Apparatus, method, and control system for producing energy from waste and other output products

Abstract

Aspects of the present disclosure include apparatus, systems, methods, and control systems for processing raw materials into an output product having variable preselected characteristics. Various system components may include: 1) a feeder configured to convey the raw materials; 2) a mechanical grinder configured to grind the raw materials received by the feeder into ground raw materials; and 3) an air conveyor for conveying an air stream to the mechanical grinder and drawing the air stream from the mechanical grinder to a fines separator. The ground raw materials include one or more heavy fines, fine particles, moisture, or combinations thereof. The air stream from the mechanical grinder includes at least a portion of the ground raw materials, and a portion of the ground raw materials is conveyed by the air stream.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 293,981, filed December 27, 2021, and U.S. Nonprovisional Patent Application No. 17 / 825,344, filed May 26, 2022, and hereby incorporates by reference the contents of such provisional patent applications. This application is related to co-pending U.S. patent application Ser. No. 17 / 133,073, entitled "Apparatus, Method, and Control System for Generating Energy from Waste and Other Output Products," filed on June 28, 2019, which is a continuation of U.S. patent application Ser. No. 16 / 457,431, entitled "Apparatus, Method, and Control System for Generating Energy from Waste and Other Output Products," filed on June 28, 2019, which is now U.S. Patent No. 10,898,903, issued on January 26, 2021, and claims priority to U.S. Provisional Application No. 62 / 692,369, entitled "Apparatus, Method, and Control System for Generating Energy from Waste and Other Output Products," filed on June 29, 2018, each of which is incorporated herein by reference in its entirety.

[0002] Aspects of the present disclosure relate generally to the field of waste treatment and production of energy and other output products, such as syngas, pyrolysis products, and soil additives. [Background technology]

[0003] There remains an unmet need for methods, systems, apparatus, and control systems for processing waste into usable products, such as syngas, pyrolysis products, and soil additives. Summary of the Invention [Problem to be solved by the invention]

[0004] [Means for solving the problem]

[0005] Aspects of the present disclosure include apparatus, systems, methods, and control systems for processing waste into usable products, such as syngas, pyrolysis products, and soil additives.

[0006] Embodiments of the system may include processing of one or more feedstocks, which may include, for example, trash (including organic matter), biosolids, agricultural waste, paper pulp, food waste, digestate, and / or other biomass, and other materials. The feedstocks may be dried and otherwise processed, such as by grinding, which may result in, among other things, the production of water from the drying and other processing.

[0007] Various components of one example of a system for treating waste according to an embodiment of the present disclosure may include one or more of: 1) a material loading area, which may arrive, for example, above a chipping floor area; 2) a shredder; 3) a magnet-based separator; 4) an eddy current non-magnetic metal separator; 5) additional sorting equipment, such as a ballistic separator and / or an optical separator, optionally including one or more sorting observation areas; 6) a mechanical separator, which may include or further include one or more ring mills, horizontal hammer mills, or vertical shaft impactors (VSIs); 7) one or more material separation equipment, such as one or more cyclones; 8) an air conveyor, such as a blower or fan; 9) a compressor, such as one or more rum balers; 10) a packaging machine, such as one or more bale wrappers; and 11) one or more material analysis equipment, such as moisture and calorie data analysis and collection equipment.

[0008] In one exemplary embodiment, the system may include various improved features for dewatering / drying various organic feedstocks, including one or more of: 1) a shredder; 2) a mechanical grinder, such as a ring mill, horizontal hammer mill, or vertical shaft impactor (VSI); 3) a variable or relatively constant speed air conveyor (such as a blower or fan) that draws high velocity air through the grinder, cyclones, baghouse, and / or other air filtration systems that may be required by local regulations; 4) optional screens to control the size of the air-conveyed feedstock exiting the grinder and to facilitate residence time of pre-screened feedstock in the grinder; 5) a cyclone to facilitate separation of dewatered / dried feedstock (e.g., "fluff") for processed fuel derived fuels (ERDF); 6) a baghouse to capture micron-sized particulates, including, for example, features that may be required to meet local clean air or other requirements, and additional air filtration systems, including, for example, features that may be required by local air quality requirements.

[0009] In operation, an exemplary system with improved capabilities for dewatering / drying various organic raw materials may include, for example, the following operations / functions: 1) the organic raw materials may be chopped to an appropriate size based on the origin and moisture level of the raw materials; 2) pre-sorted organic raw materials of appropriate size and containing up to 60% moisture (water or other fluid) by weight may enter the crusher / horizontal hammer mill / VSI; 3) the pre-sorted raw materials may be exposed to an air conveyor, e.g., a blower or fan may be located external to the crusher / hammer mill and may pull or push ambient (or, e.g., pre-conditioned) high velocity air through the crusher / hammer mill; 4) the crusher / hammer mill pulverizes the pre-sorted raw materials, thereby increasing the surface area of ​​the pre-sorted raw materials while the high velocity air mixes with the pre-sorted raw materials, separating the moisture from the surface of the pre-sorted raw materials. 4) The air-entrained raw material may be separated and dried (to a predetermined level) and moisture may be conveyed onto the smaller (less than 20 micron) particles from the hammer mill; 5) The optional crusher / hammer mill exits through a screen configured to retain larger aggregates longer (increasing residence time) as moisture and smaller particles exit the crusher / hammer mill; 6) The existing raw material may be conveyed (e.g., via high velocity air from an air conveyor; such conveyed raw material is also referred to interchangeably herein as "air-entrained raw material") to a cyclone to separate the air-entrained raw material, and the high velocity air may be filtered for fine particles in a bag house; 7) The high velocity filtered air exiting the bag house may undergo other filtration / purification as necessary before being released into the ambient air. The output of the pneumatically conveyed feedstock from drying and other processing, instead of being compressed and packaged, may include the production of processed recycled derived fuels (e.g., fluff) that can be used to generate other inputs for further processing, such as pellets or (pyrolysis, gasification (e.g., synthesis gas "syngas"), and / or combustion. The pyrolysis process may also be used, for example, to generate biochar.The syngas process and / or biochar process may be used, for example, to produce biocoal, bio-oil, advanced bioproducts, and synthetic natural gas, and / or may be used for combined cycle generation, soil improvement products, filtration products, activated carbon precursors, and / or activated carbon products.

[0010] Further aspects of the systems, apparatus, and methods of the present disclosure may include a control system for electrically or pneumatically managing and / or controlling the monitoring, operation, and / or interaction of various processing devices within a processing system. One exemplary implementation of a control system according to aspects of the present disclosure may include the use of a matrix bus as well as the use of various devices and processes connectable via machine-to-machine interfaces to receive parameters, provide mechanisms / algorithms for adjusting parameters, otherwise provide monitoring of the system, provide and control communication to, from, by, and between the devices of the system, and perform functions. Among other things, control via such a matrix bus enables the control system to recognize data from the equipment and processes, control the overall operation of the system, determine whether each equipment / process is functioning properly, control the operation of each equipment / process (e.g., speed up or slow down each equipment / process), control input changes to operating parameters and / or other characteristics of operation, including for use in adjusting specific product outputs from the system such as fuel characteristics, schedule and monitor maintenance and other routine operations, use video and IR thermography for various analyses of the system, monitor and control various electrically operated features such as conveyors, gates, doors, and other electrically driven system components, enable overrides of various subsystem components, analyze moisture in raw materials and other aspects of the process, and assess the presence of hazardous materials to assist in monitoring and control.

[0011] Further aspects of the disclosed systems, apparatuses, and methods may include a system for processing raw materials into an output product having one or more variable preselected characteristics. The system may include a feeder, a mechanical grinder, an air conveyor, one or more sensors, and a controller. The feeder may be configured to convey raw materials. The mechanical grinder may be configured to receive the raw materials from the feeder and to grind the raw materials received by the feeder into ground raw materials. The ground raw materials may include one or more of heavy fines, fine particles, moisture, or combinations thereof. The air conveyor may convey an air flow to the mechanical grinder and draw the air flow from the mechanical grinder into a fine separator. The air flow from the mechanical grinder may include at least a portion of the ground raw materials. The at least a portion of the ground raw materials is conveyed by the air flow. The one or more sensors may be configured to determine information indicative of at least one characteristic of the raw materials. The controller may be configured to control one or more of the group consisting of the feeder, the mechanical grinder, and the air conveyor based on information indicative of the characteristic of the raw material.

[0012] Additional advantages and novel features of these aspects will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or upon learning by practice of the present disclosure.

