Portable system and method for processing waste to be placed in landfill

Abstract

A portable system and method for processing waste to be solidified and placed in an active cell of a landfill. A portable base frame for supporting a landfill waste enclosure such as a silo or pressurized vessel may be used. An improved slide gate for use with the silo, as well as an improved feed hopper for conveying landfill waste, are also disclosed.

Claims

1. A portable system located on a landfill for use in storing and processing waste so that it can be made landfill-ready, wherein the portable system may be moved between different open cells on the landfill, comprising: a portable silo for receiving and storing the waste, the portable silo having support legs; a base frame portable over a surface of the landfill, wherein the base frame is connected to the support legs at attachment points, and the base frame supports the portable silo on the landfill surface; wherein the base frame comprises support members and at least three outrigger legs, and wherein two of the outrigger legs extend a first distance outside a perimeter formed by the attachment points, wherein the first distance is substantially further outside the perimeter than a second distance by which the remaining outrigger legs extend outside the perimeter, to thereby substantially increases the moment arm required to overturn the base frame.

2. The portable system of claim 1, wherein the base frame comprises skids which may be slid along a surface of the landfill.

3. The portable system of claim 1, wherein the base frame support members and outrigger legs are attached to each other, and the support members are attached to the silo support legs.

4. The portable system of claim 1, further comprising a conveyor for transferring landfill material from the silo to a portable pugmill.

5. The portable system of claim 4, wherein, the conveyor is connected to the portable base frame and to the silo by cables or other structural supports.

6. The portable system of claim 1, wherein the enclosure comprises a pressurized vessel.

7. A portable system located on a landfill for use in storing and processing waste so that it can be made landfill-ready, wherein the portable system may be moved between different open cells on the landfill, comprising: a portable silo for receiving and storing the waste, the portable silo having support legs; a base frame portable over a surface of the landfill, wherein the base frame is connected to the silo support legs at attachment points, and the base frame supports the portable silo on the landfill surface; wherein the base frame comprises support members and at least three outrigger legs, and wherein two of the outrigger legs extend a first distance substantially outside a perimeter formed by the attachment points, wherein the first distance is substantially further outside the perimeter than a second distance by which the remaining outrigger leg(s) extend outside the perimeter, to thereby substantially increase the moment arm required to overturn the base frame; and a portable pugmill supported by a sled, wherein landfill material may be transferred from the silo to the portable pugmill.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The novel features which are characteristic of the invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages thereof, can be better understood by reference to the following description taken in connection with the accompanying drawings, in which:

(2) FIG. 1 is a perspective view of one preferred embodiment of the present invention;

(3) FIG. 2 is an enlarged view of the portion of the system circled on FIG. 1;

(4) FIG. 3 is a sectional view taken along reference line 3/3 of FIG. 2;

(5) FIG. 4 is a perspective view of an alternative embodiment of the present invention;

(6) FIG. 5 is a perspective view of another alternative embodiment of the present invention;

(7) FIG. 6 is a top view of a silo frame according to one preferred embodiment of the present invention;

(8) FIG. 7 is a front, sectional view of the silo frame along reference line 7-7 of FIG. 6;

(9) FIG. 8 is a top and side, parts perspective view of the silo frame shown in FIGS. 6-7;

(10) FIG. 9 is a side perspective view of one preferred embodiment of the invention showing a silo frame, silo, conveyor belt and pug mill;

(11) FIG. 9A is a top view of the pugmill/conveyor/silo system of FIG. 9;

(12) FIGS. 10 and 10A are top and side perspective views, respectively, of a prior art slide gate;

(13) FIG. 11 is a top perspective view of a slide gate according to a preferred embodiment of the present invention;

(14) FIG. 11A is a side, sectional view along reference line 11A-11A of FIG. 11;

(15) FIG. 11B is an enlarged perspective view of a corner of the slide gate circled in FIG. 11;

(16) FIG. 12 is a top and side perspective view of a slide gate according to a preferred embodiment of the present invention, prior to its insertion into the slide gate track located below a lower, conical portion of the silo shown;

(17) FIG. 12A is a sectional view taken along line 12A-12A of FIG. 12;

