APPARATUS AND METHOD FOR PROCESSING ORGANIC MATERIAL

Description

TECHNICAL FIELD

[0001] The present invention relates to a plant for processing organic material and a method for processing the same. STATE OF THE ART

[0002] The natural process of life cycles and nutrition of insects / larvae requires a certain temperature to ensure optimal growth and utilization of food.

[0003] For industrial use, e.g., the extraction of the actual larvae as animal feed, or products derived from these larvae and their byproducts, using organic raw materials such as biowaste or waste products from food production, this temperature must be adjusted by heating or cooling. This results in costs for the necessary technical components and their maintenance during operation, as well as their energy consumption, which must be minimized.

[0004] Previously known processes utilize a discontinuous processing sequence or batch operation, in which fixed amounts of starting material are mixed with so-called young larvae and then maintained under the necessary environmental conditions until the desired growth stage / utilization of the starting materials is reached. This is typically 10 to 14 days, determined by the insect life cycle. Such a process requires storage and traffic areas. Scaling up these known processes would increase personnel costs and storage space accordingly.

[0005] In other words, such a discontinuous process hinders the optimization of the process's performance and economic efficiency. By energy-optimizing the process for continuous operation, these disadvantages can be significantly reduced and the benefits of such plants significantly increased.

[0006] CN112996382A describes a facility for insect breeding. It describes an industrial facility consisting of multiple, identical, vertically aligned tiered batteries.

[0007] KR102013244B1 describes a modularized system for mass rearing of insects capable of producing insects in large quantities using a non-powered method while rearing insects, and designed to facilitate labor. The modularized system for mass rearing of insects comprises: a rearing chamber that can be ventilated, cooled, and heated; and a rearing device arranged in the rearing chamber and designed to accommodate and rear insects in large quantities. TASK

[0008] Therefore, the object of the invention is to provide an improved, more easily scalable, more automatic device for processing organic material using insect larvae. DISCLOSURE OF THE INVENTION

[0009] According to the invention, a plant for processing organic material with insect larvae is proposed according to claim 1. This plant comprises a rail arrangement with a gradient, a plurality of containers arranged for movement on the rail arrangement, and a casing surrounding the rail arrangement and the plurality of containers. The plant is designed such that the containers move with the assistance of the gradient or gravity. The plant further comprises a turbine wheel driven by a fluid flowing in the casing, and a generator driven by the turbine wheel. The turbine wheel and the generator can be operated as a fan and drive motor.

[0010] The rail arrangement is preferably made of metal. The rail arrangement, in particular, has a supporting function for the system. Alternatively, the rail arrangement can comprise a supporting cable or be designed as a supporting cable. The containers can be guided along the supporting cable in a cable-car-like manner. This has the advantage that a non-supporting material, such as recycled plastic, can be used for the casing. The supporting cable can comprise coupling devices, in particular at equidistant intervals. A coupling device is designed to releasably hold a cable harness. The cable harness is preferably arranged on one of the containers.

[0011] Alternatively, the rail arrangement can include a chute or be designed as a slide. The containers can slide down the chute, assisted by the slope of the chute.

[0012] Preferably, the containers have polygonally arranged side walls. During the sliding process, a dense packing or arranging of the containers can automatically occur. The side walls of the containers are, in particular, hexagonal. In other words, the containers can be honeycomb-shaped.

[0013] The rail arrangement preferably has an incline or gradient of 2 to 12°. In particular, the gradient is 5°.

[0014] The shell can create a sealed enclosure for the system. The sealed enclosure can improve the utilization of waste heat and / or ventilation within the system.

[0015] The organic material includes in particular plant and / or animal materials, such as organic waste, waste products from food production, slaughterhouse waste, green waste, sewage sludge, pomace, sugar beet pulp, algae, molasses, linseed oil, etc. If the containers are filled with insect larvae or young larvae and the organic material, the latter can serve as food for the insect larvae. Young larvae are preferably used as insect larvae. Young larvae are particularly larvae that have already hatched from an insect egg. The insect larvae mature into adult larvae over a period of 10 to 14 days, for example, while they feed on the organic material. The protein content of the insect larvae increases up to a threshold value. In other words, an insect larva or young larva can develop into the adult stage in the containers. Once the protein threshold value is reached, high-quality protein orProtein is harvested, with the organic material largely processed or disposed of. The protein can be used, for example, as fish feed or general animal feed.

