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Senior Design
Utilization of Food Waste
Joe Hummer, Cassidy Laird, James Rogers
23 November, 2015
Introduction
Recognize and Define Problem
❖ Americans waste ⅓ food
➢ 133 billion pounds/yr (513 Tg)
➢ National food waste limit (50% by 2030)1
❖ Clemson University
➢ Same situation
➢ 30,000 people
➢ 700 tons/year (635,000 kg/year)
➢ Composting in place
1. Aubrey, 2015.
Image from Briggs, 2013.
Define Goals
❖ Biological
➢ Design process to consume significant amount of food
waste (130 kg/day)
➢ Viable products to offset time/costs
➢ Reduce food waste to usable compost (GI > 80%)1
❖ Structural
➢ Batch, continuous, or plug flow design
➢ Able to contain decaying food waste
❖ Mechanical
➢ Heater and/or fan to provide constant temperature
➢ Oxygen/Moisture control (varies)
➢ Able to remove products for utilization
1. Zucconi et al, 1981
Constraints/Considerations
❖ Constraints
➢ Required size can fit within campus infrastructure
(Cherry Crossing: ~3 Acres )
➢ Must be compatible with existing transport and loading equipment
➢ Staff time is limited
❖ Considerations
➢ Nutrient rich compost runoff can be a pollutant
➢ Harmful and pathogenic bacteria present in decaying material
➢ Large amounts of fresh food can attract local wildlife
➢ Anaerobic reactions can produce potent greenhouse gasses
User, Client & Designer Questions
❖ User
➢ What type of training will I need to operate this system?
➢ What type of maintenance will the system require?
➢ How frequently will the system parameters need to be
checked?
❖ Client
➢ What is the expected return on investment?
➢ How consistent do the system conditions need to be?
➢ How consistent are the properties of the products?
❖ Designer
➢ What state will the food waste come in as?
➢ How much waste will come in per day?
➢ What, if any, systems already exist to address the problem?
Literature Review
Past Data
Compiled from the municipal waste documents of Tom Jones, Director of Custodial & Recycling Services,
Clemson University Facilities
Past Data
❖ Compost Analysis Report
Compound Wet basis [%] Dry Basis [%]
Total Nitrogen 1.01 4.10
Carbon 12.37 50.04
C:N Ratio 12.21 12.21
Crude Protein 6.3 25.6
Fiber - NDF 5.9 23.7
Nonfiber Carbs -- 33.1
Fat 3.5 14.3
Ash 0.8 3.2
Bulk density 399 lb/yd3
Moisture 75.28 %
Performed October 2014 by the
Clemson University Agricultural
Service Laboratory
Possible Methods
Static Pile Composting
❖ Relatively easy to maintain
❖ Fertilizer
❖ Length of process
➢ 1-6 mos., + curing 1
❖ Low mass reduction (20%)2
Anaerobic Digestion
❖ Production of biogas
❖ Faster than static
composting (30+ days)3
❖ 40% mass reduction4
❖ More complex installation
❖ Higher costs - labor,
implementation
➢ Up to $11,000-51,000 per
year5
And...
1. Zucconi et al, 1981
2. Cornell Composting
3. American Biogas Council
4. Appels, et al., 2011.
5. Michigan Farm Bureau
Black Soldier Flies
❖ Self-harvest
❖ Valuable products
❖ Waste reduction
(40-60%)1
1. Diener, et al., 2009.
Potential Models
❖ Fed Batch
➢ BioPods
❖ Continuous
➢ Vermicomposting
(flow through)
Food waste in
Fertilizer
Food waste in
Fertilizer out
Habitable zone
Fertilizer
Habitable zone
Larvae
Food Waste Composition Over Time
1. Ritika, 2015.
Black Soldier Flies
❖ Current system (BioPods)
➢ 4 pods that hold 38.5 kg (85 lbs) of food each1
➢ consumes 11.3 kg (25 lbs) of food per pod per day
➢ produces 0.454 kg (1 lb) of BSF per day (on average)
➢ Cleaned every 70 days (depending on larvae
density)
1. Approximate values from
David Thornton, organics
and Biofuels Project
Director
Image from Binh Dinh, 2012.
