DESC:FIELD OF THE INVENTION
The present invention relates to process and apparatus for upcycling of wastewater sludge into high value products. More specifically, the present invention provides a process of thermo chemical reaction for upcycling of wastewater sludge into high value products. Also, the present invention discloses a novel apparatus for upcycling of wastewater sludge into value added products comprising of hopper, screw conveyor, gear box, motor, housing, gate valve, graphite gland, canopy, plain roller, grove roller, heat exchange condenser, separator, oil receiver and header.

BACKGROUND AND PRIOR ART OF INVENTION
Alternatives to conventional fossil fuels are more needed than ever because of the ongoing depletion of fossil fuels, the growing effects of CO2 emissions, and the expanding need for energy. The world also has to deal with the relatively high pace of garbage generation. Due to the fact that recycling programs and technological advancements are frequently insufficient to keep up with the rising amount of waste produced, the aging of current waste management facilities, and the availability of land for new facilities, waste management has become an increasingly complex issue.
Several methods have been disclosed for waste management but they are either impractical, generate further pollution, or are too costly in terms of energy and economics. Some of these methods for recycling approaches to waste management such as biotreatment, incineration and gasification have their own drawbacks. Biotreatment in the form of aerobic and anaerobic digestion requires long holding times, strict monitoring and control of operating conditions, e.g., oxygenation, pH, temperature, etc. Incineration/combustion involves the use of equipment and parts to comply with toughened emission regulations. Large volumes of gas are produced and must be disposed of using large and specialized equipment. Pyrolyzers have been used to break down organic matter to gas, oils and tar, and carbonaceous materials. A pyrolyzer typically heats organic materials at high temperatures, about 400-500° C., with poor energy efficiency. Gasification achieves a partial combustion of waste materials but, like pyrolysis, does not operate efficiently with wet waste as energy is expended to remove water from the feedstock.
However, the above disclosed methods have many disadvantages such as they are highly expensive and complicated to handle, poor efficiency and environmentally non-sustainable methods. None of the above methods reported an upcycling process and apparatus for obtaining higher value compounds from the organic materials in the value added products. Furthermore, none of the processes provides thermo-chemical upcycling of wastewater sludge into high value products at moderate temperatures. Thus, there still exists a need for a commercial process and apparatus for upcycling of wastewater sludge into higher value fuels and chemicals. The present invention provides a novel and efficient novel integrated technology for producing high quality fuel, chemical grade products and agricultural products.
The present invention discloses a novel apparatus for upcycling of waste water sludge in to value added products comprising of hopper, screw conveyor, gear box, motor, housing, gate valve, graphite gland, canopy, plain roller, grove roller, heat exchange condenser, separator, oil receiver and header.
EA024049B1 disclosed sludge treatment method and apparatus and application of said method and apparatus for wastewater bio-treatment and it relates to the sludge treatment method comprising the following steps: (1) blending a sludge feed from wastewater bio-treatment process and a first sludge mixture to obtain a second sludge mixture; (2) aerating the second sludge mixture to obtain a third sludge mixture; (3) treating the third sludge mixture under anoxic conditions to obtain a fourth sludge mixture; (4) separating the fourth sludge mixture to obtain a supernatant liquid and a first concentration sludge mixture; (5) discharging the supernatant liquid and returning at least some part of the first concentration sludge mixture as the first sludge mixture to the step (1), wherein the amount of the sludge in the first concentration sludge mixture not returned to the step (1) being less than that of the sludge feed. The present invention also relates to an application of the sludge treatment method in wastewater bio-treatment. The sludge treatment method can stably operate for a long period of time without the need of discharging sludge.
CN 105855275A disclosed a method for processing sludge and kitchen wastes and it relates to a method for processing sludge and kitchen wastes comprises by utilizing sludge and kitchen wastes as principal raw materials; separating waste oil from kitchen wastes to be taken as the raw material of fuel or bioplastics; taking biological fuel gas, which takes methane as main material and is generated through fermentation, as an external fuel supply; absorbing the nutrient in biogas slurry by the charcoal generated through pyrolysis and then taking the charcoal as a charcoal fertilizer. The method for processing sludge and kitchen wastes provided by the invention meets the increasingly urgent requirement of processing the sludge and kitchen wastes in China at present; ; the method can be used for efficiently solving the problems of separately processing sludge and kitchen wastes; the classification and valuable utilization of by-products are realized; various by-products are low-carbon high-efficient cleanly utilized; the purposes of best use, energy conservation, environment protection and cost lowering are achieved; the method has excellent economic benefit and environmental benefit.
