Self-generating oil and protein production line from wastewater

Abstract

In an embodiment, a reactor for separating oil and protein from sludge material. The reactor includes a pressure-rated vessel with an inlet for sludge, one or more solvent injectors fluidly coupled to a solvent supply, and an agitator configured to macerate the sludge and enhance solvent contact. A load cell processing system measures sludge mass and meters solvent addition accordingly. A pressure system applies positive head pressure, while an integrated variable-pressure filter plate and a vacuum system withdraw a solvent-oil phase and retain a protein-rich fraction. Internal serpentine flow-directing elements positioned adjacent the agitator guide liquid phases downward and solids upward. A heating system with heated-air inlets at a upper portion of the vessel introduces air downwardly to assist drying of the protein-rich fraction. Separate discharge mechanisms eject the protein-rich fraction and the oil fraction following separation, enabling efficient recovery of higher-value protein and oil products.

Description

Attorney Docket No.: 134545-0001W001SELF-GENERATING OIL AND PROTEIN PRODUCTION LINE FROM WASTEWATERTECHNICAL FIELD

[0001] The embodiments described herein are generally directed to self-generating oil and protein production lines from wastewater.BACKGROUND

[0002] Dissolved air flotation (DAF) systems are widely implemented in animal processing facilities to clarify wastewater by removing fats, oils, and suspended solids. The sludge generated from these systems contains a complex mixture of water, oils, and proteins. Conventional handling of this byproduct involves drying the entire mass, an approach that is highly energy intensive and detrimental to protein quality. Because the oils in the sludge require elevated temperatures to liquefy, the proteins are simultaneously exposed to excessive heat, resulting in denaturation and loss of nutritional value. Furthermore, drying large amounts of water and oil increases processing time, raises operating costs, and necessitates expensive drying equipment. As a result, current methods fail to recover proteins and oils at their maximum value.

[0003] While extraction technologies such as solvent extractors and continuous oilseed processors are effective in other industries, they are not optimized for high-solid sludge streams like those produced by DAF systems. These systems lack integrated mechanisms to separate oils from proteins efficiently while preserving protein quality within a single process. They also fail to utilize process enhancements such as precise solvent dosing, internal flow-directing elements to improve phase separation, or bottom-up heating to accelerate drying of protein solids. This results in reduced oil recovery, diminished protein digestibility, and elevated1134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 production costs, all of which limit the economic and environmental sustainability of current DAF sludge management practices.

[0004] Accordingly, the present invention discloses a custom reactor, an integrated system, and methods designed specifically to overcome these shortcomings.SUMMARY

[0005] Provided herein is a reactor for separating oil and protein from a sludge material, comprising: a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein; one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel; an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact; a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass; a pressure system configured to apply a positive pressure at the head of the vessel; at least one integrated variable-pressure filter plate disposed within the vessel; a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solventoil phase through the filter while retaining a protein-rich solid fraction within the vessel; a set of internal flow-directing elements arranged in a serpentine configuration within the vessel, the flow-directing elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel; a heating system including one or more heated-air inlets disposed at an upper portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-rich solid fraction; a first discharge mechanism including a side-mounted outlet operable to eject a protein-rich fraction following separation; and a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation.

[0006] The disclosed reactor combines solvent injection, controlled agitation, serpentine flow-directing elements, and pressure-vacuum operation with a bottom-up heating system to efficiently separate oils and proteins from, for example, DAF sludge. By enabling high-yield oil recovery while preserving protein quality and reducing energy consumption, the invention provides significant advantages over conventional sludge processing technologies. The disclosed system therefore addresses unmet needs in animal processing and wastewater2134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 treatment, offering a scalable and sustainable solution for producing valuable protein and oil co-products.

[0007] Also provided herein is a method of separating oil and protein from sludge material using a reactor, comprising: introducing a sludge material comprising oil and protein into a pressure-rated vessel; distributing a solvent into the sludge material within the vessel using one or more solvent injectors; measuring the mass of sludge material with a load cell processing system and metering the solvent addition based on the measured mass; agitating the sludge material to disrupt floc structures and enhance contact between the solvent and the oil, wherein the agitation is assisted by internal serpentine flow-directing elements within the vessel that guide the sludge material along pathways (e.g., tortuous pathways) to enhance mixing and phase separation; applying a positive pressure to a headspace of the vessel and a vacuum connected to the fdter to draw a solvent-oil phase through an integrated filter while retaining a protein-rich solid fraction within the vessel; introducing heated air through one or more inlets at an upper portion of the vessel to assist in drying the protein-rich solid fraction; and discharging a protein-rich fraction from the vessel for drying and storage.

[0008] Also provided herein is a system for extracting oil and protein from dissolved air flotation (DAF) sludge, comprising: a decanter configured to remove water from the sludge to form a concentrated cake of oil and protein; a reactor configured to separate oil from protein within the concentrated cake, including a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein, one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel, an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact, a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass, a pressure system configured to apply a positive pressure at the head of the vessel, at least one integrated variable-pressure filter plate disposed within the vessel, a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter while retaining a protein-rich solid fraction within the vessel, a set of internal flow-directing elements arranged in a serpentine configuration within the vessel, the flow-directing elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel, a heating system including one or more heated-air inlets disposed at a lower portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-3134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 rich solid fraction, a first discharge mechanism including a side-mounted outlet operable to eject a dry protein-rich fraction following separation, and a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation; a solvent recovery subsystem in fluid communication with the reactor and configured to recover solvent from the solvent-oil phase; and an oil polishing subsystem configured to receive the solventoil phase and separate a purified oil product.