Black Soldier Flies
❖ Temperature ranges
➢ Survive- 0-45 ℃1
➢ Thrive- 23-43 ℃2
❖ Moisture Content
➢ Ideal- 50-60%3
❖ Available Oxygen
➢ Habitable- 15-20%4
❖ Microorganism reduction
➢ At 31℃, 99.99% reduction of E. coli5
❖ Composition varies with diet 1. Newby, 1997
2. Newby, 1997
3. Houg, 1993
4. Houg, 1993
5. Liu, et al., 2008
❖ dm/dt equals zero in steady state (SS) conditions
❖ Multiple reactions can occur in a given system
❖ Sometimes easiest to analyze a process with multiple mass
balances
Mass Balance Equations
Steady State Non-Steady State
Ficks Law
❖ Where:
➢ Fx
is mass flux through the system
➢ D is diffusivity, a constant of the medium
➢ C is concentration of mass
➢ x is distance into system
Governing Equations
❖ Growth Rate
➢ Sigmoidal model used in insect
growth literature
❖ Most interested in knowing
development time
k = growth constant
a = k*inflection time
b = k
1. Banks, et al., 2014.
Governing Equations
❖ Thermodynamics and Heat Transfer
➢ Thermal Energy Equation
❖
➢ Heat generation term - modified Arrhenius
1. Gillooly, et al., 2001.
1
Governing Equations
❖ Aerobic Respiration
❖ Chemical Oxygen Demand
➢ For complete oxidation
❖ Moisture Mass Balance
1. Houg, 1997
1
1
1
Heuristics
❖ Past experience with BSF
➢ Joe and James
❖ Internships - composting
❖ Past data from waste stream composition analysis
❖ Experience in classes and labs
➢ Microorganisms and growth rates
➢ Bioreactors and design
➢ Mass and energy balances
Collected Field Data
❖ Density
Volume of food waste added: 2 gal = 0.00757082 m3
Mass of food waste added 7.803 kg
Density (m/V) = 7.803 kg/0.00757082 m3
= 1030 kg/m3
Optimum Moisture Analysis
❖ Confirmed optimum moisture of media as a
fraction of field capacity
Wightman et al
Confirming Development Time and
Weights
❖ Pupation time has potential to be as small as 10 days
Design Methodology &
Materials
Analysis of Information
❖ Based on the information gathered through journal
articles, company websites, and heuristics, the
Black Soldier Fly design is believed to be the best
option.
❖ BSFs reduce food waste at a much faster rate and
produce multiple valuable products
❖ Compatible with current research at Clemson
Analysis of Information
❖ Identify knowns/given inputs:
➢ Mass flow rate (130 kg per day)
➢ Constant daily influent
➢ Needs to fit at Cherry Crossing
❖ Determine important design factors with black
soldier flies based on sources
➢ Temperature - winterization (year round operation)
➢ Air flow/oxygen - fans/pumps
➢ Moisture content
➢ Ramp slope/roughness
➢ Feeding rate
❖ Mass Balances with respect to:
➢ Food:
➢ Fertilizer:
➢ Biomass:
❖ Total BSF Mass Balance:
Mass Balance Analysis
0
0
0
0
Growth Analysis
❖ Rgrowth
= Final weight/development time = average weight gain/time
❖ Development time
➢ affected nonlinearly for
feeding rate, temp, and
moisture
❖ Final weight
➢ affected linearly by feeding
rate
1. Data from Diener, et al., 2009.
Synthesis of Design
Fed Batch (BioPods) Continuous (Vermicomposting)
Image from Olivier, 2004.
Image from Vermivision, 2012.
