WO2009056895A2 - Process and apparatus for the production of organic fertilizer - Google Patents

Process and apparatus for the production of organic fertilizer Download PDF

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Publication number
WO2009056895A2
WO2009056895A2 PCT/HU2008/000127 HU2008000127W WO2009056895A2 WO 2009056895 A2 WO2009056895 A2 WO 2009056895A2 HU 2008000127 W HU2008000127 W HU 2008000127W WO 2009056895 A2 WO2009056895 A2 WO 2009056895A2
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WO
WIPO (PCT)
Prior art keywords
mixing
basin
aerating
aerating unit
unit according
Prior art date
Application number
PCT/HU2008/000127
Other languages
French (fr)
Other versions
WO2009056895A3 (en
Inventor
János Pál LOVAS
Original Assignee
LO-KA Környezetvédelmi Kft.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by LO-KA Környezetvédelmi Kft. filed Critical LO-KA Környezetvédelmi Kft.
Priority to EP08845464A priority Critical patent/EP2217547A2/en
Publication of WO2009056895A2 publication Critical patent/WO2009056895A2/en
Publication of WO2009056895A3 publication Critical patent/WO2009056895A3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F3/00—Fertilisers from human or animal excrements, e.g. manure
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F17/00—Preparation of fertilisers characterised by biological or biochemical treatment steps, e.g. composting or fermentation
    • C05F17/60—Heating or cooling during the treatment
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F17/00—Preparation of fertilisers characterised by biological or biochemical treatment steps, e.g. composting or fermentation
    • C05F17/70—Controlling the treatment in response to process parameters
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05F—ORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C, e.g. FERTILISERS FROM WASTE OR REFUSE
    • C05F17/00—Preparation of fertilisers characterised by biological or biochemical treatment steps, e.g. composting or fermentation
    • C05F17/90—Apparatus therefor
    • C05F17/921—Devices in which the material is conveyed essentially horizontally between inlet and discharge means
    • C05F17/939—Means for mixing or moving with predetermined or fixed paths, e.g. rails or cables
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
    • Y02A40/10—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture
    • Y02A40/20—Fertilizers of biological origin, e.g. guano or fertilizers made from animal corpses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00—Technologies for wastewater treatment
    • Y02W10/30—Wastewater or sewage treatment systems using renewable energies
    • Y02W10/37—Wastewater or sewage treatment systems using renewable energies using solar energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/40—Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Definitions

  • the present invention relates to a process for the conversion of simultaneously biodegradable waste material into an organic fertilizer, as well as a supporting mixing-aerating apparatus.
  • Hungarian Patent No. 181389 discloses a method for separating the liquid and solid fractions of manure and sewage sludge. It does not provide, however, a solution for the decontamination of the drained liquid phase and the remaining solid phase.
  • Hungarian Patent No. 181389 discloses a method for the aeration of rotting material, wherein air is sucked through the rotting material stored in digestion tanks by means of nozzles driven by compression medium. This solution does not solve the problem posed by the environmental load of the gases produced, only accelerates the rotting process by intensive aeration.
  • Hungarian Patent Appl. No. 9000776 discloses a method for processing and recycling communal waste water and liquid manure. According to the disclosed solution, mineral filtering materials or mixtures provided in replacable containers are used in the existing storage beds. The solid phase is odorless, germ-free and there is no need for mixing.
  • Hungarian Patent Appl. No. 9006950 discloses a method for the utilization of agricultural side products, wherein the waste material is processed in a pressurized vessel under vacuum. After introducing a liquid with a defined composition, the pressure is equalized, and the wetted material is further processed.
  • WO 0215945 discloses a method for decreasing the number of viable microorganisms and/or prions in soils, wherein the organic material collected is hydrolyzed at 100-220 0 C with the addition of calcium chloride and the ammonia produced is removed, therefore organic material with decreased number of viable microorganism is produced. It is obvious that the latter two solutions do not provide a feasible alternative in view of the amounts of waste discussed above.
  • Hungarian Patent Appl. No. 9600301 discloses a basin for the treatment of liquid manure, having well defined geometry: bottom plates at different levels with different slopes form special drain and flow surfaces.
  • the method includes composting and rotting technology, and does not disclose advantageous solutions for decreasing the environmental load.
  • the goal of the present invention was to develop a method that is suitable for the simultaneous, environmentally friendly conversion of fresh and stored organic materials, humus materials, as well as stabilized sewage sludge stored in desiccating ponds or storage ditches into a organic fertilizer reusable in intensive agricultural production.
