Two-Stage Meat-and-Bone Meal Processing for Fertilizer Ash
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Solution Overview
Problem
Existing methods for processing meat-and-bone meal do not provide a safe and efficient means to produce ashes that can be used for fertilizer production while simultaneously generating energy, as they are prone to damage incinerators and fail to effectively destroy BSE-causing prions.
Innovation Solution
A method utilizing a catalytic fluidised bed gasifier and thermal boiler process with hydrogen-enriched gas to convert meat-and-bone meal into synthetic gas and ashes, followed by grinding and separation, achieving high-energy and ash output suitable for fertilizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If incineration is carried out at high temperature to destroy BSE prions, then the destruction of BSE prions is improved, but the incinerator is prone to damage
Solution Approach 1:
The incineration process is divided into two distinct stages: a gasification stage at lower temperature (400-1000°C) where meat-and-bone meal is converted to syngas, and a combustion stage at higher temperature (600-2000°C) where the syngas is burned to destroy BSE prions. This segmentation allows the incinerator to avoid direct exposure to the damaging phosphorus components during high-temperature combustion, while still achieving effective prion destruction through the syngas combustion phase.
Solution Approach 2:
Syngas acts as an intermediary substance that mediates between the meat-and-bone meal and the incinerator. The syngas produced in the gasification stage serves as a cleaner fuel for the combustion stage, eliminating the need to directly combust the phosphorus-containing meat-and-bone meal at high temperatures, thus protecting the incinerator while maintaining prion destruction effectiveness.
2Power
If phosphorus component is present during combustion, then the energy output is improved, but the strength of materials used for gasification and combustion deteriorates
Solution Approach 1:
The phosphorus-containing solid residue (ashes) is extracted and removed from the combustion process. By separating the ash production step from the combustion step, the patent eliminates the damaging effect of phosphorus on combustion materials while still utilizing the energy content of the meat-and-bone meal through syngas combustion.
Solution Approach 2:
The process segments the treatment of phosphorus-containing materials from the energy generation process. The gasification stage handles the phosphorus-containing solid material separately, producing syngas that can be burned without phosphorus interference, thus protecting combustion materials while maintaining energy output.
3Productivity
If conventional incineration methods are used, then the processing speed is improved, but the manufacturing precision of safe ashes for fertilizer is worsened
Solution Approach 1:
The patent implements continuous processing where meat-and-bone meal is continuously fed into the gasifier, syngas is continuously generated and combusted, and ashes are continuously produced and collected. This continuous operation maintains consistent temperature conditions and process control, ensuring both high processing speed and the safety/quality precision required for fertilizer-grade ashes.
Solution Approach 2:
The patent utilizes controlled parameter changes in temperature (400-1000°C for gasification, 600-2000°C for combustion) to achieve both efficient processing and safe ash production. By optimizing these temperature parameters and maintaining them within specific ranges, the process achieves high productivity while ensuring the ashes meet safety standards for fertilizer use.
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
The method efficiently produces approximately 20 Kg of ashes from 100 Kg of meat-and-bone meal, effectively destroying BSE prions and generating energy, with the ashes being usable for fertilizer applications.
Implementation Method 1
feeding a catalytic fluidised bed gasifier with a meat-and-bone meal and an orthosilicate with a gas stream comprising oxygen, for obtaining a synthetic gas stream and ashes, wherein the catalytic fluidised bed gasifier is set at a temperature from 400° C. to 1000° C.
Implementation Method 2
catalytic fluidised bed gasifier
Implementation Method 3
feeding a thermal boiler with the ground ashes, the obtained synthetic gas, and a gas stream comprising oxygen for separating the ashes from the orthosilicate; wherein the thermal boiler is at a temperature from 600° C. to 2000° C.
Implementation Method 4
thermal boiler is at a temperature from 600° C. to 2000° C.
Implementation Method 5
grinding the obtained ashes
Data Source
AI summary
A method for processing meat-and-bone meal for obtaining ashes includes steps of: feeding a catalytic fluidized bed gasifier with a meat-and-bone meal and an orthosilicate with a gas stream comprising oxygen, for obtaining a synthetic gas stream and ashes, wherein the catalytic fluidized bed gasifier is at a temperature from 400° C. to 1000° C.; grinding the obtained ashes; feeding a thermal boiler with the ground ashes, the obtained synthetic gas and a gas stream comprising oxygen for separating the ashes from the orthosilicate, wherein the thermal boiler is at a temperature from 600° C. to 2000° C.; and collecting the separated ground ashes.