Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This is a Continuation of application Ser. No. 10/794,844 filed Mar. 5, 2004, entitled BIOFILTER. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to biofilters and more particularly to biofilters using a filter media that is primarily comprised of a rubber material to efficiently and inexpensively treat volatile organic compounds. 
         [0004]    2. Description of the Prior Art 
         [0005]    At the turn of the twentieth century it was discovered that a leach field could purify liquid waste before the waste could seep into the water table. It was further discovered that the leach fields eliminated the noxious odors emanating from the liquid waste before the odors could reach the air above ground. Since that discovery, biofiltration has evolved into an important method for controlling air pollution emanating from paint shops, farms, sewage treatment plants and mill towns. Most modern biofilters used in these capacities are comprised of engineered beds of soil or compost. Organic waste, whether in gaseous, liquid or solid form is disposed beneath, or adjacent to, the biofilter so that the organic gasses slowly diffuse through the biofilter media. Billions of microorganisms indigenous to the soil or compost media are used to convert the organic compounds to carbon dioxide and water. 
         [0006]    While prior art biofiltration systems have proven to be effective in the treatment of organic compounds, they suffer from a number of shortcomings. Typically, compost media has a limited life span and must be completely replaced every two to five years. During its life span, the compost media requires the adjustment of PH levels. Airflow through the compost media is also inconsistent over time, as back pressure gradually increases and air channels form throughout the compost. Compost media also tends to be hydrophobic, as it is difficult to rehydrate compost after it dries out. Accordingly, compost media typically requires the attentive care of its operator and can be quite costly over the lifetime of the treatment facility due to its maintenance, removal and replacement every few years. 
         [0007]    Soil media has several significant advantages over compost media. However, soil media biofilters can be difficult to properly construct and may have a relatively high start up cost. Moreover, the use of soil media biofilters does not easily lend itself to a wide range of applications including uses where a plurality of smaller output filters are used within a single system, such as a municipal sewer system. Many soil media systems also suffer from compaction problems over time, causing inconsistent or wholly ineffective air flow. 
         [0008]    The treatment and purification of wastewater is one of the more crucial areas in which biofilters can be used to benefit the public health and the ecological well-being of land and water resources. Natural byproducts of wastewater treatment include the odors and noxious gases generated by microbial activity. Many prior art methods of dealing with wastewater odor control fail to completely solve the problem. Chemical addition technologies, for example, oxidize the noxious compounds in the wastewater before they are emitted as odorous gasses by feeding oxidizing chemicals to the sewage. However, nonspecific reactions occurring within the high organic load of the sewage can lead to the formation of volatile organic compounds that may be highly caustic if not toxic. Wet chemical scrubbers use large volumes of potentially dangerous chemicals and the drainage generated from such systems creates yet another form of wastewater that must be treated prior to its release into the environment. Other systems utilize only a carbon filter. However, the organic gases and odorants are only removed from the passing air until the carbon is saturated. Due to the fact that the carbon does not actually treat the passing air, it must be frequently replaced. Moreover, the effectiveness of carbon filters over time may be diminished by other environmental conditions including moisture from the passing volume of air. 
         [0009]    Accordingly, what is needed is a novel biofilter that utilizes a filter media that is simple and inexpensive to implement but that exhibits a high level of effectiveness over a perpetual lifetime, with minimal maintenance. 
       SUMMARY OF THE INVENTION 
       [0010]    The biofilter of the present invention is generally provided with a container having side and bottom walls, which define an inner chamber. A layer of rubber particulate is at least partially disposed within the inner chamber of the container. In one preferred embodiment the bottom wall of the container is provided with a plurality of apertures to allow the passage of contaminated gasses upwardly through the container and the rubber particulate. A cover may be provided for the container so that the biofilter could be used in place of a manhole cover for a sewer system. In one preferred embodiment the rubber particulate is provided in the form of crumb or chip-shaped rubber derived from recycled tires. The shapes of the rubber particulate and its porous surfaces provide an ideal platform on which the naturally occurring microbial ecosystem can thrive. 
         [0011]    In another embodiment, an open container is provided with a layer of rubber particulate, which floats on a layer of fluid within the container. Optional conduits may deliver contaminated gas, sludge and/or solid waste to the container. Contaminated gases emanating from the waste at the bottom of the container rise through the fluid and are substantially reduced by the microbial ecosystem which inhabit the rubber particulate. 
         [0012]    It is therefore one of the principle objects of the present invention to provide a biofilter for use in treating contaminated gases using a filter media comprised substantially of rubber particulate. 
         [0013]    It is a further object of the present invention to provide a biofilter for use in treating volatile organic compounds using a filter media comprised of rubber particulate formed from recycled products such as automobile tires. 
