System and method for treatment of organic matter

Abstract

Machines, processes, and methods in relation to processing of waste, in particular food or organic waste, are provided. Some embodiments described herein include: a drum to receive waste; mixing blades to break down waste; a heated air supply subsystem including an air heater, a fan, and a first air supply line to supply a first heated air stream into the drum; an ion generator to receive an inlet air stream and generate an ionised air stream at an outlet of the ion generator; a coupling conduit coupled at one end to the outlet of the ion generator and coupled at an opposite end to an ionised air inlet into the drum to supply the ionised air stream to the drum; wherein the first air supply line and the coupling conduit are configured so that mixing of the ionised air stream and the first heated air stream occurs downstream of each of the ion generator and the air heater.

Description

"System and method for treatment of organic matter" Technical Field

[0001] The present disclosure relates to systems, methods, machinery, and processes for treatment of organic matter, such as organic waste. In particular, embodiments relate to systems and methods for treatment of organic matter, such as decomposition of food waste.Background

[0002] Food waste is a problem in many areas. Not only is there a cost associated with unused or wasted food, there can be a significant financial or environmental impact associated with such waste. Many hotels, restaurants and supermarkets or produce markets must deal with disposal of food waste on a daily basis. Similarly, food processing facilities such as seafood, poultry or meat processing plants, fruit and vegetable processing facilities may also produce organic animal and / or vegetable waste that must be disposed of. This may involve temporary storage of the waste on or near the premises, which takes up space, can result in unpleasant odours and may attract vermin. Alternatively, the food waste can be transported away from the premises, but this represents an additional business cost and shifts the task of disposal to another party.

[0003] Some machines exist that can process food waste. However, some such machines process the food waste by physically breaking down the food waste while heating it in order to “cook” or denature it. Such heating is typically done at high temperatures in excess of 100 degrees Celsius (°C). Such heating requires a lot of energy and the power consumption of such machines can represent a significant cost. Additionally, such machines can take a relatively long time, such as days, to process the food waste into a form that can be disposed of effectively.

[0004] It is desired to address or ameliorate one or more shortcomings or disadvantages associated with prior techniques for food waste processing, or to at least provide a useful alternative thereto.

[0005] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0006] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.Summary

[0007] Some embodiments relate to an organic waste processing system, the system may include: a drum defining a space to receive waste to be processed; a mixer having mixing blades rotatable in the drum to break down waste in the drum; a motor to drive rotation of the mixer; an inlet hatch to receive the waste into the drum; an outlet hatch for removal of processed waste residue from the drum; a heated air supply subsystem including an air heater, a fan and a first air supply line to supply a first heated air stream into the drum; an ion generator to receive an inlet air stream and generate an ionised air stream at an outlet of the ion generator; a coupling conduit coupled at one end to the outlet of the ion generator and coupled at an opposite end to an ionised air inlet into the drum to supply the ionised air stream to the space; wherein the first air supply line and the coupling conduit are configured so that mixing of the ionised air stream and the first heated air stream occurs downstream of each of the ion generator and the air heater.

[0008] The first air supply line and the coupling conduit may be configured so that mixing of the ionised air stream and the first heated air stream occurs only in the drum. The first air supply line may be configured to provide heat to the ionised air stream.

[0009] The heating subsystem may include a heat exchanger in the first air supply line and the heat exchanger may be configured to provide heat to the coupling conduit, when the first heated air stream passes through the heat exchanger to heat the ionised air stream.

[0010] The coupling conduit may pass through the heat exchanger. The coupling conduit may be configured to supply the ionised air stream directly from the ion generator into the drum via the ionised air inlet. The first air supply line may be configured to supply the first heated air supply stream into the drum via a first heated air inlet in a wall of the drum.

[0011] The ionised air inlet may be disposed in a first end wall of the drum. The ion generator may be disposed close to an outside of the first end wall.

[0012] The mixer may include a mixing shaft supported by the first end wall and by an opposite second end wall of the drum, wherein the ionised air inlet is above a level of the mixing shaft.

[0013] The coupling conduit may configured to have a single bend between the outlet of the ion generator and the ionised air inlet. The ion generator may be configured to provide the ionised air stream with a concentration of greater than zero and less than or equal to 200 million negative ions per cubic centimetre at the outlet of the ion generator.

[0014] The fan may be a first fan and the heating subsystem may include a second fan and a second air supply line for supplying a second heated air stream into the drum. The second air supply line may be coupled to the drum to supply the second heated air stream into the drum at at least one different inlet location to the first heated air stream.The second air supply line may be configured to split the second heated air stream into multiple sub-streams and to provide the multiple sub-streams into the drum at spaced locations.

[0015] The outlet hatch may be in an end wall of the drum and / or is positioned above a level of a mixing shaft of the mixer. The system may further include a controller to control operation of the motor, the heated air supply subsystem, and the ion generator.

[0016] Some embodiments relate to an organic waste processing system, the system may include: a static drum defining an interior space to receive organic waste to be processed; a mixer having mixing blades to rotate in the space to break down waste in the drum; a motor to drive rotation of the mixer; an inlet hatch to receive the waste into the drum; an outlet hatch to allow disgorgement of processed waste residue; an air heating subsystem to supply heated air into to drum; an ion generator to generate an ionised air stream into the drum; and a drum heating subsystem to heat a lower part of a drum wall of the drum, the drum heating subsystem including a first heater on the drum wall and a second heater on the drum wall that is spaced from the first heater, wherein the first heater and the second heater are independently controllable; a controller to control operation of the motor, the air heating subsystem, the ion generator, and the drum heating subsystem.

[0017] The mixer may include an axial mixing shaft that defines a longitudinal axis, wherein the first heater and the second heater may be configured to extend along an outside of the drum wall. The first heater and the second heater may extend in a longitudinal direction. The first heater and the second heater may be circumferentially spaced from each other along the drum wall.

[0018] The inlet hatch may be disposed on a forward side of the drum and wherein the first heater is disposed on the drum wall on or forward of a vertical line extending down from the mixing shaft and the second heater is disposed on the drum wall rearward of the vertical line.

[0019] The drum heating subsystem may include between three and six heaters, each of which is independently controllable by the controller. The controller may be configured to alter temperature set points for each of the heaters over time during a processing operation that includes rotation of the mixer in the drum.

[0020] The heaters may be asymmetrically circumferentially spaced across the lower part of the drum wall. The first heater and the second heater may each include an electrical heating element. The first heater and the second heater may each include a fluid heating element. The first heater and the second heater may each include a base block to support the electrical heating element and the fluid heating element.

[0021] The base block may include a material having high thermal conductivity and / or the base block defines a non-planar engagement surface to engage with the drum wall and / or the base block extends between about 70% to about 95% of a length of the respective heater.

[0022] The first heater and the second heater may each be coupled to the drum wall with a paste having a high thermal conductivity. The first heater and second heater may each extend along between about 50% and about 90% of a longitudinal length of the drum wall. Each of the heaters may be circumferentially spaced from another of the heaters by a minimum distance of 2 cm. The first heater and the second heater may be longitudinally offset from each other along the drum wall. The system may further include clamps to clamp the first heater and the second heater to the drum wall. The static drum may be a cylindrical drum.

[0023] The controller may control the drum heating subsystem and the air heating subsystem to bring the temperature of waste in the drum to a temperature in the range of 50 degrees to 80 degrees, optionally in the range of 55 degrees to 75 degrees, optionally in the range of 60 degrees to 70 degrees.Brief Description of Drawings

[0024] Embodiments of the present disclosure will now be described by way of nonlimiting example only with reference to the accompanying drawings, in which:

[0025] Figure l is a block diagram of a distributed waste processing system comprising one or more waste processing machines, according to some embodiments;

[0026] Figure l is a block diagram of a power supply arrangement of a waste processing machine, according to some embodiments;

[0027] Figure 3 is a block diagram of a control and communication arrangement of a waste processing machine, according to some embodiments;

[0028] Figure 4 is a block diagram of an air flow system of a waste processing machine, according to some embodiments;

[0029] Figure 5A is a perspective view of a waste processing machine shown without the waste loader system, according to some embodiments;

[0030] Figure 5B is a side view of the waste processing machine of Figure 5A;

[0031] Figure 5C is a front view of the waste processing machine of Figure 5 A;

[0032] Figure 5D is a top view of the waste processing machine of Figure 5 A;

[0033] Figure 6 is perspective view of a portion of the waste processing machine, according to some embodiments;

[0034] Figure 7A shows an inside view of a drum wall of the waste processing machine, according to some embodiments;

[0035] Figure 7B shows an outside view of a drum wall of the waste processing machine, according to some embodiments;

[0036] Figure 7C shows an outside view of a drum wall including an outlet hatch, according to some embodiments;

[0037] Figure 8A shows a front view of a drum of the waste processing machine including a plurality of drum heaters, according to some embodiments;

[0038] Figure 8B shows a rear view of the drum of Figure 8 A including the plurality of drum heaters, according to some embodiments;

[0039] Figure 8C shows a bottom view of the drum of Figure 8A including the plurality of drum heaters, according to some embodiments;

[0040] Figure 9A shows a top view of a drum heater, according to some embodiments;

[0041] Figure 9B shows a side view of the drum heater of Figure 9A, according to some embodiments;

[0042] Figure 9C shows an end view of the drum heater of Figure 9A, according to some embodiments;

[0043] Figure 10 shows a side view of a portion of an alternate waste processing machine including a plurality of drum heaters, according to some embodiments;

[0044] Figure 11A shows a perspective view of an ion generator, according to some embodiments;

[0045] Figure 11B shows an end view of the ion generator of Figure 11 A, according to some embodiments;

[0046] Figure 11C shows an end view of an example mounting assembly including the ionising elements of the ion generator, according to some embodiments; and

[0047] Figure 11D shows a perspective view of the mounting assembly including ionising elements of the ion generator, according to some embodiments.Description of Embodiments

[0048] Embodiments of the present disclosure generally relate to systems, methods, machinery, and processes related to organic matter processing, and in particular to decomposition of food waste, for example. Specific embodiments employ a mixing element, such as a shaft comprising multiple mixing or processing blades projecting therefrom, that rotates within a processing chamber within which the food waste is deposited. Such embodiments break down the food waste over time by the mechanical action of the mixing element in combination with a source of heated air. In some embodiments, the heated air is heated to have a temperature of ambient to about 200°C. In some embodiments, there is provided a source of air rich in ionised oxygen, such as radicalised oxygen, for example.

[0049] Embodiments also relate to food waste processing systems that allow usage tracking of a waste processing machine. Such embodiments include a reader disposed on or adjacent the food waste processing machine or a waste loader and arranged to read a unique identifier of a machine-readable element on or carried by a waste loading bin used to load waste into the waste processing machine.

[0050] Waste processing machines described herein are suited for organic (including food) waste processing on-site with the source of the waste. For example, such machines can be located in a hotel premises, near a food court, or at a chicken farm, fishery, or abattoir premises, for example, so that there is no immediate need to transport the organic waste to another site for disposal. Waste processing machines described herein are configured to process the waste over a time less than 24 hours to reduce the weight and volume of the waste and produce a waste residue that isrelatively dry and easy to dispose of. Waste processing machines of greater capacity may be configured to process the waste over a time of between about 24 hours and about 48 hours to reduce the weight and volume of the waste and produce a waste residue that is relatively dry and easy to dispose of. The volume may be reduced by at least 50 to 60% and up to about 80% of the original volume of the organic material loaded into the machine, for example. The resultant residue is free of noxious or string odours and can be stored for long periods of time in dry environments without rotting.

[0051] Described embodiments can help to: reduce costs associated with food and waste management; reduce contributions to greenhouse gas emissions; improve site cleanliness and safety through the removal or avoidance of rotting waste which can attract vermin and insects; reduce odours associated with food and organic waste storage; and reduce the quantity of collection bins required on site.

[0052] Embodiments described herein are improvements and modifications upon embodiments described in International Patent Publication no. WO2019 / 169425, the entire contents of which is hereby incorporated by reference.

[0053] Referring to Figure 1, there is shown a block diagram of a distributed waste processing system 100. The distributed waste processing system 100 includes a series of waste processing machines 110 in communication over a network 170.