[0009] Accordingly, provided herein are the following items:Item 1. A reactor for separating oil and protein from a sludge material, comprising: a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein; one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel; an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact; a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass; a pressure system configured to apply a positive pressure at the head of the vessel; at least one integrated variable-pressure filter plate disposed within the vessel; a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter while retaining a proteinrich solid fraction within the vessel; a set of internal flow-directing elements arranged within the vessel, the flowdirecting elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel; a heating system including one or more heated-air inlets disposed at an upper portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-rich solid fraction; a first discharge mechanism including an outlet operable to eject a protein-rich fraction following separation; and4134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation.Item 2. The reactor of item 1, wherein the internal flow-directing elements are in a serpentine configuration.Item 3. The reactor of items 1-2, wherein the agitator comprises a top-entry sweep blade configured for variable speed operation to macerate the sludge material.Item 4. The reactor of items 1-3, wherein the agitator comprises a sweep blade operable in forward and reverse rotation to selectively mix sludge during extraction and assist in discharge of solids.Item 5. The reactor of items 1-4, wherein the solvent injectors comprise sparging rings.Item 6. The reactor of items 1-5, wherein the solvent injectors are configured to deliver solvent in a controlled ratio of sludge-to-solvent in a range of 1:3 to 3: 1 by weight.Item 7. The reactor of items 1-6, wherein the vessel is equipped with fixed and moving rakes positioned adjacent the filter to create solvent pathways through the sludge material.Item 8. The reactor of items 1-7, wherein the pressure system is configured to apply a head pressure in a range of 10 psi to 20 psi.Item 9. The reactor of items 1-8, wherein the pressure system further comprises a nitrogen or compressed gas inlet to supply the positive pressure.Item 10. The reactor of items 1-9, wherein the vessel includes solvent return lines positioned above and below the integrated filter, the return lines in fluid communication with a pump that circulates solvent through the vessel in a closed-loop path.Item 11. The reactor of items 1-10, wherein the vessel is configured with clean- in-place (CIP) sanitation features for in-process cleaning.Item 12. The reactor of items 1-11, wherein the solvent comprises at least one of hexane, pentane, toluene, xylene, or 2-methyltetrahydrofiiran.Item 13. The reactor of items 1-12, wherein the load cell processing system is configured to tare the sludge material and automatically meter solvent addition based on measured mass.Item 14. The reactor of items 1-13, wherein the heating system further comprises a radiant heat source, the radiant heat source configured to reclaim exhaust heat from a5134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 dryer and direct the reclaimed heat into the lower portion of the vessel to assist in heating and drying the protein-rich fraction.Item 15. A method of separating oil and protein from sludge material using a reactor, comprising: introducing a sludge material comprising oil and protein into a pressure-rated vessel; distributing a solvent into the sludge material within the vessel using one or more solvent injectors; measuring the mass of sludge material with a load cell processing system and metering the solvent addition based on the measured mass; agitating the sludge material to disrupt floc structures and enhance contact between the solvent and the oil, wherein the agitation is assisted by internal flow-directing elements within the vessel that guide the sludge material along pathways to enhance mixing and phase separation; applying a positive pressure to a headspace of the vessel and a vacuum connected to the fdter to draw a solvent-oil phase through an integrated filter while retaining a protein-rich solid fraction within the vessel; introducing heated air through one or more inlets at an upper portion of the vessel to assist in drying the protein-rich solid fraction; and discharging a protein-rich fraction from the vessel for drying and storage.Item 16. The method of item 15, wherein the agitation is performed with a topentry sweep blade.Item 17. The method of items 15-16, wherein the sweep blade is operated in forward and reverse rotation to enhance mixing and assist in cake discharge.Item 18. The method of items 15-17, wherein the pressure is applied by introducing nitrogen or compressed gas into the headspace of the vessel.Item 19. The method of items 15-18, further comprising guiding the solvent-oil phase downward toward the integrated filter before applying the positive pressure.Item 20. The method of items 19, further comprising initiating, before applying the positive pressure, upward separation of solids by directing flow through internal serpentine flow-directing elements within the vessel.Item 21. The method of item 15-20, further comprising :6134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 recovering, based on applying the positive pressure, the solvent-oil phase for downstream solvent recovery and oil polishing; and directing heated air from a lower portion of the vessel upwardly through the sludge material to assist in drying a protein-rich fraction before discharging the proteinrich fraction from the vessel for storage.Item 22. The method of item 15-21, wherein the solvent comprises a bioproduced solvent selected from 2-methyltetrahydrofuran, bio-produced aromatic hydrocarbons, or combinations thereof.Item 23. The method of items 15-22, wherein the solvent comprises a hydrocarbon mixture containing at least one additive selected from octane, heptane, or combinations thereof.Item 24. The method of items 15-23, wherein the solvent comprises a mixture of hexane and 2-methyltetrahydrofuran.Item 25. The method of items 15-24, further comprising modifying an aqueous phase of the sludge material by adjusting pH with at least one of a sodium salt, calcium salt, or phosphate salt.Item 26. The method of items 15-25, further comprising adding at least one protease selected from papain, bromelain, or combinations thereof to the sludge material.Item 27. The method of items 15-26, further comprising adding a reducing agent selected from p-mercaptoethanol or equivalents to the sludge material to reduce disulfide bonds in proteins.Item 28. The method of items 15-27, further comprising adding an antioxidant selected from vitamin E, vitamin C, or combinations thereof to the sludge material.Item 29. The method of items 15-28, further comprising adding a surfactant or flocculation modifier selected from sodium dodecyl sulfate, sodium dodecylbenzene sulphonate, sodium alkyltrioxyethylene sulphate, or combinations thereof to the sludge material.Item 30. The method of items 15-29, wherein the aqueous phase modification increases protein digestibility, reduces biogenic amine formation, or enhances amino acid recovery in the protein-rich fraction.Item 31. A system for extracting oil and protein from dissolved air flotation (DAF) sludge, comprising:7134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 a decanter configured to remove water from the sludge to form a concentrated cake of oil and protein; a reactor configured to separate oil from protein within the concentrated cake, including a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein, one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel, an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact, a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass, a pressure system configured to apply a positive pressure at the head of the vessel, at least one integrated variable-pressure filter plate disposed within the vessel, a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter while retaining a protein-rich solid fraction within the vessel, a set of internal flow-directing elements arranged within the vessel, the flow-directing elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel, a heating system including one or more heated-air inlets disposed at an upper portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-rich solid fraction, a first discharge mechanism including an outlet operable to eject a dry protein-rich fraction following separation, and a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation;8134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 a solvent recovery subsystem in fluid communication with the reactor and configured to recover solvent from the solvent-oil phase; and an oil polishing subsystem configured to receive the solvent-oil phase and separate a purified oil product.Item 32. The system of item 31, wherein the internal flow-directing elements are in a serpentine configuration.Item 33. The system of items 31-32, wherein the outlet is side-mounted.Item 34. The reactor of items 1-14, wherein the outlet is side-mounted.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:

[0011] FIG. 1 illustrates a reactor for separating oil and protein from a sludge material, according to an embodiment;

[0012] FIG. 2 illustrates a method of separating oil and protein from sludge material using a reactor, according to an embodiment;

[0013] FIG. 3 illustrates a system for extracting oil and protein from dissolved air flotation (DAF) sludge, according to an embodiment;

[0014] FIG. 4 illustrates an equipment list corresponding to a system for extracting oil and protein from dissolved air flotation (DAF) sludge, according to an embodiment;

[0015] FIG. 5 illustrates a processing system that may be used to implement processes described herein, according to an embodiment.DETAILED DESCRIPTION

[0016] The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments, and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that embodiments of the invention can be practiced without these specific details.9134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001

[0017] In some instances, well-known structures and components are shown in simplified form for brevity of description. In addition, it should be understood that the various components illustrated herein are not necessarily drawn to scale. In other words, the features disclosed in various embodiments may be implemented using different relative dimensions within and between components than those illustrated in the drawings.

