The disclosure relates to anaerobic digestion of liquid waste streams.
The anaerobic digestion of organic liquid waste streams has been a fundamental part of waste treatment for hundreds of years. Municipal and industrial wastes have been treated utilizing anaerobic digestion techniques for over 100 years in the United States, and within the last thirty years, anaerobic digestion of higher strength animal wastes has also become an accepted practice. However, a limitation of the bacterial-based anaerobic digestion process has been the inability of anaerobic bacteria to grow outside the parameter of a narrow pH range.
Anaerobic digestion comprises two main classes of anaerobic bacteria: acid forming bacteria (acid formers) and methanogenic bacterial (methane formers). The acid forming bacteria perform best at a pH of about 6.0 to about 7.0 and the methanogenic bacteria perform bets at a pH of about 6.5 to 8.0. These narrow pH ranges preclude effectively utilizing anaerobic digestion waste treatment technology for the treatment of high-strength organic, liquid waste streams having a pH below about 6.5 or above about 8.0.
A high-strength organic liquid waste stream typically has a solids content of about 5% to about 40%. Acidic high-strength organic liquid wastes have a pH of less than about 5.0 Examples of such wastes include acidic cheese whey, with a pH of about 3.5, and the rapidly growing wastes from ethanol plants, with a pH of about 3.5 to 4.0 and a solids content of about 30% to about 35%. When anaerobic digestion has been attempted with acidic high-strength organic liquid wastes in mixed digesters, the traditional response has been to adjust the pH of the acidic wastes to about 7 with either the addition of expensive chemical pH adjusters or the blending of alkaline waste streams with the acidic wastes. Alkaline high-strength organic liquid wastes have a pH greater than about 8.0. Examples of such wastes include the glycerin by-product waste from biodiesel plants that convert animal oils or vegetable oils into biodiesel. Glycerin typically has a pH of about 12 to about 14 and a high solids content of about 20% to about 35%. When anaerobic digestion has been attempted with alkaline high-strength organic liquid wastes in mixed digesters, the traditional response has been the addition of expensive, corrosive acids, such as sulfuric or citric acids, to lower the pH of the entire digester prior to the anaerobic biodegradation so that the influent pH of the waste stream is continually adjusted to a pH of about 7.
In one embodiment, the disclosure relates to a system for treating liquid waste. In one embodiment, the system for treating liquid waste comprises: an acid forming chamber that at least partially converts carbon molecules in the liquid waste to acids; a plug-flow methanic chamber downstream from the acid forming chamber that at least partially converts the acids in the liquid waste to methane; a weir structure provided between the acid forming chamber and the methanic chamber; a solid-liquid separator downstream from the methanic chamber, the separator separating a portion of the liquid waste into alkaline sludge and effluent; and a first flow path that recycles alkaline sludge to at least one of the acid forming chamber, the methanic chamber, and combinations thereof.
In one embodiment, the system for treating waste further comprises a center wall that divides the methanic chamber into a first leg and a second leg. In one embodiment, a portion of the center wall forms a partial division between the acid forming chamber and the methanic chamber.
In one embodiment, the system for treating waste further comprises an enclosure surrounding the acid forming chamber, the methanic chamber, the solid-liquid separator and the first flow path.
In one embodiment, the weir structure is positioned between the enclosure and the portion of the center wall forming the partial division between the acid forming chamber and the methanic chamber.
In one embodiment, the weir structure has a first weir wall at a level below an operating liquid level of both the acid forming chamber and methanic chamber.
In one embodiment, the weir structure has a second weir wall at a level approximately equal to the operating liquid level of the acid forming chamber, wherein the operating liquid level of the acid forming chamber is greater than the operating liquid level of the methanic chamber.
In another embodiment, the second weir wall is inclined from the methanic chamber to the acid forming chamber.
In one embodiment, the disclosure relates to a system comprising: an acid forming chamber that at least partially converts carbon molecules in a liquid waste to acids; a plug-flow methanic chamber downstream from the acid forming chamber that at least partially converts the acids in the liquid waste to methane; and a weir structure provided between the acid forming chamber and the methanic chamber, wherein the weir structure has a first weir wall at a level below an operating liquid level of both the acid forming chamber and methanic chamber.
In another embodiment, the disclosure relates to a system comprising an enclosure surrounding an acid forming chamber and a methanic chamber that is downstream from the acid forming chamber, wherein the enclosure has a roof; a center wall that divides the methanic chamber into a first leg and a second leg; wherein a portion of the center wall forms a partial division between the acid forming chamber and the methanic chamber; and a weir structure positioned between the roof of the enclosure and the portion of the center wall forming the partial division between the acid forming chamber and the methanic chamber.
Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The methods and apparatuses are capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if a compositional, physical or other property, such as, for example, molecular weight, viscosity, melt index, etc., is from 100 to 1,000, it is intended that all individual values, such as 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated. For ranges containing values which are less than one or containing fractional numbers greater than one (e.g., 1.1, 1.5, etc.), one unit is considered to be 0.0001, 0.001, 0.01 or 0.1, as appropriate. For ranges containing single digit numbers less than ten (e.g., 1 to 5), one unit is typically considered to be 0.1. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure. Numerical ranges are provided within this disclosure for, among other things, relative amounts of components in a mixture, and various temperature and other parameter ranges recited in the methods.
As used herein, the singular forms “a,” “an,” and “the” refer to one or more than one, unless the context clearly dictates otherwise.
As used herein, the term “anaerobic digester effluent” refers to effluent produced at any stage during a manure management lifecycle. Anaerobic digester effluent includes effluent directly removed from the anaerobic digester, effluent removed from the digester and separated from large solids, effluent removed from the digester and separated from fine solids, effluent removed from the digester and separated from large and fine solids; effluent removed from the digester and aerated; effluent removed from the digester and heated; effluent removed from the digester and heated and aerated; effluent removed from the digester heated and aerated and separated from solids; effluent removed from the digester heated, aerated and used to remove H2S from a biogas, effluent removed from the digester heated, aerated, separated from solids; used to remove H2S from biogas; effluent removed from the digester heated, aerated, used to remove H2S from a biogas and regenerated to an alkaline pH; effluent removed from the digester heated, aerated, separated from solids; used to remove H2S from biogas, and regenerated to an alkaline pH; effluent removed from the digester heated, aerated, used to remove H2S from a biogas, regenerated to an alkaline pH, and used to remove CO2 from a biogas; and effluent removed from the digester heated, aerated, separated from solids; used to remove H2S from biogas, regenerated to an alkaline pH and used to remove CO2 from biogas. Anaerobic digester effluent and effluent may be used interchangeably unless stated otherwise.
As used herein, the term “includes” means “comprises.” For example, a device that includes or comprises “A” and “B” contains “A” and “B” but may optionally contain “C” or other components other than “A” and “B.” A device that includes or comprises “A” or “B” may contain “A” or “B” or “A” and “B,” and optionally one or more other components such as “C.”
As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed terms. For example, when used in a phrase such as “A and/or B,” the phrase “and/or” is intended to include both A and B; A or B; A (alone); and B (alone). Likewise, the term “and/or” as used in a phrase such as “A, B and/or C” is intended to encompass each of the following embodiments: A, B and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone).
Spatial terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of device in use or operation in addition to the orientation depicted in the figures. For example, if the device is turned over, elements described as “below” or “beneath” other elements or features would then be orientated “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90° or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
As used herein, the term “manure” is meant to refer herein to animal wastes including animal dejections, feed remains and hair.
As used herein, the term “treated biogas” refers to biogas that has been in direct or indirect contact with an alkaline effluent.
The present invention allows for the treatment of acidic high-strength organic liquid wastes with little or no chemical pH adjustment and without the requirement of blending with other higher pH liquid wastes. This waste treatment system allows the host waste production facility to treat its own wastes economically, on-site with a small plant footprint, and to utilize the resultant high-energy biogas internally in its plant process. As used herein, the term “acidic high-strength organic liquid waste” (hereinafter “acidic liquid waste”) means a process waste, organic in nature, with a pH of less than about 5.0 and with a solids content of greater than about 5%.
The challenge in completing the anaerobic degradation of acidic liquid wastes is an imbalance in the biological system. Anaerobic degradation relies on acid forming bacteria to break down the complex carbon molecular structures of the organic input feed into simpler molecular structures such as acetic acid. Subsequently, methanogenic bacteria break down the simpler acid molecular structures into a biogas consisting primarily of methane and carbon dioxide. Suitable acid forming bacteria and methanogenic bacteria may be found in nature, such as, but not limited to, the bacteria found naturally in a cows stomach. Examples of acid forming bacteria may include, but are not limited to, at least one of Clostridia, Fibrobacter succinogenes, Ruminococcus albus, Butyrivibrio fibrisolvens, Selenomanas ruminatium, Streptococcuslovis, Eubacterium ruminatium, external enzymes, and combinations thereof. Examples of methanogenic bacteria may include, but are not limited to, at least one of Methanothrix, Methanosarcina, Methanospirillum, Methanobacterium, Methanococcus, Methanobrevibacterm, Methabnomicrobium-mobile, Methanosaeta, Methanobacterium thermoautotrophicum, Methanobacterium formicicum, Methanobactotrophicum, Methanobacterium formicicum, Methanobacterium thermoalcahphilum, Methanococcus thermolithotrophicus, Methanosarcina thernophila, Methanosaela thermoacetophila and combinations thereof. The bacteria production of biogas consumes the acids in the liquid waste and creates a higher pH, alkaline solution. In traditional waste such as municipal and animal wastes, the input wastes have a neutral pH of about 7 and possess sufficient natural fiber and alkalinity so that the acid forming and the acid reducing reactions take place concurrently and the pH of the treatment process remains in the range of about 6.0 to about 8.0. This chemically and biologically balanced system allows for unimpeded degradation of the organic wastes and production of energy in the form of biogas.