  • the problem is solved by a method in which biologically degradable waste material is milled, and optionally desiccated; communal waste water or sewage sludge is admixed to the desiccated material, thereby providing a biomass with 40 to 70 percent dry matter content; then the biomass is fed into a temperature-controlled mixing-aerating unit; where the biomass is mixed and passed forward in a controlled manner, while the gases produced optionally mixed with air are continuously re-injected into the biomass.
  • the present method comprises an intensive processing system, and is based on the action of aerobic thermomphilic microorganisms.
  • the composition of the organic fertilizer obtainable by the present method can be manipulated by mixing the input waste materials, such as: organic fertilizer 70-75%; moisture content 14-18%; N content 3-5,5%; P 2 O 5 content 4-5%; K 2 O content 3-4%; Ca content 3-10%.
  • the percentage of mineral elements with smaller quantity (B 0,009%, Cu 0,006%, Mn 0,07%, Mg 0,9%, Fe 0,5%, Zn 0,05%) can be similarly controlled.
  • the application field of the organic fertilizer of the invention i. e. the culture under production, is definitive. These characteristics also show that the organic fertilizer produced is not only makes the soil fertile, but also enriches it. Applicability of the product is wide, because the end product of the method is a complete fertilizing material that is free of added biochemical compounds.
  • the appropriately preprocessed biomass entering the mixing-aerating unit has a moisture content of about 60%, which is necessary to the continuity of the method, since under these conditions the humification of the organic material content takes place, and oxidized forms of the plant nutrients are formed.
  • the particular advantage of the processing method is that the organic fertilizer produced contains very active bacterial flora and humus material, as the remnants of the method, but it is non-infective and the seeds of any weeds are unable to germinate due to the well-defined temperature treatment during the process.
  • Figure 1 shows the flowchart of the process according to the invention
  • Figure 2 shows a schematic side view of the mixing-aerating unit
  • Figure 3 shows the temperature profile within the different zones of the mixing-aerating unit.
  • the flowchart in Fig. 1 shows that the agricultural waste material 1, liquid manure 2 and/or solid manure 3 to be processed are collected separately in closed storage containers.
  • the collection may be performed on a daily basis, or the system may be set up next to existing storages.
  • the waste material is fed into the next phase from the storages in controlled amounts.
  • the process is also suitable for the processing of dry litter, large animal, cow or horse, manure, without other simultaneously biodegradable waste materials.
  • the collected waste may be desiccated as needed.
  • the dehydrator applied in this step may be any known process and/or apparatus used for this purpose in the field.
  • the use of a mobile device of special construction may be advantageous for the dehydrator 4.
  • dehydrator Preferably, dehydrator
  • the dry matter content of the desiccated material is preferably from 2 to 5%, but can be adjusted at the output up to 65 %.
  • composition of the dry matter content of the biomass greatly influences the composition of the final product. This can be manipulated substantially by the ratio of the three base components, as well as by their quality. Therefore, the type of both the liquid and solid manure and the composition of the communal waste influence the composition of the organic fertilizer produced, and therefore affects the usability thereof.
  • a part of the mixed biomass is communal cellulose waste material, in a quantity of about 15%, and 15% of agricultural waste material. Accordingly, this step ensures the final setting of the dry matter content of the mixture, by generating a biomass with a dry matter content of 40 to 70%.
  • the milled and desiccated mixture is admixed with communal sewage sludge from storage 5 in a predefined ratio, 20 to 25%.
  • the sewage sludge can exclusively be of communal origin, and the quality thereof must be checked continuously to meet the regulations.
  • Setting of the moisture content of the biomass is performed through the moisture-setting conduit 6. Setting of the moisture content is performed with the waste water produced during the process. Therefore, the waste water generated during the desiccation of the organic fertilizer is recycled, thus further reducing the environmental load of the process.
  • the minimal mixing volume is about 1 m 3 .
  • Shipping of the organic material to be homogenized should be carried out in such a way that the environmental load thereof is to be kept minimal, including the odors.
  • Another important factor is the daily volume of the agricultural waste material, for example manure, since the method is based on a self- sustained process. Accordingly, the daily input of the process is about 18 to 20 m 3 /units. Larger quantities may be processed in several units in parallel, if necessary.
  • the mixture is fed intermittently into a temperature-controlled mixing-aerating unit.
  • the method according to the invention may be carried out with any mixing-aerating unit suitable for this purpose.
  • the biomass is fed at one end of an elongated space (which is termed herein as the "front” part), and the biomass, as being mixed thoroughly, is passed forward with a predetermined, quite slow speed along in the elongated shaped biomass bulk.
  • the finished organic fertilizer reaches the "rear" end of the biomass bulk, where it is removed. It is apparent that it is reasonable to limit the crosswise spreading of the biomass to achieve efficient mixing. Implementation of such mixing is presented below for the preferred embodiment of the present invention.