[0054] Network 170 may comprise one or more local area networks or wide area networks that facilitate communication between elements of Figure 1. For example, according to some embodiments, network 170 may include the internet. However, network 170 may comprise at least a portion of any one or more networks having one or more nodes that transmit, receive, forward, generate, buffer, store, route, switch, process, or a combination thereof, etc. one or more messages, packets, signals, some combination thereof, or so forth. Network 170 may include, for example, one or more of: a wireless network, a wired network, an internet, an intranet, a public network, a packet-switched network, a circuit-switched network, an ad hoc network, an infrastructure network, a public-switched telephone network (PSTN), a cable network,a cellular network, a satellite network, a fibre-optic network, or some combination thereof.

[0055] The network 170 communicates with a server system 150 and a database 160. Data from the waste processing machines 110 may be sent to the server system 150 over the network 170 to be stored on the database 160. One or more client computing devices 140 may access the database 160 and server system 150 through the network 170 to retrieve information stored by the waste processing machines 110. This stored information in database 160 may include service logs, performance statistics, real-time sensor data, or other operational information sent by the waste processing machines 110, for example.

[0056] The client devices 140 may also send instructions to the waste processing machines 110 via the network 170 to start or stop waste processing machine processes, specify threshold values, control operational parameters, or control other functions of the waste processing machines 110, for example. For this purpose, the one or more client devices 140 may store and execute application software configured to display operational information of one or more of the waste processing machines 110 and to facilitate interaction of a supervisor with one or more of the waste processing machines 110.

[0057] Embodiments of the waste processing machines 110 are now described in further detail, with reference to various drawings. For example, Figure 2 is a block diagram of power-consuming components 200 of a waste processing machine 110, illustrating a power-supply configuration for the waste processing machine 110.Generally, the power-consuming components 200 all draw power from a power supply 280 in the waste processing machine 110. Power supply 280 draws on an external 3-phase AC power supply, such as 240V or 110V mains power, for example.

[0058] Power is supplied by power supply 280 through standard insulated electrical cabling throughout the waste processing machine 110, sufficient to resist operating temperatures of the waste processing machine 110. In some embodiments, the powersupply 280 may be supplemented or configured to run from generators, power storage devices such as batteries, solar panels, or other suitable electrical power supply means. In some embodiments, power may be supplied directly from the power supply 280 to certain ones of the system components 200. In other embodiments, a power hub or bus 330 may be supplied. In some embodiments, power is supplied to smaller components, such as drum or chute sensors, through a hub or bus 330 in communication with the controller 210.

[0059] Each waste processing machine 110 comprises a controller 210, an air flow system 220 with an ioniser and at least one air heater, a waste processing drum 230 with drum weight sensors 235, a motor 240 to drive a mixing shaft in the drum 230, an outlet chute system 250, a waste loader system 260, and a human-machine interface (HMI) 270. In some embodiments, waste processing machine 110 further comprises a drum heating system 290. The controller 210 generally controls operation of or receives output signals from the other power-consuming components 200 of the waste processing machine 110. The controller 210 directly or indirectly controls supply of power to the power-consuming components 200 from the power supply 280.

[0060] Figure 3 is a block diagram illustrating data or signal communication and / or control between computing and sensor components 300 of the distributed waste processing system 100. Controller 210 may be or comprise a computing device on board the waste processing machine 110 that communicates with the various components within the waste processing machine 110 to receive information and pass instructions. The controller 210 comprises at least one computer processor 212 and memory 214 (storing program instructions executable by the processor 212) that in combination allow the execution of one or more control modules 215 by the controller 210 to exert operational monitoring and control of the operation of the waste processing machine 110.

[0061] In some embodiments, controller 210 may be implemented using a suitable programmable logic controller, such as a Siemens™ SIMATIC S7-1200. The HMI 270 provides an interface for an onsite operator to access the data stored on-board thecontroller 210 and input control instructions via the controller 210 for exerting operational control over one or more operations of the waste processing machine. In some embodiments, the HMI 270 may be implemented using a Weintek™ MT8090XE HMI, for example.

[0062] The controller 210 also communicates with the server system 150 through a network 170. Although Figure 3 illustrates a particular arrangement of the waste processing machine 110, system server 150, client device 140, and network 170, this disclosure contemplates any suitable arrangement of waste processing machine 110, system server 150, client device 140, and network 170. As an example and not by way of limitation, one or more of client devices 140, system server 150, and waste processing machine 110 may be connected to each other directly, bypassing network 170. As another example, controller 110 and system server 150 may be physically or logically co-located with each other in whole or in part.

[0063] The server system 150 comprises at least one computer processor 152 and memory 154 (local and / or remote from processor 152) that stores executable program instructions for execution by processor 152. The executable program instructions stored in memory 154, when executed, function as software modules implementing a web application 342 and data collection agents 344. The web application 342 provides dashboards to display and report on status information of one or more waste processing machines 110 in the distributed waste processing system 100. In some embodiments, the web application 342 also allows an administrator to remotely administer waste processing machines 110 by passing on commands from an administrator to the controller 210 of a specific waste processing machine 110. The instructions may include instructions to stop in an emergency, instructions to offload processed waste, or instructions to load a positioned waste bin, for example. Most of the operations of individual waste processing machines 110 may be automated so as to allow the distributed waste processing system 100 to function as autonomously as possible. Controls through the system server 150 may be used for proactive monitoring or for responding to unexpected machine conditions. The web application 342 may be implemented using an ASP.NET web application framework, for example.

[0064] Controller 210 comprises or cooperates with a communication interface 320 that allows the controller 210 to pass information to and receive information from the network 170. In some embodiments, the communication interface 320 may be implemented using a 3G cellular router and a fixed public IP SIM card, for example. In other embodiments, the communication interface 320 may be implemented using a wired router connected to a wide area network. The system server 150 also comprises a communication interface 335 that may be implemented in some embodiments using a wired router in connection with a wide area network. Both the communication interfaces 320 and 335 may be implemented using other suitable alternative wired or wireless technologies.

[0065] Within the waste processing machine 110, a communication bus 330 may be implemented to allow the transfer of data and commands between the various components of the waste processing machine 110 and the controller 210. In some embodiments, some components of the waste processing machine 110 may communicate wirelessly with the controller 210 and may not rely on the communication bus 330 to receive or transmit signals.

[0066] Voltage inverters may be installed in the waste processing machine 110 to supply a specifically required AC voltage to system components. Such components may include the motor 240, one or more intake fans 420, and one or more exhaust fans 450. The voltage inverters may be configurable to cater for different energy requirements, with different configurations available with an interface on the voltage inverter, or remotely over a network 170. The voltage inverters may comprise variablefrequency drives or low voltage converters.

[0067] In some embodiments, three separate voltage inverters are installed within the waste processing machine 110. In such embodiments, each voltage inverter provides a separately regulated power to one of the motor 240, the one or more intake fans 420, and the one or more exhaust fans 450; allowing each particular motor’s power requirement to be separately controlled to meet their individual ratings, and for ease ofmaintenance. In some embodiments, the voltage inverters may comprise Siemens™ SINAMICS V20 Basic converters.

[0068] In some embodiments, the waste processing machine 110 may also include a camera 350 mounted within the drum 230 or near the inlet aperture (i.e. loading hatch) of the drum 230 to provide images of waste being loaded and / or processed. Images captured by the camera 350 may be transmitted by the controller 210 to the system server 150 for storage in database 160. A client device 140 may access the images stored in database 160 via the system server 150.

[0069] The system server 150 is also configured to communicate with a database 160. The database 160 may be implemented on or accessed through a separate server or the same server as system server 150. The database 160 may be used to store sensor data generated by all the waste processing machines 110 that are a part of the distributed waste processing system 100. The software modules implementing the data collection agent 344 may mediate the collection of sensor data from various waste processing machines 110 and then store the received data to the database 160. In some embodiments, processes implementing the data collection agent 344 may poll each waste processing machine 110 every 3 seconds over a Modbus UDP protocol to query all the relevant sensor and other data generated by each waste processing machine 110, for example. In some embodiments, processes implementing the data collection agent 344 may poll each waste processing machine 110 every 15 minutes via an FTP protocol, for example. The data collection agent 344 may segment its queries over more than one polling cycle to maintain latency of collected data without generating communication bottlenecks over the network 160. For example, data-intensive but low-priority queries could be undertaken at a lower frequency cycle such as one query every 15 minutes, for example. On the other hand, data-light but high-priority queries could be undertaken at a higher frequency, such as one query every 3 seconds, for example.

[0070] The data stored in the database 160 may be retrieved and accessed through the web application 342. In some embodiments, the system server 150 may be implemented using a Windows™ operating system, for example. In someembodiments, the database 160 may be implemented using a Microsoft™ SQL Server, for example. Other suitable operating systems and database implementations may be used instead.

[0071] Motor: The motor 240 may comprise an electric DC motor providing sufficient torque to rotate the waste processing mixer 622 when loaded with a maximum waste load (e.g. 500-600kg for a 1000 litre drum), at a configurable (selected) rotation speed. In some embodiments, the motor 240 may comprise a belt drive motor, or electric AC motor, such as a direct drive motor.

[0072] The motor 240 may be configured to accommodate drums 230 of varying sizes, where a larger drum may be able to process more waste at a time but may require a heavier and / or larger mixing shaft which requires greater torque to rotate in comparison to a smaller drum. As such, a larger drum may have a motor 240 rated at a sufficient torque value for its size that is higher than the torque value of a motor 240 for a smaller drum, for example.

[0073] In some embodiments, the rotation speed of the mixer 622 is selected to rotate the waste processing mixer 622 at about 5 RPM. This rotation speed is selected to provide a relatively high level or rate of effective waste decomposition for relatively minimum or lower power draw by the motor 240. In other embodiments, another speed, such as 10 RPM may be selected. The rotation speed of the mixer 622 may be selected to maximize energy efficiency, processing efficiency, or both. The rotation speed of the mixer 622 may be selectively varied throughout the course of processing a waste load.Air flow system

[0074] The air flow system 220 supplies at least one heated air stream and an ionised air stream into the drum 230, and exhausts spent ionised oxygen and decomposition fumes out of the waste processing machine. That is, the air flow system 220 supplies heated air and ionised air into the space defined by the drum 230. The air flow system220 may supply a first heated air stream and a second heated air stream to the drum 230, for example.

[0075] The air flow system 220 may comprise an ionised air intake having an intake air filter 410, an ion generator 415 (also referred to as ioniser 415), an intake fan 420, and a coupling conduit 703. The ionised air may enter into the drum 230 via an ionised air inlet 438. The ion generator 415 is configured to receive an inlet air stream and generate the ionised air stream at an outlet of the ion generator 415.

[0076] The coupling conduit 703 is coupled at one end to an outlet of the ion generator 415 and coupled at an opposite end to the ionised air inlet 438. The coupling conduit 703 supplies the ionised air stream from the ion generator 415 to the drum 230 via the ionised air inlet 438. The coupling conduit 703 may be configured to directly supply the ionised air stream from the ion generator 415 into the drum 230 via the ionised air inlet 438.

[0077] In some embodiments, it may be desirable to have a plurality of ionised air intakes, each having a separate ion generator 415. That is, a plurality of separate ionised air streams generated by a plurality of ion generators 415 may be input into the drum 230 at spaced locations to increase the concentration of ions in the drum 230, for example. The plurality of ionised air intakes may each have a separate ionised air inlet 438 or may share one or more ionised air inlets 438, for example. Each of the plurality of ionised air intakes may include a separate intake filter 410 and intake fan 420, for example. In some embodiments, two or more ionised air intakes share an intake filter 410 and / or an intake fan 420 which provides an air stream to the two or more ion generators 415.

[0078] A plurality of ionised air intakes may be desirable where there is drum volume of greater than lOOOL, for example. That is, the number of ion generators 415 may be based on volumetric capacity of the drum 230, for example. The air flow system 220 may include 2, 3, 4, or more than 4 ion generators 415, for example.

[0079] The air flow system 220 may comprise at least one heated air supply subsystem (or heated air intake) having an intake air filter 410, an air heater 430, an intake fan 420, and an air supply line to supply at least one heated air stream to the drum 230. The heated air stream may enter into the drum 230 via one or more heated air inlets 436. In some embodiments, a single heated air intake may enter the drum 230 via two heated air inlets 436. In other words, the air flow system 220 includes an air heating subsystem to supply heated air into the drum 230 and an ion generator 415 to generate an ionised air stream into the drum 230.

