HK1182126B - Device and method for portable renewable energy microgeneration system - Google Patents

Description

Renewable energy micro power generation equipment and method

Cross Reference to Related Applications

This application claims priority from united states provisional application No. 61/323,186 filed on 12.4.2010 and united states provisional application No. 61/348,689 filed on 26.5.2010, which are hereby incorporated by reference in their entirety.

Technical Field

The present invention relates to an improved method and apparatus for providing renewable energy and making users less dependent on local utility providers by recycling their organic waste material on site. More particularly, the present invention relates to improvements to anaerobic digesters that allow users to convert organic waste into sustainable energy.

Background

There is a need in the art for a renewable energy micro-power generation system of a single, modular, portable configuration that will allow users to convert organic waste into sustainable energy on-site. There is also a need in the art for a micro-power generation system having a reduced footprint, having separate vessels for different components of the micro-power generation system, modular interconnections between the vessels, and renewable energy sources with increased throughput.

Disclosure of Invention

To address at least one of the problems and/or disadvantages described above, a non-limiting object of the present invention is to provide a renewable energy micro power generation system. The renewable energy micro-power generation system includes a portable processing container having a mixing tank for mixing waste with a liquid, a leaching pump in fluid communication with the mixing tank, the leaching pump configured to soak the waste into smaller pieces, a plurality of small storage tanks in fluid communication with the mixing tank, the small storage tanks configured to at least one of pasteurize and thermophilic anaerobic digestion the waste, a large storage tank in fluid communication with the plurality of small storage tanks, the large storage tank configured to mesophilic anaerobic digestion the waste after at least one of pasteurizing and thermophilic anaerobic digestion the waste, and a dewatering unit in fluid communication with the large storage tank, said dehydration unit configured to dry the remainder of said waste after mesophilic anaerobic digestion of said waste; a controller for automatically flowing the waste material between the mixing tank, the plurality of small storage tanks, the large storage tank and the dehydration unit such that a user does not need to complete any work for performing mesophilic anaerobic digestion after the waste material is loaded into the mixing tank; and a portable gas storage container comprising a gas storage tank configured to store biogas produced by mesophilic anaerobic digestion, wherein the portable processing container and the portable gas storage container are configured to be transported to a site and placed in fluid communication with each other such that the gas storage tank is capable of storing biogas produced by mesophilic anaerobic digestion in the processing container at the site. These and other objects, advantages and features of the present invention will become more readily apparent from the following description when taken in conjunction with the accompanying drawings and appended claims.

Drawings

Aspects of the invention may be better understood by referring to the following drawings, which are a part of this specification and which illustrate preferred embodiments of the invention:

FIG. 1A is an isometric view showing an example of a micro-power generation device for renewable energy in accordance with a non-limiting embodiment of the present invention;

FIG. 1B is an isometric view showing the apparatus of FIG. 1A with the vessel and the compressor housing removed;

FIG. 1C is a plan view showing the apparatus of FIG. 1B;

FIG. 1D is a front view showing the apparatus of FIG. 1C;

FIG. 1E is a schematic view of the apparatus of FIGS. 1A-1 CD;

FIG. 2 is an isometric view illustrating a shredder unit according to a non-limiting embodiment of the present invention;

FIG. 3 is an isometric view showing a dewatering unit according to a non-limiting embodiment of the present invention;

FIG. 4 is a schematic diagram illustrating a controller according to a non-limiting embodiment of the present invention;

FIG. 5 is an isometric cross-sectional view illustrating a gas storage tank according to a non-limiting embodiment of the present invention;

FIG. 6 is a schematic diagram illustrating water and waste conduits according to a non-limiting embodiment of the present invention;

FIG. 7 is a schematic view illustrating a gas pipeline according to a non-limiting embodiment of the present invention; and

fig. 8 is a schematic diagram showing a 6 ton per day configuration of the present invention.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.

DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION

The present invention overcomes the above-described shortcomings of the prior art and provides at least some of the advantages described below by providing a renewable energy micro-power generation system having a unitary, modular, portable configuration that enables a user to convert organic waste into sustainable energy on-site. In addition, the present invention provides a portable renewable energy micro-power generation system with reduced footprint, with modular components and component groupings, and with increased throughput. Thus, the micro-power generation system is designed to meet the needs of a particular user and can be installed and connected to existing power systems such that within a few weeks (or within hours if the system is pre-sprinkled with life digesta), the user can generate his or her own energy for heating, hot water and/or regular power requirements.

In more detail, the various components of the renewable energy micro-generation system work together to perform anaerobic digestion processes that generate heat, electricity, biogas and fertilizers from what is considered "waste". By this unique configuration of the renewable energy micro-generation system, the present invention is able to provide all the required components to accomplish the process in the form of one or more independent containers, thereby providing a portable system that can be conveniently connected to a variety of structures (e.g., homes, industrial buildings, and outdoor facilities). Furthermore, the flexibility of the renewable energy micro-generation system makes it practical for various applications, such as it provides power for remote villages, telecommunication towers, war or disaster relief areas where waste is abundant and power and/or heat demand is high.

In addition to providing electricity and heat, the renewable energy micro-generation system of the present invention also provides a "green" solution to waste treatment, maximizing the amount of useful energy that can be utilized from organic materials. It effectively eliminates the expense of removing waste by providing a user with a closed, convenient place to dispose of his or her waste. It also helps to eliminate runoff contamination. Also, in addition to allowing a user to recycle his or her organic waste on site, the renewable energy micro-power generation system of the present invention reduces pollution by allowing the user to be less dependent on using various pollution-generating energy generation methods of a utility company. In addition, it reduces carbon emissions from transporting the waste to centralized processing facilities (e.g., dumping or larger scale anaerobic digestion systems).

These and other advantages provided by the present invention will be better understood by the following description and preferred embodiments in the drawings. In describing the preferred embodiments, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

A. Device for renewable energy micro-generation

Referring to the drawings, fig. 1A-1D provide schematic multiple views of a device 100 for renewable energy micro-generation (hereinafter "REM device 100") according to a non-limiting embodiment of the present invention, and fig. 1E provides a schematic of the REM device 100 according to a non-limiting embodiment of the present invention. The REM device 100 includes a first receptacle 102 and a second receptacle 104 that provide a portable housing to house a plurality of components 106 and 128 of the REM device 100. The first container 102 houses a shredder unit 106, a surge tank 108, two small storage tanks 110, a large storage tank 112, a dehydration unit 114, a gas scrubber 116, and an Electronic Control Unit (ECU) 118. And the second vessel 104 houses a gas storage tank 120. REM device 100 further includes a biogas engine 122 disposed adjacent second vessel 104; a burner 124 disposed outside the first container 102; a liquid tank 126 disposed adjacent the first container 102; a compressor 128 disposed in a compressor housing 130 adjacent the first vessel 102; and a plurality of pumps 132A-132D, a plurality of valves 134A-134C, a plurality of conduits 136A-136C and line connections 138 for functionally connecting the components 106 and 128 together. The plurality of components 106 provided in upper and adjacent locations within these vessels 102, 104 work together with 128 to perform anaerobic digestion processes in a mobile, modular renewable energy micro-power generation system to generate heat, electricity, biogas and fertilizer from waste/dirt.

The dirt/waste is deposited into the shredder unit 106 loaded into the REM apparatus 100, and the function of the shredder unit 106 is to mix the dirt/waste loaded into the REM apparatus 100 and mix it with a liquid (e.g., drinking water and/or grey water). The function of the surge tank 108 is to store and preheat the water/dirt/waste mixture produced with the shredder unit 106. The function of the small storage tank 110 is to pasteurize the preheated water/dirt/waste mixture produced with the surge tank 108 or to partially digest the preheated water/dirt/waste mixture by thermophilic anaerobic digestion when pasteurization is not required for the entire anaerobic digestion process. The function of the large holding tank 112 is to perform mesophilic anaerobic digestion with the partially pasteurized or digested water/dirt/waste mixture produced by the small holding tank 110. The function of the dewatering unit 114 is to remove liquid from the remainder of the water/dirt/waste mixture after anaerobic digestion is completed in the small storage tank 110 and/or the large storage tank 112. The function of the gas scrubber 116 is to clean biogas generated during the thermophilic anaerobic digestion and/or mesophilic anaerobic digestion in the small storage tank 110 and/or the large storage tank 112, respectively. The function of the gas storage tank 120 is to store the cleaned biogas generated by the gas scrubber 116. The biogas engine 122 functions to simultaneously generate electricity and heat from the cleaned biogas stored in the gas storage tank 120. The function of the ECU118 is to control the flow of liquid, dirt/waste, water/dirt/waste, and biogas through the REM apparatus 100 as needed to produce heat, electricity, biogas, and fertilizer in a continuous, regenerative cycle. The function of the burner 124 is to safely burn the remaining biogas. And the function of the compressor 128 is to generate compressed air for stirring the water/dirt/waste in the small storage tank 110. Each of the containers 102 and 104 and the components 106 and 128, respectively, will be described below.