[0018] As used herein, a reference numeral with an appended letter will be used to refer to a specific component, whereas the same reference numeral without any appended letter will be used to refer collectively to a plurality of the component or to refer to a generic or arbitrary instance of the component. In addition, the terms “respective” and “respectively” signify an association between members of a group of first items and members of a group of second items. For example, the phrase “each component A connected to a respective component B” would signify Al connected to Bl, A2 connected to B2, and so on and so forth, up to AN connected to BN.

[0019] The reactor 100 and associated system are broadly applicable across industries that generate sludge materials containing recoverable oil and protein. In animal processing, wastewater treatment, and food production facilities, the vessel 110 with inlet 115 receives sludge streams, and solvent injectors 120 with sparging rings 127 efficiently release oil from aggregated solids. The integration of agitators 130, load cell processor system 500, and pressure system 140 allows precise, scalable operation regardless of sludge variability. Solvent return lines 129 and the vacuum system 150 working in conjunction with the solvent filter 155 ensure continuous phase separation and recovery of valuable fractions with minimal solvent loss.

[0020] The system is further enhanced by flow-directing elements 160 that guide liquid phases downward and solids upward, optimizing the separation process. A heating system 170 with hot air inlets 175 introduces controlled heated air through the sludge material, enabling partial drying of protein-rich solids before discharge. This reduces downstream energy demand while preserving protein quality. The coordinated discharge mechanisms for protein 180 and oil 190 provide dedicated outlets, streamlining recovery operations and improving throughput in both batch and continuous processing environments.

[0021] Beyond food and wastewater applications, the system is suitable for renewable energy, aquaculture, and bioproduct recovery sectors, where separation of oil and protein enhances overall resource efficiency. By integrating extraction, separation, and drying functions in one vessel 110, the reactor 100 provides a flexible and scalable platform technology. This adaptability allows facilities to transform diverse sludge streams into10134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 consistent, marketable protein and oil products, contributing to cost savings, improved sustainability, and higher-value utilization of byproducts across industries.

[0022] FIG. 1 illustrates a reactor 100 for separating oil and protein from a sludge material, according to an embodiment. The reactor 100 can be configured to separate oil and protein from sludge material. The reactor 100 comprises a pressure-rated vessel 110 having an inlet 115 for receiving sludge containing oil and protein. One or more solvent injectors 120 fluidly coupled to a solvent supply line, in some cases implemented with sparging rings 127, distribute solvent into the sludge material within the vessel 110. Agitators 130 can be positioned within the vessel 110 to macerate and mix the sludge, disrupting floc structures and enhancing solvent contact. A load cell processor system 500 can be operatively coupled to the vessel 110 to measure the mass of sludge material and automatically meter solvent addition. Further, a relief valve 125 can provide overpressure protection while a pressure system 140 applies positive pressure at the head of the vessel 110 during extraction.

[0023] The reactor 100 can further incorporate at least one integrated variable-pressure solvent fdter 155 disposed within the vessel 110. The vacuum system 150 can be connected to the solvent fdter 155 via a vacuum port and pump, withdrawing a solvent-oil phase while retaining a protein-rich fraction. To promote effective phase stratification, the vessel 110 can include internal flow-directing elements 160 arranged in a serpentine configuration adjacent to the agitators 130, guiding oil and water downward toward the base of the vessel 110 while channeling solids upward. Moreover, the reactor 100 can include solvent return lines 129 fluidly connected above and below the solvent filter 155 to facilitate solvent recirculation within a closed-loop system.

[0024] For drying and recovery, the reactor 100 can integrate a heating system 170 with one or more hot air inlets 175 located at the lower portion of the vessel 110 and connected to a hot air blower. The heating system 170 can direct heated air upward through the sludge material to assist in drying the protein-rich solids. Following separation, the protein-rich fraction can be discharged through a first side-mounted outlet 180, while the oil fraction can be discharged separately through an outlet gate 190 or recirculated back to the system through the solvent return line 129. The combination of solvent injection, agitation, controlled pressure, integrated filtering, vacuum withdrawal, forced air hear, indirect heat from hot oil and sparging rings 127 for the built in clean-in-place, and heated drying in a single vessel 110 provides efficient recovery of both oil and protein in a streamlined process.

[0025] The vessel 110 is a pressure-rated chamber that forms the central body of the reactor 100. The vessel 110 can be designed to receive sludge materials and maintain controlled11134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 conditions for separation. The vessel 110 can withstand internal pressure from the pressure system 140 and vacuum forces from the vacuum system 150. In some variations, the vessel 110 may include insulated walls or jackets to assist temperature control. Further, the vessel 110 can directly interact with nearly all other components, serving as the housing where solvent injectors 120, agitators 130, flow-directing elements 160, and fdters 155 operate together.

[0026] Furthermore, the inlet 115 can allow sludge containing oil and protein to enter the vessel 110. This inlet 115 may be configured with flow control valves or diverters to regulate the amount of sludge fed into the reactor 100. In variations, the inlet 115 may be designed for continuous feed or batch loading, depending on facility needs. The inlet 115 can interact closely with the load cell processor system 500, which measures the incoming sludge mass to adjust solvent injection rates. This interaction may be achieved via sensors or electronic connections.

[0027] The solvent injectors 120 can introduce solvent into the vessel 110 to dissolve oil from the sludge material incoming from inlet 115. These injectors 120 can be fluidly connected to a solvent supply line and can deliver solvent in controlled spray patterns or streams. Variations may include adjustable nozzles, atomizing injectors, ring-shaped diffusers, or sparging rings 127. The solvent injectors 120 work in conjunction with the agitators 130 to maximize solvent contact with the sludge.

[0028] Moreover, the relief valve 125 can provide overpressure protection for the vessel 110. During operation, the pressure system 140 increases head pressure, and the relief valve 125 ensures that excessive buildup is vented safely. This prevents equipment damage and maintains system integrity. Variations of the relief valve 125 may include spring-loaded or diaphragm-controlled valves calibrated for different set pressures. The relief valve 125 interacts primarily with the vessel 110 and pressure system 140.

