Biofilter apparatus module for processing and reducing industrial odour and / or emissions

Abstract

The invention to which this application relates is to an apparatus and a method for allowing the processing of gas emissions, typically from commercial or research facilities, which may include odours and / or potentially harmful materials and / or environmentally unfriendly materials. The apparatus is provided in the form of one or more modules which are substantially formed and apparatus installed therein and commissioned under factory conditions, prior to the same being moved to a location for use. The modules include therein at least one biofilter medium through which the gas passes and a liquid distribution and drainage system to introduce liquid into the biofilter medium to condition the same for effective use in processing said gases.

Description

[0001] Biofilter apparatus module for processing and reducing industrial odour and / or emissions

[0002] The invention to which this application relates is to an apparatus and a method for allowing the processing of emissions, typically from commercial or research facilities, which may include odours and / or potentially harmful materials and / or environmentally unfriendly materials.

[0003] The problem of emissions from commercial facilities is well known and is typically required to be controlled in accordance with regulatory requirements which may be in force at particular geographical locations of the emissions and typically, these regulatory requirements are enforced by inspections by environmental control officers which, if failed, can be expensive and time consuming to resolve. The lack of control of these emissions may also result in complaints from others in the environment surrounding the emissions and hence create potential conflict and adversely affect the living conditions of those in the vicinity.

[0004] As a result of this, operators of the premises are required to install appropriate apparatus and process the emissions from the premises prior to the emission of the same into the surrounding environment. Typically the apparatus used will utilise one or more processing steps and the apparatus is interconnected by ductwork and along which the emitted gases pass from the premises to the external environment. The apparatus can therefore be relatively complex and can include the provision of a primary filtering apparatus and subsequent secondary processing apparatus and typically, the systems and apparatus which are installed, are bespoke to the particular location at which the installation takes place. This, in itself, causes significant labour and time requirements and indeed metal work requirements in order to form the required filtering stations and to provide the required ducting between the processing stages of the apparatus. As a result, the installation of the apparatus can be expensive and typically requires a significant area of land to be available externally of the premises in order to accommodate the installation of the apparatus.

[0005] As a result of this and the expenditure, it is often the case that there is a deterrent to installing the appropriate apparatus and which, in itself, can result in no, or a limited, processing capacity being used instead. An aim of the present invention is to provide apparatus for the control and processing of emissions to be provided in a modular form so as to allow the apparatus to be installed more easily on site at the location for use, but with the majority and preferably substantially all of the installation works having been performed under factory conditions and within or attached to the said module. This therefore allows the module to be formed at the factory location which his typically remote from the installation location and for the module to then be transported to the location of use and installation and to be connected to the outlet from the premises of the gases which are to be filtered and treated.

[0006] A further aim of the invention is to allow the apparatus which is provided to be installed utilising a minimum of space at the premises and to operate in an environmentally friendly manner and to avoid as far as possible, the use of materials which themselves can be potentially harmful during or after use. A further aim is to provide the apparatus in a form which allows the same to continue to operate without or with minimal intervention by personnel.

[0007] In a first aspect of the invention there is provided apparatus including a module for use in the processing of gas emissions, said module including a housing including a base, side walls, end walls to define a cavity in which there is located at least one biofilter medium, an inlet to allow said gases to enter into the said cavity and then pass through the bio filter medium, an outlet to allow gas which has passed through the biofilter medium to leave the module and wherein the module includes an irrigation system to introduce liquid into the biofilter medium and to pass through the same to condition the biofilter medium for effective use in processing said gases and means to collect the said liquid that has passed through the biofilter medium, for recycling and re-use, or drainage from the module.

[0008] Typically the said module includes top wall opposing the base such that the base, side, end and top walls define a cavity in a container module and, in one embodiment, a shipping container which is built from new or converted into a module in accordance with the invention. In one embodiment the shipping container location means which are used to transport the same safely and securely are retained or reproduced on the module and used for the transport of the same from the location of creation to the location of installation and use. In one embodiment the module may have dimensions which match those of standard shipping containers such 20 ft (6.06 m) and 40 ft (12.2 m) in external length and 8ft (2.43m) external width with a height of 8ft 6” (2.59m) or 9ft 6” (2.89m).

[0009] Typically, the apparatus and / or the introduction of the biofilter medium is performed under factory conditions so as to allow a controlled environment to be used to create the module. Typically, the module can then be moved to the location for installation at which the same can be stationed for as long as required and most typically for a number of months or years as part of the factory installation. Typically, the apparatus includes one or more fan units and / or ducting which can be partially attached to the module under factory conditions or may be attached to the module at the location of installation.

