Multi-stage infectious waste treatment system

Abstract: A multi-stage treatment system for infectious waste includes a shredding stage, a granulating stage, a wetting stage, a disinfecting stage, and a dewatering stage which define a continuous treatment flowpath for the infectious waste. A plurality of blades fragment the waste in the shredding and granulating stages while simultaneously mixing the waste with disinfectant chemicals. A plurality of jets wet the waste mixture in the wetting stage with a heated aqueous liquid to form a disinfectant solution which disinfects the waste in the disinfecting stage. A flow restriction removes the aqueous liquid from the disinfected waste in the dewatering stage and renders the product suitable for landfilling.

Description: FIELD OF THE INVENTION The present invention relates generally to treatment of infectious waste. More particularly, the present invention relates to a system which mechanically fragments and decontaminates infectious waste. The present invention is particularly, though not exclusively, a system for mechanically fragmenting infectious waste with a series of blades while simultaneously treating the waste with a disinfectant that is formulated within the system. BACKGROUND OF THE INVENTION The disposal of infectious waste from hospitals and other medical establishments is a major problem. Indeed, the importance of proper and effective infectious waste disposal has become of greater concern in recent years, due to an increased awareness of health problems such as the AIDS epidemic. In part because of the AIDS epidemic, definitions of what constitutes "infectious waste" are being broadened. Consequently, the volume of infectious waste which must be disposed of is increasing. Accordingly, the need for a system or apparatus which will accomplish the safe, efficacious, and cost effective treatment of significant volumes of infectious waste for disposal is growing. One method for decontaminating infectious waste involves incineration, wherein the waste is burned and the decontaminated ashes are properly disposed. An alternative treatment method is to disinfect the waste in a steam autoclave or ethylene oxide autoclave prior to waste disposal. While effective for their intended purposes, both incinerators and autoclaves present ancillary problems. Incinerators, for example, are difficult and costly to construct and are relatively expensive to maintain in an environmentally safe manner. Autoclaves too, present additional problems, such as odor, cost and operational complexity. Additionally, waste which has been disinfected by autoclaving typically requires further treatment procedures, such as incineration, prior to final disposition of the waste in such places as landfills. With the above discussion in mind, alternative infectious waste treatment systems have been proposed to disinfect the waste in preparation for disposal. According to these proposals, a solid infectious waste is contacted with a disinfectant solution containing a chlorine compound to decontaminate the waste. The decontaminated waste may then be disposed in ordinary landfills. Unfortunately, decontamination of waste using chlorine compounds presents certain technical complications. First, liquid disinfectant loses its disinfectant potency during prolonged storage. Thus, there is a need to use liquid disinfectant that is relatively "fresh" in order to achieve an acceptable degree of waste decontamination. Second, it is relatively difficult to ensure that an appropriate concentration of the disinfectant has been contacted with the waste during the treatment process. It is also important, however, to avoid applying too high a concentration of chlorine compound to the waste, in order to avoid undesirable results, such as corrosive effects and the release of toxic gasses. The present invention recognizes that precise amounts of dry disinfectant precursors can be stored for relatively lengthy time periods without losing their potency and can be mixed with water to form a chlorinated disinfectant solution when needed. The resulting solution can be used to decontaminate infectious waste in a system that mechanically shreds the waste. US 4 884 756 discloses apparatus for treating waste having the features of the precharacterizing portion of claim 1 Accordingly, it is an object of the present invention to provide a system for waste treatment in which precise amounts of a chlorine-based disinfectant are blended with infectious waste to decontaminate the waste. Another object of the present invention is to provide a system for waste treatment which results in particle size reduction, and correspondingly bulk volume of the infectious waste while it is being disinfected. Finally, it is an object of the present invention to provide a system for waste treatment which is relatively easy and comparatively cost-effective to implement. SUMMARY OF THE INVENTION The invention provides a multi-stage system for treating an infectious waste along a continuous flowpath comprising: an inlet stage having an opening sized to receive an infectious waste into the flowpath of said system; a shredding stage for reducing the particle size of the waste to a small particle size; a disinfecting stage comprising a reactor chamber positioned to receive the wetted