(18) FIG. 13 is a top and side perspective view similar to FIG. 12 in which the slide gate has been inserted into the slide gate track;

(19) FIG. 14 is a top and side perspective view of the rear of a truck unloading landfill material into an open-ended feed hopper, as known in the prior art;

(20) FIG. 14A is a front view of the feed hopper shown in FIG. 14;

(21) FIG. 15 is a top and side perspective view of the rear of a truck unloading landfill material into an open-ended feed hopper according to a preferred embodiment of the present invention;

(22) FIG. 15A is a front view of the feed hopper shown in FIG. 15;

(23) FIG. 16 is a partial top and front perspective view of the feed hopper shown in FIG. 15; and

(24) FIG. 17 is a side perspective view of the feed hopper shown in FIG. 15.

(25) The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. In the drawings, like reference numerals designate corresponding parts throughout the several views.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(26) Set forth below is a description of what are believed to be the preferred embodiments and/or best examples of the invention claimed. Future and present alternatives and modifications to this preferred embodiment are contemplated. Any alternatives or modifications which make insubstantial changes in function, in purpose, in structure, or in result are intended to be covered by the claims of this patent.

(27) Referring now to FIG. 1, a preferred embodiment of the portable system of the present invention for solidifying sludge waste and transporting it either to haul trucks for depositing to an active cell of a landfill, or for direct discharge into the active cell, is shown and generally referred to by reference numeral 10. With system 10, dry solids may be truck-fed onto an intake conveyor 15, and discharged into pugmill 20, such as a double-paddle mixing pugmill having blades 20a set on multiple rotor shafts 20b. Simultaneously, a liquid pump (not shown), such as a 3-inch or 4-inch diameter liquid pump, may be used to feed liquid/sludge waste into pugmill 20. The liquid pump may have flexible inlet piping to connect to liquid waste storage containers which may be mounted on a tanker trailer, for example (not shown). The liquid pump may also have flexible outlet piping (with a flow-restricting valve, not shown, to control flow rate) to connect to pugmill 20, to deliver liquid/sludge waste stored in the tanker trailer(s) (e.g., liquid waste, leachate or water) to pugmill 20. The flow rate of the liquid feed should be sufficient to control dust, or to wet the dry solids to the point where the mixture will meet the Paint Filter Test (PFT) requirements. The resulting solidified waste, suitable for landfill storage, may then be discharged from outtake conveyor 25 into a haul truck, or directly into an active cell 30 of a landfill. As examples, conveyor 15 may be about 12-feet in the air at its highest point, whereas conveyor 25 may be about 15-feet in the air at its highest point.

(28) Approximate mixing ratios have been developed that will pass the required PFT test for two common solid feed materials that may be processed by the present invention: (a) coal ash (1:1 by weight, solids to water-based liquids); and (b) scrubber waste (2:1 by weight, solids to water-based liquids). (In a coal power plant, combustion products from the stack are scrubbed, removing sulfur and other pollutants, using components such as calcium carbonate and gypsum.) The pugmill solid and liquid feed rates may be adjusted in order to provide these ratios.

(29) Other solid feed materials may be used, of course, and different weight ratios may be developed. Non-limiting examples of solid feed materials that may be treated by the present invention include: scrubber waste from scrubber systems operating on other combustion products (e.g., cement kilns, etc.); sawdust; auto fluff (shredded, non-metal portions of automobiles); by-products from the coal combustion, such as fly ash, bottom ash; diapers, or any other solidification materials approved by the permit, etc.

(30) Referring again to FIG. 1, solidified waste discharged from pugmill mixer 20 may be permitted to drop onto receiving conveyor 25, which can be configured to deposit the material directly into a waiting haul truck, or directly into an active cell of a landfill. Samples of the material discharged from the pugmill mixer may be periodically obtained and subjected to a Paint Filter Test to verify that no free liquids are present.

(31) As a non-limiting example, the conveyors and pugmill may be obtained from Pugmill Systems Inc. of Tennessee, or other manufacturers in the industry.