The present invention is distinguished over the above said prior art in general, and these patents in particular by process and apparatus for upcycling of waste water sludge in to high value products have disadvantages of operated at high temperature, very expensive, inconvenience malfunctioning and complexity of apparatus.
As evident from the prior art, it becomes challenging to provide a novel, simple, efficient, economical apparatus and process for producing high quality value - added products by upcycling of waste water sludge without catalyst.
The discussion of documents, acts, materials, devices, articles and the like are included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
OBJECTIVES OF THE INVENTION
• Main objective of this invention is to provide novel apparatus for upcycling of waste water sludge in to value added products.
• One more objective of the present invention is to provide simple, efficient, and low-cost method of thermo chemical upcycling of waste water sludge in to value added products.
• Yet another objective of this invention is to provide high quality fuel, chemical grade products and agricultural products by using novel integrated technology for upcycling of waste water sludge.

SUMMARY OF INVENTION
The present invention relates to process and apparatus for upcycling of wastewater sludge into high value products. More specifically, the present invention provides a process of thermo chemical reaction for upcycling of waste water sludge in to high value products. Also, the present invention discloses a novel apparatus for upcycling of waste water sludge in to value added products comprising of hopper, screw conveyor, gear box, motor, housing, gate valve, graphite gland, canopy, plain roller, grove roller, heat exchange condenser, separator, oil receiver and header.
According to the present invention there is provided a novel, simple, energy efficient and low cost apparatus and process for producing high quality value added products from waste water sludge. The process of thermo chemical upcycling of waste water sludge in to high value added products comprised of 1) drying of feed using a separate low temperature dryer. The stream entering in this system contains around 85-90% solids in dried form 2) reduction of size of feed is carried out in integrated dryer assembly 3) entering the dried feeding to the reactor chamber at ambient conditions, heat up along the reactor length via multi stage burners and converts into volatiles and solid product with downstream separation of both phases with temperature range of 400-7000 C for time period of 30-60 mins. 4) the volatile phase enters multi step condensation unit for separation of liquid phase compounds from non-condensable gases 5) generation of gases to provide heat energy to the process and for energy integration required for drying and other heating applications 6) finally the generated liquid stream is upgraded for both chemical and fuel value. The solid stream is user for both agricultural and non-agricultural applications.
According to present embodiment the yield obtained from thermo-chemical upcycling of waste water sludge to value added products ranging from 18-28 % of liquid product and 40-60 % solid product.

BRIEF DESCRIPTION OF DRAWINGS
For more complete understanding of the features and advantages of the present invention, the detailed description of the invention is made along with the figures and in which:
Figure 1: Describe the schematic diagram of process and apparatus for upcycling of waste water sludge in to value added products
Figure 2: Describe the FTIR (Fourier Transform Infra Rays) spectrum of high value products from waste water sludge
Figure 3: Describe the TGA Thermogravimetric Analysis of waste water sludge in to high value products
Figure 4: Describe the SEM (Scanning Electronic Microscopy) Analysis Of waste water sludge in to value added products
Figure 5: Describe the Percentage distribution of various elements across different Biochar treatments and fractions of waste water sludge in to value added products

DETAILED DESCRIPTION OF INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
The present invention relates to process and apparatus for upcycling of wastewater sludge into high value products. More specifically, the present invention provides a process of thermo chemical reaction for upcycling of wastewater sludge into high value products. Also, the present invention discloses a novel apparatus for upcycling of waste water sludge in to value added products comprising of hopper, screw conveyor, gear box, motor, housing, gate valve, graphite gland, canopy, plain roller, grove roller, heat exchange condenser, separator, oil receiver and header.
The main embodiment of the present invention relates to process and apparatus for upcycling of waste water sludge in to high value products.
According to main embodiment, the present invention discloses a novel apparatus (Figure No.1) for upcycling of waste water sludge in to high value products comprising of hopper (1), screw conveyor (2), gear box (3), motor (4), housing (5), gate valve (6), graphite gland (7), canopy (8), plain roller (9), grove roller (10), heat exchange condenser (11), separator (12), oil receiver (13), header (14).
According to main embodiment, hopper is used to handle the material and enter the feed in to the conveyor.
According to main embodiment, the present invention discloses screw conveyor to transfer the material from one end to another one.
According to main embodiment, the present invention discloses a gear box for preheating of nitrogen gas in the reaction vessel.
According to main embodiment, the present invention discloses a motor for providing mechanical energy in to the reactor.
According to main embodiment, the present invention discloses a housing for vacuum holding used for sealing with dimension of 320-324mm.
According to main embodiment, the present invention discloses a gate valve for feeding raw material.
According to main embodiment, the present invention discloses a graphite gland with dimension of 16 mm for sealing.