granular waste and sized to retain the waste for a selected residence time; an auger to transport the waste to a waste discharge port; and a dewatering stage; characterized in that the shredding stage comprises a plurality of opposingly rotatable blades in the flowpath of the waste; and further comprising a wetting stage comprising a liquid jet positioned at the flowpath to inject a liquid medium into the waste and to simultaneously wet and mix a disinfectant in the waste material; a granulating stage provided beneath the wetting stage for further reducing the particle size of the waste to a smaller granular particle size, said granulating stage having at least one stationary blade and at least one rotatable blade rotatably positionable against said stationary blade to form a cutting surface; and wherein the dewatering stage comprises a flow restriction in the waste flowpath, said dewatering stage being in fluid communication with said wetting stage to recycle water from said dewatering stage to said wetting stage. A preferred embodiment of the present invention provides a system for treating infectious waste comprising a series of continuous treatment stages. The multi-stage treatment system has an inlet stage as its front end which comprises an opening for receiving the infectious waste and desired treatment chemicals. The waste may be fed in any form through the opening, but in a preferred embodiment, the opening is sized to receive a sealed compartmentalized plastic bag in which the waste and treatment chemicals are stored. The bags are fed through the opening into the system in their entirety. In this manner, waste handlers operating the present system need never come in direct contact with the infectious waste or treatment chemicals. The preferred waste bag has a primary compartment containing the infectious waste, and has one or more secondary prefilled and sealed compartments containing the disinfectant chemicals or other process additives in isolation from the waste all of which are to be introduced into the system. As will be seen below, the entire contents of the bag are released from the bag and commingled during operation of the treatment system. The inlet opening accesses a fragmenting chamber positioned therebelow which encloses the shredding, wetting and granulating stages of the system. The waste drops under the force of gravity from the inlet stage down into the shredding stage which comprises a plurality of opposingly rotating blades. The shredding blades destroy the waste bag, spilling its contents into the fragmenting chamber. Any disinfectant chemicals or process additives contained in the bag become mixed with the waste in the shredding stage. The blades also function to break up the large frangible waste into small size particles. The wetting stage is performed in conjunction with the shredding stage to wet the mixture of small particle size waste and disinfectant chemicals or additives as they fall through the shredding blades. The wetting stage comprises a plurality of jets positioned at the interior walls of the fragmenting chamber adjacent the shredding blades. The jets are directed radially into the chamber and are capable of producing a controlled spray of a liquid medium into the waste mixture. The liquid medium is preferably an aqueous liquid, such as fresh tap water and/or recycled process water, which has been preheated to an elevated temperature and which uniformly contacts the falling waste mixture to form a hot mash. The granulating stage is provided beneath the wetting stage and comprises a plurality of travelling blades axially mounted on a shaft and rotatable against a pair of stationary blades mounted on the walls of the fragmenting chamber to form cutting surfaces. The traveling blades rotate in a radial plane which is substantially parallel to the flow of the mash. At the cutting surfaces, the granulating blades break up the already small particle size waste into yet smaller particle sizes and cut any fibrous material which has not been previously fragmented by the shredding blades. The blades also more fully mix the components of the waste mash, thereby dissolving at least a portion of the disinfectant chemicals in the liquid medium to form a disinfectant solution. The granulating stage product preferably is fully wetted by the disinfectant solution and in gross has a smaller granular particle size than the product of the shredding stage. The outlet conduit from the fragmenting chamber houses the screening stage which comprises a screen functioning in cooperation with the granulating stage. The screen is sized to allow the smaller granular particle size waste to fall through the screen into a disinfectant reactor chamber below while retaining any waste which has not been sufficiently fragmented in the granulating stage. Waste which is retained by the screen is scooped up by the traveling blades rotating against the screen and returned to the cutting surfaces for additional particle size reduction until the waste is sufficiently small to pass through the screen. It is noteworthy that up to this point substantially all of the work to convey the waste through the above-recited stages is performed by gravity. The screening stage is followed by the disinfecting stage. The disinfecting stage comprises a disinfectant