FIELD OF THE INVENTION:

The invention relates to a field of vermicomposting system. More particularly the present invention relates to an apparatus for vermicomposting.

BACKGROUND OF THE INVENTION:

In pre-existing designs such as Worm Wigwam, there is probability of the earthworms getting injured or killed as a crank is used for harvesting. In case of high efficiency vermiculture process and apparatus also, a strong light source or fan blowing air is required to make the worms move away from the unloading end. These contraptions are not needed with present invention. In the pre-existing institutional and industrial size flow-through vermireactors, ventilation systems have to be provided for proper aeration, which increases the capital costs.

The cited patent US 6197573 discloses about a micro organism based fermentation batch that combines all of the operations of microorganism cultivation (sterilization, inoculation, cultivation, extraction, and post extraction treatment). This solid state fermentation device is modular in nature and operates in a contained manner so that the live microorganisms from the reactor cannot come into contact with the environment and pollute the environment and also so that the environment inside the bioreactor is aseptic. Another aspect of this invention allows fermentation of microorganisms without inhibiting the growth of the microorganism. Specifically, the bioreactor is designed to remove heat that accumulates inside the bioreactor during fermentation by conduction. Additionally, there is a mechanism to add fluid to the interior of the bioreactor that permits equal distribution and precise control of a variety of environmental parameters. For example, the bioreactor of the present invention provides a means to add nutritive media to the microorganisms at any time during the fermentation process without disturbing the fermenting microorganisms. Furthermore, the bioreactor of the present invention provides a mechanism to mix the contents of the bioreactor at any time and for any duration during the fermentation process. Finally, the present bioreactor provides a means of extracting desired microbial products from the bioreactor without opening the bioreactor. The operation of the cited patent required continuous maintenance, control of temperature and oxygen level, mixing and sterilization of cultivation device.

In another prior art, box type arrangement is disclosed. US 2003/0059931 discloses about a vermicomposting apparatus and method . The cited patent includes a housing and plurality of vermicomposting drawers in the housing. The plurality of vermicomposting drawers is in a stacked relationship with in the housing. Due to the box type structure of the drawers, it is limited in terms of scaling and modular changes.

In some patents, tanks and pipe arrangement is disclosed. US 2005/0133442 discloses about a method and apparatus for biosustainingwaste. The cited patent includes a holding tank for receiving and initially processing the sewage. A treatment tank, connected to the holding tank by a first pipe, is used for treating the initially processed sewage from the holding tank to ensure optimal pH, percent of solids, and electrical conductivity of the sewage. A distribution tank, connected to the treatment tank by a second pipe, is used for heating or cooling the sewage from the treatment tank as necessary. A distribution apparatus, connected to the distribution tank by a third pipe, distributes the sewage to a vermicular environment, wherein the vermicular environment contains a plurality of worms which digest the distributed treated sewage into vermicompost activated vermicular environment. The cited needs separate heating and cooling system for maintaining the temperature.

The cited patent US 6223687 discloses about an apparatus and process for the efficient vermicomposting of organic containing wastes. A continuous thin layer of biomass is formed in which worms are established and encouraged to compost and migrate. The thinness of the biomass layer increases uniformity and allows for a higher rate of worm activity. By moving the biomass upon a conveying surface a continuous open system is created. New matter is introduced, digested and withdrawn while maintaining the active worms within a portion of the biomass. Spatial efficiency is provided by creating multiple beds in a stacked configuration. The cited patent the depends on the movement of conveyer belt which is very costly and construction is complicate.

With a view to accomplish the above needs, the following solutions are provided in the present invention.

OBJECTS OF THE INVENTION

The first object of the present invention is to provide an apparatus and a method for production of vermicompost from the organic waste with less cost and simplified method.
The another object of the invention is to provide a continuous process of production of vermicompost of organic waste.

The another object of the invention is to provide an apparatus for continuous generation of the vermicompost but without using external control force but the system being self independent which is achieved by providing for moving modules continuously and steadily from loading point to unloading point one after the another. The modules are preferably of the same size but may be different in size in a specific arrangement.

The further object of this invention is to provide apparatus which minimizes the flow space of the apparatus by vertically building the apparatus.

The another object of the invention is to eliminate the batch process of preparation and maximizes the rate of decomposition by providing continuous process.

Another object of the invention is to provide an apparatus and methods wherein there is no dependents on external aerations or external ventilation.

