Stacked Insect Larvae Waste Processing System
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Solution Overview
Problem
Existing systems for processing animal and bird feces using insect larvae face issues with low productivity, costly heating and ventilation, substrate degradation, and inefficient air flow, leading to high operational expenses and environmental pollution.
Innovation Solution
A system with stacked, elongated reaction vessels for organic waste processing, featuring a plenum wall with air openings for cross-ventilation and a feeder system that preheats and mixes only the substrate being moved, reducing the need for large facilities and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyer belt systems are used for substrate processing, then continuous processing is achieved, but the systems become very bulky and require huge facilities with low productivity per occupied area
Solution Approach 1:
The patent transitions from horizontal conveyer belt processing to vertical stacked tray processing. Multiple trays are stacked one on top of another, utilizing the vertical dimension to increase processing capacity within a compact footprint. This dimensional change allows continuous processing while dramatically reducing the horizontal space required, thereby increasing productivity per occupied area.
Solution Approach 2:
The patent implements nested trays where younger larvae trays are positioned inside or adjacent to older larvae trays in a stacked configuration. This nesting arrangement allows multiple processing stages to occupy overlapping spatial volumes, maximizing the use of available space and increasing the number of processing units within a given facility volume.
2Object-generated harmful factors
If air flow speed along the tunnel is increased to improve ventilation, then decomposition gases are removed more effectively, but the substrate at the beginning of the tunnel gets very dry and larvae cannot process it
Solution Approach 1:
The patent applies different air flow rates to different locations within the processing system. Faster air flow is directed at trays generating more decomposition gases, while slower air flow is applied to trays where substrate moisture must be preserved. This localized quality adjustment allows effective gas removal without causing excessive substrate drying.
Solution Approach 2:
The patent dynamically adjusts air flow parameters (speed and volume) based on the specific needs of different processing stages and locations. By changing air flow parameters rather than maintaining a constant high speed, the system achieves effective ventilation while preventing substrate moisture loss that would occur with continuously high air flow rates.
3Object-generated harmful factors
If tunnel height is increased to 60-70 cm to decrease air speed and improve ventilation distribution, then sufficient air flow is achieved, but the system becomes very messy and bulky
Solution Approach 1:
The patent moves from horizontal tunnel ventilation to vertical stacked tray ventilation with air flow distributed through the vertical dimension. Air is introduced at the bottom and flows upward through multiple tray levels, or is distributed through side walls of vertically stacked trays. This vertical air distribution achieves uniform ventilation without requiring excessive horizontal tunnel height.
Solution Approach 2:
The patent divides the processing system into multiple separate, manageable tray modules stacked vertically rather than using a single large horizontal tunnel. Each tray or stack of trays can be independently ventilated with appropriate air flow rates, allowing precise control of ventilation distribution without requiring a uniformly high tunnel ceiling throughout the entire processing length.
4Reliability
If triple conveyer systems are used to prevent older larvae migration, then substrate processing completeness is improved, but heating and ventilation complexity increases and facilities become bulkier
Solution Approach 1:
The patent nests younger larvae trays inside or adjacent to older larvae trays in a vertical stack, creating a nested arrangement where multiple processing stages coexist in overlapping spatial volumes. This nesting ensures that larvae of different ages remain in their designated zones without migrating between horizontal sections, maintaining processing completeness while simplifying the overall system configuration compared to multiple horizontal conveyer lines.
Solution Approach 2:
The patent resolves the larvae migration problem by using vertical stacking with controlled air flow in the vertical dimension rather than relying on multiple horizontal conveyer sections. Air flow patterns are designed to maintain stable larval zones vertically, preventing migration without requiring complex multi-section horizontal conveyer systems with intricate heating and ventilation controls for each section.
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 configuration enhances productivity, reduces energy costs, and minimizes environmental impact by ensuring uniform airflow and preventing substrate drying, allowing larvae to process waste more efficiently and effectively.
Implementation Method 1
an air circulation system for circulating air through the air spaces by passing air through the openings in the plenum wall
Implementation Method 2
a feeder system for loading raw organic waste onto the reaction vessels... preheats and mixes only the substrate being moved
Data Source
AI summary
The present invention is a system for processing organic waste using insect larvae, which has the advantage of being able to process large quantities of organic fecal waste material. The system includes a plurality of substantially flat reaction vessels stacked one on top of the other in parallel arrangement to form a processing blocks 11. Each of the reaction vessels in the processing block 11 are dimensioned and configured to contain a quantity of organic waste, each reaction vessel having front and back ends and side edges, the reaction vessels each being separated from the reaction vessel above by an air space 23, the processing block being contained in a plant enclosure having side walls. At least one of the side walls of the plant enclosure (plenum wall 38) is positioned adjacent the processing block such that the plenum wall is adjacent one of the side edges of the reaction vessels. The plenum wall has a plurality of openings which open to the air spaces and the openings positioned on the plenum walls such that openings are immediately adjacent air spaces. The system further includes an air circulation system for circulating purified and adjusted air through the air spaces by passing air through each of the openings in the plenum wall. The system also includes a feeder system for loading raw organic waste onto the reaction vessels and a discharge system for removing processed organic waste from the reaction vessels.