METHOD AND DEVICE FOR LOADING A MATERIAL IN LAYERS, AND SYSTEM COMPRISING SUCH A DEVICE

Abstract

A method and a device for loading a material in layers, in which a first fraction of the material intended to form a first layer is fed to a belt conveyor located above a loading zone, tilting the conveyor about its longitudinal axis such that the entire first fraction is poured into a receiving zone in a receptacle to form a first layer, feeding a subsequent fraction of the material intended to form a subsequent layer to the conveyor, and then tilting the conveyor about its longitudinal axis such that the entire subsequent layer is poured onto the receiving zone to thereby form the subsequent layer.

Claims

1-20. (canceled)

21. A method for loading a material in layers, the method comprising: feeding a first fraction of the material intended to form a first layer to a belt conveyor located above a loading zone; forming the first layer by tilting the belt conveyor about its longitudinal axis such that the first fraction in its entirety is poured into a receiving zone in a receptacle; feeding a subsequent fraction of the material intended to form a subsequent layer to the belt conveyor; and forming the subsequent layer by tilting the belt conveyor about its longitudinal axis such that the subsequent layer in its entirety is poured onto the receiving zone.

22. The method of claim 21, wherein: forming the first layer comprises tilting the belt conveyor about its longitudinal axis in a first direction such that the first fraction in its entirety is poured onto the receiving zone, and forming the subsequent layer comprises tilting the belt conveyor about its longitudinal axis in a second direction opposite said first direction such that the subsequent layer in its entirety is poured onto the receiving zone.

23. The method of claim 21, further comprising, after forming the first layer and before forming the subsequent layer, levelling the first layer formed on the receiving zone.

24. The method of claim 21, wherein containing and decompaction of the first layer and the subsequent layer accumulated in the receptacle are carried out after a trajectory thereof in two successive phases between tilting the belt conveyor and the receiving zone.

25. The method of claim 21, wherein the belt conveyor is fed via an oblique cleated belt conveyor or a vertical cup conveyor located upstream of the belt conveyor.

26. The method of claim 21, further comprising forming as many successive layers as a feed rate allows, while observing a minimum biological retention times which vary from 10 days to 30 days according to a composition of a mixture of materials to be treated.

27. The method of claim 21, wherein the material comprises organic materials.

28. The method of claim 21, wherein the belt conveyor is tilted about its longitudinal axis via a tilting device.

29. The method of claim 21, wherein an automation device is used to stop movement of the belt conveyor when the belt conveyor is loaded, and/or automatically alternate a tilting direction of the belt conveyor.

30. The method of claim 21, wherein each material fraction is poured onto the receiving zone by gravity.

31. The method of claim 21, wherein the belt conveyor is tilted about its longitudinal axis via a dual-action actuator having an actuator body and a rod which is articulated in relation to the longitudinal axis.

32. The method of claim 31, wherein tilting the belt conveyor about its longitudinal axis comprises moving the rod of the dual-action actuator in relation to the actuator body.

33. A loading assembly for loading a material in layers, the assembly comprising: a belt conveyor operable to receive a fraction of the material; a feeding device operable to feed the belt conveyor with the material; a tilting device operable to tilt the belt conveyor about a longitudinal axis of the belt conveyor; and a receptacle having a receiving zone to receive the fraction of the material.

34. The loading assembly of claim 33, further comprising a device for containing and decompacting the fraction of the material during trajectory thereof between the belt conveyor and the receiving zone.

35. The loading assembly of claim 33, wherein the device for containing and decompaction comprise a series of pairs of rollers.

36. The loading assembly of claim 33, wherein the tilting device comprises a dual-action actuator having a rod which is articulated in relation to the longitudinal axis of the belt conveyor.

37. The loading assembly of claim 33, further comprising an oblique cleated belt conveyor or a vertical cup conveyor, located upstream of the belt conveyor, operable to feed the belt conveyor.

38. The loading assembly of claim 33, further comprising a discharge conveyor, located downstream from the receptacle, operable to receive formed layers of the material.

39. The loading assembly of claim 33, further comprising an automation device operable to stop movement of the belt conveyor belt when the belt conveyor is loaded with the material, and/or automatically alternating a tilting direction of the belt conveyor.