Design Options
Sizing for Food Waste
❖ Based on TOC analysis, 40 days are needed for
complete food removal
❖ assuming:
➢ A habitable depth of 6” (0.152 m):
➢ Food waste density of 1029 kg/m3 1
❖ Retention area:
Aretention
= (Ṁfood
*τfood
/ρfood
)/(dhabitable
)
Aretention
= (130 kg/day*40 days/1029 kg/m3
)/(.152 m)=33.1 m2
❖ Daily thickness:
130 kg/day*40 days ÷ 28.4 m2
= 0.44 cm
1. epa.vic.gov.au
Batch Process Reactions
Time (days)
Optimizing Population
❖ For a given population:
➢ τBSF
= development time = 7.57*Rfeeding
-0.379
➢ Rfeeding
= Ṁfood
/Population = Ṁfood
/(Eggsin
*τBSF
)
❖ Can control feeding rate by adjusting daily egg and
food input
❖ Change inputs to yield the most products
Developementtime(days)Growthrate(g/day)ComposterBiomass(g)
Time (days)
Aeration of Media
❖ Approached as a method of increasing habitable
depth and decreasing surface area needed
❖ Flow of oxygen in reaches equilibrium with oxygen
uptake rate
❖ Needed to determine oxygen uptake rate
Carbon-Oxygen Demand
❖ O2
consumption directly related to growth/activity
with microbes
❖ COD = 1.44 g O2
/g FW
❖ At STP:
➢ [O2
]air
= 23.2% (by wgt)
➢ ρair
= 1.20 kg/m3
❖ Volume of air required for total oxidation of daily
food waste in flow is 168,350 L air/day
Aeration of Media
❖ Assuming:
➢ Rrespiration
= 0.5683 μl/mg/hr1
Fx
= -D*(dc/dx) = Biomass*Rrespiration
/Acomposter
Fx
= 1000 mgBSF
*0.5683 /0.621 m2
= 915.1 μl/hr/m2
1. Nespolo, et al., 2003.
Flow of Oxygen
Moisture
❖ Composting tends to be a dehydrating environment
➢ biological activity decreases at moisture levels < 50%
❖ Assume:
➢ Ss
= 25%, Sp
= 40%
❖ W = (1-0.25)/0.25 - (1-0.40)/0.40 = 1.50 g H2
O/g dry
FW
❖ Must lose 48.75 kg of water per day to maintain 60%
moisture content in reactor
Side effects of Aeration
❖ dm/dt = Wrespiration
-Wevaporation
≠ 0
❖ Evaporation increases with aeration
❖ Water source needed with aeration
Synthesis of Design
Winterization
❖ Determination of heat generation constants
`
1. Gillooly, et al., 2001.
Temperature-1
(1000/K)
ln(B0
/m3/4
)(W/g3/4
)
BO
≍ Eg
in energy balance
Synthesis of Design
❖ Flow of Thermal Energy
Synthesis of Design
Ambient Temp. (K) Method Final Temp. (K) Final Temp. (℃)
318
(45 ℃)
m= 0.9 kg/s 299 26
m= 0.9 kg/s
Wood insul., 1 in thick
299 26
m= 0.005 kg/s
Wood insul., 1 in thick
320 47
298
(25 ℃)
m= 0.9 kg/s 298 25
m= 0.9 kg/s
Wood insul., 1 in thick
298 25
m= 0.005 kg/s
Wood insul., 1 in thick
300 27
273
(0 ℃)
m= 0.9 kg/s 281 8
m= 0.9 kg/s
Wood insul., 1 in thick
293 20
m= 0.005 kg/s
Wood insul., 1 in thick
275 2
m= 0.9 kg/s, Full wood insul., 1 in 296 23
Extending Living Space
❖ Same amount of oxygen is needed, but aeration must
supply minimum concentrations (15%) throughout
❖ Available oxygen must be greater than or equal to
respiration rate or dead zone appears
Jjc senior final.pptx
Aeration Placement: Too Deep
Aeration Placement: Too Shallow
Goldilocks!