[0080] In some embodiments, the air flow system 220 comprises two heated air supply subsystems. That is, the air flow system 220 comprises a first heated air supply subsystem and corresponding first air supply line 702 and a second heated air supply subsystem and corresponding second air supply line 704 for supplying first and second heated air streams, respectively, into the drum 230, for example.

[0081] The first and second air supply lines 702 and 704 are configured to supply their respective heated air streams into the drum via heated air inlets 436. In some embodiments, the first air supply line 702 and the second air supply line 704 are each coupled to the drum 230 via different heated air inlets 436. That is, the first air supply line 702 and the second air supply line 704 supply their respective first and second air supply streams to the drum 230 at different locations, for example.

[0082] In some embodiments, the second heated air supply line 704 is configured to split the second heated air stream into multiple sub-streams. For example, the second heated air supply line 704 may include a T-intersection for splitting the second heated air stream. The multiple sub-streams are provided into the drum 230, via two or more heated air inlets 436, at spaced locations.

[0083] In some embodiments, the heated air supply subsystems and the ioniser air intake have a shared intake manifold from which each respective intake fan 420 draws air from. In some embodiments, the shared intake manifold is coupled to a dehumidifier to reduce the moisture content of the air being supplied to the drum 230.

[0084] In some embodiments, the first air supply line 702 and the coupling conduit 703 are configured so that mixing of the ionised air stream and the first heated air stream occurs downstream of each of the ioniser 415 and the air heater 430. In some embodiments, the first supply line 702 and the coupling conduit 703 are configured so that mixing of the ionised air stream and the first heated air stream occurs only in the drum 230.

[0085] The air flow system 220 may comprise at least one exhaust having an exhaust air filter 445 and an exhaust fan 450. The drum 230 receives low-humidity heated air and ionised air from the respective intakes and exhausts air from the exhaust. The exhaust air typically has higher humidity than the heated / ionised air received at the drum 230 at the respective intakes because of the moisture entering the air from the food waste as it is processed in the drum 230.

[0086] The air flow system components may be connected through air conduit sections. The air conduit sections may be comprised of aluminium, plastic, PVC, stainless steel, or other suitable materials.

[0087] In some embodiments, pressure sensors form part of the air flow system 220, positioned within the drum 230, sending pressure data to the controller 210. Expected pressure ranges may be between -3 to +3 mbar, with an ideal pressure within the drum 230 being slightly negative, for example at least around -0.01 mbar relative to an external environment of the processing drum. A sufficiently negative pressure may ensure optimal airflow from the internal chamber of the drum 230 into the exhaust, rather than airflow into the environment through the inlet aperture 702.

[0088] Heat Exchanger: In some embodiments, the first air supply line 702 is configured to provide heat to the ionised air stream. The heated air supply subsystem may further comprise a heat exchanging device, such as heat exchanger 442, in the first air supply line. The heat exchanger 442 may be configured to provide heat to the coupling conduit 703 when the first heated air stream passes through the heatexchanger 442 to heat the ionised air stream. In some embodiments, the coupling conduit 703 passes through the heat exchanger 442.

[0089] The heat exchanger 442 is configured to facilitate transfer of heat from the first heated air stream in the first air supply line to the ionised air stream in the coupling conduit 703 prior to the respective air streams entering the drum 230. That is, the first heated air stream may be used to heat the ionised air stream prior to entering the drum 230, for example. In some embodiments, the heat exchanger 442 is an air-to-air heat exchanger. The heat exchanger 442 may be manufactured using copper and aluminium, or another material suitable for exchanging heat, for example.

[0090] In some embodiments, the first heated air stream and the ionised air stream are mixed prior to entering the drum 230. That is, the first heated air stream and the ionised air stream are mixed to form a single air stream and enter the drum 230 via a single inlet, for example. In such an embodiment, the mixing of the first heated air stream and the ionised air stream causes the ionised air stream to be heated. In such an embodiment, the heat exchanger 442 may be a pipe connection, or other suitable means, for joining the heated air intake and the ionised air intake to produce a single intake air stream.

[0091] In embodiments including the heat exchanger 442, the first heated air stream travels through a first air supply line which includes at least an air heater 430, an intake fan 420, the heat exchanger 442, and a heated air inlet 436.

[0092] Intake Air Filter: The intake air filter 410 may comprise a conical air filter of a suitable type to ensure pollution or contaminants from environmental air are filtered prior to being drawn in to the system. The intake air filter 410 is coupled directly to the intake of the ioniser 415. The intake air filter 410 is easily accessed through outer housing panels of the waste processing machine 110, allowing maintenance or replacement of the intake air filter 410. This configuration also ensures the intake air filter 410 receives minimal exposure to contaminants and unfiltered air, which may impede the ionisation process and operation of the ioniser 415. In some embodiments,the intake air filter 410 may be a flat panel air filter or cylindrical air filter. In some embodiments, the intake air filter 410 may be contained within a filter housing, with defined inlet portions, allowing air flow to be directed across the filter in an optimal filtering direction.

[0093] Exhaust Air Filter: The exhaust air filter 445 may comprise a conical air filter sufficient to filter waste particulate from the air within the drum 230, to minimise or prevent airborne waste particulate from being dispersed into the atmosphere. The exhaust air filter 445 may be contained within a filter housing arranged to provide easy maintenance access, allowing easy filter replacement. The filter housing may be constructed from aluminium, PVC, stainless steel, or other suitable materials, for example. In some embodiments, the exhaust air filter 445 may be a flat panel air filter or cylindrical air filter. In some embodiments, the exhaust air filter housing has defined inlet portions, allowing air flow to be directed across the filter in an optimal filtering direction.

[0094] Ioniser: The ion generator 415, or ioniser 415, ionises and / or radicalises oxygen in an air stream and provides air rich in reactive oxygen species to the processing chamber 606 of drum 230 through the air flow system 220. The ioniser 415 may be a low energy plasma device, utilising a mixed ion reactive approach to generate variety of reactive oxygen species. The addition of ionised or radicalised oxygen to the waste load accelerates the natural decomposition process of the organic waste, and allows reduction of waste volume through the waste processing machine 110 by between 60-90%.

[0095] Examples of ionised oxygen produced by the ioniser 415 may include superoxide anion radicals (Ch"), hydrogen peroxide (H2O2), and hydroxyl radicals (OH" ). The ioniser 415 therefore produces negatively charged ions. In some embodiments, the ioniser 415 may be configured to produce positively charged ions. In some embodiments, the ioniser 415 is configured to produce both positively and negatively charged ions, which may improve the efficiency and effectiveness of the decomposition effect.

[0096] In some embodiments, the ion generator 415 is configured to provide the ionised air stream with a concentration of greater than zero and less than or equal to 200 million negatively charged ions per cubic centimetre at the outlet of the ion generator 415. In some embodiments, the ion generator 415 is configured to provide the ionised air stream with a concentration of about 50 million to about 100 million negatively charged ions per cubic centimetre at the outlet of the ion generator 415.

[0097] In embodiments including a heat exchanger 442, the heating of the ionised oxygen, or the charged ions, may result in a multiplication of the ionised oxygen and an increase in the concentration of ions in the ionised air stream.

[0098] In some embodiments, each waste processing machine 110 comprises an ioniser array. The ioniser array may comprise at least two ionisers 415 connected in parallel with the air stream to ionise the airstream, thereby providing a greater amount of radicalised oxygen ions when compared to embodiments comprising a single ioniser 415. In such embodiments, the ioniser array may comprise between 2 and 5 ionisers 415 connected in parallel. In some embodiments, the ioniser array comprises between 2 and 5 ionisers 415 in series. In some embodiments, the ioniser array comprises between 2 and 5 ionisers 415, connected in a combination of series and parallel configurations. In other embodiments, a greater number of ionisers 415 are provided.

[0099] The ioniser array is thought to accelerate the decomposition of waste, due to the increase in number of simultaneously active ionisers 415 which produce a greater amount of radicalised oxygen. This strengthened effect is intended to increase efficiency of the decomposition of the waste within the processing chamber 606 of the drum 230 and thereby increase waste residue output and decrease operation time over a given period of time.

[0100] It is thought that the addition of ionised or radicalised oxygen or other negative ions in the decomposition process expedites the release of water from the waste load by breaking down otherwise resistant cell structures in the food waste (plantcells, for example). It is thought that this effect contributes significantly to the short decomposition timeframe of waste loads by the waste processing machine 110.

[0101] Additionally, it is thought that the addition of ionised or radicalised oxygen in the decomposition process reduces the output of volatile chemicals throughout decomposition, and accordingly neutralises odours in the processed waste residue particulate.

[0102] Referring to Figures 11A and 11B, there are shown a perspective view and an end view, respectively, of an ion generator 415, according to some embodiments. The ion generator 415 has housing with a box-like structure, or a generally rectanguloid shape. The housing of the ion generator 415 comprises first and second opposing side walls 1126 and adjacent first and second end walls 1128. The housing of the ion generator 415 further comprises a bottom wall 1127 and a top portion 1130, each positioned adjacent the side walls 1126 and the end walls 1128. The side walls 1126, end walls 1128, bottom wall 1127, and top portion 1130 form the box-like casing.

[0103] The ion generator 415 includes an inlet aperture 1102 defined by a first annular piece 1122 disposed in the first end wall 1128. The inlet aperture 1102 allows an inlet air stream to pass therethrough and enter the ion generator 415 to be ionised. The ion generator 415 further comprises an outlet aperture 1104 defined by a second annular piece 1124 disposed in the second end wall 1128. The outlet aperture 1104 allows an ionised air stream generated by the ion generator 415 to pass therethrough. The first annular piece 1122 and the second annular piece 1124 are configured to be coupled to an air conduit of the air flow system 220.

[0104] In some embodiments, the ion generator 415 may be configured to be air tight, in which air may only flow in / out via the inlet aperture 1102 and the outlet aperture 1104. That is, the ion generator 415 may comprise a closed housing except for the inlet aperture 1102 and the outlet aperture 1104 which allows airflow to travel therebetween within the ion generator 415, for example.

[0105] The ion generator 415 further comprises a plurality of ionising elements 1106. The ionising elements 1106 may be arranged in a 2-dimensional or 3-dimensial array configuration surrounding an airflow path defined between the inlet aperture 1102 and the outlet aperture 1104. The direction of the airflow path through the ion generator 415 is indicated by the direction indicator 1114.

[0106] As the inlet air stream enters the inlet aperture 1102, the ionising elements 1106 generate a plurality of negatively charged ions. The negatively charged ions are then carried by the inlet air stream along the airflow path and exit the ion generator 415 at the outlet aperture 1104 in the form of an ionised air stream.

[0107] The ion generator 415 further comprises a power socket 1110 configured to connect to a power source, such as power supply 280, to provide electrical energy to the ionising elements 1106. The ion generator 415 may further comprise a plurality of status LED indicators 1112 configured to provide a status indication of the ion generator 415.

[0108] An example of the 2-dimensional or 3-dimensial array configuration is further shown in Figures 11C and 11D. In some embodiments, first and second ionising elements 1106 are positioned on a first side of the airflow path, the first ionising element 1106 positioned vertically above the second ionising element 1106. Third and fourth ionising elements 1106 are positioned opposite the first and second ionising elements 1106 on a second side of the airflow path opposing the first side, the third ionising element 1106 positioned vertically above the fourth ionising element 1106. A fifth ionising element 1106 is positioned adjacent the second and fourth ionising elements 1106 at a lower position at a lower portion of the airflow path adjacent the first and second sides of the airflow path.

[0109] The ionising elements 1106 may be mounted to an inner support structure comprised of a mounting assembly that includes a supporting bracket 1134 coupled to an upper mounting bracket 1132. The ionising elements 1106 may be mounted to the supporting bracket 1134 via individual ioniser mounts 1136. The ioniser mounts 1136may be coupled to the supporting bracket 1134 via a fastener, such as a nut and bolt, for example.

[0110] The upper mounting bracket 1132 is coupled to one or more of the side walls 1126, the end walls 1128 and the top portion 1130 to secure the inner support structure to the box-like casing of the ion generator 415. In some embodiments, the upper mounting bracket 1132 divides the internal space defined by the box-like casing into lower and upper portions, the lower portion for receiving and ionising an air stream and the upper portion for housing additional electronic components and circuitry.

