprises a device which is capable of processing the gas from the biogas plant and from the thermochemical unit to produce electrical energy.

[0010] The variable system for waste processing, treatment and use according to the present invention can comprise a biological filter having a height of 1.0 to 2.0 meters and a filter bed consisting of a mixture of wood chips, peat and coconut fibers, microorganisms present on the surface of the above-mentioned particles removing low concentrations of sensory organic substances contained in the extraction gas stream. It is provided with a pH regulator, an automatic backflushing spray device and a temperature regulator in the range of 10 to 40°C.

[0011] The variable system for waste processing, treatment and use can be located on a ship and the waste containers, meters, waste shredders, treatment equipment, biogas plants, thermo-chemical units for production of energy fuels and at least one liquefied gas tank are connected to each other by flexible joints.

[0012] The main idea of the invention is to construct a comprehensive variable system that enables complete waste processing, treatment and use. The aim is to treat waste so that part of it is recycled and part of it is used to produce electricity. The system can separate the useful components in the waste, such as metals, and treat the rest for subsequent use, for example in agriculture after biological treatment. The advantage of the system is that it can be adjusted to the individual site, conditions and composition of the waste. The system comprises an integrated comprehensive material flow management system and monitoring of the material flow, which enables maximum efficiency in waste processing.

[0013] After mechanical treatment, waste classification is completed by sorting and separating for subsequent processing. The uniqueness and arrangement of the system enable the needs of the economy of waste utilization and even if the processing line is already installed and in operation, it can be adjusted to changes in the market. The facility uses technological optical sensors to sort different waste appropriately. All sensors are designed appropriately and located at key points, which enables perfect monitoring of all processes. The sensors are connected to the unified control unit of the processing line control. The comprehensive management system enables changes in the composition of the waste and adjustment of the operation of the processing line so that the output products have consistent quality and the maximum economic value of the waste is achieved.

[0014] Material shredding and preparation technology uses mechanical treatment and separation of waste for subsequent processing. The shredder shreds the input material into precise sizes for different waste for downstream processing. Since the input material in the waste includes various types, it is necessary to separate the oversized individuals from the waste at the inlet first and then to process them using a slow-running shredder with a special screen, in which process control is used to ensure even pressure on the screen and thus uniform particle size for easy subsequent sorting and processing.

[0015] The processing equipment involves technologies such as mechanical processing, cleaning, drying, separation and granulation, plus subsequent preparation to enable subsequent processing or sale of, for example, PET granules. The granules formed after the mechanical processing and cleaning procedures are further separated according to the type of plastic using a technologically advanced optical sensor, so as to be used for recycling or for a thermochemical unit. The optical sorter is composed and connected in the system in such a way that it is able to separate any type of plastic freely for subsequent processing, thus responding flexibly to market demand. Mixed plastics that are not sorted and thus not suitable for sale can be used as an additive for energy fuel or can be fed into a thermochemical unit.

[0016] The biogas plant is a facility for processing and treating organic material, thus recovering energy and subsequently using it for composting.

[0017] The thermochemical unit is a facility for processing and outputting energy fuel from municipal waste, PET and sorted plastic from tyre granules. Proper distribution of the waste enables the temperature distribution in the retort to be determined and measured. The thermochemical unit is provided with airtight dosing devices, which differ depending on whether granular material is used or plastic dosing is performed by an extruder. Subsequent cleaning of the gas and oil ensures continuity and stable quality. Gas quality is maintained by liquefying the gas and mixing it in a tank. The system is designed in such a way that the output products, i.e. gas, oil and carbon, have the same quality when leaving the system, thus enabling good exchange of the above-mentioned products.

[0018] The gas management and energy centre can generate electrical energy. The gas output from the composting facility and the thermochemical unit is cleaned and of very high quality, and can be used to generate the electrical energy required for its own consumption. Thus, after the entire system is started, it is able to operate in island mode within one hour. The rest of the electrical energy can be sold to the grid. All the thermal energy generated during electricity generation is used for drying the input material, i.e. waste, or for heating buildings, or for supplying heat to town, village, etc. heat users.

[0019] The present invention provides a remarkable and comprehensive waste treatment solution, which makes good use of various energy types while eliminating the on-site environmental burden. The solution of the present invention is a fully automated system, which is a progressive technology, and its advantages include environmental improvement and increased regional employment, the main advantage being that 90 to 97% of the waste can be used for recycling.