  • the intermittent feeding is determined by the speed of mixing, and vice versa. It is expedient to mix through the whole amount of biomass thoroughly starting from the front end, downstream to the rear end. When mixing is completed, the next batch of the premixed raw biomass is fed into the front end of the biomass bulk, and the mixing cycle may start over.
  • the biomass is continuously mixed and passed further alongside to the rear end of the mixing-aerating unit.
  • the gases produced as the result of the microbiological reactions are continuously re-injected into the bulk of biomass.
  • the gases produced are mixed with air as necessary for the oxidation reaction.
  • this ensures a more even material flow in the places where the amount of gas released is of lesser quantity, due to the fact that the microbiological reactions are close to be finished and the maturation of the fertilizer reaches its end. It is expedient to re-inject the gases into the bottom region of the biomass, which facilitates the mixing on one hand, and the other hand it minimizes the chance that the gases reach the environment.
  • the finished organic fertilizer reaching the rear end of the mixing-aerating unit are powdered and/or granulated as desired, or formulated according to any standard technique accepted in the field.
  • the temperature-controllable room is preferably an industrial shed, made of galvanized and bolted materials, covered with polycarbonate, and the floor is made of high-strength, water and acid resistant concrete.
  • the room is temperature-controlled by employing high-capacity fans and heat exchangers.
  • the basin or basins for holding the biomass may be built for the purpose or lowered into ground, with a cumulative length of 60 to 120 m, with a width of 3 to 6 m and depth of 0.6 to 1 m.
  • the temperature in phase I of the process is about 40 to 50 °C, in phase II 70 to 85 °C, therefore the floor and optionally the side walls of the sections of the basin(s) are provided with heating elements.
  • Fig. 2 shows a preferred embodiment of the mixing-aerating unit according to the invention.
  • the unit has a traveling frame 10 with wheels 9 to be moved alongside the basins 11 on rails 12, and contains a mixer 13, which comprised of a rotor 14 and blades 15 driven by the rotor 14, rotating in the direction of arrow Y.
  • the unit may be raised and lowered by tilting in the direction arrow X around a shaft fixed on the frame 10.
  • the mixing unit is provided with a heat reflecting screen 16 covering the whole unit, which can be raised and lowered together with the mixing unit 13.
  • the heat reflecting screen 16 is comprised of a curved cover 17 and a heat reflecting layer 18 mounted on said cover from the inside.
  • the unit also contains an exhausting-injecting unit 19, which contains a vacuum pump 20 exhausting fresh air form the tempered room and gases from the basin 11 and re-injecting these together into the basin 11.
  • the compression side of the vacuum pump 20 is connected to a controlled-height telescopic injector 21 reaching into the basin 11.
  • The. height of the injector 21 is adjustable in the direction of arrow Z.
  • the compression side of the vacuum pump 20 connected to the blades 15 mounted on the drum of the mixing unit 13. In both cases, the fresh air together with the ammonia extracted from the basin 11 is re-injected back to the basin 11, in the whole width of it.
  • the speed of the unit, the level of the mixing unit 13 together with the heat reflecting screen 16, as well as the rotational speed of the rotor is adjustable continuously.
  • the amount of fresh air/gas injected is controllable, as well.
  • the manipulator unit is provided with temperature, humidity and level detectors, and preferably with an electronic control. The unit passes forward the biomass within the basin 11 during mixing and homogenization, and changes the depth of mixing automatically, as well as the speed of rotation and advancement, according to the technological phases of the process.
  • the unit is covered on the whole width by the heat reflecting screen 16, which reflects the heat released during the process back to the basin 11 continuously.
  • the released ammonia is re-injected together with fresh air under the material flow by the exhausting-injecting unit 19 in the whole with of the basin. Since ammonia is heavier than air, it always reaches the layer where the effect of oxidation is the most intensive during the process.
  • the air released into the environment is passed through a biofilter.
  • the organic fertilizer reaches a grinder-storage container 21 a finisher 22 (Fig. 1).
  • the power-requirement of the process is provided at least partially by solar energy.
  • Fig. 3 shows the controlled temperature profile maintained in the mixing-aerating unit.
  • thermophil and biophil bacteria added with the starting materials provide the self-sustained nature of the process according to the invention.
  • the decomposing process starting in zones I and II produces heat, but in order to sterilize the organic fertilizer, zones II and III in the basin may be kept at the desired temperature by heating elements.
  • sterilization means that undesired weed seeds are rendered non- fertile in the organic fertilizer produced, as well as maggots are killed.
  • sterilize does not include rendering microorganisms unviable, since those are required for the process of the invention, and they are valuable components of the organic fertilizer produced, which can be used advantageously by the end users during soil regeneration.
