Description:FIELD OF THE INVENTION
The present invention broadly relates to biowaste processing. Particularly, the present invention relates to a stand-alone system for converting biowaste into a variety of sustainable energy products such as hard carbons, syngas, and protein feed in one production line even without using any external power source.

BACKGROUND OF THE INVENTION
Biowaste discarded as agricultural waste, forestry residues, gardening, and organic waste are either used as fuels for domestic cooking or dumped in lowland areas, which certainly cause environmental pollution, spread foul odours and diseases. Although these biowastes have huge potentiality for producing multi spectrum energy products [such as fertilizers/biochar, nutrients (cattle/poultry feed), hard carbons (energy storage device or battery components), syngas (biofuel)]; however, their optimal utilization is hardly achieved. Therefore, there is felt a need of developing a single production line system that can produce multiple energy products from single biowaste source, thus contributing towards this green energy revolution era.

Traditional biochar production methods often involve high temperatures and long pyrolysis times, which can be energy-intensive and may lead to the release of harmful pollutants. Bioinspired char (hard carbon) production, on the other hand, seeks to mimic the natural processes of charcoal formation, which occur at lower temperatures and over longer periods of time. This results in a biochar that is not only more sustainable but also more effective in its intended applications. Bioinspired char production methods are designed to minimize environmental impact by using natural materials and processes and operating at lower temperatures. Further, different non-vector species (such as black soldier fly) can also convert organic components of such waste into nutrient material (protein and fat) for use as animal feed and fertilizer. These approaches can reduce energy consumption and greenhouse gas emissions compared to traditional biochar production methods.

Bioinspired char can significantly improve soil health by increasing water retention, nutrient availability, and microbial activity. It can also help to remediate contaminated soils and mitigate soil erosion. Bioinspired char has a high carbon content and is highly stable, making it an ideal material for carbon sequestration. It can effectively store carbon in the soil for hundreds or even thousands of years, helping to mitigate climate change. Bioinspired char can be used to purify water by removing contaminants such as heavy metals, pesticides, and organic pollutants. Its porous structure and high surface area make it an effective adsorbent for a wide range of pollutants. It can be used as electrode components used in energy storage devices or batteries. Further, significant amount of syngas is generated during the pyrolysis burning (reaction), and the same can be stored for use as biofuel.

A reference may be made to CN116835588A that discloses a hard carbon preparation system and method in which alkali liquor (NaOH or KOH) is mixed with biomass raw material in a material pretreatment device and then introduced pyrolysis chamber that runs using external heating/power source, thus, appears to be energy intensive.

Another reference may be made to US9650254B2 that discloses a method of production of active carbon by pyrolysis of organic materials, in which the organic materials are subjected to pyrolysis reaction in pyrolysis unit to produce combustible gas, tar and char. Combustible gas is reformed through reforming unit then enters into the drying unit for drying organic materials.

One more reference may be made to CN114763498B that discloses a system/method for producing hydrogen and co-producing biochar by biomass pyrolysis and gasification, in which multistage reactors such as a microwave pyrolysis reactor, a gasification reactor, a reforming conversion reactor and a combustion regenerator are used in the production line.

However, all the existing/conventional or commercially available biomass pyrolysis reactors (biochar and syngas production devices) have many limitations towards their sustainability, material selection, chemical usage, process parameters, quality of end products (biochar and syngas) and complexity involved in manufacturing/configuration/installation, it is required to devise an improved approach, especially a self-sustainable biowaste processing system that can produce multi-spectrum energy products using single biowaste source in one production line in more simple, eco-friendly, and cost-effective manner. Moreover, it is desired to develop a system for processing biowaste into energy products (hard carbon, syngas, protein feed) which includes all the advantages of the conventional/ existing techniques/methodologies and overcomes the deficiencies of such techniques/methodologies.

