AN APPARATUS AND A METHOD FOR CONVERTING INDUSTRIAL WASTE INTO ALTERNATIVE FUEL

Abstract

An apparatus and a method for converting industrial waste into alternative fuel is provided. The apparatus includes a collection unit (110) for gathering waste materials, specifically lead slag and bio sludge from textile processing industries. The collected materials are then processed through a pulverizing unit (120) to reduce the size of the slag using a pulveriser machine. Following this, a drying unit (130) employs a rotary dryer machine to lower moisture content with hot air. The dried materials are further reduced in size by a shredding unit (140). These shredded materials are blended in a specific ratio by a mixing unit (150) to create a uniform alternative fuel suitable for cement kilns. Finally, a transportation unit (160) packages and delivers the blended fuel to the cement factory. FIG. 1

Specification

Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of waste management and environmental sustainability, specifically to an apparatus and a method for converting industrial waste materials into alternative fuels and raw materials for use in the cement industry.
BACKGROUND
[0002] Industrial waste management is a critical aspect of environmental sustainability, particularly in sectors such as metal smelting and textile processing, where large volumes of hazardous and non-hazardous waste are generated. Among the most challenging waste streams are lead slag from lead smelters and bio sludge from textile wastewater treatment plants. Traditionally, these waste materials are disposed of in landfills, both authorized and unauthorized, leading to severe environmental consequences, including land and water contamination, air pollution, and potential health risks to nearby populations. These practices not only harm the environment but also miss the opportunity to reclaim valuable resources from waste.
[0003] Conventional waste management systems have struggled to provide effective solutions for the disposal and utilization of industrial waste materials. Lead slag, composed of toxic elements such as lead and iron, and bio sludge, rich in carbon and other impurities, are often disposed of without any attempt to recycle or repurpose them into useful products. The primary method of disposal remains landfilling, which is not only environmentally damaging but also unsustainable given the growing volumes of waste.
[0004] Traditional systems often lack the necessary integration and technological capabilities to transform these wastes into valuable products, such as alternative fuels for the cement industry. Current processes are typically inefficient, costly, and unable to meet the specific parameters required by cement plants for alternative fuels, such as appropriate calorific value, chloride content, and heavy metal concentrations. These conventional methods fail to provide a comprehensive solution that addresses both the environmental impact and the economic potential of waste materials.
[0005] Hence, there is a need for an improved an apparatus and a method for converting industrial waste materials into alternative fuels and raw materials for use in the cement industry, which addresses the aforementioned issue(s).
OBJECTIVE OF THE INVENTION
[0006] An objective of the present invention is to develop a system that converts industrial waste materials, such as lead slag and bio sludge, into alternative fuels and raw materials for the cement industry, thereby reducing environmental contamination and promoting sustainable waste management practices.
[0007] Another objective of the present invention is to minimize the need for landfilling of hazardous and non-hazardous waste materials by repurposing them into valuable products, thus mitigating the negative environmental impact associated with conventional waste disposal methods.
[0008] Another objective of the present invention is to transform waste materials that are typically considered pollutants into economically beneficial products, such as alternative fuels, thereby supporting the circular economy and adding value to the waste management process.
[0009] Another objective of the present invention is to ensure that the alternative fuels produced from the waste materials meet the stringent specifications of the cement industry, including parameters like calorific value, chloride content, sulphur levels, and heavy metal concentrations.
[00010] Another objective of the present invention is to provide an integrated system that streamlines various waste processing stages-collection, pulverizing, drying, shredding, mixing, and transportation-ensuring efficiency, cost-effectiveness, and consistency in the quality of the final product.
[00011] Another objective of the present invention is to utilize specialized equipment and precise processing methods that optimize the conversion of industrial waste into alternative fuels, making the process more efficient and scalable.
[00012] Another objective of the present invention is to align the waste conversion process with environmental regulations and standards set by pollution control boards and the cement industry, thereby ensuring safe and compliant use of alternative fuels.
[00013] Another objective of the present invention is to offer a cost-effective alternative to traditional waste disposal methods by converting waste into products that have market value, reducing the overall costs associated with waste management for industries.
