A NOVEL METHOD AND AN APPARATUS IN CONVERTING UNSORTED MUNICIPAL SOLID WASTE INTO GEO-POLYMER PELLETS/BRIQUETTES AND GEO-POLYMER BRICKS/PAVER BLOCKS

Abstract

Apparatus and method in converting municipal solid waste into geo-polymer briquettes and geo-polymer bricks comprising bag opener cum crushers, magnetic separators for ferrous and-eddy current separators for non-ferrous things; squeezer for removing liquid content; inter particle collision driers for drying; pulverizer for pulverizing, and devolatizing carbonization reactor for carbonisation of combustible MSW to produce solid char with low water content. Solid char is mixed with geo-polymer binding agent/starch/tar/to form combustible pellet/briquette. These highly combustible briquette/pellets have high calorific value. The pellet/briquette is formed by rotating combustible char at high rpm and compaction. Pellet has a water content of less than 5% by weight and fuel value of 5500 to 6500 KCAL. This process produces non-combustible geo-polymer brick. The non-combustible MSW separated by a trommel is crushed by inter particle collision crusher and pan mixers mixing with geo-polymer binding agent/fly ash/quarry dust/chips or china clay and moulded.

Claims

1. A novel method in converting all municipal solid waste into geo-polymer pellets/briquettes and geo-polymer bricks/paver blocks comprising of the following stages: i. unsorted MSW being moved from the dump yard through a conveyor belt onto a ramp and then passing through a bag opener for opening household bags containing MSW; ii. opening the household bags containing MSW; iii. simultaneously crushing and squeezing as a result of which the breakable items such as building materials are broken into particles of smaller sizes and removing liquid content which gets delivered into an effluent treatment plant; iv. putting unsorted MSW through a magnetic separator for removing ferrous things and eddy current separator for non-ferrous things before being put into trommel; v. separating the unsorted dry MSW devoid of ferrous and non ferrous things by a trommel for separation into substantially combustible and non-combustible MSW where combustible MSW passes through inter particle collision drier, inter particle collision pulverizer and de-volatizing and carbonizing reactors resulting in creation combustible high calorific value pellets and briquettes and non-combustible MSW passes through inter particle collision crusher and pan mixer resulting in the making of bricks and paver blocks; vi. and thereby converting the whole unsorted municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or paver blocks with minimal recycling, zero residue waste and zero land filling requirement.

2. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein bag opening and crushing is done with the spikes of the bag opener and shearing the household bags containing unsorted MSW and letting unsorted MSW into the wedge between the concurrently rolling two stage serrated double drum crusher with heavy colliding springs crushing and removing 50% of liquid content of unsorted MSW.

3. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein drying the shredded combustible MSW is done by a heating process generated by collision of inter particles due to their rotation caused by a flat blades on a rotating shaft across the stationary flat blades on the walls, and the drum shaped inter particle drier at high speed resulting in heat generation and drying while an inbuilt moisture absorber sucks the moisture through a moisture separating, heat exchanging, dust collecting cyclone system leaving combustible MSW dry.

4. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein pulverizing by inter particle collision pulverizer that cuts the dry combustible MSW further into finer particles performing moisture separating, heat exchanging and dust collecting.

5. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein de-volatizing and carbonization of combustible MSW is done by passing them through five stage reactor in which four stage step by step heating of the combustible MSW takes place by thermic fluid heat increasing process from 50 Degree Celsius at the first stage to 300 degree in the fourth stage ensuring carbonization and controlled removal of volatile gases.

6. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein the cooling of combustible MSW is done at fifth stage of the five stage reactor by a single stage cooling system at the bottom intensifying the density of carbon molecules by de-volatizing carbonization process converting the combustible MSW into high calorific value fuel, reducing moisture and removing of volatile gases.

7. A novel method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 1, wherein an inter particle collision crusher which has both stationary sharp blades and flat moving blades moving at high speed creating centrifugal force crushes the non-combustible MSW repeatedly and it gets sheared and converted into powder form during which process the heat generated and the moisture is removed through a moisture separating, heat exchanging, dust collecting cyclone system.

8. An apparatus for carrying out the method in converting all municipal solid waste into pellets and geo-polymer briquettes and geo-polymer bricks comprising i. a conveyor belt for moving the unsorted MSW from the dump yard onto a ramp and made to pass through a bag opener; ii. a bag opener and crusher for opening household bags containing unsorted MSW to compress the unbreakable and break the breakable components and for crushing and squeezing to remove liquid content; iii. a magnetic separator for removing ferrous things and eddy current separator for non-ferrous things from MSW before being put into a trommel; iv. a trommel for separation into substantially combustible and non-combustible MSW through size separation; v. inter particle collision drier, inter particle collision pulverizer and de-volatizing and carbonizing reactors to make combustible MSW into combustible high caloric value pellets or briquettes; vi. Inter particle collision crusher and pan mixer to crush the non-Combustible MSW and a brick/paver molding plant to make into bricks and paver blocks;

9. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, the trommel is for size separation and inter particle collision crusher and pan mixer, moulder and drier to process the non-combustible MSW with addition of quarry dust/chips and fly ash to add strength and geo-polymer agents for inseparable bonding using geo polymerization process.

10. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, the trommel is for size separation and inter particle collision crusher and pan mixer, moulder and drier are meant to process the non-combustible MSW consisting of materials like glass, stone, mud and debris are crushed and pulverized and mixed with china clay/fly ash, quarry dust/chips, river sand, cement and molded into fly ash bricks and fly ash paver blocks.

11. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, the bag opener has spikes in the bag opener for piercing and shearing the household bags containing unsorted MSW and twin stage serrated double rolling drum crushers for letting unsorted MSW into the wedge between the concurrently rolling two stage double drum crusher with serrated ridges tangential to the axis of rotation of the crusher drum in the first stage and serrated ridges perpendicular to the axis of rotation of the crusher drum in the second stage in order to avoid slipping of material and increases the efficiency of the crusher, with heavy colliding springs crushing the breakable items such as building materials into finer particles and squeezing unbreakable items such as food waste and plastic. And simultaneously removing 50% of liquid content of unsorted MSW and delivering it to an effluent treatment plant.

12. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, the fluid extractive compressor which has a top end inlet for combustible MSW to be put inside and an outlet placed at the bottom for compressed combustible MSW to pass through which completes one cycle of compression and retraction every minute as two pistons moving against each other with heavy force for compressing and thereafter the front end piston retracting and back end piston pushing the compressed combustible MSW instantaneously until it falls through outlet simultaneously letting liquid content to the effluent treatment plant.

13. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, inter particle collision drier top shutter and bottom shutter which are in turn operated by a PLC controlled hydraulic system and which contains an inlet for making the 5 MM shredded Combustible MSW to go through a drying process due to heat generated by collision of inter particles due to their rotation of flat blades mounted on a rotating shaft across the stationary flat blades mounted on the walls, of the drum shaped drier being rotated at high speed resulting in heat generation and drying, while an inbuilt moisture absorber sucks the moisture through a moisture separating, heat exchanging, dust collecting cyclone system leaving Combustible MSW dry.

14. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or pavers as claimed in claim 8 wherein, the inter particle collision pulverizer provided with an input feeding and output discharging screw conveyor and which has sharp moving as well as sharp stationary blades of unique shape of sickle devices to cut the dry combustible MSW further into finer particles for moisture separating, heat exchanging dust collecting cyclone system.

15. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks as claimed in claim 8 wherein de-volatizing and carbonization of combustible MSW is done by passing them through five stage reactor (of which the last stage is cooling stage) that heats up the combustible MSW step by step in four stages by thermic fluid heat increasing process from 50 Degree Celsius at the first stage to 300 degree in the fourth stage ensuring carbonization and controlled removal of volatile gases.

16. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets or briquettes and geo-polymer bricks or paver blocks as claimed in claim 8, wherein the combustible MSW powder passed into the first cylinder of five stage de-volatizing carbonization reactor where the moisture is removed due to the heating of dry powdered combustible MSW by hot thermic fluid jacket surrounding the cylinder. This vaporizes the moisture content from the particle which is in turn removed by dust collecting moisture extracting cyclonic system fitted with heat exchanger.

17. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets and briquettes and geo-polymer bricks and pavers as claimed in claim 8 wherein, the inter particle collision crusher contains both stationary sharp blades and flat moving blades which move at high speed with centrifugal force due to which the non-combustible MSW repeatedly crushed and shredded and converted into powder form during which heat generates and removes moisture through a moisture separating, heat exchanging ,dust collecting cyclone system.

18. An apparatus for carrying out the method in converting all municipal solid waste into geo-polymer pellets and briquettes and geo-polymer bricks and pavers as claimed in claim 8 wherein the moisture content is reduced by six stage moisture reduction processes at various levels by way of crushing, shredding, fluid extracting, drying, pulverizing and devolatizing carbonization reactor.

19. A bag opener with twin stage double rolling drum crushers provided with the spikes for shearing the household bags containing unsorted MSW and letting unsorted MSW into the wedge between the concurrently rolling two stage double drum crusher with heavy colliding springs crushing and removing about 50% of liquid content of unsorted MSW.

20. A fluid extractive compressor having a top end inlet for putting inside combustible MSW and an outlet placed at the bottom for passing the compressed combustible MSW which completes one cycle compression and retraction every minute as two pistons moving against each other with heavy force for compressing and thereafter the front end piston retracting and back end piston pushing the compressed Combustible MSW instantaneously until the compressed Combustible MSW falls through outlet simultaneously letting liquid content to the effluent treatment plant.

21. An inter particle collision drier containing an inlet for 5 MM shredded combustible MSW to go through a drying process due to heat generated by collision of inter particles due to their rotation caused by flat blades mounted on a rotating shaft across the stationary flat blades mounted on the walls, of the drum shaped drier being rotated at high speed resulting in heat generation and drying, while an inbuilt moisture absorber sucks the moisture through a moisture separating, heat exchanging, dust collecting cyclone system leaving Combustible MSW dry.

22. An inter particle collision pulverizer with provision for input feeding and output exit conveyor and which has sharp moving and stationary blades of unique shape of sickle devices that cuts the dry Combustible MSW further into finer particles having moisture separating, heat exchanging, dust collecting cyclone system.