OBJECT OF THE INVENTION
It is an object of the present invention to utilize biowastes as discarded from agricultures fields, forestry residues, gardening, and vegetable food wastes towards minimizing environmental pollution and solving the energy crisis.

It is another object of the present invention to develop a stand-alone and self-sustainable single production line system to convert the biowastes into multi-spectrum energy products.

It is one more object of the present invention to design a cost-effective and user-friendly mechanism to produce high quality hard carbon and hydrogen rich syngas.

It is a further object of the present invention is to devise a system for processing biowaste into energy products.

SUMMARY OF THE INVENTION
In one aspect, the present invention provides a system for processing biowaste into energy products. The system comprises at least one first enclosure, a second enclosure, a pelletizer, a vertical pyrolysis reactor, a hot media transporting channel, and a control unit. The first enclosure, the second enclosure, the pelletizer, and the pyrolysis reactor are coupled serially in one production line. The hot media transporting channel is coupled to the pyrolysis reactor at one end, and the both enclosures at another end. The first enclosure is used as biowaste degradation chamber. The second enclosure is used for separating/sieving the degraded biowaste materials into frass and nutrient material. The pelletizer is used to produce pellets from the frass and such pellets are conveyed into the reactor for synthesis of the hard carbon accumulated at bottom and the syngas accumulated at top. The first enclosure has a gate at top to introduce biowaste and degrading subject, and is internally provided with plurality of steam sprayers to sterilize the biowaste before introducing the degrading subject, and a motorized auger to move the degraded biowaste from its a first end to its a second end therein. The second enclosure wall is formed as a hollow jacket and encloses a sieve that is coupled with the second end of the auger at an inclination of 6-12 degree angle (adjustable at both side) and internally provided with a motorized agitator/rotor to separate the frass from the nutrient. A water recirculating channel is coiled up around wall of the reactor to receive water from a water injecting device and produce steam therefrom during pyrolysis. The hot media transporting channel is adapted to transport hot media (steam, gas/air, water) from the pyrolysis reactor into the steam sprayers of the first enclosure, and the hollow jacket of the second enclosure, where plurality of first valves are installed along the hot media transporting channel to regulate flow of the hot media thereinto. Both the enclosures have at least one second valve to release the steam, gas/air, water to outside, and at least one third valve to introduce air into the enclosures. The control unit is configured to control operations of the auger, the sieve, the pelletizer, the water injecting device, and the valves based on commands received through a user interface device.

Other aspects, advantages, and salient features of the present invention will become apparent to those skilled in the art from the following detailed description, which delineate the present invention in different embodiments.

BRIEF DESCRIPTION OF DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying figures.

Fig. 1 is schematic diagram illustrating all components of the biowaste processing system, in accordance with an embodiment of the present invention.

Fig. 2 illustrates configuration of biowaste degradation chamber (first enclosure) of the system, in accordance with an embodiment of the present invention.

Fig. 3 illustrates configuration of frass separation/sieving chamber (second enclosure) of the system, in accordance with an embodiment of the present invention.

Fig. 4 illustrates configuration of frass pelletizer and pyrolysis reactor of the system, in accordance with an embodiment of the present invention.

Fig. 5 illustrates operation flow chart of conversion of biowaste into energy products (hard carbon), in accordance with an embodiment of the present invention.

List of reference numerals
100 first enclosure
102 gate
104 steam sprayer
106 motorized auger
106a first end
106b second end
106c motor
108 ammonia trapper
200 second enclosure
202 sieve
204 motorized agitator/rotor
204a motor shaft
206 hollow jacket
206a outer wall
206b inner wall
206c cavity
208 frass tray
210 nutrient tray
300 frass pelletizer
302 frass receiving hopper
304 pellet dispensing port
306 pressing piston with dice/mould
306a motor
400 vertical pyrolysis reactor
402 water recirculating channel
404 water injecting device (pump)
406 motorized agitator/rotor
408 syngas collecting outlet
410 hard carbon collecting outlet
412 pellet feeder
414 conveyor
414a motor
500 hot media transporting channel
600 control unit
602 user interface device
V1 first valves
V2 second valves
V3 third valve
S sensors
H heater/burner (heat producing device)
DM degraded (biowaste) material
F frass
N nutrient
P pellets