[0010] In one embodiment, a plurality of the modules are provided, in one embodiment, the said modules are provided in a series or, alternatively, provided in parallel and in either case so as to increase the capacity of the combined apparatus and / or the throughput speed and / or the level of filtering which can be achieved.

[0011] In one embodiment, the interior walls, floor and / or lid of the container are coated internally with a sealant material such as glass reinforced plastics (GRP) or another sealant material. The sealant material is provided so as to seal the interior cavity and also prevent or minimise corrosion of the module walls which are typically made from metal.

[0012] In one embodiment, there is provided at least one distribution duct which is connected to an inlet of the gases from the factory or processing installation which are to be treated and said duct passes along the majority of the length of the cavity so as to introduce the gas along the biofilter medium in the cavity and into the biofilter medium at a plurality if, typically equally spaced apart locations.

[0013] Typically the said distribution duct is located adjacent the base of the module and located under a platform floor. In one embodiment, the platform floor acts to support the biofilter medium in the cavity. In one embodiment, the said platform is formed from a plurality of recyclable plastics components. In one embodiment the platform includes a series of sectors, each of which is connected to the duct to allow the introduction of the gas into the biofilter medium in each of the sectors. In one embodiment there is provided a drainage and / or recycling system typically under the platform floor and sectors which allows the collection and drainage of liquid which has passed through the biofilter medium and which passes the same through drainage outlet for collection and disposal or recycling. Typically the decision whether to recycle the liquid and return the same to the irrigation system to be passed through the biofilter medium again may be repeated a number of times whilst the liquid is determined to be in an acceptable condition to maintain the biofilter medium in an acceptable condition. The decision to pass the liquid for drainage and collection may be taken when the liquid and / or biolfilter medium condition is determined to be outwith an acceptable range such as, for example, the acidity of the liquid is too high. In addition, the recycled liquid may have fresh, clean liquid added thereto and / or the liquid may be replaced by a new clean quantity of liquid.

[0014] In one embodiment, the module includes a liquid distribution system which, typically, includes a plurality of spaced apart outlets located along the length of the said biofilter medium and / or across the width of the same so as to allow a relatively uniform distribution of the liquid onto the biofilter medium which typically is positioned intermediate the water distribution system and the platform floor of the module. In one embodiment the liquid distribution system outlet are located above the biofilter medium when the module includes a top wall.

[0015] In one embodiment, the water distribution means are a series of nozzles and the pipework for the flow of liquid to said nozzles, is mounted externally of the container with the nozzles been connected by pipework which passes through, typically the top wall of the container into the cavity. The provision of this and the control means allows access to be obtained to the water system and the control generally, without affecting the operation of the biofilter medium.

[0016] In one embodiment, the biofilter medium comprises a mixture of or a plurality of layers of filtering components which, in one embodiment comprise any or any combination of pumice stone, woodchip, coconut husk and / or COIR materials. However, it should be appreciated that the particular biofilter medium materials which are used for the mixture or respective layers can be selected to suit the particular filtering requirements for the gas which is to pass through the apparatus. In one embodiment, above and attached to the top wall of the module there are provided a plurality of handrails which provide guidance and safety for personnel who may be moving across the external surface on top of module.

[0017] In one embodiment, the control means for the operation of the apparatus may be provided in a housing which is provided at one end of the cavity or alternatively located adjacent to the said module with suitable connections passing through the wall of the container.

[0018] In one embodiment the module is provided with a top which is open to the environment and which allow the emission of processed gases which have passed through the biofilter medium directly into the environment rather than passing through outlet ducting.

[0019] In one embodiment the gas emissions which are to be processed may be pre treated in one embodiment to humidify the same, by applying liquid to the gas. In one embodiment this is achieved by passing the gas through an atomised spray of liquid such as water, through a spray of liquid such as water, prior to the gas being passed into the biofilter medium. The pretreatment may occur within the duction within the module or in apparatus located intermediate the module and the source of the gas emissions.

[0020] In one embodiment the liquid which is introduced into the biofilter medium is provided to a sufficient extent to maintain the bacteria in the biofilter medium in an active state and hence provide efficient processing of the gas which passes through the same.

[0021] In one embodiment the liquid is water.

[0022] In one embodiment nutrients may be added to the biofilter medium at the start of operation of the apparatus and / or during operation of the same so as to activate and / or maintain the active state of the bacteria.