BRIEF DESCRIPTION
[00014] In accordance with an embodiment of the present disclosure, and apparatus to convert industrial waste into alternative fuel is provided. The apparatus includes a collection unit configured to collect waste materials, including lead slag and bio sludge from textile processing industries. The apparatus also includes a pulverizing unit operatively coupled to the collection unit and configured to reduce the size of slag materials using a pulveriser machine. The apparatus further includes a drying unit operatively coupled to the pulverizing unit and configured to employ a rotary dryer machine to reduce moisture content of the collected waste materials using hot air. The apparatus also includes a shredding unit operatively coupled to the drying unit and configured to cut or tear the waste materials into smaller pieces. The apparatus also includes a mixing unit operatively coupled to the shredding unit and configured to blend shredded waste materials in a specific ratio of lead slag to bio sludge to produce a homogeneous mixture suitable as an alternative fuel for cement kilns. The apparatus also includes a transportation unit operatively coupled to the mixing unit and configured to package blended waste materials and transport them to the cement factory.
[00015] In accordance with another embodiment of the present disclosure, a method for converting industrial waste into alternative fuel is provided. The method includes collecting industrial waste materials, including lead slag and bio sludge from textile processing industries. The method also includes pulverizing the collected slag materials into smaller particles using a hammer or pulveriser machine. The method also includes drying the collected waste materials using a rotary dryer machine with hot air. The method further includes shredding the dried waste materials into smaller pieces. The method further includes preparing a formula for the finished product by analysing the parameters and characteristics of the waste materials. The method also includes mixing the pulverized, dried, and shredded waste materials in a ratio of lead slag to bio sludge using a mixer machine, to form a uniform blend that meets the parameters required by the cement factory for alternative fuels. The method also includes packaging the blended waste materials in one-ton jumbo bags and transporting them to the cement factory.
[00016] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[00017] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0001] FIG. 1 illustrates a schematic representation of an external view of an apparatus to convert industrial waste into alternative fuel, in accordance with an embodiment of the present disclosure;
[00018] FIG. 2 illustrates a flow chart representing the steps involved in a method for converting industrial waste into alternative fuel, in accordance with an embodiment of the present disclosure; and
[00019] FIG. 3 illustrates an exemplary flow chart representing the steps involved in the process for converting industrial waste into alternative fuel of FIG. 2, in accordance with an embodiment of the present disclosure.
[00020] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[00021] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[00022] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[00023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[00024] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise.
[00025] Embodiments of the present disclosure relate to the field of waste management and environmental sustainability, specifically to an apparatus and a method for converting industrial waste materials into alternative fuels and raw materials for use in the cement industry. The apparatus includes a collection unit configured to collect waste materials, including lead slag and bio sludge from textile processing industries. The apparatus also includes a pulverizing unit operatively coupled to the collection unit and configured to reduce the size of slag materials using a pulveriser machine. The apparatus further includes a drying unit operatively coupled to the pulverizing unit and configured to employ a rotary dryer machine to reduce moisture content of the collected waste materials using hot air. The apparatus also includes a shredding unit operatively coupled to the drying unit and configured to cut or tear the waste materials into smaller pieces. The apparatus also includes a mixing unit operatively coupled to the shredding unit and configured to blend shredded waste materials in a specific ratio of lead slag to bio sludge to produce a homogeneous mixture suitable as an alternative fuel for cement kilns. The apparatus also includes a transportation unit operatively coupled to the mixing unit and configured to package blended waste materials and transport them to the cement factory.
[00026] FIG. 1 illustrates a schematic representation of an external view of an apparatus to convert industrial waste into alternative fuel, in accordance with an embodiment of the present disclosure. The apparatus (100) includes a collection unit (110) configured to collect waste materials, including lead slag and bio sludge from textile processing industries. The collection unit (110) is a critical component of the system designed to gather and handle industrial waste materials, specifically lead slag from lead smelters and bio sludge from textile processing industries. It initiates the waste conversion process by efficiently collecting, transporting, and preparing these materials in an environmentally responsible manner. The collection unit (110) employs dedicated vehicles such as dump trucks, tippers, and flatbed trucks, each equipped to handle the specific needs of transporting lead slag and bio sludge. For the handling of lead slag, JCB machines or similar heavy equipment may be used to load and unload the dense materials, reducing manual handling and enhancing operational safety. In the case of bio sludge, the collection unit (110) utilizes hydraulic tippers and forklifts with specialized attachments to handle both bulk and bagged sludge. Tippers enable the controlled unloading of sludge by tilting their containers, while forklifts securely transport and unload bagged sludge, minimizing spillage and exposure.