Acidic liquid wastes create a special problem for the traditional anaerobic digestion processes. Acid forming bacteria are much more robust, faster population multipliers, and more tolerant of lower pH conditions than the slower breeding, pH sensitive methanogenic bacteria. When presented with an acidic liquid waste that has very slight natural alkalinity with it, such as ethanol by-product wastes, the acid forming bacteria out-produce the methanogenic bacteria. As a result, the pH of the liquid waste rapidly drops to a pH of about 4.0 or less. The entire digestion process stops and the organic waste becomes “dead” due to bacteria inaction at this low pH level. In the traditional mixed anaerobic digester industry, the response to this type of acidic waste and the resultant problems has been digester technology avoidance or continuous heavy chemical usage for pH balancing with high technology/monitoring and low biogas production.
One aspect of the present invention is to modify a plug-flow anaerobic digester system to treat acidic liquid wastes using a two-step anaerobic biodegradation process. In the first step, acid forming bacteria are cultivated to break down the complex carbon molecular structures in the liquid waste into simpler acid molecules. In the second step, methanogenic bacteria are cultivated to subsequently break down the simpler acid molecules into biogas. Examples of plug-flow systems that may be modified for this purpose are disclosed in U.S. Pat. No. 6,451,589 issued to Dvorak on Sep. 17, 2002, U.S. Pat. No. 6,613,562 issued to Dvorak on Sep. 2, 2003, U.S. Pat. No. 7,078,229 issued to Dvorak on Jul. 18, 2006, U.S. application Ser. No. 10/694,244 (U.S. Publication No. 2004/0087011) filed on Oct. 27, 2003, and International Patent Application No. PCT/US2006/045414 entitled “Anaerobic Digester Employing Circular Tank,” GHD, Inc. filed on Nov. 27, 2006 (MBF Case No. 031154-9005) the contents of each of which are hereby fully incorporated by reference.
The roof 90 of the digester enclosure 20 is located about 16 feet above the floor 52 of the digester enclosure 20. The roof 90 is constructed of about ten-inch thickness of hollowcore precast concrete panels 98 (e.g., Spancrete® Hollowcore® available from Spancrete, Inc., Green Bay, Wis.) topped by a layer of insulation 94 with a thickness between about four and about eight inches.
A biogas storage chamber 102 (optional) is located above the roof 90. The primary component of the biogas storage chamber 102 is a liner 106 including an upper liner section 110 and a lower liner section 114. The liner 106 is preferably constructed from high-density polyethylene (HDPE), but may be any other suitable material. The liner 106 is sealed around the edges 118 of the liner 106 by capturing the edges 118 beneath six-inch channel iron 122, which is removably attached to the digester enclosure wall 54 using nuts 126 on a plurality of anchor bolts 130 embedded in the digester enclosure wall 54. A ten-inch PVC pipe 134 is inserted around the periphery of the chamber 102 within the liner 106 to assist in maintaining the seal around the periphery of the liner 106. The liner 106 is constructed such that it can flexibly fill with biogas as the biogas is produced in the methanic chamber 40, and can be emptied of biogas as is needed. The biogas storage chamber 102 may be replaced by any other suitable gas storage system including a roofed storage system.
As shown in
An influent conduit 18 transfers liquid waste from the pH monitoring station to the acid forming chamber 30. An internal heating device 22, such as heat exchanging coils, located within the acid forming chamber 30 maintains the liquid waste at a temperature that facilitates bacterial activity. Stirring mechanisms within the acid forming chamber 30 prevent temperature stratification and promote better bacterial growth. Stirring mechanisms may include, but are not limited to, mechanical stirrers, agitation from recycled biogas, hydraulic agitation with recycled waste liquids, or combinations thereof. A pH monitoring station A in
The liquid waste from the acid forming chamber 30 is transferred via horizontal plug-flow movement of the liquid waste to the methanic chamber 40. As shown in
As shown in
In addition to controlling the temperature within the methanic chamber 40, the heating device 72 may facilitate the mixing of the liquid waste as it flows through the methanic chamber 40. The heating device 72 may be used to heat the liquid waste, causing the heated liquid waste to rise up the center wall 65 under convective forces. In embodiments employing one or more partitions 70, heated waste material flows upwardly in the space created between the partitions 70 and the center wall 65. At the same time, liquid waste near the inner wall of the relatively cooler digester enclosure 20 falls under convective forces. As a result, the convective forces cause the liquid waste to follow a circular flow path upward along the center wall 65 and downward along the digester enclosure 20. At the same time, the liquid waste flows along the first leg 46 and second leg 48 of the methanic chamber 40, resulting in a combined corkscrew-like flow path for the liquid waste. Mixing of the plug flow prevents stratification in the digester.