[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more exemplary aspects of the disclosure and, together with the detailed description, serve to explain the principles and implementations thereof. [Brief description of the drawings]

[0014] [Figure 1] 1 illustrates various exemplary system components according to aspects of the present disclosure. [Diagram 2] 1 illustrates a pictorial representation of a portion of an example system and method including receiving waste material at a material loading area, according to aspects of the present disclosure. [Diagram 3] 1 illustrates a pictorial representation of a portion of an example system and method including delivery of raw material to a shredder, according to aspects of the present disclosure. [Figure 4] FIG. 1 illustrates a pictorial representation of an initial processing portion of an example system and method that includes the use of a magnet-based separator to assist in separating magnetic materials from raw materials, according to aspects of the present disclosure. [Diagram 5] FIG. 1 shows a pictorial representation of the process portion of an example system and method that includes the use of an eddy current separator for separating non-ferrous metals from raw materials, according to an aspect of the present disclosure. [Figure 6] 1 shows a pictorial representation of a processing portion of an example system and method including one or more sorting areas, such as one or more quality sorting platforms, according to an embodiment of the present disclosure. [Figure 7] FIG. 1 shows a pictorial representation of a processing portion of an example system and method including a first dryer and a grinder that may include or further include one or more horizontal hammer mills according to an embodiment of the present disclosure. [Figure 8] 1 shows a pictorial representation of a processing portion of an example system and method including a first material separation device according to an embodiment of the present disclosure. [Figure 9] FIG. 1 shows a pictorial representation of a processing portion of an example system and method including a second dryer and a grinder that may include or further include one or more horizontal hammer mills according to an embodiment of the present disclosure. [Figure 10] 1 shows a pictorial representation of a processing portion of an example system and method including a second material separation device, according to an embodiment of the present disclosure. [Figure 11] 1 shows a pictorial representation of the processing portion of an example system and method including an example baler, according to aspects of the present disclosure. [Figure 12] 1 illustrates a pictorial representation of the processing portion of an example system and method including an example packager according to aspects of the present disclosure. [Figure 13] 1 includes a representative flowchart of an example of various components and / or functions of a system according to an aspect of the present disclosure. [Figure 13A] FIG. 1 illustrates a pictographic representation of high levels of MSW for fluffing into clean coal product, according to an embodiment of the present disclosure. [Figure 13B] FIG. 1 illustrates a pictographic representation of high levels of MSW for fluffing into a syngas product, according to an embodiment of the present disclosure. [Figure 14] 1 illustrates various devices and processes within an exemplary control system in accordance with aspects of the present disclosure. [Figure 15] 15 shows a representative diagram of the various components / subsystems and their various interactive operations for processing raw material through the matrix bus of FIG. 14. [Figure 16] Additional components / subsystems for further processing of the raw material according to the representative diagram of FIG. 15 are shown. [Figure 17] According to the representative diagram of FIG. 15, additional components / subsystems for further recycling of raw materials are shown. [Figure 18] Included are representative diagrams of example computer system components capable of carrying out various functions described in example implementations of control systems and other processes according to aspects of the present disclosure. [Figure 19] FIG. 1 is a block diagram of various example system components on a network for use in accordance with aspects of the present disclosure. [Figure 20] 13A-13C show representative aspects of various improved features for dehydration / drying of various organic raw materials for other exemplary embodiments according to aspects of the present disclosure. [Figure 21] 13A-13C show representative aspects of various improved features for dehydration / drying of various organic raw materials for other exemplary embodiments according to aspects of the present disclosure. [Figure 22] 13A-13C show representative aspects of various improved features for dehydration / drying of various organic raw materials for other exemplary embodiments according to aspects of the present disclosure. [Figure 23] FIG. 1 is a block diagram of an example process for separation, mechanical drying and downstream processing of pre-sorted raw material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The detailed description set forth below in conjunction with the accompanying drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the various concepts. However, it may be apparent to one skilled in the art that these concepts may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form to avoid obscuring such concepts.

[0016] Aspects of the present disclosure include apparatus, systems, methods of operation, and control systems for processing waste materials into usable products, such as fuel stocks, soil additives, and usable by-products.

[0017] Next, an overview of example system components and processes according to aspects of the present disclosure will be provided.

[0018] A first example of various system components according to aspects of the disclosure is shown in Figure 1. In Figure 1, a first portion 100 of such an exemplary system may include one or more of: 1) a material loading area 110, which may arrive, for example, on a chipping floor area; 2) a shredder 120; 3) a magnet-based separator 130; 4) an eddy current separator 140; 5) additional sorting equipment 150, such as a ballistic separator, an optical sorter for removing high-value plastics, such as a finger slot (e.g., flats) separator, and optionally a sorting observation area; 6) a mechanical separator 160, which may include or further include one or more horizontal hammer mills, VSIs, and / or ring mills; 7) one or more material separators 170, such as one or more cyclones; 8) a compactor 180, such as one or more rum balers; and 9) a packager 190, such as one or more bale wrappers. In some aspects, the shredder 120, the magnet-based separator 130, the eddy current separator 140, and the additional sorting equipment 150 may be optional. In such embodiments, the system may receive pre-sorted waste, non-recycling material recovery facility (MRF) waste, biosolids, agricultural waste, paper pulp, raw waste, digestate, and / or other types of biomass waste. The shredder 120 and / or related embodiments thereof may be referred to interchangeably herein as a "pre-shredder."

[0019] As shown in FIG. 2, the system and method may begin with receipt of waste material 200, also interchangeably referred to herein as “raw material,” arriving at a material loading area 110, such as a tipping floor area, similar to a typical transfer station. Delivery of the waste material 200 may occur, for example, via a payloader and / or a grapple operator. In some aspects, the waste material 200 may include municipal solid waste (MSW). The waste material may be scanned and organized (e.g., sorted) for hazardous and other undesirable materials. In some aspects, the waste material 200 may include pre-sorted waste, non-recycling materials recovery facility (MRF) waste, biosolids, agricultural waste, paper pulp, raw waste, digestate, and / or other types of biomass waste.

[0020] In some aspects, the feedstock material may then be delivered to a shredder 120, as shown in FIG. 3, which can shred the feedstock material into approximately uniform sizes. In some aspects, the shreds may be about 6 inches in diameter or less. An exemplary shredder 120 can include, for example, a shear-type shredder manufactured by American Pulverizer Company of St. Louis, Missouri. Such shredders can include, for example, counter-rotating cutter disks to tear and shear the waste material, and can include electric or hydraulic drives.

[0021] In some aspects, the shredded raw material is then mechanically transported (e.g., by a feeder such as a hopper, conveyor belt or other conveying mechanism, or manually, e.g., with a shovel) to an area for further initial processing. An exemplary conveyor may be made by Hustler Conveyor of O'Fallon, Missouri. Initial processing may include the use of a magnet-based separator 130 to help separate magnetic materials (e.g., ferrous materials) from the raw material, for example, as shown in FIG. 4. An exemplary magnet-based separator may include drum magnet technology manufactured by Dings, Co. of Milwaukee, Wisconsin.

[0022] Additional initial processing may include, for example, the use of an eddy current separator 140 to separate non-ferrous metals from the raw material, as shown in FIG. 5. An exemplary eddy current separator may include an eccentric rotor eddy current separator manufactured by Dings, Co. of Milwaukee, Wisconsin. Such separators may include a magnetic rotor configured to rotate at a faster rate than a conveyor belt associated with the magnetic rotor. The non-ferrous metals may be deflected further from the conveyor belt than the non-magnetic materials to form a first waste stream comprising the non-ferrous metals and a second separate waste stream comprising the non-magnetic materials.

[0023] One or more sorting areas 150, such as one or more quality sorting platforms, may also be included in the process, as shown in Figure 6. Further initial processing may include, for example, the use of a ballistic separator to separate two-dimensional material from three-dimensional material, as well as various fines from the raw material. The fines may be separated, for example, using a screen or other fine separator. Such fines may proceed to a drying process at this point, as further described below.

[0024] In some aspects, the separated feed of two-dimensional and three-dimensional materials may then be diverted to an optical sorter where high value plastics (e.g., number 1 and number 2 plastics) may be identified and separated from the feed, for example, by use of a software-based device. In some aspects, the software may be configured to receive, for example, near infrared spectroscopy data and determine material parameters based on the near infrared spectroscopy data. Exemplary material parameters may include caloric value, polyvinyl chloride content, and / or moisture content. In some aspects, the software may be configured to determine material parameters based on near infrared spectroscopy by comparing the received near infrared spectroscopy data to stored or other pre-existing near infrared spectroscopy data, such as data stored in a materials database or other data repository. These plastics, along with the separated ferrous and non-ferrous metals, may be baled, sorted, and sold to a recycling company. In addition to separating plastics from the feed, any polyvinyl chloride (PVC)-containing material may also be separated. In one exemplary embodiment, a target of 0.5% of PVC is sufficient.

[0025] The remaining material in the pre-screened raw material can then proceed to a drying and grinding stage. Such drying and grinding can be accomplished by mechanical processing, such as using a first dryer and mechanical grinder 160 (FIG. 7) of one or more dryer and crusher / separators 165, as shown in FIGS. 7-9. In some embodiments, the system components (e.g., the blower and / or mechanical grinder 160) can generate an airflow of about 1,000 cubic feet per minute (cfm) to about 50,000 cfm. In some embodiments, the system components (e.g., the blower and / or mechanical grinder 160) can generate an airflow of at least 5,000 cfm. In some embodiments, the system components (e.g., the blower and / or mechanical grinder 160) can generate an airflow of more than 50,000 cfm. In some embodiments, the blower can provide a majority of the aforementioned airflow, and the mechanical grinder 160 can add to the airflow provided by the blower. An exemplary mechanical crusher 160 may include a ring mill, such as the ring mill manufactured by American Pulverizer Company of St. Louis, Missouri. A ring mill may include a rotor coupled to one or more shafts. Each shaft may have multiple rings rotatably coupled thereto. In some embodiments, the rings may include multiple teeth. In other embodiments, the rings may be smooth. During operation of the ring mill, rotation of the rings and shafts may crush waste material within the ring mill. Another exemplary mechanical crusher 160 may include a horizontal hammer mill. A horizontal hammer mill may include a rotor coupled to multiple hammers. As the rotor rotates, the hammers swing outward and rotate rapidly to crush the material being processed. In some embodiments, the horizontal hammer mill may include a grate, mesh, or screen. In such embodiments, crushed material smaller than the openings in the grate, mesh, or screen may fall through the grate, mesh, or screen for further processing. Another exemplary crusher 160 may include a vertical shaft impactor (VSI), such as the VSI manufactured by Hopkins, Michigan.The VSI may include, for example, a hammer mill type mechanism arranged horizontally relative to the feed direction. The hammer mill may include, for example, the use of blunt metal blades. For any type of material that has a closed cell structure, among other results of the VSI operation, the VSI may rupture the cell structure. The VSI may pulverize the feed and generate an airflow from its operation. In one embodiment, the VSI may generate an airflow of approximately 18,000 cfm. The mechanical pulverizer 160 may also be referred to interchangeably herein as a ring mill, a horizontal hammer mill, and / or a VSI.

