This invention relates to a method for treating municipal solid waste material and more particularly to such a method which is adapted to separate and classify municipal solid waste into various inorganic, organic and synthetic fractions thereof. The major portion of the inorganic fraction consists of metal and glass containers while the remainder consists of bits of masonry, ceramics, automobile parts, building materials and the like. The synthetic fraction usually consists of plastic containers, plastic film, toys, toothbrushes and the like in addition to a variety of materials such as articles of clothing. The organic fraction usually represents more than 80% by weight of the municipal solid waste and consists largely of ligno-cellulose, such as paper products, with the remainder consisting of yard waste, food scraps, dead animals and the like.

The organic fraction of municipal solid waste represents the industrial world's largest economically assessible source of ligno-cellulose feed stock for conversion to alcohol and other industrial chemicals. At the same time, municipal solid waste is an environmental concern to which the industrial world is attempting to find a solution due to the depletion of natural resources and the dwindling availability of land fill areas.

Heretofore, the most common method for classifying municipal solid waste materials has been by air classification wherein the waste materials are first shredded or ground for particle size reduction. This material is then subjected to currents of upwardly flowing air whereby the lighter fraction thereof tends to float as the heavier materials sink. The major portion of this lighter fraction consists of paper, plastic film, fabric and the like while the heavier fraction consists of wet paper, metals, glass, plastic, fruit, vegetables, meats, wood and the like. This method requires considerable time and energy in the shredding of the municipal solid waste materials. Also, bits of glass and metal are embedded in the lighter fraction since the waste material has not been properly classified into metal, glass, plastic, paper, food scraps and the like.

Another known method uses the paper industry's technique for pulping, in which the solid waste is subjected to size reduction and is then placed in large vats where the organic fraction is pulped into a slurry of approximately 3% solids. The heavier metals, glass, masonry and the like may then be removed by settling or centrifuging. This method is also energy intensive in that large quantities of water are required in order to produce a slurry of 3% solids. This excess water must then be removed, such as by de-watering the slurry to a cake of less than 50% moisture to produce a product which may then be used as a fuel.

United States Patent No. 4050899 discloses a method for fragmenting solid waste wherein the waste material is dehydrated, comminuted and expelled into an open ended composting pit. In United States Patent No. 4342830, steam pressure separation is disclosed wherein softened organics are forced through perforations upon sudden release of pressure whereby inorganics, such as cans and bottles are left behind. This method is somewhat more energy intensive than some of the methods heretofore employed to classify municipal solid waste in that the steam used to force the softened organics out is difficult to recover.

It is now proposed, according to the invention, to provide a method of treating municipal solid waste material in the presence of moisture for the separation and recovery of inorganic matter and organic matter including fermentable material, said method comprising the following steps:

• (a) feeding said waste material into a pressure chamber;
• (b) agitating said waste material while in said pressure chamber in the presence of moisture;
• (c) subjecting said waste material in said pressure chamber to heat under a pressure ranging from approximately 2.7 bar to 5.1 bar gauge for a period ranging from approximately 30 minutes to 90 minutes to cook and sterilize said waste material and soften said organic matter contained therein;
• (d) controlling the moisture content of said waste material cooked in said pressure chamber so that the fines of said organic fraction thereof have a residual moisture content ranging from approximately 60% to 70%;
• (e) releasing the pressure from said chamber;
• (f) discharging the cooked waste material from said chamber, and
• (g) separating and classifying said cooked waste material into various fractions thereof, including an inorganic fraction and the fines of said organic fraction having a residual moisture content ranging from approximately 60% to 70%.

The solid material produced within the pressure chamber may be readily separated and classified on conventional separating apparatus, such as vibrating screens common to the extractive industry. The solid waste materials can thus be disposed of at a profit. Preferably water is added to the waste and at least part of this is in the form of sewage sludge which can increase the yield of alcohol or other industrial chemicals.

The method of the invention can improve sterilizing, particle size reduction and partial hydralization of the organic fraction of the municipal solid waste feed stock for fermentation, without shredding prior to separation.