i. Container 102 and container 104

In order to enable the REM device 100 to be shipped as a modular unit to substantially any location, the container 102 and the container 104 that house the various components 106 and 128 of the REM device 100 are configured to meet the size and weight requirements of the relevant road regulatory and governmental agencies. For example, in FIG. 1A, the first container 102 (shown with the top removed) is a standard 40-inch containerContainers of the size "high containers" (40 feet x8 feet x9.5 feet; payload: 60,350 lbs; volume: 2,376 ft)³) And the second vessel 104 (again shown with the roof removed) is a standard 20-foot "tall" container (size: 19.8 feet x8 feet x8.5 feet; payload: 48,600 lbs; volume: 1,164ft³). Such containers are specifically designed to be operated by ship-to-shore gantry cranes, stacked and stored to container ships, and connected to container transport trailers, making these containers 102 and 104 particularly suitable for commercial and marine transport. These containers 102 and 104 are also particularly well suited for military air transport using some military aircraft, such as Sikorsky SKYCRANE brand helicopters and Lockheed C-130HERCULES brand aircraft. Other standard containers (e.g., 45-foot and 30-foot containers) may also be used.

a. Substrate

The first vessel 102 includes a concrete base that houses a number of conduits 136A-136C that interconnect the various components 106-128 of the REM device 100. In fabrication, the conduits 136B and 136C are assembled using a jig to ensure that all of the components 106 and 114 can be properly positioned in a repeatable, modular manner. The clip is made using the reverse profile of these components 106 and 114. It is preferred to use straw-based concrete to form the base of the container 102, as straw-based concrete is a sustainable material that can provide a degree of plasticity in the concrete base.

The concrete base is designed to support the plurality of components 106 in the first vessel 102 and 114 by the profile of the underlying tank base. This structure not only provides stability along the outer walls that support the canister in place, but also supports the components 106 and 114 to ensure that the pipe fitting does not break off during transport. These components 106 and 114 may also be supported in the container 102 using insulating materials designed to provide a tight fit between those particular components 106 and 114 and the container 102. Optionally, the base of the first container 102 may include a metal frame to create the force and allow the member 106 and 114 to slide into the first container 102.

b. Dashboard 140 and loading platform 142

The first container 102 also includes a dashboard 140 and a loading platform 142 at the same end for loading dirt/waste into the shredder unit 106 and for unloading fertilizer output by the dehydration unit 114. The instrument panel 140 includes a door 144 that can be opened to allow a user to access the plurality of components 106 and 114 contained therein. The first container 102 also includes a pair of outer double doors 146 located at the same end as the instrument panel 140 of the first container 102. Although these doors 144 are not shown in the first container 102 for clarity purposes, they are clearly shown in the second container 104. These doors 146 are of the type commonly found in existing 40-foot or 20-inch shipping containers.

The instrument panel 140 provides protection for a user from the plurality of components 106 and 114 contained in the first container 102. And the door 144 provides access for maintenance and security checks in these components 106 and 114. The instrument panel 140 may also include access openings (not shown) for accessing portions of the distal sides of the plurality of components 106 and 114 disposed adjacent to the instrument panel 140 to provide a maximum amount of access and maneuverability for the user to perform maintenance and/or safety checks on these components 106 and 114.

The loading platform 142 is configured to allow dirt/waste to be loaded into the shredder unit 106 and solid waste (e.g., mulch) to be transported away from the dewatering unit 114 using a wheelbarrow or other similar wheeled conveyance. The loading dock 142 is also configured to fold between the instrument panel 140 and the pair of double doors 146 so that it can be stowed during transport of the first container 102. A control box 148 for operating and monitoring the REM apparatus 100 through the function of the ECU118 is also provided on the dashboard 140, and the control box 148 will be folded over behind the double door 146 of the first container 102 during transport. Emergency stop and all-off features are also located on the instrument panel 140. Since access to the gas storage tank 120 should not be required after the REM apparatus is in operation (except for routine maintenance and safety checks), it is preferred that the component gas storage tank 120 remain secured behind the double door 146 of the second container 104 during shipping and during operation of the REM apparatus 100.

The loading platform 142 is sufficiently strong to support a significantly greater weight so that a user can load a large amount of dirt/waste into the anaerobic digester at one time. A ramp 150 may also be provided at the loading platform 142 so that wheeled transport, such as a wheelbarrow, may be easily moved to and from the top of the loading platform 142. Ramp 150 is constructed of standard square tubes that are welded together at their tops with a spot weld so that it provides a disposable surface for all weather conditions. Ramp 150 is removably attached to loading platform 142 using an angled hook that can clip ramp 150 to a corresponding receiver of loading platform 142, which allows a user, such as a horse park, to remove ramp 150 and use their existing ramp in its place. The loading platform 142 and ramp 150 are preferably made of galvanized steel to protect them from elemental corrosion and reduce manufacturing costs. The multiple legs of loading platform 142 and ramp 150 are preferably adjustable according to different terrain to provide maximum stability, for example, on uneven surfaces.

c. Ventilation device

Preferably a forced air system may be incorporated into each container 102 and 104 to avoid the accumulation of odors and explosive air. Namely, the forced ventilation system includes: an electric fan (not shown) that creates a pressure differential between the interior of each container 102 and 104 and the air to circulate air through the louvers disposed therein in each container 102 and 104. This process not only avoids the accumulation of hazardous gases in the vessels 102 and 104, it also removes heat to aid in cooling the machinery located in the first vessel 102. A roof-top circular vent (not shown) may also be provided to allow heat to escape while avoiding water ingress. If the electric fan fails, the ECU118 will issue a warning and initiate the shutting down 128 of the various components 106 in the REM device 100.

d. Roof with a plurality of layers of material

The first and second containers 102, 104 may include a radiator roof that heats water using solar energy using a pliable water conduit 136A. Because such standard containers have grooves formed on their roofs, pliable water conduits 136A can be disposed in those grooves. The water conduit 136A will be covered with a UV-protected plastic sheet to encapsulate the heat, which in turn heats the water in the water conduit 136A. Solar panels may also be provided on the roof of the first and second containers 102 to heat water and/or generate electricity using solar energy. Such warm water and power may be used to support the operation of the other components 106 and 128 of the REM apparatus 100 (e.g., to heat the dirt/waste and/or to power the plurality of pumps 132A-132D and other electronics) and/or it may be used to supplement the heat and power generated by the biogas engine 122. Rainwater may also be collected from the roof of the container 102 and the container 104 for the shredder unit 106. The roof may also include a lightning rod, or equivalent means, for protecting the container 102 and the container 104 and their contents from lightning strikes.

A shredder unit 106

The shredder unit 106 is disposed at the distal end of the first container 102 and acts as an input device for loading dirt/waste deposits into the REM apparatus 100. As shown in fig. 2, the shredder unit 106 includes a hopper 200, a mixing tank 202, and a homogenizing pump 204. The hopper 200 is formed as an opening to the shredder unit 106 to help dirt/waste material be loaded therein more easily. The hopper 200 includes a pair of doors 206 that must be opened to load the shredder unit 106. Those doors 206 are adjacent the instrument panel 140 of the first container 102 and are held closed with magnetic snaps. The hopper 200 is preferably made of stainless steel or other corrosion resistant material (e.g., galvanized steel) because it may be hit and scratched by a shovel/spade or other loading device, and the door 206 is preferably made of a durable transparent material (e.g., plexiglas) so that the user can observe the mixing/soaking process when the door 206 is closed. These doors 206 also provide a safety function that prevents operation of the shredder unit 106 when they are opened, thereby preventing a user or tool from falling into the mixing tank 202 through the homogenizing pump 204. This function is controlled by the ECU 118.

The shredder unit 106 also functions to homogenize the dirt/waste that is moved through the hopper 200 to the mixing tank 202. Liquid (e.g., potable and/or grey water) is supplied to the shredder unit 106 through water conduit 136A and mixed with the dirt/waste in the mixing tank 202 using the homogenizing pump 204 to recirculate, soak, and homogenize the liquid and the dirt/waste. The water/dirt/waste mixture is shredded by the homogenizing pump 204 sufficiently finely that it does not clog the waste valve 134B or the waste conduit 136B of the REM apparatus 100 as it moves between the components 106 and 114 of the REM apparatus 100. The liquid is pumped to the mixing tank 202 by the mix feed pump 132A as needed to provide a suitable mixture of liquid and dirt/waste in the mixing tank 132 for hydrolysis needs. The flow rate is controlled by the ECU118 based on the amount of dirt/waste deposited in the mixing tank 202. And the liquid is preferably grey water that is recirculated from the dehydration unit 114 back into the mixing tank 202 in a regenerative manner to further increase the efficiency of the REM apparatus 100.

The blending tank 202 is disposed below the hopper 200 such that the dirt/waste material is fed directly to the blending tank 202 through the hopper 200. The mixing tank 132 preferably includes an integrated stone trap 154 (fig. 1E) to catch larger debris that may clog the waste valve 136B or the waste line 128B. The stone remover 154 will need to be expelled according to a period determined after commissioning of the REM device 100, and therefore it is preferably easily accessible through a hatch in the instrument panel 140. The shredder unit 106 may be sized to meet the output requirements of the user and/or the particular type of dirt/waste being processed. Because the soil/waste types typically have high volumes and low weights or high weights and low volumes, the mixing tank 202 will have visible liquid level indicia, and the mixing tank 202 can be filled with essentially any type of soil/waste without exceeding the limits of the REM apparatus 100.