reactor chamber preferably integral with an auger. The auger has two ends; a liquid medium collection tank and inlet port are at one end of the auger and a disinfected solid waste discharge port is at the other end. The auger is inclined upwardly toward the disinfected solid waste discharge port and accordingly the auger conveys the waste upwardly from the inlet port to the discharge port The length of the auger wherein the disinfection reaction occurs constitutes the disinfectant reactor chamber. The disinfection reaction is preferably completed by the time the waste reaches a point about two-thirds up the auger incline. The controlled rate at which the auger screw carries the waste up the incline to the discharge port enables a sufficient residence time for disinfection of the waste. The final stage is the dewatering stage. The dewatering stage comprises a flow restriction in the flowpath of the waste. Although some of the liquid medium is removed from the waste by gravity at the lower end of the auger, the bulk of the liquid medium is removed from the waste by compressing the mash through the flow restriction which is preferably positioned adjacent the waste discharge port. The liquid medium driven from the mash at the flow restriction exits the auger through perforations in the housing and is passed to the heated collection tank for recycling to the wetting stage. In operation, process control for the present system is provided by regulating the disinfectant concentration in the system as a function of the liquid medium temperature. Temperature is in turn a function of liquid medium flow, and heater and auger operating parameters. It is apparent that the above-described system satisfies the present objective of providing an infectious waste treatment apparatus which contacts precise amounts of a disinfectant with an infectious waste to disinfect the waste while simultaneously fragmenting the waste to reduce its bulk volume. It is further apparent that the system provides an infectious waste disposal apparatus which is relatively easy and comparatively cost-effective to implement and operate. The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which: BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective of the multi-stage waste treatment system of the present invention; Figure 2 is a cross-section of the multi-stage waste treatment system of the present invention along line 2-2; Figure 3 is a cross-section of the multi-stage waste treatment system of the present invention along line 3-3; Figure 4 is a cross-section of another embodiment of the waste outlet flow restriction; and Figure 5 is a schematic of a control unit for the multi-stage waste treatment system of the present invention. Figure 6 is a generalized curve for the functional relation between disinfectant solution temperature and disinfectant concentration. DESCRIPTION OF PREFERRED EMBODIMENTS Referring initially to Figure 1, the infectious waste treatment system of the present invention is generally designated 10 . System 10 comprises a plurality of treatment stages including an inlet stage 12 , a shredding stage 14 , a wetting stage 16 , a granulating stage 18 , a screening stage 20 , a disinfecting stage 22 , and a dewatering stage 24 which define a continuous flowpath for the waste. The terms "disinfect" and "decontaminate" are used synonymously herein and refer to the destruction of a substantial portion of infectious constituents within the infectious waste sufficient to render the waste substantially noninfectious. Inlet stage 12 comprises an opening 28 at or near the top of a fragmenting chamber 30 which houses stages 14 , 16 , and 18 . Inlet stage 12 opens down into shredding stage 14 at the upper level of fragmenting chamber 30. As shown in Figure 2, shredding stage 14 comprises multiple pairs of rotating blades 31a,b, 32a,b, 33a,b . Blades 31a , 32a , 33a , are mounted on shaft 34 and blades 31b , 32b , 33b are mounted on shaft 35 such that blade 31b is rotatably fitted between blades 31a , 32a and so on for all the blades as shown. Each blade 31 , 32 , 33 is a disk 34 having a plurality of hook-shaped teeth 40 about the periphery 41 of disk 39 . Stationary scrapers 39a , 39b are fixed to chamber walls 40 opposite blades 31a , 32a , 33a and 31b , 32b , 33b respectively to channel waste into the blades and to prevent waste from accumulating in shredding stage 14 . Shafts 34 , 35 are positioned opposite one another and rotate in a vertical plane which is substantially parallel to the vertical flowpath of the waste. Shredding action is provided by rotating shaft 39 in the opposite direction from shaft 40 . Referring to Figure 3, a wetting stage 16 is provided simultaneous with shredding stage 14 . Wetting stage 16 comprises a plurality of liquid jets 42a,b,c,d which are mounted in the wall 40 of chamber 30 around the radial periphery of the waste flowpath and adjacent the bottom side of blades 31 , 32 , 33 . A liquid medium feed line 46 is connected to each jet 42 . Thus, as shown in Figure 1 , liquid medium feed lines 46a,b,c,d are connected to jets 42a,b,c,d respectively. Feed lines 46 are connected opposite jets 42 to a recycle pump 48 across a liquid distribution manifold 50 . Pump 48 receives liquid medium from a recycle line 54 connected to a liquid medium