Counter Current Feedstock Extraction for Near-Zero Waste Conversion
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Solution Overview
Problem
The food processing industry faces challenges in managing waste efficiently, with billions of kilograms of organic waste generated annually, leading to environmental and economic issues, and there is a need for improved energy management and production efficiency to reduce waste and greenhouse gas emissions.
Innovation Solution
A process and system for real-time optimization of feedstock processing using IoT-based sensors and an Efficiency Digital Algorithm, which includes steps like feedstock profiling, washing, counter current diffusion, and decortication, to minimize waste and maximize the conversion of feedstock into valuable products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional waste management methods (landfill, composting) are used, then waste disposal is achieved, but environmental harm increases (greenhouse gas emissions, pollution)
Solution Approach 1:
The patent converts organic waste, which would normally decompose and release harmful greenhouse gases, into valuable products through anaerobic digestion to produce biogas for energy, and further processes to create fertilizers and animal feed. This transforms the harmful waste stream into beneficial resources, eliminating environmental harm while reducing waste loss.
Solution Approach 2:
The system recovers multiple valuable components from organic waste that would otherwise be discarded: biogas for energy production, digestate for fertilizer, and processed materials for animal feed. This comprehensive recovery approach addresses both environmental harm reduction and waste minimization simultaneously.
2Object-affected harmful factors
If waste is minimized through better processing, then environmental impact reduces, but processing complexity increases
Solution Approach 1:
The patent divides the waste processing system into distinct functional modules: anaerobic digestion unit for biogas production, separation unit for digestate processing, drying unit for fertilizer production, and processing unit for animal feed. This segmentation allows each component to be optimized independently and simplifies overall system management while achieving comprehensive waste minimization and environmental protection.
3Productivity
If more feedstock is converted into products, then productivity increases, but energy consumption increases
Solution Approach 1:
The anaerobic digestion process is self-heating, generating thermal energy from the decomposition of organic matter that can be used to maintain optimal digestion temperatures and power processing equipment. This self-service energy generation reduces external energy consumption while maintaining high conversion efficiency of feedstock into valuable products.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces waste, enhances production efficiency, and allows for the conversion of nearly all feedstock into valuable products, improving energy management and reducing environmental impact.
Implementation Method 1
regulating a diffusion process in which a counter current diffusion takes place between an organic phase and an aqueous phase
Data Source
AI summary
The invention relates to a process, method and devices for recovery of products from a feedstock such as an organic, non-organic or biodynamic feedstock. The products include consumables such as high nutrition foods, nutraceuticals and bioactive compounds and/or non-consumables such as energy and synfuels. The invention typically includes real-time process optimisation. The devices include a counter current diffusion extractor and a decorticator for deriving useful products from a feedstock, optionally for consumption in further processing.