[0029] The sparging rings 127 are a specific form of solvent injectors 120 configured to distribute solvent evenly throughout the vessel 110. Positioned near the elevated sections of the vessel 110, sparging rings 127 create bubbles or fine jets that disperse solvent effectively into the sludge. In some embodiments, multiple sparging rings 127 may be stacked to ensure full coverage. Further, sparging rings 127 can operate in close interaction with agitators 130 and flow-directing elements 160 to enhance mixing efficiency. For example, sparging rings 127 can be located strategically to ensure that solvent is being distributed evenly throughout the flow-directing elements 160. In addition to solvent distribution, sparging rings 127 may also be utilized for clean-in-place (CIP) operations, allowing cleaning solutions to be circulated and dispersed throughout the vessel 110 without disassembly, thereby simplifying maintenance and improving sanitation.12134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001

[0030] Additionally, the reactor 100 may include solvent return lines 129 allow solvent to be reclaimed and recirculated within the system. Positioned above and / or below the solvent fdter 155, these return lines 129 connect to recirculation pump 195 that enable closed-loop solvent reclaim when oil discharge 190 is in closed position. Solvent return lines 129 can recirculate non-saturated solvent / oil mixture to the system for further processing until the solvent / oil mixture is saturated and ready for discharge via oil discharge 190. Variations may include single or dual return circuits, with optional valves for selective routing. The solvent return lines 129 interact with the vacuum system 150, solvent filter 155, and vessel 110 to minimize solvent loss and improve efficiency.

[0031] The agitators 130 are mechanical mixers located within the vessel 110. These agitators 130 macerate sludge, disrupt floc structures, and / or distribute solvent for maximum oil release. In variations, the agitators 130 may include sweep blades, paddles, or helical impellers capable of forward and reverse operation. The agitators 130 can interact strongly with the flow-directing elements 160 and solvent injectors 120, ensuring effective contact between sludge and solvent. In addition, when operated in reverse, the agitators 130 can assist in unloading the protein-rich solids from the reactor through the exit gate, reducing buildup within the vessel 110 and improving discharge efficiency.

[0032] Furthermore, reactor 100 can be controlled via the load cell processor system 500, including measuring the mass of sludge within the vessel 110. By detecting weight changes, the system 500 can automatically adjust solvent addition through the injectors 120 to achieve optimal ratios. In variations, the system 500 may be integrated into a control panel or PLC for remote monitoring. The load cell processor system 500 interacts with the inlet 115 and solvent injectors 120, creating a feedback loop for accurate dosing. Processor system 500 may control other components in reactor 100. For example, processor system may control the amount of solvent entering the vessel 110 for mixing with the sludge. Further details and elements for processor system 500 are described in FIG. 5.

[0033] The pressure system 140 can apply positive pressure at the head of the vessel 110. This pressure system 140 may include nitrogen or compressed gas inlets that ensure oil-solvent phases are forced downward through the solvent fdter 155. Variations may allow pressure ranges from 10 psi to 20 psi depending on sludge composition. The pressure system 140 can work with the relief valve 125 and vacuum system 150 to create controlled extraction conditions.

[0034] The vacuum system 150 can withdraw the solvent-oil phase from the vessel 110. This system 150 typically comprises a vacuum pump connected to a vacuum port positioned13134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 adjacent the solvent filter 155. Variations may include single-stage or multi-stage vacuum pumps for different throughput levels. The vacuum system 150 can interact with the solvent filter 155, pressure system 140, and solvent return lines 129 to facilitate phase removal and solvent recycling. In some instances, the solvent can be reclaimed and / or reintroduced to the reactor via solvent return lines 129.

[0035] The solvent filter 155 can be an integrated variable-pressure plate filter located within the vessel 110. Solvent filter 155 can retain protein-rich solids while allowing the solvent-oil phase to pass through under the influence of pressure and vacuum. Variations may include multi-layer filter plates or replaceable filter screens with different porosities. The solvent filter 155 interacts with the vacuum system 150 and solvent return lines 129 for efficient separation.

[0036] Moreover, the flow-directing elements 160 can be arranged in a serpentine configuration within the vessel 110 and serve as passive structures that manipulate fluid and solid movement during mixing and separation. These elements 160 establish pathways (e.g., tortuous pathways) that slow and redirect flow, causing oil and water phases to migrate downward toward the base of the vessel 110 while lighter protein-rich solids are directed upward. This stratification is critical for efficient separation across the solvent filter 155, as it ensures that the solvent-oil phase is concentrated in the lower portion of the vessel 110 where the vacuum system 150 can effectively withdraw it. Variations of the flow-directing elements 160 may include fixed baffles welded into the vessel 110, removable angled plates designed for specific sludge types, or adjustable channels that can be repositioned depending on operating conditions. In some embodiments, the flow-directing elements 160 may be coated or textured to reduce fouling and enhance directional guidance of phases. The flow-directing elements 160 work synergistically with the agitators 130 by shaping circulation patterns created during agitation, preventing short-circuiting of solvent flow, and ensuring more uniform contact between sludge material, solvent introduced by injectors 120, and heat delivered through hot air inlets 175. This interaction improves both oil recovery efficiency and the drying performance of the protein-rich fraction, making the flow-directing elements 160 a critical feature of the reactor 100 for maintaining consistent yields across a wide variety of sludge feedstocks.

[0037] The heating system 170 can introduce controlled heat into the vessel 110 to assist in drying the protein-rich solids. This system 170 may utilize recovered heat, radiant sources, or external heaters. In variations, the heating system 170 may include integrated controls to14134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 synchronize heating with air injection. The heating system 170 interacts with hot air inlets 175 to deliver airflow upward through the sludge.

[0038] The hot air inlets 175 are positioned at the upper portion of the vessel 110 and connected to a hot air blower. These inlets 175 inject heated air downward into the sludge material, accelerating moisture and solvent removal from protein solids. Variations may include perforated manifolds or diffusers to control airflow distribution. The hot air inlets 175 interact with the heating system 170 and vessel 110 to optimize drying efficiency. In some embodiments, an indirect heat tube may be positioned below the filter to provide supplemental heating of the sludge, further assisting in solvent evaporation and accelerating the drying of the protein-rich fraction. This indirect heating feature can work in combination with the hot air inlets 175 to reduce drying time and improve overall separation performance.

[0039] In certain embodiments, the reactor 100 may further include a waste heat conduction system 177 configured to capture and repurpose heat generated elsewhere in the process. This waste heat conduction system 177 can be coupled directly to the heating system 170, allowing exhaust heat from dryers, blowers, or solvent recovery units to be transferred back into the vessel 110. By reutilizing this recovered energy, the heating system 170 can assist in raising the temperature of the sludge material more efficiently, thereby accelerating the drying of the protein-rich fraction. This approach optimizes energy usage, lowers operational costs, and maintains consistent heating performance, while reducing the overall thermal load required from primary heat sources.