23. An de-volatizing and carbonizing reactor having on its top an inlet for the dry combustible MSW to pass through five stage reactor that heats up the Combustible MSW in four stages through step by step by thermic fluid heat increasing process from 50 Degree Celsius at the first stage to 300 degree in the fourth stage ensuring carbonization and controlled removal of volatile gases and the fifth stage being a single stage cooling system at the bottom to intensify the density of carbon molecules after the de-volatizing carbonization process involving the conversion of combustible MSW into high calorific value fuel, reduction of moisture and maximum removal of volatile gases.

24. An inter particle collision crusher comprising both stationary sharp blades and flat moving blades which move at high speed with centrifugal force due to which the non-combustible MSW repeatedly crushed and sheared and converted into powder form during which heat generates and removes moisture through a moisture separating, heat exchanging, dust collecting cyclone system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0102] The accompanying drawings describe the invention in greater detail containing same reference numbers across figures to refer to like parts, machines, equipments or components.

[0103] FIG. 1 shows a block diagram of this whole invention to produce the combustible and noncombustible material in the final production of pellets/briquettes or bricks/paver blocks respectively from the unsorted MSW collected.

[0104] FIG. 2 shows a detailed block diagram showing fully about the conversion of the combustible MSW into pellets/briquettes.

[0105] FIG. 3 shows a detailed block diagram showing clearly about the conversion of the non-combustible MSW into pellets and paver blocks.

[0106] FIG. 4 is a perspective view of Bag opener cum crusher unit of the present invention.

[0107] FIG. 5 is a perspective view of Fluid extractive compressor unit connected between the 10 MM output blade shredder and 5 MM output blade shredder of the present invention.

[0108] FIG. 6 is a perspective view of the Inter-particle collision drier unit of the present invention.

[0109] FIG. 7 is a perspective view of the Inter-particle collision pulverizer unit of the present invention.

[0110] FIG. 8 is a perspective view of the De-volatizing Carbonization Reactor unit of the present invention.

[0111] FIG. 9 is a perspective view of the Inter-particle collision crusher unit of the present invention.

DESCRIPTION OF THE INVENTION IN NUTSHELL

[0112] The machinery/apparatus and process of this invention do the conversion of the MSW into combustible and non-combustible components. Those components are converted into fuel of high calorific value in the form of pellets/briquettes and bricks/paver blocks. The combustible components of MSW includes materials consisting of forest waste, food waste, agricultural waste, backyard waste, plastics, papers & card boards, textile waste, tires & rubbers etc.

[0113] The non-combustible components of MSW conist of inert waste which is neither chemically nor biologically reactive and will not decompose including building materials, glass, bottles and such things.

[0114] MSW always contains liquid content which has to be first separated besides removing inert materials. The layout of the Apparatus commences with an automatic chain conveyor feeder.

[0115] At the first stage of the Apparatus the unsorted MSW is transported through a conveyor into specially designed combined bag opening and crushing unit called as bag opener cum crusher that does two functions simultaneously. It removes almost completely the liquid content which are collected and diverted through pipes to an effluent treatment plant [ETP] and the inert materials are crushed and broken into particles of small sizes.

[0116] The crushed and squeezed MSW which is an assorted mixture is passed through metal separators in which both ferrous and non-ferrous metals are separated, the MSW free from metals passes through a twin drum trommel. The trommel in addition to size separation, it particularly divides the MSW into two major constituents consisting of combustible and non-combustible compositions.

[0117] Thereafter the invention takes the entire combustible MSW into a series of processes such as primary shredding, double compression squeezing, and secondary shredding, inter particle drying, inter particle pulverizing and the like. In all these stages the size of the particle is reduced gradually and converted into powder form. Simultaneously the moisture reduction takes place at all these stages due to inter particle collision.

[0118] Finally the combustible low moisture powder is passed through to de-volatizing carbonization reactor, here the particles carbon concentration is increased, the process is carried out in the absence of oxygen in such a way that volatile gases are contained and the density of the particle is increased. The output from the de-volatizing carbonization reactor is either mixed with geo polymer binding agents/tar/starch etc., or by high speed compacting to form pellets and briquettes of high calorific value. On the other hand the non-combustible or inert MSW materials consisting of Stone, Glass, Mud and the like in the MSW mixture is passed through inter particle crusher and mixed with geo-polymer agents and converted into bricks and pavers after molding and drying.

[0119] Thus the invention results in two useful products as aforesaid. Even the solid waste generated after liquid that is put through the ETP is brought back to the first stage as a result of which there is not only zero effluent discharge but also the entire MSW is converted into two Products enabling the combustible pellets or briquettes for being used for fuel as a coal and the effluent free non-combustible bricks for being used as building blocks.

[0120] The invention also results in generating two by-products too. When the gas from de-volatizing carbonization reactor is passed through gas cleaning system, a condensed Tar and Syngas is produced respectively, while Tar is used as a binding agent for pellet & briquette conversion and the syngas is used to heat the reactor.

DETAILED DESCRIPTION OF THE INVENTION

[0121] In FIG. 1 the blocks are serially numbered from 101 to 119. 101 is the stage where the unsorted municipal solid waste (MSW) is collected from the dump yard. Unsorted MSW, consisting of food wastes, paper, cardboard, plastics, textiles, glass, metals, wood, street sweepings, landscape and tree trimmings and general wastes from parks, beaches, and other recreation areas etc., collected from the dump yard, goes through a ramp to go into a bag opener and crusher.