In order that the invention may more readily be understood, the following description is given, merely by way of example, reference being made to the accompanying drawings, in which:-

• Figure 1 is a schematic diagram showing one embodiment of apparatus which may be employed to carry out the method of the invention;
• Figure 2 is a graph showing the effect of cook time on the distribution of processed municipal solid waste among materials having fine size particles, middle size particles and larger size particles;
• Figures 3 and 4 are graphs showing the effect of pressure on the distribution of processed municipal solid waste among materials having fine size particles, middle size particles and larger size particles;
• Figure 5 is a graph showing the effect of the amount of water added per 272 kgs (600 pounds) of municipal solid waste in the distribution of processed municipal solid waste in the distribution of processed municipal solid waste among materials having fine size particles, middle size particles and larger size particles; and
• Figure 6 is a graph showing the effect of total steam used during the run on the distribution of processed municipal solid waste among materials having fine size particles, middle size particles and larger size particles.

Referring now to Figure 1, there is shown a pressure chamber 10 having a hatch 11 in the top thereof through which municipal solid waste may be introduced, having been fed by an endless conveyor belt 12. Preferably the pressure chamber 10 is in the form of an elongated cylindrical chamber which is sloped approximately 15⁰ from the horizontal whereby gravity aids in discharging the final product through a discharge door 13 provided in the lower portion of the discharge end wall 15 of the pressure chamber 10. The pressure chamber 10 is capable of withstanding a pressure of at least 5.1 bar (gauge).

The waste material fed in chamber 10 is agitated by an agitator, e.g. mixing fins, carried by a centrally disposed, longitudinal shaft 16 which is driven by a motor 17.

A steam supply conduit 18 communicates with the lower portion of the pressure chamber 10, as shown. The pressure in the chamber 10 is controlled by a pressure regulating valve 19 to be approximately 2.7 bar to 5.1 bar (gauge) for a period ranging from approximately 30 minutes to 90 minutes to cook and sterilize the waste material and soften the organic matter contained therein. Preferably, the pressure is maintained at approximately 3.4 bar for a period of approximately 60 minutes. The temperature in the pressure chamber 10 is maintained in the range approximately 130°C to approximately 160°C by the steam.

The product discharged through the door 13 of the pressure chamber 10 falls onto a vibrating screen unit, indicated generally at 21, having an upper screen element 22 which is approximately of a 50 mm mesh and a lower screen element 23 which is approximately of a 13 mm mesh. Accordingly, the materials having fine and middle size particles pass through the upper screen element 22, while the materials having a larger particle size are retained on the upper screen element 22 until discharged therefrom at 24. The materials having fine size particles pass through the lower screen 23 and are discharged at 27, while the materials having middle size particles are retained on the lower screen 23 until discharged at 26.

In order for the vibrating screens 22 and 23 to separate and classify the waste effectively, the internal environment of the pressure vessel must be controlled accurately. In addition to the parameters of maintaining a pressure ranging from approximately 2.7 bar to 5.1 bar for a period ranging from approximately 30 minutes to 90 minutes to cook and sterilize the waste material and soften the organic matter contained therein, there is an additional parameter which is critical and which must be controlled accurately to assure proper separation and classification of the various fractions of the municipal solid waste material. That is, it is essential that the moisture content of the waste material cooked in the pressure chamber be controlled so that the fines of the organic fractions thereof have a residual moisture content ranging from approximately 60% to 70%, in actual practice, preferably of approximately 65%. It has been found that unless the moisture content of the waste material cooked in the pressure chamber 10 be controlled accurately to produce fines of the organic fraction which have a residual moisture content as set forth above, the various fractions of the cooked waste material cannot be separated from each other and classified economically.

To provide efficient heat-mass transfer and efficient mixing of the constituents introduced into the pressure chamber, the volume of all constituents fed into the pressure chamber should not exceed approximately 70% of the total volume of the pressure chamber.