40. An installation system for treating a material in layers, the installation system comprising: a loading assembly for loading the material, the assembly including: a belt conveyor operable to receive a fraction of the material, a feeding device operable to feed the belt conveyor with the material, a tilting device operable to tilt the belt conveyor about a longitudinal axis of the belt conveyor, and a receptacle having a receiving zone to receive the fraction of the material.

Description

DRAWINGS

[0063] The invention will be described hereinafter, with reference to the appended drawings, given merely by way of non-limiting example, wherein:

[0064] FIG. 1 is an end view, illustrating a treatment installation equipped with a device for loading a material in layers, suitable for use thanks to the loading method according to the invention.

[0065] FIG. 2 is a front view, illustrating the treatment installation in FIG. 1.

[0066] FIG. 3 is a front view, illustrating the loading device belonging to the installation in FIGS. 1 and 2.

[0067] FIG. 4 is a top view, illustrating the loading device belonging to the installation in FIGS. 1 and 2.

[0068] FIG. 5 is an end view, illustrating the loading device belonging to the installation in FIGS. 1 and 2.

[0069] FIG. 6 is a front view similar to FIG. 3, illustrating further design details of the loading device in FIGS. 3 to 5.

[0070] FIG. 7 is a top view similar to FIG. 4, illustrating further design details of the loading device in FIGS. 3 to 5.

[0071] FIG. 8 is an end view similar to FIG. 4, illustrating further design details of the loading device in FIGS. 3 to 5.

[0072] FIG. 9 is an end view, illustrating a first functional position of the loading device, implemented according to the loading method according to the invention.

[0073] FIG. 10 is an end view, illustrating a second functional position of the loading device, implemented according to the loading method according to the invention.

[0074] FIG. 11 is an end view, illustrating a third functional position of the loading device, implemented according to the loading method according to the invention.

[0075] FIG. 12 is a perspective view, illustrating a treatment installation according to an alternative embodiment of the invention.

DESCRIPTION

[0076] The loading device according to the invention mainly comprises a belt conveyor (1), a longitudinal axis (2), a tilting device (3), an automation device (4), as well as optionally two rakes for levelling the discharging cones, formed of any suitable material. As seen in particular in FIGS. 1 and 2, this loading device is placed at the top part of an installation for treating the material, initially loaded by means of this device.

[0077] The belt conveyor (1) generally comprises a frame (5) composed of two side rails with spacers and rollers and a loading belt composed preferably of a series of planar meshes (6) organized in chains rather than a coated woven belt or belt optionally made of elastic composite. One or more rollers must be motorized by external connection to an electric or hydraulic motor or with a motor integrated in some rollers. Lateral guides disposed from place to place on the side of and along the conveyor belts, on the top face thereof, advantageously prevent the offset of said belt under the effect of gravity when the conveyor is tilted.

[0078] The longitudinal axis (2) is, most simply, composed of a tube (8) traversing triangular supports (9) to which it is attached, and which are connected at the top to the bottom of the frame of the conveyor (5). At each of its ends, this tube rests on a bearing (10) and at one thereof it is connected to a perpendicular arm, or coupling arm (11) which is connected to the tilting device (3).

[0079] The tilting device (3) is, most simply, composed of a dual-action actuator (3), which is hydraulic or pneumatic, optionally electric for small installations. The end of the cylinder (13) of this actuator is articulated on a fixed support and the end of the piston rod of the actuator (14) is articulated on the lower end of the coupling arm (11). The actuator is placed perpendicularly to the coupling arm (11) to which it communicates a thrust in one direction and a traction in the other direction which induce a half-rotation of the longitudinal axis, thereby actuating in the partial rotation thereof the frame of the belt conveyor. The return of the conveyor of the conveyor to the horizontal position results from an intermediate thrust or traction which returns the coupling arm (11) to the vertical position.

[0080] The automation device (4), which has a dual purpose, makes it possible on one hand to stop the travel of the belt of the conveyor (6) automatically when the latter is loaded satisfactorily along the entire length thereof. Moreover, it makes it possible to automatically alternate tilting on one side to the other of the axis of the conveyor (2). For the first need, this device can reasonably result from the use of a photoelectric cell (4) placed at the end of the conveyor at the level of the average uppermost point of the load thereof and the beam whereof will be interrupted when the loading interferes between the emitter and the receiver of the cell. This cell, which is connected to a relay which closes or opens the power supply circuit of the conveyor motors, also controls the activation of the second automation device by a relay.

