Decarboscruber apparatus

Abstract

A decarboscrubber apparatus (100) is disclosed that performs for de-carbonization of grass feed for generating liquid fertilizer, fuel gases and carbon The apparatus 100 includes a control unit 204, a de-carbonizer unit 104, a gas purifier unit 108, an input unit 120 and an output unit 220. The apparatus 100 receives grass material as feed such as coconut shell fiber, bamboo, baboo residue etc., that is fed in the de-carbonizer unit 104. The apparatus 100 is operable in two modes such as a regular mode and power saving mode. The controller controls the indirect heating of the apparatus 100 by controlling the heating / cooling pads and controls the direct heating by controlling the heating / cooling of rods.

Description

[0001] “DECARBOSCRUBER APPARATUS”

[0002] FIELD OF THE INVENTION:

[0003] The present invention relates to a heat treatment apparatus for generating liquid fertilizer, and more particularly to a heat treatment apparatus that generates liquid fertilizer, gas and other outputs from grass type material.

[0004] BACKGROUND OF THE INVENTION:

[0005] In recent years, sustainable and eco-friendly practices have gained significant attention, especially in the fields of agriculture and energy production. This shift towards more environmentally conscious approaches has prompted the development of innovative technologies that can convert organic waste materials into valuable resources. One such area of focus has been the conversion of grasstype materials, such as lawn clippings, bamboo, agricultural residues, and other plant biomass, into useful products like liquid fertilizer, gaseous fuel, and black carbon residue.

[0006] Certainly, pyrolysis is a versatile process that has been explored for converting a range of organic materials, including plastic, tires, municipal waste, and biomass like grass and agricultural residues. However, it's important to note that while pyrolysis holds promise for waste management and resource recovery, there are limitations and potential environmental impacts associated with the process, particularly when it comes to biomass conversion or use of agricultural produce like grass, bamboo etc.

[0007] The pyrolysis process requires significant amounts of energy to reach the necessary high temperatures for decomposition. This energy requirement can sometimes offset the benefits gained from the produced outputs. Further, emission of Greenhouse Gases is a concern of pyrolysis. While pyrolysis is generally considered more environmentally friendly than traditional incineration, it still produces greenhouse gases, including carbon dioxide and methane, depending on the specific conditions of the process. These emissions contribute to climate change. The absence of oxygen during pyrolysis means that a significant portion of the nutrients present in the biomass, including valuable micronutrients, can be lost as gases during the process. This is a concern, especially when the goal is to produce valuable outputs like liquid fertilizer for agricultural use.

[0008] Another approach to convert organic materials to liquid fertilizer or fuel is the process of decarbonization followed by scrubbing. Decarbonization is the reduction of carbon dioxide from a material. The removed carbon dioxide is then transferred to the scrubbing agent such as lime to form carbon black. However, the process is not efficient as it causes a lot of wastage of energy and gaseous fuel. Further, the micronutrients generated from this process are also wasted as their collection is not possible.

[0009] CN113623031 A discloses a Biomass-based electric heating gas fertilizer that includes a biomass boiler that combusts biomass at high temperatures to generate fertilizers. CN201334480Y discloses a Countryside biomass resource recovery and comprehensive utilization production plant. This plant includes thermal hydrolysis reaction pot that is connected to a feeding bin and conducts methane fermentation. Thus, the techniques in the prior art lack an apparatus that decarbonizes feed material to generate liquid fertilizer, gaseous fuel and the like.

[0010] EP3623453A1 discloses an enriched air gasifier that includes a feedstock thermal reformer with oxygen enriched air. EP3623453A1 discloses gas formation along with biochar from the 2-cyclone system. However, this application fails to teach 2 different heating cycles that lead to formation of liquid fertilizer along with gaseous fuel for energy generation.

[0011] There is a need of an apparatus for decarbonization and scrubbing of grass feed type organic material for generating liquid fertilizer, gaseous fuel and micronutrients. There is also a need of a decarboscrubber apparatus that generates liquid fertilizer, gaseous fuel and micronutrients in an efficient manner.