[0023] In a further aspect of the invention there is provided a method for providing a biofilter apparatus in the form of a module for use in the processing of gas emissions, said module including a housing including a base, side walls, end walls to define a cavity in which there is located at least one biofilter medium, an inlet to allow said gases to enter into the said cavity and then pass through the biofilter medium, an outlet to allow gas which has passed through the biofilter medium to leave the module and providing an irrigation system to introduce liquid into the biofilter medium and to pass through the same to condition the biofilter medium for effective use in processing said gases and means to collect the said liquid that has passed through the biofilter medium, for recycling and re-use, or drainage from the module and wherein the said module is substantially assembled under factory conditions at a first location geographically remote from the location of use and transported as an at least partially assembled module to the location of use.

[0024] Typically the said module is at least partially commissioned and tested at the said first location.

[0025] In one embodiment the module is wholly assembled and formed the said first location of use and at the in-use location is connected to external liquid supply, drainage and electrical services and the gas emissions inlet.

[0026] In one embodiment the said biofilter medium is introduced into the cavity at the first location.

[0027] In one embodiment the said biofilter medium is introduced into the cavity at the said in-use location.

[0028] Specific embodiments of the invention are now described with reference to the accompanying drawings; wherein

[0029] Figure 1 illustrates a plan view of a module in accordance with one embodiment of the invention.

[0030] Figure 2 illustrates a plan view from the underside of the module showing the floor construction;

[0031] Figure 3 illustrates a cross section elevation along line AA of the module in accordance with one embodiment of the invention;

[0032] Figure 4 illustrates a module formed in accordance with the invention in a schematic manner;

[0033] Figure 5 illustrates a module formed in accordance with another embodiment of the invention; and

[0034] Figure 6 illustrates a filter media platform in accordance with one embodiment of the invention. In accordance with the invention, there is provided a module 2 which, in one embodiment, can be formed of similar dimension to and be movable as, a shipping container or similar using shipping container systems on vehicles and ships therefore allowing the modules to be transported by road and sea to the location of use and in a partially or wholly assembled condition. In the embodiment illustrated in Figures 1-4, the module includes a base 4, side walls 6,8, end walls 10,12 and a top wall 14. The Figures show the module at the location of use with the module located on a support surface 16 which in this case is formed of concrete and typically in accordance with the invention the module will have been assembled or at least partially assembled at a location remote from the location of use, such as in a factory, and then transported to the location of use for installation and commissioning. The time required to do this at the location of use in accordance with the invention is greatly reduced in comparison to conventional apparatus of this type which is typically wholly assembled and installed at the location of use, as in accordance with the invention the majority of the assembly of the apparatus and the commissioning of the module operation can be performed at the remote location under factory conditions and in a much more controlled environment.

[0035] The walls of the module define a cavity in which there is provided a support platform 18 formed from a series of legs 20 and plates 22 which in conjunction, form the support platform 18 which is separated from the base 4 of the module by a predefined space 24. Along said space 24, there is provided a gas duct 26 which has an inlet 28 into which gases which are to be treated pass from a processing premises adjacent to which the module 2 is installed and which then has a series of dispensing outlets 30 through which the gas passes and through apertures in the plates 22 into the biofilter medium 36 which may, in one embodiment, be located in a number of sectors. The size of the duct 26 may decrease as the same travels along the longitudinal axis 40 of the cavity 38 in which the biofilter medium is held so as to ensure that each part of the bio filter medium receives a substantially qual proportion of the gas. Fans may also be provided to ensure the efficient passage of the gas to, through and from the biofilter medium. The gas which passes through the biofilter medium then leaves the cavity and module through at least one outlet provided typically in an end wall 12 or top wall 14 of the module.

[0036] Also provided is a dram outlet 42 which allows the drainage of liquid which is applied to the biofilter medium and which is not be reused, to leave the cavity. In this embodiment, the biofilter medium 36 comprises a first layer 44 and a second layer 46, with the first layer been formed of pumice stone particulates and the second layer formed of COIR fibre material. By passing the gas through the said biofilter medium, so contaminants can be removed from the gas by active bacteria in the biofilter medium so that the gas which then leaves the module is treated and therefore cleaner and has less contamination than when it entered the module.