[0026] From the drying and grinding process, the pneumatically conveyed raw material may then proceed to a first material separator (e.g., device 170 of FIG. 8) of one or more material separators 170, 175 as shown in FIGs. 8 and 10, such as a cyclone. Various exemplary cyclone components usable in accordance with aspects of the present disclosure may be manufactured by Imperial Systems, Inc. of Jackson Center, Pennsylvania. The generated fugitive air stream may proceed to a baghouse for fines removal, and heavier materials in the air stream may collect below the air stream.

[0027] Water may be reclaimed from the raw materials during some of the aforementioned processes. For example, water may be recovered from the mechanical grinders 160, 165 and / or material separators 170, 175. The amount of reclaimed water may be significant and may produce useful products. Note that typical MSW may average about 43% moisture content. As the moist air leaves the baghouse during processing by the grinder / dryer, water vapor in the air may condense into a water output stream. In one embodiment according to aspects of the present disclosure, about 1200 gallons of water may be recaptured from the processing of about 14 tons / hour of MSW. Such water discharge from municipal waste may be particularly valuable for processing in arid lands, where, for example, the water+biochar soil improvement output may be used in large-scale agricultural reclamation projects (e.g., desert reclamation for agricultural applications). For example, recaptured water from biogenic raw materials may be reused, for example, in agricultural applications. Recaptured water from other types of raw materials may be further analyzed and / or purified before reuse.

[0028] The pneumatically conveyed raw material feed may then proceed to a second dryer mill (e.g., dryer and mill 165 of FIG. 9) for a second drying and final sizing step, followed by a second processing through a cyclone (e.g., second material separator 175 of FIG. 10) to remove the remaining moisture of the feed. Fines may again be collected from the air stream in a baghouse. After the air stream passes through the baghouse, the remaining moisture may be recycled as water. The second dryer mill 165 may be referred to interchangeably herein as a ring mill, horizontal hammer mill, and / or VSI.

[0029] At this point in the process, an engineered fuel derived fuel (ERDF) can be produced, which can comprise the dry MSW with a fluff component. The ERDF ("fluff") can then be baled (e.g., using an exemplary baler 180 as shown in FIG. 11) and cross-wrapped (e.g., using a packager 190 as shown in FIG. 12) as needed for use as a fuel having, for example, a higher British Thermal Units (BTU) per unit weight than standard MSW waste that has not been treated according to the aforementioned portions and systems and methods according to aspects of the present disclosure. An exemplary baler that can be used according to aspects of the present disclosure can be made by Maren Balers & Shredders of South Holland, Illinois.

[0030] Instead of being baled and cross-wrapped for transport and / or later use, the fluff consistency ERDF can be further processed.

[0031] For example, in some embodiments, the fluff can be burned as a fuel. In some embodiments, the composition of the feedstock 200 can be controlled to produce fluff that can be used as a fuel that can generate a target amount of energy. For example, varying the plastic content of the feedstock can change the amount of energy that can be generated by the fluff. For example, increasing the amount of plastic in the feedstock can increase the amount of energy that can be released when burning the fluff as a fuel. In some embodiments, the heat released during combustion can be used to generate steam, which can then be used to generate electricity.

[0032] In another exemplary embodiment, the fluff ERDF can then proceed to a gasifier where it is used to produce "syngas." The syngas can be used as an input to various downstream processes configured to produce, for example, methanol, ethanol, diesel, gasoline, etc. The syngas can be further processed to produce high value products such as ethanol, jet fuel, diesel, gasoline, natural gas, etc.

[0033] Figure 13 includes a representative flow chart of various example components and / or functions of a system according to an embodiment of the disclosure. As shown in Figure 13, flow 1300 can include processing of one or more feedstocks 1305, which can include, for example, municipal solid waste (MSW), biosolids, agricultural waste, paper pulp, raw waste, digestate, other biomass materials, non-biological materials, and / or inorganic materials, as well as other materials. The feedstocks may be dried and otherwise processed 1310, such as by grinding, which can result in the production of water 1315 from the drying and other processing 1310, among other things.

[0034] The output of the feedstock from drying and other processing 1310 can include the production of fluff 1320, which can then be used to produce pellets 1325 or other outputs 1330 via additional processing methods 1335. Exemplary processing methods can include combustion, gasification, and pyrolysis. Combustion can be used to produce power. Gasification can be used to produce syngas. Pyrolysis can be used to produce oil, gas, and / or char.

[0035] FIG. 13A shows a pictographic representation of high levels of MSW for fluffing into clean coal (e.g., bio-coal) product according to an embodiment of the disclosure.

[0036] FIG. 13B shows a pictographic representation of high levels of MSW for fluffing into a syngas product, according to an embodiment of the disclosure.

[0037] Aspects of the present disclosure may include a control system for managing and / or controlling the monitoring, operation, and / or interaction of various process equipment throughout an MSW processing system, as previously described. Such a control system may include various aspects and features, as representatively shown in Figures 14-17. In Figure 14, various equipment and processes are shown that may be connected to a machine interface via a matrix bus as well as a machine to receive parameters, provide mechanisms / algorithms for adjusting parameters, and otherwise provide monitoring, and provide and control communication between and among the equipment of the system. Among other things, control via such a matrix bus enables the control system to recognize data from equipment and processes, control the overall operation of the system, determine whether each equipment / process is functioning properly, control the operation of each equipment / process (e.g., speed up or slow down each equipment / process), control input changes to operating parameters and / or other characteristics of operation, schedule and monitor maintenance and other routine operations, use video and IR thermography for various analyses of the system, monitor and control various electrically operated features such as conveyors, gates, doors, and other electrically driven system components, enable overrides of various subsystem components, analyze moisture in raw materials and other aspects of the process, and evaluate for the presence of detrimental materials and assist in monitoring and control.

[0038] As shown in FIG. 14, the devices and processes in the control system may include, for example, a heat / BTU test and comparator function 1410, a maintenance dispatch and verification function 1415, an infrared (IR) video recognition and thermography function 1420, a voltage control (VC) / frequency control (FC) motor controller function 1425, a human machine interface (HMI) override function 1430, a moisture analysis function 1435, and a HazMat evaluation function 1440. Each of the above devices and processes may have its own control operation (e.g., for standalone control via an HMI console) for standalone operation, and may also have one or more communication ports and / or communication interface functions (e.g., an Ethernet connection to provide input / output communication with the device / process). Each of the above devices and processes may be operated, for example, mechanically, electromechanically, hydraulically, or pneumatically. However, the above devices and processes generally do not have the ability to interoperate with each other by themselves. Thus, for example, to control the overall operation in the absence of such interoperability, each device and / or process must be individually controlled to generate an overall system output.

[0039] As further shown in FIG. 14, in one implementation, the bus can include several communication buses (also referred to interchangeably herein as “communication paths” or “communication highways”) that can provide communication regarding, for example, hazardous material data 1401, maintenance data 1402, scanning machine / process operation and flow control 1403, and verification data 1404, such as IR thermography (IRT) and video. The hazardous material data bus 1401 can provide information communication regarding the presence / handling of hazardous materials. For example, human video monitoring and / or automated video analysis can be used to identify the possible presence of hazardous materials in raw materials. The maintenance data bus 1402 can be used to communicate maintenance information, such as scheduled maintenance activities for a particular machine. The scanning machine / process operation and flow control bus 1403 can provide a communication path for information regarding machine operation, for example. The IRT and verification video bus 1404 can provide a video feed, such as video for monitoring a scheduled service of a machine service technician, for example. Such video may include, for example, either an existing machine / process monitoring video feed or a separately installed video monitoring device to an existing machine / process. In one exemplary implementation, triggering of video recording for such a maintenance feed may be by signaling, for example, via the initiation of a maintenance action (e.g., a service technician signals the start of a maintenance operation or a maintenance action is detected by technician activity).

[0040] 14, in the heat / BTU test and comparator function 1410, samples of the processed feedstock may be taken, for example, at various points in the processing of the feedstock to measure the characteristics of the feedstock and its consistency with processing expectations. For some machines / processes, such characteristics may be determinable via a stand-alone machine / process and the comparator function 1410 may further act as a check on that machine / process determination of the characteristics.

[0041] A maintenance dispatch and verification function 1415 can store information about maintenance requests and can be used to trigger maintenance functions and verify proper completion. Additional functions can include monitoring functions such as the use of cameras to check machine operation or characteristics (e.g., an IR camera to identify excessive heat from a machine part that is in the process of predicted failure).