  • the introduced materials according the process of the invention become simultaneously biodegradable in zone II, thus ensuring favorable conditions for the microorganisms.
  • the process accelerated by mixing and aerating prevents the development of anaerobic zones, therefore intensive oxidation processes may only take place.
  • the formation of nitrogen and hydrocarbons is also prevented because of the continuous oxygen input and mixing.
  • the third phase of the process sterilization and loss of weed germination capability is completed at the appropriate temperature of 75 to 85 0 C, after the required staying time during continuous mixing and forward movement.
  • This stage comprises a section length of about 20 m of the basin of the mixing-aerating unit.
  • the organic fertilizer reaches the appropriate temperature in the mixing-aerating unit, and the loss of nutrients and the odors are minimized.
  • zone IV the partially homogenized and oxidized mixture is further processed and rested. There is no need for additional heating of the basin in this zone, it is sufficient to keep the temperature-control of the enclosing room of the mixing-aerating unit. Of course, supplemental heating is possible, if desired.
  • the final setting of the chemical composition of the finished organic fertilizer takes place in zone V. Heating of the basin is also important in his phase. The elevated temperature promotes the completion of the microbiological processes and processing of the degradable organic material present in the organic fertilizer. If desired, the organic fertilizer may be supplemented by admixing chemical components in this phase, if the amounts thereof requires correction in view of the intended application. Finally, in phase VI the organic fertilizer reaches the grinder-storage container 21, then the final product is formulated in the finisher 22 as desired.
  • the final product may be fine or coarse beads, or a granulate.
  • the packaging may be of any type; preferably the finished organic fertilizer may be packed into bags, boxes, or into containers on demand.
  • the organic fertilizer according to the present invention may be used in several fields of agriculture due to its high biological and mineral contents. In one example, it may be used for stopping of desertification. The plants utilize these organic nutrients faster, therefore higher yields are achieved in much shorter times.
  • the organic fertilizer according to the invention belongs to the group of soil fertilizing materials.
  • the organic material content is humif ⁇ cated during the process according to the invention, and the plant nutrients are in oxidized forms, which are more available for the plants.
  • the following table shows some characteristic usage parameters for the organic fertilizer according to the invention with the preferred amounts in the different applications:
  • the organic fertilizer according to the invention By using the organic fertilizer according to the invention, regeneration of soils may be promoted where the biochemical balance degraded or the soil is chemically infected, due to the use of chemicals, communal and industrial sewage sludge (chemical treatments, artificial fertilizers), resulting in greatly decreased yields. Contrary to humus (compost), which are still infectious at the end of the technological process and recycled back into circulation, and risks the water reservoirs, the organic fertilizer according to the invention is devoid of these drawbacks. In addition, it should not be overlooked that by using the process according to the invention, no greenhouse gases (methane, etc.) are released into the environment.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Biochemistry (AREA)
  • Biotechnology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
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  • Fertilizers (AREA)
  • Treatment Of Sludge (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

The present invention relates to a process for the conversion of simultaneously biodegradable waste material into an organic fertilizer, as well as a supporting mixing-aerating apparatus. The process consists in mixing biodegradable waste which has been milled with communal sewage sludge, thereby providing a biomass with 40 to 70 percent dry matter content. The biomass is fed into a mixing-aerating device containing a basin and one manipulator movable along the axis of the basin. The basin contains heating elements and the manipulator is provided with a raising and lowering mixing unit and an exhausting-injecting unit.

Description

PROCESS AND APPARATUS FOR THE PRODUCTION OF ORGANIC FERTILIZER
The present invention relates to a process for the conversion of simultaneously biodegradable waste material into an organic fertilizer, as well as a supporting mixing-aerating apparatus.
These days the storage of humus material originating from the intensive agricultural production causes a major problem, because the infiltration of hazardous materials (nitrates, bacteria, genetically manipulated materials, drugs, heavy metals) into the underground water reservoirs presents an environmental load. Accordingly, the present regulations do not allow the recycling of these materials into production in unaltered form, but impose a longer or shorter storage/repository time. The released methane, in addition to the unpleasant odors, contributes to the enlargement of the ozone whole.
Another component involved in the environmental load of developed civilizations is the ever increasing production and storage of communal waste. The treatment of these wastes includes natural stabilization (long term, with environmental load), which requires large artificial desiccating ponds or storage ditches, the size of which is difficult to determine.
Efforts to decrease this environmental load were concentrated on two fields. Hungarian Patent No. 181389 discloses a method for separating the liquid and solid fractions of manure and sewage sludge. It does not provide, however, a solution for the decontamination of the drained liquid phase and the remaining solid phase.