❖ Placed 0.26 meters (10.2”) deep
❖ Habitable zone greater than 0.4 meters (15.7”)
Aeration Through Piping
❖ Based on minimal oxygen concentrations at 5.1”
➢ dead zones are possible at 5.1” from any air source
➢ must space aeration to eliminate dead zones
Far
zone
5.1”5.1”
5.1”
x x
45°45°
x = sin(45°)*5.1” = 3.62”
Spacing = 2*x = 7.24”
Pipe Sizing
❖ Using orifice equations:
➢ ⅛” (3.2 mm) orifice diameter
➢ 8 radial orifices per segment
➢ 7.24” spacing
➢ 2” pipe diameter
➢ alternating air flow between pipes (below)
➢ 7 psi stagnation pressure
air
air
Crowe et al 2009
Jjc senior final.pptx
Physical Design
❖ Side view
❖ Top View
How Constraints Handled
❖ Limited staff time
➢ 40 minutes per day for feeding
➢ 1 hour per day for BSF nursery
❖ Ramps on vermicomposter
➢ Dividers w/ramps
❖ Winterization - heated air flow with limit
Evaluations
Sustainability
● Ecological - Reduce waste going into environment
● Economic - Potential marketable products
○ Biodiesel
○ Protein
○ Fertilizer
● Social/Ethics
○ Aesthetics (smell), Bug cruelty (3 Rs)
○ Changing household ideologies to reduce the
amount of wasted food
Budget/Economics
Jjc senior final.pptx
Bill of Materials
Evaluation of Alternatives
Fed Batch System Continuous System
Aeration N/A Aerated Non-aerated
Mass Reduction 43% 43% 43%
Space ~ 50 m2
~ 13 m2
~ 34 m2
Winterization Possibly Yes
(air flow control +
insulation)
Yes
(air flow control +
insulation)
SS viability Nonexistent Theoretical Probable
Costs ~ $14,000 ~ $1530 ~ $2800
ROI 19 years 2.5 years 4.5 years
Evaluation of Alternatives
Fed Batch System Continuous System
Aeration N/A Aerated Non-aerated
Mass Reduction 43% 43% 43%
Space ~ 50 m2
~ 13 m2
~ 34 m2
Winterization Possibly Yes
(air flow control +
insulation)
Yes
(air flow control +
insulation)
SS viability Nonexistent Theoretical Probable
Costs ~ $14,000 ~ $1530 ~ $2800
ROI 19 years 2.5 years 4.5 years
Conclusions
❖ Goal achieved:
➢ Reduces mass by 43 %, converts rest to marketable
products
❖ Costs:
➢ $1530 overhead
➢ $25 per day on labor
➢ $1.40 per day on electricity
❖ Sustainability:
➢ Reduces amount of waste going to landfill
Conclusions
Questions Answered
❖ User
➢ What type of training will I need to operate this system?
➢ What type of maintenance will the system require?
➢ How frequently will the system parameters need to be
checked?
❖ Client
➢ What is the expected return on investment?
➢ How consistent do the system conditions need to be?
➢ How consistent are the properties of the products?
❖ Designer
➢ What state will the food waste come in as?
➢ How much waste will come in per day?
➢ What, if any, systems already exist to address the problem?
Timeline
References
❖ American Biogas Council. 2015. Frequent Questions. American Biogas Council. https://www.americanbiogascouncil.
org/biogas_questions.asp. Accessed November 2015.
❖ Appels, L., J. Lauwers, J. Degreve, L. Helsen, B. Lievens, K. Willems, J.V. Impe and R. Dewil. 2011. Anaerobic digestion in
global bio-energy production: Potential and research challenges. Renewable and Sustainable Energy Reviews. 15(9): 4295-
4301.
❖ Aubrey, Allison. 2015. It’s Time To Get Serious About Food Waste, Feds Say. NPR. Available at: http://www.npr.
org/sections/thesalt/2015/09/16/440825159/its-time-to-get-serious-about-reducing-food-waste-feds-say. Web accessed 16
September 2015.
❖ Binh Dinh, 2012. https://binhdinhwssp.wordpress.com/tag/binh-dinh/.
❖ Briggs, Justin. 2013. US Food Waste. Food Waste. Stanford University. http://large.stanford.edu/courses/2012/ph240/briggs1/.
Accessed Nov 2015.
❖ Cornell Composting. 1996. The Science and Engineering of Composting. Cornell Composting Science and Engineering.
Cornell Waste Management Institute. http://compost.css.cornell.edu/science.html. Accessed November 2015.
❖ Gillooly, J.F., J.H. Brown, G.B. West, V.M. Savage and E.L. Charnov. 2001. Effects of Size and Temperature on Metabolic
Rate. Science. 293(5538): 2248-2251.
❖ Houg, R. T. 1993. The Practical Handbook of Compost Engineering. Boca Raton, FL: Lewis Publishers.