[0042] In the case of the IR video recognition and thermography functionality 1420, video and IR cameras are used to monitor various activities, machinery, etc. to ensure proper operation / fault prediction. Some aspects of the IR video recognition and thermography functionality 1420 may overlap with aspects of the maintenance dispatch and verification 1415.

[0043] The voltage control (VC) / frequency control (FC) motor controller function 1425 can monitor and control various aspects of electrical operation, such as controlling machine operation and conveyor speeds, the opening and closing of gates, valves, and doors, as well as the operation of various other devices such as actuators and diverters.

[0044] With HMI override functionality 1430, a control system and / or operator may be provided with the ability to override operations normally controlled via, for example, an HMI.

[0045] For the moisture analysis function 1435, the actual moisture level can be collected (e.g., via a sensor) and used for comparison to a calculated / predicted moisture level, which may be important for quality control of the product output. For example, the length of time of machine / process operation can be changed to control moisture at various points in the operation of the overall system. The sensed results may also require the input of moisture to the raw material if insufficient moisture is present.

[0046] For the HazMat assessment function 1440, various sensors may be used to identify the presence of hazardous materials and to communicate and / or control the response thereto. Such sensors may include, for example, video and / or IR cameras, chemical sensors, and radiation sensors.

[0047] FIG. 15 shows a representative view of a first portion of various components / subsystems for the system and method for processing waste material, and the interactive operation of such components / subsystems, via the matrix bus of FIG. 14. As representatively shown in FIG. 15, waste material may enter the system at the tip floor 1501. At the tip floor 1501, communication and other functions regarding the initial analysis of the waste material may occur via the IRT and verification video bus 1404, which may, for example, communicate one or more video and / or other inputs at this location, as well as feeds with the hazardous material data bus 1401. The waste material is then loaded / picked 1505 onto the conveyor system 1510, where it may proceed to the crusher 1515. After transport from the tip floor 1501 to the crusher 1515, the IRT and verification video bus 1404 may, for example, provide communication and other functions via one or more feeds with video and / or other inputs at this location. Communications and other functions may occur between the grinder 1515 position and maintenance data bus 1402 and the scanning and flow control bus 1403 .

[0048] 15 may then proceed to a material analyzer 1520 where communication and other functions may occur via all four bus lines 1401, 1402, 1403, 1404 (same or similar connections as for the grinder 1515, as well as hazardous material data). Communication and / or other functions regarding moisture and calorific value data 1525 to the material analyzer 1520 may also occur via a connection with a system control module 1530.

[0049] The raw material can then proceed to a ballistic separator 1535, as well as the crusher area 1515, where an IRT and verification video bus 1404 can provide communications and other functions, such as providing video and / or other inputs, as well as a maintenance data bus 1402 and a scanning and flow control bus 1403.

[0050] As further shown in Figure 15, the process can then proceed to either further processing (from Figure 16) or recycling (Figure 17). For example, the conveyor 1510 can include multiple separate flows of raw material, the flows relating to the separated materials based on content. Decision communications and other functions relating to raw material processing for the next action 1540 (e.g., decision functions regarding whether the next step in the process should be performed), as well as the crusher 1515 and ballistic separator 1535, can include couplings to the IRT and verification image bus 1404, as well as the maintenance data bus 1402 and the scanning and flow control bus 1403.

[0051] 15, communication and other functions 1545 may also occur between the system control module 1530 and the loader / grapple 1505. For example, the system control module 1530 may provide communication and / or control regarding the loading rate onto the conveyor 1510.

[0052] FIG. 16 shows the continuation of the process flow of FIG. 15 from decision point 1540 for further processing of the raw material in the form of ERDF, such as bale fluff or pellets, for energy-based and other uses. A feeder 1550 can deliver the pre-sorted raw material to a first mechanical grinder 1555, such as a ring mill, horizontal hammer mill, or VSI, which may include the use of a dryer 1560, such as a cyclone, after and / or as part of the process. In some aspects, the feeder 1550 can include a drum feeder. Some or all of the pre-sorted raw material can then proceed to a second mechanical grinder 1565 and / or a second dryer 1570. As further shown in FIG. 16, a feed of make-up air, such as air generated from a make-up air system 1575, can provide an air source for use by the dryers 1560, 1570. Each of the feeders 1550 , grinders 1555 , 1565 , dryers 1560 , 1570 , and make-up air system 1575 may be coupled to a maintenance data bus 1402 , a scan and flow control bus 1403 , and an IRT and verification video bus 1404 .

[0053] The output ERDF after processing by the mechanical grinders 1555, 1565 and dryers 1560, 1570 can proceed to a next decision point 1580 for ERDF processing for the next processing activity. Such next processing activity can be or can include, for example, processing by a thermal screw feed and buffer storage device 1585. This device 1585 can selectively feed the ERDF for further processing, for example, via a decision point 1590, via a thermal screw technology for buffering the ERDF and processing the ERDF compressible into pellets. Exemplary thermal screw technologies that can be used (or modified) in accordance with aspects of the disclosure include thermal screw technologies manufactured by Therma-Flite of Benicia, California. Each of the decision points 1580, the thermal screw feed, the buffer storage device 1585, and the decision points 1590 can be coupled to a maintenance data bus 1402, a scanning and flow control bus 1403, and an IRT and verification video bus 1404.

[0054] 16, instead of going to the thermal screw feed and buffer storage device 1585, decision point 1580 may direct the ERDF to the baler 1600, shredder 1605, and buffer storage device 1610. Decision point 1590 can selectively feed the ERDF from the buffer storage device, as well as the output from the thermal screw feed and buffer storage device 1585, to a processor for further processing. Each of the baler 1600, shredder 1605, and buffer storage device 1610 can be coupled to the maintenance data bus 1402, the scan and flow control bus 1403, and the IRT and verification image bus 1404.

[0055] Figure 17 shows the continuation of the process flow of Figure 15 from decision point 1540 for further processing of the separated material delivery for recycling and / or storage in bale form. As shown in Figure 17, the feedstock may first proceed to a magnetic separator 1650, such as drum magnet technology, to separate magnetic materials from the feedstock, and the separated magnetic materials may be selectively redirected, for example, to a ferrous hopper 1685. From the magnetic separator 1650, the remaining feedstock may proceed to a non-magnetic metal separator 1655, such as an eddy current generator, for example, to separate non-ferrous metals from the feedstock, and the separated non-magnetic materials may be selectively redirected, for example, to a non-ferrous hopper 1690.

[0056] From the non-magnetic metal separator 1655, the remaining raw material may proceed to an optical sorter 1660 to separate the optical materials from the raw material. The optical sorter 1660 may use, for example, air knife technology to separate identified materials, such as certain plastics, and separate those materials from the raw material. From the optical sorter, the raw material may proceed to a decision point 1665, from which the flow of material may be directed to any of the hoppers 1675, 1680, 1685, 1690 as appropriate, or may continue to the recycle baler 1670. The remaining separated plastics, ferrous metals, and non-ferrous materials may be sent to the respective hoppers 1675, 1680, 1685, 1690 for storage, or may then be sent to a baler (e.g., baler 1670) for, for example, sale, transportation, or further processing. The recycle baler 1670 may also selectively receive material from one or more of the hoppers 1675, 1680, 1685, 1690. Material from the baler 1670 and respective hoppers 1675, 1680, 1685, and 1690 may also proceed to recycle baler storage 1695. The magnetic separator 1650, non-magnetic separator 1655, and optical sorter 1660, respectively, and the plastic hoppers 1675, 1680, ferrous hopper 1685, and non-ferrous hopper 1690, respectively, may be coupled to a maintenance data bus 1402, a scanning and flow control bus 1403, and an IRT and verification video bus 1404.

[0057] 20-22 show representative aspects of various improved features for dewatering / drying various organic feedstocks for other exemplary embodiments according to aspects of the present disclosure. The exemplary embodiments according to aspects of the present disclosure are configured to operate at ambient temperature. In the embodiments shown in FIGS. 20-22, the system 2100 can receive pre-sorted waste, non-recycling material recovery facility (MRF) waste, biosolids, agricultural waste, paper pulp, raw waste, digestate, food manufacturing waste, wood waste, paper mill waste, and / or other types of biomass waste as pre-sorted feedstock. In some aspects, the pre-sorted waste can be or include organic materials, inorganic materials, or a mixture of organic and inorganic materials. In some aspects, the pre-sorted waste can include wet sand. In some aspects, the feedstock can include a target value and / or an estimated value or range of values ​​for calorific value. For example, in some embodiments, the raw materials can have a caloric content of about 4,000 British Thermal Units per pound (BTU / lb) to about 30,000,000 BTU / lb. In some embodiments, the raw materials can have a caloric content of about 7,000 BTU / lb to about 32,000 BTU / lb.

[0058] In some embodiments, the raw material may include multiple types of ingredients. In some embodiments, the raw material may include a single ingredient. In some embodiments, the raw material may include a predetermined moisture content. For example, in some embodiments, the raw material entering the grinder may include up to 60% moisture by weight. In some embodiments, one or more characteristics of the raw material may be determined (e.g., by a sensor, a material analyzer such as material analyzer 2207, etc.). Exemplary characteristics may include the moisture content and / or the calorific value of the raw material.