Stirring mechanisms are also located within the methanic chamber 40 and may include mechanical stirrers, agitation from recycled biogas, hydraulic agitation with recycled liquid waste, or combinations thereof. In some embodiments, recycled biogas agitation is maintained for waste mixing in a direction perpendicular to the waste flow direction. As illustrated in
pH monitoring stations are located at various sites throughout the methanic chamber 40 to maintain the pH of the liquid waste at a level that facilitates bacterial activity.
In addition to producing activated sludge, the anaerobic digestion in the methanic chamber 40 also produces biogas in the form of methane gas, which is collected above the liquid level 58 and can be stored in the biogas storage chamber 102, or utilized directly as a bio-fuel. Liquid that condenses within the chamber 102 may be directed through an effluent conduit to a liquid storage lagoon. The collected biogas may be used to fuel an internal combustion engine that, in combination with an electric generator, may be used to produce electricity that is used within the waste treatment system 10, sold to a power utility, or a combination thereof. The cooling system of the internal combustion engine may also produce hot coolant that may be used to heat liquid waste in the acid forming chamber 30 and/or to heat and agitate the liquid waste in the methanic chamber 40. Hot water from the engine may pass through an air/water cooler to reduce the temperature of the water from the about 180° F. temperature at the exit of the engine to about 160° F. for use in the acid forming chamber 30 and the methanic chamber 40.
The effluent pit 50 is located adjacent to the sludge pit 60. The liquid waste plug flows sequentially from the acid forming chamber 30 into the methanic chamber 40 into the sludge pit 60 and into the effluent chamber 50. At least a portion of the sludge may be recirculated via one or more flow paths 42, 44 to the acid forming chamber 30 and methanic chamber 40. In some embodiments, a sump conduit from the effluent chamber 50 leads to a standard solids press to separate the digested liquid from the digested solids. The liquid from the solids press may be recycled to the acid forming chamber 30 for further processing. The solids from the solid press may be sent to a composter and bagged for commercial sale.
A natural gravity system may be used to separate solids from liquids in the sludge pit 60 at the end of the waste treatment system 10. However, it should be understood by one skilled in the art that any solid-liquid separator may be used in place of, or in addition to, the gravity system. Any solid-liquid separator that separates solids from liquids by gravity, differential settling velocity, or size-exclusion may be employed. Examples of additional solid-liquid separators include settling ponds, hydrocyclones, centrifuges, and membrane filters or separators.
In operation of the waste treatment system 10, as illustrated in
The liquid waste is transferred from the pH monitoring station 16 via the influent conduit 18 to the acid forming chamber 30. In the acid forming chamber 30, the internal heating device 22 adjusts the temperature of the influent to facilitate the growth of acid forming bacteria. Temperature control is important for methanogenic bacteria (less so for acid forming bacteria) and the temperature is closely regulated in the acid forming chamber 30 so that the temperature is kept constant as the liquid “plug flows” from the acid forming chamber 30 into the methanic chamber 40. The temperature can be site determined to be about 97° F. to about 103° F. for a mesophilic operating digester or about 132° F. to about 138° F. for a thermophilic digester. The liquid waste in the acid forming chamber 30 is continuously stirred to eliminate temperature stratification in the liquid waste and to promote better bacterial growth. In one embodiment, the contents of the acid forming chamber are continuously stirred with recycled biogas agitation.
Within the acid forming chamber 30, acid forming bacteria convert complex carbon molecules into simpler acids. These acids in turn lower the pH of the liquid waste in the acid forming chamber 30. In order to prevent the pH from dropping too low to sustain bacterial activity, the pH of the liquid waste must be frequently adjusted upward. Rather than add additional pH adjusters from outside the waste treatment system, the pH can be adjusted internally by mixing alkaline sludge from the sludge pit 60 at the end of the waste treatment system 10 with the existing influent in the acid forming chamber 30 to maintain the pH of the influent at about 6.0 to about 7.0 for maximum acid-forming bacteria growth rates and efficiency. The pH of the sludge in the sludge pit is typically between about 7.0 to about 8.0. In addition to changing pH, the sludge can also “seed” the influent in the acid forming chamber 30 with mature acid forming bacteria and methanogenic bacteria. In some embodiments, a roof mounted pH monitor identified by station A in
As new influent enters the acid forming chamber 30, the treated liquid waste within the acid forming chamber 30 will plug flow into the methanic chamber 40. In the methanic chamber 40, an environment to foster the growth of the methanogenic bacteria is maintained. The pH of the liquid waste in the methanic chamber 40 is maintained at a pH of about 6.5 to about 8.0, and particularly at a pH of about 7.5 to about 8.0. To accomplish this, pH monitoring stations (B-D) are located throughout the methanic chamber 40. If the drops below a set value, such as 6.5, at any of these stations, the pH monitors will activate one or more vari-speed sludge recirculation pumps to add alkaline sludge from the sludge pit 60 to the liquid waste in the methanic chamber 40. The corkscrew mixing of the liquid waste in the methanic chamber 40 by the utilization of the recirculated biogas and/or heating ensures a homogeneous pH mix and prevents pH stratification within the vessel. Heat exchanging coils within the methanic chamber 40 maintain the temperature of the liquid waste within a range of about 1 to about 2 degrees of the set point temperature. The set point temperature for a mesophilic temperature digester will be about 100° F. and about 134° F. for a thermophilic digester. The heating coils can be utilized for heating or cooling as determined by the influent liquid temperature. The liquid waste within the methanic chamber 40 is continuously mixed with recycled biogas jetted into the liquid waste in a direction perpendicular to the waste flow direction. Mixing prevents stratification within the methanic chamber and enhances biodegradation.
