Biomass converters and processes

Abstract

This invention pertains to a bio-mass processing system, and method of processing waste bio-mass, wherein one or more mixers mixes a bed of bio-mass material such as manure at substantially any and all locations in a defined length and width portion of the bed, in a dryer. Heated air percolates upwardly through the bed. Separation apparatus separates a relatively dryer fraction of the bio-mass material from the dryer. The separated finished product from the dryer is optionally fed to a boiler where the dried bio-mass material is burned. Heat of combustion from the boiler is used as dryer heat for drying the bio-mass feed material in the dryer. Excess heat is optionally used to produce steam, which powers a turbine, which powers an electrical generator. Residual ash from the combustion process comprises about 2% by weight of the solids content of e.g. a feed stream coming into the dryer.

1 - 23 . (canceled) 
     
     
         24 . A bio-mass processing system, comprising:
 (a) a dryer receiving wet bio-mass material to be dried, said dryer having an inlet and an outlet;   (b) an air supply system providing a supply of heated air to such bed of bio-mass material in said dryer, and percolating such heated air through the bed of bio-mass material such that the air emerges from the bed of bio-mass material;   (c) one or more mixers adapted to mix the bed of bio-mass material while the heated air is percolating upwardly through the bed of bio-mass material;   (d) a longitudinal transport mechanism which transports the bio-mass material from the dryer inlet to the dryer outlet whereby a relatively drier, first portion of the bio-mass material is generally displaced from a relatively wetter second portion of the bio-mass material in the bed of bio-mass material;   (e) separation apparatus separating at least a portion of the relatively drier first portion of bio-mass material as produced from said dryer;   (f) a combustor receiving the relatively drier first portion of the bio-mass material from said dryer, and burning such first portion of the bio-mass material to produce heat energy; and   (g) an electrical energy converter, converting heat energy from said combustor into electrical energy.   
     
     
         25 . A bio-mass processing system as in  claim 24 , said dryer comprising a containment receptacle containing the bed of bio-mass material said containment receptacle having upstanding walls, said air supply system supplying heated air between said upstanding walls and said one or more mixers mixing the bed of bio-mass material between said upstanding walls. 
     
     
         26 . A bio-mass processing system as in  claim 24 , said combustor being configured to burn such first portion of such bio-mass material processed in said processing system, such first portion of such bio-mass material contains up to 40 percent by weight water. 
     
     
         27 - 28 . (canceled) 
     
     
         29 . A bio-mass processing system as in  claim 24  wherein at least one said mixer is inclined at an angle of about 10 degrees to about 50 degrees from vertical, such that mixing activity of the respective said mixer moves such bio-mass material toward the exit end of the bed of bio-mass material such that said longitudinal transport mechanism comprises said at least one mixer. 
     
     
         30 . A bio-mass processing system as in  claim 24 , the bed of bio-mass material having a length and a width, further comprising transport structure which moves said one or more mixers about the length and width of the bed of bio-mass material. 
     
     
         31 . A bio-mass processing system as in  claim 30 , further comprising a computer controller which directs movement of said transport structure, within a the length and width of the bed, so as to periodically mix-process the bio-mass material throughout substantially the entirety of the bed of bio-mass material. 
     
     
         32 . A bio-mass processing system as in  claim 30  wherein said air supply system is divided into at least two substantially mutually exclusive and different supply zones, optionally at least three substantially mutually exclusive and different supply zones, along the length of the bed of bio-mass material, so as to enable feeding different air temperatures and/or different air flow rates in the respective different zones. 
     
     
         33 . A bio-mass processing system as in  claim 32 , further comprising a computer controller providing control of at least one of air flow rate and air temperature, going to at least two of the respective dryer zones, rate of separating the relatively drier first portion of the bio-mass material from said dryer. 
     
     
         34 - 37 . (canceled) 
     
     
         38 . A method of processing animal manure, comprising:
 drying the animal manure to an end moisture content by   (a) collecting and containing a bed of manure to be dried, in a work location, over a floor of a dryer, the bed of manure having a length and a width, an air supply system being associated with the floor and being effective to release air into the bed of manure at or adjacent the floor;   (b) supplying heated air through the air supply system to the bed of manure, thus to percolate the heated air upwardly through the bed of manure over substantial portions of both the length and the width of the bed of manure to be dried;   (c) mixing the bed of manure to be dried while percolating the warm air upwardly through the bed of manure;   (d) moving the manure progressively through the dryer whereby a relatively drier first portion of the manure is generally displaced from a relatively wetter second portion of the manure in the bed of manure; and   (e) removing relatively dryer manure product of the drier first portion from the bed of manure and supplying fresh feed material to the dryer to replenish the manure in the dryer, thereby to operate a relatively continuous drying process.   
     
     
         39 . A method as in  claim 38 , further comprising burning the removed product to produce heat. 
     
     
         40 . A method as in  claim 39 , further comprising converting the heat to one or more other forms of energy such as mechanical energy, electrical energy, hydraulic energy, pneumatic energy, or chemical energy. 
     
     
         41 . A method as in  claim 39 , further including using heat produced by the burning in supplying the warm air through the air supply system in the dryer. 
     
     
         42 . A method as in  claim 38 , the dryer comprising a receptacle having upstanding walls, the method including containing the manure in the container while supplying the heated air, mixing the manure, and moving the manure through the dryer. 
     
     
         43 . A method as in  claim 38 , the moving of the manure progressively through the dryer comprising moving the manure along a generally horizontal path from proximate a wetter inlet end of the dryer toward a relatively drier exit end of the dryer, thereby to produce the relatively drier manure product. 
     
     
         44 - 66 . (canceled) 
     
     
         67 . A bio-mass processing system as in  claim 24 , further comprising a moisture sensor sensing a moisture level of the bed of bio-mass material in said dryer, and a controller adjusting one or more of air temperature being supplied to the bed of bio-mass material in said dryer, mass flow rate of air being supplied to the bed of bio-mass material in said dryer, or frequency or rate of mixing of the bio-mass material in said dryer, in response to the sensed moisture level in the bed of bio-mass material in said dryer, thereby to maintain an aerobic environment in said dryer. 
     
     
         68 . A bio-mass processing system as in  claim 24 , further comprising a retention system retaining bio-mass material, to be fed to said dryer, under substantially aerobic conditions prior to such web bio-mass material being introduced into said dryer. 
     
     
         69 . A bio-mass processing system as in  claim 68 , further comprising an agitator in said retention system, continuously agitating such wet bio-mass material in said retention system. 
     
     
         70 . A bio-mass processing system as in  claim 24 , further comprising an air handler venting to atmosphere the air emerging from the bed of bio-mass material in said dryer. 
     
     
         71 . A bio-mass processing system as in  claim 24 , further comprising a recycle stream recycling residual heated air from said electrical energy converter to said air supply system. 
     
     
         72 . A bio-mass processing system as in  claim 24 , further comprising a recycle stream recycling a portion of the relatively drier separated bio-mass material, separated from the outlet of said dryer, to the inlet of said dryer.