[0122] Unsorted MSW from dump yard 101,is first sorted out as MSW which is above 150 MM to pass through the 150 MM output CAM shredder (102) and then it is transferred manually into a bag opener cum crusher (103 & 104). But the MSW which is sorted out as below 150 MM size is passed directly through a conveyer to a combined unit of Bag Opener and Crusher 103 & 104 respectively. The apparatus Bag opener cum crusher is illustrated in FIG. 4. In the bag opener cum crusher, bag opener is the first receptacle of the unsorted MSW which is located at a height above 15 ft. from the ground level, the bag opener Part No. 1 receives the unsorted MSW which are below 150 mm, the MSW that gets dropped in a continuous process makes it possible for the dropped MSW to go through the crusher as the bag gets opened simultaneously. The combined unit is rotated by motor and gear system Parts No. 4 & 5. The bag opener consists of a rotating shaft with spikes Part No. 3, opens and separates the bags containing MSW through piers and tearing action.

[0123] As the bag is opened MSW is moved into the crusher Part No. 2. The reverse flow of the material from the crusher is avoided due to vertical gravity feed & unidirectional input from the bag opener.

[0124] The bag opening stage is primary and important stage where in all the unsorted MSW materials are uncovered and opened for further processing. In the absence of bag opening stage, there may be a possibility of crushable waste getting skipped and slipping into next stage. If such things escape, it may not get exposed to the ferrous and non-ferrous separators which can create undesired problems and delays and can even result in halting of the operation due to safety or emergency tripping of the process line if the material gets struck at later stages.

[0125] The crusher consists of multiple rotating roller drums Part No. 3, with serrated ridges tangential to the axis of rotation of the crusher drum in the first stage and serrated ridges perpendicular to the axis of rotation of the crusher drum in the second stage in order to avoid slipping of material and increases the efficiency of the crusher. Here, after this stage all MSW materials are passed through the crusher (104) where they are squeezed and the materials like glass, stone, debris are crushed. Crushing separates materials such as nails and screws deeply embedded to lose grip which helps when the unsorted MSW goes through the subsequent stage where magnetic and eddy current separation takes place to remove ferrous and non-ferrous items.

[0126] The crushed and squeezed MSW is transported through conveyor to metal separators 105 & 106. In this process ferrous and nonferrous metals are separated, the ferrous metals are separated in the magnetic separator 105 where in the MSW is passed through an overhead magnetic rolling belt which is placed perpendicular to the line of chain conveyor. The magnetic rolling belt collects the ferrous materials from the MSW. The MSW minus ferrous things is passed through eddy current separator 106 which is placed along the line of conveying system. The eddy current forces are created when a magnetic rotor turns at a high speed and repels non-ferrous materials with varying degrees of force depending on their metallic composition. In this process non-ferrous materials like aluminum, copper etc., are separated from wood, plastic etc. and ejected out and collected in a container. The collected materials from 105 & 106 are sent for recycling.

[0127] Separation of all the ferrous and non-ferrous materials are separated by magnetic and eddy current separators (105 & 106) shall be taken as the Stage 1 separation. I. The processed MSW is then sent to an automatic feeder by means of a conveyor into a twin trommel with 30 mm inner screen and 6 mm outer screen, which divides the processed MSW into heaps of three categories, one for materials above 30 mm and one below 30 mm and the third one for materials of less than 6 mm. In the second stage of separation, the separation of the combustible and non-combustible materials happens at twin drum trommel separator (107), where the MSW is separated into above 30 mm, below 30 mm and below 6 mm respectively. The above 30 mm solid waste then sent to an automatic feeder by means of a conveyer to a CAM shredder. The shredded solid waste from CAM shredder and below 30 mm MSW which are combustible fraction is further shredded by sending it to an automatic feeder by means of a conveyer to a 10 mm output blade shredder.

[0128] In the shredding stage I the cam shredder (108) and blade shredder I (109), ensures the size of the shredded combustible MSW is 10mm; In the Shredding stage II (109), the 10 mm shredded combustible MSW is shredded to 4 to 5 mm by blade shredder II (109);

[0129] The remaining MSW which predominantly comprising of squeezed combustible materials passing through the second screen of size 30 mm and the particles above 30 mm size passes directly to the next stage. The next stage is where the combustible MSW conversion takes place. Due to size separation, the trommel automatically separates the MSW into combustible and non-combustible composition. From here onwards, the process actually takes two different routes one for processing combustible MSW and another for Non-combustible MSW.

[0130] FIG. 2 consists of blocks 201 to 217, depicting the manner in which combustible MSW are converted into fuel of high calorific value through a series of sequential processes.

[0131] In the fluid extraction stage the shredded material is compressed in a fluid extractive compressor (110). The shredded MSW from blade shredder is then sent to an automatic feeder by means of a conveyer into a fluid extractive compressor to remove moisture. Effluent from fluid extractive compressor is treated in a waste water treatment plant and treated water is used in heat exchangers and for domestic cleaning purposes. The above 30 mm material is passed through a belt conveyor into a cam shredder 202 for size reduction below 30 mm. The size reduction is achieved by means of horizontal inward rotating blades (like a cam) with spacers in between.

[0132] The blades and spacers are arranged in an orderly fashion on two rotating shafts rotated by two electric motor and gear system. This shreds the above 30 mm fed combustible MSW to a lesser size. The 6 to 30 mm combustible MSW as mentioned and the less than 30 mm output MSW from cam shredder 202 passes through same process in two identical lines which comprises of further shredding and material compression actions.