[0020] The thermal decomposition procedure is a highly environmentally friendly procedure, which processes organic material and outputs tradable petroleum products. The system of the present invention provides a revolutionary solution in the field of waste treatment. BRIEF DESCRIPTION OF DRAWINGS

[0021] The present invention, which includes a variable system for waste processing, treatment and use of waste sorting, mechanical treatment, separation and processing, will be described in detail below with reference to the accompanying drawings based on a specific embodiment, wherein Figure 1 is a schematic view of waste sorting. Figure 2 is a schematic view of waste shredding. Figure 3 is a schematic view of a thermo-chemical unit. DETAILED DESCRIPTION

[0022] According to the icon example, the present invention, which is a variable system for waste processing, treatment and use of waste sorting, mechanical treatment, separation and processing, includes a waste container 1 provided with a plurality of waste quantity sensors 2 and a plurality of other waste movement sensors 3. A waste shredder 5 with a load sensor 6 is connected to the container 1 via a meter 4. The waste quantity sensors 2, other waste movement sensors 3 and load sensor 6 are interconnected to a control unit 7, which is connected to a conveyor belt drive controller in the waste container 1, meter 4 and shredder 5, respectively. Here, the shredder 5 is a slow-running shredder with a press sieve 10, which achieves a uniform particle size for subsequent sorting and processing. Behind the shredder 5 is provided with a waste treatment plant, a sorter and a thermo-chemical unit 8. The waste treatment plant is used for mechanical treatment, cleaning, drying, separation and granulation, which is followed by a biogas plant for processing organic material to recover energy and subsequently used as compost. The sorter can sort the formed particles according to plastic type for recycling. The thermo-chemical unit 8 is used to produce energy fuel in the form of gas, oil and carbon, and is followed by a liquefied gas tank 9, which includes a mixing device. The thermo-chemical unit 8 is provided with an air-excluding metering feeder 11, a heat source 12 interconnected to the control unit 7 and a sensor 13 in the distiller of the thermo-chemical unit 8. The system of the present invention also includes a plant for processing gas from the biogas plant and the thermo-chemical unit 8 to produce electrical energy.

[0023] The variable system for waste processing, treatment and use is provided with a biological filter with a filter bed having a height of 1.0 to 2.0 meters, which is composed of a mixture of wood chips, peat and coconut fibers, and microorganisms present on the surface of the above-mentioned particles can remove low concentrations of sensory organic substances contained in the extraction gas stream. It is provided with a pH regulator, an automatic backflushing spray device and a temperature regulator in the range of 10 to 40°C.

[0024] In another embodiment, the variable system for waste processing, treatment and use of the present invention is arranged on a ship, and the waste container 1, meter 4, waste shredder 5, treatment plant, biogas plant, thermo-chemical unit 8 for producing energy fuel and liquefied gas tank 9 are interconnected via flexible joints.

[0025] The building is provided with a structurally separated receiving area where the waste vehicle deposits the incoming waste on a floor of concrete provided with a penetrating coating, which floor is inclined towards a non-draining chamber which concentrates the liquid components of the waste or other leaking liquids so that these liquids do not destroy the environmental quality.

[0026] A wheeled loader with a bucket in the receiving area of the building separates the waste from objects such as stones and waste which are not suitable for treatment by mechanical biological treatment. The stone fraction is separately enclosed in containers and directly sent to a landfill.

[0027] The loader loads the waste into a hopper, from which the waste is transported by a conveyor belt to the processing area of the building. A biological filter is provided at the exit of the receiving area to prevent the spreading of odours.

[0028] A main shredder processes the incoming waste, including the adjustment of the particle size, loosening and placing the waste in bags or boxes. The shredded waste is advanced on a conveyor belt and is poured into a magnetic separator by a pourer, which separates the iron metal included in the waste. After the separation of the metal, the glass, stones and, in particular, the plastics are manually separated from the waste fragments. The glass and the iron are sent to recycling, and the stones which cannot be used are sent to a landfill. The plastics are sent to a thermochemical unit for energy processing. The manual separation has the advantage that the number of types of waste which can be separated is easily increased. If the area is provided with a processor for paper, for example, paper which is suitable for recycling can also be separated from the waste.

[0029] Subsequently, the remaining part, which mainly consists of biological waste, is shredded into fine particles for active fermentation and composting.

[0030] The waste processing line is provided with extraction openings of individual work areas, where the processed waste is handled or poured. The first extraction area is the infeed shredder, followed by the pourer above the magnetic separator, the manual sorting line and the final shredder. An air conditioning system leads the extracted air out of the channel provided with a fibrous dust collector. A biological filter device for reducing the emission of odours is provided behind the separator.