(32) In a particularly preferred embodiment of the present invention, the pugmill, short silo and conveyors may be mounted on sleds, such as structural steel sleds 60, providing both the ability to transport this equipment, while also the ability to do so in a stable manner, despite often the presence of difficult (uneven, muddy, etc.) landfill terrain. A sled can also more easily be leveled than wheeled conveyors. (Alternatively, although less preferred, a trailer may be used to mount the pugmill, short silo and conveyors. As discussed below, bearing pads (such as for the portable silo) or wheeled structural devices may also be used.)

(33) Preferably, the sled is flexible enough to accommodate uneven and unstable landfill terrain, while strong and stiff enough to hold the operating equipment in a stable manner under dynamic loading during operation. Further, the sled frame must be able to be easily leveled using, e.g., timbers at different frame locations, as dictated by the ground conditions of the final set-up, without inducement of excessive stress.

(34) Ancillary equipment for the system may include a portable trailer (or, alternatively, sled-mounted or bearing-pad mounted) which may be used to mount one or more diesel-powered generators, such as with a capacity of 200-300 KW (460/480V 3-phase) or larger, liquid storage containers, and an electric-powered (e.g., 3-4 inch diameter) liquid pump. The generator can be electrically connected to the pugmill system control panel, which then powers all necessary electric equipment.

(35) A control panel (not shown) may be used to control the speed/rate of intake conveyor 15, pugmill 20 and discharge conveyor 25, and other ancillary equipment which may be used, such as a silo airlock, a silo aerator and a silo dust-house vibrator (discussed below).

(36) Depending on the waste being landfilled, some landfill customers may require delivery of their waste in trucks with live floor trailers, which then deposit the waste onto an inclined feed conveyor (feed mode A or FMA) leading to the pugmill. (One live floor trailer which may be used is the 45-foot Aluminator trailer (4266542) manufactured by Valley Farm Industries of Nebraska, which allows the discharge of solids with minimal dust generation.) Other landfill customers may have different waste which requires its delivery via pneumatic trucks, which may then feed the waste into short-silo storage (feed mode B or FMB), which in turn gravity-deposits the waste into the pugmill, using the airlock to control feed rate. In FMB, for example, one to four pneumatic trucks may be used to unload solids simultaneously for immediate processing. (Again, no long-term material storage is required).

(37) Referring to FIG. 4, an embodiment in FMA mode is shown. Here, a truck with a live floor trailer 65 may be positioned, for example, and delivers solid waste down chute 68 onto conveyor 15, which delivers the solid waste to pugmill 20, where it may be mixed with liquids (not shown) and the resulting waste suitable for a landfill may be delivered by conveyor 25 either to a haul truck for delivery to an active cell 30 of the landfill, or discharged directly into an active cell 30 of the landfill, for example.

(38) Referring to FIG. 5, an embodiment in FMB mode is shown. A short portable silo 70 may be employed to straddle or stand beside pugmill 20 (portable structural components for holding the silo over the pugmill are not shown), allowing unloading and feeding solids using pneumatic trucks (not shown), into the silo, and then from the silo into the pugmill. A pumper truck 50 can also deliver sludge or water-based waste into the pugmill, as shown. Instead of resting on a transportable sled or a trailer, portable silo 70 may rest on bearing pads (e.g., flat steel plates), which rest directly on the active cell of a landfill. When it needs to be moved, portable silo 70 may be lifted and dropped by a crane or other device, or it may be dragged on its bearing pads. Portable silo 70 has no fasteners (such as anchor bolts) tied to the landfill. However, the columns supporting the portable silo may be welded to the bearing pads. Alternatively, a wheeled structural device may be used to support the silo.

(39) Preferably, the present invention can accommodate either of the two modes FMA or FMB. The system solid feed mode may preferably be switched back and forth between FMA and FMB, at the operator's discretion, taking negligible time to do so. For example, if in FMA mode and the operator desires to switch to FMB mode, power to the feed conveyor (intake to pugmill) may be switched off, and a chute may be opened between the short silo and the pugmill; now, hose/pipe fittings for one or more pneumatic trucks may be connected to the silo intake nozzle(s), and the short silo airlock, dusthouse equipment and vibrators may be powered on; and finally the pneumatic truck systems may be started, conveying the solids into the short silo, which then gravity-feed into the pugmill through the airlock which controls the feed rate.