As the waste stream plug flows through the methanic chamber 40, it is not mixed with the newer incoming waste material and is, therefore, allowed to biodegrade in multiple sections as it travels in a horizontal corkscrew-like pathway through the first leg 46 and the second leg 48 of the methanic chamber 40. As the methanogenic bacteria function, they consume the acids created in the acid forming chamber 30 and effectively raise the pH of the liquid waste stream and increase the alkalinity of the liquid waste. At the end of the methanic chamber 40, with properly engineered hydraulic retention times based on influent characteristics, the acid forming bacteria will have long completed their function and the methanogenic bacteria will have consumed the bacteria-produced acids. This results in a waste effluent of high pH and alkalinity in comparison to the influent. The greatest alkalinity and bacteria population at the very end of the waste treatment system 10 will be in the bacteria “sludge” that is allowed to settle in the sludge pit 60 located at the end of the waste treatment system 10. The sludge pit 60 does not have mixing and thus the sludge is allowed to settle to the bottom. This sludge, with its higher alkalinity, pH, and bacteria population, is the recirculated sludge utilized at the various points (stations A, B, C and D) throughout the waste treatment system 10 for pH control and bacterial seeding.
The biodegraded effluent may be further treated or disposed of by the generating facility as required. Biogas generated by the anaerobic biological process may be collected in the gas collection space above the liquid level and under the ceiling of the methanic chamber 40. The biogas may be utilized as a “BTU replacement” in the production of electricity or natural gas.
The waste treatment system 10 will treat acidic liquid wastes with a solids percentage varying between about 5% and about 40%. It does this by monitoring and closely controlling the pH in the liquid waste and by utilizing the naturally generated alkalinity and pH rise associated with the two-step anaerobic biodegradation process of acid forming bacteria followed by methanogenic bacteria and their resultant biological waste products. Use of a mixed plug flow is preferred. Additionally, the plug-flow separation of the processed wastes over the designed hydraulic retention time enables the natural increase in pH and alkalinity, thus allowing for the production of the returned sludge. Mixing of the plug flow prevents stratification in the acid forming chamber 30 and methanic chamber 40. Eliminating stratification in the acid forming chamber 30 and methanic chamber 40 prevents buildup of acid forming bacteria colonies and the resultant high acidic liquid (low pH) “dead” spots, facilitates better methanogenic bacteria growth to achieve better and faster acid neutralization and alkalinity production, and provides for more uniform hydraulic retention time in the waste treatment system 10 by preventing “short circuiting” of the liquid pathflow.
As shown in
It will be appreciated that, with the described structures, liquid from the acid forming chamber 30 is able to flow over the wall portion 65a and into the methanic chamber 40. Reverse flow from the methanic chamber 40 into the acid forming chamber 30, however, is prevented. Similarly, the weir structure 67 acts as a double sewer trap to prevent gases from escaping the methanic chamber 40.
In a particular embodiment, the height difference between the first weir wall portion 67a and the second weir wall portion 67b is from 3 inches, or 4 inches, or 5 inches, or 6 inches to 7 inches, or 8 inches, or 9 inches, or 10 inches. In a further embodiment, the height difference between the first weir wall portion 67a and the second weir wall portion 67b is from 5.0 inches, or 5.2 inches, or 5.4 inches, or 5.6 inches, or 5.8 inches or 6.0 inches to 6.2 inches, or 6.4 inches, or 6.6 inches, or 6.8 inches, or 7.0 inches. In still a further embodiment, the height difference between the first weir wall portion 67a and the second weir wall portion 67b is from 5.7 inches, or 5.8 inches, or 5.9 inches, or 6.0 inches to 6.1 inches, or 6.2 inches, or 6.3 inches, or 6.4 inches. In a specific embodiment, the height difference between the first and second weir wall portions 67a, 67b is approximately 6 inches.
