INDUSTRIAL UTILISATION OF GARBAGE WITH EFFECTIVE RECYCLING AND WITH 0PTIMISATION IN ENERGY PRODUCTION

Abstract: An original and profitable industrial method is described to process garbage, in which are included: a) separation of written paper on the incoming garbage mechanically or manually which is deinked and pulped to chemical pulp; b) cutting the garbages to 3-5 cm and subjecting them to water flotation in a canal slowly running water in which are separated floating light products processed to separate polymers and to produce pulp, heavy precipitating products processed to separate iron metals, soft metals and glass and suspended organic mass which is further processed; c) utilisation of suspended organic mass after further purification and after prehydrolysis to produce digestible lignocellulosics in anaerobic digestion in the thermophilic region to yield high amounts of biogas, 85 % in methane content, utilised to produce electric energy at high yield; d) utilisation of the anaerobically digested sludge in the production of mixed fertilisers humic-chemical-organic after co-composting treatment in the thermophilic region. That way the garbage is utilised fully and nothing is rejected so that landfilling is not needed.

Description: INDUSTRIAL UTILISATION OF GARBAGE WITH EFFECTIVE RECYCLING AND WITH OPTIMISATION IN ENERGY PRODUCTION By G., Valkanas and Ap. Vlysidis We have invented and proved widely in practice a unit of anaerobic digestion working with high stability in the thermophilic region described in our patent E.P. 0474895 Al. We have aditionally invented and proved in practice the treatment of sludge resulted after anaerobic digestion in aerobic composting in the thermophilic region with production of mixed fertilisers humic- chemical-organic of high purity and fertilising value which are described in our patent GR. 1001916 We have also invented and developed knowledge in the production of pulp and paper which is described in our patent GR (appl.) 9501001 10 and we have introduced it in our solution for garbage , where paper makes a main constituent. This is the separation of paper and treatment with deinking and with mild chemical pulping for the production of pulp of high value The garbages after the separation of 75-80% of paper have the composition Paper 14-17% Food wastes 40-50% Garden wastes 8-10% Polymers 10-12% Metals 7-9% Glass 7-9% We have also invented and proved in practice additional elements so that a process has been developed for complete utilisation of garbage with effective recycling and with using the remaining materials for energy production by anaerobic digestion in the thermophilic region most profitably The process developed consists of: 1. A water flotation unit in which after cutting the garbages to 3-5 cm are separated a) floated products :polymers, used paper and woody materials b) a precipitating part which contains heavy ingedients : metals, glass and inerts, processed to recycle and c) a digestible organic mass which is flowing suspended in water. 2. The suspended organic mass after being specially treated to tolerate high presence of lignocellulosics is used to produce energy by anaerobic digestion 3. An aerobic composting unit in which the digested sludge from the anaerobic treatment is processed aerobically to produce mixed fertilisers of humic-chemical-organic composition of high utility and value The garbages are mixtures of wastes resulting from household everyday life and to a minor extent from social and industrial activities, They make a mixture containing high values but also contain toxic metals and toxic matter. For the utilisation of the garbages there is still research in progress to find solutions 5 which could lead to ecologically balanced complete utilisation of the huge existing volumes .However, the knowledge today to come to this achievement is not satisfactory o The following methods are currently in use 1. Landfilling where the garbages are covered with soil to be fermented .If moisture would be available a part up to 30-35% would have been fermented 5 because the rest is not digestible and accumulates. Landfilling, thus, is an amassement which leads to the creation of nuisances and of hazards in the region where they operate because of which a strongly negative public opinion has been developed 0 2. Destruction methods of garbages Burning of garbages with addition of oil or of coal , which, however, is leading to high investments and operational cost and to emission of toxins in air and to the disposal of toxic metals in soil Pyrolytic treatment has been developed and worked in practice by which the garbages are heated up to 500-600o in the absence of air to produce gas, a pyrolytic organic mass and activated carbon. Complete gasification of garbages is advanced in the presence of excess of hydrogen at temperatures exceeding the lOOO-l lOOo leading to fuel gases of high thermal value, These solutions lead also to intensive investments and to products difficult to market 3. Fermentation treatments has been advanced for the