[0133] The placing of two identical processes enables handling of higher volume of input combustible MSW so has to achieve higher process output at this stage.

[0134] All 6 to 30 mm combustible MSW is further shredded to a size between 5 to 10 mm in a blade shredder 203. It comprises of sharp blades rotating in a horizontal shaft supported by bearings, the blades are arranged across the rotating blades in a staggered manner for effective shredding to a size between 5 mm to 10 mm. In order to get powdered char fuel with high calorific value and low moisture content from the combustible MSW, the material has to undergo further size reduction in the secondary twin line blade shredders block 205. For effective size reduction in the secondary shredder the moisture has to be reduced further. Size reduction is an essential requirement for combustible materials for achieving better carbon intensification at a later stage. To achieve this, combustible MSW from primary blade shredder 203 is passed through twin line fluid extraction process 204 in the double piston fluid extractive compressor as illustrated in FIG. 5.

[0135] The apparatus consists of double acting cylinders Parts No. 1 & 3. The cylinders and the mechanisms are operated by PLC controlled hydraulic system. The combustible MSW is drawn from primary shredder in to loading chamber Part No. 4. The material from the feeding hopper is pushed by the pressing cylinder Part No. 3, simultaneously the closing cylinder Part No. 1, is drawn inside for material compression. The MSW undergoes fluid extraction process due to the double acting compression between the two cylinders. Once the material compression is completed the closing cylinder retracts back and the pressing cylinder pushes the compressed MSW further to the material delivery tray, Part No. 6. The latchet which comes out during squeezing action is collected in the channel Part No. 7 of and in turn sent to ETP for treatment. Thus the apparatus further reduces the moisture content of combustible MSW by means of material compression which brings out the effluent from the waste through, double piston compression technology. In this stage moisture is further reduced between 10 to 15% which in turn enables the combustible MSW to be shredded below the size of 5 mm in the twin line blade shredders block No. 205 of FIG. 2, which is a 5 mm output blade shredder. It comprises of blades rotating in a horizontal shaft supported by bearings, the blades are arranged in multi stages in a staggered manner in order to shred the combustible MSW effectively to a size below 5 mm.

[0136] The process from 206 to 208 are twin line process and the processes from 209 is again single line process the combustible shredded MSW below 5 mm from 205 is passed through a conveyor to inter particle collision drier 206; the apparatus is illustrated in FIG. 6. It's a novel apparatus used to dry combustible waste, of size less than 5 mm. It comprises of a horizontal cylinder with a rotating shaft which is balanced by bearings at both ends. The shaft is rotated between 1500 RPM to 3000 RPM by an electric motor fitted with Variable Frequency Drive [VFD] which varies the speed according to the output requirement The shaft has rotating replaceable flat blades Part No. 3 which on one side angled at 60 degrees over fan blade shaped frame, which when rotated at high speed, makes the particles to colloid with each other: The inner wall is fitted with flat stationary replaceable flat blades Part No. 4. The stationary flat blade creates obstruction to the rotating particles and helps in stirring and it also boosts inter particle collision. The apparatus has got a top shutter part no. 1 and bottom shutter Part No. 2 which is operated by means of Programmed Logic Controls [PLC] controlled hydraulic system. This helps in feeding and discharging of particles in a cycled manner. The cylindrical drier has two doors through which maintenance of the machine can be carried out and also helps in replacing the blades when needed. The door operation and material conveying screw conveyors are controlled by PLC operated hydraulic system.

[0137] The heat generated by the inter particle collision vaporizes the moisture around the particle. The moisture is removed through a hollow pipe attached to one of the cylinder cover. This pipe is connected to a heat exchanger to heat the vapor, other end of heat exchanger connected to a suction blower which is attached to a dust collecting cyclone system. The cyclone separates the dust and the dust collects in the bag kept beneath the cyclone. The moisture evaporates through the upper end of the cyclone to the atmosphere. The dust collected in the bag is mixed with the MSW for further processing. The, less than 5 mm size dried combustible MSW from Inter Particle Collision Drier block no. 206 as explained in FIG. 2 is passed to Inter particle collision pulverizer, Block No. 207 of FIG. 2, illustrated in FIG. 7. It's a novel apparatus which is used to convert dry combustible waste less than 5 mm into powder form of size less than 1 mm.

[0138] Inter Particle Collision Pulverizer consists of a vertical cone shaped cylinder with a rotating shaft balanced by bearings in top and bottom ends, which is rotated between 1500 RPM to 3000 RPM by an electric motorfitted with VFD which varies the speed according to the output requirement The rotating shaft has specially designed curved periodically replaceable sharp blades Part No. 3 which is fixed on the rotating shaft, which at highspeed, pulverizes the particles and makes the particle to collide with each other. The inner wall has curved sharp periodically replaceable stationary blades Part No. 2 which creates obstruction to the stirring of the particle, shearing of particles, makes the particle to collide with each other and at the same time pulverizes the particles. The cylinder has two doors through which maintenance of the machine can be carried out and also helps in replacing the blades when needed. The door operation and material conveying screw conveyors are controlled by Programmed Logic Controls operated hydraulic system.

