Abstract:
A composting floor system is disclosed for accelerated and uniform decomposition of organic matter, the composting floor system including a gas delivery system, wherein the floor system facilitates drainage and collection of leachate generated during the composting process, and a collection of leachate and an efficiency and speed of aerobic composting are maximized.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a floor system for composting, and more particularly to a composting floor system that facilitates a forced aeration of the organic material within the compost pile and a capture of leachate generated during the process.  
       BACKGROUND OF THE INVENTION  
       [0002]     Composting is a biological process which transforms organic materials into a stable, easily handled, and potentially valuable product called compost. Compost bins are commonly employed to contain a mixture of organic matter, such as vegetable refuse, municipal solid waste, sludge, manure, animal mortalities, and the like, for converting the same into useful compost for fertilizing and conditioning soil. The composting process requires a carbon source such as sawdust, a nitrogen source such as the organic matter listed above, moisture, and oxygen. A common approach to composting includes mixing and stacking the carbon source and the nitrogen source in a compost bin and introducing air to the mixture of organic materials through various means.  
         [0003]     The composting process consumes large amounts of oxygen. Thus, an air or gas delivery means is typically used to introduce air or gas to the organic material. The delivery means commonly consists of compressed air supplied through perforated pipes or plates disposed on the base of the compost bin or pile. The pipes or plates are often damaged by associated equipment such as front-end loaders used during the unloading of compost from the bin.  
         [0004]     The air delivery means used in prior art structures often results in insufficient amounts of oxygen being supplied to certain areas of the compost bin. Without sufficient oxygen, these areas within the composting bin tend to process at a slower rate than the rest of the material, and undesirable odors may emanate from the composting mixture.  
         [0005]     In order to optimize the composting process, the moisture content of the mixed ingredients should be between 40 percent and 60 percent. Given these higher levels of moisture, and the natural inconsistency of the materials being composted, leachate will be generated. The floor systems used in prior art structures often require that parts of the floor be removed to clean out the leachate that accumulates during the composting process since leachate is allowed to drain through holes in the floor and collect underneath the floor. Thus, it becomes difficult to capture the leachate for disposal or reuse in the composting process.  
         [0006]     Another method of reducing the leachate generated is to compensate for excess moisture by reducing the overall moisture content to a level where little or no leachate is generated. However, this practice significantly reduces the efficiency of the composting process, and increases the amount of time required to complete the composting process.  
         [0007]     It would be desirable to produce a floor system for composting having a gas delivery system, wherein the flooring system facilitates drainage and collection of leachate generated during the composting process, and a collection of leachate and an efficiency and speed of aerobic composting are maximized.  
       SUMMARY OF THE INVENTION  
       [0008]     Consistent and consonant with the present invention, a floor system for composting having a gas delivery system, wherein the flooring system facilitates drainage and collection of leachate generated during the composting process, and a collection of leachate and an efficiency and speed of aerobic composting are maximized, has surprisingly been discovered.  
         [0009]     In one embodiment, the floor system for composting comprises a base portion having a plurality of trenches formed therein; a plurality of gas distribution conduits, each of the gas distribution conduits disposed in one of the trenches of the base portion and having a plurality of apertures formed therein, the plurality of gas distribution conduits adapted to be in fluid communication with a source of pressurized gas; and a header portion having a trench formed therein cooperating with the trenches of the base portion to facilitate drainage of leachate from the compost system, the header portion abutting an end of the base portion.  
         [0010]     In another embodiment, the floor system for composting comprises a base portion having a plurality of trenches formed therein; a plurality of gas distribution conduits, each of the gas distribution conduits disposed in one of the trenches of the base portion and having a plurality of apertures formed therein, the plurality of gas distribution conduits adapted to be in fluid communication with a source of pressurized gas; a header portion having a trench formed therein cooperating with the trenches of the base portion to facilitate drainage of leachate from the compost system, the header portion abutting an end of the base portion; and a leachate collection conduit disposed in the trench of the header portion and adapted to be in fluid communication with one of a leachate storage system and a leachate treatment system, the leachate collection conduit having a plurality of apertures formed therein to facilitate a collection of the leachate in the leachate collection conduit to drain the leachate to the one of the leachate storage system and the leachate treatment system.  
