Apparatus and method for transforming solid waste into useful products

Abstract

A system and method for processing solid waste disposal includes a hydrolyzer ( 80 ) and a injection assembly ( 30 ) for transferring waste to the hydrolyzer ( 80 ). The injection assembly ( 30 ) includes a sleeve ( 40 ), in which waste is compressed with a ram ( 37 ), and a movable gate ( 52 ), which opens to allow the compressed waste ( 68 ) to exit the sleeve ( 40 ) and enter the hydrolyzer ( 80 ). The hydrolyzer ( 80 ) includes a pressure vessel ( 84 ), a rotating shaft ( 108 ) contained within the vessel ( 84 ), and agitates attached to the shaft for moving and processing the material through the hydrolyzer ( 80 ).

1 . A material injection assembly for transferring waste to a waste processing apparatus, comprising: 
 a sleeve having an inlet, through which waste may enter said sleeve, and a passageway, through which material may exit said sleeve;    a ram receivingly operational within said sleeve for compressing waste; and    a gate including a movable gate plate positioned between said inlet and said passageway, said gate plate defining an aperture configured to pass compressed waste through said passageway.    
   
   
       2 . The material injection assembly of  claim 1 , further comprising a cylinder having a shaft connected to said ram, said cylinder for manipulating said ram within said sleeve.  
   
   
       3 . The material injection assembly of  claim 1 , further comprising controls for opening and closing said gate plate in relation to the position of said ram.  
   
   
       4 . The material injection assembly of  claim 1 , further comprising a hopper for receiving waste, having an open bottom which is operationally connected to said inlet of said sleeve.  
   
   
       5 . The material injection assembly of  claim 1 , further comprising a means for excluding portions of said waste from entering said sleeve.  
   
   
       6 . A system for processing waste, comprising: 
 a material injection assembly, further comprising: 
 a sleeve having an inlet, through which waste may enter said sleeve, and a passageway, through which material may exit said sleeve;  
   a ram receivingly operational within said sleeve for compressing waste; and    a gate including a movable gate plate positioned between said inlet and said passageway, said gate plate defining an aperture configured to pass compressed waste through said passageway; and    a hydrolyzer for processing the waste exiting said sleeve.    
   
   
       7 . The system of  claim 6 , further comprising: 
 a material handling apparatus, for shaping material processed by said hydrolyzer, including:    a compaction chamber, having an inlet through which processed material from said hydrolyzer enters said chamber;    a means for operationally connecting the interior of said hydrolyzer with the interior of said chamber; and    a ram, receivingly operational within said chamber for compressing said processed material.    
   
   
       8 . A material handling apparatus for further processing material processed by a hydrolyzer, comprising: 
 a compaction chamber, having an inlet through which processed material may enter said chamber;    a plunger assembly, including a ram receivingly operational within said chamber for compressing said processed material into a block; and    a block cutter assembly, for cutting said block.    
   
   
       9 . The material handling apparatus of  claim 8 , wherein said plunger assembly further comprises a plunger cylinder and plunger shaft operably connected to said ram, enabling said ram to compress material within said chamber upon actuation of said plunger cylinder and extension of said plunger shaft.  
   
   
       10 . The material handling apparatus of  claim 8 , wherein said block cutter assembly further comprises a block forming section for holding a portion to be cut from the block of processed material.  
   
   
       11 . The material handling apparatus of  claim 10 , further comprising a containment assembly, including: 
 a stop plate, creating a backstop for said ram distally opposite said material, said stop plate being retractably positioned between said block forming section and a containment cylinder; and    a containment cylinder including a containment shaft, operationally connected to and controlling the cycling of said stop plate between said forming section and containment cylinder.    
   
   
       12 . The material handling apparatus of  claim 11 , wherein said block cutter assembly further comprises a knife for cutting a portion from the block.  
   
   
       13 . The material handling apparatus of  claim 8 , further comprising a means for supporting and mobilizing said apparatus.  
   
   
       14 . The material handling apparatus of  claim 12 , further comprising an expansion chamber for receiving a severed portion of said block.  
   
   
       15 . A hydrolyzer for processing solid waste disposal, comprising: 
 a pressure vessel having an inlet for receiving said solid waste disposal, and an exit port through which processed material exits said vessel;    a rotating shaft positioned within said pressure vessel, and having spaced apart ends; and    a means for agitating attached to and extending radially from said shaft.    
   
   
       16 . The hydrolyzer of  claim 21 , wherein at least some of said means for agitating extend radially outward in a helical spiral pattern when viewed from either of the spaced apart ends.  
   