[0059] In aspects where the characteristic is moisture content of the feedstock, the computer system 1900 may be configured to receive information indicative of the moisture content of the feedstock (e.g., from a sensor, a material analyzer such as material analyzer 2207, etc.). The computer system 1900 may be configured to compare the received information indicative of the moisture content of the feedstock to a target value or range of values. The computer system 1900 may be configured to modify the operation of the air conveyor 2115 and one or more of the devices configured to convey material from the shredder 2105 (e.g., conveyor belt, metering drum) to the mechanical crusher 2110 based on the comparison. For example, in response to determining that the moisture content of the feedstock is above the target threshold, the computer system 1900 may increase the air velocity generated by the air conveyor 2115 and / or decrease the speed of the devices configured to convey material from the shredder 2105 to the mechanical crusher 2110. In response to determining that the moisture content of the feedstock is below the target threshold, the computer system 1900 can decrease the air velocity generated by the air conveyor 2115 and / or increase the speed of an apparatus configured to convey the material from the shredder 2105 to the mechanical crusher 2110. In some aspects, the computer system 1900 can be configured to increase the residence time of the feedstock in the mechanical crusher 2100, such as in response to determining that the moisture content of the feedstock is above a predetermined threshold. For example, in some aspects, the computer system 1900 can be configured to decrease the speed of the mechanical crusher 2100 in response to determining that the moisture content of the feedstock is above a predetermined threshold. In some aspects, the computer system 1900 can decrease (e.g., slow down) the speed of an apparatus configured to convey the material from the shredder 2105 to the mechanical crusher 2110 in response to determining that the moisture content of the feedstock is above a predetermined threshold.

[0060] In aspects where the characteristic is a calorific value of the feedstock, the computer system 1900 may be configured to receive information indicative of the calorific value of the feedstock (e.g., from a sensor, a material analyzer such as material analyzer 2207, etc.). The computer system 1900 may be configured to compare the received information indicative of the calorific value of the feedstock to a target value or range of values. The computer system 1900 may be configured to modify or notify an operator to modify the composition of the feedstock entering the shredder 2105 in response to the comparison. For example, in response to determining that the calorific value of the material feedstock is above a target threshold, the computer system 1900 may increase or instruct an operator to increase the amount of organic matter in the feedstock entering the shredder 2105. In response to determining that the calorific value of the feedstock is below a target threshold, the computer system 1900 may increase or instruct an operator to increase the amount of one or more of plastic, paper, agricultural waste, wood, and / or automobile shredder residue to the feedstock entering the shredder 2105.

[0061] As shown in FIG. 20, the system 2100 may include and / or consist of one or more of a shredder 2105, a mechanical grinder 2110, an air conveyor (interchangeably referred to herein as a blower or fan) 2115, an optional screen 2120, a fines separator 2125, a fines collector 2130, and an additional air filtration system 2135.

[0062] The shredder 2105 may be similar to the shredder 120 shown and described with respect to FIG. 3. The shredder 2105 and / or its related features may be referred to herein interchangeably as a "pre-shredder." The pre-sorted feedstock moves to the crusher via a conveyor belt, metering drum, or the like. The shredder 2105 may be configured to reduce the initial component sizes of the pre-sorted feedstock to selected pre-sorted feedstock sub-component sizes before the pre-sorted feedstock is delivered to the mechanical crusher 2110.

[0063] The mechanical grinder 2110 may be a ring mill, a horizontal hammer mill, or a vertical shaft impactor (VSI). In some embodiments, the mechanical grinder 2110 may be similar to the grinder 160 shown and described with respect to Figure 7. The mechanical grinder may include certain other optional features as shown and described with respect to Figures 9-10.

[0064] The air conveyor, as indicated by representative arrow 2115, may be a variable or relatively constant speed blower and / or may include other features to draw high velocity air through the system 2100, and / or other air filtering components (e.g., part of the system 2100), as required by local regulations, for example. In some aspects, the air conveyor 2115 may generate air velocities between about 1000 and 24,000 feet per minute (ft / min). In some aspects, the air conveyor may generate air velocities between about 1800 and 18,000 ft / min. Various features and details regarding an exemplary blower and / or other features that may be used with this component 2115 are also shown and described with respect to the air conveyor 2330 of FIG. The air conveyor 2115 can be positioned downstream of the mechanical grinder 2110, the optional screen 2120, the fines separator 2125, the fines collector 2130, and / or an additional air filtration system 2135. In some aspects, the computer system 1900 may be configured to vary, for example, one or more of the speed of the mechanical grinder 2110, the air flow rate of the air conveyor 2115, and the speed of a device configured to convey material from the shredder 2105 and dry the raw material to a target moisture content.

[0065] In some aspects, the air conveyor 2115 may be configured to convey the air flow to the air inlet of the mechanical grinder 2110 and draw the air flow through the air outlet of the mechanical grinder 2110 into the fine separator 2125. In some aspects, the air conveyor 2115 may be disposed downstream of the mechanical grinder 2110 and configured to generate a suction configured to pull the pneumatically conveyed raw material through the mechanical grinder 2110 and other elements of the system 2100. The pneumatically conveyed raw material exiting the mechanical grinder 2110 is dry enough to be conveyed by the air flow generated by the pneumatic conveyor 2115 and is not transported by mechanical methods. In some aspects, the pneumatically conveyed raw material may include particles having a particle size of, for example, less than about 1 micron to about a quarter inch (about 7 mm). In some aspects, the raw material entering the mechanical grinder 2110 may have a strong odor. In such embodiments, the odor of the pneumatically conveyed feedstock may be reduced as compared to the odor of the feedstock entering the mechanical grinder 2110. In some embodiments, the pneumatically conveyed feedstock may be substantially odorless. This reduction in odor may occur, for example, because bacteria living in the feedstock entering the mechanical grinder 2110 may become dormant as the moisture content in the feedstock becomes low enough that the feedstock can be pneumatically conveyed. In some embodiments, the pneumatically conveyed feedstock may have a moisture content of 50% by weight or less and be substantially odorless.

[0066] In embodiments including the optional screen 2120, the screen 2120 may be coupled to the outlet of the mechanical mill 2110. The size of the openings in the screen 2120 may be dimensioned to control the size of the air entrained feedstock exiting the mechanical mill 2110 and to facilitate the residence time of the pre-screened feedstock within the mill 2110. For example, pre-screened feedstock particles that are too large (and / or have too high a moisture content) to pass through the screen 2120 may continue to be processed by the mechanical mill 2110 until the ground pre-screened feedstock is small enough to pass through the screen and is dry enough to be entrained by air. In some embodiments, the area of ​​the openings in the screen 2120 may be, for example, about 0.0031 square inches (in2 ) ~ approx. 16in 2 In some embodiments, the area of ​​the openings in the screen 2120 can be in the range of, for example, about 0.0031 in 2 In some embodiments, the area of ​​the opening in the screen 2120 may be, for example, 16 in 2 In some aspects, the openings in the screen 2120 can have a square or circular cross-sectional shape. In some aspects, the openings in the screen 2120 can have cross-sections with different or varying geometric shapes.

[0067] The pre-sorted raw material entering the mechanical grinder 2110 typically cannot be conveyed via air (e.g., an air stream generated by the air conveyor 2115) because the pre-sorted raw material has too much moisture content. The mechanical grinder 2110, the air conveyor 2115, and the optional screen 2120 are configured to, among other things, dry / dewater the pre-sorted raw material such that the dried / dewatered pre-sorted raw material can be conveyed via the air stream generated by the air conveyor 2115 (e.g., as an air-conveyed raw material). The pre-sorted raw material entering the mechanical grinder 2110 has a first moisture content, and the air-conveyed raw material has a second moisture content that is lower than the first moisture content. For example, the material entering the mechanical grinder 2110 (e.g., the pre-sorted raw material) can have a moisture content of about 20 to about 60% by weight. In some embodiments, the pneumatically entrained feedstock exiting the mechanical mill 2110 may have a moisture content of about 5 to about 35% by weight. In some embodiments, the pneumatically entrained feedstock exiting the mechanical mill 2110 may have a moisture content of up to 35% by weight. In some embodiments, the pneumatically entrained feedstock exiting the mechanical mill 2110 may have a moisture content of up to 20% by weight. In some embodiments, the pneumatically entrained feedstock exiting the mechanical mill 2110 may have a moisture content of up to 15% by weight. In some embodiments, the pneumatically entrained feedstock exiting the mechanical mill may include heavy fines, particulates, and / or moisture.

[0068] During mechanical grinding, many fine particles are generated, which may be interchangeably referred to herein as particulates. In some embodiments, the particulates may be or include micron or submicron sized particles. In some embodiments, the particulates may be 20 μm or less. In some embodiments, the particulates may be 10 μm or less. In some embodiments, the particulates may be 2.5 μm or less. These fine particles act as nucleation sites to bind moisture released from the pre-sorted raw material, such as may occur during grinding by the mechanical grinder 2110. These nucleated waste particles typically exit the mechanical grinder 2110 after a short residence time (relative to the larger pieces of pre-sorted raw material) and bind water molecules to dry the bulk waste, and exit the mechanical grinder 2110 quickly relative to the larger pieces of pre-sorted raw material. Preferably, with very cold air, which is less likely to carry moisture, the mechanical grinder 2110 saturates the air with these fine particles such that the air becomes supersaturated with the fine particle nucleation sites, which bind the moisture released from the pre-sorted raw material as it is ground. It is therefore possible to dry the pre-sorted raw material in the mechanical grinder 2110 sufficiently that the ground pre-sorted raw material can be air-conveyed at a temperature of about -20°F to about 100°F. Such temperatures may also be interchangeably referred to herein as "ambient temperatures." It is therefore possible to dry the pre-sorted raw material through the mechanical grinder 2110 sufficient that the ground pre-sorted raw material can be air-conveyed with ambient air having a humidity in the range of about 0% to about 100%.