[00027] To ensure safe and secure storage of the collected waste materials, the collection unit (110) incorporates designated storage areas or containers designed to prevent cross-contamination and leakage. Heavy-duty storage bins or silos are used for lead slag, while bio sludge is stored in lined pits or enclosed containers to control odors and prevent environmental contamination. The collection unit (110) also incorporates safety and environmental controls, such as dust suppression systems during the handling of lead slag to prevent the release of airborne particles, and containment barriers around storage areas to prevent runoff or spills. Personal protective equipment (PPE) and strict safety protocols are mandated for all personnel involved in the collection process to ensure compliance with environmental regulations and to protect workers.
[00028] The collection unit (110) follows a structured workflow, which includes scheduled collection times, predefined routes for transportation, and standard operating procedures (SOPs) for loading, unloading, and handling each type of waste material. This organized approach helps streamline the waste management process, ensuring materials are collected promptly and consistently. Additionally, the unit is equipped with data logging systems to capture details such as the type, quantity, and source of the collected waste materials, which ensures traceability and aids in monitoring the efficiency of the collection process. This data is crucial for optimizing logistics, ensuring regulatory compliance, and supporting reporting requirements.
[00029] The apparatus (100) also includes a pulverizing unit (120) operatively coupled to the collection unit (110), and configured to reduce the size of slag materials using a pulveriser machine. The pulverizing unit (120) plays a crucial role in the waste conversion process by transforming large chunks of lead slag into smaller, more manageable particles suitable for further processing. The pulverizing unit (120) employs a pulveriser machine, which utilizes mechanical forces such as impact, compression, and shear to break down the slag materials into finer particles. The pulveriser machine is equipped with hammers, blades, or grinding elements that rotate at high speeds, striking the slag material repeatedly to achieve the desired particle size.
[00030] The design of the pulverizing unit (120) ensures efficient operation, with mechanisms to control the feed rate of slag materials from the collection unit (110). Slag is fed into the pulveriser machine through a hopper or conveyor system, which regulates the flow to maintain consistent processing conditions. The pulverising machine is engineered to handle the abrasive and dense nature of lead slag, with durable components and wear-resistant materials that extend the equipment's operational life. The pulverizing unit (120) also incorporates adjustable settings, allowing operators to modify the particle size output according to the requirements of subsequent processing stages or specific cement industry standards.
[00031] To enhance safety and environmental performance, the pulverizing unit (120) is equipped with dust collection and suppression systems. These systems capture airborne particulates generated during the pulverizing process, preventing the release of dust into the work environment and reducing potential health risks to operators. Additionally, the pulverizing unit (120) is designed with noise reduction features, such as soundproof enclosures or damping materials, to minimize noise pollution during operation.
[00032] Operational efficiency is further supported by automated controls and monitoring systems integrated within the pulverizing unit (120). Sensors track key performance parameters, such as particle size distribution, throughput rate, and machine vibrations, enabling real-time adjustments to optimize the pulverizing process. The data collected from these sensors is logged and can be used for performance analysis, maintenance scheduling, and ensuring consistent quality of the pulverized slag.
[00033] Furthermore, the apparatus (100) includes a drying unit (130) operatively coupled to the pulverizing unit (120), and configured to employ a rotary dryer machine to reduce moisture content of the collected waste materials using hot air. The drying unit (130) plays a crucial role in preparing the waste materials for further processing by ensuring that excess moisture is removed, which is essential for maintaining the quality and efficiency of the subsequent stages in the waste conversion process. The rotary dryer machine employed by the drying unit consists of a large rotating drum that is slightly inclined to allow the continuous movement of materials from the feed end to the discharge end.
