Abstract:
A device, system, and method to produce alcohol and Bio fuels from bulky organic matter with a Sea based Fermentor with low cost per unit volume, formed from a plastic separator barrier which is flexible plastic film, a solar based distillation still with vacuum assist are disclosed. In one embodiment, a device includes a Fermentor coupled to a inlet channel made of plastic film separator, converted to Continuous process Fermentation channel, a Bio Gas digester to generate methane, a floating platform having engine, pumps, centrifuge and sterilization unit and a crane, a water treatment unit formed from plastic film is provided

Description:
CLAIMS OF PRIORITY 
       [0001]    This patent application claims priority from the Provisional Patent Application No. 2070/CHE/2010 filed on 20 Jul. 2010. 
       FIELD OF TECHNOLOGY 
       [0002]    This disclosure relates generally to technical fields of Alcohol and Bio Fuel production, and in one embodiment to a device to produce Alcohol used as a fuel with the devise comprising of a plastic separator barrier based flexible Fermentor in the sea, with floating Solar energy based Distillation still with vacuum assist, solid state fermentor as pre treatment to breakdown cellulose and lignin, a floating platform to carry out sterilization, product separation and storage and media removal for transfer from solid state fermentor to main Fermentor, open and closed type flexible film based channels with Isolator connector to transfer media, fresh water and spent matter back as fertilizer. 
       BACKGROUND OF INVENTION 
       [0003]    It is essential that the Alcohol and other organic Bio fuel like butenol production process consume less energy for production than the caloric value of the fuel produced and cost of production kept below the cost of fossil fuels for sustainable commercial production and use. This is possible only by having a low cost per unit volume of fermentor, which can be realized on the sea where the sea acts as a virtual chamber with plastic barrier film forming the separation between the organic Media and sea water. Solar energy based distillation with vacuum assist from wave energy reduces carbon footprint of production. Burning of cellulosic and lignin waste cuts the phosphorus and other nutrient cycle as the world food production will be limited by the availability of Phosphorus by mining which is a finite resource. so it is important to extract the fuel value of organic wastes and return the nutrients like phosphorus back to the biosphere as fertilizer. 
         [0000]    The advantage of the present invention lies in the Flexible structures made of plastic with Leak detection system and multiplayer protective layers to prevent leakage thereby enabling large volume of fermentor chamber at low cost per unit volume.
 
Organic waste mainly containing cellulose and Lignin, Cellulosic and Ligin material being bulky need large volume at low costs for the slow fermentation process to yield fuels without consuming large amount of energy to produce the same. The present invention addresses this problem.
 
The main advantage of the invention is the very large volume of Fermentor at a low cost. The present invention addresses both the above requirement enabling bio fuel production from organic waste, together with the use of recycled plastics for structural strength. This devise, system and method is a True and Real Green technology needed to address the Global warming problem.
 
       SUMMARY 
       [0004]    A device, system, and method to a device to produce Alcohol, Bio fuel and other Organic chemicals from cellulosic, ligin and organic matter using a plastic separator barrier based flexible Fermentor chamber in the sea. In one aspect, a device includes a Fermentor coupled to a inlet channel made of plastic film separator based channels to convey fresh water and media, the Fermentor is held by multi-chambered floats forming the upper periphery with a rigid frame covered with plastic film, a protection jacket being multi-chambered made from plastic film encloses the Fermentor to enable detection of leakage for taking up repair, an occurrence of leakage is detected through electrodes as sensors. A layer of netting is provided for protection from fish and other aquatic animals 
         [0005]    In another aspect, the Media and fresh water are conveyed by channel made of plastic component may be an open type channel, and a closed type channel and the open type channel may be formed of flexible plastic film reinforced by fiber threads and polymeric fabric coated with plastic and of rubber sheet reinforced with fiber thread and metal cable for strength, held by multi-chambered floats with Isolator Connector being rigid having directional valve, and points for fixing plastic ropes for anchorage, and stabilization, and floats with detachable weights for wave management which may be reattached later and till that time held by separate floats. The plastic flexible film based channel is surrounded by leakage detection chambers with sensors, and the Closed type channels is formed of flexible plastic film reinforced with fiber threads, with Isolator Connector being rigid having directional valve, and points for fixing plastic ropes for anchorage, and stabilization, and floats with detachable weights for wave management which may be reattached later and till that time held by separate floats, and the plastic flexible film surrounded by leakage detection chambers with sensors. The open type, and closed type channel to have ‘U’ shaped connecting chamber made of rigid material with swivel joints, to allow the ships to cross the channel. The Closed channel is converted into a Fermentation chamber for Continuous process of fermentation by including a stirring mechanism powered by one of fluid pressure pneumatic and of sealed electric motor, a heat exchanger, a camera monitoring and sensors for process parameters pH, temperature, and other parameters required with provision for taking samples for testing. 