[0012] SUMMARY OF THE INVENTION:

[0013] The present invention discloses a decarbo scrubber apparatus for decarbonizing and generating liquid fertilizer, fuel gases and carbon generation of liquid fertilizer and gaseous fuel including a de-carbonizer unit for converting grass feed into liquid fertilizer and gas fuel, the de-carbonizer unit being connected to a gas purifier unit by a connecting pipe with a safety valve for transfer of generated gas. The apparatus of the present invention further includes a control unit configured to operate the apparatus in a first heating cycle and a second cooling cycle and being configured to monitor a plurality of parameters such as health, time, power consumption and temperature of the apparatus. Further, this apparatus includes a gas purifier unit including a first scrubber unit, a second separator unit and a third refrigerated scrubber unit for purifying and discharging gas into the gas cylinder; a gas cylinder being connected to the gas purifier unit by an output pipe for collection for purified gas. Further, the de-carbonizer unit includes a second output pipe that is connected to a liquid fertilizer collector tank for collection of generated liquid fertilizer; an input unit for configuring operational parameters of the apparatus including a control panel, keys, display, and a plurality of switches, allowing the user to configure the inputs to the apparatus. The present apparatus also includes an output unit for collecting liquid fertilizer, gaseous fuel, and black carbon residue; and the apparatus including two operational cycles, a first heating cycle and a second a cooling cycle, both being executed and monitored by the control unit for generation of liquid fertilizer and gaseous fuel; wherein the de-carbonizer unit being connected to the gas purifier unit via a first connecting pipe and being configured to process the grass-type feed material through indirect and direct heating in the first heating cycle, and wherein the gas purifier unit scrubbing and separating the output gases in the second cooling cycle.

[0014] The decarboscrubber apparatus of the present invention further includes, the de-carbonizer unit that is a cylindrical structure that encloses the input cylinder that includes a sensor, a plurality of heating pads, a plurality of heating rods, an insulation jacket and a door for heating the inputted grass feed, wherein the input cylinder being made of high tensile mild steel and having a length of 3 meters and a diameter of 1.5 meters. The decarboscrubber apparatus further includes the control unit which is including a controller operable in a regular mode and a powersaving mode, and that is being configured to control the heating and cooling of the de-carbonizer unit by regulating the heating pads and heating rods. Further, the decarboscrubber apparatus includes the first scrubber unit of the gas purifier unit including a first container and a second container, that includes ethylene and water in the ratio of approximately 1:4 for filtering the gas. Also, the decarboscrubber apparatus includes the second separator unit of the gas purifier unit with iron pieces, silica-sulphur and hydrogen gas for dry scrubbing the gas received from the first scrubber unit through a radiator and transferring it to the third refrigeration unit. It is noted that the decarboscrubber apparatus of the present invention includes, the third refrigeration unit of the gas purifier unit cooling the high temperature gas received from the second separator unit and having an outlet for cooling the output gases and collecting micronutrients and a connecting pipe discharging the gas to the gas cylinder.

[0015] Furthermore, the decarboscrubber apparatus of the present invention includes the first heating cycle including heating of the de-carbonizer unit to 460°C form 3-5 hours, with l / 3rd of the input cylinder of the decarbonizer unit being filled with liquid scrubber. Also, the decarboscrubber apparatus includes, the second cooling cycle being initiated when the temperature of the input cylinder reaches preferably at 460°C and the heat is cut off to achieve a temperature of 50°C and liquid fertilizer is collected in the liquid fertilizer collector at predefined temperature points, wherein a buzzer signal indicates the end of the cooling cycle. It is also noted that the gas is collected from one connecting pipe when the temperature of more than 60° is achieved inside the input cylinder of the decarbonizer unit. Further, the liquid scrubber being added to the gas purifier unit may be water, ethylene, iron pieces etc. Also, the generated gas is utilized as fuel for generator providing energy to the apparatus. The apparatus further including a sensor unit with a first sensor and second sensor for sensing temperature and a third sensor for sensing gas quality and a timer that senses and relays temperature and time information to the control unit.

[0016] The decarboscrubber apparatus is configured for receiving grass-type materials, including bamboo, paddy, bagasse, cotton sticks, and coconut shell fiber, as input material, and wherein the de-carbonizer unit processes the input material irrespective of its moisture content. Also, the output unit of the present invention is configured to separately discharge gaseous fuel, liquid fertilizer, and black carbon residue, and wherein the apparatus is capable of emitting zero carbon emissions during operation. Furthermore, the decarboscrubber apparatus, includes a generator configured to receive gaseous fuel from the gas purifier unit, the generator being operable to supply power to the apparatus, wherein the control unit is configured to switch the apparatus to generator power when sufficient fuel gas is available. It is noted that the decarboscrubber apparatus includes a safety valve being positioned on the first connecting pipe between the de-carbonizer unit and the gas purifier unit, the safety valve being configured to automatically release excess gases to prevent overpressure conditions.

