Description:TECHNICAL FIELD
[0001] The present invention relates to the field of waste management and sustainable construction materials. Specifically, it pertains to methods and systems for converting organic waste sourced from landfills into durable biobricks suitable for construction applications.
BACKGROUND ART
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Landfills and plastic pollution have emerged as pressing environmental concerns, posing significant threats to ecosystems, public health, and the global climate. With the exponential increase in municipal solid waste (MSW) generation worldwide, effective waste management strategies are imperative to mitigate these challenges and transition towards a more sustainable future.
[0004] Each year, over 2.01 billion tonnes of MSW are generated globally, a figure projected to escalate to 3.40 billion tonnes by 2050, marking a staggering 70% increase. While not all MSW ends up in landfills, a substantial portion, estimated at least 33%, is inadequately managed, often leading to landfill disposal. This alarming trend has fueled rapid landfill expansion, with approximately 40 million hectares of land already occupied by landfills worldwide.
[0005] The ramifications of landfilling extend far beyond the mere accumulation of waste. Landfills act as significant contributors to climate change, emitting potent greenhouse gases such as methane, which possesses a heat-trapping capacity 25 times greater than carbon dioxide. Moreover, the decomposition of waste generates leachate, a toxic liquid that contaminates surrounding soil and groundwater, endangering ecosystems and jeopardizing public health.
[0006] Furthermore, the expansion of landfills encroaches upon valuable land resources that could otherwise support thriving ecosystems and sustain local communities. Additionally, landfills emit volatile organic compounds and particulate matter, exacerbating respiratory conditions such as asthma and bronchitis, particularly among vulnerable populations such as children, the elderly, and individuals with compromised respiratory health.
[0007] Plastic waste exacerbates the landfill crisis, with plastics being a particularly persistent and pervasive pollutant. The world's plastic production has surged over the past few decades, resulting in unprecedented levels of plastic waste accumulation. Despite efforts to promote recycling and reduce single-use plastics, a significant proportion of plastic waste still ends up in landfills, where it persists for centuries, polluting the environment and endangering wildlife.
[0008] Addressing the challenges posed by landfills and plastic pollution requires innovative and sustainable solutions that prioritize waste diversion, resource recovery, and circular economy principles. While various initiatives have aimed to mitigate the impacts of plastic pollution, few have addressed the broader issue of landfill waste management comprehensively.
[0009] One promising avenue for addressing the landfill crisis involves transforming organic waste from landfills into valuable resources. By repurposing organic waste materials such as wood, textiles, agricultural residues, and food waste, it is possible to create alternative building materials with minimal environmental impact. This approach not only diverts waste from landfills but also reduces the demand for virgin materials, mitigating the environmental footprint of construction activities.
[0010] Moreover, converting organic waste into durable building materials aligns with the principles of the circular economy, wherein waste is regarded as a valuable resource that can be recycled, reused, or repurposed in a closed-loop system. By harnessing the potential of organic waste, it is possible to create a more sustainable and resilient built environment while reducing reliance on finite resources and minimizing environmental degradation.
[0011] In light of these considerations, there is a critical need for innovative technologies and systems that can effectively convert organic waste from landfills into durable and sustainable construction materials. Such solutions have the potential to revolutionize waste management practices, mitigate the environmental impacts of landfills, and pave the way for a more sustainable future.
[0012] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
OBJECTS OF THE INVENTION
[0013] The principal object of the present invention is to overcome the disadvantages of the prior art.
[0014] Another object of the present invention is to provide a method and system for sustainable Biobrick production from organic waste.
[0015] Another object of the present invention is to prioritizes health and safety by ensuring the exclusion of hazardous materials from the hydrothermal process and adhering to strict quality control standards.
[0016] Another object of the present invention is to to divert organic waste materials, including wood, textiles, agricultural residues, and food waste, from landfills, thereby reducing the volume of waste destined for landfill disposal.
[0017] Another object of the present invention is to provide an elegant, reliable and precise approach towards the method and system for sustainable Biobrick production from organic waste.
[0018] Yet another object of the present invention is to provide a process of improving functionalities of the method and system for sustainable Biobrick production from organic waste.
SUMMARY
[0019] The invention introduces a novel method and system for addressing the environmental challenges associated with landfills and plastic pollution by repurposing organic waste materials into durable and sustainable building materials. The technical aspects of the invention can be summarized as follows:
[0020] The core of the invention involves a sophisticated hydrothermal process designed to transform a diverse range of organic waste materials, including wood, textiles, agricultural residues, and food waste, into bio-bricks or blocks. This process employs controlled heat and pressure within a cylindrical reactor, optimizing the reaction efficiency and ensuring uniform heat transfer for the production of robust and reliable building materials.