         [0006]    The Fermentor may be held by multi-chambered plastic floats embedded with plastic ropes to provide hold for strong anchorage, and stabilization, and the Fermentor to rest on sea bed where it is shallow. The Fermentor may be made of plastic flexible film with reinforcing fiber thread and polymeric fabric coated with plastic. The plastic film is made of two layers including a strong thick outer layer made of recycled plastic, and an inner thin layer made of much thinner newly synthesized plastic to give better sealing. 
         [0007]    In yet another aspect, stainless steel electrodes may be used in the multi-chambered wall which are connected by at least metallic wire embedded in plastic film and of conductive plastic to detect salt water leakage which leads to increased electrical conductivity detected by electronic system and thereby enable repair at the needed place. 
         [0008]    The suction channel may be provided to the Fermentor to remove remaining spent media which is treated in a Bio gas Digestor coupled through a inlet channel made of plastic film separator to Fermentor, the spent media containing fresh water is allowed to decompose releasing methane, the digester chamber is held by multi-chambered floats forming the upper periphery, a protection jacket being multi-chambered made from plastic film encloses the storage chamber to enable detection of leakage for taking up repair, an occurrence of leakage is detected through electrodes as sensors, a plastic sheet is used to cover the storage chamber to collect methane gas, the plastic sheets slides over the floats, weights are attached to the plastic sheet to hold in tight position, and to apply pressure to allow the flow of methane gas, the methane gas is burnt after scrubbing, on the floating Platform in a engine to which is coupled a electric generator to generate power and operate pumps, and vacuum pump, a suction channel coupled to the Bio Gas digestion chamber is provided to remove digested organic matter which is pumped out and sent to coast for use as fertilizer, the channel runs parallel to supply channels. The remaining fresh water may be pumped into storage system formed of flexible plastic film reinforced by fiber thread, held by floats for water treatment sedimentation and filtration and with chemical treatment with at least chlorine, and used for the process with excess pumped to coast. The fresh water is treated in the sea by this device allowing fresh water treatment in the sea and the sent back to land for use. 
         [0009]    In yet another aspect, the alcohol generated by fermentation is pumped from the Fementor to a solar powered distillation unit comprising a heater one of glass tube having heat exchanger surrounded by vacuum enclosed in a floating plastic container with glass sheet cover on top to trap solar radiation and prevent heat from escaping and one of heat exchanger enclosed in a floating plastic container with glass sheet cover on top to trap solar radiation and prevent heat from escaping, with vapour of alcohol condensing in the floating retort having balancer floats and condenser which is cooled using cold water circulated by pump support in a closed circuit so that minimum pumping energy is used. The evaporation is assisted by vacuum derived from pumps operating on tidal and sea waves and from vacuum pump on platform. The solar powered distillation unit is used to generate fresh water and hot water for generating steam for sterilization. 
         [0010]    In yet another aspect, a floating platform having engine and pumps, a sterilization unit with steam generated using hot water from solar distillation unit with supplementary heating using one of bio gas from bio gas generator and a tank for chemical sterilization and UV radiation source, a storage tank for products and media, a centrifuge to separate products from the media, a crane to lift solid state fermentor to remove pretreated media, disintegrate for sending it to Fermentor for breakdown to alcohol, a Microprocessor based control system connected to sensor and camera signal outputs from Fermentor and distillation unit for interpretation of the process and provide signal for actuation of motors and valves by means of dedicated software, and provide a resting place for workers. 