         [0011]     In another embodiment, the floor system for composting comprises a base portion including a plurality of block portions, each of the block portions having a trench formed therein; a plurality of gas distribution conduits, each of the gas distribution conduits disposed in one of the trenches of the block portions and having a plurality of apertures formed therein; a header portion having a trench formed therein cooperating with the trenches of the base portion to facilitate drainage of leachate from the compost system, the header portion abutting an end of the base portion; a gas supply header disposed in the trench of the header portion and providing communication between a source of pressurized gas and the gas distribution conduits; and a leachate collection conduit disposed in the trench of the header portion and adapted to be in fluid communication with one of a leachate storage system and a leachate treatment system, the leachate collection conduit having a plurality of apertures formed therein to facilitate a collection of the leachate in the leachate collection conduit to drain the leachate to the one of the leachate storage system and the leachate treatment system.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:  
         [0013]      FIG. 1  is a partial perspective view of a composting floor system according to an embodiment of the invention;  
         [0014]      FIG. 2  is a sectional view of the composting floor illustrated in  FIG. 1  taken along line  2 - 2 ;  
         [0015]      FIG. 3  is an end view of a gas supply header and a leachate collection conduit illustrated in  FIG. 1 ;  
         [0016]      FIG. 4  is an enlarged plan view of a gas supply conduit illustrated in  FIG. 1  and showing apertures formed in the conduit;  
         [0017]      FIG. 5  is a sectional view of the gas supply conduit illustrated in  FIG. 4  taken along line  5 - 5 ;  
         [0018]      FIG. 6  is a sectional view of the leachate collection conduit illustrated in  FIGS. 1 and 3 ;  
         [0019]      FIG. 7  is a partial perspective view of a composting floor system according to another embodiment of the invention;  
         [0020]      FIG. 8  is an end view of a composting floor block portion showing an end of the block opposite the end abutting a header portion; and  
         [0021]      FIG. 9  is an end view of a header portion showing the gas supply header and the leachate collection conduit illustrated in  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0022]     The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.  
         [0023]      FIG. 1  illustrates a floor system  10  for composting according to an embodiment of the invention. A compost bin or pile (not shown) is disposed on the floor system  10 . A length and width of the floor system  10  can be adjusted to match that of the compost bin or pile. Walls (not shown) can also extend upwardly from a periphery of the floor system  10 .  
         [0024]     The floor system  10  includes a base portion  12  and a header portion  14 . A plurality of spaced apart, substantially parallel trenches  16  are formed in the base portion  12 . Any desired cross sectional shape can be used for the trenches  16  such as a V-shape, a rectangular shape, or a rounded or semicircular shape, for example. The base portion  12  is sloped towards the header portion  14 . It is understood that a substructure  18  of the base portion  12  can be sloped to result in the desired slope of the base portion  12 .  
         [0025]     The header portion  14  is disposed at an end of the base portion  12 . The slope of the base portion  12  is towards the header portion  14 . A trench  20  is formed in the header portion  14  to be substantially perpendicular to the trenches  16  of the base portion  12 . The trenches  16  of the base portion  12  are in fluid communication with the trench  20  of the header portion  14 . In the embodiment shown, the header portion  14  is not sloped. However, it is understood that the header portion  14  or the trench  20  of the header portion.  14  can be sloped as desired.  
         [0026]     A leachate collection conduit  22  is disposed in the trench  20  of the header portion  14 . The leachate collection conduit  22  is in fluid communication with a leachate storage system (not shown), a leachate treatment system (not shown) as desired, or simply permitted to drain from the floor system  10 . As clearly shown in  FIG. 6 , the leachate collection conduit  22  includes an annular array of apertures  24  formed therein. In the embodiment shown, the apertures  24  are disposed in the bottom portion of the leachate collection conduit  22  to facilitate the collection of leachate  26 . The apertures  24  permit the leachate  26  to enter the leachate collection conduit  22  and be removed from the floor system  10 . A direction of flow of the leachate  26  is indicated by the arrows L. A cap  28  is disposed at an end of the leachate collection conduit  22  to militate against leachate  26  escaping. However, it is understood that both ends of the leachate collection conduit  22  can be in communication with the leachate storage or treatment system.  
         [0027]     A gas supply header  30  is disposed adjacent the leachate collection conduit  22  in the trench  20  of the header portion  14 . In the embodiment shown, air is used. However, it is understood that other gases such as a mixture of gases containing oxygen can be used. The gas supply header  30  is in communication with a source of pressurized gas (not shown) such as a pressurized tank or a fan, for example. Typically, it is desired to have the gas supply header  30  in the trench  20  at a higher point than the leachate collection conduit  22  as illustrated in  FIG. 3 . An end cap  32  is disposed on an end of the gas supply header  30  to militate against the escape of gas therefrom.  