[0017] A method for generating liquid fertilizer and gaseous fuel by the decarboscubber apparatus includes first filling approximately 90% of the input cylinder of the apparatus with grass feed and subsequently closing and sealing the door while keeping the gas output valve open. Next, liquid scrubbers are introduced into the gas purifier unit and a heating cycle is initiated by heating the input cylinder of the apparatus until a temperature of 460° C is achieved over a period of 3 to 5 hours. Then, the third refrigerator scrubber is set to 20°C through the control unit, causing de-carbonization of the grass feed material within the input cylinder during the heating cycle, thereby releasing gases into the gas cylinder. The liquid fertilizer is then collected in the liquid fertilizer collector at temperature of approximately 100°C and 200°C is achieved in the input cylinder during the heating cycle. After this, a cooling cycle is initiated by cutting off the heat supply when the input cylinder reaches a temperature of 460°C. The cooling cycle is cooled until the temperature of the input cylinder is reduced to approximately 50°C and the liquid fertilizer is collected from the output valve of the input cylinder continuously from when the temperature of the apparatus reaches 200°C in the heating cycle. Further, the gaseous fuel is collected through the collection pipe when the temperature of the input cylinder is approximately 60°C.

[0018] BRIEF DESCRIPTION OF DRAWINGS:

[0019] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0020] FIG. 1 shows a schematic of a decarboscrubber apparatus in accordance with the present invention; FIG. 2 is a front view of the decarboscrubber apparatus of the FIG. 1;

[0021] FIG. 3 is a gas de-carbonizer unit of the decarboscrubber apparatus of FIG. 1;

[0022] FIG. 4 is a side view of a gas purifier unit of the decarboscrubber apparatus of FIG. 1;

[0023] FIG. 5 is a schematic of the input unit of the decarboscrubber apparatus of FIG. 1; and

[0024] FIG. 6 is an operational flowchart of the control unit of the decarbo scrubber apparatus of FIG. 1.

[0025] DESCRIPTION OF THE INVENTION:

[0026] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0027] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0028] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.

[0029] Referring to FIG. 1 and 2, a decarboscrubber apparatus for decarbonization of grass feed for generating liquid fertilizer, fuel gases and carbon (hereinafter referred to as apparatus 100) is described. The apparatus 100 includes a decarbonizer unit 104, a gas purifier unit 108, a liquid fertilizer collector 112 and a gas cylinder 116. The de-carbonizer unit 104 is connected to the gas purifier unit 108, liquid fertilizer collector 112 and the gas cylinder through a plurality of connecting pipes (124, 128, 132).

[0030] The de-carbonizer unit 104 is defined by an outer jacket including a input unit 120. The outer jacket defines the body of the decarbonizer unit 104 which is cuboid in shape and includes the input unit 120 which is a cylindrical structure. This cylindrical input unit 120 is approximately centrally positioned inside the outer jacket such that a central axis of the jacket along a horizontal line coincides with the cylindrical axis of the input unit 120. The jacket of the decarbonizer unit acts as a heat resistant unit that prevents direct access to the cylinder. In accordance with the present invention, the input unit 116 is completely coated from outside by heat resistant material, for example glass wool or the like. Input material that is converted to liquid fertilizer and gaseous fuel in the apparatus 100 is inputted inside the input unit 120 of the de-carbonizer unit 104. For example, the input material includes grass type organic material such as vertical fiber grass, coconut shell fiber, bamboo, baboo residue and may vary in other embodiments of the present invention. The de-carbonizer unit 104 is connected to the gas purifier unit through the connecting pipe 124.