         [0011]    A solid state fermentor made of flexible plastic film held by rigid End connectors made of plastic material, with inlet and outlet channels to connect to supply channels to add media which is sterilized by chemicals and heat, a matrix of plastic helps to disintegrate the pretreated media, a pipe with holes to force fresh water to enable disintegration of the fungus grown media. The solid state fermentor is used to produce edible mushrooms on the platform as a by product of the devise. 
         [0012]    The device, systems, and methods disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form of a machine-readable medium embodying a set of instructions that, when executed by a machine, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from the accompanying drawings and from the detailed description that follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which: 
           [0014]      FIG. 1  is a system view of entire devise illustrating processing of media in Main fermentor conveyed through separator barrier channel, pretreatment in solid state fermentor, platform for sterilization and transfer of pretreated media from solid state fermentor and storage and control, Solar energy base distillation still with vacuum assist, bio gas digestor according to one embodiment. 
           [0015]      FIG. 2  is a cross section view of the Main Fermentor (chamber) and its components, according to one embodiment. 
           [0016]      FIG. 3  is a cross sectional view of Continuous Fermentation process Channel, according to one embodiment. 
           [0017]      FIG. 4  is a cross section view of the open channel, according to one embodiment. 
           [0018]      FIG. 5  is a top view of the open channel, according to one embodiment 
           [0019]      FIG. 6  is a cross section view of the closed channel, according to one embodiment. 
           [0020]      FIG. 7  is a side view of the closed channel, according to one embodiment 
           [0021]      FIG. 8  is a side view of the open channel, according to one embodiment. 
           [0022]      FIG. 9  is a side view of the closed channel, according to one embodiment. 
           [0023]      FIG. 10  is a cross section view of a towing boat, according to one embodiment. 
           [0024]      FIG. 11  is a system view of bellow chamber with isolator to cross ships, according to one embodiment. 
           [0025]      FIG. 12  is a system view of a ‘U’ shaped connectivity chamber, according to one embodiment. 
       
    
    
       [0026]    Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows. 
       DETAILED DESCRIPTION 
       [0027]    A device, system and method to produce Alcohol, Bio fuels and other organic compounds in a sea based fermentor. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. 
         [0028]      FIG. 1  is a system view of the entire devise with floating units on the sea illustrating pretreatment in solid state fermentor, fermentation in main fermentor, distillation in the solar based still and processing of spent waste in Bio gas digestor to produce methane, Platform to carry out sterilization, storage and control according to one embodiment. Particularly,  FIG. 1  illustrates a media and fresh water conveyed by channel  101  from coast with Isolater connector with attached damper  102 , a solid state fermentor  103  with attachable and detachable weight  104 , tube with holes to apply water at force to disintegrate pretreated media with the help of one of fungus  105 , main fermentor  106  with stirrer  107 , heat exchanger  108 , the fermentor having a framework on top  110 , a channel (pipe or tube)  111  to transfer spent media to the Bio gas Digestor  113 , channel (tube)  120  to transfer fermented media to solar based distillation unit to recover alcohol, the solar heater  121  with glass tubes held by frame, the evaporated alcohol vapour passed to the distillation resort  122  having balancer floats  123  and condensor  124  which has cooling from cold water drawn from deep sea by pump  131  through pipe (channel)  132 , the distillation process is assisted by vacuum through vacuum line  125  which derives vacuum from one by pumps operated by tidal waves on cylinder  127  connected to float  129 , having piston  127  connected to weight  126  which is anchoured to sea floor, the devise being connected to a damper  128 , according to one embodiment. 