collection tank 56 of a recycle stage 26 . If it is desired to remove metals from the waste stream after shredding and wetting, a metal segregating stage 58 may be provided immediately after stages 14 , 16 . Metal segregating stage 58 comprises a magnet 60 which is mounted in the wall 40 of chamber 30 . Magnet 60 contacts the waste as it falls toward granulating stage 18 to segregate the metals therefrom. Access is provided in wall 40 to enable periodic removal of metals from magnet 60 . Granulating stage 18 is positioned at the lower level of fragmenting chamber 30 and comprises a plurality of travelling blades 62a,b,c,d,e and stationary blades 64a,b . Travelling blades 62 are axially mounted on a rotating shaft 66 which in turn is rotatably mounted on chamber wall 40 . Travelling blades 62 have a vertical plane of rotation which is substantially parallel to the vertical flowpath of the waste. Travelling blades 62 are rotatable against stationary blades 66a , 66b , each of which is fixably mounted on opposite sides of chamber wall 40 adjacent travelling blades 62 . As travelling blades 62 rotate, travelling blades 62 periodically pass stationary blades 64 to form transient cutting surfaces. Figure 2 shows travelling blade 62b meeting stationary blade 64b to form transient cutting surface 68 . Screening stage 20 is positioned immediately beneath and adjacent granulating stage 18 . Stage 20 comprises a screen 70 stretched cross-sectionally across conduit 72 which connects fragmenting chamber 30 and auger 74 . Auger 74 encloses stages 22 and 24 which are described hereafter. Screen 70 has a mesh size which allows particles at or below a given particle size to pass through while preventing particles having a larger particle size than the given particle size from passing through. Screen 70 preferably has a 1/4 inch mesh size although other mesh sizes are within the purview of the skilled artisan. Screen 70 is positioned to cooperate with travelling blades 62 of granulating stage 18 . As travelling blades 62 rotate, travelling blades 62 periodically pass screen 70 to scoop waste retained on screen 70 . Figure 2 shows travelling blade 62c meeting screen 70 to return waste retained by screen 70 to transient cutting surface 68 . Disinfecting stage 22 comprises a disinfectant reaction chamber 76 which is integral with auger 74 . Auger 74 is inclined upward away from auger inlet 78 to enable precise control of the waste residence time in reaction chamber 76 and to facilitate dewatering as described hereafter. The inclination angle of auger 74 is defined as .  is selected between about 10° and 30° and preferably between about 15° and 25°. Reaction chamber 76 is sufficiently sized to hold the throughput of system 10 for a residence time which enables disinfection of the waste before discharge from system 10 . Auger 74 has a screw 80 extending axially the entire length of auger 74 which is rotatably mounted therein to carry waste from auger inlet 78 to a waste solid discharge port 86 at the upper end 87 of auger 74 . Dewatering stage 24 is likewise integral with auger 74 and comprises a flow restriction at solid disinfected waste discharge port 86 . A portion of liquid medium exits auger 74 under gravity through port 82 to collection tank 56 in fluid communication with port 82 . A perforated plate 88 is provided at port 82 having a plurality of perforations 89 , each significantly smaller than the mesh size of screen 70 , and preferably about 1/8 inch, to prevent substantial quantities of waste from exiting auger 74 thereat. However, the primary function of port 82 is to enable fluid intrusion into auger 74 as will be shown. The flow restriction placed at waste discharge port 86 removes the bulk of liquid medium from the waste before it exits system 10 . In one embodiment the constriction is a nozzle 90 having a fixed narrow opening 91 at the end of waste discharge port 86 . In another embodiment, Figure 4 shows an adjustable nozzle comprising a pair of doors 92a , 92b , the lower door having a pneumatically biased hinge 93 to render the size of opening 91 pressure responsive. In any case, the restriction applies a compacting force to the disinfected waste before the waste exits the system 10 . Liquid medium driven from the disinfected waste by the compacting force exits auger 74 through perforations 94 in auger housing 96 adjacent discharge port 86 . Perforations 94 are sized smaller than the waste particle size to restrict the solid waste from the liquid stream. A sleeve 98 around housing 96 at perforations 94 channels the liquid medium into a collection tank return line 100 which is in fluid communication with tank 56 through recycle inlet port 102 . Collection tank 56 has two chambers 104 , 106 in fluid communication with one another, but separated by a weir 108 . Port 82 of auger 74 is submerged in primary chamber 104 which receives recycle inlet port 102 . Secondary chamber 106 receives the overflow of primary chamber 104 and has a recycle outlet port 110 connected to recycle line 54 . Heater elements 112 , 114 are submerged in primary and secondary chambers 104 , 106 respectively for heating the liquid medium as necessary. Fresh liquid medium may be added to system 10 via a fresh liquid medium line 116 connected to a source (not shown) such as a municipal