[0081] An electromechanical device (4) composed for example of a contact plate disposed perpendicularly to the belt of the conveyor at the output end and moved by the thrust of the load conveyed at the end of travel, may represent a quite effective alternative. This plate pivoting on an upper horizontal axis assisted preferably by an adjustable-tension spring, will be connected to a spring-mounted contactor which will activate the set of relays.

[0082] The automation of the alternating tilting can be electromechanical for example, via the use of a two-state switch which is activated in contact with a push-button strategically disposed at the bottommost point on one side or the other of the frame of the conveyor, so that it coincides with the maximum cyclic travel thereof. The dual-action contactors open or close a circuit which controls the thrust or retraction of the actuator, which in turn moves the coupling arm. Failing electromechanical means, photoelectric cells or any other electronic device, of a type known per se, may be used with the same effectiveness.

[0083] The decompaction and discharge equipment is essentially composed of the assembly of clod-breaking equipment disposed in pairs across the entire width of the silo and horizontally along the entire length. Each pair comprises two clod-breaking cylinders (15) equipped with teeth, the arrangement whereof can vary according to the composition of the materials to be decompacted. The cylinders are moved preferably by a hydraulic motor (18) engaged on an end of one of the cylinders, the motricity connection with the other cylinder being provided either by a set of gear-trains (17), placed at the other end of the pair and which also makes it possible to obtain a rotation in the opposite direction in the clod-breaking pair. Another movement solution will consist of a system of chains associated with gear-trains engaged at each side of the axes of the rollers, the hydraulic motor actuating a motor gear-train. Another movement alternative can finally consist of an actuator which actuates transfer rods associated with a universal joint engaged with disks in turn associated with the axes of the rollers. These stainless or galvanized steel cylinders must have a sufficient thickness and diameter so as not to bend under the mass of the compost which bears thereon and so that the torque load remains within the limits of elasticity of the system. The cylinders (15) are equipped over the entire outer surface thereof with a set of steel teeth (16) wherein the shape and size which mostly determines the cutting, pulling and extraction power of the clod-breaking pairs is adapted to the type of compost to be mobilized.

[0084] At the ends thereof, the clod-breaking cylinders rest in bearings (19), in turn set up on a strutted steel beam (20) between each pair of cylinders with a vertical blade, which is rewelded onto the upper beam. The arrangement of these resting structures must not only ensure the rigidity of the system, but it must also enable the removal of a pair of cylinders without having to disassemble the entire clod-breaking assembly.

[0085] Advantageously, a horizontal discharge conveyor (21) completes this device. It is placed below, typically at about 1 meter, the clod-breaking cylinder assembly (15), and can be composed of a heavy-duty extra-wide belt conveyor or preferably of an endless floor conveyor. The role of this device is firstly that of collecting the compost produced by the clod breaking and storing it for a few hours (e.g. 24 hours) without any risk of leaching, then discharging it from the silo in a reduced time before receiving a new load. An insufflation line is disposed at either end of the conveyor or at the midpoint thereof to diffuse, in the curing windrow thus formed on the conveyor, breathing air drawn at the top of the silo. The discharge corridor is therefore closed at both ends thereof, but a filtered air outlet is arranged in the exit door.

[0086] The commissioning of the loading device, as described above, will be explained below with reference to FIGS. 1 to 11.

[0087] It is assumed firstly that the upstream conveyor, not shown, is located to the left of the loading device, in FIG. 1. The belt conveyor is started up, along the arrow F0, while actuating the upstream conveyor cited above. Consequently, a first fraction of the material, intended to be loaded thanks to this device, is fed onto the belt of this conveyor. When the material occupies the entire belt, this event is detected by the automation device (4), and the upstream conveyor and the main conveyor are stopped. Then, the actuator rod is moved along the arrow F1, so as to pivot the conveyor about the longitudinal axis thereof along the arrow f1, as shown in FIG. 10. The first fraction of the material, initially present on the belt surface, is then discharged onto the loading zone so as to form a first layer.