According to main embodiment, the present invention discloses a canopy in reactor for insulation in the reactor.
According to main embodiment, the present invention discloses plain and grove roller having overall dimension of 100- 80 mm with 25 mm shaft for rotating the reactor.
According to main embodiment, the present invention discloses grove roller having overall dimension of 100- 80 mm with 25 mm shaft for rotating the reactor.
According to main embodiment, the present invention discloses shell and tube type heat exchange condenser made up of stainless steel with 7-10 mm diameter and a length ranging from 1000-1500 mm for heating of material feedstock.
According to main embodiment, the present invention discloses a shell and tube heat exchanger with size tube of 4-6 mm, surface area ranging of 0.10- 0.15 m2 for transfer of heat in to the reaction vessel.
According to main embodiment, the present invention discloses separator i.e., expansion tank for separating oil and carbon with overall dimension of 300-500 mm and length is ranging from 800-1000.
According to main embodiment, the present invention discloses oil receiver for collecting final product of high value oil.
According to main embodiment, the present invention discloses header for handling of cold water.
According to main embodiment, the present invention discloses gate valve for opening and closing of cold water.
The one of essential embodiment of the invention is method of thermo-chemical upcycling of waste water sludge to value added products comprising of;
1. Drying of feed using a separate low temperature dryer.
2. Reduction of size of feed is carried out in integrated dryer assembly.
3. Introducing the dried feed to the reactor chamber at ambient conditions, heat up along the reactor length via multi stage burners with temperature range of 400-7000 C for time period of 30-60 mins.
4. Conversion of material into volatiles and solid product with downstream separation of both phases.
5. Entering the volatile phase enters multi step condensation unit for separation of liquid phase compounds from non-condensable gases.
6. Generation of gases to provide heat energy to the process and for energy integration required for drying and other heating applications.
7. Finally, the generated liquid stream is upgraded for both chemical and fuel value.
According to present embodiment the yield obtained from thermo-chemical upcycling of waste water sludge to value added products ranging 18- 28 % of liquid product and 40-60 % solid product.
The present invention is further described with the help of the following examples, which are given by way of illustration and therefore should not be construed to limit the scope of the invention in any manner.
,CLAIMS:
We Claim,
1. An apparatus for upcycling of wastewater sludge into high value products comprising;
Hopper (1) characterized in that handle the material and enter the feed
in to the conveyor,
Screw conveyor (2) characterized in that transfer the material from one
end to another one,
Gear box (3) for preheating of nitrogen gas in the reaction vessel,
Motor (4) characterized in that mechanical energy in to the reactor,
Housing (5) characterized in that vacuum holding used for sealing,
Gate valve (6) for feeding raw material,
Graphite gland (7) for sealing of valve,
Canopy (8) characterized in that insulation in the reactor,
Plain roller (9) characterized in that rotating of the reactor,
Grove roller (10) characterized in that rotating of the reactor,
Heat exchange condenser (11) characterized in that heating of material
feedstock,
Separator (12) characterized in that separating oil and carbon from the
mixture,
Oil receiver (13) characterized in that collecting final product,
Header (14) characterized in that handling of cold water.
2. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein housing (5) has dimension ranging from 320-324mm.
3. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein graphite gland (7) has dimension ranging from 10-20 mm.
4. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein plain roller (9) has dimension ranging from 100- 80 mm with 25 mm shaft.
5. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein grove roller (10) has dimension ranging from 100- 80 mm with 25 mm shaft.
6. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein shell and tube type heat exchange condenser (11) diameter ranging from 7-10 mm and length ranging from 1000-1500 mm.
7. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein separator (12) has dimension ranging from 300-500 mm and length ranging from 800-1000 mm.
8. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 1, wherein shell and tube type heat exchange condenser is selected from group of stainless steel, aluminum etc.
9. A process for upcycling of wastewater sludge into high value products comprising;
Drying of feed using a separate low temperature dryer,
Reduction of size of feed is carried out in integrated dryer assembly,
Introducing the dried feed to the reactor chamber at ambient
conditions, heat up along the reactor length via multi stage burners,
Passing of volatile material through primary condenser,
Separation of liquid phase from non-condensable gases by using ice-salt bath,
Collecting the liquid oil in graduated vessels,
Measuring the non-condensable gas by soap film meter,
Removal of unreacted solid residue from vessel .
10. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 9, wherein temperature is ranging from 400-7000 C for time period ranging from 30-60 mins.
11. An apparatus for upcycling of wastewater sludge into high value products as claimed in Claim 9, wherein yield is ranging from 18 -28 % of liquid product and 40-60 % solid product.