[00034] Inside the rotary dryer, hot air is introduced and flows either co-currently or counter-currently with the waste materials, facilitating the efficient transfer of heat. The hot air is typically generated using a burner or heat exchanger, and its temperature and flow rate are precisely controlled to achieve optimal drying conditions without damaging the materials. As the drum rotates, the waste materials are lifted and tumbled through the hot air stream by a series of internal flights or lifters, which increases the surface area exposed to the heat and enhances the drying efficiency.
[00035] The drying unit (130) is equipped with sensors and control systems to monitor key parameters such as temperature, airflow, moisture content, and residence time of the materials within the drum. These sensors provide real-time data that allows for continuous adjustments to the drying process, ensuring that the materials are dried to the desired moisture levels while avoiding overheating or over-drying. The dried materials exit the rotary dryer with reduced moisture content, which is crucial for improving the handling, mixing, and combustion characteristics of the final alternative fuel product.
[00036] To minimize environmental impact, the drying unit (130) includes dust collection and emission control systems, such as cyclones, bag filters, or wet scrubbers, to capture any particulate matter or volatile emissions generated during the drying process. These systems ensure that the drying operation complies with environmental regulations and maintains a clean and safe working environment.
[00037] Also, the apparatus (100) includes a shredding unit (140) operatively coupled to the drying unit (130), and configured to cut or tear the waste materials into smaller pieces. The shredding unit (140) is an essential part of the waste conversion process, designed to further reduce the size of the waste materials to meet the specific requirements for blending and use as alternative fuels in cement kilns. The shredding unit (140) employs a shredder equipped with robust cutting mechanisms, such as rotating blades, knives, or shears, that are capable of processing a variety of materials with differing densities and compositions.
[00038] As the dried materials are fed into the shredding unit (140), they pass through a series of sharp, durable cutting elements that operate at high speeds to break down the waste into smaller fragments. The configuration and speed of the blades can be adjusted based on the characteristics of the waste materials, allowing the unit to tailor the shredding process to achieve the desired particle size. The shredder is designed to handle the tough, fibrous nature of bio sludge and the dense, abrasive properties of lead slag, ensuring consistent and efficient size reduction.
[00039] The shredding unit (140) is equipped with automated feed systems, such as conveyors or hoppers, that regulate the input of dried materials from the drying unit (130), maintaining a steady flow and preventing overloading of the shredder. Sensors and control systems continuously monitor the operation, providing real-time feedback on parameters like shredder speed, throughput rate, and particle size distribution. This data allows for dynamic adjustments to the shredding process, ensuring that the output meets the specific size requirements necessary for optimal blending and further processing.
[00040] To enhance safety and minimize environmental impact, the shredding unit (140) includes protective features such as enclosed cutting chambers, emergency stop mechanisms, and dust suppression systems. These features help contain the noise and dust generated during shredding, creating a safer and cleaner work environment. Additionally, the shredding unit (140) is designed with maintenance accessibility in mind, allowing for easy inspection, cleaning, and replacement of wear parts, which ensures continuous, reliable operation.
[00041] Furthermore, the apparatus (100) includes a mixing unit (150) operatively coupled to the shredding unit (140) and configured to blend shredded waste materials in a specific ratio of lead slag to bio sludge to produce a homogeneous mixture suitable as an alternative fuel for cement kilns. In one embodiment, the mixing unit (150) is configured to blend the shredded waste materials, including lead slag and bio sludge, in a specific ratio of 30:70 to produce a homogeneous mixture that meets the requirements of an alternative fuel for cement kilns. The mixing unit (150) is critical in ensuring that the waste materials are uniformly mixed to achieve consistent quality and performance as a fuel substitute. The mixing unit (150) employs a high-capacity mixer machine equipped with powerful rotating paddles, blades, or agitators designed to thoroughly combine the shredded lead slag and bio sludge.
[00042] As the shredded materials are fed into the mixing unit from the shredding unit (140), the mixer's blades rotate at controlled speeds, creating a vigorous mixing action that evenly distributes the different components throughout the blend. The mixing process is carefully monitored to maintain the precise 30:70 ratio of lead slag to bio sludge, which is essential for achieving the desired calorific value, chemical composition, and physical properties required by cement kilns. Sensors integrated within the mixing unit continuously measure the input materials and adjust the feed rates to ensure the ratio remains consistent.
