초록 ▼

An apparatus for the aerobic in-vessel rotary drum composting of feedstock into nutrient-rich compost comprising means for shredding said input material, said means configured and powered for shredding said feedstock into a particle size no larger than one cubic inch, a vessel having an input port o

An apparatus for the aerobic in-vessel rotary drum composting of feedstock into nutrient-rich compost comprising means for shredding said input material, said means configured and powered for shredding said feedstock into a particle size no larger than one cubic inch, a vessel having an input port on top of such vessel and a discharge port, said vessel comprising one chamber, said vessel configured and powered for composting said shredded feedstock, and said vessel tilted from the input port to the discharge port, means for passing said feedstock from said means for shredding into said vessel, means for rotating said vessel, means for introducing air into said vessel and a process controller, said process controller communicating with said means for shredding, said vessel, said means for rotating said vessel and said means for introducing air into said vessel.

대표청구항 ▼

1. An apparatus for the in-vessel composting of feedstock into nutrient-rich compost comprising: a shredder that operates to reduce the volume and increase the surface area of the feedstock into one or more particles having a particle size that is about one cubic inch or no larger than one cubic inc

1. An apparatus for the in-vessel composting of feedstock into nutrient-rich compost comprising: a shredder that operates to reduce the volume and increase the surface area of the feedstock into one or more particles having a particle size that is about one cubic inch or no larger than one cubic inch;a vessel operating to compost and digest the shredded feedstock having: (i) one chamber only, (ii) a first surface, a second surface and a third surface, the first and second surfaces of the vessel being spaced apart and substantially parallel to each other and the third surface of the vessel extending from the first surface to the second surface, thereby defining the one chamber only of the vessel therein, (iii) an input port disposed on, and in communication with, the third surface near, or adjacent to, the first surface of the vessel, and (iv) a discharge port disposed on, and in communication with, the second surface of the vessel, wherein the vessel is tilted such that at least a portion of the first surface is always at a higher elevation than at least a portion of the second surface;a conveyor operating to pass the shredded feedstock from the shredder into the input port of the vessel;a rotator system operating to rotate the vessel;an aeration system operating to at least one of (i) introduce air into the vessel and (ii) exhaust vaporized water from the vessel; anda process controller operating to communicate with, and control, the shredder, the vessel, the rotator system, the aeration system and the conveyor. 2. The apparatus of claim 1, wherein at least one of: (i) the conveyor comprises: an input hopper operating to facilitate feeding or introduction of the feedstock into the shredder, the input hopper being connected to the shredder, andan auger and a chute or conveyance tube, or a bucket elevator, connecting the shredder to the input port of the vessel;(ii) the input hopper includes a lid with a magnetic switch that operates to prohibit actuation of one or more cutting blades of the shredder if the lid is open, thereby adding a safety feature to the apparatus;(iii) the input port of the vessel includes a loading door with a magnetic switch that operates to prohibit actuation of the auger when the loading door is closed and operates to permit actuation of the auger when the loading door is opened, thereby avoiding loss of the feedstock;(iv) the chute or conveyance tube of the conveyor is in communication with the input port of the vessel such that the chute or conveyance tube operates to pass the feedstock from the auger to the vessel;(v) the auger operates until the conveyance tube is empty;(vi) the tilt of the vessel is on a 1-2 degree down angle from at least the portion of the first surface, or the input port on the third surface when the input port is at its substantially highest or highest elevation, to at least the portion of the second surface or the discharge port of the vessel;(vii) the vessel includes a layer of insulated material;(viii) the vessel is cylindrical; and(ix) the layer of insulated material of the vessel is disposed between two metal layers of the vessel, the metal layers and the layer of insulated material at least being included in the third surface of the vessel. 3. The apparatus of claim 1, wherein at least one of: (i) the vessel includes one or more baffles that operate to tumble the shredded feedstock located inside the vessel, thereby facilitating mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates;(ii) the one or more baffles comprises at least two baffles disposed inside the vessel, connected to the third surface and extending from the third surface radially inwards towards the center of the vessel for a predetermined distance;(iii) the one or more baffles comprises only two or three baffles disposed inside the vessel, connected to the third surface and extending from the third surface radially towards the center of the vessel for a predetermined distance;(iv) the one or more baffles extend along the entire length of the vessel;(v) at least a surface of the aeration system operates as an additional baffle such that the at least one surface of the aeration system facilitates the mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates;(vi) at least two surfaces of the aeration system operate as one or more additional baffles such that the at least two surfaces of the aeration system facilitate the mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates; and(vii) a first baffle of the at least two baffles is positioned at 90 degrees of the circumference of the vessel and a second baffle of the at least two baffles is positioned at 270 degrees of the circumference of the vessel. 