organic mass The composting has been received with enthousiasm , nevertheless , composting with recycling in dry form are procedures of high cost and the compost produced contains still toxic metals and is of low fertility to be accepted To realise a useful solution for garbages their constitution should be considered In dry form the garbages contain: Paper 30-35% Food wastes 30-35% Garden wastes 5-10% Polymers 10-12% Metals 7-8% Glass 8-9% Recycling the garbages together with production of energy by anaerobic digestion would be a solution In the garbages both recycling and production of energy by anaerobic digestion had to consider the high presence of lignocellulosics. Paper is a 100% such product , the garden wastes sre of similar constitution and the food wastes also contain 40-50% at least lignocellulosics. Then in the whole of digestable mass in garbages the lignocellulosics make the 50 to 60% Being these problems and having knowledge of lignocellulosics behaviour in anaerobic digestion in the thermophilic region , which is the other essential item to profitably utilise garbages , we have researched and constructed an orininal model solution for the profitable utilisation of garbages The procedure we have invented and considered runs as follows a. The handling of paper in garbages is organised for separation in the incoming mass. We separate paper in amounts making the 70-85% of total paper in gabages The written paper is subjected to effective deinking and then to chemical pulping wasting about the 30% of the whole. The deinking is advanced by three successive floating treatments so at the end is obtained a pulp of high brightness. The pulping to chemical pulp is performed in mild conditions to produce a pulp of high performance. The processing of wastepaper to produce products of value like described can be advanced only in presence of the facilities offerred in the solution we consider. That way paper is very effectively and beneficially recycled. The used paper is taken with the garbages in the flotation line and is mainly collected in the floating part with polymers and woody mass. Those are pulped in 4% lime at 90-100o after which the mass obtained is screened to effective separation of the polymers to market quality and a pulp solution is formed which is directed into the hydrolysis tank of the anaerobic digestion unit b. The precipitating mass in water flotation consisting of metals, glass, and inerts is collected and separated to products. After being washed is subjected to magnetic separation by which the 50-60% of iron metals are collected.The rest is pulverised and subjected once more to magnetic separation after which the iron metals are wholly collected and the remaining mass is heated to 500-600o where the soft metals coagulate. That mass is poured into water to separate the glass and the metals in pure form most effectively. c. The organic mass suspended in water is further pulped to fine constitution and then is subjected to density classification by which are formed three zones an upper zone of mostly paper and a precipitating zone of heavy articles which are collected and rejected. The main middle part is directed to the anaerobic digestion unit and the upper zone to the co-composting treatment of the digested sludge. d. The anaerobic digestion unit is working in the thermophilic region described in our patent E.P. 0474895 Al, The digestible part is subjected to a hydrolysis treatment as a precondition for effective anaerobic digestion.The solution is kept alcaline at pH 9,5-10,5 with lime presence and in that treatment the alcaline wastes in the processing of paper are advanced .The organic mass is kept for 12 hrs in temperature 80-90o maintained by inserting raw steam introducing also agitation after which the mass is pulped and becomes highly digestible.That treatment is essential for effective anaerobic digestion since the organic mass in garbages because of lignocellulosics present is not highly biodegradable. Without the prehydrolysis treatment the bioconvertion is only 50-55% while after the described prehydrolysis treatment it reaches highly optimised levels of 80 -85% e. The wastewater resulting from the anaerobic digestion is purified and recycled. Air stripping is adopted to collect ammonia and decanting for separation of the suspended mass. The wastewater then is subjected to ionexchange treatment in special, ionexchange resins which swell in water up to 300 times and after these purification treatments the water is recycled in pure form f, Heavy metals , therefor, are not accumulated and the digested sludge received is subjected to co- composting by aerobic fermentation in the thermophilic region at 60-62o after which the organic toxicities are also destroyed. Finally fertilisers are obtained of composion: humic 25-30%, chemical 30- 35% , organic 35-45% The process described for industrial utilisation of garbages which is analysed in the Examples and is also shown in the diagrams submitted is original and most profitable leading to ecologically balanced