Another object of the invention is to provide an apparatus and methods wherein the environment is most conducive for decomposing the waste material into vermicompost in the shortest duration without degeneration and further waste.

SUMMARY OF THE INVENTION:

The present invention relates to an inclined parallel stack continuously operable (IPSCO) vermireactor system. The system is based on a set of modular reactors arranged in multiple stacks. It includes a loading mechanism, an unloading mechanism, several vermicomposting modules, a sprinkler system and a harvesting unit. Discrete modules containing the substrate shall be 'loaded onto the system using a loading mechanism which shall deliver the modules to the respective stacks. The modules are square shaped and are made up of fiber-reinforced plastic to ensure high strength at low material density, adequate elasticity, and flexibility. The vermicompost shall be harvested using a harvesting unit and shall be sun dried, packed and stored.

BRIEF DESCRIPTION OF THE DRAWINGS:

Fig 1 illustrates the inclined parallel stack continuously operable(IPSCO)
verminreactor system with loading mechanism and unloading mechanism.

Fig 2 illustrates the working of inclined parallel stack continuously operable(IPSCO)
verminreactor system with loading mechanism and unloading mechanism..

Fig 3 illustrates the loading mechanism of Inclined parallel stack continuously
operable (IPSCO) system

Fig 4 illustrates the unloading mechanism of Inclined parallel stack continuously
operable (IPSCO) system.

Fig 5 illustrates the sprinkler and drain pipe of the module along with locking means.

Fig 6 illustrates the flow chart of the inclined parallel stack continuously operable
vermireactor system.

DESCRIPTION OF INVENTION :-

This novel design is based on a set of modular reactors arranged in multiple , sloping stacks(2). It includes loading (3) and unloading mechanisms(4), several vermicomposting modules (1), sprinkler system (5) and a harvesting unit(12).

The distinguishing features of the design include discrete modules (1) which may be fed with different substrates and can be loaded onto the system using a loading mechanism(3) which delivers the modules(1) to the respective stacks(2). The frequency of loading and, unloading of modules(1) can be adjusted to suit the rate of vermicomposting of the given substrate-species combination. The product (vermicompost) is harvested using a harvesting unit(12) for sun drying, packing and storing.

The flow chart of the system is depicted in Figure 6.

In one of the embodiment each inclined parallel stack continuously operable vermireactor unit typically includes five stacks, each with a modest slope but parallel to each other. Each stack(2) is 11 m long and 1.2 m wide. The length is chosen to facilitate ten 1m long reactor modules(1) to move through and reach the end of the stack(2). The stacks(2) have tracks made up of mild steel. Each stack(2) can typically hold 10 modules. A distance of 10 cm with support structure is provided to prevent each module(1) from clashing with the next module. The stacks(2) are inclined at an angle of about 5° to enable the modules(1) to move at the desired speed by gravity.

The height of a typical inclined parallel stack(2) continuously operable unit is 4.1 m. The modules(1) are square shaped (1 m x 1 m x 0.12 m), made up of fiber- reinforced plastic to ensure high strength at low material density, adequate elasticity, and flexibility. The square shape is chosen for ease of handling, too. The feed is laid upto height of 8cm with the buffer space of 4 cm; the total depth of the module(1) has been set as 12 cm.
The reactor dimensions as disclosed in the invention enable vermicomposting at much faster rate (15-20 days) compared to 4-6 months taken for the same output in existing systems. This has been made possible by setting the reactor dimensions in such a way that access of earthworms to the feed is maximized, deposition of vermicast is facilitated, and possibilities of anaerobic pockets being developed (which hinder the process) are eliminated. This is another absolutely novel aspect of this system.

This is based on the high-rate vermicomposting. A support structure has been provided at the end of each module(1) which controls the movement of the modules(1) and prevents the modules from clashing with each other. Each module(1) has four wheels attached to enable it to move through the inclined stacks(2).

The loading mechanism(3) carries the modules(1) and drops them in the respective stack(2). It includes a base tray(6) that carries the modules(1), a lifting rope(7), a motor assembly(8), and a rack-and-pinion assembly(9).

The unloading mechanism(4) which works on a principle similar to the loading mechanism(3) is equipped with a base tray(6), a lifting rope(7) and, a lock. A motor(8) has been provided to help in bringing down the modules(l) to be sent to the harvester.