4. The apparatus of claim 1, wherein the aeration system comprises at least one of: an air pipe that operates to pass air from outside of the vessel and introduce the air into an aeration port of the vessel;an aeration pipe connected to the aeration port of the vessel and extending through the vessel, the aeration pipe operating to release air along at least a portion of the length of the vessel or along the entire length of the vessel;an aeration plenum surface defining an aeration plenum located between the third surface of the vessel and the aeration plenum surface and having one or more perforations therein such that the air passing from outside the vessel through the air pipe into the aeration port and through the aeration pipe is released into the aeration plenum and then diffused into the remaining portion of the vessel via the one or more perforations of the aeration plenum surface;an aerator that operates to force air through the aeration pipe, through the one or more perforations of the aeration plenum surface and through the vessel;an aeration plenum surface defining an aeration plenum located between the third surface of the vessel and the aeration plenum surface and having a plurality of perforations therein such that the air passing from outside the vessel through the air pipe into the aeration port and through the aeration pipe is released into the aeration plenum and then diffused into the remaining portion of the vessel via the plurality of perforations of the aeration plenum surface;an aerator that operates to force air through the aeration pipe, through the plurality of perforations of the aeration plenum surface and through the vessel; andan exhaust vent operating to exhaust at least one of the air that passes through the vessel and vaporized water, the exhaust vent being disposed on at least one of the second surface of the vessel and the third surface of the vessel. 5. The apparatus of claim 4, wherein pressure from the aeration pipe operates to force the air into and through at least one of the one or more perforations and the plurality of perforations of the aeration plenum surface. 6. The apparatus of claim 1, wherein at least one of: (i) the apparatus and/or the vessel further operates to maintain the temperature of the vessel in the range of at least one of: 100° F. to 135° F.; 100° F. to 150° F.; 131° F. to 135° F.; 95° F. to 150° F.; 95° F. to 135° F.; and 131° F. to 150° F.; and(ii) the feedstock is placed into the vessel when the feedstock has a temperature within the range of at least one of: 100° F. to 135° F.; 100° F. to 150° F.; 131° F. to 135° F.; 95° F. to 150° F.; 95° F. to 135° F.; and 131° F. to 150° F. 7. The apparatus of claim 1, wherein the rotator system comprises: (i) a base frame extending from and coupled to the vessel; and (ii) at least one of: (a) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base;(b) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base, wherein the drift shaft extends substantially along a predetermined length of the vessel and is connected to, and operates to turn, at least one or more drive wheels; and(c) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base, wherein the drift shaft extends substantially along a predetermined length of the vessel and is connected to, and operates to turn, at least two drive wheels. 8. The apparatus of claim 1, further comprising at least one of: (i) a discharge door attached to the discharge port of the vessel, the discharge door operating to be closed when the vessel is composting and/or rotating and operates to be opened when the digested or composted feedstock is being removed from the vessel;(ii) a screener that operates to screen the digested feedstock as the digested feedstock is discharged from the discharge port of the vessel; and(iii) only one screener that operates to screen the digested feedstock as the digested feedstock is discharged from the discharge port of the vessel. 9. The apparatus of claim 8, wherein the screener includes a mesh that operates to at least one of: (i) screen the digested feedstock leaving the vessel and entering a discharge collection vessel or container; and (ii) remove one or more particles of the digested feedstock that are larger than ½ cubic inch. 10. An apparatus for the in-vessel composting of feedstock into nutrient-rich compost comprising: a shredder that operates to reduce the volume and increase the surface area of the feedstock;a cylindrical vessel in communication with the shredder, the vessel operating to compost and digest the shredded feedstock received from the shredder and the vessel having: (i) one chamber only, (ii) a first surface, a second surface and a third surface, the first and second surfaces of the vessel being spaced apart and substantially parallel to each other and the third surface of the vessel extending from the first surface to the second surface, thereby defining the one chamber only of the vessel therein and the cylindrical shape of the vessel, (iii) an input port disposed on, and in communication with, the third surface near, or adjacent to, the first surface of the vessel, and (iv) a discharge port disposed on, and in communication with, the second surface of the vessel, wherein the vessel is tilted such that at least a portion of the first surface is always at a higher elevation than at least a portion of the second surface; anda rotator system operating to rotate the vessel. 11. The apparatus of claim 10, further comprising: a conveyor operating to pass the shredded feedstock from the shredder into the input port of the vessel;an aeration system operating to at least one of (i) introduce air into the vessel and (ii) exhaust vaporized water from the vessel; anda process controller operating to communicate with, and control, the shredder, the vessel, the rotator system, the aeration system and the conveyor. 12. The apparatus of claim 11, wherein at least one of: (i) the shredder is directly connected to the vessel or the apparatus further includes a conveyor operating to pass the shredded feedstock from the shredder into the input port of the vessel;(ii) the conveyor comprises an auger and a chute or conveyance tube, or a bucket elevator, connecting the shredder to the input port of the vessel, and an input hopper operating to facilitate feeding or introduction of the feedstock into the shredder, the input hopper being connected to the shredder;(iii) the input hopper includes a lid with a magnetic switch that operates to prohibit actuation of one or more cutting blades of the shredder if the lid is open, thereby adding a safety feature to the apparatus;(iv) the input port of the vessel includes a loading door with a magnetic switch that operates to prohibit actuation of the auger when the loading door is closed and operates to permit actuation of the auger when the loading door is opened, thereby avoiding loss of the feedstock;(v) the chute or conveyance tube of the conveyor is in communication with the input port of the vessel such that the chute or conveyance tube operates to pass the feedstock from the auger to the vessel;(vi) the auger operates until the conveyance tube is empty;(vii) the tilt of the vessel is on a 1-2 degree down angle from at least the portion of the first surface, or the input port on the third surface when the input port is at its substantially highest or highest elevation, to at least the portion of the second surface or the discharge port of the vessel;(viii) the vessel includes a layer of insulated material; and(ix) the layer of insulated material of the vessel is disposed between two metal layers of the vessel, the metal layers and the layer of insulated material at least being included in the third surface of the vessel. 