utilisation of garbages. EXAMPLE 1 In a Pilot Plant which we operated according to our invention , comprising: a. mechanical means and manual facilities for separating the written papers b. cutting machine to cut garbages to 3-5 cm length c. flotation unit to separate recyclables and digestibles d. unit of anaerobic digestion in the thermophilic region e. unit of co-composting the resulted digested sludge Garbages 2,5 tons/day of moisture were introduced and of composition: recyclables (paper, polymers, metals, glass, inerts )30-35% and digestibles 65-70% The garbages in dry mass had the analysis: recycled paper (separated) 20-25% used paper 10-15% polymers 6-8% metals 7-8% glass 5-6% food wastes 25-40% inerts 5-10% a. The Water Flotation Unit The garbages in quantities 100-120 kg/hr are charged to a cutting machine of 5 HP where they are cut to 2-5 cm and are added to a canal of water of dimensions : 1 m width, 20 m length and 1,5 m depth of flow 200 m3 /hr The cut to peaces garbages during the flow are separated in floating part , in precipitating part and in suspended in water digestible part. At the start of the canal a screen is adjusted to recycle to the cutting machine the heavier mass. With the water floating are separated 15-25% of light recyclables which contain polymers, paper and woody materials, 25-30% of heavy precipitating articles which contain metals, glass and inerts and 45-50% of suspended in the flowing water organic mass. The floating and the precipitation products are continuously withdrawn .The floating are directed to a tank of IO m3 where they are washed and the precipitating part are taken in a 5 m3 tank where they are washed and all are processed to trade products. The suspended mass of digestibles of composition: food wastes ,70-75% , used paper lO- 15% and others 10-15% are flown towards the canal end where with a screen are separated and the water is recycled to the canal begining .The organic mass is then directed to a pulping machine where is pulped to fines to 0.5 mm end is directed to a density classification tank, an upper layer is formed containing polymers and paper (6-8% of dry weight) a precipitating zone is formed consisting of glass , metals and inerts (4-7% by weight ) and a main mass as central layer consisting of organic digestible matter ( 45-55% in dry form) which makes a water suspension 10-12% in solids With the water flotation treatment the garbages are separated to the following products: - paper 28-35% recycled by 60-70% - polymers 6-8%, recycled by 97-99% - metals 6;7% recycled by 97-98% - glass 5-6%, recycled by 99-100% - organic digestible part 45-55% dry weight which after the density classification has the composition - food wastes 80-85% dry weight - pulped used paper 10- 15% - others 1-1,5% b. The Prehydrolysis and the Anaerobic Digestion of the Organic Digestible Mass The organic mass as a suspension with 10-12% organic solids in quantity 30-40 kgs/hr is charged to the prehydrolysis tank .This is a tank of 20 m3 capacity which is heated and agitated with raw steam to 80-90o .In that tank are directed the alcaline wastes from the anaerobic digestion and the alcaline wastes from the paper processing and the tank solution with addition of lime is kept at 9.0-10.0 pH and with solid content of 5-8% In those onditions the organic mass consisting mainly of lignocellulosics is partly hydrolysed in a physical-chemical biological treatment with very beneficial results for the anaerobic digestion This quantity with flow 5-6% in organic solids is directed to the bioreactor of slurry bed type and are advanced all the biological reactions that of hydrolysis, that of acidogenesis, that of ecetogenesis leading to methanogenesis in a surrounding of high biological activity with increased presence of bicarbonates (150 gr/liter) in which are based beneficial operations of bioreactions and is inhibited the production of hydrogen sulfide from the biotransformation of sulfur containing organic and inorganic substancies. All these benefits of operation and others are described in our patent E.P. 0474895 Al c. The Waste Water Handling On the line of wastewater resulting after the anaerobic digestion a unit of ammonia stripping is installed comprising of a pipe type perpendicularly placed tank of 10 m3 capacity filled with solid material of high specific surface (140 m2/m3) The wastewater feeding is from top with steam while reversely is introduced air. The water is collected in the tank bottom and is further treated to be recycled.The air coming through is rich in ammonia and is directed to the co-composting unit for the digested sludge with flow 1.000 m3./m3 of wastewater treated.The wastewater after precipitation or decanting treatment is introduced to a tank where a frame anoxidal steel is hanged containing ionexchange resins of the special type described which swell in water 150-250 times and make a product easily introduced and removed.The potential of the ionexchange resins is high and the column can collect 500 gramequivalent of heavy metal ions That