         [0029]    The Media and Fresh water channel  100  (e.g., the open type channel, and the closed type channel) may be used to convey the Media and fresh water to Fermentor chamber. The Media  102  may be cellulosic and Lignin waste, heat treated corn, cellosic waste treated by heat and enzymes on the coast based heater, other organic matter. The multi-chambered wall  104  made by plastic film coupled to the storage chamber to enable detection of salt water leakage for repair. chamber to remove remaining undigested organic matter. A floating platform  130  having pump  131  to pump cold water from deep sea by pipe  132 , having engine  135 , supplied by methane gas by pipe  136  connected to the biogas units gas pipe  116 , a sterilization unit with steam source  133  and centrifuge  134  for separating products from fermentation, and crane  137  to help in lifting solid state fermentor for transferring pretreated media to fermentor, 
         [0030]    In example embodiment,  FIG. 2  illustrates the Fermentor  203 , with inner removable layer which is sterilized  206 , the fermentor being held by floats  202 , the top of the fermentor having a rigid frame with flexible hinged joints and covered by plastic film providing attachment to inlet pipes, pulley of cables to stirrer  207 . A aerator pipe  208  is provided, the media with fresh water is feed to the fermentor by channel  212 , a camera  210  for monitoring flow and turbidity  210 , a suction pipe  217  to transfer spent waste to Bio gas digestor, attachable and detachable weights  204 , a vacuum assist to the fermentation process by removing excess alcohol  215  is provided. the whole fermentor is surrounded by a multi chamber jacket  203  with electrodes to detect leakage. The fermentor is also surrounded by a Netting  214  for protection from fish and aquatic animals. 
         [0031]      FIG. 3  is a system view of a Continuous flow Fermentor according to one embodiment. Particularly  FIG. 3  illustrates multi chamber outer protective layer  301  the Isolator connector  307  which has fixed to it heat exchanger  306 , and provided with valve to a opening, a stirrer  302  operated by one of pneumatic motor and one of sealed electric motor and moved by cables wound around pulley  309 , provided with an aerator  308  and tow line  310 . 
         [0032]      FIG. 4  is a cross section view of the open channel, according to one embodiment. Particularly,  FIG. 4  illustrates a leak protection chamber  401 , media and fresh water  402 , a float  406 , electrodes  404 , and a netting  405 , according to one embodiment. 
         [0033]    The leak protection chamber  401  may be used to detecting the leakages of fresh water in the channel (e.g., may be open type, and closed type channel). The media and fresh water  402  may be transferred from the coast. The float  403  (e.g., flexible, and made of plastic film component) may be connected at the end of the flexible film which may be used to float the channels on the surface of the sea. The electrodes  404  attached in the channel is used to sense the salt water leakage in the channel. The netting  405  may be spread over to protect the channel from the fish, and sharks. 
         [0034]    In example embodiment, the fermentor that may be connected to channel. The open channel may be held by the float  403  at both the ends of the channel. The netting  405  is used to protect the channel. 
         [0035]      FIG. 5  is a top view of the open channel, according to one embodiment. Particularly,  FIG. 5  illustrates the float  403 , the media fresh water  402 , a tow line  406 , and a isolator  407 , according to one embodiment. 
         [0036]    The towing line  406  made of plastic may be used tow the channels, based on error signal to generated through the microprocessor from triangulation signal transmitted by three antennas on the coast for correct designated position of the floating channel. The isolator connector  407  (e.g., may be made of rigid plastic frame with latch) with a drop down valve may be used to connect a channel section with a lift up floats with detachable weights. The isolator connector  407  may also be used to detach, and attached back the floating channel during severe storm, to pass wave energy, to prevent damage to the device, and accidental collusion with ships. 
         [0037]    In example embodiment, the top of the isolator connector  407  may be attached with a tow line  406 . 
         [0038]      FIG. 6  is a cross section view of the closed channel, according to one embodiment. Particularly,  FIG. 6  illustrates the leak detection chamber  401 , media and fresh water  402 , and the electrodes  404 , according to one embodiment. 
         [0039]      FIG. 6  illustrates another type channel called the closed type channel to collect and transfer the media containing the fresh water  404  along with the electrodes  408  and the leak detection chamber  401  which may be used to detect the salt water leakage in the channel. The functionality of the open type channel and the closed type channel is similar. 
         [0040]      FIG. 7  is a side view of the closed channel, according to one embodiment. Particularly,  FIG. 7  illustrates the media with fresh water  402 , a drop down valve  408 , and the latching connector to drop down valve, according to one embodiment. 
