FIELD OF THE INVENTION

The invention relates to a bunker storage system for flammable materials. The bunker storage system is designed to avoid dangerous outcomes resulting from the ignition of flammable materials stored in the bunker and any associated environmental damage resulting from such an event. The bunker storage system is equipped to detect the various signatures of ignition of flammable materials, such as elevated heat and pressure. Specifically, the bunker storage system can be used for the storage of flammable materials such as plastic and rubber that are manufactured from oil or petroleum byproducts. More particularly, the bunker storage system can be used for the storage of waste vehicle tyres. The bunker storage system will accommodate a large volume of waste vehicle tyres safely and can be equipped to detect changes in temperature or pressure that would be indicative of ignition of the waste tyres.

BACKGROUND OF THE INVENTION

Tyres and tyre shred are stored in mass quantities in locations around the world. In order to provide an idea of the scale and magnitude of the challenge presented by waste vehicle tyres, it is estimate that approximately 1.8 billion vehicle tyres are discarded each year around the world. They are generally discarded in the form of intact tyres or tyre shred and are somewhat difficult to break down into their constituents beyond these two forms. Processing of the tyres and/or tyre shred into diesel or other forms of fuel is known, but a very high percentage of waste tyres either remain intact indefinitely or they are stored for a period of time before being processed into fuel and other products.

Ignition and burning of waste tyres and waste tyre shred is a known and serious problem. When waste tyres or tyre shred is placed in a storage bin or other storage vessel, there can be an increase of heat and/or pressure that sometimes can lead to ignition of the material. This is particularly true in hot climates, or in the summer months in more temperate climates. Once waste tyres or tyre shred ignite, the resulting fire can be very difficult to extinguish. The fire can also result in a significant amount of black, acrid smoke along with other associated forms of environmental pollution. Certain areas that are situated in sensitive environments, or jurisdictions that are very sensitive to environmental issues, have simply banned mass storage of waste tyres because the risk is too great.

Increasing amount of recycling and reprocessing of waste tyres into fuel is being conducted around the world. However, even in the most optimistic reprocessing or recycling scenario, tyres and tyre shred will still need to be stored for a period of time. Accordingly, there is a need for a tyre storage solution that is equipped to prevent ignition of the waste tyres and/or tyre shred and the associated environmental damage. The need exists for a safe storage solution that can be deployed in all areas, including environmentally sensitive areas where ordinarily tyre storage, or the storage of other flammable materials, would not be allowed.

SUMMARY OF THE INVENTION

The invention is innovative and unparalleled in its ability, to not only detect heat signatures within the stored material, but also to quench any ignition and thereby preventing a full fire from igniting. This means that not only can this storage system be rolled out and used sensibly and safely for many types of flammable material storage systems, but it can be specifically deployed in areas that are more sensitive and otherwise would have prohibited a facility from being built in the first place.

The present inventors have direct experience with a fire at a tyre recycling facility in their local area. The inventors are engaged in the development of innovative tyre recycling facilities and view the safe storage of the incoming feed stock (tyre and tyre shred) as an integral part of their overall process. The tyre storage component is fundamental to the overall recycling process so as to ensure the safety of people and the environment. Accordingly, the present inventors developed a safe and effective bunkering system that greatly reduces or eliminates altogether the risk of ignition of stored tyres and tyre shred.

The system has unique modifications throughout.

According to various aspects of the present invention, the following stages are how the storage bunker was designed to ensure that it was safe and would prevent ignition of combustible materials under any conditions:

1. The first step was to combat simple initial ignition. This was achieved by looking for heat signatures within the stored material. By using thermal cameras specifically aimed at the piles of stored material, this would enable an alert system to be triggered if any heat signature is detected at any time. 2. The second step is designed for prevention of arson. This is achieved through a novel covering system which either manually or mechanically (depending on the user’s needs) slides down over the top of the pile of stored material while the material is stationary inside.

3. The third step focusses on the ease of loading and unloading of the materials. These materials are stored underground. The bay is open sided and open to the elements before the cover is closed. There is a simple ramp going down into the base. The base then flattens off with a slight slope towards the back where the material is stored. The materials are both loaded and unloaded by the same front entrance ramp.