[0111] As shown in Figure 11C, the airflow path exemplified by circle 1138 travels between the ionising elements 1106 mounted to the supporting bracket 1134. The circle is representative of the inlet aperture 1102 and the outlet aperture 1104 and it is understood that airflow may deviate from the area shown by circle 1138 within the box-like casing of the ion generator 415. In some embodiments, the ion generator 415 further comprises a diffuser 1139 for dispersing the inlet air stream toward the ionising elements 1106. The diffuser 1139 may result in better airflow across the ionising elements 1106 and subsequently a greater concentration of ions in the ionised air stream output by the ion generator 415, for example.

[0112] Above the 2-dimensional or 3-dimensional array configuration of ionising elements 1106, in the upper portion of the space within the ion generator 415, there are positioned a plurality of high voltage power supplies (ionising power supply) 1108. Each ionising power supply 1108 may be coupled to the upper mounting bracket 1132 via a power supply mount 1137. The ionising power supplies 1108 may be coupled to the mounting bracket 1132 via a shared power supply mount (not shown), for example. The power supply mount 1137 may be coupled to the upper mounting bracket 1132 via one or more fasteners, such as a nut and bolt, for example.

[0113] The ionising power supplies 1108 are configured to receive electrical energy from an external power source via the power socket 1110 and subsequently provide electrical energy to the ionising elements 1106. The ion generator 415 may include anionising power supply 1008 corresponding to each ionising element 1106. That is, each ionising element 1106 has its own ionising power supply 1108, for example. The ionising power supplies 1108 are positioned above the airflow path so as to not affect the ionising of the air stream.

[0114] Each ionising element 1106 and corresponding ionising power supply 1108 may form an ionising unit. The ionising units may be commercially available off-the-shelf products, such as the muRata MHM314 series Ionizer module commercially available from Murata Manufacturing Co., Ltd, for example. In some embodiments, the ion generator 415 comprises five ionising elements 1106 and corresponding ionising power supplies 1108. In other embodiments, fewer or greater numbers of ionising elements 1106 may be used in the ion generator 415. For example, as few as two , three or four and as many as 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 ionising elements 1106 may be used in each ion generator 415. The number of ionising elements 1106 in an ion generator 415 may be increased above 20 based on volumetric capacity of the drum 230, for example.

[0115] The ionising element 1106 may have an operating temperature range of between about -10°C and about 70°C. The ionising power supply 1108 may have an operating temperature range of between about -10°C and about 50°C. Each ionising power supply 1108 may have an operating voltage of between about 10.8V and about 13.2V, for example. Each ionising power supply 1108 may have an operating current of between 0 mA and about 200mA, for example. Each ionising power supply 1108 may draw between about 0.9W and about 2W, for example. In some embodiments, the ion generator 415 draws between about 4.5W and about 10W.

[0116] Intake Fan: The intake fan 420 is configured to receive instructions from the controller 210. The air flow speed, power operation, and other functions of the air intake fan 420 may be configurable and controlled through the controller 210. The intake fan 420 may be affixed on at least one supporting member of the machine frame 560, providing clearance from other air system components and further allowing access for servicing and maintenance.

[0117] In some embodiments, the intake fan 420 of the ionised air stream feeds air into the ioniser 415. That is, the intake fan 420 of the ionised air stream is positioned upstream of the ioniser 415 and blows air therethrough, for example. In some embodiments, the intake fan 420 of the ionised air stream pulls air through the ioniser 415. That is, the intake fan 420 of the ionised air stream is positioned downstream of the ioniser 415 and sucks air therethrough, for example.

[0118] In some embodiments, the intake fan 420 in communication with the ioniser 415 is configured to provide air through the ioniser 415 at a flow rate of between 0 m3 / hr and about 230 m3 / hr. The intake fan 420 in communication with the ioniser 415 may be configured to provide air through the ioniser 415 at a flow rate of about 200 m3 / hr, for example. The intake fan 420 in communication with the ioniser 415 may have a wattage input of between about 0.5kW and about 3kW, for example. The intake fan 420 in communication with the ioniser 415 may have a wattage input of about 1.7kW, for example.

[0119] In some embodiments, the intake fan 420 of the at least one heated air supply subsystems feeds air into the respective air heater 430. That is, the intake fan 420 of the heated air supply subsystem is positioned upstream of the air heater 430 and blows air therethrough, for example. In some embodiments, the intake fan 420 of the at least one heated air supply subsystem pulls air through the air heater 430. That is, the intake fan 420 of the heated air supply subsystem is positioned downstream of the air heater 430 and sucks air therethrough, for example.

[0120] In some embodiments, the intake fans 420 in communication with each air heater 430 are configured to provide air through the air heater 430 at a flow rate of between 0 m3 / hr and about 350 m3 / hr. The intake fans 420 in communication with the air heater 430 may be configured to provide air through the air heater 430 at a flow rate of about 300 m3 / hr, for example. The intake fans 420 in communication with each air heater 430 may have a wattage input of between about IkW and about 5kW, for example. The intake fans 420 in communication with each air heater 430 may have a wattage input of about 3kW, for example.

[0121] Exhaust Fan: The exhaust fan 450 may comprise a similar or identical unit to the intake fan 420. The exhaust fan 450 is arranged to draw air, spent ionised oxygen, and / or airborne waste residue, through one or more exhaust ducts towards the air exhaust air filter 445, and to blow the filtered exhaust air into the nearby outside environment / . The exhaust fan 450 may be affixed on the interior of the machine frame 560, providing clearance from other air system components and further allowing access for servicing and maintenance.

[0122] Air Heater: The air heater 430 is provided to heat an air stream to a configured temperature to provide a desired temperature within the processing chamber 606 of the drum 230. The air heater 430 may be controlled by the controller 210 and arranged to receive temperature control and operation instructions. The air heater 430 may heat the air stream to a temperature exceeding the predetermined target chamber temperature (e.g. by 10-200%) to ensure that an acceptable chamber temperature range is met when the heated air stream enters the larger volume of the interior of the processing chamber 606. The input of the air stream into the air heater 430 through air conduit sections may be physically located on the top or bottom of the air heater, depending on space and optimisation requirements. In some embodiments, the air stream is provided at the bottom of the air heater 430, with the heated air outlet provided at the top, to maximise air flow efficiency as the heated air stream rises. The air supply conduits of the heated air intake and / or the ionised air intake may be insulated in order to minimise temperature loss prior to the respective air streams entering the drum 230.

[0123] Each air heater 430 may have a power input of between IkW and about 12kW, for example. Each air heater 430 may have a power input of between about 5kW and about lOkW, for example. Each air heater 430 may have a power input of about 8kW, for example.

[0124] The target temperature range of waste residue in the processing chamber 606 of the waste processing machine 110 is selected to warm the waste material as it is being subjected to physical forces by the mixing blades to break it down, but not to heatit so much as to effectively “cook” the waste. For example, the target temperature range of 50°C -85°C (optionally around 55°C-65°C) has the advantage of warming the waste to a level where moisture in the food waste can readily enter the air in the processing chamber as vapour, while not heating it so much as to substantially denature and / or degrade the potentially nutritional contents of the waste. The processing of a waste load is achieved by the churning action of the waste processing mixer 622, in conjunction with the accelerated decomposition afforded by the heated air stream and the ionised air stream. For example, a high (e.g. 100+ °C) overall temperature may break down a waste load by cooking or thermally decomposing the waste.

[0125] In some embodiments, the target temperature range of the waste in the processing chamber 606 is between 50°C-85°C, with an average temperature of around 65°C. In some embodiments, the target temperature range of the waste in the processing chamber 606 is between 55°C-65°C, with an average temperature of the waste residue of around 60°C. In some embodiments, the temperature range of the waste residue may be dynamically controlled by the controller 210 via adjustment of the various heating systems of the waste processing machine 110, such as heated air input from the air heaters 430 or drum heaters 900 described below, throughout the course of a decomposition cycle. The desired temperature range of the waste may be dependent on the particular type of waste to be processed, and may be adjusted in order to provide ideal decomposition conditions. In some embodiments, the air heater 430 may be controlled by controller 210 to temporarily provide heated air through the heated air intake of the air flow system 220 at an increased temperature to compensate for heat loss during the opening of the waste processing machine 110 during waste load top ups, and to accommodate the additional heat requirement for the additional waste load. Such a temporary increase may be controlled to occur for 15 to 45 minutes and may involve increasing the outlet temperature at the heater 430 by 10% to 50%, for example. In a further example, the temporary increase may be controlled to occur for around 20 to 30 minutes and may involve increasing the outlet temperature at the heater 430 by 15% to 40%.

[0126] In some embodiments, the air heaters 430 are configured to operate at a temperature of up to about 600°C. The air heaters 430 are configured to operate at a temperature of about 500°C, for example. The temperature of the heated air stream may be between about 30°C to about 250°C, for example. The temperature of the heated air stream may be between about 60°C to about 200°C, for example.

[0127] Air Inlets: The heated air stream is directed from the air heater 430 into the drum 230 by the at least one heated air inlet 436. The at least one heated air inlet 436 comprises a respective aperture on a vertical side wall of the drum 230 that allows the heated air stream to be provided directly into the processing chamber 606, as shown in Figure 6, for example.

[0128] The ionised air stream is directed from the ioniser 415 into the drum 230 by the ionised air inlet 438. The ionised air inlet 438 comprises an aperture on a vertical side wall of the drum 230 that allows the ionised air stream to be provided directly into the processing chamber 606, as shown in Figure 6, for example.

[0129] The at least one ionised air inlet 438 may be positioned close to the waste load or within the expected volume of waste, to allow the maximum amount of contact between the ionised air stream and the waste load during the peak effectivity window of the ionised oxygen. The peak effectivity window of the ionised oxygen may be variable depending on the ioniser 415, and may be configurable by the controller 210. In some embodiments, the peak effectivity window of the ionised oxygen may be up to 6 seconds.

[0130] The mixing action of the waste processing mixer allows greater penetration of the air stream into a waste load present in the chamber 606 of the drum 230, providing greater surface area exposure to the heated air stream and the ionised air stream. The heat and movement of the heated air stream, in addition to the ionised or radicalised oxygen, allows for effective evaporation of liquid from the waste load.

[0131] Exhaust Vents: Exhaust vents 440 comprise at least one port providing an outlet from the chamber 606 of the waste processing machine 110. In some embodiments, the exhaust vents 440 may be positioned external to the chamber, such as immediately outside the loading aperture, to minimise or avoid exhausting heated / ionised air within its peak effectivity window. In some embodiments, the exhaust vents 440 are positioned proximal to either side of an inlet aperture 610 or an inlet hatch 564, minimising the exhausting of active ionised air and providing position to exhaust spent air away from the inlet aperture 610 or the inlet hatch 564. When the inlet hatch 564 is open, the exhaust fan 440 may continue to operate, in order to minimise human exposure to waste fumes.

[0132] In some embodiments, the exhaust vents 440 may be situated at the top of the drum 230, for example as shown in Figure 6. In some embodiments, the exhaust vents 440 comprise a combination of ports and exhaust plenums.

[0133] Air conduit sections: The components of the air flow system 220 may be connected through air conduit sections. The air conduit sections may include the first air supply line 702, the second air supply line 704, and the coupling conduit 703. The air conduit sections may comprise conduits and joining sections composed of steel, galvanised steel, stainless steel, copper, aluminium, plastic, PVC, corrugated tube, or other suitable materials. In some embodiments the air conduit section material is selected based on minimising heat loss throughout the system. In some embodiments the air conduit sections comprise flexible tube portions, facilitating ease of access to air flow system components for maintenance, servicing, or removal. In some embodiments, the air conduits are encased in an insulating material, such as thermal wrapping, to reduce heat dissipation from the air conduit.

[0134] In some embodiments, the coupling conduit 703 is about 0.5 inches to about 1.5 inches in diameter. In some embodiments, the coupling conduit 703 is about 1 inch in diameter. In some embodiments, the coupling conduit 703 is configured to have a single bend between the outlet of the ion generator 415 and the ionised air inlet 438.

[0135] In some embodiments, the first air supply line 702 of the first heated air subsystem is about 1 inches to about 3 inches in diameter. In some embodiments, the first air supply line 702 of the first heated air subsystem is about 2 inches in diameter. In some embodiments, the second air supply line 704 of the second heated air subsystem is about 1 inches to about 3 inches in diameter. In some embodiments, the second air supply line 704 of the second heated air subsystem is about 2 inches in diameter.