❖ Larson, Judd, Sendhil Kumar, S. A. Gale, Pradeep Jain, and Timothy Townsend. "A Field Study to Estimate the Vertical Gas
Diffusivity and Permeability of Compacted MSW Using a Barometric Pumping Analytical Model." A Field Study to Estimate the
Vertical Gas Diffusivity and Permeability of Compacted MSW Using a Barometric Pumping Analytical Model. N.p., 2012. Web.
22 Nov. 2015.
❖ Liu, Q., J.K. Tomberlin, J.A. Brady, M.R. Sanford and Z. Yu. 2008. Black Soldier Fly (Diptera: Stratiomyidae) Larvae Reduce
Escherichia coli in Dairy Manure. Environ. Entomol. 37(6): 1525-1530.
❖ Michigan Farm Bureau. Frequently asked questions about Anaerobic Digesters (ADs). https://www.michigan.
gov/documents/mda/MDA_AnaerobicDigesterFAQ_189519_7.pdf.
❖ Nespolo, R. F. "Intrapopulational Variation in the Standard Metabolic Rate of Insects: Repeatability, Thermal Dependence and
Sensitivity (Q10) of Oxygen Consumption in a Cricket." Journal of Experimental Biology. 206.23 (2003): 4309-315. Web.
❖ Olivier, Paul A. 2004. Disposal apparatus and method for efficiently bio-converting putrescent wastes. US 6780637 B2.
❖ Ritika, Pathak, and Sharma Rajendra. "Study on Occurrence of Black Soldier Fly Larvae in Composting of Kitchen Waste."
International Journal of Research in Biosciences 4.4 (2015): 38-45. Web.
❖ Vermivision, 2012. http://vermivision.net/?page_id=2
❖ Zucconi, Franco, Antonia Pera, Maria Forte, and Marco De Bertoldi. "Evaluating Toxicity of Immature Compost." BioCycle 22.2
(1981): 54. Web.
❖ Wightman, J. A., and M. Fowler. "Rearing Costelytra Zealandica (Coleoptera: Scarabaeidae)." New Zealand Journal of
Zoology 1.2 (1974): 225-30. Web.
Questions?

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Jjc senior final.pptx

  • 1. Senior Design Utilization of Food Waste Joe Hummer, Cassidy Laird, James Rogers 23 November, 2015
  • 2. Introduction Recognize and Define Problem ❖ Americans waste ⅓ food ➢ 133 billion pounds/yr (513 Tg) ➢ National food waste limit (50% by 2030)1 ❖ Clemson University ➢ Same situation ➢ 30,000 people ➢ 700 tons/year (635,000 kg/year) ➢ Composting in place 1. Aubrey, 2015. Image from Briggs, 2013.
  • 3. Define Goals ❖ Biological ➢ Design process to consume significant amount of food waste (130 kg/day) ➢ Viable products to offset time/costs ➢ Reduce food waste to usable compost (GI > 80%)1 ❖ Structural ➢ Batch, continuous, or plug flow design ➢ Able to contain decaying food waste ❖ Mechanical ➢ Heater and/or fan to provide constant temperature ➢ Oxygen/Moisture control (varies) ➢ Able to remove products for utilization 1. Zucconi et al, 1981
  • 4. Constraints/Considerations ❖ Constraints ➢ Required size can fit within campus infrastructure (Cherry Crossing: ~3 Acres ) ➢ Must be compatible with existing transport and loading equipment ➢ Staff time is limited ❖ Considerations ➢ Nutrient rich compost runoff can be a pollutant ➢ Harmful and pathogenic bacteria present in decaying material ➢ Large amounts of fresh food can attract local wildlife ➢ Anaerobic reactions can produce potent greenhouse gasses
  • 5. User, Client & Designer Questions ❖ User ➢ What type of training will I need to operate this system? ➢ What type of maintenance will the system require? ➢ How frequently will the system parameters need to be checked? ❖ Client ➢ What is the expected return on investment? ➢ How consistent do the system conditions need to be? ➢ How consistent are the properties of the products? ❖ Designer ➢ What state will the food waste come in as? ➢ How much waste will come in per day? ➢ What, if any, systems already exist to address the problem?