[0016] Larvae generally include maggots and caterpillars. Maggots, especially the larvae or juvenile larvae of soldier flies, are suitable for the present invention. Even more suitable are the larvae of the black soldier fly, also known as Hermetia illucens. Hermetia illucens can convert 2 kg of feed into 1 kg of body mass. Hermetia illucens contains approximately 58% protein.

[0017] The containers can each comprise a leveling device. The leveling device, in particular, ensures a horizontal container base. For uniform and efficient processing of the organic material, it may be necessary for the layer thickness of the organic material along the container base to be as constant as possible. If the container base or a container is tilted, organic material could slide to one side, resulting in an unfavorable difference in the layer thickness of the organic material. The leveling device can comprise the cable harness that suspends the containers from the support cable. The cable harness can comprise a centrally arranged pulley so that the containers each align themselves horizontally. The leveling device can comprise a gimbal suspension and an inner container arranged in or on the container.If the container itself is tilted, the gimbal ensures leveling of the inner container. Furthermore, the leveling device can include a wedge located beneath the container, designed to compensate for the slope of the rail assembly so that the container is leveled. Conventional devices that convey organic material loosely on chutes or belts, etc., without a container are less suitable, as the loose conveying causes the layer thickness of the organic material to vary greatly, resulting in uneven and inefficient processing of the organic material.

[0018] The containers may comprise stackable containers. In other words, a first container may be stacked on top of a second container. This allows several of the containers to be stacked on top of one another.

[0019] A preferred layer thickness of the organic material with larvae is, for example, 5-10 cm, more preferably approximately 8 cm. The containers are, in particular, upwardly open vessels with a flat bottom and side walls arranged at right angles to the bottom. The side walls are preferably 1 to 2 cm higher than the layer thickness of the organic material with larvae. In particular, the containers have a height of approximately 10 cm. Several containers can be stacked on top of one another and conveyed or moved along the rail arrangement. Preferably, 2, 3, 4, or 5 containers can be stacked on top of one another to enable efficient throughput through the system.

[0020] During the maturation of the insect larvae, heat energy is generated. According to a further embodiment of the invention, the system according to the invention preferably comprises a fan. The fan can be used to evenly distribute heated air or fluid within the enclosure. In particular, adult insect larvae generate more waste heat in the containers than younger insect larvae. The fan can distribute the waste heat more evenly within the enclosure. This advantageously saves energy.

[0021] Furthermore, the rail arrangement can be spiral or have spiral sections. Furthermore, the rail arrangement can have straight sections. Alternatively, the rail arrangement can have spiral and straight sections. The spiral sections achieve the gradient in particular. The straight sections allow the system to be designed to be scalable. In other words, the system can be designed to be more oval or longer in length using straight sections in order to be able to convey more containers. The system is therefore more scalable than conventional systems. The time required to guide the containers in the sleeve depends in particular on the travel distance for the containers along the rail arrangement. The time required to guide the containers in the sleeve can depend on the number and / or size of the containers in the system.

[0022] In a further embodiment, the shell can be cylindrical or oval-cylindrical. Depending on the available space for the system, the shell can be cylindrical or oval-cylindrical. The shape of the shell can be designed to match the shape of the rail arrangement. If the rail arrangement has a load-bearing function, the shell can be made of a non-load-bearing material, whereby the shell can be arranged on the load-bearing rail arrangement.

[0023] According to a further development, the casing can comprise a first opening for loading containers and a second opening for removing the containers. The containers are in particular arranged removably on the rail arrangement. The containers comprise metal or a durable plastic. The containers can be designed to be reusable. Since several containers are conveyed in the system simultaneously, a continuous process is present in particular. Conventional processes are sequential, i.e. larvae mature in a bioreactor. The bioreactor can only be refilled with new larvae and organic material once the larvae from a previous bioreactor loading have reached the adult stage. This is generally discontinuous, manually laborious, and difficult to scale.The system according to the invention, on the other hand, enables a continuous input of freshly filled containers and a continuous output of containers containing adult larvae and largely eaten organic material.