[0069] Fines separator 2125 may be configured to facilitate separation of the dewatered / dried air conveyed feedstock by particle size.

[0070] In some aspects, the fines separator 2125 can include a cyclone and / or multiple screens or other selective filtering mechanisms with different sized openings. The fines separator 2125 can be configured to separate the flow of dried / dehydrated pneumatically conveyed raw material into a first flow and a second flow based on size, density, and / or weight thresholds. The first flow can include larger, denser, and / or heavier particles, including heavy fines such as fluff and aggregates. In some aspects, one or more properties of the material from the first flow can be determined. Exemplary properties can include moisture content and / or heating value of the material from the first flow.

[0071] In aspects where the characteristic is moisture content of the material from the first flow, the computer system 1900 may be configured to receive information indicative of the moisture content of the material from the first flow (e.g., from a sensor, a material analyzer such as material analyzer 2207, etc.). The computer system 1900 may be configured to compare the received information indicative of the moisture content of the material from the first flow to a target value or range of values. Based on the comparison, the computer system 1900 may be configured to generate or notify / generate a signal to modify one or more of the operations of the air conveyor and the equipment configured to convey the material from the shredder 2105 (e.g., conveyor belt, metering drum) to the mechanical crusher 2110. For example, in response to determining that the moisture content of the material from the first flow is above the target threshold, the computer system 1900 may increase the air velocity generated by the air conveyor 2115 and / or decrease the speed of the equipment configured to convey the material from the shredder 2105 to the mechanical crusher 2110. In response to determining that the moisture content of the material from the first flow is below the target threshold, the computer system 1900 may decrease the air velocity generated by the air conveyor 2115 and / or increase the speed of an apparatus configured to convey the material from the shredder 2105 to the mechanical grinder 2110.

[0072] In aspects where the characteristic is a calorific value of the material from the first flow, the computer system 1900 may be configured to receive information indicative of the calorific value of the material from the first flow (e.g., from a sensor, a material analyzer such as material analyzer 2207, etc.). The computer system 1900 may be configured to compare the received information indicative of the calorific value of the material from the first flow to a target value or range of values. The computer system 1900 may be configured to modify or notify / generate a signal for an operator or an automated or other feature to modify the composition of the feedstock entering the shredder 2105 based on the comparison. For example, in response to determining that the calorific value of the material from the first flow is above a target threshold, the computer system 1900 may increase or instruct an operator to increase the amount of organic matter in the feedstock entering the shredder 2105. In response to determining that the calorific value of the material from the first flow is below a target threshold, the computer system 1900 may increase or instruct an operator to increase the amount of one or more of plastic, paper, agricultural waste, wood, and automobile shredder residue to the feedstock entering the shredder 2105.

[0073] In some aspects, the material of the first flow may be directed to an apparatus 2135 for further processing, such as a pellet mill, gasifier, pyrolyzer, etc. In some aspects, the material of the first flow may be collected for further processing.

[0074] The second flow may include smaller particles, less dense particles, and / or lighter particles. In some aspects, the lighter particles may include micron and / or submicron sized particulates. The second flow may be directed to a fines collector 2130.

[0075] In some aspects, the fines separator 2125 may be configured to separate fluff from fines. In some aspects, the fines separator 2125 may be configured to separate aggregates from fines. In some aspects, the fines separator 2125 may be configured to separate heavier fines, such as fluff and / or aggregates, from lighter particles, such as micron or submicron sized fines. Various features and details regarding the exemplary fines separator 2125 may be described with respect to the material separators 170, 175 shown and described with respect to Figures 8 and 10, and with respect to Figure 24, item 1.

[0076] The fine collector 2130 may be configured to capture particulates larger than a certain size threshold, including features that may be required to meet, for example, local clean air or other requirements. For example, in some aspects, the fine collector 2130 may be configured to capture particles 10 μm or larger. In another example, the fine collector 2130 may be configured to capture particles 2.5 μm or larger. In some aspects, the fine collector 2130 may be a bag house. Various features and details regarding an exemplary bag house and / or other features that may be usable with this part 2130 are also shown and described with respect to the fine collector 2320 of FIG. 22. In some aspects, the air passing through the fine collector 2130 may be discharged to the environment or recirculated to the mechanical grinder 2110. In some aspects, the particles captured by the fine collector 2130 may be directed to an apparatus 2135 for further processing.

[0077] The additional air filtration system 2135 may include features that may be required, for example, by local air quality requirements.

[0078] Figure 21 illustrates an exemplary flow diagram 2200 of the operation of various features of system 2100, including other features similar to system 2200 illustrated in Figure 21. In operation, the exemplary system 2200 can include various features for dehydrating / drying various organic pre-sorted feedstocks, including, for example, the following operations / functions illustrated in Figure 21:

[0079] The system 2200 can include a shredder 2205 configured to shred the organic raw materials to an appropriate size based on the pre-selected origin and moisture level of the raw materials.

[0080] The system 2200 may include one or more material analyzers or sensors 2207. The material analyzer 2207 may be configured to obtain / provide information about the pre-sorted raw material entering the mechanical grinder 2210 and to be used to transmit information about the pre-sorted raw material to the mechanical grinder 2210 and / or the computer system 1900. The material analyzer 2207 may also be configured to analyze the material exiting the mechanical grinder 2210 and transmit information to the computer system 1900. The material analyzer 2207 may also be configured to analyze the material received in the collector 2233 and / or the first flow and transmit the information to the computer system. In some aspects, the system may include an air quality analyzer or sensor 2208. The air quality analyzer may be configured to analyze the air exiting the mechanical grinder 2210, the cyclone 2115, the filtration and / or air conditioning system 2225, and / or the blower 2230, all of which are described in more detail below.

[0081] The system 2200 can include a mechanical grinder 2210, such as a horizontal hammer mill, VSI, and / or ring mill. In some aspects, the mechanical grinder 2210 can be similar to the mechanical grinder 2100. Organic pre-screened feedstock of suitable size and containing 60% or less moisture (water or other fluid) by weight can enter the mechanical grinder 2210, such as a horizontal hammer mill, VSI, and / or ring mill, along with air (e.g., ambient or pre-conditioned). As used herein, "pre-conditioned" can refer to pre-screened feedstock (and / or air entering the mechanical grinder 2210) that has been heated and / or dehumidified. In some aspects, the system 2200 can include downstream waste treatment components, such as a boiler, gasifier, pyrolyzer, etc. In such an embodiment, the system 2200 can be configured to use the boiler, gasifier, and / or waste heat from the boiler to heat and / or dehumidify the pre-sorted raw materials and / or air entering the mechanical crusher 2210. The air can enter the mechanical crusher 2210 at a point above, below, or beside the pre-sorted raw materials. One or more material analyzers / sensors 2207 can also be used to obtain / provide information regarding the pre-sorted raw materials entering the mechanical crusher 2210.

[0082] The pre-sorted raw material may be exposed to other air conveying mechanisms, such as an air blower 2230 and / or an air conveyor 2115 while in the mechanical grinder 2210. For example, the air blower may be located outside the mechanical grinder 2210 and may pull or push ambient (or, e.g., pre-conditioned) high velocity air through the mechanical grinder 2210. The mechanical grinder 2210 may grind the pre-sorted raw material, thereby increasing the surface area of ​​the pre-sorted raw material, while the high velocity air stream may mix air with the pre-sorted raw material as it is being ground. The ground air-entrained raw material may include small particles (e.g., less than 20 microns). The fine particles may absorb moisture from the pre-sorted raw material. The air stream may convey the dry ground air-entrained raw material from the mechanical grinder 2210 (up to a predetermined level of moisture) through any mechanical grinder exit screen, such as screen 2120 of FIG. 20. In such an embodiment, the multiple openings in the screen 2120 can maintain the larger aggregates within the mechanical crusher 2210 for a longer period of time (i.e., increased residence time) as moisture bound to the smaller particles exits the mechanical crusher 2210 after a shorter residence time, thereby separating the moisture from the larger pieces of pre-sorted raw material within the mechanical crusher 2210.

[0083] The exiting ground raw material may be pneumatically conveyed (e.g., via high velocity air) to a fines separator 2215, such as a cyclone, to separate the pneumatically conveyed raw material into a first flow and a second flow. The first flow may include heavy fines that have been separated from the pneumatically conveyed ground raw material. The high velocity air with the heavy fines may be collected (e.g., by collector 2233) and / or sent to apparatus 2235 for further processing, for example, as described with respect to FIG. 20.

[0084] The second flow contains smaller fines (e.g., particulates) that may not be removed from the airflow by fines separator 2215. The smaller fines of the second flow may be filtered for particulates in a fines collector 2220, such as a baghouse. The high velocity filtered air exiting the baghouse may undergo further filtering / purification via other filtration / conditioning mechanisms 2225 as may be required before being released into the ambient air.