[0139] In the Inter Particle. Collision Pulverizer too, the particle collision generates heat which vaporizes the moisture contents from the particle. The moisture is removed through a hollow pipe attached to one of the cylinder cover. This pipe is connected to a heat exchanger to heat the vapour, other end of heat exchanger connected to a suction blower which is attached to a dust collecting cyclone system. The cyclone separates the dust and the dust collects in the bag kept beneath the cyclone. The moisture evaporates through the upper end of the cyclone to the atmosphere. The dust collected in the bag is mixed with the MSW for further processing. The apparatus IPCP pulverizes the below 5 mm combustible MSW to powder form to a size below 1 mm and also further reduces the moisture from the particle, the pulverized dry powder when passed to de-volatizing and carbonization reactorgets converted into char fuel of high calorific value having low ash and low moisture content.

[0140] The dried and pulverized powder from inter particle collision pulverizer 207 is passed into de-volatizing carbonization reactor (DCR) 208; the apparatus is illustrated in FIG. 8. The apparatus is considered to be the heart of the combustible MSW conversion process. The apparatus consists of five cylinders with inner and outer shell positioned horizontally and placed vertically one above the other. Volume of each cylinder reduces gradually from top to bottom. Each cylinder will have a stirrer which in turn rotated by geared motor. Each cylinder will have top and bottom shutters which are controlled by PLC assisted hydraulic system so that discharge and filling of each cylinder is done in an orderly fashion from bottom to top so that in each chamber the raw material is held and stirred continuously for 10 minutes before getting discharged into next chamber from top to bottom.

[0141] Feeding hopper Part No. 1 with a double star lock system feeds raw material in to top cylinder Part No. 2 to ensure and maintain strict anaerobic (absence of oxygen) conditions. Bottom most system will have PLC controlled discharge system.

[0142] Top four cylinders Parts No. 2 to 5 will have thermic fluid heating jacket system Part No. 15 and bottom most cylinder Part No. 06 is surrounded by a water cooled jacket. Top cylinder is fitted with a hollow pipe for removal of left over moisture and air which would have got trapped along with the particles while feeding into the first cylinder from interparticle collision pulverizer. The pipe is connected to a heat exchanger to heat the vapor, the other end of heat exchanger connected to a suction blower which is attached to a dust collecting cyclone system. In this DCR also, there is dust collecting cyclone system. The cyclone separates the dust and the dust collects in the bag kept beneath the cyclone. The moisture evaporates through the upper end of the cyclone to the atmosphere. The dust collected in the bag is mixed with the MSW for further processing. The removal of moisture and air from the first cylinder of de-volatizing carbonization reactor ensures that the particle is free from moisture and more so the absence of oxygen during the carbonization process. The second cylinder to fourth have suction system attached to a gas cleaning system Part No. 07, after gas cleaning, the gas is stored in a buffer tank the compressed gas is then fed to a burner Part No. 11, which heats the thermic fluid boiler Part No. 10.

[0143] Through separate oxygen Part No. 9 (oxygen generator) fueled pellet gasification plant Part No. 8, the syngas is generated which after passing through gas cleaning system Part No. 7 is stored in a buffer tank, the gas is compressed and then fed to a burner Part No. 11 which heats the thermic fluid boiler Part No. 10.

[0144] Hot thermic fluid oil is circulated in first four cylinders in order to heat the raw materials the thermic fluid is circulated from bottom cylinder Part No. 5 one by one to top cylinders Part No. 2 so that temperature of the particle inside the cylinder is increased gradually. The bottom cylinder Part No. 6 is cooled by water jacket in order to densify the char powder.

[0145] The flow of hot thermic fluid transfers the heat to the MSW and loses its own heat gradually and the process is carried out in an anaerobic condition by double feeding and discharge system as a result of which maximum removal of volatile gas is achieved and collection too takes place gradually. The volatile gas is passed through a gas cleaning system Part No. 12 and results in production of syngas which is in turn reused in the burner Part No. 11 to heat the thermic fluid boiler Part No. 10.

[0146] The De-volatizing Carbonization Reactor is considered has the heart of the MSW conversion process as it not only removes volatile gases and moisture but also intensifies the carbon concentration which is known as carbonization

[0147] The powdered dry char from the reactor DCR 208 as explained in FIG. 2 is converted into pellets or briquettes in stages 209 & 210. The pellet/briquette formation process in 209 consists of mixing the dry powdered char from de-carbonization reactor 209 with geo-polymer binding base or with materials such as starch or tar. The pellet or briquette may also be formed as per the step in 210 where in it consists of High RPM pallet compacting process without any binding agent. The pellet formed in this process will, have very high caloric value, lowest ash content and lowest moisture content due to absence of binding agent and also due to high RPM rotation heat generating pallet compacting machine 210. The High calorific value, low ash content low moisture content fuel pellet/briquettes 211 are formed out of combustible MSW conversion processes.

[0148] Heating of thermic fluid happens through a separate process wherein the oxygen from oxygen generator 212 is supplied to pallet based gasifier system 213 the gas from the system is passed through a gas cleaning system 214, the compressed syngas 215 thus obtained from gas cleaning system is supplied to a burner 216 which heats up thermic fluid boiler 217.

[0149] The combustible MSW conversion consists of four major processes which happen at specific stages they are 1) shredding 2) moisture reduction 3) removal of volatile gas 4) increasing the carbon concentration. While the process 1 & 2 shredding and moisture reduction happens at various stages the processes 3 & 4 happens in de-volatizing carbonization reactor (DCR) 208.