The volume indicated by the level indicator (e.g., 60 liters) includes the dirt/waste that is loaded into the mixing tank 202 by the user and the liquid that is fed into the shredder unit 106 through the water conduit 136A. The ECU118 will automatically determine the appropriate amount of liquid to mix with the waste/dirt based on the weight and type of waste/dirt. For example, very dry and/or dense waste/dirt (e.g., horse dung) requires up to 9: 1, while wet and/or less dense waste water/soil (e.g., vegetable waste) requires 4: 1 dilution ratio. Since the dense waste/dirt weighs less than the less dense waste/dirt, the total volume of water/waste/dirt obtained in the mixing tank 108 will be the same regardless of the type of waste/dirt placed therein (i.e. 15 kg of horse manure and 45 kg of vegetable waste will fill a volume of 60 litres when an appropriate amount of liquid is added). The type and/or weight of the waste/dirt may be input to the ECU118 by a user and/or automatically determined by the ECU118, for example with an electronic scale, so the ECU118 may determine the appropriate amount of liquid to mix with the waste/dirt.

Buffer tank 108

The buffer tank 108 receives the water/dirt/waste mixture from the shredder unit 106 and stores it before it moves to the small storage tank 110. Because it is used for storage, not just for mixing, the buffer tank 108 is larger in size than the mixing tank 202 of the shredder unit 106. The water/dirt/waste mixture is moved from the mixing tank 202 of the shredder unit 106 to the surge tank 108 with the homogenizing pump 204, the homogenizing pump 204 causing the recirculation loop to close and the direction of the water/dirt/waste mixture to the surge tank 108 to be changed again by opening one waste valve 134B and closing the other. The opening and closing of the waste valves 134B is controlled by the ECU118 according to a predetermined cycle time.

The buffer tank 108 functions as a "buffer tank" for the small and large storage tanks 110, 112 by heating the water/dirt/waste mixture before it moves into the small and large storage tanks 110, 112. The heating is preferably performed by a heat exchanger 156 arranged in the buffer tank 108. The heat exchanger 156 receives thermal energy by pumping the heated and partially pasteurized or digested water/dirt/waste produced by the small storage tanks 110 through the heat exchanger 156 before depositing it into the large storage tank 112. This exchanged thermal energy is necessary not only for completing the pasteurization process, but also for reducing the temperature of the heated and partially pasteurized or digested water/dirt/waste mixture to 35-40 ℃ before it is deposited into the large storage tank 112.

The heated and partially pasteurized or digested water/dirt/waste is pumped and operated by a digester feed pump 132B controlled by the ECU118 to feed the heated and partially pasteurized or digested water/dirt/waste to the large storage tank 112. This operation not only provides pre-heating of the water/dirt/waste mixture before it is moved to the small storage tank 110, it advantageously removes heat before moving the heated and partially pasteurized or digested water/dirt/waste to the large storage tank 112. As discussed below, the heated and partially pasteurized or digested water/dirt/waste is preferably cooled to about 40 ℃ before being deposited into the large storage tank 112.

A waste pipe 136B that moves the preheated water/dirt/waste to the small holding tank 110 is preferably mounted to the bottom of the container 102 so that the buffer tank 108 can be drained from the bottom and the small holding tank 110 can be fed from the bottom. If space is not allowed and the small reservoirs 110 must be fed from the top, it is preferred that the feed pipe extends to the bottom of the buffer tank 108 and/or each small reservoir 110 so that the mixture will drain from the bottom of the buffer tank 108 and/or be deposited at the bottom of the small reservoir 110. The buffer tank 108 is preferably sized to allow at least 2 days of continuous operation of the REM apparatus 100. And it is preferably made of steel or fiberglass to reduce manufacturing costs.

Small holding tank 110

Returning to fig. 1A-1E, the preheated water/dirt/waste is pumped from the buffer tank 108 to the small holding tank 110 by the pasteurization feed pump 132C. The feed pump 132C is controlled by the ECU118 to operate at a predetermined feed period. In the small storage tank 110, the preheated water/dirt/waste is heated and stirred for pasteurization or if pasteurization is not required for the entire anaerobic digestion process, then thermophilic anaerobic digestion is performed. The preheated water/dirt/waste in each small storage tank 110 is continuously agitated with a gas mixer 158 (fig. IE) to keep solids and liquids in suspension during pasteurization or thermophilic anaerobic digestion. The mixture is heated to about 55-75 c using a heater 160 (map IE) capable of heating the mixture contained therein. The gas mixer 158 is pressurized by the compressor 128 and the gas mixer 158 includes a lance that injects air directly into the bottom of each small holding tank 110 to facilitate thermophilic aerobic digestion to supplement the heat requirements of the pasteurization process. And the heater 140 is an electric immersion heater or an aqueous boiler coil heater disposed inside the small storage tank 110 so that the water/dirt/waste mixture can be directly heated.

Each small storage tank 110 has a relatively small volume (e.g., about 1800 liters) to reduce the energy required to heat the water/dirt/waste located therein. The load on the heater 160 may be further reduced by the heat recovered from the biogas engine 122 and/or the engine may drive the homogeneous pump 204, the dehydration unit 114, or any other pump 132A-132D of the REM apparatus 100 in a regenerative manner to further increase the efficiency of the REM apparatus 100. And as described above, the small storage tank 110 may be used to perform pasteurization or thermophilic anaerobic digestion of the water/dirt/waste placed therein, depending on the pasteurization required for the overall anaerobic digestion. If they are used for thermophilic anaerobic digestion, biogas will be produced in the small storage tanks 110 and similar precautions discussed below for the large storage tank 112 will need to be taken (e.g., mixing water/dirt/waste with biogas instead of air, pumping biogas out to gas storage tanks, separating the small digestion tanks 110 from the machinery and electronics may create sparks, etc.). The small storage tank 110 may also be used for other purposes, such as to prevent the digestion process of the grey water in the liquid tank 126.

The small holding tank 110 operates in a batch mode that includes offset periods of feeding, storing and discharging. For example, after the first small holding tank 110 is fed and filled with preheated water/dirt/waste from the buffer tank 108, as discussed above, it will hold the preheated water/dirt/waste while it is agitated and heated. The second small holding tank 110 will be fed and filled after the first small holding tank 110. The heated and partially pasteurized or digested water/dirt/waste will then be drained from the first small holding tank 110 and stored in the second small holding tank 110, stirring and heating the preheated water/dirt/waste it is filled with. The heated and partially pasteurized or digested water/dirt/waste will then be drained from the first and second storage tanks 110, while the second small storage tank 110 is filled with a new batch of preheated water/dirt/waste from the buffer tank 108. The water/waste/dirt is circulated through the small holding tanks 110, repeatedly back and forth between the first and second digester tanks 110 as needed. The amount of filling is controlled by the ECU118 using a set of Level Sensors (LS) in the small reservoir tank 110. Also, while only two small holding tanks 110 are shown in fig. 1A-1E, the REM apparatus can use as many small holding tanks 110 as needed to meet the processing requirements of the user.

The waste conduit 136B of the heat exchanger 136 that moves the heated and partially pasteurized or digested water/waste into the buffer tank 108 is preferably mounted at the bottom of the container 102 so that the mixture is fed through the bottom of the buffer tank 108 to provide a suitable temperature gradient (i.e., bottom hottest and top coldest) as the heated and partially pasteurized or digested water/waste flows through the heat exchanger 156 in the buffer tank 108 and into the large holding tank 112. Each small storage tank 110 is insulated to increase its efficiency. Preferably, the small storage tank 110 is formed of PVC to reduce manufacturing costs and to provide a "green" material, such as wool, to be used to form the insulation. The insulation may be modular, interlocking pieces that can be connected together to surround the small storage tank 110.

v. large holding tank 112

The heated and partially pasteurized or digested water/dirt/waste is pumped from the small storage tank 110 to the large storage tank 112 by the digester feed pump 132B. Like the pasteurized feed pump 132C, the digester feed pump 132B is controlled by the ECU118 to operate at a predetermined feed cycle. Since the heated and partially pasteurized or digested water/dirt/waste must be cooled to about 40 ℃ before it is deposited into the large storage tank 112, it passes through the heat exchanger 156 in the buffer tank 108 as it is pumped from the small storage tank 110 to the large storage tank 112. As discussed above, the heated and partially pasteurized or digested water/dirt/waste is cooled by transferring the thermal energy of the heated and partially pasteurized or digested water/dirt/waste through the heat exchanger 156 to the water/dirt/waste mixture in the mixing tank 108. In this manner, the thermal energy consumed in supporting pasteurization or thermophilic anaerobic digestion in the small storage tank 110 is reused in a regenerative manner, further increasing the efficiency of the REM plant 100.

