Systems and methods for environmentally undisruptive disposal of food waste

Abstract

A processing facility can dispose of food waste in environmentally undisruptive manners. The processing facility can convert the food waste into bio-energy and bio-fuel products, such as bio-diesel, ethanol, and electricity. The processing facility can sort the food waste based on the fats or carbohydrates content of the food waste, and the processing facility can include a fluidized bed combustion module for combusting portions of the food waste.

1 . A system for converting food waste into bio-energy, the system comprising:
 a receiving module in which a food waste stream is received and sorted based on relative fats and carbohydrates levels of food waste within the food waste stream, wherein the receiving module sorts the food waste stream into at least a first feedstock that comprises food waste having a fats content above a fats threshold value and a second feedstock that comprises food waste having a carbohydrates content above a carbohydrates threshold value;   a rendering module configured to receive the first feedstock from the receiving module and to separate fats from the first feedstock;   a fats processing module configured to receive fats from the rendering module and produce one or more of bio-diesel and glycerin from the fats;   a fluidized bed combustion module configured to receive from the rendering module at least a portion of the first feedstock that has been defatted, and further configured to receive at least a portion of the second feedstock, wherein the fluidized bed combustion module is configured to combust the feedstock materials received therein.   
     
     
         2 . The system of  claim 1 , further comprising a steam processing module coupled with the fluidized bed combustion module, wherein the steam processing module is configured to produce high-pressure steam using heat produced by the fluidized bed combustion module and to convert the high-pressure steam into electricity and low-pressure steam, wherein at least a portion of the electricity produced by the steam processing module provides power to the receiving module, the rendering module, and the fats processing module. 
     
     
         3 . The system of  claim 2 , wherein at least a portion of the low-pressure steam is delivered as process steam to one or more of the receiving, rendering, and fats processing modules. 
     
     
         4 . The system of  claim 2 , wherein at least a portion of the electricity produced by the steam processing module is provided to an external power grid. 
     
     
         5 . The system of  claim 2 , further comprising a carbohydrates processing module configured to receive the second feedstock from the receiving module and to produce ethanol and distiller coproducts from the second feedstock, wherein at least a portion of the distiller coproducts are delivered to the fluidized bed combustion module. 
     
     
         6 . The system of  claim 5 , wherein the receiving module further sorts the food waste stream into a third feedstock that comprises food waste having both a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value, wherein the third feedstock is delivered to the rendering module for fats extraction, and wherein fats removed from the third feedstock is delivered to the fats processing module and at least a portion of the defatted third feedstock is delivered to the carbohydrates processing module. 
     
     
         7 . The system of  claim 6 , further comprising an anaerobic digestion module that receives process wastewater from one or more of the receiving, fats processing, and carbohydrates processing modules, wherein the anaerobic digestion module produces bio-gas that is delivered to the fluidized bed combustion module. 
     
     
         8 . The system of  claim 7 , wherein bio-gas produced by the anaerobic digestion module is selectively delivered to the fluidized bed combustion module to supplement feedstock material delivered to the fluidized bed combustion module from the fats processing and carbohydrates processing modules so as to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         9 . The system of  claim 8 , wherein water is recycled within the system such that a majority of make-up water used by the carbohydrates processing module is delivered to the carbohydrates processing module from the anaerobic digestion module, and wherein the anaerobic digestion module produces said majority of make-up water from process wastewater received from one or more other modules within the system. 
     
     
         10 . The system of  claim 9 , wherein the carbohydrates processing module comprises a chiller that uses a refrigerant. 
     
     
         11 . The system of  claim 10 , wherein at least a portion of the low pressure steam is delivered from the steam processing module to the chiller to operate the chiller. 
     
     
         12 . The system of  claim 5 , further comprising an anaerobic digestion module that receives process wastewater from one or more of the receiving, fats processing, and carbohydrates processing modules and that produces bio-gas from the process wastewater, wherein at least a portion of the bio-gas produced by the anaerobic digestion module is selectively delivered to the fluidized bed combustion module to supplement feedstock material delivered to the fluidized bed combustion module from the fats processing and carbohydrates processing modules so as to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         13 . The system of  claim 5 , wherein water is recycled within the system such that a majority of make-up water used by the carbohydrates processing module is delivered to the carbohydrates processing module from an anaerobic digestion module, and wherein the anaerobic digestion module produces said majority of make-up water from process wastewater received from one or more other modules within the system. 
     
