1.     Equipment Description (Bioreactors)


The Model 1060 (10’ foot diameter x 60 foot-long) in vessel rotary bioreactor is designed to operate continuously. The system is composed of a rotating cylindrical steel drum, a base frame with drive wheels, infeed and outfeed end frames, and a control panel. The vessel can be filled with compostable organic material up to a maximum weight of 73 tons during operation. The drum rotates at a fixed rate of approximately ten revolutions per hour. It can be manually stopped and started in manual mode or controlled with a variable time cycle in automatic mode. After the required processing time in the vessel, the composted material is discharged by an auger. The sterilized material is fluffy and odorless and can be safely handled as necessary.



Figure 2: Components. The final design may vary slightly on installation









2.     Additional features included:


a.     Soft-Touch Screen Features


b.     Timer/PLC can control the drum operation by programming intervals for starting or stopping.


c.     Remote monitoring of the drum operation option is available; data sent to a cell phone or computer


d.     One (1) Infrared temperature sensor aimed at a customized point in the drum interior to measure temperature, which can then be read separately on the soft touch screen. One (1) manual temperature gauge.


e.     Data collection for temperatures/drum operation that is accessible digitally or graphically.


f.      E-stops front and back (on main panel and remote panel)


g.     Lockable main disconnect on front of the main panel


h.     System status light beacon mounted on top of the main panel indicates a fault operates in auto or manual mode.


i.      Manual/auto mode selector switches for each motor group.


j.      Variable negative ventilation fan for temperature control.

3.     Safety features and testing


a.     Continuous Drum Rotation Run


The drum will be run (constant speed drum rotation) continuously for 2 hours to ensure proper function. During the run, the drum/drive wheel interfaces and end frame/drum interfaces must be visually and audibly monitored for any unusual noises or misalignments.


b.     Discharge Door


The discharge door will be tested to ensure proper function.


c.     Exhaust Fan Run


The exhaust fan will be run for 30 minutes at the rated frequency to ensure proper function. The fan will also be accelerated from the minimum speed to the maximum speed to ensure the variable frequency drive functions correctly.


d.     Infrared Temperature Sensor Test


The infrared temperature sensor will be tested by putting a hot object with a temperature of approximately 80 degrees Celsius (upper end of sensing range) in the range of the sensor and then an object with a temperature of approximately 5 degrees Celsius (lower end of sensing range) to ensure that the sensor is measuring correctly.


e.     Safety System (e-stop) Function Test


Stop system during automatic and manual operation using the e-stop on the control panel and then reset the e-stop to ensure the system properly resets.


f.      Remote Access Test


Test remote access to verify proper function.


g.   Test System Faults and Resets


Test all system faults and resets.




2.     Equipment Description (Material Handling)


The material handling can be designed to handle 75 tons per day (24 hours) at specific intervals to fill and discharge six bioreactors. The calculations showed the conveyor system had to handle 3. 25 tons per hour X 6 vessels X 4 cycles = 24 hours = 75 tons per day . The design was to be fully automated with a return conveyorm any wasted animal bedding that could fall off the belt while fed into the bioreactors. 


The input material was required to have 8 tons of capacity , where a two -lane system was designed to carry four tons per lane (specific to weight per holding bin and redundancy.) With a two-lane system , if there is a deficiency , it requires cleaning or mechanical breakdown , the redundant system continues to run.


       Xact and its technical team will analyze moisture fluctuations over 24 hours

       The holding bins have parallel augers on a live open floor feeding material through the system

       Two complete lines were chosen for redundancy and weight distribution

       Density loads are at 44lb up to 66lb. Load cells and more mass flow tests are required.

       Based on where Select brings their material inputs, we suggest a high conveyor dropping into the bin or building a bucket elevator.

   The automation will verify there is always enough void for the input material. (i.e., one ton- input to the vessel has enough room; therefore, one-ton output per input is required)







HiPoint AG C.Corp