In the large storage tank 112, the pasteurized or cooled and partially digested water/dirt/waste is agitated for mesophilic anaerobic digestion. Like the preheated water/dirt/waste in each small storage tank 110, the pasteurized or cooled and partially digested water/dirt/waste in the large storage tank 112 is continuously agitated with a gas mixer 158 (fig. IE) to maintain the suspension of solids and liquids, while biogas (e.g., methane and carbon dioxide) accumulates at the top of the large storage tank 112. However, unlike the preheated water/sewage/waste in each small storage tank 110, the preheated water/sewage/waste in each small storage tank 110 is agitated with compressed air from the compressor 128, but the pasteurized or cooled and partially digested water/sewage/waste in the large storage tank 112 is agitated by recirculating biogas through the gas mixer 158 of the vacuum pump 162 using corrosive gas. In the absence of air, the bacterial population breaks down the organic solids in the water/dirt/waste mixture into biogas and more stable solids. Therefore, biogas is used instead of air to agitate the water/dirt/waste as introducing oxygen into the mixture will form explosive air. In addition, a mixing pump (not shown) may be used to mix the water/dirt/waste mixture by intermittently circulating the water/dirt/waste mixture in the large storage tank 112.

The operating temperature of the large storage tank 112 is preferably in the range of 32-40 deg.c. The lower temperature allows the large storage tank 112 to have a larger volume (e.g., about 14000 liters) than the small storage tank 110 because less energy is required to maintain such a lower temperature. In fact, the large storage tank 112 may need to be cooled rather than heated. To accomplish this, the large storage tank 112 may be made as a double-layer tank so that a cooling fluid (e.g., potable and/or grey water) may be circulated between the inner and outer shells to cool the water/dirt/waste in the inner shell. The use of an electrically conductive material such as steel for the inner shell and an insulating material for the outer shell provides a suitable means of achieving this function.

In addition, the large storage tank 112 may be formed as a single tank using low cost reinforced thermoformed fibers. These materials allow a plurality of large storage tanks 112 to be quickly manufactured using inexpensive molds. These materials are also very flexible so that the large storage tank 112 will not be broken when all liquid (e.g., 1.5 meters all 20 kilometers of travel) falls. In another embodiment, the large storage tank 112 may be coated with nanotechnology carbon in the shape of lotus leaves to inhibit bacteria and silicate to avoid methane leakage through the tank walls. The large storage tank 112 is preferably free of two types of bacteria-anammox and methanogen, which are used to consume ammonia and break down carbon chains. The large storage tank 112 may also include cathodes and anodes that capture free electrons from the digestion process, such that the large storage tank 112 may be used as a large battery to power the REM device 100 or to power other devices. The small storage tank 110 may be similarly fabricated.

The large storage tank 112 operates in a "draw and fill" mode, wherein a known amount of water/dirt/waste is drawn into the large storage tank 112 by the digester feed pump 132C until it is filled to a predetermined level. The amount of draw and fill is controlled by the ECU118 using a set of Level Sensors (LS) in the large storage tank 112. The feed rate of water/dirt/waste into the large storage tank 112 is controlled by the ECU118 so that it provides the shortest 15 days of retention time for the mesophilic anaerobic digestion process. And biogas is preferably drawn from the gas storage tank 120 back into the large storage tank 112 during the drawing process to maintain an operating pressure of 15-20 mbar in the large storage tank 112.

The large storage tank 112 is sufficiently sealed to prevent gaseous oxygen from entering the system and hindering the anaerobic digestion process. The large storage tank 112 includes a safety relief valve 164 that vents to the outside of the first container 102 and relieves pressure from the large storage tank 112 if the pressure is near unsafe levels. The large storage tank 112 is also insulated to improve its efficiency. Preferably, the outer shell of the large storage tank 112 is formed of fiberglass to reduce manufacturing costs and provide a "green" material, such as wool, that is used to form the insulation. The insulation may be modular, interlocking pieces that can be connected together to surround the large storage tank 112.

As mesophilic anaerobic digestion proceeds in the large storage tank 112, biogas is collected at the top of the large storage tank 112. While the pneumatic pump recirculates some of the biogas back to the water/dirt/waste as part of the mixing operation, the remaining biogas is drawn from the large storage tank 112 and pumped through the gas scrubber 116 before being deposited into the gas storage tank 120. Preferably, biogas is vented from the large storage tank 112 at an operating pressure of 15-20 mbar. And after the mesophilic anaerobic digestion process is completed, the digested water/dirt/waste mixture is pumped to the dehydration unit 114 by the sludge pump 132D, the sludge pump 132D being controlled by the ECU118 according to the retention time required for the mesophilic anaerobic digestion process.

Since methane and other combustible gases are produced in the large storage tank 112, the large storage tank 112 may have to be provided in a separate container from the other components of the REM apparatus 100-in particular, those components that include moving machinery and electronics may generate sparks (e.g., the shredder unit 106, the dehydration unit 114, the biogas engine 122, the air compressor 128, the mix feed pump 132A, the digester feed pump 132B, the pasteurization feed pump 132C, the sludge draw pump 132D, the gas vacuum pump 162, and the homogenizing pump 204). Further, the container may be divided into separate spaces using airtight partition walls to separate the large storage tank 112 from the mechanical and electrical components of the REM apparatus 100. Such a separate container or container space preferably separates hazardous materials and explosive atmospheres from the mechanical and electronic components of the REM apparatus 100 according to local, national and/or international standards, such as european union air explosion (ATEX) directives and hazardous materials and explosive atmosphere regulations (DSEARs).

Dewatering unit 114 and liquid tank 126

The dewatering unit 114 removes liquid from the fully digested water/dirt/waste to produce a composted bi-directional product and a more concentrated digestate that can be used as solid and liquid manure. As shown in fig. 3, the dewatering unit 114 includes a dewatering box 300 where digested water/dirt/waste is received from the large storage tank 112. The dewatering unit 114 further comprises a conveying pipe 302 and an electric motor 304 for rotating a shaftless screw conveyor arranged in the conveying pipe 302. As it rotates, the screw conveyor conveys solid sewage/waste from the water/sewage/waste mixture of the dewatering tank 300 through the conveying pipe 302 and is discharged through the nozzle 306 provided at the upper end of the conveying pipe 302. The solid dirt/waste material as solid fertilizer can be collected in a container located on the loading platform 142 below the spout. And the remaining grey water or liquid in the dewatering box 300 is then sent to the liquid tank 126 as liquid manure with gravity.

The dewatering unit 114 is positioned adjacent to the chopper unit 106 at the same end of the first vessel 102 so that the method of the present invention is completed at the same location as it was started. Thus, a user may load the dirt/waste into the shredder unit 106 and extract the resulting solid waste produced during anaerobic digestion performed by the same location. For the same purpose, the liquid tank 126 is preferably disposed adjacent the same end of the first container 102. And while the anaerobic digestion process may take several weeks to complete, after the first cycle is complete, the user should have ready extractable solid and liquid manure each time loading the shredder unit 106 with new dirt/waste. The solid fertiliser may be a cover suitable for animal bedding. And at least a portion of the grey water may be recycled with the mixing feed pump 132A for hydrolysis of the mixture with dirt/waste as needed that is loaded into the mixing tank 132. The recirculation of grey water using the mixed feed pump 132A is controlled by the ECU118 by automatically operating the pump 132A and opening/closing the associated water valve 134A that directs the flow of grey water as needed.

The liquid tank 126 is disposed adjacent to the first container 102 below the dewatering box 300 adjacent to the dewatering unit 114 so that the solid manure and the liquid manure produced by the dewatering unit 114 can be gravity fed into the liquid tank 126. To accomplish this, the dewatering box 300 is disposed on a base 308 that supports it in a position above the liquid tank 126. The liquid tank 126 is preferably made of PVC to reduce manufacturing costs. Although liquid tank 126 is shown as being disposed adjacent first container 102, it may also be disposed inside first container 102, similar to the relationship of dewatering unit 114 and first container 102.

Gas scrubber 116

A gas scrubber 116, or desulfurization unit, is disposed between the large storage tank 112 and the gas storage tank 120. It is configured to purge the biogas extracted from the water/dirt/waste in the large storage tank 112 before it is stored in the gas storage tank 120. The gas scrubber 116 may be of any suitable type, such as an activated carbon filter or a compressed gas filter (e.g., an amine gas filter). The gas scrubber 116 is used to treat the biogas and refine it as a fuel-i.e. by reducing the content of hydrogen sulphide in the biogas. However, if the biogas does not need to be treated, such as when it is not being used for fuel or does not include prohibitive levels of certain chemicals, the gas scrubber 116 may not be needed.