[0037] In order to maintain the operation and effectiveness of the biofilter medium 36, a liquid, typically water, is required to be introduced into and pass through, the bio filter medium so as to maintain the bacteria therein in an active, and hence filtering, condition. To do this a distribution system 48 is provided which includes a water inlet 50 which passes via pipework 52 which in this embodiment is mounted externally on the module to a series of distribution means in the form of nozzles 54 each of which is connected to the pipework via branch connections 56 and the nozzles 54 are located within the cavity 38 and at spaced locations therealong as illustrated in Figures 1 and 3. Each of the nozzles is provided with water to be sprayed onto the biofilter medium as indicated by the spray patterns 58 and so provide a uniform distribution of the water and / or other liquids onto the bio filter medium 36. The pipework 52 and branch connections 56 are located externally of the container as shown for example in figure 3 so as to allow ease of access for maintenance and repair. In addition to the introduction of clean water to pass through the biofilter medium, the distribution system can include a supply connection to the drainage system under the platform in the module so as to allow the liquid which has passed through the biofilter medium and which is collected to be recycled and passed to the nozzles 54 so as to be applied again to the biofilter medium and this may be repeated a number of times until it is determined, typically by testing of samples of the drainage liquid, that the liquid is no longer suitable for recycling and at which time the liquid is passed for collection and disposal via the drainage system.

[0038] The top wall also includes a series of apertures 60 which typically are covered but which can be removed to allow access to be gained to the cavity and there is also typically provided at end 62, a door to allow access into the cavity. Between the end wall 12 and an interior wall 64 which includes inspection hatches 66, there is a housing in which can be provided control means for the operation of the apparatus or alternatively the control means may be provided in a housing externally but adjacent to the said container.

[0039] Handrails 68 may also be provided for safety purposes on the top of the module as shown.

[0040] Typically, in order to avoid the water, biofilter medium and / or gas affecting the integrity of the walls of the container, the same are typically coated in GRP at least on their interior surfaces.

[0041] In one embodiment, the biofilter media can be any or any combination of pumice stone, woodchip and / or coconut husk or any other alternative media which is suitable for the gas passing therethrough.

[0042] In a further embodiment of the invention shown in Figures 5 and 6 there is provided another form of module 102 which again is capable of being assembled and partially commissioned under factory conditions and then, in one embodiment, moved from the factory to the location of use, typically using standard shipping container transport means and systems, as with the first embodiment of the module. In this embodiment, no top wall is provided and instead the top surface of the biofilter medium is open to the external environment. The module includes a base 104, side walls 106,108 and end walls 110,112 and an opening to the environment 114. In this embodiment, the gas which is to be processed enters the module via at at least one inlet 116 which is provided at or adjacent to the base 104 of the module. The gas is then encouraged to pass through the bed of bio filter media 120 which is formed and supported by a support platform 118 similar to that described in Figures 1-4 and which is close to, but spaced apart from, the base 104 of the module. As the gas passes through the biofilter media, the same is filtered and the relatively cleaner gas as emitted from the top surface of the bio filter media and through the opening 114 into the environment 124 as indicated by arrows 122.

[0043] In one embodiment, the module is provided with an area 126 below the platform 118 on which the bio filter media is supported and in this chamber the drainage and / or recycling apparatus is located for liquid which has passed through the biofilter medium in the direction of arrows 132.

[0044] Typically the platform includes a series of walls or barriers 128 as shown in Figure 6 which split the biofilter medium bed 120 into sectors and into which the biofilter medium is located substantially in equal amounts. Typically each of the sectors is connected to an inlet 130 from the inlet duct 116 so that the gas which is to be filtered is supplied in substantially equal proportions to each of the respective sectors and hence provides a substantially uniform dispersion of the gas across and through the bio filter medium and so ensures a more effective filtering using all of the bio filter medium and the bacteria therein.

[0045] The apparatus may also include one or more fans and / or dust filters to encourage the flow of the gas through the module and enable filtration of dust entering the module respectively.

[0046] In both embodiments liquid can be introduced to pass through biofilter media consistently or at intervals in order to maintain the bacteria within the bio filter media in a suitable condition to cause the filtration to occur. In one embodiment, there may be a pre-processing step in which the gas which enters into the module is humidified before entering the biofilter medium, typically by passing the same through an atomiser spray. Atomising spray means may also be provided within the chamber and in any case, the liquid which passes through the biofilter media may be recirculated.

Claims

CLAIMS1. Apparatus including a module for use in the processing of gas emissions, said module including a housing including a base, side walls, end walls to define a cavity in which there is located at least one biofilter medium, an inlet to allow said gases to enter into the said cavity and then pass through the biofilter medium, an outlet to allow gas which has passed through the biofilter medium to leave the module and wherein the module includes an irrigation system to introduce liquid into the biofilter medium and to pass through the same to condition the biofilter medium for effective use in processing said gases and means to collect the said liquid that has passed through the biofilter medium, for recycling and re-use, or drainage from the module.

2. Apparatus according to claim 1 wherein the said base and walls define a cavity and the module is of the dimensions of a shipping container and includes formations to allow the same to be transported using shipping container transport systems.