[0040] Finally, the protein discharge 180 can provide an outlet for the separated proteinrich fraction. Positioned as a side-mounted outlet, the protein discharge 180 may include a valve or gate to control ejection. In variations, the discharge 180 may feed directly into a drying conveyor or hopper. The protein discharge 180 interacts with the flow-directing elements 160, agitators 130, and heating system 170 to ensure that solids are ready for recovery and further processing.

[0041] Similarly to the protein discharge 180, the oil discharge 190 can provide a dedicated outlet for the separated oil fraction. Configured as a gated port, the oil discharge 190 allow solvent-oil phases collected by the vacuum system 150 to exit the vessel 110 for downstream polishing and solvent recovery. Variations may include bottom or side-mounted configurations depending on plant layout. The oil discharge 190 can interact with the solvent filter 155, vacuum system 150, and solvent return lines 129 to maintain efficient oil removal.

[0042] In some embodiments, reactor 100 can include a recirculation pump 195. In some embodiments, the reactor 100 may further include a sensor 185 for measuring the oil / solvent15134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 ratio within the vessel 110 to optimize extraction and solvent efficiency, as well as a liquid level sensor 187 configured to monitor and control liquid levels during operation. These sensors provide real-time data to system controls, enabling adjustments to pressure, solvent flow, or recirculation as needed.

[0043] Recirculation pump 195 can be positioned at the oil discharge 190 to enable reprocessing of the protein fraction when additional rinsing is required. The recirculation pump 195 may redirect the partially processed oil back into the vessel 110 for further solvent exposure if laboratory analysis indicates that excess oil remains in the proteins. This determination may be based on the oil-to-protein ratio of the sludge entering the reactor 100, as at a certain point the solvent becomes saturated and can no longer efficiently extract oil. By testing the residual oil content, operators can decide whether the protein fraction requires an additional solvent rinse cycle. The recirculation pump 195 thus provides a feedback mechanism to ensure that oil is effectively separated from the protein fraction, improving product quality and yield while allowing the process to adapt dynamically to sludge variability.

[0044] Furthermore, the reactor 100 may include a clean-in-process (CIP) 196 system integrated into the vessel 110 to allow internal sanitation without requiring disassembly. The CIP 196 system can utilize the sparging rings 127, which are adapted not only for solvent distribution but also for dispersing cleaning solutions uniformly throughout the vessel 110. By circulating cleaning agents through the sparging rings 127, the system can flush residue from the agitators 130, flow-directing elements 160, solvent filter 155, and vessel walls. This functionality reduces downtime between processing cycles, ensures compliance with sanitation requirements, and extends the service life of the reactor 100 by preventing buildup of organic matter or solvent residues.

[0045] FIG. 2 illustrates a method of separating oil and protein from sludge material using a reactor 100, according to an embodiment. As shown in FIG. 2, the process begins with sludge material comprising oil and protein being introduced into the pressure-rated vessel 110 through the inlet 115 (subprocess 110). Once inside, one or more solvent injectors 120, which may include sparging rings 127, distribute solvent evenly into the sludge. The load cell processor system 500 measures the mass of the incoming sludge and meters solvent addition accordingly to maintain a controlled ratio. In certain embodiments, the solvent used in the process may comprise a bio-produced solvent such as 2-methyltetrahydrofuran, bio-produced aromatic hydrocarbons, or combinations thereof, or may be formulated as a hydrocarbon mixture containing additives such as octane, heptane, or mixtures thereof. In other embodiments, the solvent may include a mixture of hexane and 2-methyltetrahydrofuran to balance extraction16134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 efficiency and sustainability. The process may further be enhanced by modifying the aqueous phase of the sludge material through pH adjustment with sodium salts, calcium salts, or phosphate salts, or by the addition of proteases such as papain or bromelain to improve protein breakdown. Reducing agents such as P-mercaptoethanol may be introduced to reduce disulfide bonds in proteins, while antioxidants including vitamin E or vitamin C can be added to preserve protein quality and reduce spoilage. Surfactants or flocculation modifiers such as sodium dodecyl sulfate, sodium dodecylbenzene sulphonate, or sodium alkyltrioxyethylene sulphate may also be incorporated to alter floc structure and enhance separation. Collectively, these modifications to the solvent or aqueous phase can increase protein digestibility, reduce biogenic amine formation, and improve amino acid recovery in the protein-rich fraction.

[0046] Agitators 130 then macerate and mix the sludge to disrupt floc structures, while internal serpentine flow-directing elements 160 (subprocess 130) guide the mixture along pathways (e.g., tortuous pathways). This interaction enhances solvent contact, breaks down aggregates, and begins separating the phases by directing oil and solvent downward and solids upward.

[0047] Once mixing and stratification are established, the pressure system 140 can apply a positive head pressure to the vessel 110 (subprocess 140). Simultaneously, the vacuum system 150 draws the solvent-oil phase through the integrated solvent filter 155 (subprocess 150), leaving a protein-rich fraction behind. This combination of applied pressure and vacuum accelerates liquid removal, ensuring that the protein solids retain less entrained oil and solvent. The early separation of oil not only increases recovery yields but also improves efficiency by preparing the protein fraction for faster downstream drying.

[0048] Following filtration, the heating system 170 introduces heated air through hot air inlets 175 at the top of the vessel 110 (subprocess 160). The downward flow of heated air removes residual moisture and solvent from the retained protein-rich solids, which are then discharged through protein outlet 180. With oil already separated, drying occurs more quickly and at lower energy cost, preserving protein quality. Meanwhile, the solvent-oil phase is separately discharged through outlet 190 for polishing and solvent recovery, completing the integrated separation process.

[0049] FIG. 3 illustrates a system 300 for extracting oil and protein from dissolved air flotation (DAF) sludge, according to an embodiment. System 300 can provide an integrated process for extracting oil and protein from dissolved air flotation (DAF) sludge. The process can begin with a decanter that removes free water, forming a concentrated cake of oil and protein. This cake can be conveyed into a reactor that serves as the core separation unit. The17134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 reactor comprises a pressure-rated vessel 110 equipped with an inlet 115 for receiving the concentrated sludge. Within the vessel 110, solvent injectors 120, which may include sparging rings 127, are fluidly connected to a solvent supply and configured to distribute solvent into the sludge. A load cell processor system 500 can then measure the incoming sludge mass and automatically meters solvent delivery. Agitators 130 and internal serpentine flow-directing elements 160 macerate and mix the sludge, disrupt floc structures, and establish flow pathways (e.g., tortuous pathways) that guide oil and solvent phases downward while solids are driven upward.