[0031] This de-carbonizer unit 104 includes a door 136 and a sensor 140 on its outer wall. The de-carbonizer unit 104 is connected to the gas purifier unit 108, the liquid fertilizer unit 112 and the gas cylinder 116 through a plurality of connecting pipes (124,128,132). The dimensions of the jacket of the decarbonizer unit 104 in this one embodiment is preferably 4mtr by 3mtr. The diameter of the cylindrical input unit 120 is approximately 1.5mtr and 3 mtrs in length. Further, the gas purifier unit 108 include 3 separate units and has approximate dimensions of 2mtr by 3 mtr. The three sub units of the gas purifier unit 112 include a first scrubber unit 144, a second separator unit 148 and a third refrigerated scrubber unit 152. The output unit 120 includes a first gas fuel output, a second carbon residue output, and a third liquid output unit. It is noted that, the input unit 120, is preferably fabricated from a M.S. Steel sheet that has thickness of about 10mm. It is noted however, that the dimensions of the apparatus 100 varies in other embodiments of the present invention. The liquid fertilizer unit (112) collects the formed liquid fertilizer from the input unit 120 of the de-carbonizer unit 104 through the connecting pipe (128). Further, the gas cylinder (116) collects the purified gas from the gas purifier unit 108 through the connecting pipe (132).

[0032] The apparatus 100 further includes a control unit with a control unit 204, an control panel 208, a sensor unit 216, a timer 220 and an output unit 224. The control unit 104 includes a controller that is configured to operate the apparatus to execute a first heating cycle and second cooling cycle. The control unit 104 further monitors parameters such as the health, time, power consumption and temperature of the apparatus 100 and various components. These parameters such as power consumption, health, time, temperature and the like are included on the control panel 208. The sensors detect the parameters and display the values on the control panel 208. It is further noted that the controller is operable in two modes such as a regular mode and power saving mode. The controller controls the indirect heating of the apparatus by controlling the heating / cooling pads and controls the direct heating by controlling the heating / cooling of rods. It is noted that the user is able to input parameters such as time, temperature, ampere through the input unit 116. Further, the input unit displays the timer, input switches on its control panel.

[0033] The sensor unit 216 includes a first sensor 217, a second sensor 218 and a third sensor 219. The first sensor 217 and the second sensor 218 are temperature sensors where the first sensor senses temperature of 370 to 460 °C. Whereas, the second sensor 218 senses temperature upto 1000 °C. The first sensor 217 is positioned on the outer wall of the de-carbonizer unit 104 and senses the temperature of the input unit 120. The second sensor 218 is positioned on the gas purifier unit 108. It is noted that the third sensor 219 is a gas purity sensor that senses the percent methane purity of the gas that is being collected. The third sensor 219 is positioned inside the connecting pipe 132 which connects the gas purifier unit to the gas collection tank. There further includes the timer 220 which controls the excessive heating that may happen in the heating cycle. The timer 220 is positioned on the control panel 208 that may be adjusted by the user. Accordingly, the controller is configured to stop the power supply to heating pads 156 as per the timer inputs. The timer 220 acts as a safety measure to avoid excessive heating in case of the extended heating cycle for whatsoever reason.

[0034] It is noted that the input material is heated in two cycles such as a first heating cycle and a second cooling cycle to discharge liquid fertilizer, gases, oil and carbon though the output unit 224. The liquid fertilizer includes micronutrients such as Zink, Copper, Iron, Nitrogen, Nickel, Magnesium, Boron, Sulphur etc. that are collected from the outputs of the gas purifier unit 108 and that is collected in the liquid fertilizer collector 112. It is noted that the liquid fertilizer received is an organic fertilizer that does not include petroleum and plastics. The gases include Hydrogen, methane, and Carbon monoxide. The output oil is furnished oil, for example, liquid carbon. The output oil is usable as fuel. The cooled gas discharged from the gas purifier 108 is collected in the gas cylinder 116. The cooled gas incudes methane, hydrogen, carbon monoxide etc. The gases are collected in still cylinders and maintained at 250 bars of pressure. Alternatively, the gases are collected PVC balloons and maintained at a pressure of 10 bar.