3. Apparatus according to any of the preceding claims wherein the module includes a top wall.

4. Apparatus according to any of the claims 1-2 wherein the module has a top opening to expose the biofilter medium to the external environment.

5. Apparatus according to any of the preceding claims wherein the module includes location means which are used to locate the module in position during transport from a location of at least partial assembly and commissioning of the module which is remote to a location of installation and connection to at least one supply of said gas emissions.

6. Apparatus according to claim 3 wherein the said supply of said gas emissions is from a factory premises and / or apparatus located within said premises which create the said gas emissions and the module is located intermediate the same and the exit of said gas into the surrounding environment.

7. Apparatus according to any of the preceding claims wherein the module is formed and / or biofilter medium is introduced into the said module cavity under factory conditions.

8. Apparatus according to any of the preceding claim wherein the module includes a platform for the support of the biofilter medium thereon and said platform is adjacent to, but spaced from, the base.

9. Apparatus according to claim 8 wherein the platform is spaced from the base by a series of spaced apart legs.

10. Apparatus according to any of claims 8 or 9 wherein the platform includes a series of spaced apart walls or barriers to define platform sectors in which the biofilter medium is located.

11. Apparatus according to any of the preceding claims wherein the apparatus includes one or more fan units and / or ducting to encourage the flow of gas through the said module and / or biofilter medium.

12. Apparatus according to any of the preceding claims wherein a liquid distribution system is installed with the module to introduce liquid into the biofilter medium to pass through the same.

13. Apparatus according to claim 12 wherein the system includes a plurality of outlets located in a spaced apart configuration along substantially the length and / or width of said biofilter medium to provide a substantially uniform distribution of liquid onto the bio filter medium which is located intermediate the irrigation system outlets and the platform on which the biofilter medium is located.

14. Apparatus according to any of the claims 12-13 wherein the distribution system includes a series of nozzles and pipework for the supply of the liquid to said nozzles.

15. Apparatus according to any of the preceding claims wherein there is provided a drainage system to collect and drain liquid from the cavity and / or pass the liquid back to the liquid distribution system once the same has passed through the bio filter medium.

16. Apparatus according to claim 13 wherein the drainage system is located under the platform on which the storage medium is located.

17. Apparatus according to any of the preceding claims wherein a plurality of said modules are provided in an interconnected manner so as to increase the capacity of the apparatus to process said gas emissions and / or processing throughput speed and / or the level of filtering of the said gas emissions.

18. Apparatus according to any of the preceding claims wherein the internal facing walls of the cavity of the module are coated with a sealant material.

19. Apparatus according to any of the preceding claims wherein the module includes at least one gas distribution duct connected to the said inlet.

20. Apparatus according to claim 19 wherein said at least one gas distribution duct passes along the majority of the length of the cavity and has a series of spaced apart connections to introduce the gas at spaced intervals into the biofilter medium in a substantially uniform manner.

21. Apparatus according to claim 20 wherein said connections are located so that there is provided at least one connection located to introduce said gas into each of the sectors of the platform and into the biofilter medium located in each sector.

22. Apparatus according to any of claims 19-21 wherein the said at least one gas distribution duct is located under the said platform which supports the biofilter medium in the cavity.

23. Apparatus according to any of the preceding claims wherein the biofilter medium comprises a plurality of layers of filtering components.

24. Apparatus according to any of the preceding claims wherein control means for the operation of the apparatus are provided in a housing in the cavity and / or adjacent to the said module and connections pass through at least one wall of the said module between the control means and apparatus therein.

25. A method for providing a biofilter apparatus in the form of a module for use in the processing of gas emissions, said module including a housing including a base, side walls, end walls to define a cavity in which there is located at least one biofilter medium, an inlet to allow said gases to enter into the said cavity and then pass through the biofilter medium, an outlet to allow gas which has passed through the biofilter medium to leave the module and providing an irrigation system to introduce liquid into the biofilter medium and to pass through the same to condition the biofilter medium for effective use in processing said gases and means to collect the said liquid that has passed through the biofilter medium, for recycling and re-use, or drainage from the module and wherein the said module is substantially assembled under factory conditions at a first location geographically remote from the location of use and transported as an at least partially assembled module to the location of use.

26. A method according to claim 25 wherein said module is at least partially commissioned and tested at the said first location.

27. A method according to any of claims 24 and 25 wherein the module is wholly assembled and formed the said first location of use and at the in-use location is connected to external liquid supply, drainage and electrical services and the gas emissions inlet.

28. A method according to claim 25 wherein the said biofilter medium is introduced into the cavity at the first location.

29. A method according to claim 25 wherein the said biofilter medium is introduced into the cavity at the said m-use location.

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