[0050] Separation is enhanced by the application of positive head pressure from the pressure system 140 and the simultaneous withdrawal of solvent-oil through the integrated variable-pressure filter 155 using the vacuum system 150. The solvent-oil fraction can be directed through solvent recovery subsystems that include filtration skids, cold traps, and falling film evaporators (items 21-23 in FIG. 4) to reclaim solvent and deliver a concentrated oil phase. This oil fraction can be then transferred to an oil polishing subsystem, such as a centrifuge system with preheater (item 26), to remove fine impurities and residual water, and yield a purified oil product suitable for storage in tanks (items 25 and 33).

[0051] Meanwhile, the retained protein fraction inside the vessel 110 undergoes drying by the heating system 170, which includes hot air inlets 175 coupled to a hot air blower (item 38). Heated air falls through the protein-rich solids, removing residual moisture and solvent. The heated air may include the optional indirect heat. The partially dried solids are discharged through the protein discharge 180 and conveyed to a drying subsystem, such as enclosed conveyors and paddle dryers (items 18 and 19), which complete the removal of residual solvent. The result is a stable protein-rich product suitable for storage in a protein hopper (item 29). By integrating solvent recovery, oil polishing, and protein drying into a closed-loop design, system 300 ensures efficient valorization of DAF sludge into high-value oil and protein outputs with minimized energy consumption and solvent losses.

[0052] FIG. 4 illustrates an equipment list corresponding to a system 300 for extracting oil and protein from dissolved air flotation (DAF) sludge, according to an embodiment. Figure 4 provides an equipment list corresponding to system 300 for extracting oil and protein from dissolved air flotation (DAF) sludge. System 300 may include preliminary handling components such as a CIP / pumping station, wastewater disposal systems, and storage tanks for both sludge and solvents. Solvent management is supported by dedicated solvent storage tanks, solvent recovery skids, chillers, and cold traps, ensuring that solvent introduced into the reactor18134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 can be efficiently reclaimed and reused. These components establish the foundation for safe material handling, solvent containment, and process sanitation within the integrated system.

[0053] The separation and recovery stages of system 300 may further include custom reactors (items 16, 35), filtration skids (item 32), centrifuge systems with preheaters (item 26), and enclosed conveyors (items 18, 19, 28) that move the protein-rich fraction between processing stages. Drying is facilitated by paddle dryers and hot air blowers (item 38), while solvent evaporation is handled by falling film evaporators (items 22, 23). Oil storage tanks, buffer tanks, and flammable storage cabinets provide safe intermediate storage of recovered fractions. Control and monitoring of the entire system are achieved through master control panels (item 36), load cell assemblies (item 27), pumps, valves, and transmitters that regulate flow, pressure, and temperature throughout system 300.

[0054] Together, these elements demonstrate how system 300 integrates mechanical, thermal, and chemical processes into a unified plant. The equipment list of Figure 4 highlights the modular nature of the system, where each unit — from solvent recovery to oil polishing and protein drying — contributes to efficient valorization of DAF sludge into purified oil and stable protein products.

[0055] FIG. 5 illustrates an example load cell processing system 500 that may be used as controller / processor 510. System 500 may comprise one or more processors 510. Processor(s) 510 may comprise a central processing unit (CPU). Additional processors may be provided, such as a graphics processing unit (GPU), an auxiliary processor to manage input / output, an auxiliary processor to perform floating-point mathematical operations, a special-purpose microprocessor having an architecture suitable for fast execution of signal-processing algorithms (e.g., digital-signal processor), a subordinate processor (e.g., back-end processor), an additional microprocessor or controller for dual or multiple processor systems, and / or a coprocessor. Such auxiliary processors may be discrete processors or may be integrated with a main processor 510. Examples of processors which may be used with system 500 include, without limitation, any of the processors (e.g., Pentium™, Core i7™, Xeon™, etc.) available from Intel Corporation of Santa Clara, California, any of the processors available from Advanced Micro Devices, Incorporated (AMD) of Santa Clara, California, any of the processors (e.g., A series, M series, etc.) available from Apple Inc. of Cupertino, any of the processors (e.g., Exynos™) available from Samsung Electronics Co., Ltd., of Seoul, South Korea, any of the processors available from NXP Semiconductors N.V. of Eindhoven, Netherlands, and / or the like.19134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001

[0056] Processor 510 may be connected to a communication bus 505. Communication bus 505 may include a data channel for facilitating information transfer between storage and other peripheral components of system 500. Furthermore, communication bus 505 may provide a set of signals used for communication with processor 510, including a data bus, address bus, and / or control bus (not shown). Communication bus 505 may comprise any standard or nonstandard bus architecture such as, for example, bus architectures compliant with industry standard architecture (ISA), extended industry standard architecture (EISA), Micro Channel Architecture (MCA), peripheral component interconnect (PCI) local bus, standards promulgated by the Institute of Electrical and Electronics Engineers (IEEE) including IEEE 488 general-purpose interface bus (GPIB), IEEE 696 / S-100, and / or the like.

[0057] System 500 may comprise main memory 515. Main memory 515 provides storage of instructions and data for programs executing on processor 510, such as one or more of the functions and / or modules discussed herein. It should be understood that programs stored in the memory and executed by processor 510 may be written and / or compiled according to any suitable language, including without limitation C / C++, Java, JavaScript, Perl, Python, Visual Basic, .NET, and the like. Main memory 515 is typically semiconductor-based memory such as dynamic random access memory (DRAM) and / or static random access memory (SRAM). Other semiconductor-based memory types include, for example, synchronous dynamic random access memory (SDRAM), Rambus dynamic random access memory (RDRAM), ferroelectric random access memory (FRAM), and the like, including read only memory (ROM).

[0058] System 500 may comprise secondary memory 520. Secondary memory 520 is a non-transitory computer-readable medium having computer-executable code and / or other data (e.g., any of the software disclosed herein) stored thereon. In this description, the term “computer-readable medium” is used to refer to any non-transitory computer-readable storage media used to provide computer-executable code and / or other data to or within system 500. The computer software stored on secondary memory 520 is read into main memory 415 for execution by processor 510. Secondary memory 520 may include, for example, semiconductor-based memory, such as programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable read-only memory (EEPROM), and flash memory (block-oriented memory similar to EEPROM).