An Electronic Control Unit (ECU)118

The flow of liquids (e.g., potable and/or grey water), dirt/waste, and biogas through the REM apparatus 100 of the present invention is controlled by the ECU 118. As shown in fig. 4, the ECU118 includes a Programmable Logic Controller (PLC) programmed to monitor, record and control various stages (e.g., temperature, volume and flow rate) in the anaerobic digestion process. It provides visual feedback to the user of these services through a graphical user interface such as a computer display or touch screen. The ECU118 automatically operates the anaerobic digestion process by turning on or off the various components 106 and 128 of the REM apparatus 100 based on the values it monitors and records. The ECU118 determines which components 106 and 128 are open and closed based primarily on the contents of the dirt/waste material loaded into the REM device 100, which may be monitored with suitable sensors and/or may be input by a user via a user interface of the ECU 118.

For example, the ECU118 will automatically operate the appropriate pumps 132A-132D, 204 and 162 and open/close the appropriate valves 134A-134C to pump the fully digested water/dirt/waste from the large storage tank 112 to the dehydration unit 114 after the ECU118 monitors the completion of the anaerobic digestion process. The ECU118 automatically feeds from the small storage tanks 110 in a batch mode, holds and discharges water/dirt/waste, according to the liquid level monitored by a Level Switch (LS) and the time that water/dirt/waste has been held in each small storage tank 110. The ECU118 will determine whether to activate the heater 160 in the small reserve tank 110 based on the Temperature Sensor (TS) in each small reserve tank 110. And the ECU118 will determine the flow rate and cycle time of the moving water/dirt/waste between the various components 106-128 of the REM apparatus 100 by monitoring the anaerobic digestion process at multiple stages using clock circuits, liquid Level Sensors (LS), Temperature Sensors (TS) and Pressure Sensors (PS) located in the REM apparatus 100, thereby enabling the ECU118 to adjust the anaerobic digestion process in real time as required to maintain optimal digestion.

The ECU118 may determine such things as the amount of liquid added to the dirt/waste mixture and the amount of biogas expected to be generated from the dirt/waste based on answers to a series of questions posed to the user through the user graphical interface of the ECU 118. For example, a user may be required to enter a description of where the dirt/waste is collected, the services provided, the type of wastewater/dirt (e.g., feces, vegetable waste, etc.), the amount of wastewater/dirt, the intended use of the covering to be produced, and the intended use of the grey water to be produced. Thus, the ECU118 can customize the digestion process for each batch of dirt/waste loaded into the REM device 100 by enabling the user to input answers to those questions for different batches of dirt/waste loaded into the REM device 100. Some of these answers may also be automatically obtained by the ECU118, for example using a scale provided on the shredder unit 106 or the loading platform 142 to weigh the dirt/waste loaded into the REM apparatus 100.

The PLC of the ECU118 is also programmed to monitor and maintain the safety of the entire anaerobic digestion process. Monitoring not only allows close control of mechanical and electrical equipment to avoid physical injury to the user, it also allows close control of process parameters as risk assessment and critical control parameters (hacpcs). For example, the ECU118 monitors the pressure of biogas in the gas storage tank 120 and the level of water/dirt/waste in the small and large storage tanks 110, 112 to ensure that they are maintained at safe operating levels (e.g., Level Sensors (LS) will be provided in the small and large storage tanks 110, 112 to ensure that the immersion heater 160 does not attempt to heat the empty tank). An alarm may be sounded if/when a large amount of biogas and/or a large amount of water/dirt/waste is adjacent to an unsafe level. The ECU118 also includes a supervisory control and data acquisition (SCADA) interface and/or internet and wireless network (e.g., GSM, GPRS, wifi, etc.) functionality for providing the user with remote monitoring functions for efficiency, diagnostics, operation and safety. Preferably, the ECU118 is located at the same end of the first container 102 as the shredder unit 106, the dehydration unit 114 and the liquid tank 126, so that the anaerobic digestion process can be controlled from the same location where the dirt/waste is loaded into the REM apparatus 100 and where the fertilizer is removed from the REM apparatus, thereby providing a greater degree of convenience to the user.

The ECU118 includes a Human Machine Interface (HMI) for communication among the various components 106 and 128 of the REM device 100, the various pumps 132A-132D and the various valves 134A-134C. It also includes a cloud monitoring application for zonal monitoring of the status of the components 106 and 128, the plurality of pumps 132A-132D, and the plurality of valves 134A-134C. Any computing device used through the SCADA interface and/or internet and wireless capabilities (e.g., personal computer, laptop, tablet, Personal Digital Assistant (PDA), smartphone, etc.) may establish communication with the ECU118 to enable a user to remotely monitor, control, and troubleshoot the REM device 100. For example, a smart phone application communicates with the ECU118 through a bus interface to a CAN bus node that communicates with low cost sensors and devices such as those used in the automotive industry.

All of the interfaces for the user to input information to the ECU118 and otherwise control the operation of the ECU118 are provided in the control box 148 located on the instrument panel 104 of the first container 102 so that the user can operate the different components 106 and 128 of the REM apparatus 100 from the same location where dirt/waste is loaded into the REM apparatus 100 and where solid and liquid manure is removed from the REM apparatus 100, thereby adding more convenience to the user. The control box 148 and its associated interface are in electrical data communication with the ECU118 via electrical lines 138. Further, they may be in wireless data communication with each other via any suitable, secure wireless functionality (e.g., GSM, GPRS, wifi, etc.).

The ECU118 also provides a source of power for the various components 106 and 128 of the REM device 100, the various pumps 132A-132D, and the various valves 134A-134C. It includes a Miniature Circuit Breaker (MCB) for each of these components 106 and 128, a plurality of pumps 132A-132D, a plurality of valves 134A-134C, and Light Emitting Diodes (LEDs) that indicate their respective status (e.g., "on", "fault", etc.). These miniature circuit breakers are accessible via a breaker box 166 (fig. 1A) disposed outside of the first container 102. The circuit breaker box 166 is disposed outside of the first container 102 so that those miniature circuit breakers can be easily accessed without accessing the container 102 which presents a high risk of injury to the user due to the number of machines contained therein. Other components of the ECU118 are preferably disposed in a housing inside the first container 102 to provide better protection for the components.

The power bus of the ECU118 preferably receives power supplied from a 16 amp, 240 volt mains power supply. It may also receive power from biogas engine 122. Also, while fig. 5 shows only four Temperature Sensors (TS) and seven "low" Level Switches (LS), the ECU118 is connected to several other Temperature Sensors (TS) and liquid Level Sensors (LS) to support its control of the REM apparatus 100. For example, the ECU118 also includes at least seven "high" Level Sensors (LS) and at least three additional Temperature Sensors (TS). See, for example, the graph IE. The ECU118 may also be connected to other types of sensors as needed, such as gas composition sensors, Pressure Sensors (PS), voltmeters, etc., to support its control of the REM device 100. The circuitry 138 of the ECU118 and its various connections conform to local, national and/or international standards, such as those specified in the water industry mechanical and electrical specifications (WTMES).

ix, gas storage tank 120

After the biogas is extracted from the large storage tank 112, and cleaned by the gas scrubber 116 (when cleaning is required), the biogas is stored in the gas storage tank 120. As shown in fig. 5, the gas storage tank 120 includes a flexible bladder 500 disposed in a sturdy, double-walled tank 502. Double-walled tank 502 may be filled with a liquid (e.g., potable and/or grey water) and made of a material strong enough to withstand the high pressures associated with storing biogas under pressure. Gas storage tank 120 includes a water inlet 504 and a water outlet (not shown), so liquid can be pumped into and out of double-walled tank 502 through water conduit 136A to equalize and maintain a constant, fixed pressure of biogas in flexible bladder 500. The gas storage tank 120 also includes a safety relief valve 168, which if the pressure is near an unsafe level, the safety relief valve 168 vents to the outside of the second container 104 and releases the pressure in the flexible bladder 500. Any remaining biogas that cannot be stored by the gas storage tank 120 is safely burned off with the burner 124, thereby avoiding unsafe levels of pressure from occurring. The burner 124 has an indicator light disposed at or adjacent to the first vessel 102 that is powered by the propane storage tank 170.

To determine the volume of gas stored in the flexible bladder 500, separate flow meters are provided at the inlet and outlet gas lines 136C of the gas storage tank 120. The difference between the readings of these flow meters is used by the ECU118 to monitor the amount of gas stored in the gas storage tank 120. Further, provided at the outlet gas pipe 136C are a flow control valve 134C for controlling the flow of biogas from the gas storage tank 120 and a flame arrester (not shown) for preventing flame diffusion into the gas storage tank 120 through the flow control valve 134C. In this manner, biogas can be extracted from the gas storage tank 120 and used to generate heat, electricity, or any other form of gas-generated energy as desired. One of the means for generating heat and electricity is a biogas engine 122.