[0136] Figure 4 depicts an overall system diagram indicating positions and connections of the air flow system 220. In this embodiment, environmental air is drawn in through the intake air filter 410 by activation of the intake fan 420, and into the ioniser 415 in the ionised air stream of the air heater 430 in the heated air stream. After heating of the filtered air stream takes place, the heated air is directed by the air intake fan 420 through the heat exchanger 442.

[0137] Similarly, after the ionisation of the filtered air stream takes place, the ionised air is directed by the air intake fan 420 through the heat exchanger 442. As previously described, the heat exchanger 442 acts to transfer some of the heat energy from the heated air stream to the ionised air stream to cause a multiplication, and subsequent increase in concentration, of the ions in the ionised air stream, After the ionised air stream is heated to increase the concentration of ions present in the ionised air stream, the ionised air stream is directed through the ionised air inlet 438 into the chamber 606.

[0138] From the chamber 606, waste air is exhausted through the exhaust vents 440. The exhaust fan 450 draws the waste air through the exhaust vents 440 and into the exhaust air filter 445. Waste particulate is trapped within the exhaust air filter 445 before the filtered exhaust air stream is directed out into the atmosphere.

[0139] Waste Loader System: The waste loader system 260 is configured to receive a variety of standard sized wheel-bins, and to load their waste contents into the drum 230 of the waste processing machine 110. In some embodiments, the waste loader system 260 may comprise a modified Simpro Dumpmaster™, capable of receivingstandard sized wheel-bins of up to 250kg, and be capable of a tipping height of up to 1.8 metres.

[0140] A reader may be present on the waste processing machine 110 to detect a Radio Frequency identification (RFID) tag, near-field communication (NFC) tag or other machine-readable item on a bin, to read a unique bin identifier on the bin. The database 160 may hold records associating the unique bin identifiers with a subscriber or user of the distributed waste processing system 100. In some embodiments, when the waste loader system 260 loads waste from bin; the unique bin identifier may be read and transmitted to the controller 210.

[0141] After loading the contents of the bin, the variation in the total weight of contents of the drum may be determined using information from drum weight sensor 235 by the controller 210. The variation in the total weight of contents of the drum may be associated with the read unique bin identifier as the weight of the contents deposited. The read unique bin identifier value and the weight of contents value may be transmitted by the controller 210 to the database 160 along with a timestamp and a unique identifier for the particular waste processing machine 110. The recorded unique bin identifier values and the weight of contents values may be used to invoice or bill users of the distributed waste processing system based on the weight of the waste processed through specific waste bins allocated to the users. In some embodiments, the waste loader system 260 may require authentication by a user before waste is loaded into the drum. The authentication may occur through the HMI 270 or a near field communication device (not shown) mounted on the waste loader system 260.

[0142] Authentication by a user before loading waste may serve the function of identifying the user of the distributed waste processing system 100 and may eventually be used for billing or invoicing purposes. In some embodiments, information about the identity of the user of the distributed waste processing system or the unique bin identifier may also be used to identify the origin of waste loaded at a particular time. In cases of malfunction of the waste processing machine 110, this information could allow the discovery of the source of waste that could be the cause of the malfunction of thewaste processing machine 110. For example, loading of metal objects in the drum may impede the operation of the waste processing machine. With information of identity of the user or the unique bin identifier, the user or subscriber responsible for loading of the metal object may be identified.

[0143] Multiple unit waste loader system: In some embodiments, raw waste can be deposited through a collecting hopper, which feeds the waste into a macerator. The macerator physically breaks down the waste and churns into finer particulate. The waste is then pumped through inlet conduits by a pump and fed into waste processing machines 110.

[0144] Inlet Hatch: The inlet hatch 564 is configured to be openable to receive waste into the drum 230 via the inlet aperture 610. The inlet hatch 564 is disposed on a forward (or front) side of the drum 230. The inlet hatch 564 comprises a set of housing panels 520 arranged perpendicularly, forming a 90° angle at the top of the machine housing 510. The inlet hatch 564 may be hinged to allow actuation by an inlet actuator arm in response to control signals from controller 210, providing access to the chamber 606 by way of the chamber waste inlet aperture 610. The inlet hatch 564 may be controlled by controller 210 to open and close automatically during the loading process, or manually as required to inspect the drum 230 during servicing operations.

[0145] In some embodiments, the inlet hatch 564 comprises a shielding layer, installed on the interior of the housing. The shielding layer may reduce the risk of processed waste residue and new waste loads from falling outside of the waste inlet aperture 610.

[0146] In some embodiments, additional shielding may be installed on the inlet hatch 564 on either side of the hatch, such that in an open position the shielding would minimise human interference and risk of injury from the top or sides of the waste processing machine 110. In some embodiments, the periphery of the inlet hatch 564 may include a rubber environmental seal, reducing the risk of waste entering the outside environment; minimising pollution and odours.

[0147] Machine Housing: Referring to Figures 5A-D, the waste processing machine 110 is housed within a machine housing that may comprise a series of housing panels 520 affixed to a machine frame 560.

[0148] The housing panels 520 may be sheet metal panels made of aluminium, stainless steel, acrylic, or other suitable materials. The housing panels 520 may be powder coated for heat resistance and protection against environmental weathering. In some embodiments, the housing panels 520 are protected by paint, wrap coatings, or other suitable means.

[0149] The housing panels 520 may be affixed and removed from the machine frame 560 in sections, allowing access to all inner components of the waste processing machine 110 for maintenance or servicing. In some embodiments, housing panels 520 may be installed on hinges suitable to open and close regularly accessed areas of the machine housing 510, such as the power and controls systems.

[0150] The housing panels 520 may be fitted with handles or housing panel hand grips 540 allowing easier removal of housing panels 520.

[0151] Housing panels 520 may define one ventilation aperture or a series of ventilation apertures 530 for air flow system 220 components such as air conduits to vent waste air into the atmosphere.

[0152] The machine frame 560 comprises a plurality of frame sections arranged to provide an overall structure for the housing panels 520. The machine frame 560 may be made of aluminium, stainless steel, or other suitable materials sufficient to provide structural integrity against environmental or operational damage.

[0153] In some embodiments, the machine frame 560 includes a number of frame sections arranged as structural supports for waste processing machine components, such as air flow system 220 components.

[0154] The machine frame 560 may be installed upon a mounting floor 562, comprising a flat surface provided to form the base of the waste processing machine 110. The mounting floor 562 may provide a stable surface to mount waste processing machine components on, including the drum 230, air flow system components, and the machine housing 510. The mounting floor 562 may also serve to prevent environmental contamination by processed waste residue or unprocessed waste falling out of the chamber drum 230 or outlet chute 556.

[0155] In some embodiments, the mounting floor 562 defines a mounting floor aperture beneath the drum chamber shroud 602, which may assist in ventilation and providing access to environmental air to be drawn into the air flow system 220.

[0156] A plurality of frame support feet 558 are affixed to the underside of the mounting floor 562 and machine frame 560. The frame support feet 558 elevate the machine housing 510 a distance above the ground, allowing for improved environmental air flow through the mounting floor aperture, reducing potential damage to the machine housing from contact with the hard ground surfaces, and reducing potential damage to ground surfaces by the moving, installation, or removal of the waste processing machine 110.

[0157] Drum: Referring to Figure 6, there is shown a portion of the drum 230, according to some embodiments. The drum 230 comprises a chamber shroud 602 (also referred to as a cylindrical drum wall 602), a first chamber wall 603 (shown in Figures 8A-C), and a second chamber wall 604 defining an internal chamber 606. That is, the drum 230 defines a space to receive waste to be processed, for example. The drum 230 may be made of aluminium, steel, stainless steel, or other suitable materials. The chamber size, as defined by the drum 230, may be of a suitable size to contain lOOOL at maximum capacity. In some embodiments, the chamber size may be of a size to contain a different maximum waste volume, such as 200L, 400L, 800L, WOOL, 2000L, 2400L, 3000L, 4000L, 5000L or 10,000L for example. In some embodiments, the drum 230 may be configured to have other volumetric capacities. For example, in someembodiments, the chamber size may be of a size to contain a maximum waste volume of between about 500L and about 20,000L.

[0158] The drum 230 acts as a mixing drum where waste loads are combined with existing processed waste residue inside the chamber 606 and subjected to the process of mixing, churning, aerating, and exposure to the heated air stream and the ionised air stream in order to rapidly decompose the food waste. In some embodiments, the first chamber wall 603 and the second chamber wall 604 are separated by a distance of between about 1000mm and about 2000mm. The first chamber wall 603 and the second chamber wall 604 may be separated by a distance of about between about 1250mm and about 1750mm, for example. The first chamber wall 603 and the second chamber wall 604 may be separated by a distance of about 1600mm, for example.

[0159] The chamber shroud 602 comprises a cylindrical tube section with a chamber waste inlet aperture 610 allowing waste loads to be deposited within the chamber 606 to undergo processing. In some embodiments, the chamber shroud 602 comprises a ‘U’ shaped profile, having a curved bottom, and providing a flat roof which may allow for better clearance for drum weight sensors 235, exhaust vents 440, and other internal chamber components. That is, the ‘U’ shaped profile drum may have a flat roof and a curved wall extending from the roof to form the ‘U’ shape, for example.

[0160] The first chamber wall 603 and the second chamber wall 604 act as end walls of the drum 230 and provide external support to the chamber shroud 602, affixing it to the mounting floor, and elevation in order to allow for larger bins to fit beneath the outlet chute 556.

[0161] The first chamber wall 603 is positioned next to the motor 240, and has suitable apertures allowing the mixing shaft 612 to extend through the first chamber wall 603 and rotate within the chamber 606. The second chamber wall 604 has a mixing shaft end mounting fixture 705 (as shown in Figure 7B) for mounting the end of the mixing shaft while allowing it to freely rotate under the drive force of the motor 240. The second chamber wall 604 may also define a chamber outlet aperture 706 foran outlet hatch 740 and external fixtures for an outlet actuator arm fixing plate and outlet chute 556. The chamber outlet aperture 706 may be of a sufficient height on the second chamber wall 604 to ensure clearance for standard wheeled bins to be positioned open beneath the outlet chute 556.

[0162] The first chamber wall 603, the second chamber wall 604, and the chamber shroud 602 may be permanently joined together by welding, or other suitable processes, such that they form a substantially leak proof seal preventing waste particulate from falling out of the chamber 606. In some embodiments, the first chamber wall 603, the second chamber wall 604, and the chamber shroud 602 may be separable for maintenance, cleaning, or servicing purposes.

[0163] Referring to Figures 7A-B, there is shown a view of the second chamber wall 604 from the inside of the processing chamber 606 and the outside of the processing chamber 606, respectively, according to some embodiments. As shown, a plurality of heated air inlets 436 and the ionised air inlet 438 are disposed in the second chamber wall 604. The heated air inlets 436 and the ionised air inlet 438 may be disposed at or above a horizontal centreline defined by the mixing shaft 612. This may assist in avoiding impedance or blockages caused by waste residue in the processing chamber 606, for example.

[0164] As shown in Figure 7B, the ion generator 415 may be disposed close to the outside of the second chamber wall 604.

[0165] In some embodiments, drum support feet 708 may be installed on the lower portion of the first chamber wall 603 and the second chamber wall 604, providing additional mounting or support between the drum 230 and the mounting floor 562.

[0166] The drum 230 has at least one drum weight sensor 235, which may comprise at least one load cell, allowing accurate weight measurements of the drum contents, and at least one temperature sensor, allowing temperature readings to be taken from the air streams at the air inlet plenum and the exhaust plenum. The sensors may be installeddirectly within the chamber 606 or may be disposed on a mounting protruding into the chamber 606.

[0167] Load cells are provided to enable accurate measurement of the weight of drum contents. The load cells provide weight readings to the controller 210. In some embodiments, three load cells are used to provide more accurate measurements. The load cells may be installed on or under the first chamber wall 603 and the second chamber wall 604, within the chamber shroud 602, or on at least one drum support foot 708.

[0168] The load cells may provide continuous weight data to the controller 210 in order to calculate load weight (for newly added food waste loads), offload weights, operational weights, and overall weight variations (e.g. reductions) before, during and after processing. Load cell data received by controller 210 may be used in reporting the overall performance waste processing machine 110.