DETAILED DESCRIPTION OF THE INVENTION
Various embodiments described herein are intended only for illustrative purposes and subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of terms “comprises”, ‘includes’ or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms, “an” and “a” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The term “plurality” herein is used to indicate multiple number of components/features to be essentially present in the invention. Further, the terms such as “inner”, “outer”, "below", "above", "lower", "upper", “bottom”, “top” and the like, may be used herein to describe relationships between different elements as depicted from the figures. Further, the term ‘biowaste’ used herein refers to agricultural wastes, forestry residue wastes, and organic waste which have no use for human beings. The term ‘biowaste degrading subject’ used herein refers to any non-vector species/matter (such as black soldier fly) that can degrade the biowaste without involving any chemical. Furthermore, the term ‘media’ used herein refers to steam, air/gas, and water flowing from one part to another part in the system.

According to an embodiment of the present invention, as shown in Fig. 1, the biowaste processing system is depicted. The system is configured to convert biowaste material into multi-spectrum products in one (same) production line without using external power source. The products include hard carbon, nutrient materials, fertilizers, and syngas. The system comprises at least one first enclosure (100), a second enclosure (200), a pelletizer (300), a vertical pyrolysis reactor (400), a hot media transporting channel (500), and a control unit (600). The first enclosure (100), the second enclosure (200), the pelletizer (300), and the pyrolysis reactor (400) are coupled serially in one production line. The hot media transporting channel (500) is coupled to the pyrolysis reactor (400) at one end, and the both enclosures (100, 200) at another end. The hot media transporting channel (500) is adapted to transport a hot media such as steam, air/gas, water/fluid from the reactor (400) into the enclosures (100, 200). A set of first valves (V1) are used in the hot media transporting channel (500). Further, on walls of both the enclosures are provided with a set of second valves (V2) and a set of third valves (V3). The first enclosure (100) is used as biowaste degradation chamber. The second enclosure (200) is used for separating/sieving the degraded biowaste materials into frass and nutrient material. The pelletizer (300) is used to produce pallets from the frass and such pellets are conveyed into the reactor (400) for synthesis of the hard carbon accumulated at bottom, and the syngas accumulated at top.

According to an embodiment of the present invention, as shown in Fig. 2, the first enclosure (100) comprises a gate (102), plurality of steam sprayers (104), a motorized auger (106), and an ammonia trapper (108). The gate (102) is built at top of the first enclosure (100) to introduce biowaste and degrading subject for causing degradation of the biowaste within a period of 5-8 days. The steam sprayers (104) are provided inside the first enclosure (100) to sterilize the biowaste before introducing the degrading subject. The motorized auger (106) employs a motor (106c) adapted to move the degraded biowaste material (DM) from its a first end (106a) to a second end (106b) inside the first enclosure (100) (material flow direction is indicated as dotted arrow marks). The ammonia trapper (108) is made up of activated carbon-based material, and zeolite/wet scrubber. The ammonia trapper (108) is configured to trap ammonia produced during the degradation of biowaste, which help in growth of its nutritious components to be separated as protein feed for poultry/cattle. The first enclosure (100) includes one or more second valves (V2) to controllably release the air/gas to outside (atmosphere), and one or more third valves (V3) to introduce air into the enclosure (causing air ventilation). The number of first enclosure (100) may vary to scale up the biowaste degradation operation in the production line.