[0035] The de-carbonizer unit 104 is connected to the gas purifier unit 108 by a first connecting pipe 124. The first connecting pipe 124 also includes a safety valve. The gas purifier unit 108 releases gases that are collected in the gas cylinder 116. The de-carbonizer unit 104 has a second output pipe 128 that is connected to oil and liquid fertilizer collector tank 112. The gas purifier unit 108 has a third output pipe 132 that is connected to a gas cylinder 116. The output of the gas cylinder 116 discharges the gases as per the present invention. This output is provided to an electrical generator in another embodiment. Referring to FIG. 3, the de-carbonizer unit 104 includes a casing 300 that includes an input unit 120. In this embodiment, the input unit 120 is defined by an input cylinder 304. The de-carbonizer unit 108 also includes the safety valve 212, a first sensor 308, a plurality of heating pads 312, a plurality of heating rods (Not Seen), and an insulation jacket 316. The input cylinder 304 is positioned horizontally parallel to the ground. The input cylinder 304 includes a hinged door 320 at one end. The door 320 is packed on the cylinder 304 with a gasket preferably made of asbestos material. In this one embodiment, the input cylinder 304 is made of high tensile mild steel i.e. Bakelite. The input cylinder 304 is 3m in length and has a diameter of 1.5m.

[0036] The input cylinder 304 includes an insulation that is securely mounted across the upper half portion of the input cylinder 304. The lower half of the input cylinder 304 has the heat pads 312. The door 320 is approximately centrally positioned on the cylinder 304. The other end of the input cylinder 304 includes the first output 216 i.e. liquid fertilizer and oil. The heating pads 312 perform indirect heating of the cylinder 304, and the rods perform direct heating of the cylinder 304.

[0037] As shown in FIG. 4, the gas purifier unit 112 includes a first scrubber unit 144, a second separator unit 148, and a third refrigerated scrubber unit 152. The first scrubber unit 144 includes a first container 412 and a second container 416 that are connected by a pipe 420. The first container 412 has an outlet 424 from which the micronutrients are collected. It is noted that the first scrubber unit 144 includes ethylene and water in the ratio of 1:4 of ethylene to water. This first scrubber unit 144 filters the gas received from the de-carbonizer unit and filters it by carbon drying methods.

[0038] The second separator unit 148 is defined by a radiator that receives high temperature gas from the first scrubber unit 144. Further, the second scrubber unit 148 is a dry scrubber that includes iron pieces and a silica-sulphur compound. The filtered gas from the first scrubber unit 144 is received in the second scrubber unit 148 that separates clean gas by heating the received gas at high temperatures of about 70°C to 200°C. The high temperature gas (70°C to 200°C) passes through the second unit 148 and the gas is cooled by around 50°C and provided to the third refrigerated scrubber unit 152. Furthermore, the third scrubber unit 152 is a refrigerated scrubber unit that includes pure water that cools the heated gas and reduces temperature to about 50 °C. The third refrigerated unit 152 includes an outlet 432 from which micronutrients are also collected. The cooled gas discharged from the third refrigerated scrubber unit 408 is then discharged in the gas cylinder 116.

[0039] Now referring to FIG. 5, the components of the input unit 120 of the apparatus 100 are described. The input unit 116 includes a control panel 504, keys and a plurality of switches 508. The input unit 116 allows the user to configure inputs to the apparatus 100 through the control panel 504, keys and switches 508. Further, the input unit 116 includes sensor meters 516 that include heat meter and ampere meter to display the values of the sensed parameters. The ampere meter monitors the current supplied to the system and this ampere meter is positioned on the control panel. Further, the control panel also includes a Kilowatt meter and a Volt meter that detects faults in the supplied current wattage. In case there is a fault, the kilowatt meter directs the controller to shut off the apparatus. In this particular embodiment, the optimum values of the meters on the control panel are 25Kilowatts, 410-420V on the voltmeter and 27 to 30 Ampere on the ampere meter. Further, there also includes a heat meter on the control panel that measures the temperature of the apparatus. It is noted that the Main Circuit Control Board (MCCB) (520) is a controller which controls the apparatus 100. The MCCB 520 initiates the generator, thereby initiating the heating cycle of the system and also cuts off the generator thereby controlling the temperature and finally stopping the operation of the apparatus 100. The input unit communicates with the sensor unit 124, to display the values of the sensors onto the control panel 504.

[0040] Referring to FIG. 6, an operational flowchart of the control unit 124 in the apparatus 100 is described. In a first step 604, the control unit is turned ON by the user. In a second step 608, the generator is started by the control unit. Accordingly, the first heating cycle is initiated. In the next step, timer is set as per the type of mode of operation. In a next step 612, the user selects the mode. If regular mode is selected by the user, the timer of the cycle is set manually. Further, the generator has to be manually switched off when the temperature of the input cylinder reaches 460°C.