[0031] Composting facility - fermentation chamber

[0032] The mixed municipal waste contains a large amount of biodegradable components, and the effect of the controlled aerobic fermentation procedure is to reduce the biological activity of the fraction below the screen to less than 10 mg O2 per gram dry matter of oxygen uptake respiration activity. Otherwise, if the activity is not sufficiently reduced, the waste can form methane gas by anaerobic procedures, and methane has a greenhouse effect which is about six times higher than that of carbon dioxide, which is a natural biodegradation product.

[0033] After this forced oxidation process is completed, the exhaust gas can no longer be used for power generation in the cogeneration unit and for the utilization of waste heat from gas combustion.

[0034] The innovative implementation of this facility can be a windrow composting system set up in a closed building, which uses a backhoe for active turning and is combined with additional irrigation equipment for substrate seeding. This procedure is slower, but it can significantly reduce costs.

[0035] Under the appropriate turning and wetting pattern, the solution achieves the same results as using a fermentation tank, with the only difference being that the procedure is about a month slower. Therefore, sufficient area should be selected so that the substrate is sufficiently delayed in the procedure.

[0036] The turning frequency can be 3 to 5 times a week, depending on the requirements and the time of year. The building area is used for placing the compost windrows. Intensive fermentation for 6 weeks is carried out in the fermentation room, and then the substrate is sent to the maturation area.

[0037] The building is provided with concrete slabs 5 meters high, so the compost windrows can be laid over the entire building area, reducing dust.

[0038] Above the concrete slabs, light-transmitting materials are provided, such as polycarbonate. Thus, a closed building object is created with an air and moisture extraction system, which avoids dust and enables the use of biological filters to filter out odor substances.

[0039] Composting site - maturation area

[0040] After the fermentation of the material, it is transferred from the fermentation room to the compost maturation area. This area is preferably built as a concrete floor inclined towards the retention tank, so that rainwater can flow from the compost material and be retained in the tank.

[0041] The compost is also formed into windrows in this area and stays for 6 to 8 weeks. During the stay, it is turned and wetted as appropriate, at a frequency of about once a week.

[0042] Biological filter

[0043] Waste air biological filtration is a method of decomposition or biological conversion of harmful substances using microorganisms. The method is implemented by passing dirty air through a biological filter, which is filled with a porous material coated with a biomass layer. When the gas passes through the biological filter, the biomass surface retains (absorbs) the pollutants, which are then biologically decomposed. Thus, the basic principle of biological decomposition is the combination of pollutant absorption and biochemical decomposition using appropriate bacterial cultures.

[0044] The interior of the biofilter must be maintained under optimum conditions in many aspects, including humidity, pH, temperature, and concentration of nutrient components. Prior to operation, the biofilter must be inoculated with an appropriate microbial culture and supplied with inorganic nutrients.

[0045] Air from the extraction zone and the system is passed through the biofilter, thus avoiding the problem of free diffusion of odors in the air. The required biofilter capacity and size depend on the amount of air to be discharged from the air conditioning unit.

[0046] The biofilter is equipped with a filter bed, 1.5 meters high, composed of a mixture of wood chips, peat, and coconut fibers. The microorganisms present on the surface of the particles remove the low concentrations of sensory organic substances contained in the extraction air stream.

[0047] The device is equipped with pH adjustment, automatic backwash spraying, and temperature adjustment. It operates without any human intervention. The only condition is that the input air temperature range is between 10 and 40°C.

[0048] Sorting and separation

[0049] This part of the plant combines proven optical and mechanical separation procedures in a way that guarantees high-quality sorting to obtain recyclable material pieces. The process of this plant ensures that the output material has an excellent and particularly uniform quality. The present invention separates mixed plastics by type, so they can be immediately used to make pellets and bales that are acceptable to recyclers.

[0050] Material shredding and preparation technology

[0051] This part of the plant is designed and constructed for the treatment of specific input materials, i.e., waste, such as old tires. It gradually breaks down the input material into fine particles. The individual parts of the plant are connected by conveyor belts. The system includes a sorter and a magnetic metal separator, which separates, for example, steel cords and other steel materials extracted from the tires for subsequent processing. The typical throughput of the entire system is 2 to 3 tons of shredded material per hour.

[0052] Treatment plant

[0053] This part involves technologies including mechanical treatment, magnetism, optics, and color separation, as well as pulping and pelletizing, plus subsequent preparation, to enable subsequent processing or sale of, for example, PET pellets.

[0054] Biogas plant

[0055] The base of the biogas plant is made up of so-called garage-type airtight and watertight digestion tanks, the operating capacity of which is about 800 cubic meters of material. Emptying and filling of the tanks is performed by a wheel loader. The input raw material inoculation procedure is to mix fresh biological waste (about 60% of the batch) with already fermented biomass (about 40% of the batch), and then to spray process water on the fermented biomass in the closed tank.