water line. Line 116 terminates with a jet 118 entering conduit 72 . Figure 5 is a schematic for process control of system 10 which is provided by automated control unit 120 in electrical communication with auger 74 , heaters 112 , 114 , a valve 121 on fresh liquid line 116 , recycle pump 48 and door 92b . Control unit 120 accordingly regulates the speed of auger screw 80 , the heat output of heaters 112 , 114 , the fresh liquid medium feed rate of valve 121 , the liquid medium recycle rate of pump 48 and the compaction force applied by door 92b to the waste at solid waste discharge port 86 . These parameters are regulated in response to the primary input parameters to unit 120 which are the ClO 2 concentration and the temperature of the liquid medium in tank 56 . ClO 2 concentration data is provided to unit 120 by means of a conventional air stripper 122 in tank 56 and ClO 2 gas analyzer 124 . Temperature data is provided to unit 120 from a conventional thermometer 126 . It is understood that although waste treatment system 10 has been described above in a specific sequence of multiple stages, certain stages may be omitted or reordered within the scope of the present invention as is apparent to one skilled in the art. As such, the present invention is not limited to the above-recited sequence of stages. METHOD OF OPERATION With cross-reference to the drawings, operation of system 10 in a continuous mode may be seen. System 10 is particularly suited to the treatment of infectious wastes generated by hospitals and other medical facilities. Such wastes are primarily solid wastes consisting of plastic, paper, fabric, glass, and metal and embody a broad range of medical items including syringes, bottles, tubes, dressings, and the like. "Waste treatment" as the term is used herein constitutes fragmenting of the waste to a relatively small granular particle size and disinfecting the waste to render it substantially innocuous and suitable for ordinary landfilling. The infectious waste is fed through inlet opening 28 into system 10 in any form. In a preferred embodiment, however, the waste is stored in a sealed compartmentalized plastic bag 128 which is then fed through opening 28 into system 10 in its entirety. Waste bag 128 has a primary compartment 130 containing the infectious waste, and also has other prefilled and sealed compartments 132 , 134 containing disinfectant chemicals or other process additives which are introduced into system 10 via inlet opening 28 . Preferred disinfectant chemicals are dry particulate disinfectant precursors, sodium chlorite and citric acid, which are maintained in isolation in bag 128 , but react in solution as will be shown, to form a disinfectant, i.e., chlorine dioxide. Additives may include dyes, defoamers, or surfactants. The waste is inserted through inlet opening 28 into the top of fragmenting chamber 30 by an operator. The waste drops under the force of gravity from opening 28 down into opposingly rotating blades 31 , 32 , 33 of shredding stage 14 . Blades 31 , 32 , 33 destroy waste bag 128 , spilling the waste, disinfectant chemicals, and additives into chamber 30 where they are commingled to form a waste mixture. Blades 31 , 32 , 33 also break up the frangible waste to a small particle size. Wetting stage 16 operates simultaneously with stage 14 , whereby jets 42 wet the waste mixture with a stream of a liquid medium. The liquid medium is pumped to jets 42 from recycle line 54 connected to liquid medium collection tank 56 . With efficient operation of dewatering stage 24 , the bulk of liquid medium in system 10 is recycled. The liquid medium is preferably an aqueous liquid, such as fresh tap water and/or recycled process water. The liquid medium may be within a temperature range between about 0°C and 100°C and preferably between about 5°C and 70°C. The liquid medium has more preferably been preheated above ambient temperature to an elevated temperature of at least about 40°C and most preferably at least about 50°C. The liquid medium uniformly contacts the falling waste mixture to form a wet mash. The mash falls through metal segregating stage 58 where metals are removed and continues falling down into granulating stage 18 where travelling blades 62 and stationary blades 64 break up the already small particle size frangible waste into yet a smaller granular particle size which is preferably slightly less than 1/4 inch. Blades 62 , 64 also fragment any fibrous material which has not been previously fragmented by shredding blades 31 , 32 , 33 to about the same smaller granular particle size as the frangible material. Blades 62 , 64 also more fully mix the mash, thereby dissolving at least a portion of the disinfectant chemicals in the liquid medium to form the chlorine dioxide-containing disinfectant solution. Thus, the solids in the resulting mash of granulating stage 18 are preferably fully wetted by the disinfectant solution and the bulk of the solids preferably have a smaller granular particle size which is slightly less than about 1/4 inch. The liquids content of the mash is typically on the order of about 60% by weight. Upon exiting granulating stage 18 , the mash drops onto screen 70 which functions in cooperation with the granulating stage 18 to allow the smaller granular particle size waste to fall