By providing the weir structure 65, it is easy to isolate the acid forming chamber 30 from the methanic chamber 40 by simply decreasing the liquid level in the acid forming chamber. The ability to completely seal the acid forming chamber 30 from the methanic chamber 40 is beneficial to permit flow adjustments to drive biogas production. It also allows for the cleaning of the acid forming chamber 30 and continued operation of the methanic chamber 40 during that cleaning.
As shown in
The first leg 346 and the second leg 348, as illustrated in
The heating device(s) 372 and the partition(s) 370 are shown in greater detail in
As illustrated in
Referring to
As illustrated in
The series of conduits 374, 378 illustrated in
As illustrated in
The acid forming chamber 430 includes an influent conduit 418 for receiving liquid waste from the pH monitoring station 416 into the acid forming chamber 430. A cutout 459 is formed in a wall 461 between the acid forming chamber 430 and the methanic chamber 440 to allow liquid waste to flow from the acid forming chamber 430 into the methanic chamber 440. The acid forming chamber 430 also includes a heating device 422 for heating the liquid waste as it flows through the acid forming chamber 430. The heating device 422 may, for example, be a heating conduit or other conduit containing a liquid or gas. The heating device 422 may include discharge nozzles (not shown) to further agitate the liquid waste. Additionally, a pH monitoring station A measures the pH of the liquid waste within the acid forming chamber 430 and triggers the delivery of alkaline sludge from the sludge pit 460 to the acid forming chamber 430 via flow path 442 to maintain the pH of the liquid waste in the acid forming chamber 430 at about 6.0 to about 7.0.
The methanic chamber 440 includes a first leg or passageway 441, a second leg or passageway 443 and a third leg or passageway 445. The first and second legs 441, 443 are separated from one another by a first divider 447, while the second and third legs 443, 445 are separated from one another by a second divider 449. The first leg 441 has a first end 441a and a second end 441b, the second leg 443 has a first end 443a and a second end 443b, and the third leg 445 has a first end 445a and a second end 445b. The first end 441a of the first leg 441 is adjacent the cutout 459, which thus also serves as an inlet for receiving liquid waste into the methanic chamber 440. The second end 441b of the first leg 441 is adjacent the first end 443a of the second leg 443. The second end 443b of the second leg 443 is adjacent the first end 445a of the third leg 445. The second end 445b of the third leg 445 is adjacent the sludge pit 460. The first divider 447 has an end 447a around which the liquid waste flows from the first leg 441 to the second leg 443. Likewise, the second divider 449 has an end 449a around which the liquid waste flows from the second leg 443 to the third leg 445. From the methanic chamber 440, the liquid waste flows into the optional sludge pit 460.
The methanic chamber 440 forms a flow path for the liquid waste that is generally S-shaped. It should be noted, however, that additional dividers could be employed to increase the length of the flow path, by adding additional legs or passageways. The methanic chamber 440 provides a relatively long flow path for the liquid waste within the relatively small area enclosed by the outer wall 454.
The methanic chamber 440 may optionally include one or more partitions 470 positioned relative to the first divider 447 and the second divider 449 such that a space 480 is created between the partition 470 and the respective divider. The partitions 470 may comprise at least one of a rigid board or plank, curtain or drape, tarp, film, and a combination thereof. In addition, the partition 470 may be constructed of a variety of materials including, without limitation, at least one of metal, wood, polymer, ceramic, composite, and a combination thereof. The illustrated partition 470 is substantially vertical and shorter in height than the methanic chamber 440, such that heated liquid waste can move over the top edge of the partition 470 and out of the space 480 between the partition 470 and the divider 447, and cooled liquid waste can move under the bottom edge of the partition 470 and into the space 480.
The waste treatment system 410 as illustrated in
Although the above embodiments were described in the context of treating acidic liquid wastes, it should be understood by those skilled in the art that the same embodiments may also be used to treat high-strength organic liquid wastes having an influent pH of about 7.
Another aspect of the present invention is to modify a plug-flow anaerobic digester system to treat alkaline high-strength organic liquid wastes. As used herein, the term “alkaline high-strength organic liquid waste” (hereinafter “alkaline liquid waste”) means a process waste, organic in nature, with a pH greater than about 8.0 and with a solids content greater than about 5%.
As shown in
The acid forming chamber 630 includes an influent conduit 618 for receiving liquid waste from outside the digester enclosure 620 into the acid forming chamber 630. The acid forming chamber 630 has an upstream end 630a and a downstream end 630b. Liquid waste enters the acid forming chamber 630 at the upstream end 630a and exits the acid forming chamber 630 at the downstream end 630b. A cutout 659 is formed in a wall 661 between the acid forming chamber 630 and the methanic chamber 640 to allow liquid waste to plug flow from the acid forming chamber 630 into the methanic chamber 640. The acid forming chamber 630 used to treat alkaline liquid waste is typically larger than the acid forming chambers used to treat acidic liquid waste. In some embodiments, the acid forming chamber 630 is about four times larger than those used to treat acidic liquid waste.