[0021] The invention emphasizes the careful selection and pre-processing of organic waste materials. It identifies suitable waste streams, such as shredded wood chips, textiles, and agricultural residues, while excluding undesirable components like glass, metals, hazardous waste, and plastics. Mechanical or manual waste separation is employed, and the waste is shredded to a uniform size for optimal processing during the hydrothermal reaction.
[0022] To optimize the hydrothermal process, approximately 50-60% of the waste undergoes moisturization. This step involves the use of rotary dryers or solar drying methods to remove excess moisture from wetter waste, ensuring the efficiency of the subsequent reactions within the cylindrical reactor.
[0023] The invention employs a cylindrical reactor with a specific design to facilitate uniform heat transfer and pressure distribution. The circular geometry promotes efficient reactions and allows for adjustments to the reactor's length and diameter according to production needs. This design choice enhances the overall cost-effectiveness of the process.
[0024] The reactor is constructed using materials like Stainless Steel (316L grade) or Titanium, depending on factors such as temperature, pressure, and corrosion resistance. The choice of materials is critical to ensuring the durability and effectiveness of the reactor in handling various waste materials and reacting conditions.
[0025] The hydrothermal process involves specific parameters, including temperature (around 180-220°C), pressure (15-20 bar), and residence time (3-6 hours). These parameters are carefully chosen to achieve efficient breakdown and binding reactions, resulting in bio-bricks or blocks with the desired strength, durability, and other characteristics. The optimal values are influenced by the composition of the waste and the desired properties of the end product.
[0026] Paddle agitators and screw conveyors are employed for internal agitation within the reactor. Paddle agitators ensure uniform blending and heat distribution, preserving delicate materials like plant fibers. Screw conveyors are utilized for waste mixes that require more forceful mixing. The choice of agitation method depends on the properties of the waste being processed.
[0027] The addition of alkali hydroxides (NaOH or KOH) serves as a catalyst, facilitating the depolymerization of organic materials like cellulose and lignin. This enhances block formation and properties. The selection between NaOH and KOH depends on factors like availability and reaction rates, and the dosage and timing are determined based on the specific hydrothermal process and waste properties.
[0028] After the hydrothermal reaction, solid-liquid disentanglement is employed to separate bio-brick precursors from the liquid broth. The separated solids undergo additional processes, including the addition of fibers, mineral binders, and chemical additives to enhance their properties. The final brick formation involves filling molds with precursors, followed by a drying and curing process, sanding, and polishing for industrial purposes.
[0029] The invention emphasizes energy efficiency and sustainability throughout the process, exploring options such as renewable energy integration and water management to minimize environmental impacts.
[0030] These and other features will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. While the invention has been described and shown with reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0031] So that the manner in which the above-recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may have been referred by embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0032] These and other features, benefits, and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein: Figures attached: N.A.
DETAILED DESCRIPTION OF THE INVENTION
[0033] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and the detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim.
[0034] As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein are solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents acts, materials, devices, articles, and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
[0035] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element, or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.
[0036] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations.
[0037] The invention pertains to a groundbreaking method and system aimed at mitigating the environmental impact of landfills and plastic pollution. By employing a unique hydrothermal process, a wide array of organic waste materials, such as wood, textiles, agricultural residues, and food waste, is transformed into durable and sustainable bio-bricks or blocks.
[0038] Hydrothermal Process: At the heart of the invention is the hydrothermal process, a controlled reaction involving heat and pressure within a cylindrical reactor. This process is carefully designed to break down organic waste materials and facilitate the formation of robust bio-bricks. The choice of a cylindrical reactor allows for uniform heat distribution, optimizing the efficiency of the reactions.
[0039] Waste Material Selection and Pre-processing: The method begins with the meticulous selection of organic waste materials suitable for the hydrothermal block project. Materials like wood, textiles, and agricultural residues are chosen for their potential to contribute to the strength, flexibility, and insulation properties of the bio-bricks. On the contrary, undesirable components like glass, metals, hazardous waste, and plastics are excluded to ensure the purity of the final product.
[0040] The waste undergoes a pre-processing phase involving mechanical or manual separation. This is crucial for removing unwanted elements and preparing the waste for subsequent steps. Shredding equipment, such as hammer mills, shredders, or ball mills, is utilized to achieve a uniform size of 1-2 cm, optimizing the mixing and processing during the hydrothermal reaction.