[00043] To further enhance the uniformity of the mixture, the mixing unit (150) may be equipped with a sophisticated control system that allows for real-time adjustments based on feedback from in-line analysers. These analysers measure key parameters such as moisture content, particle size, and homogeneity, ensuring that the final mixture meets the specific standards set by the cement industry for alternative fuels. The mixing process is also designed to minimize air entrainment and ensure that the mixture remains free of clumps or segregations, which could affect the performance of the fuel in the cement kiln.
[00044] Safety and operational efficiency are prioritized within the mixing unit (150) through the use of enclosed mixing chambers, dust control measures, and automated shut-off systems to prevent overloading or mechanical failures. The mixing unit (150) is designed with accessibility in mind, allowing for easy cleaning, maintenance, and inspection, which helps maintain consistent operation and prolong the lifespan of the equipment.
[00045] In addition, the apparatus (100) includes a transportation unit (160) operatively coupled to the mixing unit (150) and configured to package blended waste materials and transport them to the cement factory. The transportation unit (160) serves the crucial role of handling the final stages of the waste conversion process by ensuring that the homogeneous mixture of lead slag and bio sludge is securely packaged and delivered in optimal condition for use as an alternative fuel. Once the mixing unit (150) completes the blending of the shredded waste materials into the specified 30:70 ratio, the transportation unit (160) initiates the packaging process, typically using large, durable one-ton jumbo bags designed for industrial use.
[00046] The packaging process involves automated filling systems that carefully load the blended material into the jumbo bags, ensuring consistent weight and proper sealing to prevent spillage or contamination during transit. Each bag is equipped with secure closures and lifting straps, facilitating easy handling and loading onto transport vehicles. The transportation unit (160) utilizes dedicated trucks specifically outfitted for carrying these heavy-duty bags, ensuring that the bags remain stable and intact during transport.
[00047] To maintain quality and compliance with cement industry standards, the transportation unit (160) includes a quality control checkpoint where the filled bags undergo a final inspection. This includes verifying that the bags are properly sealed, labelled with relevant information such as material composition and batch details, and meet the required safety standards for hazardous materials transport. Additionally, the transportation unit (160) is equipped with tracking and monitoring systems that provide real-time data on the location and condition of the cargo, enhancing the reliability and efficiency of the delivery process.
[00048] The transportation unit (160) is designed with environmental considerations in mind, employing measures such as dust suppression and spill containment systems to minimize environmental impact during loading and transport. Moreover, the vehicles used are selected for their fuel efficiency and compliance with emissions regulations, aligning with the overall goal of reducing the environmental footprint of the waste conversion process.
[00049] In operation, the apparatus (100) operates as an integrated system for converting industrial waste, specifically lead slag and bio sludge from textile processing industries, into alternative fuels suitable for use in cement kilns. The process begins with the collection unit (110), which gathers the waste materials using dedicated vehicles and handling equipment like JCB machines and forklifts, ensuring safe and efficient transport to the processing site. The collected waste is then fed into the pulverizing unit (120), where a pulveriser machine reduces the size of the lead slag into smaller particles through high-impact forces, preparing it for further processing. Next, the pulverized materials are transferred to the drying unit (130), which employs a rotary dryer machine that uses hot air to reduce the moisture content of the waste. This step ensures that the materials meet the necessary dryness levels for efficient handling and subsequent use. Following drying, the materials move to the shredding unit (140), where they are cut or torn into smaller pieces using high-speed blades, achieving the particle size required for optimal blending. The shredded waste is then directed to the mixing unit (150), which blends the lead slag and bio sludge in a precise 30:70 ratio. This mixing process is crucial for producing a homogeneous mixture that meets the alternative fuel specifications of the cement industry, with sensors and controls ensuring the consistency and quality of the blend. Finally, the transportation unit (160) packages the blended material into secure one-ton jumbo bags and arranges for their transport to the cement factory. This unit ensures that the packaged materials are handled, inspected, and delivered safely, with measures in place to maintain quality and minimize environmental impact during transit. Overall, the apparatus (100) provides a comprehensive and efficient solution for converting hazardous waste into valuable alternative fuels, contributing to sustainable waste management and supporting the circular economy within the cement industry.