Since methane and other combustible gases are stored in the gas storage tank 120, it may be necessary to provide them in a separate vessel 104 from some other components of the REM apparatus 100-particularly, those components that include moving mechanical and electronics may generate sparks (e.g., the shredder unit 106, the dehydration unit 114, the biogas engine 122, the air compressor 128, the mix feed pump 132A, the digester feed pump 132B, the pasteurization feed pump 132C, the sludge draw pump 132D, the gas vacuum pump 162, and the homogenizing pump 204). In the alternative, the container may be divided into separate spaces using airtight dividing walls to separate the large storage tank 112 from the mechanical and electronic components of the REM apparatus 100. Such a separate container or container space would preferably provide separation of all hazardous materials and explosive air from the mechanical and electronic components of the REM apparatus 100 according to local, national and/or international standards, such as the european union's ATEX directive and DSEARs.

x. biogas engine 122

The outlet gas conduit 136C of the gas storage tank 120 is connected to the biogas engine 122, which simultaneously generates electricity and heat energy from the biogas through an internal combustion engine (e.g., an internal combustion engine or stirling engine). Biogas engine 122 is preferably a 3600 kilowatt Combined Heat and Power (CHP) unit. The CHP unit may be a modified diesel genset/biogas-fired steam engine (e.g., a standard-style or rotary piston engine that directly drives a generator) that burns biogas or pyrolyzed syngas.

Since biogas engine 122 requires a specific input pressure (e.g., 100 mbar) to operate, a booster fan 172 is used to maintain the biogas in gas storage tank 120 at this pressure. The electricity generated by biogas engine 122 may be connected to the user's power grid and used to operate household devices, such as lights and appliances. And the generated heat may be connected to a user's heating, ventilation and air conditioning (HVAC) system and/or a water heating system and used for space heating and/or water heating. The biogas engine 122 may also be used to operate the various pumps 134A-134D, 204 and 162 of the REM device or any component 106 operated electrically 128 and provide heat to the small storage tank 110 to further improve the efficiency of the present invention.

To further move the REM apparatus 100, the biogas engine 122 is preferably provided on its own trailer. It is also preferably connected to the gas storage tank 120, the power bus of the ECU118, and the user's power grid using standard connections.

xi. burner 124

The burner 124 produces a flame that burns the remaining methane and/or propane according to the eu particulate standard. The burner 124 includes an indicator light connected to the propane tank 170 through the gas conduit 134B to ensure that the remaining biogas ignites immediately and remains ignited so that it does not accumulate in and/or around the REM apparatus 100 in unsafe combustible quantities. The burner may comprise two separate indicator lights-the first indicator light burning methane and the second indicator light burning propane. Piezoelectric lighters or automatic ignition systems with visual flame detection may also be used and integrated with the functions of the ECU118 for automatic control.

xii. pipes 136A-136C

a. Water conduit 136A

The water conduit 136A may be any suitable low pressure conduit, such as a PVC conduit, for supplying liquid (e.g., drinking and/or grey water) to the shredder unit 106. As shown in fig. 6, the water conduit 136A provides potable water to the chopper unit 106 from an external water source, such as a water well or a local utility, and provides grey water from the dehydration unit 114 to the chopper unit 106. In order for the REM apparatus 100 to be connected to an external water source, the water conduit 136A preferably includes a standard connector, such as a garden hose connector, at an entry location outside of the first receptacle 102.

Figure 6 also shows that grey water from the dehydration unit 114 is circulated between the inner and outer shells of the large storage tank 112 and between the outer shell of the gas storage tank 120 and a flexible bladder to aid in the cooling of the contents of the large storage tank 112 and the gas storage tank 120. The ECU118 controls the amount of cooling provided to maintain the desired operating temperature in the large storage tank 112 and the gas storage tank 120 by opening and closing the appropriate water valve 134A and operating the mixed feed pump 132A, as needed. Also, while FIG. 6 shows grey water being pumped through the large storage tank 112 and the gas storage tank 120, one or both of these components 112 and 120 may be bypassed by opening and closing appropriate water valves 134A.

b. Waste pipe 136B

The waste conduit 136B provides a complex network that works around the fixed components 106 and 128 of the REM device 100. Standard tubing lengths are used where possible to facilitate fabrication. The material for the waste pipe 136B is preferably high density polyethylene. The properties of this material are such that it withstands chemical and biological damage, to withstand temperatures up to 137 ℃, and to withstand pressures up to 12 bar. In addition, its thermal insulating properties help to further increase the efficiency of the REM apparatus 100. A standard drain connection is preferably provided on the outside of the first container 102 to facilitate connection of the waste pipe 136B to a sump for draining water from the buffer tank 108, the small holding tank 110, the large holding tank 112, the liquid tank 126, the mixing tank 202 and the dewatering tank 300 as needed for cleaning and maintenance thereof.

Fig. 6 also illustrates that the waste conduit 136B provides the water/dirt/waste mixture to the buffer tank 108 before providing the water/dirt/waste mixture to the small holding tank 110. The heated and partially pasteurized or digested water/dirt/waste mixture then passes through the heat exchanger 156 in the buffer tank 108 from the small digestion tank 110 to the large storage tank 112 as it moves. And after mesophilic anaerobic digestion in the large storage tank 112 is completed, the fully digested water/dirt/waste mixture is moved to a dewatering unit 114. The ECU118 controls the amount of water/dirt/waste between these components 106 and 114 by opening and closing the appropriate waste valves 134B and operating the digester feed pump 132B, the pasteurization feed pump 132C, the sludge draw pump 132D and the homogenizing pump 204 as needed to optimize the anaerobic digestion process. Also, while fig. 6 shows the heated and partially pasteurized or digested water/dirt/waste mixture being pumped through the heat exchanger 156 in the surge tank 108, the heat exchanger 156 can be bypassed by opening and closing the appropriate waste valve 134B.

c. Gas line 136C

The gas conduit 136C is preferably stainless steel due to the corrosive nature of the elements in the biogas. For example, it may be H in biogas₂S (hydrogen sulfide). The stainless steel tubing did not react with the media. And as shown in fig. 7, the gas conduit 136C forms two separate circuits. The first loop circulates air through the small storage tank 110 with the compressor 128 to agitate the water/dirt/waste in the small storage tank 110. And the second loop circulates biogas through the large holding tank 112 with a gas vacuum pump 162 to agitate the water/dirt/waste in the large holding tank 112. The first loop is an "open" loop because it allows air to be introduced into the small storage tank 110, and the second loop is a "closed" loop because it only utilizes biogas that is already in the large storage tank 112.

After the biogas is scrubbed with the gas scrubber 116, the second loop also moves the biogas from the large storage tank 112 to the gas storage tank 120. From the gas storage tank 120, the scrubbed biogas is moved to the biogas engine 122 using a booster fan 172 to maintain the biogas at operating pressure as needed for the biogas engine 122. Any remaining biogas that cannot be stored in the gas storage tank 120 is safely burned off using the burner 124 so that unsafe levels of pressure are avoided from occurring. And as discussed above, the biogas may be recycled back to the large storage tank 112 to maintain the desired working pressure therein during the extraction process. The ECU118 controls the amount of biogas moving between these components 112, 116, 120 and 122 to perform these operations by opening and closing the appropriate gas valves 134C and operating the gas vacuum pump 162 and booster fan 172 as needed. Also, while FIG. 7 shows biogas being circulated back to the large storage tank through the gas scrubber 116, the gas scrubber 116 may do so by opening and closing the appropriate gas valve 134C while operating the gas vacuum pump 162 in reverse through the bypass. Although fig. 7 shows two separate circuits, these circuits may be interconnected as needed to recover biogas from the small storage tank 110.

xiii. exhaust stack 174

To counter potentially offensive odors produced during anaerobic digestion, each of the surge tank 108, the small storage tank 110, the dehydration unit 114, and the liquid tank 126 is provided with an exhaust stack 174 having a filter element, respectively. The filter element preferably utilizes an organic filter material, such as a combination of steel wool and ferns, to remove potentially offensive odors from the gases generated in these components 108, 110, 114 and 126. The exhaust stack 174 preferably extends through the roof of the first vessel 102 so that these gases are discharged outside of the first vessel 102. As discussed above, the large storage tank 112 does not include the exhaust stack 174 because the biogas produced therein is highly combustible. Thus, the biogas may be stored in the gas storage tank 120 or burned by the burner 124.

B. Method for renewable energy micro power generation

The various components 106-128 of the REM device 100 are preferably described as forming separate nodes during anaerobic digestion. At node 1, the shredder unit 106 receives the variable solids content soil/waste (e.g., raw materials) that has been diluted to about 8-10% total solids and about a 1:4 ratio of soil/waste to diluent (e.g., potable water and grey water). Dilution is achieved by adding at node 6 recycled grey water recovered from the fully digested water/dirt/waste using the dewatering unit 114. Potable water may also be added from an external source as needed, for example, when the REM apparatus 100 is first selected for use. Based on the measurements obtained by the level sensing device, the ECU118 controls the dilution process.

After a desired amount of diluent (e.g., potable and/or grey water) is added to the dirt/waste in the mixing tank 202, the homogenizing pump 204 soaks the water/dirt/waste mixture to achieve a desired viscosity. This process should only take a few minutes and after one day there should be a sufficient amount of homogenous water/dirt/waste to start pasteurization and digestion. Preferably, the homogenizing pump 204 is configured to process 0.5 tons of waste/soil per hour. As discussed above, the REM apparatus 100 can be sized as needed to handle a user-selected daily amount of dirt/waste using modular components.