As the liquid waste flows through the acid forming chamber 630, acid forming bacteria convert complex carbon molecules into simpler acids. As a result, the pH of the liquid waste in the acid forming chamber 630 is lowest at the downstream end 630b and highest at the upstream end 630a. A pH monitoring station E in the acid forming chamber 630 measures the pH of the influent liquid waste. When the pH of the influent waste becomes too high to support the acid forming bacteria, liquid waste from the downstream end 630b of the acid forming chamber 630 is recycled via flow path 693 to the upstream end 630a of the acid forming chamber 630 to reduce the pH of the influent alkaline liquid waste. The flow path 693 may be defined by any number of devices that may include, but are not limited to, a pipe, tile, a channel, and a tube. In some embodiments, the pH monitoring station E triggers a vari-speed recirculation pump. The pump recycles an appropriate amount of liquid waste from the downstream end 630b of the acid forming chamber 630 to the upstream end 630a of the acid forming chamber 630 to adjust the influent alkaline liquid waste to a neutral pH of about 6.5 to about 7.5.
The recirculation of the lower pH liquid waste enables the waste treatment system 610 to self-regulate the pH of the influent liquid waste to a level that is within the range of bacteria acceptance and reduce or eliminate the need for outside acid addition. This recirculation of the lower pH liquid waste also serves to reseed liquid waste at the upstream end 630a of the acid forming chamber 630 with acid forming bacteria. Reseeding may increase bacterial action on liquid waste, particularly bacteria sterile influent wastes, such as glycerin waste. The amount of liquid waste recycled from the downstream end 630b of the acid forming chamber 630 to the upstream end 630a of the acid forming chamber 630 will be reflected in the increased hydraulic retention time sizing of the acid portion of the waste treatment system 610. The liquid waste, upon entering the methanic chamber 640, contains the proper pH and simple acid components for efficient conversion into methane biogas and the reduction of organic compounds, and will be processed in the established pattern of the waste treatment system 610.
The acid forming chamber 630 includes a heating device 622 for heating the liquid waste as it flows through the acid forming chamber 630. The heating device 622 may, for example, be a heating conduit (not shown) or other conduit containing a liquid or gas. The heating 622 device may include discharge nozzles to further agitate the liquid waste.
The liquid waste from the acid forming chamber 630 is transferred via horizontal plug-flow movement of the liquid waste to the methanic chamber 640. As shown in
One or more partitions 670 may run severally parallel to, and on opposite sides of, the center wall 665. The partitions 670 may comprise at least one of a rigid board or plank, curtain or drape, tarp, film, and a combination thereof. In addition, the partitions 670 may be constructed of a variety of materials including, without limitation, at least one of metal, wood, polymer, ceramic, composite, and a combination thereof. The partitions 670 are shorter than the center wall 665 and are raised off the floor of the methanic chamber 640. This allows liquid waste to flow underneath and then over the partitions 670 as it plug flows through the methanic chamber 640.
The methanic chamber 640 illustrated in
In operation of the waste treatment system 610, as illustrated in
The liquid waste enters the acid forming chamber 630 via the influent conduit 618. In the acid forming chamber 630, the internal heating device 622 adjusts the temperature of the influent to facilitate the growth of acid forming bacteria. Temperature control is important for methanogenic bacteria (less so for acid forming bacteria). The temperature is closely regulated in the acid forming chamber 630 so that the temperature is kept constant as the liquid “plug flows” from the acid forming chamber 630 into the methanic chamber 640. The temperature can be site determined to be about 97° F. to about 103° F. for a mesophilic operating digester or about 132° F. to about 138° F. for a thermophilic digester. The liquid waste in the acid forming chamber 630 is continuously stirred to eliminate temperature stratification in the liquid waste and to promote better bacterial growth. In one embodiment, the contents of the acid forming chamber are continuously stirred with recycled biogas agitation.
Within the acid forming chamber 30, acid forming bacteria convert complex carbon molecules into simpler acids. These acids in turn lower the pH of the liquid waste in the acid forming chamber 30. As a result, the pH of the liquid waste at the downstream end 630b of the acid forming chamber 630 is lower than the pH of the influent liquid waste at the upstream end 630a of the acid forming chamber 630. In some embodiments, the pH of the liquid waste at the downstream end 630b of the acid forming chamber 630 is about 6.0.
A pH monitoring station E measures the pH of influent alkaline waste as it enters the upstream end 630a of the acid forming chamber 630. If the pH of the influent liquid waste is greater than about 7, an appropriate amount of liquid waste from the downstream end 630b of the acid forming chamber 630 is recycled to the upstream end 630a of the acid forming chamber to reduce the pH of the influent liquid waste to about neutral. This insures that the pH of the influent liquid waste will be maintained at a level that fosters acid-forming bacteria growth rates and efficiency. In some embodiments, a roof mounted pH monitor identified by pH monitoring station E controls a vari-speed sludge recirculation pump to recycle liquid waste from the downstream end 630b to the upstream end 630a of the acid forming chamber 630.