According to an embodiment of the present invention, as shown in Fig. 3, the second enclosure (200) comprises a sieve (202), a motorized agitator/rotor (204), a hollow jacket (206), a frass tray (208), and a nutrient tray (210). The hollow jacket (206) is built in wall of the second enclosure (200) by way of forming an outer wall (206a), an inner wall (206b), and a cavity/space (206c) provided therebetween. The hot media transporting channel (500) introduces steam/air/water into the cavity/space (206c) of the hollow jacket (206) to keep the inner environment of the second enclosure (200) hot that helps in drying the degraded material (DM) for improved sieving. The hollow jacket (206) is provided with one or more second valves (V2) to controllably release the air/gas/water to outside (atmosphere). The second enclosure (200) includes one or more third valves (V3) to introduce atmospheric air thereinto (causing ventilation). The sieve (202) is a netted body having pore size of 1- 3 mm, and horizontally mounted at the second end (106b) of the auger (106) to receive the degraded material (DM) therefrom for sieving operation. The sieve (202) may be of any shape such as cylindrical, oval, flat, rectangular etc. The sieve (202) is coupled with an angular adjustment mechanism to make it inclined at 6-12 degree angle in any direction. The material flow directions are indicated as dotted arrow marks.

According to an embodiment of the present invention, the sieve (202) is coupled with a motor shaft to rotate at 1-100 rpm speed inside the second enclosure (200). The agitator/rotor (204) is an elongated member coupled with plurality of spikes, and extended along an axis of sieve rotation (both in clockwise and anticlockwise directions). The agitator/rotor (204) is adapted to rotate at 22-28 rpm. The rotation of sieve and/or agitator help in separating the dried degraded materials (DM) into two components such as: frass (F) and nutrient materials (N). The frass tray (208) is provided at bottom of the sieve (202) to collect the frass (F), and slightly tilted/oriented towards the pelletizer (300) to deliver the frass (F) directly thereinto for pellet formation. The nutrient tray (210) at downward inclined end of the sieve (202) to collect the nutrient (N). The nutrient tray (210) is conveyed into any external container (not shown in figure for simplicity) to supply as protein feed for poultry/cattle.

According to an embodiment of the present invention, as shown in Fig. 4, the pelletizer (300) is mounted below downward inclined end of the frass tray (208) to receive the frass (F) therefrom. The pelletizer (300) comprises a frass receiving hopper (302) at top, a pellet dispensing port (304) at one side, and a pressing unit (306) therebetween. The frass (F) directly falls into the frass receiving hopper (302) from the frass tray (208). The pressing unit includes a motor (306a) adapted to operate a hydraulic piston into mould to convert a predefined amount of frass (F) into pellets (P) of 80-100 mm size. The pellets (P) are dispensed through the pellet dispensing port (304) into a conveyor (414) that is coupled to the vertical pyrolysis reactor (400).

According to an embodiment of the present invention, the pyrolysis reactor (400) is adapted to operate at a temperature of 250 oC - 1250 oC in absence of oxygen to produce hard carbon and syngas from the pellets (P) as conveyed from the pelletizer (300). The reactor (400) includes a funnel shaped hollow body in which coupled a water recirculating channel (402), a water injecting device (404), a motorized agitator/rotor (406), a syngas collecting outlet (408), a hard carbon collecting outlet (410), a pellet feeder (412), and a heater/burner (H). The water recirculating channel (402) is coiled up around wall of the reactor (400) to receive water from the water injecting device (404) and produce steam therefrom during pyrolysis heating/burning. The water recirculating channel (402) may be used as a heat absorbing channel to make the air/gas (inert gas) flowing along its length heated so that the same hot gas/air is introduced into the enclosures (100, 200) as per the requirements. The water injecting device (404) may include a water pump coupled with a water flow regulating valve. The agitator/rotor (406) is mounted along central axis of the vertical hollow body (400). The pellets (P) are carried upto the feeder (412) using a motor (414a) operated conveyor belt (414) and therefrom fall into the reactor centre where they come in contact with the burning/heating flame to cause pyrolysis, finally resulting in the hard carbon and the syngas (mixture of hydrogen with other gases in various ratios). The hard carbon is collected through the hard carbon collecting outlet (410) at bottom of the reactor, and the syngas is collected through the syngas collecting outlet (408) at top of the reactor. The hard can be used in making electrodes of energy storage devices and the syngas can be used as fuel (energy source) for various industrial application.