Hungarian Patent No. 181389 discloses a method for the aeration of rotting material, wherein air is sucked through the rotting material stored in digestion tanks by means of nozzles driven by compression medium. This solution does not solve the problem posed by the environmental load of the gases produced, only accelerates the rotting process by intensive aeration.
Hungarian Patent Appl. No. 9000776 discloses a method for processing and recycling communal waste water and liquid manure. According to the disclosed solution, mineral filtering materials or mixtures provided in replacable containers are used in the existing storage beds. The solid phase is odorless, germ-free and there is no need for mixing. Hungarian Patent Appl. No. 9006950 discloses a method for the utilization of agricultural side products, wherein the waste material is processed in a pressurized vessel under vacuum. After introducing a liquid with a defined composition, the pressure is equalized, and the wetted material is further processed. WO 0215945 discloses a method for decreasing the number of viable microorganisms and/or prions in soils, wherein the organic material collected is hydrolyzed at 100-220 0C with the addition of calcium chloride and the ammonia produced is removed, therefore organic material with decreased number of viable microorganism is produced. It is obvious that the latter two solutions do not provide a feasible alternative in view of the amounts of waste discussed above.
Hungarian Patent Appl. No. 9600301 discloses a basin for the treatment of liquid manure, having well defined geometry: bottom plates at different levels with different slopes form special drain and flow surfaces. The method includes composting and rotting technology, and does not disclose advantageous solutions for decreasing the environmental load.
The goal of the present invention was to develop a method that is suitable for the simultaneous, environmentally friendly conversion of fresh and stored organic materials, humus materials, as well as stabilized sewage sludge stored in desiccating ponds or storage ditches into a organic fertilizer reusable in intensive agricultural production. The problem is solved by a method in which biologically degradable waste material is milled, and optionally desiccated; communal waste water or sewage sludge is admixed to the desiccated material, thereby providing a biomass with 40 to 70 percent dry matter content; then the biomass is fed into a temperature-controlled mixing-aerating unit; where the biomass is mixed and passed forward in a controlled manner, while the gases produced optionally mixed with air are continuously re-injected into the biomass.
The present method comprises an intensive processing system, and is based on the action of aerobic thermomphilic microorganisms. The composition of the organic fertilizer obtainable by the present method can be manipulated by mixing the input waste materials, such as: organic fertilizer 70-75%; moisture content 14-18%; N content 3-5,5%; P2O5 content 4-5%; K2O content 3-4%; Ca content 3-10%. In addition, the percentage of mineral elements with smaller quantity (B 0,009%, Cu 0,006%, Mn 0,07%, Mg 0,9%, Fe 0,5%, Zn 0,05%) can be similarly controlled. In this respect, the application field of the organic fertilizer of the invention, i. e. the culture under production, is definitive. These characteristics also show that the organic fertilizer produced is not only makes the soil fertile, but also enriches it. Applicability of the product is wide, because the end product of the method is a complete fertilizing material that is free of added biochemical compounds.
The appropriately preprocessed biomass entering the mixing-aerating unit has a moisture content of about 60%, which is necessary to the continuity of the method, since under these conditions the humification of the organic material content takes place, and oxidized forms of the plant nutrients are formed. The particular advantage of the processing method is that the organic fertilizer produced contains very active bacterial flora and humus material, as the remnants of the method, but it is non-infective and the seeds of any weeds are unable to germinate due to the well-defined temperature treatment during the process.
The invention will be described more in details by way of examples, with reference to the attached drawing. In the drawing
Figure 1 shows the flowchart of the process according to the invention, Figure 2 shows a schematic side view of the mixing-aerating unit, and Figure 3 shows the temperature profile within the different zones of the mixing-aerating unit.
The flowchart in Fig. 1 shows that the agricultural waste material 1, liquid manure 2 and/or solid manure 3 to be processed are collected separately in closed storage containers. The collection may be performed on a daily basis, or the system may be set up next to existing storages. The waste material is fed into the next phase from the storages in controlled amounts. According to an embodiment, the process is also suitable for the processing of dry litter, large animal, cow or horse, manure, without other simultaneously biodegradable waste materials.
The collected waste may be desiccated as needed. The dehydrator applied in this step may be any known process and/or apparatus used for this purpose in the field. The use of a mobile device of special construction may be advantageous for the dehydrator 4. Preferably, dehydrator
4 is electric-hydraulic device with low energy consumption. The dry matter content of the desiccated material is preferably from 2 to 5%, but can be adjusted at the output up to 65 %.
The composition of the dry matter content of the biomass greatly influences the composition of the final product. This can be manipulated substantially by the ratio of the three base components, as well as by their quality. Therefore, the type of both the liquid and solid manure and the composition of the communal waste influence the composition of the organic fertilizer produced, and therefore affects the usability thereof.