         [0014]    Still another object of the present invention is to provide a biofilter system for treating contaminated gases that is adaptable for use in small scale situations including manhole covers for sewer systems. 
         [0015]    A further object of the present invention is to provide a biofilter having a filter media that is comprised of layers of activated carbon and rubber particulate. 
         [0016]    Still another object of the present invention is to provide a biofilter that is effective in treating contaminated gasses and odors, while remaining relatively inexpensive and easy to maintain. 
         [0017]    These and other objects of the present invention will be apparent to those skilled in the art. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of one possible embodiment of a wastewater treatment facility incorporating an embodiment of the biofilter of the present invention; 
           [0019]      FIG. 2A  is a partial cut-away view of one potential source of the rubber particulate filter media of the present invention; 
           [0020]      FIG. 2B  depicts an example of chip-shaped rubber particulate as the same might be used in the filter media of the present invention; 
           [0021]      FIG. 2C  depicts an example of crumb-shaped rubber particulate as the same might be used in the filter media of the present invention; 
           [0022]      FIG. 3  is a partial cut-away view of one embodiment of the biofilter of the present invention as the same could be used for treating wastewater; 
           [0023]      FIG. 4  is a cut-away view of another embodiment of the biofilter of the present invention as the same could be used in conjunction with a municipal sewer system; and 
           [0024]      FIG. 5  depicts the effectiveness of one embodiment of the biofilter of the present invention as the same could be used to treat contaminated gas over a length of time. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    The biofilter  10  of the present invention is generally depicted in various embodiments in  FIGS. 1 ,  3  and  4 . The biofilter  10  is preferably provided with a container  12  having side walls  14  and a bottom wall  16 . A layer of particulate rubber  18  is at least partially disposed within the container  12 . In one preferred embodiment the rubber particulate is obtained from recycled rubber products, such as the automobile tire  20  depicted in  FIG. 2A . Although it is contemplated that substantially all portions of the recycled tire  20  and other rubber based products could be used, it is preferred that those portions having steel reinforcing wires or other such foreign matter be avoided or used sparingly due to the undesirable nature of long term exposure of such materials to wet environments, which may cause the foreign matter to oxidize. However, the sidewall  22  and tread  24  of most modern passenger vehicle tires will likely be sufficiently free of such foreign matter for many of the contemplated uses for the biofilter  10 . 
         [0026]    The chipped rubber  26 , depicted in  FIG. 2B , and crumb rubber  28 , depicted in  FIG. 2C , provide optimal shapes for use as the filter media in the biofilter  10 . Both the chipped and the crumb shapes are fairly irregular in nature, providing a large surface area for each individual piece. This, combined with the porous nature of the rubber provides an optimal platform for the formation and maintenance of a microbial ecosystem, which naturally occurs in the treatment of organic waste material. Moreover, the irregular shape of the chipped and crumb rubber allow the particulate layer  18  to settle into a loosely packed layer that permits a consistent flow of gas through the layer of particulate rubber  18  over extended periods of time. However, the irregular shape of the particulate function to “interlock” the pieces of particulate to one another to sufficiently reduce the incidence of erosion caused by wind and weather where the layer of rubber particulate  18  is directly exposed to the elements. 
         [0027]    After the organic material  30  passes through the layer of rubber particulate  18 , the layer of rubber particulate  18  will substantially recover any openings formed by the passing organic material  30 . 
         [0028]    One contemplated embodiment of the biofilter  10  of the present invention is depicted in  FIG. 3 , which closely resembles an open-air lagoon typically utilized for liquid and/or solid organic waste  30 . Depending on the particular application and the specific organic waste  30  being treated, the side and bottom walls of the container  12  could be comprised of nearly any material, such as concrete, rubber, plastic, and various non-corrosive metals. It is further contemplated that the side walls  14  and bottom wall  12  could be comprised of earthen materials, as the container could be a lagoon formed directly in the ground adjacent an organic waste producing facility. The organic waste  30  may be dumped directly into the open upper end of the container  12  since the organic waste  30 , regardless of its composition, will substantially pass through the layer of rubber particulate  18  and settle at the bottom of the container  12  or become partially suspended within the layer of fluid  32 . In many applications, the fluid  32  will simply be comprised of water but may be comprised of sludge or other known organic slurry. It is further contemplated that a system of conduit  34  or the like could be used to deliver the organic waste  30  and/or fluid  32  to the container  12  from an adjacent or remote organic waste producing facility when top-loading of such materials is not practical or otherwise desirable. 