         [0041]    The drop down valve  408  (e.g., the drop down valve, the butterfly valve, and the flap valve) may be connected to the isolator connector may be directional to take advantage of wave to enable forward flow, and to prevent back flow of the fresh water. There may be drop down valve used during detaching, and for the reattachment of the channel. 
         [0042]      FIG. 7  illustrates the drop down valve  408  with latching connector of the isolator of the closed channel. 
         [0043]      FIG. 8  is a side view of the open channel, according to one embodiment. Particularly,  FIG. 8  illustrates the isolator connector  407 , media and the fresh water  402 , the float  403 , the tow line  406 , the drop down valve  408 , a signal board with blinking LED  412 , a damper film structure  410 , an anchorage to sea floor  409 , and a detachable weight  411 , according to one embodiment. 
         [0044]    The signal board with blinking LED  412  is carried on the isolator connector to warm ships, and fishing boat from approaching the channel. The damper film structure  410  may be suspended in deeper part of sea, is attached to the Isolator Connector  407 . The anchorage to sea floor  409  may be taken wherever necessary by anchor hooks connected to the plastic ropes for stabilization of the floating channel. The detachable weight  411  may be provided to the isolator connector  407  of the floating channel for use during severe storm. 
         [0045]      FIG. 8  illustrates a side view of the open channel having isolator connector  407  connected upwardly to the signal board with blinking LED  412 , the drop down valve  408 . The anchorage to sea floor  409  and the damper film structure  410  are also provided to the isolator connector  407  for stabilization of the device. 
         [0046]      FIG. 9  is a side view of the closed channel, according to one embodiment. Particularly,  FIG. 9  illustrates the media and fresh water  402 , the tow line  406 , the drop down valve  408 . the signal board with blinking LED  412 , and electrodes for shark repulsion  413 , according to one embodiment. 
         [0047]    The electrodes  413  (e.g., may be stainless steel) attached to the isolator connector  407  downwardly may be used to repel sharks from the device. 
         [0048]      FIG. 10  is a cross section view of a towing boat, according to one embodiment. Particularly,  FIG. 10  illustrates the tow line  406 , an antenna  505 A-C, an antenna  504 , and a microprocessor  501 , according to one embodiment. 
         [0049]    The antenna  505 A-C may be mounted on the coast to transmit triangulation signal for the corrected designated position of the floating channel. The antenna  504  is mounted in the towing boat to receive signals from coast based transmitter and enable keep the channel in correct position when drifted by waves. The microprocessor  501  may be used to generate error signal that may be used by the towing boat with plastic tow line to place the floating channel in correct designated position when drifted by waves. Motor driven spools having plastic cables enable to provide force for keeping the channels in designated position. 
         [0050]      FIG. 10  illustrates the towing boat with plastic tow line along with the antenna  504  and the microprocessors  501  using the error signal generated through the microprocessor  501  from the triangulation signal transmitted by the three antennas on the coast, and by GPS signal tow the channel into correct designated position when drifted by waves. 
         [0051]      FIG. 11  is a system view of bellow chamber with isolator to cross ships, according to one embodiment. Particularly,  FIG. 11  illustrates a bellow chamber  506 . The bellow chamber  506  may be pulled in by a pair of cables that may be driven by motor to allow large ships. The open type, and the closed type channels may have bellow chambers  506 . 
         [0052]      FIG. 12  is a system view of a ‘U’ shaped connectivity chamber, according to one embodiment. Particularly,  FIG. 12  illustrates the floating channel having ‘U’ shape connecting chamber  508  (e.g., made of rigid material with swivel joints) may be used to allow the ships to cross the channel without damaging the device. The ‘U’ shaped connecting chamber  508  may be in horizontal position which may dip down to vertical position using the ships force allowing ships to cross and return to horizontal position after the crossing of ships. 
         [0053]    Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. 
         [0054]    In addition, it will be appreciated that the various operations, processes, and methods disclosed herein may be embodied in a machine-readable medium and/or a machine accessible medium compatible with a data processing system (e.g., a computer system), and may be performed in any order (e.g., including using means for achieving the various operations). Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.