[0150] The moisture content of the unsorted MSW is about 45% by weight and the calorific value is around 1,000 to 1,200 Kcal. The calorific value determines the combustibility of the fuel. The calorific value is improved by reduction of the moisture content and increase of the carbon content. In the invention carbon content is increased in the carbonization reactor and the moisture content is reduced by six stage moisture reduction processes at various levels by way of crushing, shredding, fluid extracting, drying, pulverizing and devolatizing carbonization reactor Moisture reduction also reduces the smoking when the fuel is burnt. The moisture reduction and carbonization raises the calorific value of the combustible MSW fuel to the range of 5500 Kcal to 6500 Kcal and moisture content is reduced to 5% by weight and below.

[0151] First stage moisture removal from the unsorted MSW happens after bag opening in the multi Stage crushers where all squeezable MSW is squeezed and the water particle is collected and recycled at ETP.

[0152] Second stage moisture removal from combustible MSW happens in multiple stage shredding, single in cam shredder, I and II stage blade shredders respectively the water particle is collected and recycled at ETP.

[0153] Third stage moisture removal of shredded combustible MSW happens in fluid extractive compressor between I and II stage combustible MSW shredding process. This is an important step, wherein the 10 mm shredded combustible MSW from 1st stage shredder is passed through a fluid extractive compressor where the moisture is removed due to double acting piston compression technology and the partial shredded combustible MSW is passed to second stage shredding for size reduction of below 5 mm. The fluid is collected and sent to ETP.

[0154] Fourth stage moisture removal takes place in horizontal high RPM inter-particle collision drier, the 5 MM shredded combustible MSW particle from 5 MM blade shredder is passed through the inter particle collision drier where the moisture is removed due to the heat generated by inter particle collision, when the rotating shaft with flat moving blade is rotated at high speed against the flat fixed blade which is mounted on the wall of the drum shaped drier. The heat generated by the inter particle collision vaporizes the moisture content from the particle which is in turn removed by dust collecting moisture extracting cyclonic system fitted with heat exchanger. The dry 5 MM shredded combustible is passed to Inter particle collision pulverizer for conversion of the combustible MSW, particle into powder form.

[0155] Fifth stage moisture removal takes place in vertical cone shaped high RPM inter particle collision pulverizer, the dry 5 MM shredded combustible MSW particle from inter particle collision drier is passed to inter particle collision pulverizer where the moisture is removed due to the heat generated by inter particle collision, when the rotating shaft with sharp moving blade is rotated at high speed against the sharp fixed blade which is mounted on the wall of the cone shaped vertical pulverizer. The heat generated by the inter particle collision vaporizes the moisture content from the particle which is in turn removed by dust collecting moisture extracting cyclonic system fitted with heat exchanger. The dry combustible powder below 1 MM is passed to de-volatizing carbonization reactor for conversion of the dry powdered combustible MSW particle into carbonized char powder.

[0156] Sixth and final stage moisture removal takes place in de-volatizing carbonization reactor the dry powdered combustible MSW particle from inter particle collision pulverizer is passed to first cylinder of five stage de-volatizing carbonization reactor where the moisture is removed due to the heating of dry powdered combustible MSW by hot thermic fluid jacket surrounding the cylinder. This vaporizes the moisture content from the particle which is in turn removed by dust collecting moisture extracting cyclonic system fitted with heat exchanger. The dry combustible powder below 1 MM is passed to second cylinder of five stage de-volatizing carbonization reactor for conversion of the dry powdered combustible MSW particle into carbonized char powder.

[0157] The residue water line runs through various processes such as shredding, fluid extracting, etc., wherein the liquid collected from these processes are sent to effluent treatment plant ETP 220. The treated water from the ETP is reused with in the process line. The moisture collected from Inter particle collision drier, Inter particle collision pulverizer and devolitizing carbonization reactor is collected by moisture extracting cyclone system.

[0158] In another independent inter related process of conversion of all the non-combustible and inert materials which was crushed in crusher under goes metal separation where in both ferrous and nonferrous MSW particles are separated collected and sent for recycling. The below 6 mm size MSW from the Trommel comprising of crushed non-combustible and inert materials is processed and converted to bricks and paver blocks.

[0159] The Non-combustible MSW material of size below 6 mm is passed through inter-particle collision crusher (IPCC) the apparatus is illustrated in FIG. 9. Inter particle collision crusher is a novel apparatus which is used to shred and crush non-combustible waste, less than 6 mm which is received from outer 6 mm size separation screen of trommel.

[0160] The apparatus as explained consists of horizontal cylinder with a bearing mounted rotating shaft which is being rotated between 1500 RPM to 3000 RPM by an electric motor fitted with VFD the VFD varies the speed as per the required output desired to be in the form of powder.

[0161] The shaft has rotating fan shaped blade frame part no 4, on which replaceable flat blades are fixed on one side angled at 60 degrees. The shaft when rotated at high speed crushes the particles against the inner wall. The inner walls have replaceable sharp stationary blades part no. 5, which shreds the rotating particle and helps in converting the particles into smaller size. The apparatus has got a top shutter part no. 1 and bottom shutter part no. 2 which are operated by means of PLC controlled hydraulic system. This helps in feeding and discharging of particles in a cycled manner. The cylindrical apparatus has two doors through which maintenance of the machine can be carried out and also helps in replacing the blades when needed. The door operation and material conveying screw conveyors are controlled by Programmed Logic Controls operated hydraulic system.