4. The fourth step focuses on measures for the prevention of ignition. When the cover is down it creates a seal, in addition, the air is sucked out thereby creating a vacuum. Simply, with no oxygen there can be no ignition.

5. The fifth step focusses on stopping fire in the bunker which is achieved by the whole bunker filling with water. This step is achieved by a water system working in conjunction with the thermal cameras via a sensor.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 shows a side elevation view of a simplified overview of a storage bunker according to an embodiment of the present invention.

Figure 2 shows a detailed side elevation view, with representative dimensions, of a storage bunker for flammable materials according to an embodiment of the present invention.

Figure 3 shows a top view of a bunker storage system according to an embodiment of the present invention with multiple storage bunkers placed in a useful arrangement.

DETAILED DESCRIPTION OF THE INVENTION

As shown in Figure 1, the present invention may take the form of a storage bunker 101 with sloped ramp access 102. The storage bunker may have a lid 103 to allow for the closing of the bunker and evacuation of air from within. The lid 103 of the bunker 101 is always kept closed, except during loading and unloading. The lid 103 of the bunker 101 may be constructed of steel or other suitable material.

Figure 2 shows a more detailed view of a storage bunker 201 for flammable materials according to an embodiment of the present invention. The dimensions of the bunker 201 may vary with the particular storage needs, but may optionally be as follows: Width 10m, Height 3 metres above ground level, Depth 3 metres below ground level, Length 15 metres. The load limit should be maintained at lm below ground level. In one configuration, as shown in Figure 2, there is a 10m slope 202 descending from ground level 211 to the bottom of the storage bunker 201 that terminates at a 3m bottom surface portion 203. One of skill in the art will realise that these are representative dimensions that can be varied according to storage needs. The dimensions can optimally be varied in relative proportion to each other, but within reason can be varied according to the particular storage application. A single bunker storage system can be as small as 2 metres in length by 6 metres wide by 3 metres deep, to a maximum size of 20 metres length 9 metres width 6 metres deep. A series of these storage systems can be placed side by side. For fire prevention and speed of water filling the bunker in preventing a fire, this is an ideal configuration if the storage/industrial/processing facility has a lot of potentially combustible materials that need to be safely stored onsite. There is no limit on how many you can place side by side (within statutory frameworks and environmental policy regulations) if you take a nominal dimension size and replicate it. Alternatively the bunker system can be placed around your site in stand alone systems depending on the need for planning permission, permitting, environmental licencing etc As shown in Figures 2 and 3, the inventive storage bunker system has multiple additional features:

1. Sited just behind the storage bays are water storage tanks (307, for example) for fire prevention. These water tanks 307 are always kept filled so as to flood the bays if necessary. Each one of the bays will have 1 1/2 storage tanks that equal to 150% of the total capacity of each bay. Dependent on environmental permit requirements, this capacity can also be extended further.

2. There is also an additional tank that is used for additional water storage. Any rainwater that collects at the bottom of the material storage bay can be pumped out and put into this tank for use as necessary for flooding the system in an emergency. The storage bays are lined with waterproof concrete and heat resistant material. The rapid response water flood system can optimally fill the bay within two minutes.

3. The thermal cameras 205 have a light signalling “amber and red alert” system 207. The light system is located at the top on one side of the storage bay. Each individual bay will have its own light signalling system. CCTV cameras 204 are also provided for monitoring of the storage bay environment. Thermal sensors 206 are also provided to determine when there is a critical build up of heat in the storage bay and also when the heat has dissipated after the problem has been resolved.

4. Linked to the amber and red lighting system is a siren 306. When the amber light goes off, a short siren sounds at regular intervals to indicate there is a potential issue with the storage tyre shred material. When the issue become more prevalent (such as when there is significant ignition of the stored material) the red light is activated, and the siren sounds at a constant level to indicate the problem requires immediate attention. At this time, if manual operation has not taken over, the automated safety system will activate by the valve 208 opening and the water storage bunker automatically being piped to the bunker that has raised the alert through the thermal camera detection system.