[0024] The system according to the invention comprises the turbine wheel, which is driven by a fluid flowing in the enclosure. Waste heat generated by the larvae can cause the fluid or air to flow in the enclosure. The larvae can cause temperatures in the containers to exceed 50°C. If the temperature rises too high, the larvae die. However, a target temperature of 27°C to 30°C is more optimal. The flow can advantageously be used to drive the turbine wheel. Furthermore, the system comprises a generator driven by the turbine wheel. The generator can generate electrical energy. This makes the system particularly environmentally friendly and sustainable. In a temperature range of, for example, 12°C to 16°C, the larvae are inactive, i.e. they do not feed. Conventional methods require additional heating to initially bring the larvae to a temperature that promotes growth.The system according to the invention preferably does not require such a larval heating.

[0025] The turbine wheel and generator can also be operated as a fan and drive motor, respectively. The turbine wheel can form the fan. The generator can be conversely connected as a drive motor and drive the fan. Furthermore, the system can include a process control system that controls the drive motor or generator. The process control system can control the temperature depending on the temperature in the enclosure. The process control system can use several temperature sensors to determine the temperature at various points in the enclosure. Even more preferably, the process control system can use several temperature sensors to determine the temperature of containers containing larvae in different growth phases. In particular, more mature insect larvae generate more waste heat in the containers than juvenile larvae.

[0026] According to a further development of the invention, the system can comprise a heat exchanger which can be used to absorb thermal energy generated in the system.

[0027] In a further embodiment, the system according to the invention can comprise a continuous conveying device for conveying the containers along the rail arrangement. The continuous conveying device can comprise mechanical conveyors, gravity conveyors, and / or flow conveyors. A mechanical conveyor can comprise a roller conveyor, a vibratory conveyor, a belt conveyor, and / or a chain conveyor. A gravity conveyor can comprise a roller conveyor, a ball conveyor, and / or a rail conveyor. A flow conveyor can comprise a pneumatic or hydraulic conveyor. Continuous conveying devices are usually compact and simply constructed, require little maintenance, and require little manual operation because they operate automatically. They are particularly suitable for conveying containers along gently inclined rail arrangements.In addition, the continuous conveying device can overcome the static friction of the containers on the rail assembly, thus assisting in conveying the containers along the incline of the rail assembly. In other words, the continuous conveying device and the incline of the rail assembly combine to convey the containers along the rail assembly.

[0028] The invention further features a method according to the invention for processing organic material using the system according to the invention. The method comprises the following steps: mixing organic material, in particular organic waste, with insect larvae; filling a container with the mixture; guiding the container along a rail arrangement in a casing surrounding the rail arrangement, assisted by gravity, wherein the container is guided or conveyed in the casing for a period of time that depends on a conversion rate of the organic material from the insect larvae into a conversion product or on a content of the conversion product.

[0029] Conventional methods are manually laborious, whereas in the method according to the invention, the container is moved essentially by gravity. The speed of the process can be influenced by the arrangement and size of the container and rail arrangement. In particular, the insect larvae generate heat energy as they progressively convert the organic material into the conversion product. The conversion product essentially comprises protein from the insect larvae themselves. The heat energy can heat a fluid, particularly air, within the casing, causing the fluid to flow within the casing.

[0030] Advantageous further developments of the invention are specified in the subclaims and described in the description. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Embodiments of the invention are explained in more detail with reference to the drawings and the following description. They show: Figure 1a shows a system according to an embodiment of the invention, Figure 1b shows a further system according to an embodiment of the invention, Figure 2a shows a further system according to an embodiment of the invention, Figure 2b shows a further system according to an embodiment of the invention, Figure 3 shows a container according to an embodiment of the invention, Figure 4a shows a rail arrangement according to an embodiment of the invention and Figure 4b shows a further system according to an embodiment of the invention. EMBODIMENTS OF THE INVENTION