[0169] In some embodiments, three load cells are provided to take an overall drum weight, which may be averaged for accuracy. In such an embodiment, load cells may be placed under points on the front and back facing sections of the machine frame 560, and under the drum support foot 708.

[0170] The load cells may be used to specify a minimum drum weight, allowing for a threshold (or minimum) amount of processed waste residue to remain within the chamber 606 during offloading operations. Leaving an amount of processed waste residue within the chamber 606 has been shown during experimental operation to allow for more efficient decomposition of new waste loads and appears to help maintains consistency of the nutritional and chemical content of processed waste.

[0171] In some embodiments, the amount of residue left comprises up to 30% of the total weight capacity of the drum 230. In other embodiments, the amount of residue left comprises less than 30% (e.g. less than 25% or less than 20 %) and more than 0% (e.g.more than about 5% or more than about 10%) of the total weight capacity of the drum 230.

[0172] In some embodiments, the amount of residue left comprises between 20% and 10% of the total weight capacity of the drum 230. In other embodiments, the amount of residue left comprises less than 10% and more than 0% of the total weight capacity of the drum 230.

[0173] In other embodiments, the amount of residue left comprises up to 30% of the total volumetric capacity of the drum 230. In other embodiments, the amount of residue left comprises less than 30% (e.g. less than 25% or less than 20 %) and more than 0% (e.g. more than about 5% or more than about 10%) of the total volumetric capacity of the drum 230.

[0174] In other embodiments, the amount of residue left comprises between 20% and 10% of the total volumetric capacity of the drum 230. In other embodiments, the amount of residue left comprises less than 10% and more than 0% of the total volumetric capacity of the drum 230.

[0175] In some embodiments, the threshold amount of waste residue to be retained in the drum 230 may be 25-30% of the total maximum weight capacity of the drum. In some embodiments, the threshold amount may be a fixed weight value, such as around 100kg to around 150kg for a lOOOL drum. In some embodiments, the threshold amount may be 25-30% of the peak weight of a new waste load, or a fixed weight value, whichever is greater.

[0176] When the load cells detect the weight of the drum 230 being at or below the minimum threshold value, the waste processing machine 110 may cease offloading operations through the outlet chute system 250. Weight measurements may be taken at various points throughout a processing operation to track the drum weight and compare it against the threshold weight value.

[0177] In some embodiments, a remotely accessible camera may be installed within the chamber 606, to provide images of drum or waste conditions. In some embodiments, exhaust vents 440 are installed on the upper region of the chamber shroud 602, disposed between the first chamber wall 603 and the second chamber wall 604, for example.

[0178] Outlet Chute: The outlet chute 556 is provided to channel processed waste residue from the chamber 606 to a receiving bin on the outside of the waste processing machine 110.

[0179] Outlet Hatch: Referring to Figure 7C, there is shown an upper portion of the second chamber wall 604 with the outlet hatch 740 mounted thereto, according to some embodiments. The outlet hatch 740 may be mounted to the second chamber wall 604 by at least one framing plate. In some embodiments, the outlet hatch 740 is positioned above a level of the mixing shaft 612 of a mixer 622. The outlet hatch 740 is configured to allow disgorgement of processed waste residue.

[0180] The outlet hatch 740 is deployed into the chamber 606 by an outlet actuator arm 742 in order to receive processed waste residue by a residue scoop of the waste processing mixer. Deposited processed waste residue is then blown through the outlet chute 556 by an air knife assembly 744. The outlet chute 556 is shaped to provide an angled portion and a downward chute portion to direct the processed waste residue into a receiving bin.

[0181] Air Valve: In some embodiments, the air flow system 220 further comprises a valve (not shown) for redirecting one or more of the heated air streams and / or the ionised air stream from the drum 230 (during a normal waste processing and decomposition cycle) into an air knife assembly (during offloading or disgorgement of the waste residue). In some embodiments, the valve may be positioned to redirect nonheated air and / or non-ionised air.

[0182] Air Knife: The air knife assembly 744, positioned at the outlet hatch 740 of the waste processing machine 110, receives an air stream from the air flow system 220. The received air stream is channelled and directed by the air knife assembly 744 to form an air knife. The air knife should be of sufficient pressure to move deposited processed waste residue along the outlet hatch 740 and down through chute, into a receiving bin.

[0183] Waste Processing Mixer: The waste processing mixer (also referred to as mixer), for example mixer 622 as shown in Figure 6, comprises a rotatable shaft 612, affixed to a motor drive connection (which is in turn connected to motor 240) for causing rotation of the waste processing mixer. The mixing shaft 612 may be a solid or hollow member constructed from stainless steel, aluminium, or other suitable materials. The mixing shaft 612 may define a longitudinal axis of the drum 230.

[0184] The mixer 622 is configured to be rotatable in the drum 230 to churn and break apart / down waste deposited within the chamber 606, and to allow the waste load to receive maximum exposure to the heated air stream and the ionised air stream from the air flow system 220.

[0185] The mixing shaft 612 is held in place within the chamber 606 with one end being fixed by the motor 240 and the opposing end through the mixing shaft end fixture 705, which maintains the horizontal position of the mixing shaft 612 while permitting free rotational movement.

[0186] The waste processing mixer further comprises a plurality of mixing blades, such as mixing blades 623, for example, configured to churn and break down a waste load during a processing operation. A variety of configurations of mixing blade may be provided within a waste processing machine 110. The mixing blades may be constructed from stainless steel, aluminium, or other suitable materials. The mixing blade may employ blades of different shape and configuration to generate different churning effects with in the chamber 606 during rotation. The rotation of the mixingshaft 612 results in the mixing blades rotating in the space defined by the drum 230 to break down waste therein.

[0187] In some embodiments, the mixing blades may be arranged or configured to push the waste load towards different portions of the chamber 606. For example, waste residue within the chamber 606 may be pushed by the direction of rotation of the shaft and the mixing blades towards the rear of the chamber (opposite the loading hatch). In other words, during rotation of the waste processing mixer, a distribution of the waste residue relative to a vertical centreline defined by the mixing shaft 612 is asymmetric, for example. The asymmetric distribution of the waste residue may be biased toward the rear of the waste processing machine 110, for example.

[0188] In other embodiments, the mixing blades are arranged or configured to push the waste load towards the outlet hatch 740, allowing easier waste collection by a residue scoop, such as scoop 625, for example. Residue scoops may be provided on the waste processing mixer proximal to the outlet aperture 706, configured to carry processed waste residue from the bottom of the chamber up and over, to a point above the outlet aperture 706, allowing the angle of the residue scoop to deposit waste residue through the outlet aperture 706 and through the outlet chute 556 by gravity. The residue scoops may be a constructed from stainless steel, aluminium, or other suitable materials.

[0189] The waste processing mixer is configured depending on the drum 230 size of the respective waste processing machine 110. That is, the positioning of the mixing blades and the scoops are determined by the size of the drum 230, for example. For example, a drum of greater length may have additional an / or larger mixing blades and / or scoops and / or greater separation between mixing blades and / or scoops in comparison to a drum of smaller length. For example, a drum of greater diameter may have larger mixing blades and / or scoops or greater separation between the mixing blades and / or scoops and the mixing shaft 622 in comparison to a drum of smaller diameter.Drum Heating System

[0190] Heated Bars: In embodiments of the waste processing machine 110 further comprising the drum heating system 290, there is provided one or more drum heaters 900. Referring to Figures 8A-C, there is shown a portion of the waste processing machine 110 including a plurality of drum heaters 900 disposed on the outside of the drum chamber shroud 602 of the drum 230 (cylindrical wall of the drum 230), according to some embodiments. Figure 8A shows a front view of the drum 230 including the drum heaters 900, Figure 8B shows a rear view of the drum 230 including the drum heaters 900, and Figure 8C shows a bottom view of the drum 230 including the drum heaters 900, according to some embodiments.

[0191] The one or more drum heaters 900 may be configured to extend in the longitudinal axis defined by the mixing shaft 612. The one or more drum heaters 900 may be circumferentially spaced apart from each other along the cylindrical drum wall 602. In some embodiments, the drum heaters 900 are asymmetrically circumferentially spaced across the lower part of the cylindrical drum wall 602. Each of the drum heaters 900 may be circumferentially spaced at a minimum distance of between about 1cm and about 4cm from one another, for example. Each of the drum heaters 900 may be circumferentially spaced at a minimum distance of about 2cm from one another, for example.

[0192] In some embodiments, the configuration of a plurality of drum heaters 900 disposed on the cylindrical drum wall 602 is biased rearward. This may assist in accounting for the rearward bias of the waste residue within the drum 230 due to the rotation of the mixer 622, for example.

[0193] In some embodiments, the one or more drum heaters 900 extend along between about 50% and 90% of the longitudinal length of the cylindrical drum wall 602, wherein the longitudinal length is parallel to the longitudinal axis of the mixing shaft 612 and between the first and second chamber walls 603 and 604. The one ormore drum heaters 900 extend along between about 70% and 85% of the longitudinal length of the cylindrical drum wall 602, for example.

[0194] In some embodiments, the one or more drum heaters 900 are coupled to the cylindrical drum wall 602 using a paste having high thermal conductivity. That is, heat transfer paste may be used to couple the drum heaters 900 to the cylindrical drum wall 602, for example. In some embodiments, the drum heating system further includes clamps to clamp the one or more drum heaters 900 to the cylindrical drum wall 602.

[0195] One or more of the drum heaters 900 may be positioned forward (i.e., towards the inlet hatch 564) of a vertical line extending downward from the mixing shaft 612. One of the drum heaters 900 may be positioned on the vertical line extending downward from the mixing shaft 612. One or more of the drum heaters 900 may be positioned rearward (i.e., away from the inlet hatch 564) of the vertical line extending downward from the mixing shaft 612. One or more of the drum heaters 900 may be longitudinally offset from another one or more of the drum heaters 900 along the cylindrical wall 602.

[0196] The temperature of the one or more drum heaters 900 is adjustable to heat the drum chamber shroud 602 which in turn heats the space within the processing chamber 606. Each drum heater 900 is independently controllable, such that the temperature of each drum heater 900 can be adjusted independently of the other drum heaters 900. The adjustment may be performed by controller 210. The controller 210 may be configured to alter temperature set points for each of the drum heaters 900 over time during a processing operation that includes rotation of the mixer 622 in the drum 230.

[0197] In some embodiments, the drum heating subsystem 290 comprises between three and six drum heaters 900, each of which is independently controllable by the controller 210.

[0198] Referring to Figure 10, there is shown a portion of an alternate waste processing machine 1000, according to some embodiments. In this embodiment, the airflow system is combined such that the heated air stream and the ionised air stream are one air stream supplied to the drum 230 via a plenum 1006 coupled to the cylindrical drum wall 602. Ionised air is supplied from an ioniser 415 (not shown in Figure 10) to the air input 1002. The ionised air stream then passes through the air heater 1004 to be heated. The now heated ionised air stream is then supplied to the drum 230 via the plenum 1006. The waste processing machine 1000 further comprises a plurality of drum heaters 900 disposed on the cylindrical drum wall 602.

[0199] Referring to Figures 9A-C, there is shown a top view, a side view, and an end view, respectively, of a drum heater 900, according to some embodiments. The drum heater 900 further comprises at least one electrical heating element 904. In some embodiments, the drum heater 900 comprises two electrical heating elements 904. Each electrical heating element 904 comprises first and second electrical connectors 905 coupled to the respective ends of the electrical heating element 904.

[0200] The at least one electrical heating element 904 is configured to heat up due to electrical energy running therethrough (supplied by power supply 280) and subsequently transfer heat to the cylindrical drum wall 602 and the waste contained within the space defined by the drum 230. The at least one electrical heating element 904 may have a power input of between about IkW and about 5kW, for example. The at least one electrical heating element 904 may have a power input of about 2kW, for example. The amount of electrical energy running through the at least one electrical heating element 904 is controllable by the controller 210.

[0201] In some embodiments, the at least one electrical heating element 904 is configured to operate at a temperature between ambient temperature and about 400°C. The at least one electrical heating element 904 may be configured to operate at a temperature between ambient temperature and about 300°C, for example.

[0202] In some embodiments, the drum heater 900 further comprises a base block 902, the base block 902 including a material having high thermal conductivity. In some embodiments, the base block 902 extends between about 70% to about 95% of a lengthof the drum heater 900. The base block 902 may be manufactured from aluminium, copper, or another suitable material for facilitating heat transfer, for example.