5. An attention indicator will then illuminate blue to warn that there was an emergency that has now been rectified and the maintenance crew along with the operator must take a look to undertake the necessary safety steps required to check over the storage bunker and the bay it is located in.

6. The water level sensor 208 indicates the flooding level required. This then directs the switch in the water tank ensuring that once the bunker has been flooded effectively, the water flow is turned off once it has attained critical height and mass.

7. Once the heat or fire has been put out, the two drainage outlets 209 are opened. These outlets are located at the back of the bunker wall. The drainage system is activated via the thermal cameras and sensors, and the water is pumped out into an adjacent water processing tank.

8. The cover 210 has a dual purpose: once down it creates a seal which creates a vacuum. Air can be drawn out - once the air is drawn out, oxygen from getting to the material. When the cover is down it also prevents anyone from throwing a spark or igniting material to the storage bay. 9. The camera sensors automatically turn on and off, monitoring the temperatures; whether the materials in the bunker are cooling down or heating up.

10. The water system can be used as a fire preventative as well as completely putting out any heat.

11. The wastewater valves close when necessary, when the level of water is needed and required.

12. The light signalling system works well for both night and daytime use. This is coupled with a siren that is activated according to the light signals.

Figure 3 shows a top view of an alternative embodiment of the present invention. In this embodiment, multiple storage bunkers 301, 302, 303, 304 are placed in a useful arrangement. Each storage bunker is self-contained with its own heat sensor and warning light system 305. The various storage bunkers shown in Figure 3 are presented in different configurations, such as empty, filled with tyre waste 308 and with the lid in place 309.

Arranging storage bunkers in an array such as that shown in Figure 3 provides for workable dimensions for each individual bunker. Each bunker can be sized appropriately so that there is not an excess of material stored that could create a hazardous flammability condition. Also, the storage bunkers can be built to a size small enough to be flooded quickly enough to suppress heat or fire. However, arranging the bunkers close together in an array allows ease of access and for large volumes of material to be stored close by at a single site.

Working examples of the present according to embodiments of the present invention are now provided.

In a first example, there is a delivery of tyre crumb/shred that arrives in a delivery truck. It first comes over the weighbridge and then is directed to be dropped off into the empty storage bunker by the storage operative onsite. The truck reverses in, slowly down the slope and then tips the materials into the bottom of the storage bay. This process is repeated until the limit line of the bunker is filled.

The operator in charge of the storage facility area goes to the filled bunker and activates the lid mechanism. The cover slides into place and creates a tight vacuum within the storage bay. After that process has been completed, the temperature system is monitored constantly through the thermal camera system. During the night, the temperature starts to rise in one of the storage bunkers. The amber light switches on to signal an alert to the operator on duty to warn that the temperatures are starting to rise at this point the operator can evaluate the situation.

The operator has the following options for procedure under these circumstances:

1. Checking the seal to the lid to make sure that it is tightly fixed.

2. Activation of the air suction machine for additional sealing.

3. Flooding the bay to prevent any additional heat build-up.

4. Do nothing but continue to monitor the situation carefully.

If the operator misjudges or fails to monitor the storage system appropriately, the temperature increases to the point where the thermal cameras pick up a serious problem and at this point the red light starts to flash and the siren starts, activating the automated system. The water valves open automatically and flood the bay to the designated line within two minutes. If there is no oxygen present, there cannot be any fire which then significantly lowers the temperature as now the water has lowered the temperature and addressed any unwanted or excessive heating.

The thermal camera’s heat register has significantly dropped to a stable level for several minutes (this is programmable to any amount of time depending on materials and necessary safety fire prevention systems. In this scenario after 5 minutes the automatic valves open at the bottom of the tank storage bay and the water is pumped out into the water purification tank. All of the water is then pumped out and the blue light is activated.