[00050] FIG. 2 illustrates a flow chart representing the steps involved in a method for converting industrial waste into alternative fuel, in accordance with an embodiment of the present disclosure. The method (200) includes collecting industrial waste materials, including lead slag and bio sludge from textile processing industries in step 210. More specifically, the step includes gathering lead slag from lead smelters and bio sludge from textile processing industries using specialized equipment. Lead slag is unloaded with JCB machines, while bio sludge is handled with tippers equipped with hydraulic mechanisms for easy discharge. For sludge transported in bags, forklifts and JCBs facilitate the loading and unloading. This process ensures efficient and safe collection of waste materials, preparing them for further processing into alternative fuels for the cement industry.
[00051] The method (200) also includes pulverizing the collected slag materials into smaller particles using a hammer or pulveriser machine in step 220. More specifically, this step involves processing the collected slag materials to reduce their size into smaller, manageable particles using a pulveriser machine. This machine, equipped with hammers or grinding elements, employs mechanical forces such as impact, compression, and shear to break down the dense lead slag. The slag is fed into the pulveriser through a controlled hopper or conveyor system, where high-speed rotating components repeatedly strike the material, grinding it into finer particles. The design of the pulveriser ensures efficient operation and durability, handling the abrasive nature of lead slag while allowing operators to adjust particle size output as needed. Dust collection and suppression systems are integrated to capture airborne particulates, maintaining a safe and clean working environment.
[00052] The method (200) also includes drying the collected waste materials using a rotary dryer machine with hot air in step 230. More specifically, this step utilizes a rotary dryer machine to remove excess moisture from the collected waste materials, preparing them for further processing. In this process, the waste materials are continuously fed into a large, rotating drum that is slightly inclined to facilitate their movement. Hot air, generated by a burner or heat exchanger, is introduced into the drum and flows in either a co-current or counter-current direction with the materials. As the drum rotates, internal flights or lifters lift and tumble the materials, enhancing their exposure to the hot air and improving drying efficiency. The drying unit is equipped with sensors and control systems that monitor and adjust temperature, airflow, and moisture content to achieve optimal drying conditions. Dust collection and emission control systems are also in place to capture particulate matter and volatile emissions, ensuring compliance with environmental regulations and maintaining a clean working environment.
[00053] Furthermore, the method (200) includes shredding the dried waste materials into smaller pieces in step 240. More specifically, step involves breaking down the dried waste materials into smaller pieces using a shredder equipped with robust cutting mechanisms. The dried materials are fed into the shredding unit, where rotating blades or knives cut and tear them into smaller fragments. The shredder's configuration and speed can be adjusted to accommodate the varying densities and compositions of the waste. Automated feed systems ensure a steady flow of materials, while sensors and control systems monitor parameters such as shredder speed and particle size distribution. These systems provide real-time feedback, allowing dynamic adjustments to achieve the desired particle size. Protective features, including enclosed cutting chambers and dust suppression systems, are employed to enhance safety and minimize environmental impact.
[00054] The method (200) also includes preparing a formula for the finished product by analysing the parameters and characteristics of the waste materials in step 250. More specifically, the preparation of the formula for the finished product involves analysing the parameters and characteristics of the waste materials to ensure the final mixture meets specific requirements. This step includes assessing key factors such as moisture content, particle size, and chemical composition of the waste materials. Advanced control systems and in-line analysers continuously monitor these parameters throughout the blending process. By analysing real-time data, adjustments are made to the formulation to achieve the desired ratio and quality of the final product. The objective is to produce a homogeneous mixture that meets the calorific value, chemical properties, and performance standards required for use as an alternative fuel in cement kilns.