As one example of the manner in which the method of the invention is carried out, 272 kgs of municipal solid waste is fed to the hatch 11 of the pressure chamber 10 by the endless belt 12. 136 kgs of primary sewage sludge at 38⁰C is added to the pressure chamber. Steam is introduced into the pressure chamber and controlled by valve 19 to bring the pressure up to 3.4 bar (gauge) and this pressure is then maintained for one hour. The material is mixed continuously during the one hour period to bring about efficient mixing and heat-mass transfer between all constituents introduced into the pressure chamber. Steam is released at the end of the one hour period and the product is discharged through door 13 onto the vibrating screen unit 21. Materials having large size particles, hereinafter referred to as "overs", such as bottles, cans and the like, are retained on the 2 inch mesh screen 22. The materials having middle size particles, such as bottle caps, coins, broken glass, corncobs, bits of wood and other organics which need further treatment, hereinafter referred to as "middles" pass through the 50 mm mesh screen 22 onto the 13 mm mesh screen 23 and are retained thereon. The material passing through both of the screens 22 and 23 represents the organic fraction, hereinafter referred to as "fines", which is suitable for conversion to alcohol or other industrial chemicals.

The example set forth above was repeated several times and the averages of the municipal solid waste separation and classification on the vibratory screen unit 21 are listed as follows:

Percent by Weight of Municipal Solid Waste (MSW)

The cook time referred to herein refers to the period that starts when the pressure vessel reaches fully steam pressure and terminates when the pressure is released. Accordingly, the shorter this period, the less energy required and the more municipal solid waste and sewage sludge which can be processed per unit of time. The graph shown in Figure 2 shows the effect of cook time on the distribution of processed municipal sewage waste among "fines" indicated at A, "middles" indicated at B and "overs" indicated at C. The cook pressure was about 4.1 bar and the heating time was about 40 minutes. Approximately 90 kg of water was added to 272 kg of municipal solid waste in each run. From Figure 2, it will be seen that reducing cook time decreased the fraction of "fines" and increased that of the "middles". The weight of "overs" increased slightly with decrease in cook time with little difference being noted in its composition.

In another example, 272 kg of municipal solid waste and 90 kg of water were introduced into chamber 10 and steam was injected until the pressure reached 4.1 bar. The contents of the pressure chamber were cooked at this pressure for 60 minutes. When the weight of the three fractions "overs", "middles" and "fines" were compared with that of the starting municipal solid waste, the yield of the "fines" dropped off rapidly below 2.7 bar. Figure 3 shows the effect of pressure on the distribution of processed municipal solid waste in the above example wherein the cook time was 60 minutes and approximately 90 kgs of water was added to 272 kgs of municipal solid waste.

Figure 4 shows the effect of pressure on the distribution of processed municipal solid waste among "fines", "middles" and "overs" wherein the cook time was 30 minutes and approximately 90 kgs of water was added to 272 kgs of municipal solid waste. In this example, a decrease in the fractional weight of "fines" and increase in that of "middles" were noted with decreasing pressure. Subsequent experiments performed in the pressure range of 3.4 to 4.1 bar indicated no significant difference.

In actual practice, changes in the amount of water or sewage sludge (4% solids) added to the municipal solid waste had considerable effect on the ability to screen the steam classified organics. The most effective screening was with material having a moisture content ranging from 60 to 70 percent. This level was observed with the addition of 90 to 180 kgs of water per 272 kgs of municipal solid waste. This is illustrated in Figure 5 of the drawings.

The optimum operating conditions were found to be approximately 60 minutes cook time, 3.4 bar of steam pressure and with the moisture content being controlled in the pressure chamber to produces fines of the organic fraction which have a residual moisture content of about 65%, which can be produced with approximately 272 kgs of municipal solid waste and 90 kgs of water or sewage sludge processed at 3.4 bar pressure for a period of 60 minutes. The data in Figure 6 indicates that sewage sludge can be added to municipal solid waste as a substitute for water with no significant effect on steam classified organics.

The "middles" usually represent about 30% as much material as the "fines" in the processed municipal solid waste. Also, the "middles" includes the steam classified organics which are too coarse to pass through the 13 mm mesh screen but are fine enought to pass through the 50 mm mesh screen 22. Such steam classified organics are much too coarse for subsequent hydrolysis to glucose.

The method of the invention, it is believed, will reduce the volume of municipal solid waste to be land filled by approximately 92%. Such a volume reduction would result from the removal of "fines", reprocessing of "middles" and recycling of ferrous and non-ferrous materials. The method also enables one to recover valuable materials which heretofore have been land filled.