         [0029]    Regardless of the manner in which the organic waste  30  is delivered to the container  12 , a naturally occurring microbial ecosystem will begin breaking down the organic waste  30  within and below the layer of fluid  32 . This microbial ecosystem will also inhabit the layer of rubber particulate  18  and feed on the contaminated gasses delivered upwardly through the layer of fluid  32  to the layer of rubber particulate  18 . 
         [0030]    A test facility was created to quantify the benefits of the biofilter  10  as the same could be used in the treatment of organic waste within a manure slurry pit that was set up similarly to that depicted in  FIG. 3 . A six week testing and sampling of the manure storage containers was completed and the results are presented in  FIG. 5 . The contents of the manure storage tanks were similar to those typically observed in under-barn pit storage. Odor reduction was studied for one inch layer of rubber particulate (sample 3) and three inch layer of rubber particulate with reference to a control tank (sample 2). For the three inch layer, experiments were based on the mode of addition of manure to the storage structure simulating an under-barn pit (sample 5) and an outdoor storage unit (sample 4). A container filled with water and a three inch layer of rubber particulate (sample 1) was used to obtain background readings for the rubber particulate. Sludge, lagoon top water and manure for these experiments were produced from a swine facility. 
         [0031]    As the table in  FIG. 5  indicates, the one inch layer of rubber particulate resulted in more than eighty percent odor reduction during sampling weeks 2, 3, and 6. Odor reduction diminished in other weeks where high ambient temperatures were experienced or the manure additions were made by dropping the waste through the layer of rubber particulate, simulating under-barn tank conditions, thus temporarily disbursing portions of the layer of rubber particulate and exposing the waste being stored below. Performance of the three inch layer of rubber particulate was superior compared to the one inch layer of rubber particulate, effecting an odor reduction to the extent of eighty to ninety five percent, irrespective of the manner in which the manure was added to the tanks or the ambient temperature. Other important facts discovered in the testing of the layers of rubber particulate include a ninety nine percent reduction of hydrogen sulfide and a ninety eight percent reduction in ammonia. 
         [0032]    The biofilter  10  of the present invention is sufficiently simple in its structure and design that it is easily used as a much smaller biofilter than that depicted in  FIG. 1  or  3 . For example, it is contemplated that a plurality of biofilters such as the biofilter  10 ′ depicted in  FIG. 4  could be used throughout a waste treatment system, such as a municipal sewer system. In that particular application, the container  12 ′ will preferably be provided with a sidewall  14 ′ and a bottom wall  16 ′. The bottom wall  16 ′ will preferably have one or more apertures formed therethrough that are sized and shaped to substantially prevent the passage of the layer of rubber particulate  18 ′ therethrough. However, the apertures within the bottom wall  16 ′ will permit the contaminated gasses emanating from the organic waste  30 , which flows beneath the biofilter  10 ′ within the conduit  36 , to pass through to the layer of rubber particulate  18 ′. A slightly increased pressure of the air within the conduit  36  will tend to direct the contaminated gasses upwardly through the bottom wall  16 ′ and through the layer of rubber particulate  18 ′ which will host the naturally occurring microbial ecosystem. When a cover  38  is used, such as a manhole cover, it should be provided with a plurality of apertures similar to those formed within the bottom wall  16 ′ so that the treated air may freely pass therethrough. 
         [0033]    It is contemplated that the layer of rubber particulate  18 ′ could be divided into a plurality of layers using apertured dividing plates  39  that are coupled to the side walls  14 ′. Additionally, a layer of activated carbon  40  may be provided to absorb a substantial portion of the small amount of contaminated gases that may pass beyond the layer of rubber particulate  18 ′. 
         [0034]    The biofilter  10 ′ is simply one example of the flexibility provided by the design of the biofilter of the present invention. The functionality of the biofilter  10 ′ will be nearly identical to that of the biofilter  10  and will be expected to have similar success in the treatment of the contaminated gases emanating from the organic waste  30 . 
         [0035]    Any of the contemplated structural embodiments of the biofilter will be appropriate for use in the treatment of low and high volume contaminating air streams that are characterized by a low or high concentration of a plurality of different gases and compounds. The biofilter is particularly well suited for the treatment of hydrogen sulfide, ammonia, aldehydes, Ketones, amines, aliphatic hydrocarbons and aromatic hydrocarbons. The use of recycled tires in particulate form makes the filter media easy to apply and nearly maintenance free over an indefinite lifetime. Moreover, the use of recycled materials provides an added benefit to the environment. 
         [0036]    In the drawings and in the specification, there have been set forth preferred embodiments of the invention and although specific items are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and proportion of parts, as well as a substitution of equivalents, are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims. 
         [0037]    Thus it can be seen that the invention accomplishes at least all of its stated objectives.

Technology Category: 7