As new influent enters the acid forming chamber 630, the treated liquid waste within the acid forming chamber 630 will plug flow into the methanic chamber 640. In the methanic chamber 640, an environment to foster the growth of the methanogenic bacteria is maintained. The pH of the liquid waste in the methanic chamber 640 is maintained at a pH of about 6.5 to about 8.0, and particularly at a pH of about 7.5 to about 8.0. To accomplish this, pH monitoring stations (B-D) are located throughout the methanic chamber 640. If the pH drops below a set value, such as 6.5, at any of these stations, the pH monitors will activate one or more vari-speed sludge recirculation pumps to add alkaline sludge from the sludge pit 660 to the liquid waste in the methanic chamber 640. The corkscrew mixing of the liquid waste in the methanic chamber 640 by the utilization of the recirculated biogas and/or heating ensures a homogeneous pH mix and prevents pH stratification within the vessel. A heating device 672 within the methanic chamber 640 maintains the temperature of the liquid waste within a range of about 1 to about 2 degrees of the set point temperature. The set point temperature for a mesophilic temperature digester will be about 100° F. and about 134° F. for a thermophilic digester. The heating device 672 can be utilized for heating or cooling as determined by the influent liquid temperature. The liquid waste within the methanic chamber 640 is continuously mixed with recycled biogas jetted into the liquid waste in a direction perpendicular to the waste flow direction. Mixing prevents stratification within the methanic chamber and enhances biodegradation.
As the waste stream plug flows through the methanic chamber 640, it is allowed to biodegrade in multiple sections as it travels in a horizontal corkscrew-like pathway through the first leg 646 and the second leg 648 of the methanic chamber 640. In one embodiment, the waste stream is not mixed with the newer incoming waste material. As the methanogenic bacteria function, they consume the acids created in the acid forming chamber 630 and effectively raise the pH of the liquid waste stream and increase the alkalinity of the liquid waste. At the end of the methanic chamber 640, with properly engineered hydraulic retention times based on influent characteristics, the acid forming bacteria will have long completed their function and the methanogenic bacteria will have consumed the bacteria-produced acids. This results in a waste effluent of high pH and alkalinity in comparison to the liquid waste exiting the acid forming chamber 630. The greatest alkalinity and bacteria population at the very end of the waste treatment system 610 will be in the bacteria “sludge” that is allowed to settle in the sludge pit 660 located at the end of the waste treatment system 610. The sludge pit 660 may not have mixing and thus the sludge is allowed to settle to the bottom. This sludge, with its higher alkalinity, pH, and bacteria population, is the recirculated sludge utilized at the various points (stations B, C and D) throughout the waste treatment system 610 for pH control and bacterial seeding.
The waste treatment system 610 will treat alkaline liquid wastes with a solids percentage varying between about 5 and about 40%. It does this by monitoring and closely controlling the pH in the liquid waste and by utilizing the naturally generated alkalinity and pH rise associated with the two-step anaerobic biodegradation process of acid forming bacteria followed by methanogenic bacteria and their resultant biological waste products. Use of a mixed plug flow is preferred. Additionally, the plug-flow separation of the processed wastes over the designed hydraulic retention time enables the natural increase in pH and alkalinity, thus allowing for the production of the returned sludge. Mixing of the plug flow prevents stratification in the acid forming chamber 630 and methanic chamber 640. Eliminating stratification in the acid forming chamber 630 and methanic chamber 640 prevents buildup of acid forming bacteria colonies and the resultant high acidic liquid (low pH) “dead” spots, facilitates better methanogenic bacteria growth to achieve better and faster acid neutralization and alkalinity production, and provides for more uniform hydraulic retention time in the waste treatment system 610 by preventing “short circuiting” of the liquid path flow.
The biodegraded effluent may be further treated or disposed of by the generating facility as required. Biogas generated by the anaerobic biological process may be collected in the gas collection space above the liquid level and under the ceiling of the methanic chamber 640. The biogas may be utilized as a “BTU replacement” in the production of electricity or natural gas.
It will be appreciated that, while the embodiments of
Although the above embodiment was described in the context of treating alkaline liquid wastes, it should be understood by those skilled in the art the same embodiment may also be used to treat high-strength organic liquid wastes having an influent pH of about 7.
Thus, the invention provides, among other things, a system and method for treating high-strength organic liquid wastes. Various features and advantages of the invention are set forth in the following claims.
This application is a non-provisional patent application of and claims priority to U.S. Provisional Patent Application No. 63/280,888 filed Nov. 18, 2021, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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63280888 | Nov 2021 | US |