The key components within this system work simply and effectively. In essence, the storage bunker bay floods completely with water and significant fire cannot exist underwater. Also the very fact that the thermal cameras could pick up on any outside parameter heat signature ahead of ignition, coupled with the speed of which the bays can be flooded with water, due to the abundant storage tanks of water on standby, is the fastest and most effective way of putting out a fire or lowering heat significantly. The light systems are a good signal for in the dark or during the day with the accompanying sound system. Also, as an essential back up, the drainage system and the process whereby the water is pumped into a water processing tank so that no contaminants go into the environment without being processed in a safe and clean and environmental manner.

One of skill in the art will realise that the storage bunker has been designed not only to hold tyre crumb, but any material that could potentially heat up and ignite. These range from biomass to plastic vehicle tyres. This system is robust, automatic and reliable. Other materials that could be used in the storage system include but are not limited to Bio-mass wood, straw, scrap timber, clean timber, coal, RDF, plastics, recyclable plastics, waste plastics, even pelletized powders such as carbon black, rCB; also textiles such as fabrics and paper. You could even use it as a quarantine handling bunker storage for hazardous materials etc.

In a second working example, it's daytime, one of the trucks is coming in with the tyre crumb and it's starting to tip the material into the storage bunker. During the process of tipping the material into the bunker, an arsonist sneaks into the area and while no one is looking starts to tip petrol into the open bunker in the bay. The driver of the tipping truck pulls away not noticing the figure behind them. The trespasser intent on setting fire to the storage bay has been undetected. They strike a match and throw it into the storage bunker that is freshly filled with tyre crumb the petrol catches fire and as the flames starts to blaze. However, the thermal camera picks up the rapid speed by which a fire has started, and the red alert light and siren start simultaneously. The water starts to fill the storage tank automatically and the alert sound of the siren triggers a response throughout the team of operators on the ground. The operators onsite head towards the storage bay where the siren is sounding, and lights are shining and within two minutes they notice that the flood system has already activated and put the fire out by flooding the bay with water.

The inventive bunker storage system and its components are optimised to operate within certain parameters, although these can be altered according to user needs. The thermal cameras are set to work in the parameter range of 0 to 25 degrees Celsius. The amber light is triggered between 25 to 65 degrees Celsius. The red light is the triggered at 65 degrees.

The siren sound is triggered via the thermal camera warnings, so when the camera activates the amber light, the associated sound will start up because the temperature is in the region of 25 to 65 degrees. Given the scenario that there is a rapid increase in heat e.g., because of an arson attack, then thermal cameras will pick up on the speed of heat raise from zero to over 100 degrees and will transmit the siren sound and red light. The storage bay will instantly flood automatically and if the lid is not closed it will automatically close the lid.

The bunker storage system according to various embodiments of the present invention is made from waterproof concrete and heat resistant render, especially the underground part of the bunker which the stored material sits into. The water level is determined by measurements specific for the materials being stored for submerging.

One of skill in the art will realise that the inventive bunker storage system could also be constructed of ceramic heat proof blocks or a continuous steel frame, to offer but two examples. In general, the material chosen should be heat proof and water proof to accommodate the full function of the bunker storage system.

Above ground, in line with the top of the waterline, when flooded is the feedwater flow pipe which disperses the water into the bay; this is made from steel piping for durability purposes.

The lid is a couple of inches above that pipe. This is on a slide-out that is also made from mild steel plates which are either manually or automatically pulled out to cover the bay from any contamination going into the bay once fdled or when the base is emptied for safety purposes to personnel.

Above ground, the storage bunker is constructed from concrete fireproof blocks. These act for stability purposes; the blocks are half a metre by metre long by half a metre deep and these form the three sides with a 45-degree angle slope going from ground level to the back over the bay

Situated on top of this out of the way of any machinery and personnel other thermal cameras the siren sound system and the light-emitting diodes these are commonly made out to the best practise material for the situation and the world demographic of which they are resided in.

The wastewater piping is made out of steel piping appropriate for underground use this piping it's designed to suck the wastewater out and put it into the treatment tank above ground.

One of skill in the art will realise that the present materials have made the detailed material choices that are suitable, by way of example, for storing waste tyres and tyre shred. The skilled artisan will acknowledge that materials can be varied to accommodate other uses while still falling within the metes and bounds of the present invention.