through it into disinfectant reactor chamber 76 while retaining any waste in granulating stage 18 which has not been sufficiently fragmented. Waste which is retained by screen 70 is scooped up by traveling blades 62 , rotating against screen 70 , and returned to cutting surface 68 for additional particle size reduction until it is sufficiently small to pass through screen 70 . Inlet port 78 receives the waste mash from screening stage 20 and directs the mash to reactor chamber 76 integral with auger 74 . The disinfectant solution collected in primary chamber 104 contacts the mash initially at lower end 84 of auger 74 . Auger screw 80 turns continuously to withdraw the mash from lower end 84 at angle  up the auger incline to solid waste discharge port 86 at a controlled rate which allows a sufficient residence time of the mash in reactor chamber 76 . A sufficient residence time is typically on the order of less than about 5 minutes and preferably on the order of about 3 minutes. Auger screw 80 also maintains perforated plate 88 free of waste so that the liquid medium may infiltrate lower end 84 from primary chamber 104 to enhance disinfecting stage 22 . The disinfected and dewatered waste exiting system 10 typically has a liquids content of about 20% by weight in contrast to a liquids content in the mash of about 60% by weight. The bulk waste volume of the exit waste is on the order of about 15% of the inlet waste. Most of the liquid medium is removed from the waste as the result of compaction caused by fixed nozzle 90 or pressure responsive nozzle 92a,b positioned at waste discharge port 86 . The liquid medium exits auger 74 through perforations 94 and is collected in tank 56 for recycling to wetting stage 16 via line 54 . The dual-chamber weir arrangement of tank 56 enables collection of fines in primary chamber 104 for periodic removal. Process control for system 10 is provided by control unit 120 . The decontamination level, i.e., level of kill, attainable in system 10 is a function of several interrelated operating parameters including liquid medium flow parameters and auger and heater operating parameters as shown in Figure 5. Nevertheless, as is shown below, an operational model of system 10 can be developed as a function of a limited number of key parameters, which are level of kill, disinfectant concentration and temperature. Accordingly, process control can be effected by selecting a desired level of kill, i.e., target kill, and adjusting the disinfectant concentration and disinfectant solution temperature as a function of the operating parameters to meet the preselected target kill. For example, a target kill of 6 decades (10 6 organisms/ml) is achieved within about three minutes for a typical infectious medical waste using a chlorine dioxide solution at a concentration of 30 ppm and a temperature of 50°C. In practice, however, the process is controlled by adjusting only temperature while monitoring variations in the disinfectant concentration as a baseline for temperature adjustment. Temperature is selected as the independent variable and disinfectant concentration as the dependent variable for the practical reason that the ability to independently adjust disinfectant concentration is somewhat limited when a fixed amount of precursor is employed, while it is relatively easy to adjust solution temperature via heaters 12, 14 . The operational model of system 10 recognizes the functional relationship between solution temperature and concentration of the disinfectant, chlorine dioxide, at a given level of kill n. The model is represented by the equation: [ ClO 2 ] = a n e - k n T wherein [ClO 2 ] = chlorine dioxide concentration, T = temperature, and a n , k n = empirically determined constants for kill n . Figure 6 generally depicts the shape of the curve for equation (1). Each point on the curve defines values of [ClO 2 ] and T at which kill n can be achieved. Accordingly, process control is more specifically implemented by preselecting the target kill, empirically determining the model constants at the target kill to define a curve, and adjusting the actual values of [ClO 2 ] and T to lie on the target kill curve. Figure 6 shows a typical start-up scenario for system 10 . The treatment solution is initially at point A which is inside the required curve for the target kill. Since it is desirable to operate on the curve, automated process control 120 consequently raises the temperature of the solution in tank 56 toward point B which corresponds to the same chlorine dioxide concentration as point A, but at a higher temperature. Raising the temperature of the solution, however, increases the rate of chlorine dioxide formation, thereby increasing the chlorine dioxide concentration of the solution to a value designated by C on the vertical axis. Thus, as point B is approached, control unit 120 calculates that the required temperature on the curve has fallen. The dashed line shows the iterative equilibration procedure followed by control unit 120 whereby an operating point designated by D is ultimately attained. Operation is preferably maintained along or above the locus of points making up the curve which includes point D. Chlorine dioxide concentration in tank 56 is continuously monitored by means of air stripper 122 and gas analyzer 124 to