[0088] The basic operation above is started once again, so as to feed a second fraction of the material on the conveyor belt. When this second fraction occupies the entire belt, the two conveyors are stopped. Then, as shown in FIG. 11, the actuator rod is moved along the arrow F2, that is to say in an opposite direction to that of the movement thereof represented by the arrow F1. The conveyor then pivots about the main axis thereof along the arrow f2, that is to say along an opposite tilting direction to that represented by the arrow f1. The second fraction of the material, initially present on the belt surface, is then discharged onto the loading zone so as to form a second layer.

[0089] The basic operations above are repeated, so as to form a material thickness formed of as many layers as the silo feed allows, while observing the minimum biological retention time. Between two successive basic operations, the top layer, that is to say that which has just been discharged, is advantageously leveled.

[0090] Different examples of embodiment of the invention, relating to an intensified composting method used in various industrial treatment installations, will now be described. More specifically, we describe below an illustration of the use of the invention successively in these types of composting stations, then in an agricultural product drying application.

[0091] In a typical corridor windrow intensified composting station, the input materials, i.e., a mixture of milled structuring and volatile organic waste, are disposed as usual, thanks to a wheel loader. This vehicle removes a load with its bucket at the mixing mill outlet and will dispose it in the corridor windrow starting from the bottom of the windrow up to the open end thereof. The load is therefore vertical and sequential, each dose loaded covers the entire height of the windrow. The ground of the corridor windrow usually comprises one or more forced ventilation lines and optionally lateral moistening devices. In preferred configurations, a tarp or any other equivalent device is used to cover the windrows.

[0092] In continuous feed mode, these devices are not fully optimized in that the loading is not performed in successive layers, the first loads (at the end of the corridor) being more mature do not benefit from the insufflated air and must not be overly hydrated, the intermediate loads (in the middle of the corridor) have a decreasing requirement but still substantial hydric requirements, whereas the final loads (at the start of the corridor) need intense supplies. Furthermore, each load requires that the tarp or the covering device be partially removed or taken off.

[0093] A belt conveyor disposed at the apex of each corridor will make it possible to:

[0094] Every day, feed all or some of the corridor windrows according to input material availability by disposing successive layers of variable thickness on the entire surface of each windrow with only two small loading edges rather than a single large edge.

[0095] Every day, adjust the insufflation from the bottom and the moistening from the top according to the loading height of each windrow and particularly the incremented daily load in a layer.

[0096] Leave the windrow covered throughout loading insofar as the lateral-tilt conveyor can be very readily mounted on a mobile frame.

[0097] Furthermore, this device will make it possible to avoid:

[0098] The use and operation of a wheel loader, which requires a substantial area for maneuver for each windrow, since the milling and mixing device may be mobile and placed at the start of the conveyor and load it directly.

[0099] Frequent turning of the windrows since a single turning operation midway through the biological retention time will suffice to initiate a mesophilic phase (according to the teaching of French Patent No. 2,936,519).

[0100] In a containerized intensified composting station, the input materials, i.e. a mixture of milled structuring and volatile organic waste, are disposed as usual, thanks to a wheel loader. This vehicle removes a load with its bucket at the mixing mill outlet and will dispose it in the bin performing as many offset maneuvers as possible so as to form a rough form of homogeneous layers in height. However, unless a mechanical levelling device is available or workers performing this levelling inside the bin are available, the layers obtained will be geometrically irregular. The bin usually comprises one or more forced ventilation lines at the bottommost point thereof and optionally lateral moistening devices. In preferred configurations, a tarp or a rigid cover can be used to cover the bins. For the same reasons as explained above, in continuous feed mode, these devices are not fully optimized in that loading is not performed in homogeneous successive layers in geometrical terms.

[0101] A belt conveyor fed by an inclined conveyor, in turn receiving its load from the mixing mill, and disposed at the apex of each bin in the axis thereof and at the center thereof will make it possible to:

[0102] Every day, feed all or some of the bins according to input material availability by disposing successive layers of variable thickness on the entire surface of each bin with only two small loading edges rather than a single large edge.

[0103] Every day, adjust the insufflation from the bottom and the moistening from the top according to the loading height of each windrow and particularly the incremented daily load in a layer.