[00055] The method (200) also includes mixing the pulverized, dried, and shredded waste materials in a ratio of lead slag to bio sludge using a mixer machine, to form a uniform blend that meets the parameters required by the cement factory for alternative fuels in step 260. More specifically, this step involves combining the pulverized, dried, and shredded waste materials in a specific ratio of lead slag to bio sludge using a high-capacity mixer machine. The mixer blends the materials thoroughly, ensuring a uniform consistency and homogeneity in the final product. The machine's powerful rotating blades or paddles create a vigorous mixing action to evenly distribute the lead slag and bio sludge, adhering to the specified 30:70 ratio. Integrated sensors and control systems continuously monitor and adjust the feed rates and mixing conditions to meet the parameters required by the cement factory for alternative fuels. This process ensures that the final blend conforms to the desired calorific value, chemical composition, and performance standards for efficient use in cement kilns.
[00056] Also, the method (200) includes packaging the blended waste materials in one-ton jumbo bags and transporting them to the cement factory in step 270. More specifically, this step involves transferring the blended waste materials into one-ton jumbo bags for transport to the cement factory. The packaging process is automated, with systems ensuring consistent filling and secure sealing of each bag to prevent spillage or contamination. Once filled, the bags are equipped with closures and lifting straps for easy handling. The transportation unit uses dedicated trucks to transport the heavy-duty bags, with quality control checkpoints verifying that the bags are properly sealed, labelled, and meet safety standards. Tracking and monitoring systems provide real-time data on the cargo's location and condition, ensuring efficient and reliable delivery while minimizing environmental impact through dust suppression and spill containment measures.
[00057] FIG. 3 illustrates an exemplary flow chart representing the steps involved in the process for converting industrial waste into alternative fuel of FIG. 2, in accordance with an embodiment of the present disclosure. The process begins with the unloading of slag material in the lead slag unit using JCB machines, including backhoes and loaders, which handle the heavy slag efficiently in step 310. The slag is offloaded from transport vehicles into designated collection areas for subsequent processing.
[00058] Corresponding step involves the unloading of bio and chemical sludge and other hazardous and non-hazardous waste using tippers in step 320. Tippers, equipped with hydraulic mechanisms, tilt their cargo containers to discharge contents efficiently. For waste transported in bags, forklifts and JCBs are used to facilitate safe unloading, ensuring the integrity of the materials.
[00059] Further, is the hammering stage in step 330, wherein, slag materials are pulverized through a hammer or pulveriser machine. This process involves subjecting the slag to mechanical forces that reduce its size into smaller particles or powder. The size reduction is achieved through the use of hammers, blades, or other grinding elements within the pulveriser machine, which effectively breaks down the slag materials. Further, the drying process in step 340 is conducted using a rotary dryer machine, which consists of a rotating drum and hot air to reduce the moisture content of the waste materials. As the wet material passes through the rotating drum, it is exposed to hot air, which transfers heat to the material, causing the moisture to evaporate into the air. This step ensures that the materials are adequately dried for further processing.
[00060] Consequently, shredding in step 350 is a mechanical process that involves cutting or tearing the materials into smaller pieces. This stage is commonly used for a variety of materials, including paper, plastic, metal, and more. After sorting the waste, naturally shredded materials are separated, and those that require further reduction are shredded into small, uniform pieces, making them suitable for blending. Further is a recipe preparation process, in the recipe preparation stage, a random sample of the processed waste is taken and sent to the laboratory. The laboratory analyses the parameters and characteristics of the waste, and based on these results, a formula for the finished product is prepared in step 360. This formula specifies the percentage of each type of waste material that needs to be mixed to achieve the desired alternative fuel properties. Further, the mixing stage in step 370 involves combining two or more products through a mixer machine to create a homogeneous blend. This process ensures that the components are thoroughly mixed to achieve a consistent and uniform composition. After the hammering, drying, and shredding stages, the waste materials are mixed in the mixer machine according to the lab-derived recipes. This stage produces the final mixture, which is prepared for use as an alternative fuel for cement kilns. Once the mixed products are ready, another analysis of the finished raw materials is conducted to ensure they meet the standard parameters required by the cement factory. The finished materials are then packed into giant one-ton jumbo bags and transported to the cement factory using specialized dedicated trucks. This transportation step in step 380ensures that the alternative fuel is delivered safely and efficiently for use in cement kilns.