[0032] The object of the invention is achieved by implementing a countercurrent flow process for material flow and cooling or warm air. To achieve a continuous material flow, the predominantly organic material to be processed is conveyed into suitable containers in a spiral guide. Fig. 1a and 1bThe cylinders are moved on guide rails (rail arrangement) with the aid of gravity from the material feed point "above" to the material discharge point "below" for the time required to achieve the process result. The cylinder design requires material containers that have an identical volume, but must simultaneously guarantee a fixed material layer thickness. This is achieved as a variant by different base areas, depending on the distance from the center of rotation of the system body. Stretched cylinders require an adjustment of the container support / guiding system for movement over straight sections. Such stretched cylinders allow a larger amount of material to pass through the process, avoiding the need to simply increase the number of cylinders to increase throughput. With optimal control, the intrinsic process heat is sufficient to achieve high efficiency without the addition of external energy.The control is carried out by individually controllable slide valves in the outer cladding of the system, schematically shown in . Fig. 2a and 2bThe resulting upward movement of the air flow within the system enables energy to be recovered, depending on the operating status, through mechanical use, e.g. via a generator wheel and / or the amount of heat not absorbed during the process. In detail, the spatial guidance of the material containers allows for a high degree of automation during emptying, cleaning and filling. For this purpose, it is possible to carry out the necessary movements without manual intervention by laying the guide rails of the material containers in a spiral shape in the direction of movement. The structure of the system can be made to a considerable extent from recycled materials (in particular, but not only, this refers to the non-structurally load-bearing outer shell, which can be made from non-sorted waste plastic - e.g. from recyclable material recycled from the environment / oceans - with thermal insulation properties). The system preferably does not require a drive for the containers.The system can include a fan for circulation within the shell. If, depending on the track inclination, the resulting gravity vector is insufficient to move the containers forward in the process direction, vibratory conveying systems or other low-energy drive systems can be used.

[0033] Figure 1a shows a material flow 100. A rail arrangement with several movably mounted containers creates the material flow 100. The material includes Hermetia illucens larvae as well as plant and animal waste. The containers are loaded with the material and, assisted by gravity, are conveyed essentially automatically along the material flow 100.

[0034] Figure 1b shows a material flow 102 that has an oval-cylindrical shape. The oval shape of the material flow 102 allows for more containers to be conveyed than in the material flow 100.

[0035] Figure 2ashows a plant 104 for processing plant and animal waste. The plant 104 comprises a tight casing 106. Within the casing 106, several containers are conveyed along a spiral path. The spiral path has a gradient so that the containers glide along the path assisted by gravity. The containers are filled with young larvae of Hermetia Illucens and organic material that serves as food for the young larvae. The young larvae mature, for example, over a period of 10 to 14 days, during which their protein content increases to a threshold value. In other words, a young larva can develop to the adult stage in the containers. As the larvae mature, heat energy is generated. The heat energy heats air in the casing, which flows upwards and heats an upper region of the container, illustrated by temperature gradient 108. The casing 106 acts like a chimney.The system 104 further includes a plurality of ventilation flaps 110. A process control system uses a plurality of temperature sensors to determine the temperature at various locations in the casing 106 and controls the ventilation flaps 110 in order to establish or maintain a predetermined temperature, e.g., 27°C to 30°C, in a predetermined area of ​​the casing 106. A turbine generator system 112, which can also be operated as a fan drive motor system 112, is controlled by the process control system in such a way that a predetermined temperature can be established or maintained in a predetermined area of ​​the casing 106.

[0036] Figure 3shows a cart-shaped container 300. The container 300 comprises an outer container 302 with a bottom and six side walls. The side walls are arranged hexagonally on the bottom, creating a honeycomb shape. The container 300 further comprises an inner container 304 and a gimbal mount 306, which mounts the inner container gimbal-mounted relative to the outer container 302. The inner container 304 has slightly smaller dimensions than the inner dimensions of the outer container 302. In a horizontal position, the inner container is flush or recessed within the outer container. When the container 300 is conveyed or moved along a slope, the inner container 304 tilts in such a way that the slope is compensated or leveled. For uniform and efficient processing of organic material with larvae in the container 300, it is necessary that the layer thickness of the organic material along the bottom be as constant as possible.As the container 300 slides along a chute, the honeycomb shape of the container 300 automatically ensures tight packing or juxtaposition with other honeycomb-shaped containers on the chute.