According to an embodiment of the present invention, the hot media transporting channel (500) is extended from the water recirculating channel (402) into the steam sprayers (104) of the first enclosure (100), and the hollow jacket (206) of the second enclosure (200) to transport steam produced in the water recirculating (heat absorbing) channel (402) due to the heat liberated from the reactor chamber (400). Similarly, hot air or hot water may be transported from the reactor side (400) into the hollow jacket (206) of the second enclosure (200) to keep it hot for frass drying operation. Further, plurality of first valves (V1) are installed along the hot media transporting channel (500) to controllably inject the hot media (steam, air/gas, water) into the enclosures (100, 200). Preferably, one first valve (IV) is installed on way of the first enclosure (100), and two first valves (IV) are installed on way of the second enclosure (200). The steam sprayers (104) are configured to spray the steam at 100-125 oC temperature for 12-18 minutes while sterilizing the biowaste in the first enclosure (100). The hollow wall jacket (206) receives the steam/water/air at 100-150 oC temperature for drying the degraded waste material while sieving inside the second enclosure (200).

According to an embodiment of the present invention, the valves (V1, V2, V3) may be solenoid valves which can be activate/deactivated based on sensor signals.

According to an embodiment of the present invention, the control unit (600) is configured to control operations of the auger (106), the sieve (202), the pelletizer (300), the water injecting device (404), and the valves (V1, V2, V3) based on commands received through a user interface device (602). One or more sensors (S) are mounted in the enclosures (100, 200) and the reactor (400) to measure biowaste processing parameters associated with temperature, moisture, pressure, gaseous contents, and weight/volume; and transmit the measured parameters to the control unit (600) for generating signals to turn on/off the motors of the auger (106), the sieve (202), the pelletizer (300), and the conveyor (414), pump of the water injecting device (404), and the valves (V1, V2, V3).

According to an embodiment of the present invention, as shown in Fig. 5, the operation flow chart of the biowaste processing system is depicted. Initially, some raw (dry) biowaste are required to cause pyrolysis in the reactor using any external fuel source along with water injection into its water circulating channel, till a first batch of degraded material or pellets are formed. Once the reactor is initiated, it produces syngas and a small part of such gas can be easily used to run the system, thus it will not depend on external fuel source, making it self-sustainable. The biowaste is shredded or cut into small pieces, then introduced into the first enclosure and the valve of the steam sprayer is turned on to apply steam at 60-180 oC variable temperature for sterilization of the biowaste depending on its material properties. While the biowaste reaches at 28-30 oC temperature after sterilization, the biowaste degrading subject is introduced into the first enclosure followed by incubation period of 5-8 days for its full degradation. The degraded material is moved through the auger into the sieve inside the second enclosure with simultaneous steam/water/gas injection into to its hollow wall jacket to cause drying at 100-150 oC and separation of the frass from the nutrients. The frass is collected in the frass tray and transferred into the pelletizer to form pellets of 80-100 mm size. The pellets are conveyed into the reactor via the conveyor to produce hard carbon and syngas through pyrolysis at 250-1250 oC in absence of oxygen at the centre of the reactor. The hard carbon is collected at bottom and transported energy storage device processing unit. The syngas is collected at top and transported to external filtration unit for further processing or fuel application. The system can produce 30-40% hard carbon and 12-15% hydrogen rich syngas in each batch of the biowaste contents.