(40) To further eliminate dust, a dust hood may be provided that fits over feed conveyor 15, while allowing the trailer to back into the dust hood. The dust hood may be under induction draft fan negative pressure, so that any dust generated during solids unloading and conveying may be drawn into covered conveyor 15. A manual or automatic shutoff may be provided in the dust hood if sensors determine that dust guidelines (such as the 5-20% moisture content test, by weight) are not being met.

(41) It is believed that use of the system disclosed here will generate a negligible amount of dust in the sealed feed conveyor, pug mill and discharge conveyor. As some dust may be generated during truck unloading into the feed hopper, if needed a negative pressure dust-hood with a conventional induction draft blower may be provided, as discussed above which the truck can back into. Any dust inside the dust-hood can be conveyed to an opening in the feed conveyer.

(42) An automatic solid and liquid electronic measuring and control system can be readily engineered, such as by using microprocessors and motors available from Allen Bradley of Milwaukee, or other manufacturers, and using appropriate electronic sensors, to provide real-time feed rates to the pugmill of solid and liquid waste streams. Additionally, the electronic measuring system may also be used to provide real-time pugmill product discharge flow rates and the percentage make-up of liquids and solids in the waste discharge. Using these enhancements, a closed loop control system may be provided, in which a single operator could specify the desired liquid/solid ratios, by weight percentage, of the mixture from the pugmill, and the feed conveyor rate (i.e., belt speed) and liquid waste flow rate (flow valve) could be adjusted to produce these desired liquid/solid ratios. Only occasional sampling for PFT compliance would then be required as the waste is landfilled.

(43) Electrical switch gear (panel boxes, disconnects, breakers, etc.) may be obtained from Square D of Illinois (now owned by Schneider Electric), or other manufacturers. The electric motors, for turning the dual pugmill shafts, for driving the discharge and feed conveyor belts, for the portable silo motors, and for the fan motor for driving the dust hood fan, may be obtained from General Electric (Indiana), or other manufacturers. The GE pugmill motors turn about 1800 rpm, and the pugmill shafts turn about 30 rpm, using a speed reducer which may be obtained from Dodge/Balder (Arkansas). The variable frequency drive for the pugmill may be obtained from Danfoss (Denmark). The liquid pump(s) referenced above may be obtained from any of the following sources: Godwin (New Jersey); Wacker (Wisconsin); or Gorman/Rupp (Ohio). An electrical generator(s) may be obtained from Caterpillar Tractor Company. The short, portable silo referenced above may be obtained from Belgrade (Minnesota). The electronic controls may be obtained from Allen Bradley (Wisconsin), as described above. These items are available from alternative manufacturers as well.

(44) In the preferred embodiment disclosed here, exemplary electrical (horsepower, HP) requirements may be as follows: first pugmill motor (50 HP); second pugmill motor (50 HP); feed conveyor motor (20 HP); discharge conveyor motor (20 HP); silo air-lock motor, if used (5 HP); silo aerator motor, if used (4 HP); silo dusthouse vibrator, if used (1 HP); pump (up to 50 HP). The total power requirements may be up to 250 HP.

(45) A person of ordinary skill in this art will now readily appreciate various advantages of the present invention. The system can be made entirely portable, enabling it to be located anywhere over a landfill area that has both a certified liner and an operating leachate collection system, including an active cell face. This enables the landfill operator to process the final waste product at a location closely adjacent to its final destination. Also, once initially erected, the systems disclosed may take no more than 1-2 days to move and set-up at a new location in the landfill. Additionally, in a preferred embodiment, the system does not require any dry material storage capacity; dry solids may be processed as they are unloaded from either live-floor or pneumatic tractor trailers.

(46) If necessary, to alleviate equipment layout challenges at the selected waste solidification location, the feed conveyor can be rotated and operated up to 90 degrees in either direction from the straight-on configuration shown in FIG. 1.