  • 7. Past Data Compiled from the municipal waste documents of Tom Jones, Director of Custodial & Recycling Services, Clemson University Facilities
  • 8. Past Data ❖ Compost Analysis Report Compound Wet basis [%] Dry Basis [%] Total Nitrogen 1.01 4.10 Carbon 12.37 50.04 C:N Ratio 12.21 12.21 Crude Protein 6.3 25.6 Fiber - NDF 5.9 23.7 Nonfiber Carbs -- 33.1 Fat 3.5 14.3 Ash 0.8 3.2 Bulk density 399 lb/yd3 Moisture 75.28 % Performed October 2014 by the Clemson University Agricultural Service Laboratory
  • 9. Possible Methods Static Pile Composting ❖ Relatively easy to maintain ❖ Fertilizer ❖ Length of process ➢ 1-6 mos., + curing 1 ❖ Low mass reduction (20%)2 Anaerobic Digestion ❖ Production of biogas ❖ Faster than static composting (30+ days)3 ❖ 40% mass reduction4 ❖ More complex installation ❖ Higher costs - labor, implementation ➢ Up to $11,000-51,000 per year5 And... 1. Zucconi et al, 1981 2. Cornell Composting 3. American Biogas Council 4. Appels, et al., 2011. 5. Michigan Farm Bureau
  • 10. Black Soldier Flies ❖ Self-harvest ❖ Valuable products ❖ Waste reduction (40-60%)1 1. Diener, et al., 2009.
  • 11. Potential Models ❖ Fed Batch ➢ BioPods ❖ Continuous ➢ Vermicomposting (flow through) Food waste in Fertilizer Food waste in Fertilizer out Habitable zone Fertilizer Habitable zone Larvae
  • 12. Food Waste Composition Over Time 1. Ritika, 2015.
  • 13. Black Soldier Flies ❖ Current system (BioPods) ➢ 4 pods that hold 38.5 kg (85 lbs) of food each1 ➢ consumes 11.3 kg (25 lbs) of food per pod per day ➢ produces 0.454 kg (1 lb) of BSF per day (on average) ➢ Cleaned every 70 days (depending on larvae density) 1. Approximate values from David Thornton, organics and Biofuels Project Director Image from Binh Dinh, 2012.
  • 14. Black Soldier Flies ❖ Temperature ranges ➢ Survive- 0-45 ℃1 ➢ Thrive- 23-43 ℃2 ❖ Moisture Content ➢ Ideal- 50-60%3 ❖ Available Oxygen ➢ Habitable- 15-20%4 ❖ Microorganism reduction ➢ At 31℃, 99.99% reduction of E. coli5 ❖ Composition varies with diet 1. Newby, 1997 2. Newby, 1997 3. Houg, 1993 4. Houg, 1993 5. Liu, et al., 2008
  • 15. ❖ dm/dt equals zero in steady state (SS) conditions ❖ Multiple reactions can occur in a given system ❖ Sometimes easiest to analyze a process with multiple mass balances Mass Balance Equations Steady State Non-Steady State
  • 16. Ficks Law ❖ Where: ➢ Fx is mass flux through the system ➢ D is diffusivity, a constant of the medium ➢ C is concentration of mass ➢ x is distance into system
  • 17. Governing Equations ❖ Growth Rate ➢ Sigmoidal model used in insect growth literature ❖ Most interested in knowing development time k = growth constant a = k*inflection time b = k 1. Banks, et al., 2014.