At node 2, the water/dirt/waste mixture produced at node 1 is transferred to the surge tank 108 for preheating. The buffer tank 108 includes a heat exchanger 156 that cools the heated and partially pasteurized or digested water/dirt/waste produced in node 3 during pasteurization in the small holding tank 110 while heating the water/dirt/waste mixture produced in node 1. The heat energy lost by the water/dirt/waste heated during cooling and partially pasteurized or digested is transferred to the water/dirt/waste mixture in the buffer tank 108 to heat it from its ambient temperature before it is moved to the small storage tank 110. This process allows the water/dirt/waste mixture to enter a large digester at 35-40 ℃ to avoid thermal shock of medium temperature errors (mesophilic bugs) in the large storage tank 112 of node 4. It also preheats the water/dirt/waste mixture generated at node 1 so that there is less load on the heater 160 in the small storage tank 110 at node 3, where the water/dirt/waste mixture is heated to at least 70 ℃.

At node 3, the small storage tank 110 uses a gas mixer 158 to mix water/dirt/waste with air, which allows for the wrong use of oxygen to heat the water/dirt/waste mixture during pasteurization. The contents of these small storage tanks 110 are also heated to an operating temperature of about 70 c for at least 60 minutes using an internal heater 160. Adjustments may be made as needed to optimize pasteurization using a SCADA system interfaced with the ECU118 via a SCADA interface. Two or more small holding tanks 110 are preferably provided so that errors therein can be quickly and easily cycled through these holding tanks and the feeding, holding and discharging steps. With larger storage tanks, the feeding and discharge steps would be more time consuming and difficult. In addition, the load of the heater 160 will be greater in larger storage tanks.

After pasteurization in the small storage tank 110 is complete, the heated and partially pasteurized or digested water/dirt/waste is moved to the large storage tank 112 for mesophilic anaerobic digestion and biogas recovery at nodes 4 and 5, respectively. As discussed above, it is cooled to 35-40 ℃ at node 2 by the heat exchanger 156 in the buffer tank 108 before depositing the heated and partially pasteurized or digested water/dirt/waste into the large storage tank 112 until the predetermined fill level is achieved. In the large storage tank 112, the pasteurized or cooled and partially digested water/sewage/waste is constantly agitated using a gas agitator 158, and biogas generated during mesophilic anaerobic digestion is recirculated back to the water/sewage/waste. The feed rate to the large holding tank 112 is such that it provides the shortest retention time of 15 days. The temperature and time that the water/dirt/waste is maintained in the small storage tank 110 and the large storage tank 112 is controlled by the ECU118 to operate in accordance with the relevant hacpcs and to comply with local, national, and/or international standards, such as U.S. EPA regulation 40 c.f.r.503.32.

Biogas produced during mesophilic anaerobic digestion at node 4 is removed from the large storage tank 112 and placed in the gas storage tank 120 at node 5. As biogas is produced in the mesophilic anaerobic digestion, the biogas is moved to the gas storage tank 120 by the gas vacuum pump 162. And after this process is complete, the water/dirt/waste mixture remaining at node 6 is output to the dewatering unit 114. As the large storage tank 112 is pumped in this manner, biogas is returned from the gas storage tank 120 to the large storage tank 112 so that the operating pressure in the large storage tank 112 is maintained at 15-20 mbar during the pumping process. Subsequently, biogas moves back into the gas storage tank 120 at node 5 as the large storage tank 110 is filled with the next batch of pasteurized or cooled and partially digested water/dirt/waste at node 4.

At node 6, the fully digested water/dirt/waste drawn from the large storage tank 110 is pumped to the dewatering unit 114 for dewatering. The fully digested water/dirt/waste is pre-filtered and passed through a fine mesh to assist the separation process. The fully digested water/dirt/waste may also be subjected to a desulphated hydrogen sulphide wash, or sweetened, in the dewatering tank 300. And a coagulant may be added to gather suspended solids in the fully digested water/dirt/waste so that they settle to the bottom of the dewatering box 300, leaving a clean "ash" water, or top layer of liquid, that is recycled back to the chopper unit 106 with the mix feed pump 134B. Bacteria in the grey water may also be used as a feedstock so it may also be gravity fed to the liquid tank 126 for storage at node 7.

The solids falling to the bottom of the dewatering box 300 form a thickened layer of organic fertilizer. The electric motor 304 of the dewatering unit 114 rotates a shaftless screw conveyor provided in the conveyor pipe 302 to convey the thickened layer of organic solid fertilizer through the conveyor pipe 302 and out through a nozzle 306 provided at the upper end of the conveyor pipe 302, where it falls into a container provided below the nozzle of the loading platform 142. At the end of this process, the solid fertilizer or mulch collected in the container is preferably 75 to 85% dry. And the final solid and liquid fertilizers produced by the digestion process are preferably pathogen free.

C. Modular configuration

Although only two vessels 102 and 104 are described in accordance with the exemplary embodiments of the apparatus and methods disclosed above, the components 106 and 128 of the REM apparatus 100 may be separated into many different vessels 102 as desired to suit a particular application. For example, the processing vessel may house the shredder unit 106, the surge tank 108, the dehydration unit 114, and the ECU 118; the digestion vessel may contain a small holding tank 110, a large holding tank 112, and a gas scrubber 114; the CHP vessel may house a biogas engine 122; the liquid storage container may contain one or more liquid storage tanks 126; and the gas storage container may accommodate one or more gas storage tanks 120. In this configuration, the treatment vessel will treat all of the sewage/waste and water/sewage/waste before and after the anaerobic digestion process; the digestion vessel will undergo pasteurization or thermophilic anaerobic digestion, mesophilic anaerobic digestion, and biogas scrubbing; and the gas storage vessel will perform the storage of all biogas. Thus, one or more digestion vessels may be added to the processing vessel and the gas storage vessel until the processing capacity of the processing vessel and/or the storage volume of the gas storage vessel is reached. Accordingly, these vessels are preferably interconnected using standardized conduits 136A-136C and lines 138 (e.g., prefabricated conduit portions and wiring harnesses) so that they can be connected in a modular fashion, thereby allowing the REM device 100 to be expanded to accommodate substantially any number of requirements.

By way of more specific example, if the shredder unit 106 in each processing container can process 0.5 tons of waste/dirt per hour, a user would like to process 6 tons of waste/dirt per 8 hours per day to have two processing containers and configure them to operate in coordination so that the user processes an amount of waste/dirt that exceeds 6 hours. Likewise, two treatment vessels may be provided to treat 24 tons of waste/soil in 24 hours. The two processing vessels can then be connected to a corresponding number of digestion vessels in a chain loop configuration using the standardized tubing 136A-136C and lines 138 described above.

Since anaerobic digestion processes typically require about a 1:4 ratio of waste/sewage and dilution (e.g., potable water and/or grey water), processing 6 tons of waste/sewage per day will yield about 30 tons of water/wastewater/sewage mixture (6 tons of waste/cover + (4 × 6) tons of dilution-30 tons of water/wastewater/sewage mixture). Also, since the digestion process in the large storage tank 110 takes about 21 days, about 630 tons (-630 meters) of storage is required so that the waste/soil to be treated is continuously circulated at a speed of 6 tons per day (30 tons/day × 21 days/digestion cycle: 630 tons/digestion cycle). Thus, as shown in fig. 8, 12 digestion vessels, each with four 1800 liter small holding tanks and two 14000 liter large digestion tanks 112, would need to digest 30 tons of water/wastewater/sewage mixture in a 21 day cycle.

6 tonnes of solution per day is expected to produce 600m biogas of 55-60% methane. It is also shown in fig. 8 that in such a large volume process, two gas storage vessels would need to be provided to store biogas and at least two CHP vessels would be required to convert biogas to heat and/or electricity. Preferably, at least three biogas engines 122 will be provided between the two CHP vessels, such that two biogas engines 122 can be used to burn the biogas and the third biogas engine can be used as a backup.

Furthermore, in a 6 ton per day configuration, two liquid storage vessels would be required to store grey water that is removed from the fully digested water/dirt/waste after anaerobic digestion is complete. The cover storage container may also be arranged for storing solid manure produced from fully digested water/dirt/waste after grey water is removed. These additional containers are also shown in fig. 8.

Preferably each of the processing vessel, digestion vessel, CHP vessel, liquid storage vessel, gas storage vessel and mulch storage vessel described above is a standard 20 foot container. A 40 foot container may also be used if a larger volume of processing is desired. Also, if a 40 foot container is not suitable, modular custom containers can be used to meet the required capacity. These custom made containers can be assembled on site from prefabricated insulated concrete or metal panels. The custom-made container may be erected on a concrete slab that is poured in situ by wiring or bolting prefabricated panels together. The custom container may be square, may have rounded edges, may have a hemispherical roof, or any other suitable structure.

The large storage tank 112 may be formed in a substantially similar manner, if desired. By way of example, if 24 tons of waste/dirt are to be treated a day, two treatment vessels may be provided with three custom made large storage tanks 112 as described above-two for storing the water/waste/dirt mixture during digestion and one for storing this mixture if/when one of the other large storage tanks is in trouble.