[0162] The inter particle collision which occurs between the particles and the repeated shredding-and crushing action converts the particles into powder form due to the heating and crushing that takes place inside due to collision between particles.

[0163] Moisture is removed through a hollow pipe attached to the top of the cylinder cover. This pipe is connected to a heat exchanger which in turn connected to a suction blower which is attached to a dust collecting cyclone. The cyclone separates the dust and the dust collects in the bag kept beneath the cyclone. The moisture evaporates through the upper end of the cyclone to the atmosphere. The dust collected in the bag is mixed with the MSW for further processing.

[0164] This non-combustible MSW powder is mixed with geo-polymer binding agent (which is the product of a separate process called geopolimerization process) and other additional raw materials such as fly ash or quarry chips in a pan mixer 303. This mixture is molded in to geopolymer bricks and geopolymer paver blocks in a separate molding and drying process.

[0165] This non-combustible MSW powder can also be mixed with fly ash/china clay, quarry dust/chips, river sand, cement in a pan mixer 303. This mixture is molded in to fly ash bricks and fly ash blocks in a separate molding and water curing process.

[0166] The conversion of the non-combustible MSW into powder form with reduced moisture content is most important for further conversion into high quality bricks and pavers. Hence the Inter particle collision crusher plays a major role in the non-combustible MSW conversion to bricks and paver blocks.

[0167] Thus it leaves nothing for availability of any landfill area.

THE UNIQUE FEATURES THAT MAKE THIS SYSTEM AN INVENTION

[0168] 1) Maximum conversion of unsorted MSW to useful end products: [0169] 2) Holistic concept which converts both combustible and non-combustible materials from MSW to useful end products. [0170] 3) Avoidance of intermediate sorting of the MSW from the source to the processing area (developing countries) [0171] 4) Increase of calorific value by 6stage moisture removal: [0172] 5) Scalability and futuristic approach: [0173] 6) Closed loop system [0174] 7) Specialty of automated Sequences and Segregation System [0175] 8) Environment friendly and Non-polluting process: [0176] 9) MSW Powdering Pulverizer: [0177] 10) De-volatizing carbonization Reactor: [0178] 11) Crushing bag opener [0179] 12) Inter Particle Collision Drier [0180] 13) Char Palletization without binding agent [0181] 14) Double piston MSW fluid extracting compressor [0182] 15) Conversion of Non Combustible MSW to Geo-polymer Bricks/paver blocks

ADVANTAGES

[0183] (1) This is a unique process where the Garbage from domestic (household) sector which forms the major constituent of the MSW can be transported without intervention of any intermediate sorting team. [0184] (2) This process will avoid the pilferage and pre segregation and sorting by the garbage collection team to whom the government authorities/civic bodies have employed under contractual employment. [0185] (3) These contract teams open the bags collected from the household and do a presorting and recover the valuables. This process is being not controlled by anybody, chances of mishandling and environment pollution could not be avoided. [0186] (4) This invention can take care of present problem of utilizing already available dumped MSW which can be handled and converted to useful materials by applying 100% green waste management concept of reduce, recycle and reuse (3 Rs of waste management). [0187] (5) This apparatus can handle the domestic waste without segregation and curbside dumping the space can be cleared. The inconveniences and the risks of smell, pollution etc., are avoided. Major intermediate handling, unhygienic handling by the presorting and segregating agents is totally avoided. [0188] (6) The big menace of smell (stink, pilferage and misuse and recovery of valuables by the intermediate agents can be totally avoided through enforcement and thereby, can ensure clean handling of MSW right from the source till the processing area without need for segregation at source (segregation at source is a failure, it couldn't take off or sustain after initiation). [0189] (7) This apparatus can handle the present problem of consuming/utilizing the MSW from dump yards and once it is utilized completely, the same setup can receive and process the MSW directly from the source area just by getting the pre packed. un segregated domestic waste transported to the processing area. [0190] (8) This apparatus can handle both sorted and unsorted MSW. [0191] (9) Automatic segregation of MSW into combustible and non-combustible (inert) materials and converting both into separate and different end products. [0192] (10) This invention takes care and ensures zero pollution through air, water or land. (100% Environmental compliance is ensured) [0193] (11) Air pollution is avoided by gaseous cleaning of the exhaust gas from the De-volatizing carbonization reactor there by the emissions are maintained within the permissible limit. [0194] (12) Water pollution is avoided by collecting separated water at various process stages and treating them in effluent treatment plant. Recycled water is utilized for domestic use. [0195] (13) The land pollution is also avoided by utilizing all the constituents of MSW with in the process, leaving behind only metals for recycling. The invention ensures that no residue is left for land filling.

[0196] While the present invention has been delineated by description of a preferred embodiment and the preferred embodiment has been described in considerable details with reference to the drawings, it is not contemplated to confine or in any way restrict the scope of the appended claims and their legal equivalence to such realization. Additional applications and adaptations will readily appear to those skilled in the art. The invention in its broader aspects is therefore not bound to the specific details that are representative of apparatus and method, and illustrative features shown and described herein. Accordingly, variations may be made from such details without departing from the utility, spirit and scope:of the substantive invention.