[0041] If the power saving mode is selected, the timer is set by the controller for predefined time, for example, 3 hours or 5 hours in the next step. In the next step 616, the sensors are activated. In the next step 620, the ampere meter, Volt meter and heat meter are activated. When the temperature of 460°C is achieved by the apparatus, the sensor communicates the temperature to the control unit. In the next step 624, the control unit then cuts off power to the generator, thereby terminating the heating cycle. In the next step 628, once the heating of the apparatus 100 is stopped, the cooling cycle is initiated. Collection of liquid fertilizer is done from the time when the temperature of the apparatus reaches 100 degrees in the heating cycle. The temperature sensors monitor the temperature of the apparatus throughout the heating and cooling cycles. Once a temperature of 60°C is achieved, the cooling cycle is over system.

[0042] Now referring to FIGS. 1 to 4, in operation, the first input material i.e. grass such as bamboo, paddy, bagasse, cotton sticks, or a combination of these materials etc. is positioned in the input cylinder 304 by opening a door of the input cylinder 304. The input cylinder 304 is approximately 90% filled by the input material. Another input is liquid scrubber that is filled in the gas purifier unit 112. Here the liquid scrubber, for example, water is filled in a first scrubber unit 400, a second separator unit 404 and a third refrigerated scrubber unit 408.

[0043] The door 320 is closed and sealed. All valves are closed. The output valve of the gas output is kept in the opened position. The cut off temperature of the heating pad is set, for example it is set to 460° by providing the input to the control panel by input keys. The third refrigerator scrubber temperature is set to 20° temperature for the purpose of withdrawal of carbon dioxide. The apparatus is started by pressing the start button on the input panel. The heating of the input cylinder 304 is conducted for about 3 to 5 hours. De-carbonization of the input material is initiated, and gases are released in the input cylinder 304. The temperature display on the input panel is observed.

[0044] Now, as soon as the temperature of the input cylinder 304 is about 100°, the stage of fertilizer collection is initiated in the first heating cycle. The first output valve of the input cylinder 304 is opened to collect liquid fertilizer. Collection of liquid fertilizer is done after the apparatus reaches 200 degrees and goes on till the cooling cycle is over. As the heating cutoff is set at 460°, the heating cycle is switched off as soon as the temperature of 460° is achieved in the input cylinder 304. Now the cooling cycle starts. The temperature of input cylinder 304 is monitored. As soon as 50° temperature is achieved there is an indicator signal by buzzer to indicate the initiate end of cooling cycle. Now the liquid fertilizer is collected from the output valve by opening the valve. The gases are collected during the heating cycle and the cooling cycle.

[0045] The gas collection stage is discussed. The gas is received after the temperature of about 600plus is achieved in the input cylinder. The gases are received till the temperature is about 600in the cooling cycle.

[0046] In an operational cycle, the input material of about 1 Ton i.e. 5000 ltrs grass feed was fed to the apparatus 100 and the operation lasted for about three hours i.e the first heating cycle and the second cooling cycle lasted for about 3 hrs. In this case about 230 Kg of activated charcoal / carbon was obtained, about 200 liters of liquid carbon including micronutrients was obtained, and fuel gases of about 130 Kg was obtained. Apart from this waste volatile material of about 440 Kg was also obtained. The volatile material was released in the form of moisture. In another embodiment of the present invention, the apparatus 100 includes a generator receiving the output gas as a fuel. The other components remain the same. Accordingly, in operation, the generator includes a pump that delivers gases received from the apparatus to the inlet of the generator. As soon as a sufficient quantity of the fuel gases is received, the gas is ignited by lighters of the generator. The power generated from the generator is supplied to the apparatus 100 through the control unit 104.

[0047] Accordingly, the first power supply is cut off and the second power supply i.e. the power supply generated from the generator is utilized to operate the apparatus 100. In accordance with the present invention, when the first heating cycle reaches approximately 370° C temperature, the heating cycle comes to end and the control unit 104 cuts the power supply from the generator. In this embodiment the level of the scrubber is approximately l / 3rdof the height of the respective unit.