[0203] The base block 902 may define a non-planar engagement surface 903 to engage with the cylindrical drum wall 602. In other words, the base block surface 903 may have a surface curvature the same as a surface curvature of the cylindrical drum wall 602, for example.

[0204] The at least one electrical heating element 904 may be configured to be embedded within the base block 902 such that it is either flush with or recessed from the base block surface 903. That is, the base block 902 may include at least one groove to receive the at least one electrical heating element 904, for example.

[0205] In some embodiments, the drum heater 900 further comprises at least one fluid heating element 906. That is, the drum heater 900 may have both electrical and fluid heating elements 904 and 906, for example. In such embodiments, the drum heating system 290 further includes a reservoir for holding a volume of fluid, a fluid heater for heating the fluid, and a pump for circulating fluid through the fluid heating element 906 and the fluid heater. The fluid heater may comprise a boiler system or a heat pump, for example. The fluid used in the fluid heater may be water, glycol, or another suitable fluid for such applications, for example.

[0206] The fluid heating element 906 is configured to absorb heat carried by the heated fluid circulating therethrough and subsequently transfer heat to the cylindrical drum wall 602 and the waste contained within the space defined by the drum 230. The amount of fluid running through the at least one fluid heating element 906 and the temperature to which the fluid is heated by the fluid heater is controllable by the controller 210.

[0207] In some embodiments, the at least one fluid heating element 906 is configured to operate at a temperature between ambient temperature and about 120°C. The at leastone fluid heating element 906 may be configured to operate at a temperature between about 60°C and about 80°C, for example.

[0208] The at least one fluid heating element 906 may be configured to be embedded within the base block 902 such that it is either flush with or recessed from the base block surface 903. That is, the base block 902 may include at least one groove to receive the at least one fluid heating element 906, for example.

[0209] The configuration of the base block 902 may assist in dispersing heat carried by the at least one electrical heating element 904 and the at least one fluid heating element 906 to the cylindrical drum wall 602. That is, the base block 602 may more effectively spread the heat transfer from the heating elements to the cylindrical drum wall 602, for example.

[0210] Processed Waste: Processed waste residue as produced by the waste processing machine 110 may comprise a solid and dry decomposed organic matter particulate. Water is evaporated from the waste load during the processing operation in the chamber 606. From the evaporation of water, the accelerated decomposition by the heated air stream and the ionised air stream, and the destructive action of the waste processing mixer 622, the total weight and / or volume of input waste can be reduced to around 20% of the input waste load by the time the processing has been completed. For example, in a drum of about lOOOL volumetric capacity, an input waste load of around 450kg may be added to residue of around 150kg already in the drum (retained from previous waste processing), and that input waste load may be reduced by around 80% of its mass to about 90kg. This would then only necessitate around 90kg of residue being removed from the processing drum 230 in the next unloading step, if all remaining residue were to be removed. However, as noted elsewhere herein, it can be desirable to retain a certain minimum amount of processed waste residue in the processing drum in order to improve processing efficiency of a subsequent load of organic waste.

[0211] The processed waste residue may be of a relatively neutral or slightly basic pH, and not contribute to any corrosive damage, skin problems, or environmental issues. For example, the processed waste residue may have a pH of between about 6 and 11, between about 7 and 10, or between about 7 and 9. In some embodiments, the processed waste residue may have a pH that is at least slightly basic. For example, the processed waste residue may have a pH of at least about 7, at least about 7.5, or at least about 8.

[0212] It has been surprisingly found that according to at least some embodiments as described herein, the process can produce processed waste residue that is at least slightly basic such that introduction of the slightly basic processed waste residue with typically acidic fresh food waste can facilitate at least an initial reaction during processing to provide a further enhanced processing capability. In some embodiments, the processes described herein comprise introduction of the processed waste residue with fresh food waste for processing, or the processes comprise retaining a residual amount of processed waste residue in the processing chamber between two or more batch processes.

[0213] For example, the amount of processed waste residue provided in the chamber (i.e. introduced or retained) for processing with unprocessed food waste (by weight % of total processed waste residue and unprocessed food waste) may be at least about 5, 10, 15, 20, 25, 30, 35, 40, 45, or 50. The amount of processed waste residue provided in the chamber for processing with unprocessed food waste (by weight % of total processed waste residue and unprocessed food waste) may be less than about 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10. The amount of processed waste residue provided in the chamber for processing with unprocessed food waste (by weight % of total processed waste residue and unprocessed food waste) may be in the range of any two of the above lower and / or upper amounts, for example between about 5 and 60, 10 and 55, 15 and 50, 20 and 45, or 25 and 35.

[0214] The processed waste residue may retain a high nutrient load, containing levels of nitrogen, phosphorous, potassium, and other metals and minerals, allowing for the processed waste to be used as a fertilizer for soil improvement.

[0215] Processed waste residue having genetically modified content may be denatured and / or degraded from the exposure to ionised oxygen in a processing cycle conformed to predetermined operating conditions, to such an extent that nucleic acids (such as DNA and RNA) in the degraded waste load may not be detectable or distinguishable by testing methods such as polymerase chain reaction (PCR) testing.

[0216] A comparison of the processed waste residue with other known fertilisers is provided in the below table.

[0217] In some embodiments, the nutritional content of the processed waste residue is sufficient to be used as animal fodder. In these embodiments, the processed waste residue may be fed directly to animals or livestock, or be mixed with other feed stock to provide a lower total concentration of nutrients depending on livestock requirements.

[0218] In some embodiments, the processed waste residue may be used as a feed stock for use in anaerobic digestion. The consistency of the nutritional and calorific contents of processed waste residue may allow for more consistent energy output in these purposes. Additionally, the stability and storage life of the processed waste residue may be beneficial to transport and use of the residue as a fuel source.

[0219] The processed waste residue may be provided as solid particulates. The solid particulates may comprise individual particulates in a size range of about 1 micron to about 5 mm. The individual particulates may be less than about (in microns) 5000, 2000, 1000, 500, 250, or 100, for example. The processed waste residue comprising the solid particulates may have a certain composition provided by a solids content, water (moisture) content and remaining void volume.

[0220] The solids content of the processed waste residue (based on total weight %) may be in the range of about 10 to 80, 20 to 70, or 30 to 60. The solids content of the processed waste residue (based on total weight %) may be at least about 10, 20, 30, 40, 50, 60, or 70. The solids content of the processed waste residue (based on total weight %) may be less than about 80, 70, 60, 50, 40, 30, or 20. The solids content of the processed waste residue may be in the range of any two of the above lower and / or upper amounts.

[0221] The processed waste residue may have a moisture content (by weight % of the total waste residue) of less than about 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, or 0.1. The moisture content (by weight % of the total waste residue) may be at least about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, or 20. The moisture content (by weight % of the total waste residue) may be in the range of any two of the above lower and / or upper amounts, for example between about 1 and 30, 2 and 25, or 5 and 20.

[0222] For a given volume of solid particulates, the void volume (in % of total volume of the residue) may be at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70. For a given volume of solid particulates the void volume (in % of total volume of the residue) may be less than about 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or10. For a given volume of solid particulates, the void volume (in % of total volume of the residue) may be provided in a range of any two of the above lower and / or upper amounts.

[0223] The processed waste residue may be a substantially ionised residue. The processed waste residue may be substantially sterile or inert, for example having a low microbe content.

[0224] The processed waste residue may have a low odour level. For example, the processed waste residue may have a low sulphide content. Sulphides may include hydrogen sulphide, carbonyl sulphide, methyl mercaptan, ethyl mercaptan, dimethyl sulphide, n-propyl mercaptan, thiophene, n-butyl bercaptan, and tetrahydrothiophene. The sulphide content of any individual or total combined amount of sulphides may be (in ppm) less than about 100, 90, 80, 70, 60, 50, 40, 30, 20, 10, 5, 1, 0.5, or 0.1.

[0225] The processed waste residue may have an organic solids content (by weight % of total residue) in an amount of at least about 30, 40, 50, 60, 70, 80, 90, or 95. In another embodiment, the proportion of organic solids in the solids content of the processed waste residue may be (by weight % of total solid content) in an amount of at least about 50, 60, 70, 80, 90, 95, 98, or 99. It will be appreciated that the organic solids content is derived from the input source including food scrap remains such as from various animal and vegetable sources. It will be appreciated that the organic content comprises various carbohydrates, fats, lignins, and proteins, for example. The processed waste residue may also have a low volatile organic content, for example other than butanone volatile organic compounds, and may be (pg / m3) less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, or 0.1.

[0226] In some embodiments, the processed waste residue may comprise a loose powder or particulate of a low moisture content (15% or less, for example between about 10% to about 15%, or around 12% for some applications). In such embodiments, a low moisture content may reduce clumps of residue forming. In such embodiments, the processed waste residue may be more easily dispersed in an environment as feedstock or released into the ocean as marine animal feed, particularly in embodiments where the waste processing machine 110 may be installed within a sea-going vessel.

[0227] In some embodiments, the processed waste residue may comprise dried insect larvae. In such embodiments the dried insect larvae may comprise black solider fly larvae, mealworm larvae, or other larvae bred and used for human consumption or protein rich feed stocks for animals. In such embodiments, it may be preferable for the dried insect larvae to maintain their shape, natural appearance, and colour as a result of processing.

[0228] In some embodiments, the processed waste residue may be conformed to target recipes in situations where either a particular waste residue composition is desired, or the input waste comprises a particular variety which requires specific processing.

[0229] In such embodiments, different operational parameters may be used or configured through the HMI 270 allowing a user to vary drum temperature, airflow through the drum, mixing shaft rotational speed, plenum temperature, operation timing and / or durations, and other configurable settings.

[0230] In some embodiments, these operational parameters may be target drum temperature, airflow, paddle (drum / agitator) speed, air plenum output temperature, and cycle time. The values assigned to these settings may be stored in memory 214 of controller 210 and accessed by HMI 270 over communication bus 330.

[0231] In an operation where a user desires to engage or modify an operational setting, this may be achieved by setting or accessing the operation setting through the HMI 270. The HMI 270 then sends an instruction to the controller 210 over communication bus 330. The controller 210 then accesses the operational setting within memory 214, and enables a user to modify or engage the selected setting through HMI 270.

[0232] In some embodiments, a user may set or modify an operational setting using a client device 140 over network 170. In such embodiments, the communication interface 320 directs instructions from client device 140 over network 170 to the controller 210, which in turn provides access to the user to either engage or modify the desired operational setting.

[0233] In some embodiments, the operational parameters relate to a one or more of target drum temperature, airflow, paddle speed, air plenum output temperature, and cycle time in combination. In such embodiments, these aggregated operational parameters may relate to a desired processed residue compositions or a specific waste input compositions.

[0234] In such embodiments, the aggregated operational parameters may be stored within memory 214 and accessed, modified, or engaged in the manner described above relating to individual operational parameters.

[0235] In other embodiments, the aggregated operational parameters may be stored within database 160. In such embodiments, a user may access, modify, or engage the aggregated operational parameters through HMI 270. The HMI 270 then issues an instruction to controller 210 over communication bus 330 to send retrieval instructions to the communication interface 335 over network 170 by the communication interface 320. The communication interface 335 then retrieves the aggregated operational parameters from database 160. These settings are transmitted back to the controller 210 by a reverse method of the process described above where they may be engaged by the controller 210.

[0236] When an operational setting or an aggregated operational setting is engaged by a user, the controller 210 receives the instructions from the HMI 270 to execute the settings. The controller then interacts with the required system through the communication bus 330 to engage or execute the settings. In some embodiments, the operational setting targets may correspond to a targeted range of values. In other embodiments, the operational setting targets may be specific values.

[0237] For settings relating to the targeted drum temperature, control modules 215 may read the specified drum temperature operational setting from memory 214 and cause a series of temperature readings to be taken by temperature sensors within the drum 230 at specified time intervals. These time intervals may be associated with the operational setting, or configured independently. If temperature within the drum 230 is found to be deviating from the specified operational setting, control modules 215 may send instructions over controller 210 to the air flow system 220 to adjust the heat of the air being sent into drum 230 to match the operational setting. In some embodiments, the control module 215 takes an average temperature sampling over a period of time in order to identify an average temperature within the drum 230, and compare that average to the desired operational setting target within memory 214.