In a preferred embodiment, a part of the mixed biomass is communal cellulose waste material, in a quantity of about 15%, and 15% of agricultural waste material. Accordingly, this step ensures the final setting of the dry matter content of the mixture, by generating a biomass with a dry matter content of 40 to 70%.
In the next step, the milled and desiccated mixture is admixed with communal sewage sludge from storage 5 in a predefined ratio, 20 to 25%. The sewage sludge can exclusively be of communal origin, and the quality thereof must be checked continuously to meet the regulations.
Setting of the moisture content of the biomass is performed through the moisture-setting conduit 6. Setting of the moisture content is performed with the waste water produced during the process. Therefore, the waste water generated during the desiccation of the organic fertilizer is recycled, thus further reducing the environmental load of the process.
Next, the mixture is fed into the pulping machine 7, where the mixing step determines the scale of the whole process. The minimal mixing volume is about 1 m3. Shipping of the organic material to be homogenized should be carried out in such a way that the environmental load thereof is to be kept minimal, including the odors. Another important factor is the daily volume of the agricultural waste material, for example manure, since the method is based on a self- sustained process. Accordingly, the daily input of the process is about 18 to 20 m3/units. Larger quantities may be processed in several units in parallel, if necessary.
Next, the mixture is fed intermittently into a temperature-controlled mixing-aerating unit. The method according to the invention may be carried out with any mixing-aerating unit suitable for this purpose. To achieve appropriate mixing, it is only required that the biomass is fed at one end of an elongated space (which is termed herein as the "front" part), and the biomass, as being mixed thoroughly, is passed forward with a predetermined, quite slow speed along in the elongated shaped biomass bulk. At the end of this mixing-aerating process, the finished organic fertilizer reaches the "rear" end of the biomass bulk, where it is removed. It is apparent that it is reasonable to limit the crosswise spreading of the biomass to achieve efficient mixing. Implementation of such mixing is presented below for the preferred embodiment of the present invention.
The intermittent feeding is determined by the speed of mixing, and vice versa. It is expedient to mix through the whole amount of biomass thoroughly starting from the front end, downstream to the rear end. When mixing is completed, the next batch of the premixed raw biomass is fed into the front end of the biomass bulk, and the mixing cycle may start over.
At this stage of the process, the biomass is continuously mixed and passed further alongside to the rear end of the mixing-aerating unit. During mixing the gases produced as the result of the microbiological reactions are continuously re-injected into the bulk of biomass. The gases produced are mixed with air as necessary for the oxidation reaction. In addition, this ensures a more even material flow in the places where the amount of gas released is of lesser quantity, due to the fact that the microbiological reactions are close to be finished and the maturation of the fertilizer reaches its end. It is expedient to re-inject the gases into the bottom region of the biomass, which facilitates the mixing on one hand, and the other hand it minimizes the chance that the gases reach the environment.
At the final step of the process, the finished organic fertilizer reaching the rear end of the mixing-aerating unit are powdered and/or granulated as desired, or formulated according to any standard technique accepted in the field.
In the following section, a preferred embodiment of the mixing-aerating unit according to the present invention is described in more detail. The person skilled in the art will appreciate that the embodiment described only exemplifies the process according to the invention, and it should not be construed in any case as limiting. Homogenization is carried out in a completely closed system, which is here a mixing- aerating unit 8, containing at least one elongated basin arranged in a closed, temperature- controllable room, and at least one manipulator movable longitudinally alongside the basin or basins.
The temperature-controllable room is preferably an industrial shed, made of galvanized and bolted materials, covered with polycarbonate, and the floor is made of high-strength, water and acid resistant concrete. The room is temperature-controlled by employing high-capacity fans and heat exchangers.
The basin or basins for holding the biomass may be built for the purpose or lowered into ground, with a cumulative length of 60 to 120 m, with a width of 3 to 6 m and depth of 0.6 to 1 m. The temperature in phase I of the process is about 40 to 50 °C, in phase II 70 to 85 °C, therefore the floor and optionally the side walls of the sections of the basin(s) are provided with heating elements.
Fig. 2 shows a preferred embodiment of the mixing-aerating unit according to the invention. The unit has a traveling frame 10 with wheels 9 to be moved alongside the basins 11 on rails 12, and contains a mixer 13, which comprised of a rotor 14 and blades 15 driven by the rotor 14, rotating in the direction of arrow Y. The unit may be raised and lowered by tilting in the direction arrow X around a shaft fixed on the frame 10.
In addition, the mixing unit is provided with a heat reflecting screen 16 covering the whole unit, which can be raised and lowered together with the mixing unit 13. The heat reflecting screen 16 is comprised of a curved cover 17 and a heat reflecting layer 18 mounted on said cover from the inside.