13. The apparatus of claim 11, wherein at least one of: (i) the vessel includes one or more baffles that operate to tumble the shredded feedstock located inside the vessel, thereby facilitating mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates;(ii) the one or more baffles comprises at least two baffles disposed inside the vessel, connected to the third surface and extending from the third surface radially inwards towards the center of the vessel for a predetermined distance;(iii) a first baffle of the at least two baffles is positioned at 90 degrees of the circumference of the vessel and a second baffle of the at least two baffles is positioned at 270 degrees of the circumference of the vessel;(iv) the one or more baffles comprises only two or three baffles disposed inside the vessel, connected to the third surface and extending from the third surface radially towards the center of the vessel for a predetermined distance;(v) the one or more baffles extend along the entire length of the vessel;(vi) at least a surface of the aeration system operates as an additional baffle such that the at least one surface of the aeration system facilitates the mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates; and(vii) at least two surfaces of the aeration system operate as one or more additional baffles such that the at least two surfaces of the aeration system facilitate the mixing of, and/or the physical breakdown of, the shredded feedstock as the vessel rotates. 14. The apparatus of claim 11, wherein the aeration system comprises at least one of: an air pipe that operates to pass air from outside of the vessel and introduce the air into an aeration port of the vessel;an aeration pipe connected to the aeration port of the vessel and extending through the vessel, the aeration pipe operating to release air along at least a portion of the length of the vessel or along the entire length of the vessel;an aeration plenum surface defining an aeration plenum located between the third surface of the vessel and the aeration plenum surface and having one or more perforations therein such that the air passing from outside the vessel through the air pipe into the aeration port and through the aeration pipe is released into the aeration plenum and then diffused into the remaining portion of the vessel via the one or more perforations of the aeration plenum surface;an aerator that operates to force air through the aeration pipe, through the one or more perforations of the aeration plenum surface and through the vessel;an aeration plenum surface defining an aeration plenum located between the third surface of the vessel and the aeration plenum surface and having a plurality of perforations therein such that the air passing from outside the vessel through the air pipe into the aeration port and through the aeration pipe is released into the aeration plenum and then diffused into the remaining portion of the vessel via the plurality of perforations of the aeration plenum surface;an aerator that operates to force air through the aeration pipe, through the plurality of perforations of the aeration plenum surface and through the vessel; andan exhaust vent operating to exhaust at least one of the air that passes through the vessel and vaporized water, the exhaust vent being disposed on at least one of the second surface of the vessel and the third surface of the vessel. 15. The apparatus of claim 14, wherein pressure from the aeration pipe operates to force the air into and through at least one of the one or more perforations and the plurality of perforations of the aeration plenum surface. 16. The apparatus of claim 10, wherein at least one of: (i) the apparatus and/or the vessel further operates to maintain the temperature of the vessel in the range of at least one of: 100° F. to 135° F.; 100° F. to 150° F.; 131° F. to 135° F.; 95° F. to 150° F.; 95° F. to 135° F.; and 131° F. to 150° F.; and(ii) the feedstock is placed into the vessel when the feedstock has a temperature within the range of at least one of: 100° F. to 135° F.; 100° F. to 150° F.; 131° F. to 135° F.; 95° F. to 150° F.; 95° F. to 135° F.; and 131° F. to 150° F. 17. The apparatus of claim 10, wherein the rotator system comprises: (i) a base frame extending from and coupled to the vessel; and (ii) at least one of: (a) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base;(b) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base, wherein the drift shaft extends substantially along a predetermined length of the vessel and is connected to, and operates to turn, at least one or more drive wheels; and(c) a motorized direct-drive system having a motor, a drive shaft, at least one drive wheel, at least one guide wheel and a gearbox attached to the base, wherein the drift shaft extends substantially along a predetermined length of the vessel and is connected to, and operates to turn, at least two drive wheels. 18. The apparatus of claim 10, further comprising at least one of: (i) a discharge door attached to the discharge port of the vessel, the discharge door operating to be closed when the vessel is composting and/or rotating and operates to be opened when the digested or composted feedstock is being removed from the vessel;(ii) a screener that operates to screen the digested feedstock as the digested feedstock is discharged from the discharge port of the vessel; and(iii) only one screener that operates to screen the digested feedstock as the digested feedstock is discharged from the discharge port of the vessel. 19. The apparatus of claim 18, wherein the screener includes a mesh that operates to at least one of: (i) screen the digested feedstock leaving the vessel and entering a discharge collection vessel or container; and (ii) remove one or more particles of the digested feedstock that are larger than ½ cubic inch.