     
         14 . The system of  claim 13 , wherein the carbohydrates processing module comprises a chiller that uses a refrigerant, wherein at least a portion of the low pressure steam is delivered from the steam processing module to the chiller to operate the chiller, and wherein water that has been processed by the anaerobic digestion module is delivered to the carbohydrates processing module as process water. 
     
     
         15 . The system of  claim 5 , wherein at least a portion of the electricity produced by the steam processing module provides power to the carbohydrates processing module and at least a portion of the low-pressure steam produced by the steam processing module is delivered to the carbohydrates processing module as process steam. 
     
     
         16 . The system of  claim 15 , wherein when the fluidized bed combustion module is operational to combust materials received therein, a rate of delivery of feedstock materials into the fluidized bed combustion module is controlled such that the fluidized bed combustion module remains operational to combust materials received therein and such that electricity produced by the steam processing module is sufficient to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         17 . The system of  claim 1 , further comprising a carbohydrates processing module configured to receive the second feedstock from the receiving module and to produce ethanol and distiller coproducts from the second feedstock, wherein at least a portion of each of the distiller coproducts is delivered to the fluidized bed combustion module. 
     
     
         18 . The system of  claim 17 , wherein the receiving module further separates the food waste stream into a third feedstock that comprises food waste having a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value, wherein the third feedstock is delivered to the rendering module for fats extraction, and wherein fats removed from the third feedstock is delivered to the fats processing module and at least a portion of the defatted third feedstock is delivered to the carbohydrates processing module. 
     
     
         19 . The system of  claim 17 , further comprising an anaerobic digestion module that receives process wastewater from one or more of the receiving, fats processing, and carbohydrates processing modules and that produces bio-gas from the process wastewater, wherein at least a portion of the bio-gas is selectively delivered to the fluidized bed combustion module to supplement feedstock material delivered to the fluidized bed combustion module from the fats processing and carbohydrates processing modules so as to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         20 . The system of  claim 17 , wherein when the fluidized bed combustion module is operational to combust materials received therein, a rate of delivery of feedstock materials into the fluidized bed combustion module is controlled such that the fluidized bed combustion module remains operational to combust materials received therein and such that electricity produced using heat generated by the fluidized bed combustion module is sufficient to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         21 . The system of  claim 17 , wherein water is recycled within the system such that a majority of make-up water used by the carbohydrates processing module is delivered to the carbohydrates processing module from an anaerobic digestion module, and wherein the anaerobic digestion module produces said majority of make-up water from process wastewater received from one or more other modules within the system. 
     
     
         22 . The system of  claim 1 , wherein when the fluidized bed combustion module is operational to combust materials received therein, a rate of delivery of feedstock materials into the fluidized bed combustion module is controlled such that the fluidized bed combustion module remains operational to combust materials received therein and such that electricity produced using heat generated by the fluidized bed combustion module is sufficient to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         23 . The system of  claim 1 , wherein the receiving module separates the food waste stream into a third feedstock that comprises food waste having a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value, wherein the third feedstock is delivered to the rendering module for fats extraction, and wherein fats removed from the third feedstock is delivered to the fats processing module and at least a portion of the defatted third feedstock is delivered to a carbohydrates processing module. 
     
     
         24 . The system of  claim 1 , wherein the food waste stream comprises food contained in packaging material and wherein the receiving module comprises a depackaging sub-module configured to separate food waste from the packaging material. 
     
     
         25 . The system of  claim 1 , wherein the food waste stream comprises liquid food waste having one or more of a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value, and wherein the receiving station is configured to direct the liquid food waste to one or more of the rendering module, the fats processing module, and a carbohydrates processing module. 
     
     
         26 . The system of  claim 1 , wherein the receiving module removes items from the food waste stream that would cause the fluidized bed burner to exhaust noxious gases. 
     
     
         27 . The system of  claim 1 , wherein the fats threshold value comprises a fats content by weight of about 5% and the carbohydrates threshold value comprises a carbohydrates content by weight of about 10%. 
     