[0056] The biogas plant is manufactured on the basis of a customized design, depending on the quantity and type of raw material available and the possible site layout.

[0057] Thermochemical unit

[0058] The ECPS system (energy conversion process or system) produces energy from all biodegradable or synthetic waste. The thermochemical unit operates continuously during the production of high-quality gaseous and liquid fuels. The ECPS thermochemical system produces gaseous or liquid fuels from various sources of waste. The efficiency of the ECPS system depends entirely on the purity and energy content of the waste. The overall design of the thermochemical system complies with all European standards applicable to such equipment. The production cycle is closed throughout, without any fugitive emissions or waste.

[0059] The equipment is automated, and the thermochemical process is monitored at all times by various safety systems, without the need for human intervention.

[0060] Such a thermochemical unit can be used for the energy recovery of the following waste:

[0061] a. Tires

[0062] b. Plastics

[0063] c. Municipal waste

[0064] d. Sewage treatment plant sludge, paint factory sludge, laundry and paper pulp sludge

[0065] e. Agricultural and horticultural waste, such as manure, slurry, garden waste

[0066] f. Biomass and wood

[0067] g. Hospital waste

[0068] Gas management and energy center

[0069] Device for gas production from compost, thermochemical unit and its use for energy production

[0070] According to the present application, the facility for waste processing and energy recovery is constructed by connecting the above-mentioned various components to each other. The entire facility, including all service roads, office buildings, parking lots and storage areas, has an area of about 400 m x 200 m, estimated at a waste processing capacity of 10 tons per hour. Based on the concept of versatility, it is also possible to reconstruct existing idle industrial plants and put them to use.

[0071] Industrial applicability

[0072] The variable system of the present application can be used particularly in the processing, treatment and use of waste, especially municipal waste.

Claims

1. A variable system for waste processing, treatment, and use, comprising a waste container (1), a waste shredder (5) connected to the waste container (1) via a meter (4), a waste treatment device and a thermochemical unit (8) provided downstream of the waste shredder (5), the waste treatment device being used for mechanical processing, cleaning, drying, separation, and pelletizing, the waste treatment device being connected to a biogas station, a sorter, and a system for separating the produced pellets according to their plastic type for recycling, the biogas station being used for processing and treating organic materials to recover energy for subsequent use as compost, the sorter separating the produced pellets according to their plastic type for recycling, and the thermochemical unit (8) producing energy fuels in the form of gas, oil, and carbon, followed by at least one liquefied gas tank (9) having a mixing device, characterized in that, The waste container (1) is equipped with at least one waste quantity sensor (2) and at least one other waste movement sensor (3), and the waste shredder (5) is equipped with a load sensor (6). The waste quantity sensor (2), the other waste movement sensor (3), and the load sensor (6) are interconnected with a control unit (7), and the control unit (7) is connected to multiple conveyor belt drive controllers located in the waste container (1), the meter (4), and the shredder (5), respectively. The thermochemical unit (8) behind the shredder (5) is used to produce energy fuels in the form of gas, oil, and carbon. At least one liquefied gas tank (9) is provided behind the thermochemical unit (8). The liquefied gas tank (9) has a mixing device, wherein the pulverizer (5) is a slow-running pulverizer with a pressure screen (10) to achieve uniform material particle size for subsequent classification and processing, and the thermochemical unit (8) is provided with an airtight metering feeder (11), at least three heat sources (12) interconnected with the control unit (7) and multiple temperature sensors (13) in a distillation apparatus, wherein the thermochemical unit (8) is provided with a device for quantitatively dispensing granular material, and / or an extruder for compressing the input plastic to its melting point to homogenize the plastic, wherein the system is provided with a device for processing the gas from the biogas station and the gas from the thermochemical unit (8) to generate electricity.

2. The variable system for waste processing, treatment, and use according to claim 1, characterized in that, The system is equipped with a biofilter having a filter bed with a height of 1.0 to 2.0 meters and composed of a granular mixture of bark chips, peat, and coconut fiber. Microorganisms present on the surface of the granules remove low concentrations of sensory organic matter contained in the extraction airflow. It is equipped with an automatic countercurrent spray pH regulator and a temperature regulator in the range of 10 to 40°C.

3. The variable system for waste processing, treatment, and use according to claim 1 or 2, characterized in that, The system is located on a ship, and the waste container (1), the meter (4), the waste shredder (5), the processing equipment, the biogas station, the thermochemical unit for producing energy fuel (8), and at least one liquefied gas tank (9) are interconnected by flexible joints.

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