enable control unit 120 to determine whether the requirements of the disinfectant solution have changed. For example, if a relatively "dirty" waste is fed to system 10 , the amount of ClO 2 consumed increases, reducing the ClO 2 concentration in the solution. Accordingly, control unit 120 must iteratively increase the temperature of the solution in the manner recited above to return operation of system 10 to the curve. If a relatively "clean" waste is fed to system 10 , the ClO 2 concentration increases, correspondingly reducing the temperature requirement. Thus, control unit 120 decreases the temperature of the solution. It is preferable to preselect a target kill exceeding a minimum acceptable level of kill so that adequate decontamination of the waste is achieved even when operation falls somewhat below the curve. It has generally been found that within the presently prescribed temperature range a minimum ClO 2 concentration in the treatment solution to achieve an acceptable level of kill is about 10 ppm up to the required concentration and preferably about 12 ppm up to the required concentration. As noted in the preferred embodiment above, starting quantities of the solid chlorite salt and acid are fixed. As such, they are preferably provided in stoichiometric excess of quantities necessary to produce the required chlorine dioxide concentrations shown on the curve of Figure 6. Thus, adequate concentrations of dissolved precursors will be available in solution for chlorine dioxide production despite the fact that, in most cases, some of the solid precursors do not react, and the additional fact that a significant fraction of the chlorine dioxide is consumed by reaction with the infectious waste constituents or diffuses out of solution. By way of example, a typical relative starting concentration of precursors, solvent and waste which will provide a desired chlorine dioxide concentration, is on the order of 4.6 g/l sodium chlorite/3.3 g/l citric acid/12 kg of solid waste. While the particular Multi-Stage Infectious Waste Treatment System as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.

Claims: A multi-stage system for treating an infectious waste along a continuous flowpath comprising: an inlet stage (12) having an opening (28) sized to receive an infectious waste into the flowpath of said system; a shredding stage (14) for reducing the particle size of the waste to a small particle size; a disinfecting stage (22) comprising a reactor chamber (76) positioned to receive the wetted granular waste and sized to retain the waste for a selected residence time; an auger (74) to transport the waste to a waste discharge port (86); and a dewatering stage (24); characterized in that the shredding stage (14) comprises a plurality of opposingly rotatable blades (31,32,33) in the flowpath of the waste; and further comprising a wetting stage (16) comprising a liquid jet (42) positioned at the flowpath to inject a liquid medium into the waste and to simultaneously wet and mix a disinfectant in the waste material; a granulating stage (18) provided beneath the wetting stage (16) for further reducing the particle size of the waste to a smaller granular particle size, said granulating stage (18) having at least one stationary blade (64) and at least one rotatable blade (62) rotatably positionable against said stationary blade (64) to form a cutting surface (68); and wherein the dewatering stage (24) comprises a flow restriction in the waste flowpath, said dewatering stage (24) being in fluid communication with said wetting stage (16) to recycle water from said dewatering stage (24) to said wetting stage (16). A multi-stage system for treating an infectious waste according to claim 1 characterised by further comprising a screening stage (20) having a screen (70) positioned across the flowpath of the waste, said screen (70) sized to enable the smaller granular particle size waste to pass through said screen (70) and to return the small particle size waste to said granulating stage (18). A multi-stage system for treating an infectious waste according to claim 1 or 2 characterised in that the shredding stage (14) comprises first and second blades having planes of rotation substantially parallel to the flowpath of the waste; and wherein the rotatable blade of the granulating stage (18) has a plane of rotation substantially parallel to the flowpath of the waste. A multi-stage system for treating an infectious waste according to any one of claims 1 to 3 characterised in that the auger (74) is inclined upwardly toward the disinfected waste discharge port (86) to facilitate dewatering A multi-stage system for treating an infectious waste according to claim 4 characterised in that said auger (74) has a perforated housing portion (96) proximal and upstream of said discharge port (86), said perforated housing portion having a plurality of perforations (94) smaller than the smaller granular particle size of the waste. A multi-stage system for treating an infectious waste according to claim 4 or 5 characterised in that said auger (74) has an inlet port (78) for receiving the granular waste from said granulating stage (18) and wherein the angle of inclination of said auger (74) is between 10° and 30°. A multi-stage system for treating an infectious waste according to claim 