[0059] System 500 may comprise an input / output (I / O) interface 535. I / O interface 535 provides an interface between one or more components of system 500 and one or more input and / or output devices. For example, sensors may be connected to I / O interface 535 as an input, and may be connected to I / O interface 535 and / or display screen as an output.20134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001

[0060] System 500 may comprise a communication interface 540. Communication interface 540 allows software to be transferred between system 500 and external devices (e.g., sensor), networks, or other information sources. For example, computer-executable code and / or data may be transferred to system 500, over one or more networks, from a network server via communication interface 540. Examples of communication interface 540 include a built-in network adapter, network interface card (NIC), Personal Computer Memory Card International Association (PCMCIA) network card, card bus network adapter, wireless network adapter, Universal Serial Bus (USB) network adapter, modem, a wireless data card, a communications port, an infrared interface, an IEEE 1394 fire-wire, and any other device capable of interfacing system 500 with a network or another computing device. Communication interface 540 preferably implements industry-promulgated protocol standards, such as Ethernet IEEE 402 standards, Fiber Channel, digital subscriber line (DSL), asynchronous digital subscriber line (ADSL), frame relay, asynchronous transfer mode (ATM), integrated digital services network (ISDN), personal communications services (PCS), transmission control protocol / Intemet protocol (TCP / IP), serial line Internet protocol / point to point protocol (SLIP / PPP), and so on, but may also implement customized or non-standard interface protocols as well.

[0061] Software transferred via communication interface 540 is generally in the form of electrical communication signals 555. These signals 555 may be provided to communication interface 540 via a communication channel 450 between communication interface 540 and an external system 545. In an embodiment, communication channel 550 may be a wired or wireless network, or any variety of other communication links. Communication channel 550 carries signals 555 and can be implemented using a variety of wired or wireless communication means including wire or cable, fiber optics, conventional phone line, cellular phone link, wireless data communication link, radio frequency (“RF”) link, or infrared link, just to name a few.

[0062] Computer-executable code is stored in main memory 515 and / or secondary memory520. Computer-executable code can also be received from an external system 545 via communication interface 540 and stored in main memory 515 and / or secondary memory 520. Such computer-executable code, when executed by processor(s) 510, enable system 500 to perform the various functions of the disclosed embodiments as described elsewhere herein.21134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001Industrial Applicability

[0063] Industrial animal processing and food production facilities generate large volumes of dissolved air flotation (DAF) sludge containing water, oils, and proteins. Traditionally, this sludge has been handled by bulk drying, which is inefficient, energy intensive, and damaging to protein quality. High drying temperatures required to evaporate water and liquefy fats denature proteins, diminishing their value for use in feed, food, or specialty products. In addition, conventional extraction equipment is not designed for high-solid sludge streams and often fails to achieve high yields of recoverable oils and digestible proteins. These limitations reduce both the economic value and sustainability of current sludge management practices. Any source of sludge containing proteins and / or oils is contemplated for use with the invention methods and systems, such as from the dairy and cheese industry, and the like.

[0064] Accordingly, a reactor 100 for separating oil and protein from a sludge material is disclosed. The reactor 100 comprises a pressure-rated vessel 110 having an inlet 115 for receiving a sludge material comprising oil and protein; one or more solvent injectors 120 fluidly coupled to a solvent supply line, the injectors 120 configured to distribute a solvent into the sludge material within the vessel 110; an agitator 130 configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact; a load cell processing system 500 coupled to the vessel 110, the load cell processing system 500 configured to measure the mass of sludge material and meter solvent addition based on the measured mass; a pressure system 140 configured to apply a positive pressure at the head of the vessel 110; at least one integrated variable-pressure filter 155 plate disposed within the vessel 110; a vacuum system 150 including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter 155 while retaining a protein-rich solid fraction within the vessel 110; a set of internal flow-directing elements 160 arranged in a serpentine configuration within the vessel 110, the flow-directing elements 160 positioned adjacent the agitator 130 and operable to guide oil and water downward toward the bottom of the vessel 110 and solids to the top of the vessel 110; a heating system 170 including one or more heated-air inlets 175 disposed at a lower portion of the vessel 110 and connected to a hot air blower, the heating system 170 operable to introduce heated air upwardly through the sludge material to assist in drying the protein-rich solid fraction; a first discharge mechanism 180 including a side- mounted outlet operable to eject the protein-rich fraction following separation; and a second discharge mechanism 190 including a gate at the vessel 110 operable to eject an oil fraction following separation.22134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001

[0065] A reactor of this type offers significant industrial benefits by increasing recovery yields, reducing energy consumption, and improving protein digestibility. For example, in rendering and feed production, the integrated solvent extraction and bottom-up drying system produces higher-quality proteins suitable for animal nutrition, while simultaneously generating purified oils for use as biofuels, feedstock, or industrial inputs. By incorporating solvent recycling, flow-directing elements, and waste-heat integration, the reactor provides a scalable and sustainable solution to valorize what is otherwise treated as waste. The invention is therefore applicable across multiple sectors, including food processing, animal feed, renewable energy, and environmental management, supporting circular economy practices and enhancing profitability for industrial operators.

[0066] It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. Aspects described in connection with one embodiment are intended to be able to be used with the other embodiments. Any explanation in connection with one embodiment applies to similar features of the other embodiments, and elements of multiple embodiments can be combined to form other embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

[0067] The preceding detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. The described embodiments are not limited to usage in conjunction with a particular type of system. Hence, although the present embodiments are, for convenience of explanation, depicted and described as being implemented in a reactor for separating oil and protein from a sludge material, it will be appreciated that it can be implemented in various other types of reactor systems, and in various other systems and environments. Furthermore, there is no intention to be bound by any theory presented in any preceding section. It is also understood that the illustrations may include exaggerated dimensions and graphical representation to better illustrate the referenced items shown, and are not considered limiting unless expressly stated as such.23134545-0001PV01 / 9957291.7

Claims

Attorney Docket No.: 134545-0001W001CLAIMS1. A reactor for separating oil and protein from a sludge material, comprising: a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein; one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel; an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact; a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass; a pressure system configured to apply a positive pressure at the head of the vessel; at least one integrated variable-pressure filter plate disposed within the vessel; a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter while retaining a proteinrich solid fraction within the vessel; a set of internal flow-directing elements arranged within the vessel, the flowdirecting elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel; a heating system including one or more heated-air inlets disposed at an upper portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-rich solid fraction; a first discharge mechanism including an outlet operable to eject a protein-rich fraction following separation; and a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation.

2. The reactor of claim 1, wherein the internal flow-directing elements are in a serpentine configuration.

3. The reactor of claims 1-2, wherein the agitator comprises a top-entry sweep blade configured for variable speed operation to macerate the sludge material.24134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W0014. The reactor of claims 1-3, wherein the agitator comprises a sweep blade operable in forward and reverse rotation to selectively mix sludge during extraction and assist in discharge of solids.

5. The reactor of claims 1-4, wherein the solvent injectors comprise sparging rings.

6. The reactor of claims 1 -5 , wherein the solvent inj ectors are configured to deliver solvent in a controlled ratio of sludge-to-solvent in a range of 1:3 to 3: 1 by weight.