The plant has a sprinkler system(5) which includes a motorized pump, and horizontal and vertical pipe lines with sprinklers. Each module(1) is provided with a set of four sprinklers to release the water required in each module(1).

A drainage system runs parallel to the stacks(2). The modules(1) have a small hole at the bottom wherein the excess moisture gets collected. It is then led through a trough to a drain pipe(10) which collects excess moisture from all the stacks(2) and sends it in to a collecting vessel.

The distinguishing features of the inclined parallel stack(2) continuously operable Vermireactor design are many.

Firstly the design is nnodular, with a nnultiple parallel stack system that can be easily scaled up or to suit the desired plant capacity.

With this design, it is found it maximizes the use of floor area by optimal use of vertical space.

Further the parallel stack(2) design has separate loading and unloading points for each stack(2). The modules(1) are loaded at the loading point to travel the whole stack(2) and reach the unloading point after pre-determined number of days (usually 10-15). This duration can be easily altered to suit the rate of the process by alterations in frequency of loading and unloading.

The invention discloses an efficient loading mechanism(3) which employs easy-to- fabricate steel channels, bearing wheels, gear box, rope drum and motor to lift the modules(1) to the respective stacks(2).

The shape of the modules(1) is also such that it optimizes the material cost and maximizes the surface area-to-volume ratio. It also facilitates handling.

In another preferred embodiments, the modules(l) are 1 m x 1 m in length and breadth, of a size which is adequately large yet convenient to handle. It is not too large to endanger the mechanical stability of the overall structure.

Further wheels are fixed to each module(1) for easy movement along the tracks.

An unloading mechanism(4) is provided to easily bring down the modules(1) from respective stacks(2) as per the invention.

A sprinkler system(5) is convenient to operate and control and many known method and system may be utilized.

The Novelty of the inclined parallel stack(2) continuously operable vermireactor design lies in the inclined parallel stack(2) system is unique as it makes loading/unloading automatic and easy. The overall system also enables economy of space and materials.
The reactor dimensions as disclosed in the invention enable vermicomposting at much faster rate (15-20 days) compared to 4-6 months taken for the same output in existing systems. This has been made possible due to various innovative measures taken of which use of very high surface area : substrate depth ratios. With this high surface area and with the use of moistened jute cloth there is an effort effective to maximize the reactor volume usage in the invention. To this there is also an intentional use of high earthworm densities. Furthermore due to the low depth and high surface area there is a high level of exclusion of the possibility of the formation of an anaerobic pockets thereby ensuring unhindered vermicomposting and obviating the very need for artificial ventilation or temperature control which was almost mandatory in all the prior art. With the modular design the uniform application of moisture to the substrate has been possible and also the modular structure allows vermicomposting different substrates in different modules simultaneously using substrate specific earthworm species thereby accelerating the process efficiency as a whole. Inclined parallel stack continuously operable vermicomposting system is scalable both stack wise and module wise; its ability to extend vertically enables it to process more quantity of waste in lesser floor area.

As against prior art systems which are based on large bins, the low-height discrete modular reactor system of inclined parallel stack continuously operable vermireactors protects any contamination or pest attack occurring in any module from spreading to rest of the other modules.

Inclined parallel stack continuously operable (IPSCO) vermireactor system is also unique in that it utilizes moist jute cloth of certain porosity, and thickness as the earthworm bedding instead or the elaborate gravel-sand-soil bedding used conventionally. This enormously enhances the effective reactor space and reduces bedding costs.

The modular system enables different substrates to be vermicomposted simultaneously and also different species to be utilized simultaneously without the danger of interfering with each other.

In the pre-existing institutional and industrial size flow-through vermireactors as in known prior art, ventilation systems have to be provided for proper aeration, which increases the capital costs. But the inclined parallel stack continuously operable system does not require any extra ventilation system for aeration, as the substrate depth in one of the embodiments is only 8 cm and the module(1) is open. Hence it can't get heated-up as deep and large vermicomposting bins often do.

In pre-existing designs such as Worm Wigwam, which is prior art there is probability of the earthworms getting injured or killed as a crank is used for harvesting. In case of high efficiency vermiculture process and apparatus also, a strong light source or fan blowing air is required to make the worms move away from the unloading end. These contraptions are not needed with inclined parallel stack continuously operable.

Some of the existing processes prior art depend on the movement of conveyer belt which is very costly compared to the inclined parallel stack continuously operable vermireactor system.