  • 18. Governing Equations ❖ Thermodynamics and Heat Transfer ➢ Thermal Energy Equation ❖ ➢ Heat generation term - modified Arrhenius 1. Gillooly, et al., 2001. 1
  • 19. Governing Equations ❖ Aerobic Respiration ❖ Chemical Oxygen Demand ➢ For complete oxidation ❖ Moisture Mass Balance 1. Houg, 1997 1 1 1
  • 20. Heuristics ❖ Past experience with BSF ➢ Joe and James ❖ Internships - composting ❖ Past data from waste stream composition analysis ❖ Experience in classes and labs ➢ Microorganisms and growth rates ➢ Bioreactors and design ➢ Mass and energy balances
  • 21. Collected Field Data ❖ Density Volume of food waste added: 2 gal = 0.00757082 m3 Mass of food waste added 7.803 kg Density (m/V) = 7.803 kg/0.00757082 m3 = 1030 kg/m3
  • 22. Optimum Moisture Analysis ❖ Confirmed optimum moisture of media as a fraction of field capacity Wightman et al
  • 23. Confirming Development Time and Weights ❖ Pupation time has potential to be as small as 10 days
  • 25. Analysis of Information ❖ Based on the information gathered through journal articles, company websites, and heuristics, the Black Soldier Fly design is believed to be the best option. ❖ BSFs reduce food waste at a much faster rate and produce multiple valuable products ❖ Compatible with current research at Clemson
  • 26. Analysis of Information ❖ Identify knowns/given inputs: ➢ Mass flow rate (130 kg per day) ➢ Constant daily influent ➢ Needs to fit at Cherry Crossing ❖ Determine important design factors with black soldier flies based on sources ➢ Temperature - winterization (year round operation) ➢ Air flow/oxygen - fans/pumps ➢ Moisture content ➢ Ramp slope/roughness ➢ Feeding rate
  • 27. ❖ Mass Balances with respect to: ➢ Food: ➢ Fertilizer: ➢ Biomass: ❖ Total BSF Mass Balance: Mass Balance Analysis 0 0 0 0
  • 28. Growth Analysis ❖ Rgrowth = Final weight/development time = average weight gain/time ❖ Development time ➢ affected nonlinearly for feeding rate, temp, and moisture ❖ Final weight ➢ affected linearly by feeding rate 1. Data from Diener, et al., 2009.
  • 29. Synthesis of Design Fed Batch (BioPods) Continuous (Vermicomposting) Image from Olivier, 2004. Image from Vermivision, 2012. Design Options
  • 30. Sizing for Food Waste ❖ Based on TOC analysis, 40 days are needed for complete food removal ❖ assuming: ➢ A habitable depth of 6” (0.152 m): ➢ Food waste density of 1029 kg/m3 1 ❖ Retention area: Aretention = (Ṁfood *τfood /ρfood )/(dhabitable ) Aretention = (130 kg/day*40 days/1029 kg/m3 )/(.152 m)=33.1 m2 ❖ Daily thickness: 130 kg/day*40 days ÷ 28.4 m2 = 0.44 cm 1. epa.vic.gov.au
  • 32. Optimizing Population ❖ For a given population: ➢ τBSF = development time = 7.57*Rfeeding -0.379 ➢ Rfeeding = Ṁfood /Population = Ṁfood /(Eggsin *τBSF ) ❖ Can control feeding rate by adjusting daily egg and food input ❖ Change inputs to yield the most products
  • 34. Aeration of Media ❖ Approached as a method of increasing habitable depth and decreasing surface area needed ❖ Flow of oxygen in reaches equilibrium with oxygen uptake rate ❖ Needed to determine oxygen uptake rate
  • 35. Carbon-Oxygen Demand ❖ O2 consumption directly related to growth/activity with microbes ❖ COD = 1.44 g O2 /g FW ❖ At STP: ➢ [O2 ]air = 23.2% (by wgt) ➢ ρair = 1.20 kg/m3 ❖ Volume of air required for total oxidation of daily food waste in flow is 168,350 L air/day
  • 36. Aeration of Media ❖ Assuming: ➢ Rrespiration = 0.5683 μl/mg/hr1 Fx = -D*(dc/dx) = Biomass*Rrespiration /Acomposter Fx = 1000 mgBSF *0.5683 /0.621 m2 = 915.1 μl/hr/m2 1. Nespolo, et al., 2003.