         [0028]     A gas distribution conduit  34  is disposed in each one of the trenches  16 . The depth of the trenches  16  and the diameter of the gas distribution conduits  34  cooperate to maintain a top portion of the gas distribution conduits  34  at or below planar surface portions  35 . The gas distribution conduits  34  are in fluid communication with the gas supply header  30 . Flow of gas through the gas distribution conduits  34  is indicated by the arrows A. A valve (not shown) can be disposed between the gas supply header  30  and the gas distribution conduits  34  to control the flow of gas into each of the gas distribution conduits  34 . Additionally, a control system (not shown) can be used to regulate flow into the gas supply header  30  and the gas distribution conduits  34  as desired. The control system may include timers and valves, for example. An annular array of spaced apart apertures  36  are formed in the gas distribution conduits  34 , as clearly shown in  FIGS. 2, 4 , and  5 . In the embodiment shown, the apertures  36  are disposed in the upper portion of the gas distribution conduit  34  to direct the flow of the gas upwardly. A diameter, quantity, and location of the apertures  36  can be varied to control the flow of the gas as desired.  
         [0029]     In operation, organic material is disposed on the floor system  10 . The gas is supplied to the organic material by the gas supply header  30  and the gas distribution conduits  34 . The flow of gas is directed into the organic material by the apertures  36  formed in the gas distribution conduits  34  to facilitate the composting process. The oxygen supplied with the gas provides the needed oxygen to the aerobic microorganisms in order to begin the decomposition of the organic material. In one embodiment, the flow of gas into the organic material is accomplished by the alignment of the apertures  36  of the gas distribution conduits  34  in two rows spaced substantially ninety degrees apart as illustrated in  FIG. 5 . However, it is understood that other configurations of the apertures  36  can be used without departing from the scope and spirit of the invention.  
         [0030]     During the decomposition of the organic material, any leachate  26  or excess moisture formed is directed to the header portion  14  by the base portion  12 . The leachate  26  is caused to flow to the header portion  14  by the trenches  16  formed in the base portion  12 , the slope of the base portion  12 , or a combination of the trenches  16  and the slope. The leachate  26  is collected in the trench  20  of the header portion  14 . The leachate  26  is directed towards a collection point by the trench  20 . Additionally, the leachate  26  enters the leachate collection conduit  22  through the apertures  24  formed therein. Collected leachate  26  can be stored for later removal and treatment, can be directed to a treatment system (not shown), can be re-used in the composting process, or simply permitted to drain from the floor system  10 .  
         [0031]     Once the organic material has been converted to compost material, the compost material can be removed from the floor system  10 . Any conventional removal method can be used such as by hand with a shovel or with a front end loader, as desired. The gas distribution conduits  34  are protected from damage during removal of the compost material since the top of the gas distribution conduits  34  are positioned at or below the planar surface portions  35 .  
         [0032]     Another embodiment of the invention is illustrated in  FIGS. 7, 8 , and  9 . Like structure from  FIGS. 1-6  is shown in  FIGS. 7-9  with the same reference numeral and a prime “′” symbol. In this embodiment, the base portion  12 ′ is produced from a plurality of elongate block portions  40  as shown in  FIG. 8 . Each of the block portions  40  includes a protuberance  42  such as a tongue in a tongue and groove joint, for example, formed in one side thereof. A depression  44  such as a groove in a tongue and groove joint, for example, is formed in an opposite side thereof. When individual block portions  40  are disposed adjacent and substantially parallel with one another, the protuberance  42  of one block portion  40  is received in the depression  44  of an adjacent block portion  40 . Thus, a desired width of the base portion  12 ′ can be attained by placing block portions  40  in a side by side relation until the desired width is reached.  
         [0033]     As shown in  FIG. 9 , an end of the block portions  40  abutting the header portion  14 ′ has a depression  46  such as a groove in a tongue and groove joint formed therein. The depression  46  formed on the end of the block portions  40  receives a protuberance  48  such as a tongue in a tongue and groove joint formed on the header portion  14 ′. It is understood that a depression can be formed on the header portion  14 ′ and a protuberance can be formed on the ends of the block portions  40  without departing from the scope and spirit of the invention. The protuberances  42 ,  48  and the depressions  44 ,  46  facilitate an alignment between adjacent block portions  40 , and the block portions  40  and the header portion  14 ′, and militate against relative movement therebetween. Producing the floor system  10 ′ using the block portions  40  allows for large scale production, thus minimizing costs. The block portions  40  can be produced in a variety of lengths, thereby facilitating use in a variety of applications. The operation of the floor system  10 ′ is the same as previously described for the other embodiment of the invention.  
         [0034]     The floor system  10 ,  10 ′ produced according to the various embodiments of the invention facilitates the drainage, capture, removal, treatment, or reuse of excess leachate  26 ,  26 ′ generated in the composting process. Additionally, gas supply is consistently and equally distributed throughout the organic material being composted. The floor system  10 ,  10 ′ can be economically manufactured at one or more central facilities and transported to a desired site for efficient and simple installation. The floor system  10 ,  10 ′ also readily accommodates variations in the width and length of the compost bin or pile.  
         [0035]     From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.