     
         28 . A system for converting food waste into bio-energy, the system comprising:
 a receiving module that directs a food waste stream based on relative levels of fats and carbohydrates of food waste within the food waste stream, wherein the receiving module directs at least a portion of the food waste stream into a first feedstock that comprises food waste having a fats content that exceeds a fats threshold value and a second feedstock that comprises food waste having a carbohydrates content that exceeds a carbohydrates threshold value;   a fats processing module configured to receive and alter the first feedstock;   a carbohydrates processing module configured to receive and alter the second feedstock; and   a fluidized bed combustion module configured to combust feedstock delivered thereto,   wherein at least a portion of the first feedstock is delivered to the fats processing module and is converted to one or more of bio-diesel and glycerin and at least a portion of the first feedstock is delivered to the fluidized bed combustion module and is combusted, and   wherein at least a portion of the second feedstock is delivered to the carbohydrates processing module and is converted to ethanol and at least a portion of the second feedstock is delivered to the fluidized bed combustion module and is combusted.   
     
     
         29 . The system of  claim 28 , wherein the receiving module further directs the food waste stream into a third feedstock that comprises food waste having both a fats content that exceeds the fats threshold value and a carbohydrates content that exceeds the carbohydrates threshold value, wherein at least a portion of the third feedstock is delivered to the fats processing module and at least a portion of the third feedstock is delivered to the carbohydrates processing module. 
     
     
         30 . The system of  claim 29 , wherein the third feedstock is delivered to a rendering module, wherein fats separated from the feedstock by the rendering module is delivered to the fats processing module, and wherein at least a portion of the defatted third feedstock is delivered to the carbohydrates processing module. 
     
     
         31 . The system of  claim 29 , wherein the receiving module further directs the food waste stream into a fourth feedstock that comprises food waste having both a fats content below the fats threshold value and a carbohydrates content below the carbohydrates threshold value, and wherein the fourth feedstock is delivered directly to the fluidized bed combustion module. 
     
     
         32 . The system of  claim 28 , wherein when the fluidized bed combustion module is operational to combust materials received therein, a rate of delivery of feedstock materials into the fluidized bed combustion module is controlled such that the fluidized bed combustion module remains operational to combust materials received therein and such that electricity produced using heat generated by the fluidized bed combustion module is sufficient to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         33 . The system of  claim 28 , further comprising a steam processing module coupled with the fluidized bed combustion module, wherein the steam processing module produces high-pressure steam using heat produced by the fluidized bed combustion module and converts the high-pressure steam into electricity and low-pressure steam, and wherein the steam processing module provides at least a portion of the electricity and the low-pressure steam to the receiving module, the fats processing module, and the carbohydrates processing module. 
     
     
         34 . The system of  claim 28 , further comprising a anaerobic digestion module that receives process wastewater from one or more of the receiving, fats processing, and carbohydrates processing modules and that produces bio-gas from the process wastewater. 
     
     
         35 . The system of  claim 34 , wherein bio-gas produced by the anaerobic digestion module is selectively delivered to the fluidized bed combustion module to supplement feedstock material delivered to the fluidized bed combustion module from the fats processing and carbohydrates processing modules so as to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system. 
     
     
         36 . The system of  claim 28 , wherein electricity is generated from heat produced by the fluidized bed burner, and wherein at least a portion of the electricity provides power to the receiving, bio-diesel, and carbohydrates processing modules. 
     
     
         37 . A system for converting food waste into bio-energy, the system comprising:
 a food waste stream comprising a first feedstock that comprises food waste having a fats content above a fats threshold value and a second feedstock that comprises food waste having a carbohydrates content above a carbohydrates threshold value;   a fats processing module configured to produce bio-diesel from a portion of the first feedstock;   a carbohydrates processing module configured to produce ethanol from a portion of the second feedstock; and   a fluidized bed combustion module configured to combust feedstock delivered thereto,   wherein when the fluidized bed combustion module is operational to combust materials received therein, a rate of delivery of portions of the first and second feedstocks into the fluidized bed combustion module is controlled such that the fluidized bed combustion module remains operational to combust materials received therein and such that electricity produced using heat generated by the fluidized bed combustion module is sufficient to maintain operation of the system substantially without input of energy sources other than the food waste stream into the system.   
     