By making the treatment vessel, digestion vessel, CHP vessel, liquid vessel, gas storage vessel, and cover storage vessel of the present invention, modular, REM apparatus 100 can bring these vessels together to accommodate essentially any application. Thus, instead of having to build new and different waste treatment plants for each application, the REM apparatus 100 of the present invention can be sized to accommodate each application. Furthermore, by separating the multiple components 106 in the process vessel 114 and separating the biogas engine 122 in the CHP vessel from the small storage tanks 110, 112 and 120, the potential for accidental ignition of biogas generated and/or stored in these tanks is avoided.

D. Summary of the invention

In view of the above, the present invention provides a new solution to the waste treatment problem while providing a sustainable energy source. All the user needs to do after the present invention is installed is to load his or her waste into the equipment and systems that process the waste to produce heat, biogas, electricity and fertilizer. And the user will have a continuous power supply after only a few weeks of use. The present invention provides at least the following advantages: 1) it generates electricity from horse dung throughout the year; 2) it converts the septic waste into hot water and/or heat; 3) it reduces the cost of disposal, reduces unsightly soil heaps and foul septic systems, and 4) it produces useful bi-directional products including solid and liquid fertilizers.

REM facility 100 is an automated plant that requires no intervention other than daily feeding with dirt/waste. The embodiment of fig. 1A-1E is capable of processing 400 kilograms of soil/waste (e.g., raw material) per day, which is digested for more than 15 days to produce about 2000 liters of biogas and a pasteurized mulch product to meet or exceed the PAS110 quality agreement. The grey water or liquid also meets or exceeds the quality protocol. REM plant 100 is also designed to treat soil/waste at temperatures and times consistent with relevant hacpcs and U.S. EPA regulations (e.g., 40 c.f.r.503.32). As discussed above, the ECU118 is programmed to control these temperatures and times. And the appropriate separation of components 106 and 128 is set as required to comply with the ATEX directive and DSEARs of the european union.

The apparatus and method of the present invention are particularly suitable for treating waste/sewage, such as organic and septic waste, including but not limited to different types of farm animal manure (e.g., horse, cow, pig and chicken manure); meat, blood and other slaughterhouse waste; garden and agricultural green waste; food preparation and kitchen waste; wasted/leftover/rotten spoiled food and septic tank contents. The mixture of these dirt/waste materials is digested with bacteria in an anaerobic digestion process to produce biogas (e.g., methane and carbon dioxide), and the remainder of the dirt/waste materials is separated after this process into a dry cover and liquid fertilizer. Biogas can be combusted in the CHP unit to produce heat and electrical energy; the covering can be used as an animal grass mat; and liquid fertilizers can be used to put back into the soil to increase its nutrient content and fertility. In addition, the surplus power generated with the CHP can be sold to the national grid.

The foregoing description and drawings should be considered as illustrative only of the principles of the invention. The present invention can be configured in various shapes and sizes, and the present invention is not limited by the preferred embodiments. Those skilled in the art can readily obtain multiple applications of the present invention. For example, the mixer 158 may include a rotating mechanical agitation device instead of an air jet, and the biogas engine 122 may be a biogas generator instead of a CHP. Therefore, it is not desired to limit the invention to the specific embodiments disclosed or the exact construction and operation shown and described. On the contrary, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims (24)

1. A renewable energy micro-generation device, said device comprising:

a portable processing container, said portable processing container having:

a mixing tank for mixing the waste material with a liquid,

a leaching pump in fluid communication with the mixing tank, the leaching pump configured to soak the waste material into smaller pieces,

a plurality of small storage tanks in fluid communication with the mixing tank, the small storage tanks configured to at least one of pasteurize and pyro-anaerobic digestion the waste material,

a large storage tank in fluid communication with the plurality of small storage tanks, the large storage tank configured to perform mesophilic anaerobic digestion of the waste after at least one of pasteurization and thermophilic anaerobic digestion of the waste, and

a dewatering unit in fluid communication with the bulk storage tank, the dewatering unit configured to dry a remainder of the waste after mesophilic anaerobic digestion of the waste;

a controller for automatically flowing the waste material between the mixing tank, the plurality of small storage tanks, the large storage tank and the dehydration unit such that a user does not need to complete any work for performing mesophilic anaerobic digestion after the waste material is loaded into the mixing tank; and

a portable gas storage container comprising a gas storage tank configured to store biogas produced by the mesophilic anaerobic digestion,

wherein said portable processing vessel and said portable gas storage vessel are configured to be transported to a site and are disposed in fluid communication with each other such that said gas storage tank is capable of storing biogas generated by mesophilic anaerobic digestion in said processing vessel at said site.

2. The apparatus of claim 1, further comprising a biogas engine in fluid communication with said gas storage tank for converting said biogas to at least one of electricity and heat.

3. The apparatus of claim 2, further comprising a gas scrubber in fluid communication with the gas storage tank and the biogas engine, the gas scrubber configured to process and refine the biogas as fuel for the biogas engine.

4. The apparatus of claim 1, further comprising a burner in fluid communication with the gas storage tank, the burner configured to safely burn off excess biogas.

5. The apparatus of claim 1, further comprising a surge tank in fluid communication with the mixing tank and the small holding tank, the surge tank configured to preheat the waste material before the waste material reaches the small holding tank.

6. The apparatus of claim 5 wherein said surge tank includes a heat exchanger for preheating said waste material.

7. The apparatus of claim 6, wherein each of said small storage tanks includes a heater configured to heat said waste material from a pre-heated temperature to a higher temperature.

8. The apparatus of claim 7, wherein

Said heat exchanger being in fluid communication with said small storage tank and said large storage tank; and is

The waste in the buffer tank is heated by the higher temperature waste as the higher temperature waste is moved from the small holding tank to the large holding tank.

9. The apparatus of claim 1, wherein

At least one of the large storage tank and the gas storage tank is formed with an interior and an exterior; and is

The liquid removed from the waste material by the dewatering unit is passed between the interior and the exterior to cool at least one of the waste material and the biogas stored in the interior.

10. The apparatus of claim 9, wherein liquid removed from the waste by the dewatering unit is returned to the mixing tank and mixed with a new batch of waste as it passes between the interior and exterior of at least one of the bulk storage tank and the gas storage tank.

11. The apparatus of claim 1, further comprising a hopper configured to receive the waste material and direct it to the mixing tank.

12. The apparatus of claim 1, further comprising a liquid tank for storing liquid removed from the waste material by the dewatering unit.

13. A method for renewable energy microgeneration, the method comprising the steps of:

transporting a portable processing container and a portable gas storage container in place, said portable processing container having disposed therein a mixing tank, a leaching pump, a plurality of small storage tanks, a large storage tank, a dehydration unit and a controller, and said portable gas storage container having disposed therein a gas storage tank;

mixing the waste material with a liquid in said mixing tank;

soaking said waste material into smaller pieces using said extraction pump;

subjecting said waste material to at least one of pasteurization and thermophilic anaerobic digestion using said small holding tank;

subjecting said waste material to mesophilic anaerobic digestion with said large holding tank after at least one of pasteurization and thermophilic anaerobic digestion with said plurality of small holding tanks;

drying the remainder of the waste material with the dewatering unit after subjecting the waste material to mesophilic anaerobic digestion;

storing biogas produced by said mesophilic anaerobic digestion in said gas storage tank;

the controller is used to automatically flow the waste between the mixing tank, the plurality of small storage tanks, the large storage tank and the dehydration unit so that a user does not need to perform any work for mesophilic anaerobic digestion after the waste is loaded into the mixing tank.

14. The method of claim 13, further comprising the step of converting the biogas to at least one of electricity and heat using a biogas engine.

15. The method of claim 14, further comprising the step of processing and refining said biogas for use as fuel for said biogas engine.

16. The method of claim 13, further comprising the step of burning off excess biogas with a burner.

17. The method of claim 13 further comprising the step of preheating the waste material in a buffer tank prior to placing said waste material in said small holding tank.

18. The method of claim 17, wherein the step of preheating the waste material is performed with a heat exchanger disposed in the surge tank.

19. The method of claim 18, wherein the step of at least one of pasteurizing and pyro-anaerobic digesting the waste material comprises heating the waste material from a preheated temperature to a higher temperature.

20. The method of claim 19 wherein the step of preheating the waste material with the heat exchanger includes passing the higher temperature waste material through the heat exchanger as the higher temperature waste material is moved from the small holding tank to the large holding tank.

21. The method of claim 13, wherein

At least one of the large storage tank and the gas storage tank is formed with an interior and an exterior; and is

The method further includes the step of passing the liquid removed from the waste material by the dewatering unit between the interior and exterior to cool at least one of the waste material and the biogas stored in the interior.

22. A method according to claim 21 wherein the step of passing liquid removed from the waste material through the interior is performed while returning the liquid to the mixing tank for mixing with a new batch of waste material.

23. The method of claim 13, further comprising the step of introducing waste material into said mixing tank with a hopper.

24. The method of claim 13, further comprising the step of storing the liquid removed from the waste material by the dewatering unit in a liquid tank.