ionexchange treatment collects all metal ions and the water becomes soft and free of metal toxicity and thus is recycled. d. The Digested Sludge Utilisation The sludge resulted from the anaerobic digestion , containing 17-20% solids is charged to a substrate consisting of density classification floating matter which with aeration is advanced at a thermophilic compost treatment at 58-62o In that temperature starts the addition of sludge at a rate so that temperature is kept at 58-82o because of highly exothermal fermentation which is controlled by water evaporation .At the end a humic mass is formed accumulated for 40 days which is taken out and summed in heaps for ripening and mixing and at the end results in a product composition :humic 35%, chemical fertilisers 30% , organic mass 35% which is a fertiliser of high utility and of value EXAMPLE 2 The products to separate after water flotation treatment are : 1) the heavy products which sink (metals, glass, inerts) and 2) the light products which float (polymers, used paper , woody mass) which are in high proportion of the garbages dry weight , and their utilisation to commercial products is necessary . The heavy products received 10-30% dry weight , are washed and subjected to magnetic separation and the 50% of iron metals are collected. After it the mass is pulverised finely to 1-3 mm and is subjected to a second magnetic separation and the iron metals are all collected .The remaining mass is heated to 50O-6O00 where the soft metals coagulate and are separated from the glass received all in high purity and waste mass after dumping in water. Per ton of heavy articles are received: iron metals 308-320 kgs soft metals 9-12 kgs glass 260-320 kgs soil wastes 250-320 kgs The floated matter which contains polymers, used paper and woody mass (15-20% by dry weight) is subjected to pulping with boiling for two hrs in presence of lime 4%. The mass is screened to collect the polymers in pure form to market quality and the pulped paper and woody mass is screened and directed to the anaerobic digestion to produce energy or is collected for industrial use. EXAMPLE 3 Written paper collected from the garbages mechanically or manually is treated to produce deinked pulp and chemical quality pulp. 20 kgs of written paper is cut to 5-6 cm and subjected to chemical deinking treatment in a water solution containing 3.0 kgs lime, 1% hydrogen peroxide and 3% silicium oxide in volume 1:6. It is agitated strongly at 50o for 2 hrs and then is screened and the wastewater resulted is taken in the wastewater line Then it is directed into floating units three in series containing 0.6% of sodium oleate and 0.1 % silicium oxide with solids to water ratio l.lO.It is aerated to foaming and the foams formed are taking the ink coloured matter. That treatment in three flotations leads to a product pulp of analysis: Chemical analysis Technical analysis cellulose 50-60% breaking length 3,3 km hemicellulose 20-25% tearing factor 5.9 lignin 15-20% yield 89% ash 5-10% brightness 71 This quality pulp is already a commercial product however, it is further treated to produce chemical quality pulp. For this it is subjected to mild pulping conditions: a. pulping with chlorine b. pulping with oxygen c. pulping with air a. Chlorine Pulping In the initial pulp 5 kg taken in 10 liters of water is introduced chlorine gas 5 liter/hr-kg of pulp under stirring at 30o. The chlorination proceeds to colour change which becomes purple. The colour tone determines the reaction proceedings and when the chorine introduction terminates nitrogen is introduced to expell the unreacted chlorine.The product is poured into a 3% sodium hydroxide solution to neutralise it and to extract the chlorinated lignin .The pulp is received in high colour quality and of very low lignin, lower than 4% and shows the following technological characteristics breaking length 10.000 m folding efficiency 800 tearing strength 15.6 colour 80 lovipont units 25% chlorinated lignin is also produced b. Oxygen Pulping 5 kgs initial pulp is taken in 10 volumes of water containing 16% of NaOH and 1% MgC03 to the weight of the pulp.The whole is heated to 120o for 60 minutes in the presence of oxygen of pressure 2 atm and of flow 5 liter/kg pulp-hr The pulp material is washed with water and received in yields 69% with the foUowing technological parameters breaking length 9.000 m folding efficiency 900 tearing strength 10,8 colour 79 lovipont units lignin at a yield of 15.2% was also received c. Pulping with Air Using of air in the conditions of b) by introducing air 20 liters/kg pulp-hr a pulp in yield 70% is received with the following characteristics breaking length 8,200 m folding efficiency 800 tearing strength 8.8 colour 78 lovipont units lignin was also received at a yield of 14,8% That way the paper is received in two qualities of pulp in deinking pulp and in chemical pulp both of which are of high market values. The production is advanced within the garbage industrial unit for utilising profitably the wastewaters formed