5 characterised by further comprising a liquid medium recycle stage in fluid communication with said plurality of perforations (94), said recycle stage having a collection tank (56) for holding the liquid medium exiting said plurality of perforations (94) and further having a recycle line (100) providing fluid communication between said tank (56) and said wetting stage (16). A multi-stage system for treating an infectious waste according to claim 7 characterised in that the lower end of said auger (74) is submerged and in fluid communication with said collection tank (56). A multi-stage system for treating an infectious waste according to any one of the preceding claims characterised in that said flow restriction is a nozzle (90). A multi-stage system for treating an infectious waste according to any one of the preceding claims characterised by further comprising a metal segregating stage (58) having a means for collecting metals dispersed in the waste passing through said shredding stage (14). A multi-stage system for treating an infectious waste according to any one of claims 7 to 10 characterised in that said recycle stage has a heater (112,114) in heat transfer communication with said collection tank (56). A multi-stage system for treating an infectious waste according to claim 2 characterised in that said screen (70) has a mesh size of about 1\4 inch (0.635 cm). A multi-stage system for treating an infectious waste according to any one of the preceding claims characterised in that said opening (28) is further sized to receive a dry solid disinfectant chemical into the flowpath of said system. A multi-stage system for treating an infectious waste according to claim 9 characterised in that said flow restriction is a nozzle (90,92a,92b) having an adjustable outlet size responsive to pressure against said nozzle (90,92a,92b). A multi-stage system for treating an infectious waste along a continuous flowpath comprising: an inlet stage (12) having an opening (28) sized to receive an infectious waste into the flowpath of said system; a shredding stage (14) for reducing the particle size of the waste to a small particle size; a disinfecting stage (22) comprising a reactor chamber (76) positioned to receive the wetted granular waste and sized to retain the waste for a selected residence time; an auger (74) to transport the waste to a waste discharge port (86); and a dewatering stage (24); characterized in that: the shredding stage (14) comprises a plurality of opposingly rotatable shredding blades (31a,b;32a,b;33a,b) positioned to receive the waste from the inlet opening (28); a plurality of stationary shredding blades (39a,39b) positioned opposite said rotatable shredding blades (31a,b;32a,b;33a,b), said stationary shredding blades (39a,39b) being spaced from said rotatable shredding blades (31a,b;32a,b;33a,b) by a selected distance for shredding the waste to a small particle size and further comprising a wetting stage (16) comprising a plurality of liquid jets (42a,b,c,d) positioned at the flowpath to inject a liquid medium into the waste and to simultaneously wet and mix a disinfectant in the waste material; a granulating stage (18) provided beneath the wetting stage (16) comprising a plurality of travelling granulating blades (62a,b,c,d,e) positioned to receive the shredded waste from said shredding blades; a plurality of stationary granulating blades (64a,b), said stationary granulating blades (64a,b) being positioned to form cutting surfaces (68) with said rotatable granulating blades (62a,b,c,d,e) to granulate the shredded waste to a smaller granular particle size free of any strips of waste material not fragmented by the shredding blades; a screening stage (20) comprising a screen (70) having openings sized to pass the smaller granular particle size waste and to retain larger size particles of waste for continued granulation, said screen (70) being positioned to cooperate with the travelling granulating blades (62); and wherein the dewatering stage (24) comprises a flow restriction in the waste flowpath and a perforated plate (88) having openings sized to allow liquid to pass through whilst retaining the smaller granular waste, said dewatering stage (24) being in fluid communication with said wetting stage (16) to recycle water from said dewatering stage (24) to said wetting stage (16). A multi-stage system for treating an infectious waste according to claim 15 characterised in that said inlet opening (28) is further provided for receiving a dry solid disinfectant chemical and said shredding, granulating and wetting stage (14,16,18) are further provided for mixing the waste, the chemical, and the liquid medium. A multi-stage system for treating an infectious waste according to claim 16 characterised in that the chemical comprises a disinfectant precursor and said shredding, granulating and wetting stages (14,16,18) are further provided for dissolving at least a portion of the chemical in the liquid medium to form the disinfectant. A multi-stage system for treating an infectious waste according to any one of claims 15 to 17 further comprising a means for heating the liquid medium.

Inventors: MEIJER ROBERT S, MEIJER, ROBERT S.
Applicants: WINFIELD IND, WINFIELD INDUSTRIES
Application year: 1991
Main classification: A61L11
IPC codes: A61L11, B09B3