   
       17 . A system for processing solid waste, comprising: 
 a particle size reduction apparatus; and    a hopper assembly, having a hopper defining an inlet into said particle size reduction apparatus and including a gate for blocking said inlet, said hopper pivotally connected to particle size reduction apparatus.    
   
   
       18 . The system of  claim 17 , further comprising a material injection assembly, including: 
 a sleeve having an inlet, for receiving material from said particle size reduction apparatus, and a passageway, through which material may exit said sleeve;    a ram receivingly operational within said sleeve for compressing waste; and    a movable gate plate, said gate plate defining an aperture sized to enable a plug of compressed material to pass through said aperture, wherein said plug may exit said sleeve through said passageway when the gate plate is in an open position.    
   
   
       19 . A composite material derived from a process for transforming solid waste disposal, the process comprising the steps of: 
 providing a quantity of waste having a first volume;    preprocessing the first volume into a second volume of waste;    inserting said second volume of waste into a hydrolyzer;    processing the waste within the hydrolyzer at an elevated pressure and temperature;    removing the processed material from the interior of the hydrolyzer; and    wherein the composite material is at least partially comprised of the processed waste according to the above process.    
   
   
       20 . The process of  claim 19 , wherein the inserting step further comprises continuously feeding the preprocessed waste into the hydrolyzer and continuously removing the composite material from the hydrolyzer.  
   
   
       21 . The process of  claim 20 , wherein the step of continuous feeding the preprocessed waste into the hydrolyzer further includes automatically feeding the preprocessed waste into the hydrolyzer.  
   
   
       22 . The process of  claim 21 , wherein the step of continuously removing the composite material from the hydrolyzer further includes automatically removing the composite material from the hydrolyzer.  
   
   
       23 . The process of  claim 19 , wherein the preprocessing step further includes the steps of removing objectionable components in said waste, and providing a substantially uniform hydration level to the waste.  
   
   
       24 . The process of  claim 19 , wherein the step of processing the waste within the hydrolyzer further comprises the step of introducing steam into the hydrolyzer to create elevated pressure and temperature.  
   
   
       25 . The process of  claim 19 , further comprising the step of drying the composite material that was removed from the interior of the hydrolyzer.  
   
   
       26 . The process of  claim 19 , wherein the step of removing the composite material from the interior of the hydrolyzer further includes the step of extruding the composite material and forming a block thereof.  
   
   
       27 . The process of  claim 26 , wherein the step of extruding the composite material and forming a block thereof further includes the step of molding the extruded composite material into a useful article.  
   
   
       28 . The process of  claim 25 , further comprising the step of removing objectionable fragments.  
   
   
       29 . The process of  claim 19 , further including the step of mixing the composite material with an additive.  
   
   
       30 . A method for transforming solid waste disposal into a useful composite material, comprising the steps of: 
 providing a quantity of waste having a first volume;    inserting said first volume of waste into a hydrolyzer;    processing said waste within said hydrolyzer at an elevated pressure and temperature;    removing the processed material from the interior of the hydrolyzer; and    wherein the composite material is at least partially comprised of the processed waste according to the above method.    
   
   
       31 . The method of  claim 30 , wherein the inserting step further comprises continuously feeding the waste into the hydrolyzer and continuously removing the composite material from the hydrolyzer.  
   
   
       32 . The method of  claim 31 , wherein the step of continuously feeding the waste into the hydrolyzer further includes automatically feeding the waste into the hydrolyzer.  
   
   
       33 . The method of  claim 31 , wherein the step of continuously removing the composite material from the hydrolyzer further includes automatically removing the composite material from the hydrolyzer.  
   
   
       34 . The method of  claim 31 , wherein the step of processing the waste within the hydrolyzer further comprises the step of introducing steam into the hydrolyzer to create elevated pressure and temperature.  
   
   
       35 . The method of  claim 30 , wherein the step of removing the composite material from the interior of the hydrolyzer further includes the step of extruding the composite material and forming a block thereof.  
   
   
       36 . The method of  claim 35 , wherein the step of extruding the composite material and forming a block thereof further includes the step of molding the extruded composite material into a useful material.  
   
   
       37 . The method of  claim 30 , further including the step of removing objectionable fragments.  
   
   
       38 . The method of  claim 30 , further including the step of mixing the composite material with an additive.  
   
   
       39 . The method of  claim 30 , further comprising the step of drying the processed waste that was removed from the interior of the hydrolyzer.