The inclined parallel stack continuously operable vermireactor system is by far the most versatile and flexible vis a vis the variety of substrates it can handle, species it can use, capacities it can handle, etc. it is also among the least expensive .

Further a locking means(11) may be provided in the system, most preferably at the end of the stack(2), enabling a controlled movement of the module(1) onto the unloading tray. The locking system and slope of the stack(2) is based on the desired rate of free movement of the vermicomposting modules(1) under gravity along the stack(2) from loading module end to the unloading module end. The locking system provided at the end of each stack(2) is used to control the frequency with which each module(1) in the module train is unloaded from the respective stacks(2). The unloading of the module(1) is facilitated by releasing the lock at the end of the stack (2) (unloading end). The module moves onto the unloading tray and the lock is put back in place securing other modules(1) and making room for the new module(1) to be placed at the loading end. The designed rate is adjusted to achieve a substrate retention time of 10-20 days.

The present invention provides a design of the inclined parallel stack continuously operable(IPSCO) vermireactor. The design is based on a set of modular reactors arranged in multiple stacks. It includes a loading mechanism(3), an unloading mechanism(4), several vermicomposting modules, a sprinkler system(5) and a harvesting unit(12). Discrete modules(1) containing the substrate shall be loaded onto the system using a loading mechanism(3) which shall deliver the modules(1) to the respective stacks(2). The modules(l) are generally square shaped and are made up of fiber-reinforced plastic to ensure high strength at low material density, adequate elasticity, and flexibility. The invention is however not limited by the shape or the material used. The vermicompost shall be harvested using a harvesting unit(12) and shall be sun dried, packed and stored.

The present invention lies in the design of the inclined parallel stack continuously operable (IPSCO) vermireactor. The design is based on a set of modular-reactors- arranged in multiple stacks(2).

Inventiveness of the invention lies in the inclined parallel stack system which is unique as it makes loading/unloading automatic and easy.

The design includes a loading mechanism(3), an unloading mechanism(4), several vermicomposting modules(1), a sprinkler system(5) and a harvesting unit(12). Discrete modules(1) containing the substrate shall be loaded onto the system using a loading mechanism(3) which shall deliver the modules(l) to the respective stacks. The modules(1) are square shaped and are made up of fiber-reinforced plastic to ensure high strength at low material density, adequate elasticity, and flexibility.

Inclined parallel stack continuously operable vermicomposting system is scalable both stack wise and module wise; its ability to extend vertically enables it to process more quantity of waste in lesser floor area.

The embodiments of the invention have many advantages. The invention is simpler with respect to the prior art apparatus and methods and also it can be manufactured with less cost and most importantly it is a continuous process unknown in the prior art. Many units of the sizes and dimensions may have been mentioned in the description but none of them are limiting for the purpose of the scope of the invention. More so it is to be understood that other embodiments of the invention may have different dimensions or even geometries. Various embodiments that are possible without departing from the basic scope of the invention are intended to be included within the scope of this present invention.

WE CLAIM

1. A vermicomposting system comprising of:

a. a plurality of parallel stacks arranged between a loading module at one end and an unloading module at the other end, and

b. a plurality of vermicomposting modules mounted in each stack.

2. A vermicomposting system comprising of:

a. a plurality of sloped parallel stacks arranged between a loading module at one end and an unloading module at the other end, and

b. a plurality of vermicomposting modules mounted in each stack, wherein each module having a hole at its bottom surface.

3. The stacks as claimed in claim 2 inclined downwardly sloping towards the unloading module.

4. The vermicomposting modules of claim 1 and 2 may contain different substrates in different modules.

5. The vermicomposting modules of claim 1 and 2 may be such that the module size of one module may be same or different from module size of another module

6. The stacks as claimed in claim 2 wherein the slope of the stack is based on the desired rate of free movement of the vermicomposting modules under gravity along the stack from loading module end to unloading module end.

7. The said vermicomposting modules of claims 1 and 2 further comprising a support structure means for controlling the movement of vermicomposting modules along the stack due to gravity.

8. The said vermicomposting modules of claims 1 and 2 further including wheels for mobility.

9. The said loading module of claims 1 and 2 comprising of base tray to receive the vermicomposting module, a lifting rope, a motor assembly and a rack and pinion assembly for transferring the vermicomposting module onto the stack at a specific predetermined loading point and for moving the module.