The unit also contains an exhausting-injecting unit 19, which contains a vacuum pump 20 exhausting fresh air form the tempered room and gases from the basin 11 and re-injecting these together into the basin 11. The compression side of the vacuum pump 20 is connected to a controlled-height telescopic injector 21 reaching into the basin 11. The. height of the injector 21 is adjustable in the direction of arrow Z. In another embodiment (not shown on the figure), the compression side of the vacuum pump 20 connected to the blades 15 mounted on the drum of the mixing unit 13. In both cases, the fresh air together with the ammonia extracted from the basin 11 is re-injected back to the basin 11, in the whole width of it.
The speed of the unit, the level of the mixing unit 13 together with the heat reflecting screen 16, as well as the rotational speed of the rotor is adjustable continuously. The amount of fresh air/gas injected is controllable, as well. The manipulator unit is provided with temperature, humidity and level detectors, and preferably with an electronic control. The unit passes forward the biomass within the basin 11 during mixing and homogenization, and changes the depth of mixing automatically, as well as the speed of rotation and advancement, according to the technological phases of the process.
The unit is covered on the whole width by the heat reflecting screen 16, which reflects the heat released during the process back to the basin 11 continuously. During steady mixing, the released ammonia is re-injected together with fresh air under the material flow by the exhausting-injecting unit 19 in the whole with of the basin. Since ammonia is heavier than air, it always reaches the layer where the effect of oxidation is the most intensive during the process.
The air released into the environment is passed through a biofilter. At the end of the process, the organic fertilizer reaches a grinder-storage container 21 a finisher 22 (Fig. 1). The power-requirement of the process is provided at least partially by solar energy.
Fig. 3 shows the controlled temperature profile maintained in the mixing-aerating unit.
The thermophil and biophil bacteria added with the starting materials provide the self-sustained nature of the process according to the invention. The decomposing process starting in zones I and II produces heat, but in order to sterilize the organic fertilizer, zones II and III in the basin may be kept at the desired temperature by heating elements.
The term "sterilization" as used herein means that undesired weed seeds are rendered non- fertile in the organic fertilizer produced, as well as maggots are killed. The term sterilize as used herein does not include rendering microorganisms unviable, since those are required for the process of the invention, and they are valuable components of the organic fertilizer produced, which can be used advantageously by the end users during soil regeneration.
The introduced materials according the process of the invention become simultaneously biodegradable in zone II, thus ensuring favorable conditions for the microorganisms. The process accelerated by mixing and aerating prevents the development of anaerobic zones, therefore intensive oxidation processes may only take place. In addition, the formation of nitrogen and hydrocarbons is also prevented because of the continuous oxygen input and mixing.
In the third phase of the process, sterilization and loss of weed germination capability is completed at the appropriate temperature of 75 to 85 0C, after the required staying time during continuous mixing and forward movement. This stage comprises a section length of about 20 m of the basin of the mixing-aerating unit. During this, the organic fertilizer reaches the appropriate temperature in the mixing-aerating unit, and the loss of nutrients and the odors are minimized. In zone IV, the partially homogenized and oxidized mixture is further processed and rested. There is no need for additional heating of the basin in this zone, it is sufficient to keep the temperature-control of the enclosing room of the mixing-aerating unit. Of course, supplemental heating is possible, if desired.
The final setting of the chemical composition of the finished organic fertilizer takes place in zone V. Heating of the basin is also important in his phase. The elevated temperature promotes the completion of the microbiological processes and processing of the degradable organic material present in the organic fertilizer. If desired, the organic fertilizer may be supplemented by admixing chemical components in this phase, if the amounts thereof requires correction in view of the intended application. Finally, in phase VI the organic fertilizer reaches the grinder-storage container 21, then the final product is formulated in the finisher 22 as desired. The final product may be fine or coarse beads, or a granulate. The packaging may be of any type; preferably the finished organic fertilizer may be packed into bags, boxes, or into containers on demand.
The organic fertilizer according to the present invention may be used in several fields of agriculture due to its high biological and mineral contents. In one example, it may be used for stopping of desertification. The plants utilize these organic nutrients faster, therefore higher yields are achieved in much shorter times.
The organic fertilizer according to the invention belongs to the group of soil fertilizing materials. The organic material content is humifϊcated during the process according to the invention, and the plant nutrients are in oxidized forms, which are more available for the plants. The following table shows some characteristic usage parameters for the organic fertilizer according to the invention with the preferred amounts in the different applications:
Figure imgf000009_0001
By using the organic fertilizer according to the invention, regeneration of soils may be promoted where the biochemical balance degraded or the soil is chemically infected, due to the use of chemicals, communal and industrial sewage sludge (chemical treatments, artificial fertilizers), resulting in greatly decreased yields. Contrary to humus (compost), which are still infectious at the end of the technological process and recycled back into circulation, and risks the water reservoirs, the organic fertilizer according to the invention is devoid of these drawbacks. In addition, it should not be overlooked that by using the process according to the invention, no greenhouse gases (methane, etc.) are released into the environment.