[0085] FIG. 22 shows yet another exemplary embodiment of a system 2300 having similar features as those described with respect to FIG. 20 and FIG. 21. As shown in FIG. 22, material coming from a mechanical grinder (mechanical grinder 2110, 2210, etc.) can be conveyed through ducts or other conveying structures to a fine separator 2315, such as a cyclone (hydrocyclone, etc.) (1). Heavy material can be removed through a rotary airlock at the bottom (2) 2316 and conveyed to storage and / or a pellet mill. Fugitive air and fines from the fine separator 2315 can be conveyed through duct (3) 2319 to a fines collector 2320, such as a baghouse (4), and the fines can be separated from the fugitive air (e.g., per local air quality code) through a rotary airlock (2) 2316′. The fines can be conveyed to combine with material collected from the cyclone for production and / or storage, for example, in a pellet mill. After filtering, the fugitive air can travel through duct (5) 2321 from the fines collector 2320 to an air conveyor 2330, such as a fan (6). The fugitive air can then be released (2375), for example to the atmosphere (7).

[0086] 23 shows a process 2300 for separation, mechanical drying and downstream processing of pre-sorted raw materials. This process is described with reference to system 2100 of FIG.

[0087] In block 2302, pre-sorted feedstock is received by the shredder 2105. The pre-sorted feedstock may include one or more of pre-sorted municipal solid waste, MRF waste, biosolids, agricultural waste, paper pulp, raw waste, digestate, other biomass, and the like. In some aspects, in block 3202, one or more characteristics of the feedstock may be determined. Exemplary characteristics of the feedstock may include the moisture content and / or heating value of the feedstock. In some aspects, the material composition of the pre-sorted feedstock received by the shredder 2105 may be determined and / or modified based on the heating value of the feedstock and / or the heating value of the material in the first flow of heavier airborne particles (block 2312).

[0088] At block 2304, the shredder breaks down the pre-sorted feedstock into a size suitable for processing by the mechanical crusher 2110. The shredded pre-sorted feedstock is then conveyed to the mechanical crusher 2110. In some aspects, the conveying rate of the shredded pre-sorted feedstock to the mechanical crusher 2110 can be determined based on the moisture content of the feedstock.

[0089] In block 2306, a mechanical grinder 2110, such as a ring mill, horizontal hammer mill, and / or VSI, can grind the pre-shredded raw material into heavy fines and particulates. In some embodiments, the particulates can be 20 μm or less. In some embodiments, the particulates can be 10 μm or less. In some embodiments, the particulates can be 2.5 μm or less. In block 2306, the pre-sorted raw material in the mechanical grinder 2110 can be exposed to an air flow generated by an air conveyor 2115. The particulates serve as nucleation sites for moisture molecules released by the pre-sorted raw material as it is ground, and bind to the moisture molecules, thereby drying the pre-sorted raw material as it is ground. The various components of the pre-sorted raw material can remain in the mechanical grinder 2100 until they are dry enough and / or small enough to be transported by the air flow generated by the air conveyor 2115. Thus, smaller particles (e.g., fines), which are typically bound to moisture molecules, can quickly pass through the mechanical grinder 2110 and take moisture away from the larger pre-screened raw material as it continues to be ground. In some aspects, the mechanical grinder 2110 can dry the raw material, for example, from a moisture content of 60% by weight to a moisture content of less than 35% by weight. In some aspects, the dry raw material can have a moisture content of less than 20% by weight. In some aspects, the dry raw material can have a moisture content of less than 15% by weight. In some aspects, the velocity generated by the air conveyor 2115 can be determined based on the moisture content of the chopped pre-screened raw material entering the grinder 2105 and / or the moisture content of the material in the first flow of heavier air entrained particles (block 2312).

[0090] At block 2308 , the dry ground raw material may be pneumatically conveyed (eg, conveyed by an air current) from the mechanical grinder 2110 .

[0091] At block 2310, the pneumatically conveyed feedstock may be separated based on particle size and / or density, for example, by fines separator 2125. Fines separator 2125 may be configured to separate the flow of pneumatically conveyed feedstock into a first flow and a second flow based on a size and / or density threshold.

[0092] At block 2312, the first flow of heavier air entrained particles can be collected and / or directed to equipment 2135 for further processing, such as a pellet mill, pyrolyzer, etc. The first flow can include ERDF material, such as heavy fines, such as fluff and / or aggregates. In some aspects, information indicative of characteristics of the material in the first flow of heavier air entrained particles can be determined. Exemplary characteristics can include moisture content and / or caloric content.

[0093] At block 2314, the second flow may be directed to a fines collector 2130, such as a baghouse. The second flow may include small, light, and / or low density particles, such as fines. The fines collector may capture particulates larger than a certain size threshold. For example, in some aspects, the fines collector 2130 may capture particles 10 μm or larger. In another example, the fines collector may capture particles 2.5 μm or larger.

[0094] In block 2316 , particles captured by the fines collector 2130 may be collected and / or directed to a device for further processing 2135 .

[0095] At block 2318 , the air that passes through the fines collector 2130 may be released to the environment or recirculated to the mechanical grinder 2110 .

[0096] As can be seen, system, apparatus, and method aspects of the present disclosure may include a control system for managing and / or controlling the monitoring, operation, and / or interaction of various processing devices in a processing system, as well as the overall operation of the system, which may be implemented using hardware, software, or a combination thereof, and may be implemented in one or more computer systems or other processing systems. In one variation, various aspects are directed to one or more computer systems capable of performing the functions described herein. An example of such a computer system 1900 is shown in FIG. 18.

[0097] Computer system 1900 includes one or more processors, such as processor 1904. Processor 1904 may be connected to a communications infrastructure 1906 (e.g., a communications bus, crossover bar, or network). Various software aspects are described in terms of this exemplary computer system. After reading this description, it may become apparent to one of ordinary skill in the art how to implement aspects of the specification using other computer systems and / or architectures.

[0098] The computer system 1900 may include a display interface 1902 that transfers graphics, text, and other data from a communications infrastructure 1906 (or from a frame buffer, not shown) for display on a display unit 1930. The computer system 1900 also includes a main memory 1908, preferably random access memory (RAM), and may also include a secondary memory 1910. The secondary memory 1910 may include a hard disk drive 1912 and / or a removable storage drive 1914, which may represent, for example, a floppy disk drive, a magnetic tape drive, an optical disk drive, or the like. The removable storage drive 1914 may read from and / or write to a removable storage unit 1918 in a well-known manner. The removable storage unit 1918 may represent a floppy disk, magnetic tape, optical disk, or the like that is read by and written to the removable storage drive 1914. As will be appreciated, the removable storage unit 1918 may include a computer usable storage medium having stored thereon computer software and / or data.

[0099] In alternative variations, the secondary memory 1910 may include other similar devices for allowing computer programs or other instructions to be loaded into the computer system 1900. Such devices may include, for example, a removable storage unit 1922 and an interface 1920. Such examples may include program cartridges and cartridge interfaces (such as those found in video game devices), removable memory chips (e.g., erasable programmable read-only memory (EPROM), or programmable read-only memory (PROM)) and associated sockets, and other removable storage units 1922 and interfaces 1920 that allow software and data to be transferred from the removable storage unit 1922 to the computer system 1900.

[0100] The computer system 1900 may also include a communications interface 1924. The communications interface 1924 allows software and data to be transferred between the computer system 1900 and external devices. Examples of the communications interface 1924 may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, and the like. The software and data transferred through the communications interface 1924 may be in the form of signals 1928, which may be electronic, electromagnetic, optical, or other signals capable of being received by the communications interface 1924. These signals 1928 may be provided to the communications interface 1924 via a communications path (e.g., channel) 1926. This path 1926 may carry the signals 1928 and may be implemented using wire or cable, fiber optics, a telephone line, a cellular link, a radio frequency (RF) link, and / or other communications channels. In this specification, the terms "computer program medium" and "computer usable medium" are used to refer generally to media such as removable storage drive 1914, a hard disk installed in hard disk drive 1912, and signal 1928. These computer program products provide software to computer system 1900. Aspects of the present invention relate to such computer program products.

[0101] Computer programs (also called computer control logic) are stored in main memory 1908 and / or secondary memory 1910. Computer programs may also be received via communications interface 1924. Such computer programs, when executed, enable computer system 1900 to perform features according to aspects of the present invention as described herein. In particular, computer programs, when executed, enable processor 1904 to perform such functions. Such computer programs thus represent controllers of computer system 1900.

[0102] In variations in which aspects of the disclosure are implemented using software, the software may be stored in a computer program product and loaded into the computer system 1900 using the removable storage drive 1914, the hard drive 1912, or the communications interface 1924. The control logic (software), when executed by the processor 1904, causes the processor 1904 to perform the functions described herein. In another variation, aspects of the disclosure are implemented primarily in hardware using hardware components such as, for example, application specific integrated circuits (ASICs). Implementing hardware state machines to perform the functions described herein will be apparent to one skilled in the art.

[0103] In yet another variation, aspects of the present disclosure are implemented using a combination of both hardware and software.

[0104] 19, in an exemplary implementation of a system 2000 according to aspects of the disclosure, various features for use with systems and methods according to aspects of the disclosure, including, but not limited to, a control system for managing and / or controlling the monitoring, operation, and / or interaction of various processing equipment and processes in a waste treatment system 2070, can be accessed by an accessor 2060 (also referred to interchangeably herein as a "user") via a terminal 2042, such as, for example, a personal computer (PC), minicomputer, mainframe computer, microcomputer, telephone device, or a wireless device, such as a handheld wireless device, coupled to a server 2043, such as a PC, minicomputer, mainframe computer, microcomputer, or other device having a processor and repository for data and / or coupled to a network 2044, such as, for example, the Internet or an intranet, and a processor and / or repository for data via couplings 2045, 2046, 2047. Couplings 2045, 2046, 2047 can include, for example, wired, wireless, or fiber optic links. In another exemplary implementation, methods and systems according to aspects of the present disclosure may operate in a stand-alone environment, such as a single terminal.