10. The unloading module of claims 1 and 2 comprising of a base plate for receiving the vermicomposting module from the stack, alongwith a lifting rope, a lock and a motor for unloading the vermicomposting module from the stack at a specific predetermined unloading point.

11. The said vermicomposting modules of claim 1 and 2 are made of fiber reinforced plastic.

12. The said stacks of claim 1 and 2 are made of mild steel.

13. The vermicomposting system of claim 1 and 2 further including a sprinkling means comprising of a motorized pump and a plurality of pipe lines to sprinkle water onto the moving vermicomposting modules on the stack.

14. The vermicomposting system of claim 1 and 2 further including a draining means comprising of a trough running parallel to the stacks and leading to a drain pipe to drain away water dripping out of the holes from the bottom of the vermicomposting modules.

15. The vermicomposting system of claim 1 and 2 further including a locking means, disposed at the end of each said stacks for facilitating a controlled unloading of vermicomposting module from the stack onto unloading tray.

16. The vermicomposting modules of claim 1 and 2 have moist jute cloth as earthworm bedding.

17. A method of continuous production of vermicompost from organic waste comprising of:

a. placing a plurality of compostable substrate materials and vermicomposting organisms into each of a plurality of vermicomposting modules,

b. loading the plurality of vermicomposting modules onto one of a plurality of parallel stacks at a predetermined loading point of a loading module,

c. vermicomposting the compostable material within plurality of modules as each module moves along the stack away from the loading point of the loading module over a predetermined duration of time to travel towards an unloading point, and

d. unloading each of the plurality of vermicomposting modules from the stack at a predetermined unloading point of an unloading module.

18. A method for continuous production of vermicompost from organic waste comprising of:

a. placing a plurality of compostable substrate materials and vermicomposting organisms into each of a plurality of vermicomposting modules,

b. loading the plurality of vermicomposting modules onto one of a plurality of sloped parallel stacks at a predetermined loading point of a loading module,

c. vermicomposting the compostable material within plurality of modules as each module moves along the stack away from the loading point of the loading module over a predetermined duration of time of travel towards an unloading point, due to sloped surface of the stack and gravity, and

d. unloading each of the plurality of vermicomposting modules from the stack at a predetermined unloading point of an unloading module.

19. The method as claimed in claim 17 further includes providing sloped parallel stacks with downwardly slope towards the unloading point at unloading module.

20. The method as claimed in claim 16 and 17 further providing different substrates in different vermicomposting modules.

21. The method as claimed in claim 16 and 17 includes providing plurality of modules such that the module size of one module may be same or different from module size of another module.

22. The method as claimed in claim 17 includes slope of slack based on the desired rate of movement of the vermicomposting modules along the stack from the loading module end to unloading module end.

23. The method as claimed in claim 17 and 18 further comprising providing a support structure means for controlling the movement of vermicomposting modules along the stack due to gravity.

24. The method as claimed in claim 17 and 18 further comprising providing wheels for vermicomposting modules for mobility.

25. The method as claimed in claim 17 and 18 further providing base tray to receive the vermicomposting module on the loading module alongwith a lifting rope, a motor assembly and a rack and pinion assembly for transferring the vermicomposting module onto the stack at a specific predetermined loading point and for moving the module.

26. The method as claimed in claim 17 and 18 further providing a base plate for receiving the vermicomposting module from the stack onto the unloading module alongwith a lifting rope, a lock and a motor for unloading the vermicomposting module from the stack at a specific predetermined unloading point.

27. The method as claimed in claim 17 and 18 further providing vermicomposting modules made of fiber reinforced plastic.

28. The method as claimed in claim 17 and 18 further providing stacks made of mild steel.

29. The method as claimed in claim 17 and 18 further providing a sprinkling means comprising of a motorized pump and a plurality of pipe lines to sprinkle water onto the moving vermicomposting modules on the stack.

30. The method as claimed in claim 17 and 18 further providing a draining means comprising of a trough running parallel to the stacks and leading to a drain pipe to drain away to water dripping out of the holes from the bottom of the vermicomposting modules.

31. The method as claimed in claim 17 and 18 providing moist jute cloth as earthworms bedding in the vermicomposting modules.

32. The method as claimed in claim 17 and 18 further providing a locking means at the end of each of the said stacks, for facilitating a controlled unloading of vermicomposting module from the stack onto the unloading tray.