Claims: CLAIMS 1. Method of utilisation of garbages with effective recycling and with energy production , comprising a. Separation of written paper in the entrance of the garbages and processing it to produce pulps of high quality b. Separation by water flotation , after cutting the garbages to 3-5 cm ,to light floating products: used paper, polymers and woody mass, to precipitating heavy products: metals, glass and inerts and to organic mass suspended on the moving water which is further processed to be effectively digested anaerobically c. A special hydrolysis treatment for lignocellulosics before entering to the anaerobic digestion unit at pH 9,5-10 and at 8O-IOO0 by which the digestibility is highly increased d. An aerobic co-composting unit for the digested sludge after which mixed fertilisers of high value are produced 2. Method according to claim 1 by which the separation of written paper is adopted on the incoming garbages mechanically or manually very effectively to collect the 60-80% of paper in the garbages and is processed to produce deinked pulp and at mild pulping conditions chemical pulp 3. Method according to claim 1 by which the collected floating parts in the water flotation treatment (used paper, polymers, woody mass) are pulped with 4% lime at temperature 8O-IOO0 to separate the polymers after screening and the cellulocics being pulped 4. Method according to claim 1 by which the collected precipitated parts in the water flotation treatment (metals, glass and inerts) are taken out , washed magnetically separated the iron metals then pulverised and subjected again to magnetic separation to collect all the iron metals and the rest is heated up to 6OO0 where the soft metals coagulate and the whole is taken into water to effectively separate the coagulated metal mass and the glass in high purity 5. Method according to claim 1 by which is added a prehydrolysis treatment before the anaerobic digestion at pH 9,5 to 10 and at temperature 80-90o where are also directed the alcaline wastewaters of the paper pulping for improving the bioconvertion of contained lignocellulosics 6. Method according to claim 5 by which the prehydrolysis uses lime as alcaline reagent and is of retention time IO to 12 hrs and the result in anaerobic digestion is an increase from 50-55 garbage bioconvertion to almost 80% biodegradation 7. Method according to claim 1 by which the wastewaters resulting from the anaerobic digestion are airstripped to collect ammonia , decanted to collect suspended matter and ionexchanged in special resins swelling in water up to 300 times to become entirely free of toxic metals 8. Method according to claims 1 and 2 by which the anaerobic digested sludge is subjected to aerobic co- composting treatment at thermophilic conditions 58- 62o after which with destruction of organic toxicities and by aeration with the ammonia containing air from the airstripping and after addition of other needed elements fertilisers are obtained of type humic- chemical-organic of high value 9. Method according to all claims 1 to 8 by which from the garbages as they arrive mehanically or manually is separated written paper the 60-80% of total which is processed by deinking to pulp and then to chemical pulp of high quality, then the garbages are cut to 3-5 cm and introduced to flow in slowly flowing water in a canal , where the light articles float : polymers, used paper and woody mass, which are pulped to separate the polymers and take the rest in the fermentable mass ,the heavy articles sink :metals , glass nad inerts, which are processed to separate all to commercial products , and the main organic mass suspended in water is further pulped and directed to a density classification where an upper zone is formed to be used in the co-composting of sludge , a bottom zone is formed which is rejected and the middle suspended organic mass purified is directed to prehydrolysis treatment at pH 9,5-10 and at temperature 80-90o for 12 hrs retention where are added the alcaline wastewaters and then the pulped organic fermentable mass is introduced to anaerobic digestion treatment in the thermophilic region to produce biogas of 85% methane content in yield 0.5 m3 of biogas/kg of CODr with up to 85% organic mass bioconvertion., the wastewaters resulted is airstripped to take off ammonia then is decanted and ionexchanged with special resins and being free of metal toxicities is recycled, the digested sludge is co-composted in the thermophilic region 58-62o to produce mixed fertilisers: humic-chemical-organic of high value and the biogas in high volumes and fuel value is utilised to produce electric energy in combined cycle installations , so that the garbages are utilised to give high values and nothing is to reject

Inventors: VALKANAS GEORGE N, VLYSSIDES APOSTOLOS G, VALKANAS, GEORGE, N., VLYSSIDES, APOSTOLOS, G.
Applicants: INNOVAL MANAGEMENT LIMITED, VALKANAS GEORGE N, VLYSSIDES APOSTOLOS G, VALKANAS, GEORGE, N., VLYSSIDES, APOSTOLOS, G.
Application year: 1996
Main classification: B03B9
IPC codes: B03B9, B09B3, C05F9, C05F17, D21B1