The operators may give input command to operate the motors of various components, the water pump, and the valves based on the requirements the biowaste processing. The sensors continuously monitor various data/information (temperature, pressure, moisture, gasses etc.) associated with operational status of all the components and the same are displayed in the user interface device. The control may generate appropriate signals and regulate (turn on/off) drivers of the motors/pumps/valves in a closed loop circuit in flawless manner.

The foregoing descriptions of exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable the persons skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the scope of the claims of the present invention. , Claims:We claim:

1. A system for processing biowaste, comprises:
at least one first enclosure (100) having a gate (102) at top to introduce biowaste and degrading subject for causing degradation of the biowaste within a period of 5-8 days, wherein the first enclosure (100) is internally provided with plurality of steam sprayers (104) to sterilize the biowaste before introducing the degrading subject, and a motorized auger (106) to move the degraded biowaste from a first end (106a) to a second end (106b) inside the first enclosure (100);
a sieve (202) coupled with the second end (106b) of the auger (106) at an inclination of 6-12 degree angle and internally provided with a motorized agitator/rotor (204) to separate frass (F) and nutrient (N) from the degraded biowaste (DM) as conveyed from the first enclosure (100), wherein the sieve (202) is mounted inside a second enclosure (200) having a hollow wall jacket (206);
a pelletizer (300) adapted to produce pellets (P) of 80-100 mm size from the frass (F) as conveyed from the sieve (202);
a vertical pyrolysis reactor (400) adapted to operate at a temperature of 250 oC - 1250 oC in absence of oxygen to produce hard carbon and syngas from the pellets (P) as conveyed from the pelletizer (300), wherein a water recirculating channel (402) is coiled up around wall of the reactor (400) to receive water from a water injecting device (404) and produce steam through heat liberated from the reactor (400); and
a hot media transporting channel (500) adapted to transport a hot media from the reactor (400) into the steam sprayers (104) of the first enclosure (100), and the hollow wall jacket (206) of the second enclosure (200), wherein plurality of first valves (V1) are installed along the hot media transporting channel (500) to regulate flow of hot media; and
a control unit (600) configured to control operations of the auger (106), the sieve (202), the pelletizer (300), the water injecting device (404), and the first valves (V1) based on commands received through a user interface device (602).

2. The system as claimed in claim 1, wherein the first enclosure (100) and the second enclosure (200) are provided with at least one second valve (V2) to release steam/gas/water to outside, and at least one third valve (V3) to introduce atmospheric air into the enclosures (100, 200).

3. The system as claimed in claim 2, wherein the first enclosure (100) and the second enclosure (200) are internally provided with one or more sensors (S) adapted to measure biowaste processing parameters associated with temperature, moisture, pressure, gaseous contents, and weight/volume, and transmit the measured parameters to the control unit (600) for generating signals to turn on/off the auger (106), the sieve (202), the pelletizer (300), the water injecting device (404), and the valves (V1, V2, V3).

4. The system as claimed in claim 1, wherein the first enclosure (100) is internally provided an ammonia trapper (108) to trap ammonia produced during the degradation of biowaste.

5. The system as claimed in claim 1, wherein the sieve (202) comprises a netted body having pore size of 1-3 mm.

6. The system as claimed in claim 5, wherein the netted body is coupled with a motor shaft (204a) for rotary motion at 1-100 rpm speed inside the second enclosure (200).

7. The system as claimed in claim 5, wherein the sieve (202) is provided with a frass tray (208) at its bottom and a nutrient tray (210) at its downward inclined end.

8. The system as claimed in claim 7, wherein the frass tray (208) is oriented towards a feeder (302) of the pelletizer (300) to deliver the frass (F) thereinto.

9. The system as claimed in claim 1, wherein the pelletizer (300) comprises a pellet dispense port (304) coupled with a feeder (412) of the pyrolysis reactor (400) through a conveyor (414).

10. The system as claimed in claim 1, wherein the pyrolysis reactor (400) is provided with a syngas collecting outlet (408) at top, and a hard carbon collecting outlet (410) at bottom.