[0048] In the present invention, it is noted that the feed in the form of grass, bamboo, vertical fiber etc. is useable irrespective of the moisture content in the feed. The feed dimensions for the apparatus of the present embodiment advantageously may range in the range of 3mm to 8 feet. The input water has to be partially potable to avoid any side effects relating to the purity and quality of the liquid fertilizer generated by the apparatus 100. The safety valve of the apparatus 100 releases any excess gases automatically to avoid any accident.

[0049] It is evident that the primary output of the apparatus 100 of the present invention is of interest i.e. the liquid fertilizer. Liquid fertilizers are essential for promoting healthy plant growth, as they provide readily available nutrients to the crops. By effectively converting grass-type materials into liquid fertilizer, the present invention aligns with the principles of circular economy and sustainability by repurposing organic waste to enhance agricultural productivity.

[0050] Additionally, the present invention seeks to harness the potential of gaseous fuel production from the grass-type materials. Gaseous fuels, such as biogas or syngas, have garnered attention as alternative energy sources due to their lower carbon footprint compared to conventional fossil fuels. By deriving gaseous fuel from these materials, the apparatus contributes to reducing greenhouse gas emissions and reliance on non-renewable energy sources. The apparatus 100 advantageously emits no carbon i.e. zero carbon emission.

[0051] Furthermore, the present invention introduces the concept of black carbon residue as an output. Black carbon (Biochar), a byproduct of incomplete combustion has diverse applications. It is used as a soil amendment to enhance soil fertility, as a component in filtration systems, or even as a precursor material for manufacturing processes. Overall, the invention showcases a comprehensive approach to utilizing grass-type materials effectively. By employing heat treatment processes, it maximizes the potential of these materials to produce a range of outputs, including liquid fertilizer, gaseous fuel, and black carbon residue (Biochar). The present invention not only addresses the challenge of managing organic waste but also aligns with sustainable practices and the pursuit of greener alternatives in agriculture and energy production. As such, it stands at the forefront of technological advancements aimed at creating a more harmonious relationship between human activities and the environment.

[0052] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0053] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

CLAIMS:

1. A decarboscrubber apparatus (100) for decarbonizing and generating liquid fertilizer, fuel gases and carbon generation of liquid fertilizer and gaseous fuel comprising: a de-carbonizer unit (104) for converting grass feed into liquid fertilizer and gas fuel, the de-carbonizer unit (104) being connected to a gas purifier unit (108) by a connecting pipe (124) with a safety valve (212) for transfer of generated gas; a control unit (204) configured to operate the apparatus in a first heating cycle and a second cooling cycle and being configured to monitor a plurality of parameters such as health, time, power consumption and temperature of the apparatus (100); a gas purifier unit (108) including a first scrubber unit (144), a second separator unit (148) and a third refrigerated scrubber unit (152) for purifying and discharging gas into the gas cylinder (204); a gas cylinder (116) being connected to the gas purifier unit (108) by an output pipe (132) for collection for purified gas; the de-carbonizer unit (104) including a second output pipe (128) being connected to a liquid fertilizer collector tank (112) for collection of generated liquid fertilizer; an input unit (120) for configuring operational parameters of the apparatus (100) including a control panel (208), keys, display, and aplurality of switches (508), allowing the user to configure the inputs to the apparatus (100); an output unit (224) for collecting liquid fertilizer, gaseous fuel, and black carbon residue; and the apparatus (100) including two operational cycles, a first heating cycle and a second a cooling cycle, both being executed and monitored by the control unit (204) for generation of liquid fertilizer and gaseous fuel; wherein the de-carbonizer unit (104) being connected to the gas purifier unit (108) via a first connecting pipe (124) and being configured to process the grass-type feed material through indirect and direct heating in the first heating cycle, and wherein the gas purifier unit (108) scrubbing and separating the output gases in the second cooling cycle.

2. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the decarbonizer unit (104) is a cylindrical structure that encloses the input cylinder (304) that includes a sensor (140), a plurality of heating pads (156), a plurality of heating rods, an insulation jacket (300) and a door (136) for heating the inputted grass feed, wherein the input cylinder (304) being made of high tensile mild steel and having a length of 3 meters and a diameter of 1.5 meters.

3. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the control unit (204) including a controller operable in a regular mode and apower-saving mode, and that is being configured to control the heating and cooling of the de-carbonizer unit (104) by regulating the heating pads (156) and heating rods.

4. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the first scrubber unit (144) of the gas purifier unit (108) including a first container (412) and a second container (416), that includes ethylene and water in the ratio of approximately 1:4 for filtering the gas.

5. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the second separator unit (148) of the gas purifier unit (108) including iron pieces, silica-sulphur and hydrogen gas for dry scrubbing the gas received from the first scrubber unit (144) through a radiator and transferring it to the third refrigeration unit (152).

6. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the third refrigeration unit (152) of the gas purifier unit (108) cooling the high temperature gas received from the second separator unit (148) and having an outlet (132) for cooling the output gases and collecting micronutrients and a connecting pipe discharging the gas to the gas cylinder (116).

7. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the first heating cycle including heating of the de-carbonizer unit (104) to 460°C form 3-5 hours, with l / 3rdof the input cylinder (304) of the decarbonizer unit (104) being filled with liquid scrubber.

8. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the second cooling cycle being initiated when the temperature of the inputcylinder (304) reaches preferably at 460°C and the heat is cut off to achieve a temperature of 50°C and liquid fertilizer is collected in the liquid fertilizer collector at predefined temperature points, wherein a buzzer signal indicates the end of the cooling cycle.

9. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the gas is collected from one connecting pipe when the temperature of more than 60° is achieved inside the input cylinder (304) of the de-carbonizer unit (104).

10. The decarboscrubber apparatus (100) as claimed in claim 1, claim 3 and claim 6 wherein, the liquid scrubber being added to the gas purifier unit (108) may be water, ethylene, iron pieces etc.

11. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the generated gas being utilized as fuel for generator providing energy to the apparatus (100).

12. The decarboscrubber apparatus (100) as claimed in claim 1 wherein, the apparatus (100) including a sensor unit (216) with a first sensor (217) and second sensor (218) for sensing temperature and a third sensor (219) for sensing gas quality and a timer (220) that senses and relays temperature and time information to the control unit (204).

13. The decarboscrubber apparatus (100) as claimed in claim 1, wherein the apparatus being configured for receiving grass-type materials, including bamboo, paddy, bagasse, cotton sticks, and coconut shell fiber, as inputmaterial, and wherein the de-carbonizer unit (104) processes the input material irrespective of its moisture content.

14. The decarboscrubber apparatus (100) as claimed in claim 1, wherein the output unit (220) is configured to separately discharge gaseous fuel, liquid fertilizer, and black carbon residue, and wherein the apparatus (100) is capable of emitting zero carbon emissions during operation.

15. The decarboscrubber apparatus (100) as claimed in claim 1, including a generator configured to receive gaseous fuel from the gas purifier unit (108), the generator being operable to supply power to the apparatus (100), wherein the control unit (204) is configured to switch the apparatus (100) to generator power when sufficient fuel gas is available.

16. The decarboscrubber apparatus (100) as claimed in claim 1, including a safety valve (212) being positioned on the first connecting pipe (124) between the de-carbonizer unit (104) and the gas purifier unit (108), the safety valve (212) being configured to automatically release excess gases to prevent overpressure conditions.

17. A method for generating liquid fertilizer and gaseous fuel by the decarboscubber apparatus (100) as claimed in claim 1, comprising: a) filling approximately 90% of the input cylinder (304) of the apparatus (100) with grass feed and subsequently closing and sealing the door (136) while keeping the gas output valve open; b) introducing liquid scrubbers into the gas purifier unit (108);c) initiating a heating cycle initiated by heating the input cylinder (304) of the apparatus (100) until a temperature of 460° C is achieved over a period of 3 to 5 hours; d) setting the third refrigerator scrubber (152) to 20°C through the control unit (204); e) causing de-carbonization of the grass feed material within the input cylinder (304) during the heating cycle, thereby releasing gases into the gas cylinder (116); f) collecting liquid fertilizer in the liquid fertilizer collector (112) at temperature of approximately 100°C and 200°C is achieved in the input cylinder (304) during the heating cycle; g) initiating a cooling cycle by cutting off the heat supply when the input cylinder (304) reaches a temperature of 460°C; h) continuing the cooling cycle until the temperature of the input cylinder (304) is reduced to approximately 50°C; i) collecting the liquid fertilizer from the output valve of the input cylinder (304) continuously from when the temperature of the apparatus reaches 200°C in the heating cycle; and j) collecting gaseous fuel through the collection pipe (132) when mperature of the input cylinder (304) is approximately

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