[0041] Moisture Adjustment: Approximately 50-60% of the waste is moisturized to optimize the hydrothermal process. This step involves the use of rotary dryers or solar drying methods to eliminate excess moisture from wetter waste, ensuring the efficiency of the subsequent reactions within the cylindrical reactor.
[0042] Cylindrical Reactor Design: The reactor, crucial to the success of the hydrothermal process, is designed in a cylindrical shape. This choice offers several advantages, including uniform heat transfer facilitated by a central agitator, adjustability in length and diameter according to production needs, and cost-effectiveness in fabrication compared to more complex shapes like cubes or rectangles.
[0043] Material Selection for Reactor: The construction of the reactor involves materials such as Stainless Steel (316L grade) or Titanium. This ensures resistance to temperature, pressure, and corrosion, making them suitable for handling diverse waste materials and reaction conditions.
[0044] Process Parameters (Temperature, Pressure, Residence Time): The hydrothermal process operates within specific parameters:
[0045] Temperature: Around 180-220°C, chosen based on waste composition and desired block properties.
[0046] Pressure: Approximately 15-20 bar, providing sufficient pressure for efficient reactions and block formation.
[0047] Residence Time: Approximately 3-6 hours, striking a balance between complete processing, block strength, and energy consumption.
[0048] These parameters are carefully calibrated to achieve the desired characteristics of the bio-bricks, considering factors like temperature's impact on bonding strength and porosity.
[0049] Internal Agitation: The reactor employs paddle agitators or screw conveyors for internal agitation. Paddle agitators gently stir the mixture, ensuring uniform blending and heat distribution without exerting excessive shear forces. Screw conveyors are employed for more forceful mixing, ideal for waste mixes with higher viscosity.
[0050] Additives: Alkali hydroxides (NaOH or KOH) are added as catalysts to facilitate the depolymerization of organic materials like cellulose and lignin. The choice between NaOH and KOH is determined by factors such as availability and reaction rates. The additives promote stronger intermolecular bonds, enhancing the strength and durability of the bio-bricks.
[0051] Post-processing and Brick Formation: After the hydrothermal reaction, solid-liquid disentanglement separates bio-brick precursors from the liquid broth. The separated solids undergo further processes, including the addition of fibers, mineral binders, and chemical additives to enhance their properties.
[0052] The final brick formation involves filling molds with precursors and subjecting them to a drying and curing process at temperatures around 60-80°C for several hours. This ensures the solidification of the precursors into the desired bio-brick shapes.
[0053] Energy Efficiency and Sustainability: The invention places a strong emphasis on energy efficiency and sustainability throughout the process. Considerations include the integration of renewable energy sources and effective water management to minimize environmental impacts.
[0054] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
[0055] Thus, the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
, Claims:I/We Claim:
1. A method for creating biobricks from organic waste sourced from landfills, comprising:
selecting and pre-processing landfill waste to exclude undesirable components;
shredding and moisture adjustment of selected organic waste;
adjusting the moisture content of the waste;
subjecting the waste to a hydrothermal reaction in a cylindrical reactor under controlled temperature, pressure, and residence time conditions;
introducing additives to enhance depolymerization and binding within the biobrick matrix;
post-processing the reaction mixture to solidify biobricks into desired shapes.
2. The method of claim 1, wherein the selected organic waste includes wood, textiles, agricultural residues, and excludes glass, metals, hazardous waste, and plastics.
3. A system for sustainable biobrick production from organic waste, comprising:
waste selection and pre-processing equipment;
a cylindrical reactor for conducting the hydrothermal reaction under controlled conditions;
additives delivery system;
post-processing equipment for solid-liquid separation, mold filling, and drying/curing.
4. The system of claim 3, further comprising sensors and controls for monitoring and adjusting process parameters during biobrick production.
5. A biobrick manufactured by the method of claim 1, characterized by enhanced strength, durability, and thermal properties compared to conventional construction materials.
6. The biobrick of claim 5, wherein the biobrick exhibits superior resistance to environmental degradation and thermal conductivity.
7. A cylindrical hydrothermal reactor for conducting the hydrothermal reaction, characterized by uniform heat and pressure distribution across the reaction medium, resulting in consistent biobrick properties.
8. The reactor of claim 7, wherein the cylindrical shape allows for efficient scaling and fabrication compared to complex geometries.
9. The method for creating biobricks using shredded organic waste characterized by a particle size range of 1-2 cm, to achieve enhanced surface area for reaction and improved packing density in the mold.
10. The method of claim 9, wherein the shredded waste undergoes moisture adjustment to optimize its suitability for the hydrothermal process.