     
         38 . A method of converting food waste into bio-energy, the method comprising:
 providing a system that comprises a fats processing module, a carbohydrates processing module, a fluidized bed combustion module, and a steam processing module;   separating fats from a first feedstock that comprises food waste having a fats content that exceeds a fats threshold value;   producing bio-diesel from the fats via the fats processing module;   producing ethanol from a second feedstock that comprises food waste having a carbohydrates content that exceeds a carbohydrates threshold value via the carbohydrates processing module;   combusting an input feedstock via the fluidized bed combustion module, wherein the input feedstock comprises at least a portion of the first feedstock that is not converted to bio-diesel and at least a portion of the second feedstock that is not converted to ethanol;   generating electricity and low-pressure steam via the steam processing module; and   regulating the content and feed rate of the input feedstock into the fluidized bed combustion module so as to maintain substantially continuous operation of the fluidized bed combustion module and so as to generate sufficient electricity and process steam to operate the system substantially without using energy sources other than the input feedstock.   
     
     
         39 . The method of  claim 38 , further comprising separating the first feedstock and the second feedstock from a food waste stream. 
     
     
         40 . The method of  claim 38 , wherein the system further comprises an anaerobic digestion module, wherein the method further comprises producing bio-gas via the anaerobic digestion module from process wastewater that results from said production of bio-diesel and ethanol, and wherein the input feedstock that is combusted via the fluidized bed combustion module further comprises at least a portion of the bio-gas. 
     
     
         41 . A method of converting food waste into bio-energy, the method comprising:
 providing a system that comprises a rendering module, a fats processing module, a carbohydrates processing module, and a fluidized bed combustion module;   channeling a food waste stream into a first feedstock that comprises food waste having a fats content above a fats threshold value, a second feedstock that comprises food waste having a carbohydrates content above a carbohydrates threshold value, and a third feedstock that comprises food waste having both a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value;   separating fats from the first feedstock and from the third feedstock via the rendering module;   producing bio-diesel via the fats processing module from the fats separated from the first feedstock and from the fats separated from the third feedstock via the rendering module;   producing ethanol via the carbohydrates processing module from the second feedstock and from a defatted portion of the third feedstock;   combusting an input feedstock via the fluidized bed combustion module to generate electricity, wherein the input feedstock comprises at least a portion of the first and third feedstocks that is not converted to bio-diesel and at least a portion of the second and third feedstocks that is not converted to ethanol; and   regulating the content and feed rate of the input feedstock into the fluidized bed combustion module so as to maintain substantially continuous operation of the fluidized bed combustion module and so as to generate sufficient electricity to power the system substantially without using outside sources of electricity.   
     
     
         42 . The method of  claim 41 , wherein the system further comprises an anaerobic digestion module, wherein the method further comprises producing bio-gas via the anaerobic digestion module from process wastewater that results from said production of bio-diesel and ethanol, and wherein the input feedstock further comprises at least a portion of the bio-gas. 
     
     
         43 . A method of converting food waste into bio-energy, the method comprising:
 providing a system that comprises a fats processing module, a carbohydrates processing module, and a fluidized bed combustion module;   channeling a food waste stream into a first feedstock that comprises food waste having a fats content above a fats threshold value and a second feedstock that comprises food waste having a carbohydrates content above a carbohydrates threshold value;   producing bio-diesel from the first feedstock via the fats processing module;   selectively delivering the second feedstock either to the carbohydrates processing module for production of ethanol and distiller coproduct or to the fluidized bed combustion module based at least partially on the carbohydrates content of the second feedstock; and   combusting an input feedstock via the fluidized bed combustion module to generate electricity, wherein the input feedstock comprises at least a portion of the first feedstock that is not used in producing bio-diesel and either the second feedstock or at least a portion of the distiller coproduct produced from the second feedstock.   
     
     
         44 . The method of  claim 43 , wherein the system further comprises a rendering module, the method further comprising:
 channeling the food waste stream into a third feedstock that comprises both a fats content above the fats threshold value and a carbohydrates content above the carbohydrates threshold value; and   selectively delivering the third feedstock to one or more of the rendering module, the carbohydrates processing module, and the fluidized bed combustion module based at least partially on the relative levels of fats and carbohydrates in the third feedstock.   
     