[0238] For settings related to air plenum output temperature, control modules 215 may read the specified air plenum output temperature operational setting from memory 214 and cause a series of temperature readings to be taken by temperature sensors within the air flow system 220 at specified time intervals. These time intervals may be associated with the operational setting, or configured independently. If temperature of the air at the air plenum output is found to be deviating from the specified operational setting, control modules 215 may send instructions over controller 210 to the air flow system 220 to adjust the heat of the air being sent into drum 230 to match the operational setting.

[0239] For settings related to airflow speed, modules 215 may read the specified airflow speed operational setting from memory 214 and identify the current airflow speed of the intake fans 420. If current intake airflow speed is found to be deviating from the specified operational setting, control modules 215 may send instructions over controller 210 to the air flow system 220 to adjust the speed of one or more intake fans 420 to match the operational setting.

[0240] For settings related to mixer rotation speed, control modules 215 may read the mixer rotation speed operational setting from memory 214 and cause a series of mixer rotation speed readings to be taken by motor 240 at specified time intervals. These timeintervals may be associated with the operational setting, or configured independently. If mixer rotation speed is found to be deviating from the specified operational setting, control modules 215 may send instructions over controller 210 to the motor 240 to adjust the speed of the mixer rotation to match the operational setting.

[0241] For settings related to cycle time, control modules 215 may read cycle times associated with the operation of the waste processing machine 110. In some embodiments these cycles correspond to the start and end times of waste processing operations. In other embodiments, these cycle times may correspond to a time period for specified operational parameters to run, after which a new cycle with differing operational parameters is engaged. In some embodiments a default waste load processing cycle may comprise a time of 22 to 24hrs. In some embodiments a reduced waste load cycle time may comprise a time of 8-12 hours.

[0242] In some embodiments, two or more of the above settings may be applied simultaneously by control module 215 in accordance with an aggregated operational setting profile within memory 214.

[0243] In some embodiments, a user may selectively engage or modify one or more of the operational parameters through the HMI 270, and store the one or more operational parameters as a recipe profile within memory 214. In some embodiments, recipe profiles may be entered at client device 140 and stored within memory 214 through communication interface 320 over a network 170. In other embodiments, recipe profiles may be uploaded over network 170 to database 160 by communication interface 335, and subsequently pushed to memory 214 over network 170 through communication interface 320 at scheduled memory update intervals.

[0244] Some embodiments of aggregated operational parameters may relate to recipes for processing high moisture waste loads, composed of animal and / or vegetable waste. In such embodiments, processing of the waste load may require increased drum temperature, higher airflow, extended cycle times, and lower paddle speeds, in order to thoroughly evaporate excess moisture from the waste load.

[0245] Some embodiments of aggregated operational parameters may relate to recipes for processing low moisture waste loads, such as animal faeces, composed of high proportions of vegetable waste. In such embodiments, processing of the waste load may require slower rotational speeds and lower air flow speeds to prevent the dryer material from becoming airborne.

[0246] Some embodiments of aggregated operational parameters may relate to recipes for processing hazardous or contaminated waste loads, comprising contaminated animal or plant matter which may be bacteriologically dangerous or otherwise harmful to humans or the environment. In such embodiments, a lower airspeed and a longer cycle time may be required to process the waste load, in order to maximize exposure to the ionised air stream which may sterilise the hazardous waste load through processing.

[0247] Some embodiments of aggregated operational parameters may relate to recipes for processing genetically modified (GM) material such as animal or plant waste. In such embodiments, a lower airspeed and a longer cycle time may be required to process the waste load, in order to maximize exposure to the ionised air stream which may sterilise the waste load through processing.

[0248] Some embodiments of aggregated operational parameters may relate to recipes for processing waste food material such as raw or baked pastry, fruit, or other plant material. In such embodiments, a higher airflow, modified cycle times, and varying temperature may be required to process the waste loads.

[0249] Some embodiments of aggregated operation settings may relate to recipes for processing waste food material waste loads high in oil content, such as fish waste. In such embodiments, regularly pausing the operation of the processing drum may allow a user to drain excess oil from the waste load for storage, further processing, or disposal.

[0250] Some embodiments of aggregated operational parameters may relate to recipes for processing waste food material waste loads high in fruit, vegetable, and other plant material. In such embodiments, a higher airflow, lower temperature drum, lower airplenum temperature, modified cycle times, and varying temperature may be required to process the waste loads, to avoid caramelisation of the waste load during waste processing.

[0251] Some embodiments relate to a method of processing animal faeces. Some embodiments relate to a method of processing horse faeces. Some embodiments relate to a method of processing contaminated animal faeces. Some embodiments relate to a method of processing contaminated horse faeces. Some embodiments relate to a method of processing exotic animal faeces. Some embodiments relate to a method of processing fish waste. Some embodiments relate to a method of processing salmon waste. Some embodiments relate to a method of processing cow gut. Some embodiments relate to a method of processing abattoir waste. Some embodiments relate to a method of processing vegetables. Some embodiments relate to a method of processing onions. Some embodiments relate to a method of processing tomatoes. Some embodiments relate to a method of processing fruit. Some embodiments relate to a method of processing citrus peel. Some embodiments relate to a method of processing uncooked meat. Some embodiments relate to a method of processing coffee. Some embodiments relate to a method of processing pasta. Some embodiments relate to a method of processing uncooked pasta. Some embodiments relate to a method of processing raw pastry. Some embodiments relate to a method of processing baked pastry. Some embodiments relate to a method of processing mixed loads of raw and baked pastry. Some embodiments relate to a method of processing a bulk food source material to generate a processed food material suitable for use as a livestock food source. Such bulk food source material may include seaweed or cultured insect bodies or larva, for example. Some embodiments relate to a method of processing insect larvae. Some embodiments relate to a method of processing black soldier fly larvae. Some embodiments relate to a method of processing mealworm larvae.

[0252] In some embodiments, the sensors of the system comprise heated air inlet temperature sensors, ionised air inlet temperature sensors, exhaust air temperature sensors, and drum pressure sensors. In some embodiments, exemplary sensor values expected during operation of the machine 110 may be indicated by the below table.

[0253] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. An organic waste processing system including:a drum defining a space to receive waste to be processed;a mixer having mixing blades rotatable in the drum to break down waste in the drum;a motor to drive rotation of the mixer;an inlet hatch to receive the waste into the drum;an outlet hatch for removal of processed waste residue from the drum;a heated air supply subsystem including an air heater, a fan and a first air supply line to supply a first heated air stream into the drum;an ion generator to receive an inlet air stream and generate an ionised air stream at an outlet of the ion generator;a coupling conduit coupled at one end to the outlet of the ion generator and coupled at an opposite end to an ionised air inlet into the drum to supply the ionised air stream to the space;wherein the first air supply line and the coupling conduit are configured so that mixing of the ionised air stream and the first heated air stream occurs downstream of each of the ion generator and the air heater.

2. The system of claim 1, wherein the first air supply line and the coupling conduit are configured so that mixing of the ionised air stream and the first heated air stream occurs only in the drum.

3. The system of claim 1 or claim 2, wherein the first air supply line is configured to provide heat to the ionised air stream.

4. The system of claim 3, wherein the heating subsystem includes a heat exchanger in the first air supply line and the heat exchanger is configured to provide heat to the coupling conduit, when the first heated air stream passes through the heat exchanger to heat the ionised air stream.

5. The systems of claim 4, wherein the coupling conduit passes through the heat exchanger.

6. The system of any one of claims 1 to 5, wherein the coupling conduit is configured to supply the ionised air stream directly from the ion generator into the drum via the ionised air inlet.

7. The system of any one of claims 1 to 6, wherein the first air supply line is configured to supply the first heated air supply stream into the drum via a first heated air inlet in a wall of the drum.

8. The system of any one of claims 1 to 7, wherein the ionised air inlet is disposed in a first end wall of the drum.

9. The system of claim 8, wherein the ion generator is disposed close to an outside of the first end wall.

10. The system of claim 8 or claim 9, wherein the mixer includes a mixing shaft supported by the first end wall and by an opposite second end wall of the drum, wherein the ionised air inlet is above a level of the mixing shaft.

11. The system of any one of claims 1 to 10, wherein the coupling conduit is configured to have a single bend between the outlet of the ion generator and the ionised air inlet.

12. The system of any one of claims 1 to 11, wherein the ion generator is configured to provide the ionised air stream with a concentration of greater than zero and less than or equal to 200 million negative ions per cubic centimetre at the outlet of the ion generator.

13. The system of any one of claims 1 to 12, wherein the fan is a first fan and the heating subsystem includes a second fan and a second air supply line for supplying a second heated air stream into the drum.

14. The system of claim 13, wherein the second air supply line is coupled to the drum to supply the second heated air stream into the drum at at least one different inlet location to the first heated air stream.

15. The system of claim 13 or 14, wherein the second air supply line is configured to split the second heated air stream into multiple sub-streams and to provide the multiple sub-streams into the drum at spaced locations.

16. The system of any one of claims 1 to 15, wherein the outlet hatch is in an end wall of the drum and / or is positioned above a level of a mixing shaft of the mixer.

17. The system of any one of claims 1 to 16, further including a controller to control operation of the motor, the heated air supply subsystem, and the ion generator.

18. An organic waste processing system, including:a static drum defining an interior space to receive organic waste to be processed;a mixer having mixing blades to rotate in the space to break down waste in the drum;a motor to drive rotation of the mixer;an inlet hatch to receive the waste into the drum;an outlet hatch to allow disgorgement of processed waste residue;an air heating subsystem to supply heated air into to drum;an ion generator to generate an ionised air stream into the drum; anda drum heating subsystem to heat a lower part of a drum wall of the drum, the drum heating subsystem including a first heater on the drum wall and a second heater on the drum wall that is spaced from the first heater, wherein the first heater and the second heater are independently controllable;a controller to control operation of the motor, the air heating subsystem, the ion generator, and the drum heating subsystem.

19. The system of claim 18, wherein the mixer includes an axial mixing shaft that defines a longitudinal axis, wherein the first heater and the second heater are configured to extend along an outside of the drum wall.

20. The system of claim 19, wherein the first heater and the second heater extend in a longitudinal direction.

21. The system of claim 19 or claim 20, wherein the first heater and the second heater are circumferentially spaced from each other along the drum wall.

22. The system of claim 21, wherein the inlet hatch is disposed on a forward side of the drum and wherein the first heater is disposed on the drum wall on or forward of avertical line extending down from the mixing shaft and the second heater is disposed on the drum wall rearward of the vertical line.

23. The system of any one of claims 18 to 22, wherein the drum heating subsystem includes between three and six heaters, each of which is independently controllable by the controller.

24. The system of claim 23, wherein the controller is configured to alter temperature set points for each of the heaters over time during a processing operation that includes rotation of the mixer in the drum.

25. The system of claim 23 or claim 24, wherein the heaters are asymmetrically circumferentially spaced across the lower part of the drum wall.

26. The system of any one of claims 18 to 25, wherein the first heater and the second heater each include an electrical heating element.

27. The system of claim 26, wherein the first heater and the second heater each include a fluid heating element.

28. The system of claim 27, wherein the first heater and the second heater each include a base block to support the electrical heating element and the fluid heating element.

29. The system of claim 28, wherein the base block includes a material having high thermal conductivity and / or the base block defines a non-planar engagement surface to engage with the drum wall and / or the base block extends between about 70% to about 95% of a length of the respective heater.

30. The system of any one of claims 18 to 29, wherein the first heater and the second heater are each coupled to the drum wall with a paste having a high thermal conductivity.

31. The system of claim 20, wherein the first heater and second heater each extend along between about 50% and about 90% of a longitudinal length of the drum wall.

32. The system of claims 23 to 25, wherein each of the heaters is circumferentially spaced from another of the heaters by a minimum distance of 2 cm.

33. The system of any one of claims 18 to 32, wherein the first heater and the second heater are longitudinally offset from each other along the drum wall.

34. The system of any one of claims 18 to 33, further including clamps to clamp the first heater and the second heater to the drum wall.

35. The system of any one of claims 18 to 34, wherein the controller controls the drum heating subsystem and the air heating subsystem to bring the temperature of waste in the drum to a temperature in the range of 50 degrees to 80 degrees, optionally in the range of 55 degrees to 75 degrees, optionally in the range of 60 degrees to 70 degrees.

36. The system of any one of claims 18 to 35, wherein the static drum is a cylindrical drum.

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