[0037] Figure 4a shows a rail arrangement 400 with a support cable 402 and a deflection pulley 404. The support cable 402 runs spirally from top to bottom (indicated by arrows).

[0038] Figure 4b shows a system 405 with the support cable 402, a cable coupling device 406, a cable harness 408, a leveling device 410, and several stacked containers 412. The support cable 402 has a gradient of 5° to the ground. The cable couplings 406 are arranged equidistantly on the support cable 402. The cable couplings 406 each releasably hold a cable harness 408.

[0039] Several stacked containers 412 are suspended from the cable harness. The cable harness 408 includes a leveling device 410, which can be designed as a roller, for example. While the stacked containers 412 are being conveyed, the containers are leveled or horizontally by the leveling device 410. Organic material containing black soldier fly larvae is conveyed in the containers. The material is eaten, i.e., processed, by the larvae during conveyance. For uniform processing, the containers must be leveled or aligned evenly. The cable harness 408 and the stacked containers 412 are coupled into the cable coupling device 406 at the top of the system and slowly conveyed through the system over 10 to 14 days. After this period, the cable harness 408 and the stacked containers 412 are uncoupled at the bottom of the system 405. LIST OF REFERENCE SYMBOLS

[0040] 100Material flow 102Material flow 104System 106Shell 108Temperature gradient 110Ventilation flaps 112Turbine-generator system 300Vessel 302Outer vessel 304Inner vessel 306Gimbal suspension 400Rail arrangement 402Carrying cable 404Deflection pulley 405System 406Cable coupling device 408Cable harness 410Leveling device 412Vessel

Claims

1. System (104; 405) for processing organic material with insect larvae, comprising: a rail arrangement (400, 402) which has a gradient, a plurality of containers (300, 302, 304; 412) which are arranged so as to be movable on the rail arrangement (400, 402), and a shell (106) which surrounds the rail arrangement (400, 402) and the plurality of containers (300, 302, 304; 412), the system (140; 405) being designed such that the containers (300, 302, 304; 412) move in a manner assisted by the gradient characterized in that the system comprises a turbine wheel (112) which is drivable by a fluid which flows in the shell, and a generator (112) which is driven by the turbine wheel, the turbine wheel (112) and the generator (112) being operable as a fan and drive motor.

2. System (104; 405) according to claim 1 comprising a fan.

3. System (104; 405) according to any of the preceding claims wherein the rail arrangement (400, 402) has spiral-shaped portions.

4. System (104; 405) according to any of the preceding claims wherein the shell (106) is cylinder-shaped or oval-cylinder-shaped.

5. System (104; 405) according to any of the preceding claims wherein the shell (106) comprises a first opening for loading with containers (300, 302, 304; 412), and a second opening for removing the containers (300, 302, 304; 412).

6. System (104; 405) according to any of the preceding claims comprising a heat exchanger for absorbing thermal energy which is produced in the system (104; 405).

7. System (104; 405) according to any of the preceding claims comprising a continuous conveying device for conveying the containers along the rail arrangement (400, 402).

8. System (104; 405) according to any of the preceding claims, wherein the containers (300, 302, 304; 412) each comprise a leveling device (410).

9. Method for processing organic material by means of a system according to any of the preceding claims, comprising the steps of: mixing organic material, in particular organic waste, with insect larvae; filling a container with the mixture; guiding the container along a rail arrangement, in a manner assisted by gravity, in a shell which surrounds the rail arrangement, wherein the container is guided in the shell for a period of time which depends on a conversion rate of the organic material by the insect larvae into a conversion product, or on a content of the conversion product.

10. Method according to claim 9, wherein the insect larvae generate thermal energy by means of a progressive conversion of the organic material into the conversion product.

11. Method according to claim 9, wherein the thermal energy heats a fluid in the shell, which fluid flows, in particular rises, in the shell.

12. Method according to any of claims 9 to 11, wherein the conversion product comprises protein.