[00061] Various embodiments of the present invention offer several significant advantages in waste management and environmental sustainability. By converting industrial waste materials, such as lead slag and bio sludge, into alternative fuels for the cement industry, it effectively reduces the environmental impact of hazardous waste disposal. The apparatus enhances operational efficiency through its integrated system, which includes collection, pulverizing, drying, shredding, mixing, and packaging units, each designed to optimize processing and maintain high standards of safety and environmental compliance. The use of advanced control systems and real-time monitoring ensures precise processing and consistency in the final fuel product, meeting the specific requirements of cement kilns. Additionally, the system's emphasis on dust control, emission reduction, and efficient transportation aligns with sustainability goals, supporting a circular economy by transforming waste into valuable resources while minimizing environmental footprint.
[00062] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[00063] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[00064] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. An apparatus (100) to convert industrial waste into alternative fuel, comprising:
a collection unit (110) configured to collect waste materials, including lead slag and bio sludge from textile processing industries;
a pulverizing unit (120) operatively coupled to the collection unit (110), and configured to reduce the size of slag materials using a pulveriser machine;
a drying unit (130) operatively coupled to the pulverizing unit (120), and configured to employ a rotary dryer machine to reduce moisture content of the collected waste materials using hot air;
a shredding unit (140) operatively coupled to the drying unit (130), and configured to cut or tear the waste materials into smaller pieces;
a mixing unit (150) operatively coupled to the shredding unit (140), and configured to blend shredded waste materials in a specific ratio of lead slag to bio sludge to produce a homogeneous mixture suitable as an alternative fuel for cement kilns; and
a transportation unit (160) operatively coupled to the mixing unit (150), and configured to package blended waste materials and transport them to the cement factory.
2. The apparatus (100) as claimed in claim 1, wherein the collection unit (110) comprises a JCB machines and forklifts to facilitate unloading of slag and bio sludge materials from dedicated trucks.
3. The apparatus (100) as claimed in claim 1, wherein the drying unit (130) comprises a control system to regulate temperature and airflow within the rotary dryer machine to optimize the drying process of the waste materials.
4. The apparatus (100) as claimed in claim 1, wherein the mixing unit (150) comprises one or more sensors and at least one analytical tool configured to continuously monitor and adjust the ratio and properties of the waste materials to ensure compliance with cement plant standards for alternative fuels.
5. The apparatus (100) as claimed in claim 1, wherein the transportation unit (160) comprises a quality assurance mechanism to verify that the finished blend meets the alternative fuel standards set by the cement factory before packaging and dispatch.
6. A method (200) for converting industrial waste into alternative fuel, comprising:
collecting industrial waste materials, including lead slag and bio sludge from textile processing industries; (210)
pulverizing the collected slag materials into smaller particles using a hammer or pulveriser machine; (220)
drying the collected waste materials using a rotary dryer machine with hot air; (230)
shredding the dried waste materials into smaller pieces; (240)
preparing a formula for the finished product by analysing the parameters and characteristics of the waste materials; (250)
mixing the pulverized, dried, and shredded waste materials in a ratio of lead slag to bio sludge using a mixer machine, to form a uniform blend that meets the parameters required by the cement factory for alternative fuels; and (260)
packaging the blended waste materials in one-ton jumbo bags and transporting them to the cement factory. (270)
7. The method (200) as claimed in claim 6, wherein collecting the waste materials comprises collecting the waste material using JCB machines for unloading slag and forklifts for unloading bio sludge from dump trucks or tippers.
8. The method (200) as claimed in claim 6, wherein drying the waste materials comprises drying the wasting material by exposing the materials to hot air at a controlled temperature in a rotating drum to achieve optimal moisture reduction.
9. The method (200) as claimed in claim 6, wherein mixing the waste materials includes taking random samples from the blended mixture, analysing them in a laboratory, and adjusting the blend based on the test results to meet the required specifications.
10. The method (200) as claimed in claim 6, wherein transporting the blended waste materials comprises transporting the blended waste materials by performing a final quality check of the finished product to ensure it meets the required parameters for alternative fuels in cement kilns prior to shipment.
Dated this 07th day of November 2024

Signature

Jinsu Abraham
Patent Agent (IN/PA-3267)
Agent for the Applicant

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