[0105] Although the embodiments described herein have been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements, and / or substantial equivalents, whether known or not currently anticipated or may be unanticipated, may become apparent to at least one skilled in the art. Thus, the exemplary embodiments described above are intended to be illustrative and not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure. Thus, the present disclosure is intended to embrace all known or later developed alternatives, modifications, variations, improvements, and / or substantial equivalents.

[0106] Thus, the claims are not intended to be limited to the embodiments set forth herein, but are to be accorded the full scope consistent with the language of the claims, and reference to an element in the singular does not mean "only one," but rather "one or more," unless otherwise specified. All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known, or that later become known, to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly set forth in the claims. No element of a claim is to be construed as a means-plus-function unless the element is expressly recited using the phrase "means for."

[0107] It is understood that the specific order or hierarchy of the processes / flow charts disclosed is an illustration of example approaches. Based on design preferences, it is understood that the specific order or hierarchy of the processes / flow charts may be rearranged. Further, some features / steps may be combined or omitted. The accompanying method claims present elements of the various features / steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented.

[0108] Moreover, the term "example" is used herein to mean "serving as an example, instance, or illustration." Any aspect described herein as an "example" should not necessarily be construed as preferred or advantageous over other aspects. Unless otherwise stated, the term "some" refers to one or more. Combinations such as "at least one of A, B, or C," "at least one of A, B, and C," and "A, B, C, or any combination thereof" include any combination of A, B, and / or C, and can include multiples of A, multiples of B, or multiples of C. Specifically, combinations such as "at least one of A, B, or C," "at least one of A, B, and C," and "A, B, C, or any combination thereof" can be A only, B only, C only, A and B, A and C, B and C, or A and B and C, and any such combination can include one or more members of A, B, or C. Nothing disclosed in this specification is intended to be exclusive to the public, regardless of whether such disclosure is expressly recited in the claims.

Claims

1. 1. A system for processing a raw material into an output product having variable preselected characteristics, comprising: a feeder configured to transport the raw material; a mechanical grinder configured to grind the raw material received by the feeder into ground raw material, the ground raw material comprising one or more of heavy fines, fine particles, moisture, or a combination thereof; an air conveyor for conveying an air stream to the mechanical pulverizer and drawing the air stream from the mechanical pulverizer to a fines separator, the air stream from the mechanical pulverizer containing at least a portion of the ground raw material, the portion of the ground raw material being conveyed by the air stream; A system comprising:

2. The system of claim 1 , wherein the fines separator is configured to separate the heavy fines from the fines based on one or more of weight, density, and particle size.

3. The system of claim 2 , wherein the heavy fines are collected after passing through the fines separator.

4. The system of claim 1 , wherein the heavy fines include one or more of agglomerates, fluff, and combinations thereof.

5. The system of claim 1 , wherein the particulates include material not removed from the airflow by the fines separator.

6. 2. The system of claim 1, wherein the moisture content of the ground raw material in the air stream from the mechanical grinder is up to 35% by weight.

7. 10. The system of claim 1, wherein the air flow velocity is between about 1000 and 24,000 feet per minute (ft / min).

8. 10. The system of claim 1, further comprising a shredder for reducing initial ingredient sizes in the raw material conveyed by the feeder to selected raw material sub-ingredients sizes prior to delivery to the mechanical crusher.

9. 10. The system of claim 1, further comprising a material analyzer for analyzing characteristics of the raw material, ground raw material, or reclaimed water conveyed by the feeder.

10. 2. The system of claim 1, wherein the mechanical crusher comprises a ring mill, a horizontal hammer mill, or a vertical shaft impactor (VSI).

11. The system of claim 1 , wherein at least a portion of the particulates are collected by a fines collector.

12. The system of claim 11 , wherein the fines collector comprises a baghouse.

13. The system of claim 11 further comprising a filtration component for applying filtration to the airflow from the fines collector.

14. The system of claim 1 , wherein the fines separator comprises a cyclone.

15. The system of claim 1 further comprising an air quality analyzer.

16. The system of claim 1 , wherein the air flow comprises preconditioned air.

17. The system of claim 1 , wherein the air stream is conveyed to the mechanical mill through an opening in the mechanical mill.

18. The system of claim 1 , wherein the variable preselected characteristic comprises one or more of moisture and heating value.

19. 1. A method for processing a raw material, comprising: grinding the raw material into a fine powder and moisture, the fine powder including heavy fines and fine particles; providing an air flow to draw the fines into a fines separator; separating heavy fines from said fine particles; drawing the particulates and moisture from the fines separator to a fines collector; Separating the particulates from the airflow and moisture exiting the fines collector; receiving information indicative of at least one characteristic of one or more of the raw material and the heavy fines; determining a velocity of the airflow based on the at least one characteristic; and The method includes:

20. The method of claim 19 , wherein the at least one characteristic comprises moisture content.

21. providing the raw material to a grinder at a rate determined based on the at least one characteristic; 20. The method of claim 19, further comprising:

22. The at least one characteristic includes caloric content, the method comprising: Varying the composition of the feedstock based on the at least one characteristic.

20. The method of claim 19, further comprising:

23. 1. A system for processing a feedstock into an output product having one or more variable preselected characteristics, comprising: a feeder configured to transport the raw material; a mechanical grinder configured to receive the raw material from the feeder and to grind the raw material received by the feeder into ground raw material, the ground raw material comprising one or more of heavy fines, fine particles, moisture, or a combination thereof; an air conveyor for conveying an air stream to the mechanical pulverizer and drawing the air stream from the mechanical pulverizer to a fines separator, the air stream from the mechanical pulverizer containing at least a portion of the ground raw material, the at least a portion of the ground raw material being conveyed by the air stream; one or more sensors configured to determine information indicative of at least one characteristic of the raw material; a controller configured to control one or more of the group consisting of the feeder, the mechanical grinder, and the air conveyor based on information indicative of the at least one characteristic of the raw material; A system comprising:

24. 24. The system of claim 23, wherein the at least one characteristic of the raw material includes moisture content, and the controller is configured to selectively increase a velocity of the air flow provided by the air conveyor in response to determining that the moisture content of the raw material is higher than a target moisture content.

25. 24. The system of claim 23, wherein the at least one characteristic of the feedstock comprises moisture content, and the controller is configured to selectively reduce a speed of the mechanical grinder in response to determining that the moisture content of the feedstock is higher than a target moisture content.

26. 24. The system of claim 23, wherein the at least one characteristic of the feedstock comprises moisture content, and the controller is configured to selectively increase a residence time of the feedstock in the mechanical grinder in response to determining that the moisture content of the feedstock is higher than a target moisture content.

27. 24. The system of claim 23, wherein the at least one characteristic of the raw material includes moisture content, and the controller is configured to selectively reduce a speed of the feeder in response to determining that the moisture content of the raw material is higher than a target moisture content.

28. 24. The system of claim 23, wherein the at least one characteristic of the ingredient comprises a heating value, and the controller is configured to selectively vary a composition of the ingredient in response to determining that the heating value of the ingredient differs from a target moisture content.

29. 24. The system of claim 23, wherein the raw material entering the mechanical grinder has a moisture content of about 20-60% by weight, and the feeder is configured to mechanically transport the raw material to the mechanical grinder.

30. 24. The system of claim 23, wherein the portion of the ground raw material is conveyed by the air stream at a temperature of about -20°F to 100°F.

31. 24. The system of claim 23, wherein the controller is configured to determine a velocity of the air flow sufficient to entrain the fines based on the at least one characteristic of the raw material.

32. 24. The system of claim 23, wherein the raw material conveyed to the mechanical grinder has a first odor and the ground raw material conveyed by the air stream has a second odor that is weaker than the first odor.

33. 24. The system of claim 23, wherein the ground raw material transported by the air stream is odorless.

34. 24. The system of claim 23, wherein the ground raw material transported by the air stream comprises particles having a size ranging from less than about 1 micron up to about a quarter inch in diameter.

35. 24. The system of claim 23, wherein the fines separator is configured to separate the heavy fines from the fines based on one or more characteristics selected from the group consisting of weight, density, and particle size.

36. 24. The system of claim 23, wherein the heavy fines comprise one or more selected from the group consisting of agglomerates, fluff, and combinations thereof.

37. 24. The system of claim 23, wherein the particulates include material not removed from the airflow by the fines separator.

38. 24. The system of claim 23, wherein the moisture content of the ground raw material in the air stream from the mechanical grinder is up to 35% by weight.

39. 24. The system of claim 23, wherein the air flow velocity is between about 1000 and 24,000 feet per minute (ft / min).

40. 24. The system of claim 23, further comprising a shredder configured to reduce initial ingredient sizes in the raw material conveyed from the feeder to selected raw material sub-ingredients sizes prior to delivery to the mechanical crusher.

41. 24. The system of claim 23, further comprising a material analyzer configured to analyze characteristics of the raw material transported by at least one selected from the group consisting of the feeder, ground raw material, and reclaimed water from the system.

42. 24. The system of claim 23, wherein the mechanical crusher comprises at least one selected from the group consisting of a ring mill, a horizontal hammer mill, and a vertical shaft impactor (VSI).

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