7. The reactor of claims 1-6, wherein the vessel is equipped with fixed and moving rakes positioned adjacent the filter to create solvent pathways through the sludge material.

8. The reactor of claims 1-7, wherein the pressure system is configured to apply a head pressure in a range of 10 psi to 20 psi.

9. The reactor of claims 1-8, wherein the pressure system further comprises a nitrogen or compressed gas inlet to supply the positive pressure.

10. The reactor of claims 1-9, wherein the vessel includes solvent return lines positioned above and below the integrated filter, the return lines in fluid communication with a pump that circulates solvent through the vessel in a closed-loop path.

11. The reactor of claims 1-10, wherein the vessel is configured with clean-in-place (CIP) sanitation features for in-process cleaning.

12. The reactor of claims 1-11, wherein the solvent comprises at least one of hexane, pentane, toluene, xylene, or 2-methyltetrahydrofuran.

13. The reactor of claims 1-12, wherein the load cell processing system is configured to tare the sludge material and automatically meter solvent addition based on measured mass.

14. The reactor of claims 1-13, wherein the heating system further comprises a radiant heat source, the radiant heat source configured to reclaim exhaust heat from a dryer and direct the reclaimed heat into the lower portion of the vessel to assist in heating and drying the protein-rich fraction.

15. A method of separating oil and protein from sludge material using a reactor, comprising: introducing a sludge material comprising oil and protein into a pressure-rated vessel; distributing a solvent into the sludge material within the vessel using one or more solvent injectors;25134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 measuring the mass of sludge material with a load cell processing system and metering the solvent addition based on the measured mass; agitating the sludge material to disrupt floc structures and enhance contact between the solvent and the oil, wherein the agitation is assisted by internal flow-directing elements within the vessel that guide the sludge material along pathways to enhance mixing and phase separation; applying a positive pressure to a headspace of the vessel and a vacuum connected to the fdter to draw a solvent-oil phase through an integrated filter while retaining a protein-rich solid fraction within the vessel; introducing heated air through one or more inlets at an upper portion of the vessel to assist in drying the protein-rich solid fraction; and discharging a protein-rich fraction from the vessel for drying and storage.

16. The method of claim 15, wherein the agitation is performed with a top-entry sweep blade.

17. The method of claims 15-16, wherein the sweep blade is operated in forward and reverse rotation to enhance mixing and assist in cake discharge.

18. The method of claims 15-17, wherein the pressure is applied by introducing nitrogen or compressed gas into the headspace of the vessel.

19. The method of claims 15-18, further comprising guiding the solvent-oil phase downward toward the integrated filter before applying the positive pressure.

20. The method of claims 19, further comprising initiating, before applying the positive pressure, upward separation of solids by directing flow through internal serpentine flow-directing elements within the vessel.

21. The method of claim 15-20, further comprising: recovering, based on applying the positive pressure, the solvent-oil phase for downstream solvent recovery and oil polishing; and directing heated air from a lower portion of the vessel upwardly through the sludge material to assist in drying a protein-rich fraction before discharging the proteinrich fraction from the vessel for storage.

22. The method of claim 15-21, wherein the solvent comprises a bio-produced solvent selected from 2 -methyltetrahydrofuran, bio-produced aromatic hydrocarbons, or combinations thereof.26134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W00123. The method of claims 15-22, wherein the solvent comprises a hydrocarbon mixture containing at least one additive selected from octane, heptane, or combinations thereof.

24. The method of claims 15-23, wherein the solvent comprises a mixture of hexane and 2-methyltetrahydrofuran.

25. The method of claims 15-24, further comprising modifying an aqueous phase of the sludge material by adjusting pH with at least one of a sodium salt, calcium salt, or phosphate salt.

26. The method of claims 15-25, further comprising adding at least one protease selected from papain, bromelain, or combinations thereof to the sludge material.

27. The method of claims 15-26, further comprising adding a reducing agent selected from p-mercaptoethanol or equivalents to the sludge material to reduce disulfide bonds in proteins.

28. The method of claims 15-27, further comprising adding an antioxidant selected from vitamin E, vitamin C, or combinations thereof to the sludge material.

29. The method of claims 15-28, further comprising adding a surfactant or flocculation modifier selected from sodium dodecyl sulfate, sodium dodecylbenzene sulphonate, sodium alkyltrioxyethylene sulphate, or combinations thereof to the sludge material.

30. The method of claims 15-29, wherein the aqueous phase modification increases protein digestibility, reduces biogenic amine formation, or enhances amino acid recovery in the protein-rich fraction.

31. A system for extracting oil and protein from dissolved air flotation (DAF) sludge, comprising: a decanter configured to remove water from the sludge to form a concentrated cake of oil and protein; a reactor configured to separate oil from protein within the concentrated cake, including a pressure-rated vessel having an inlet for receiving a sludge material comprising oil and protein, one or more solvent injectors fluidly coupled to a solvent supply line, the injectors configured to distribute a solvent into the sludge material within the vessel,27134545-0001PV01 / 9957291.7Attorney Docket No.: 134545-0001W001 an agitator configured to macerate and mix the sludge material to disrupt floc structures and enhance solvent contact, a load cell processing system coupled to the vessel, the load cell processing system configured to measure the mass of sludge material and meter solvent addition based on the measured mass, a pressure system configured to apply a positive pressure at the head of the vessel, at least one integrated variable-pressure filter plate disposed within the vessel, a vacuum system including a vacuum port coupled to a vacuum pump configured to withdraw a solvent-oil phase through the filter while retaining a protein-rich solid fraction within the vessel, a set of internal flow-directing elements arranged within the vessel, the flow-directing elements positioned adjacent the agitator and operable to guide oil and water downward toward the bottom of the vessel and solids to the top of the vessel, a heating system including one or more heated-air inlets disposed at an upper portion of the vessel and connected to a hot air blower, the heating system operable to introduce heated air downwardly through the sludge material to assist in drying the protein-rich solid fraction, a first discharge mechanism including an outlet operable to eject a dry protein-rich fraction following separation, and a second discharge mechanism including a gate at the vessel operable to eject an oil fraction following separation; a solvent recovery subsystem in fluid communication with the reactor and configured to recover solvent from the solvent-oil phase; and an oil polishing subsystem configured to receive the solvent-oil phase and separate a purified oil product.

32. The system of claim 31, wherein the internal flow-directing elements are in a serpentine configuration.

33. The system of claims 31-32, wherein the outlet is side-mounted.

34. The reactor of claims 1-14, wherein the outlet is side-mounted.28134545-0001PV01 / 9957291.7

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