By the use oh the process according to the invention, "natural" soil quality may be restored without the need for using artificial agricultural chemicals (chemical fertilizing agents), since a sterile fertilizer provided which is free of pathogens, parasites and weeds. Wherever the agricultural industry has the appropriate livestock a crop cultures, there is a need for the present process.

Claims

Claims
1. Process for conversion of biodegradable waste material into organic fertilizer, comprising a) the biodegradable waste material is milled and optionally desiccated; b) the mixture of a) is pulped and mixed with communal sewage sludge, thereby providing a biomass with 40 to 70 percent dry matter content; c) the biomass of b) is fed into the front part of a temperature-controlled mixing-aerating unit according to an intermittent schedule; d) the biomass is mixed and passed towards the rear of the mixing-aerating unit, while the gases produced, optionally admixed with air, are continuously re-injected into the bottom region of the basin of the mixing-aerating unit; e) if desired, the finished organic material reaching the rear end of the mixing-aerating unit is powdered and/or granulated.
2. The process according to claim 1, wherein the biodegradable waste material is a mixture of sewage sludge, animal manure and/or organic waste material.
3. The process according to claim 1 or 2, wherein the temperature of the mixing-aerating unit is controlled according to a predefined profile.
4. The process according to any one of claims 1 to 3, wherein the power requirement of the process is provided by a solar collector/solar cell system.
5. The process according to any one of claims 1 to 4, wherein the trace element content of the finished organic fertilizer is adjusted to the values required by the intended application of the finished organic fertilizer.
6. Use of the organic fertilizer obtainable by the process according to any one of claims 1 to 5 for stopping desertification.
7. Mixing-aerating unit for the treatment of agricultural waste material, containing at least one elongated basin (3) arranged in a closed, temperature-controllable room, and at least one manipulator movable along the longitudinal axis of the basin(s) (3), wherein the basin (3) is provided with heating elements in sections and the manipulator has a self-propelling frame (2), raisable and lowerable mixing unit (5) and an exhausting-injecting unit (12) are mounted on the frame (2).
8. The mixing- aerating unit according to claim 7, wherein the length of a basin or the aggregate length of the basins (3) is 60 to 120 m.
9. The mixing-aerating unit according to claim 7 or 8, wherein the width each of the basin(s) (3) is 3 to 6 m, and the depth thereof is 0.6 to 1 m.
10. The mixing-aerating unit according to any one of claims 7 to 9, wherein the self- propelling frame (2) is traveling on rails (4) arranged aligned along the basin(s) (3).
11. The mixing-aerating unit according to any one of claims 7 to 10, wherein the mixing unit contains a rotor (5), a drum (7) driven by the rotor (6), and blades (8) mounted on the drum
(7).
12. The mixing-aerating unit according to any one of claims 7 to 10, wherein the mixing unit (5) is provided with a heat reflecting screen (9) covering the manipulator, which can be raised and lowered together with the mixing unit.
13. The mixing-aerating unit according to any one of claims 7 to 10, wherein the exhausting-injecting unit (12) contains a vacuum pump (13) for exhausting fresh air form the tempered room and gases from the basin (3) and re-injecting these together into the basin (3).
14. The mixing-aerating unit according to claim 13, wherein the compression side of the vacuum pump (13) is connected to a telescopic injector (14) provided with height adjustment and reaching into the basin (3).
- II - IS. The mixing-aerating unit according to claim 13, wherein the compression side of the vacuum pump (13) connected to the blades (8) mounted on the drum (7) through the drum (7) of the mixing unit (5).
16. The mixing-aerating unit according to any one of claims 7 to 15, wherein the manipulator is provided with temperature, humidity and level detectors.
17. The mixing-aerating unit according to any one of claims 7 to 15, wherein the manipulator is provided with speed, revolution and level adjustment.
18. The mixing-aerating unit according to claim 16 or 17, provided with an electronic control.
19. The mixing- aerating unit according to any one of claims 7 to 18, wherein the temperature-controllable room is an industrial shed.
20. The process according to any one of claims 1 to 6, wherein the mixing-aerating unit is the mixing-aerating unit according to any one of claims 7 to 19.
PCT/HU2008/000127 2007-10-30 2008-10-29 Process and apparatus for the production of organic fertilizer WO2009056895A2 (en)

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US5145581A (en) * 1990-02-02 1992-09-08 County Sanitation Districts Of Los Angeles County Composting system utilizing air recirculation
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