[0104] Leave the bin covered throughout loading insofar as the lateral-tilt conveyor can perfectly well be mounted on a rail-mounted mobile frame servicing several bins.

[0105] Furthermore, this device will make it possible to avoid:

[0106] The use and operation of a wheel loader, which requires a substantial area for maneuver for each bin, since the milling and mixing device may be mobile and placed at the start of the inclined conveyor and load it directly.

[0107] Frequent turning of the windrows since a single turning operation midway through the biological retention time will suffice to initiate a mesophilic phase (according to the teaching of French Patent No. 2,936,519).

[0108] In an intensified composting station in silos of rectangular cross-section with continuous top feed and bottom discharge, the input materials, i.e. a mixture of milled structuring and volatile organic waste, are disposed as usual, thanks to a telescopic-arm loader, the pre-composted or composted substrates being extracted from the bottom of the silo thanks to a clod breaker or any other equivalent device which loads a belt or screw discharge conveyor. The maneuvers of this vehicle and the effect of these maneuvers are similar to the description above, with additionally the difficulty of steering a bucket at the end of a fork or a telescopic arm. Moreover, for the same reasons as explained above, in continuous feed mode, these devices are not fully optimized in that loading is not performed in homogeneous successive layers in geometrical terms. This failing is especially important as, in silos, up to 6 m or more of substrate can be accumulated.

[0109] A belt conveyor fed by an inclined conveyor, in turn receiving its load from the mixing mill, and disposed at the apex of each silo in the axis thereof and at the center thereof will make it possible to:

[0110] Every day, feed all or some of the bins according to input material availability by disposing successive layers of variable thickness on the entire surface of each bin with only two small loading edges rather than a single large edge.

[0111] Every day, adjust the insufflation from the bottom and the moistening from the top according to the loading height of each windrow and particularly the incremented daily load in a layer.

[0112] Leave the bin covered throughout loading insofar as the lateral-tilt conveyor can perfectly well be mounted on a rail-mounted mobile frame servicing several bins.

[0113] Furthermore, this device will make it possible to avoid:

[0114] The use and operation of a telescopic wheel loader, which requires a substantial area for maneuver for each bin, since the milling and mixing device may be mobile and placed at the start of the inclined conveyor and load it directly.

[0115] In a unit for drying agricultural or sylvicultural products, it is frequently required to dispose damp substrates such as leaves, straw, coarse sawdust, shredded wood or bark in a rectangular receptacle closed on all sides, such as a bin or a silo, which receives at the bottom thereof a supply of hot or very hot air depending on the products and the process used. Generally, the moist air resulting from the injection of hot primary air is evacuated by natural convection or by suction at the uppermost point of this receptacle and at the end of a cycle, the drying sought for the treated substrates is obtained. However, if, in this bin or this silo, geometrically irregular loading is performed, as described above, because the loading means is a bucket loader, the drying will be incomplete in some zones of the treated product, because the natural or forced convection by suction at the uppermost point will circulate more or less moist air in the loading hollow zones.

[0116] Traditional drying is also frequently performed by exposure to the wind and sun for materials that cannot be accumulated in thick layers, this is the case for example of milled products from cassava, coffee and cocoa beans, vanilla pods. This traditional drying, requiring automation however in industrial configurations is performed in shallow trays, often with a wire mesh bottom and cover. Mechanical loading with manual levelling or fully manual loading makes it possible to form geometrical homogeneous layers. However, such a practice tends to disqualify businesses economically due to their high operating cost particularly for low added-value products. The use of a lateral-tilt conveyor fed by an inclined conveyor disposed above a filling bank which receives the drying trays will obviously provide balanced loads, which are much easier to level with an improved throughout while retaining the traditional product treatment method.

[0117] FIG. 12 illustrates an alternative embodiment of the invention. According to this embodiment, the loading method described above is implemented, in particular with the decompaction devices thereof, in a silo of square or rectangular cross-section of small dimensions. In that vein, it consists for example of the lesser side of a 20-foot container, the dimensions whereof are typically 2.20 m by 2.70 m.

[0118] This embodiment does not necessarily make use of the upper lateral-tilt conveyor described above. However, all the other mechanical elements described and claimed can be incorporated in this embodiment, according to all the technically compatible combinations for a person skilled in the art.