(47) The system disclosed here will accept up to 25 tons of dry combustion waste which may include coal ash, bottom ash, or scrubber waste, from a live-floor transport trailer, and process it in a relatively short period of time, such as the about 15-minute unloading time (300 tph), in a nearly dust-free condition. The dry solids will be mixed with up to 25 tons of liquid, also in the same short period of time of about 15 minutes (300 tph=1200 gpm). Of course, the system disclosed here can be scaled up or down to process greater or lesser amounts of liquid waste. Should insufficient dry coal combustion waste be available to mix with incoming liquid wastes, any permit-approved solid/special waste or permit-approved solidification material (i.e., currently permitted reagents, absorbents and purchased solidification materials) may be used for pugmill liquid waste solidification.

(48) Landfill liquid waste, leachate waste or lakewater may be transported to the pugmill via a tanker truck.

(49) If it is desired to deliver solids via multiple pneumatic trucks, the system may be retrofitted with a short upright silo, for example, that includes a powered air-lock, aerator, and dust-house vibrator. The silo may be installed to straddle or mount beside the pugmill, and may be filled by one to four pneumatic trucks simultaneously. Each truck, holding for example 20-25 tons of solids, can deliver their solids to the silo in about 30-45 minutes. If this feature is used, this will provide two modes of feeding the pugmill that can be easily switched back-and-forth.

(50) Silo Frame (See, e.g., FIGS. 6-9)

(51) Referring first to FIGS. 6-8, in a preferred embodiment, silo base frame 100 is intended to support silo 70 on a landfill surface (FIG. 9). Silo base frame 100 may be formed from silo support members 105a, 105b and outrigger legs 105c, 105d (see FIGS. 6 and 8). (Items 105e, 105a and 105d may form one integral piece or, for travel purposes, may be three separate pieces attached together, for example.) Steel plates 107 and fasteners (not shown) may be used to attach the support members and outrigger legs to each other to form a stable, secure and portable base frame 100, as shown (FIGS. 6 and 8). To support silo 70, four silo support legs 70a (FIG. 9) may be attached to the four corners of silo base frame 100 at support plates 107, such as by welding and/or using fasteners as known in the art. The four corners, at these four attachment points, form a square and a silo base perimeter outside which outrigger legs 105c, 105d preferably extend.

(52) Outrigger legs 105c, 105d, may be field-welded or otherwise securely attached at each base frame corner, to protect against lateral forces attempting to overturn silo 70. Web stiffeners (not shown) may be provided at the corners. The ends 106 of outrigger legs 105 may be pointed (see FIG. 7-8), to allow base frame 100 to be more easily dragged over the landfill, if a separate sled is not used. Base frame 100 may include two super-extension outrigger legs 105d to further protect against lateral forces (such as provided by wind or seismic activity), and also to allow silo base frame 100 to be tied into conveyor 115 (FIG. 9) (which transfers material into pug mill 65), to provide conveyor with additional stability, and vice-versa. As a non-limiting example, the following lengths may be used (which will vary depending upon the size and full-enclosure weight, etc.): the square formed by support members 105a, 105b may be about 9-feet on each leg; outrigger legs 105c, 105e may have a length of about 3.3 feet; and super outrigger legs 105d may have a length of about 8 feet. (Again, the length of the support members and outrigger legs will obviously depend on the height and weight of the silo, the weight of the material, the type and girth of steel used for the support members and legs, etc.)

(53) Referring to FIGS. 9 and 9A, cables 120 or 123 may run from silo 70 or silo legs 70a to conveyor 115 as well as to heavy supports (e.g., large concrete blocks 121) on the landfill surface and outside of the area contained by silo base frame 100. Similarly, although not shown, cables may tie in to pugmill 20.

(54) As silo base frame 100 effectively forms moveable, pointed skids, and pugmill 20 is also portable (mounted on sled 60), this allows the entire unit (pugmill 20, conveyor 115 and silo 70) to be moved substantial distances over the uneven ground of the landfill, so that the entire unit can be moved from landfill cell to cell.