  • 38. Moisture ❖ Composting tends to be a dehydrating environment ➢ biological activity decreases at moisture levels < 50% ❖ Assume: ➢ Ss = 25%, Sp = 40% ❖ W = (1-0.25)/0.25 - (1-0.40)/0.40 = 1.50 g H2 O/g dry FW ❖ Must lose 48.75 kg of water per day to maintain 60% moisture content in reactor
  • 39. Side effects of Aeration ❖ dm/dt = Wrespiration -Wevaporation ≠ 0 ❖ Evaporation increases with aeration ❖ Water source needed with aeration
  • 40. Synthesis of Design Winterization ❖ Determination of heat generation constants ` 1. Gillooly, et al., 2001. Temperature-1 (1000/K) ln(B0 /m3/4 )(W/g3/4 )
  • 42. Synthesis of Design ❖ Flow of Thermal Energy
  • 43. Synthesis of Design Ambient Temp. (K) Method Final Temp. (K) Final Temp. (℃) 318 (45 ℃) m= 0.9 kg/s 299 26 m= 0.9 kg/s Wood insul., 1 in thick 299 26 m= 0.005 kg/s Wood insul., 1 in thick 320 47 298 (25 ℃) m= 0.9 kg/s 298 25 m= 0.9 kg/s Wood insul., 1 in thick 298 25 m= 0.005 kg/s Wood insul., 1 in thick 300 27 273 (0 ℃) m= 0.9 kg/s 281 8 m= 0.9 kg/s Wood insul., 1 in thick 293 20 m= 0.005 kg/s Wood insul., 1 in thick 275 2 m= 0.9 kg/s, Full wood insul., 1 in 296 23
  • 44. Extending Living Space ❖ Same amount of oxygen is needed, but aeration must supply minimum concentrations (15%) throughout ❖ Available oxygen must be greater than or equal to respiration rate or dead zone appears
  • 48. Goldilocks! ❖ Placed 0.26 meters (10.2”) deep ❖ Habitable zone greater than 0.4 meters (15.7”)
  • 49. Aeration Through Piping ❖ Based on minimal oxygen concentrations at 5.1” ➢ dead zones are possible at 5.1” from any air source ➢ must space aeration to eliminate dead zones Far zone 5.1”5.1” 5.1” x x 45°45° x = sin(45°)*5.1” = 3.62” Spacing = 2*x = 7.24”
  • 50. Pipe Sizing ❖ Using orifice equations: ➢ ⅛” (3.2 mm) orifice diameter ➢ 8 radial orifices per segment ➢ 7.24” spacing ➢ 2” pipe diameter ➢ alternating air flow between pipes (below) ➢ 7 psi stagnation pressure air air Crowe et al 2009
  • 52. Physical Design ❖ Side view ❖ Top View
  • 53. How Constraints Handled ❖ Limited staff time ➢ 40 minutes per day for feeding ➢ 1 hour per day for BSF nursery ❖ Ramps on vermicomposter ➢ Dividers w/ramps ❖ Winterization - heated air flow with limit
  • 55. Sustainability ● Ecological - Reduce waste going into environment ● Economic - Potential marketable products ○ Biodiesel ○ Protein ○ Fertilizer ● Social/Ethics ○ Aesthetics (smell), Bug cruelty (3 Rs) ○ Changing household ideologies to reduce the amount of wasted food
  • 59. Evaluation of Alternatives Fed Batch System Continuous System Aeration N/A Aerated Non-aerated Mass Reduction 43% 43% 43% Space ~ 50 m2 ~ 13 m2 ~ 34 m2 Winterization Possibly Yes (air flow control + insulation) Yes (air flow control + insulation) SS viability Nonexistent Theoretical Probable Costs ~ $14,000 ~ $1530 ~ $2800 ROI 19 years 2.5 years 4.5 years
  • 60. Evaluation of Alternatives Fed Batch System Continuous System Aeration N/A Aerated Non-aerated Mass Reduction 43% 43% 43% Space ~ 50 m2 ~ 13 m2 ~ 34 m2 Winterization Possibly Yes (air flow control + insulation) Yes (air flow control + insulation) SS viability Nonexistent Theoretical Probable Costs ~ $14,000 ~ $1530 ~ $2800 ROI 19 years 2.5 years 4.5 years
  • 61. Conclusions ❖ Goal achieved: ➢ Reduces mass by 43 %, converts rest to marketable products ❖ Costs: ➢ $1530 overhead ➢ $25 per day on labor ➢ $1.40 per day on electricity ❖ Sustainability: ➢ Reduces amount of waste going to landfill
  • 62. Conclusions Questions Answered ❖ User ➢ What type of training will I need to operate this system? ➢ What type of maintenance will the system require? ➢ How frequently will the system parameters need to be checked? ❖ Client ➢ What is the expected return on investment? ➢ How consistent do the system conditions need to be? ➢ How consistent are the properties of the products? ❖ Designer ➢ What state will the food waste come in as? ➢ How much waste will come in per day? ➢ What, if any, systems already exist to address the problem?
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