     
         45 . A method for converting food waste into bio-energy, the method comprising:
 providing a system that comprises a fats processing module and a fluidized bed combustion module;   segregating a first feedstock from a food waste stream, wherein the first feedstock comprises food waste having a fats content that exceeds a fats threshold value;   separating fats from the first feedstock;   producing bio-diesel from the fats via the fats processing module;   combusting an input feedstock via the fluidized bed combustion module to generate electricity, wherein the input feedstock comprises at least a portion of the first feedstock that is not converted to bio-diesel; and   altering the fats threshold value to thereby alter the relative amounts of bio-diesel and electricity produced by the system.   
     
     
         46 . The method of  claim 45 , wherein altering the fats threshold value is based on a relative demand for bio-diesel versus electricity. 
     
     
         47 . The method of  claim 45 , further comprising segregating a second feedstock from the food waste stream, wherein the second feedstock comprises food waste having a carbohydrates content that exceeds a carbohydrates threshold value, and wherein the method further comprises converting at least a portion of the second feedstock into ethanol. 
     
     
         48 . The method of  claim 47 , further comprising altering the carbohydrates threshold value to thereby alter the relative amounts of ethanol and electricity produced by the system. 
     
     
         49 . The method of  claim 45 , further comprising:
 separating recyclable packaging material from the food waste stream; and   collecting revenue for at least a portion of the recyclable packaging material.   
     
     
         50 . A method for converting food waste into bio-energy, the method comprising:
 providing a system that comprises a carbohydrates processing module and a fluidized bed combustion module;   segregating a first feedstock from a food waste stream, wherein the first feedstock comprises food waste having a carbohydrates content that exceeds a carbohydrates threshold value;   producing ethanol from the first feedstock via the carbohydrates processing module;   combusting an input feedstock via the fluidized bed combustion module to generate electricity, wherein the input feedstock comprises at least a portion of the first feedstock that is not converted to ethanol; and   altering the carbohydrates threshold value to thereby alter the relative amounts of ethanol and electricity produced by the system.   
     
     
         51 . The method of  claim 50 , wherein altering the carbohydrates threshold value is based on a relative demand for ethanol versus electricity. 
     
     
         52 . A method for environmentally undisruptive disposal of food waste, the method comprising:
 providing a food waste stream;   converting a portion of the food waste stream into bio-diesel via a fats processing module;   converting a portion of the food waste stream into ethanol via a carbohydrates processing module;   combusting a portion of the food waste stream via a fluidized bed combustion module to generate electricity;   delivering process wastewater from each of the fats processing module and the carbohydrates module to an anaerobic digestion module to produce clean graywater; and   delivering at least a portion of the clean graywater to the carbohydrates processing module as process water.   
     
     
         53 . The method of  claim 52 , wherein substantially all process wastewater output from the carbohydrates processing module is delivered to the anaerobic digestion module for processing of the process wastewater. 
     
     
         54 . The method of  claim 52 , further comprising:
 delivering condensate from the carbohydrates processing module to a water treatment module and delivering a portion of the clean graywater from the anaerobic digestion module to the water treatment module; and   cleaning the condensate and clean graywater via the water treatment module.   
     
     
         55 . The method of  claim 54 , further comprising providing a steam processing module configured to convert clean water into steam, wherein substantially all clean water used by the steam processing module is provided by the water treatment module. 
     
     
         56 . The method of  claim 52 , wherein a source of the food waste stream is physically situated at a first location, and wherein the fats processing module, the carbohydrates processing module, and the fluidized bed combustion module are physically situated at a second location that is closer to a landfill than is the first location. 
     
     
         57 . A method for environmentally undisruptive disposal of food waste, the method comprising:
 providing a system that comprises a carbohydrates processing module, an anaerobic digestion module, and a fluidized bed combustion module;   receiving food waste into the system from a source outside of the system;   converting at least a portion of the food waste into ethanol via the carbohydrates processing module;   combusting at least a portion of the food waste via the fluidized bed combustion module to thereby produce electricity for powering the system;   cleaning water via the anaerobic digestion module from process wastewater delivered to the anaerobic digestion module from one or more modules within the system; and   providing water that has been cleaned by the anaerobic digestion module to the carbohydrates processing module such that the cleaned water constitutes a majority of make-up water used in operation of the carbohydrates processing module.