(55) Slide Gate (See, e.g., FIGS. 10-13)

(56) Referring now to FIGS. 10-13, a prior art slide gate 130 is shown in FIGS. 10 and 10A, while a preferred embodiment of an improved slide gate 140 is shown in FIGS. 11, 11A, 11B, 12, 12A and 13. Slide gate 140 includes a leading edge 141 (FIG. 11A) that has inwardly-angled edges 142 (FIG. 11B) located at opposing corners of leading edge 141 (FIG. 11). Edges 142 are preferably inwardly angled so as to divert material toward the middle of leading edge 141, and away from the opposing corners of leading edge 141. Referring to FIG. 11A, leading edge 141 is preferably beveled to better cut through landfill material. Slide gate 140 is believed to substantially decrease the time needed to drive the slide gate through the material within slide gate track 150 (FIGS. 12-13), in order to stop the downward flow of material through vertical silo 70 in emergency stoppage situations, for example.

(57) Referring now to FIGS. 12, 12A and 13, again, inwardly-angled, corner-located wedges 142 may be used to tend to drive material within slide gate track 150 toward the middle of the track, down through slide gate track opening 150a, and away from the 3-sided corners 142 of track 150, where frictional resistance is greatest. Slide gate 140 is also preferably made of a high-strength spring steel, which is less deformable on impact. Referring to FIG. 11, leading edge 141 of slide-gate 140 may also be beveled, tipped or spear-shaped to better cut through the material present within slide gate track 150.

(58) Redesigned Feed Hopper (See, e.g., FIGS. 14-17)

(59) Referring now to FIGS. 14 and 14A, truck 163, which may be a dump truck as shown but which preferably is a truck with a live floor trailer (i.e., a non-tipping truck with a floor conveyor that pushes its loaded material out the rear of the truck), unloads landfill material into a conventional feed hopper 160 with flat sides 161 connecting slightly angled sides 162; the material then proceeds through the bottom of feed hopper 160 to conveyor 165, for further processing. Referring now to FIGS. 15-17, a preferred embodiment of the present invention is shown, in which feed hopper 170 has widening sides 173, 172, allowing the rear of dump truck 163 to fully unload into the new feed hopper, such that truck sides 163a lie entirely within opposing sides 171 of hopper 170. This eliminates spillage that was prevalent with conventional feed hoppers. Bumpers 191 may be located to provide the truck operator with notification that the truck has been backed-up in an appropriate location relative to the sides of hopper 170.

(60) Referring now to FIG. 17, feed hopper 160 may be mounted on sled 60. Structural supports 180 may be used to support the feed hopper in an inclined position over conveyor 165.

(61) Mixing Two Different Solids Materials Simultaneously, from the Feed Hopper and from the Silo, and Transferring them into the Conveyor

(62) It may also be useful to mix solids materials from feed conveyor 165 (shown in FIGS. 15-17, coming from feed hopper 170) and solids materials from silo 70 (via conveyor 115 of FIG. 9) into pugmill 20 (see, e.g., FIG. 9, although conveyor 165 is not shown there), in various predetermined proportions. For example, solids material from feed conveyor 165 (transferred from feed hopper 170, which has been off-loaded from a dump or pneumatic truck, for example) may have a better potential for absorbing liquids, and by mixing these solids with solids from the silo (via conveyor 115) within the pugmill, in a predetermined, desired ratio, this may provide the landfill operator with a more efficient process in order to transfer material from the pugmill directly into a landfill cell.

(63) Gravity-Fed Liquid Flow into Pugmill

(64) It may be useful to provide liquid storage tanks (not shown), elevated from the pugmill, for the purpose of adding liquid to the material within the pugmill.

(65) Use of Leachate or Other Liquid Waste

(66) Leachate (liquid passing through a landfill cell and collected at its bottom) and other liquid landfill waste has formerly been pumped into tanker trucks, and then pumped from tanker trunks into the pugmill. It is proposed to improve this process by providing a piping system (not shown), below the landfill cells, leading from the leachate storage tanks, or other liquid waste storage tanks, to allow the leachate or other liquid waste to be pumped under the influence of gravity directly into the pugmill.

(67) The above description is not intended to limit the meaning of the words used in the following claims that define the invention. Persons of ordinary skill in the art will understand that a variety of other designs still falling within the scope of the following claims may be envisioned and used. As another example, dust hoods and other accessories are optional, as indicated above. It is contemplated that these additional examples, as well as future modifications in structure, function, or result to that disclosed here, will exist that are not substantial changes to what is claimed here, and that all such insubstantial changes in what is claimed are intended to be covered by the claims.