iba 2009 distribution
TRANSCRIPT
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ORGANICS GRANULATIONBIO-FERTILIZER & VALUE-ADDED WASTE STREAMS
31st Conference of the Institute for Briquetting and Agglomeration
San Antonio, Texas, USA
September 29th, 2009
Presented by:
Brett Rittenhouse, FEECO International
(920) 468-1000
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Principles of Organics Granulation
A Technical Overview of Fertilizer Production from Waste Streams
FEECO INTERNATIONAL
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FEECO OVERVIEW
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WHO WE ARE
Worldwide supplier of process equipment
Specializing in Thermal Processing, Agglomeration,
Material Handling, and Process Systems
Founded in 1951 as Fertilizer Engineering and
Equipment Company.
By the 1960s, we had diversified into Mining, Minerals,
Pulp & Paper, and Waste Recycling and becameFEECO International.
Privately held company with about 80 employees
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WHAT WE DO
Collaborate with Customers Process Development
Feasibility Analysis
Pilot Plant Testing Financial Modeling
Plant Design and Engineering
Detailed Equipment and Plant Design
Equipment and System Supply
Project Management single equipment to turnkey supply
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STRENGTHS OF OUR TEAM
Engineering Staff from all major disciplines:
Chemical/Process
Mechanical
Civil/Structural
Environmental
Electrical
Customer-focused Project Management
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LABORATORY SERVICES
Our pilot plant can be set up for testing on a single piece of equipment or multiple
pieces as a continuous process tying together agglomeration, drying, sizing, and
recycling capabilities.
Batch Testing/Feasibility
Pilot Plant Testing (500-1000 lb/hr)
Tolling Plant (24 hr Production Runs)
Analytical Testing
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The 30,000 View
ORGANICS RECYCLING
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RECYCLING?
Recycling involves processing used materials into
new products to prevent waste of potentially useful
materials, reduce the consumption of fresh raw
materials, reduce energy usage, reduce air and waterpollution, and lower greenhouse gas emissions.
Wikipedia, September, 2009.
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ORGANIC WASTE STREAMS
Agricultural Waste (Manures, Composts)
Industrial Waste
DAF Sludge, Food Waste, Restaurant Waste
Municipal Waste (Biosolids, Composts)
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THE AG-WASTE DILEMMA
Economic pressure pushing towards herd growth
Prohibitively high land costs lead to herd growthwithout adequate land to dispose of waste
Nutrient levels saturated on fields where it iseconomically viable to spread
Excess nutrient run-off leads to surface andground water pollution
Nutrient value of manure does not get fullyrealized
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THE AG-WASTE OPPORTUNITY
Source of macro and micro nutrients
Nitrogen, Phosphorus, Potassium, Sulfur, Boron
Source of Bio-Energy Production AnaerobicDigestion
Organic industry as a growth market
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WASTE TRANSFORMATION: THE NEED
Fertilizer demand is increasing
Despite recent setbacks, non-renewable
fertilizer prices will continue to rise US production capacity is shrinking
World food demand is increasing
Increasing competition for land resources(development, energy crops, etc.)
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THE ORGANIC FOOD INDUSTRY
U.S. sales of organic food and beverages havegrown from $1B in 1990 to $20B in 2007,20.9% growth in 2006.
U.S. sales of non-food organic products were$17.7B in 2006, 26% growth in 2006.
Source: Organic Trade Association
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FERTILIZERS FROM ORGANIC
WASTES
Generally considered a low-analysis fertilizer
Macronutrient content < 10% by weight.
Wide range of feedstocks:
Slurries (80% solids)
The drier feed material can be finely divided andrelatively dusty
Limits application in the field.
Traditional granulation approaches can be implementedto improve the handling, storage, spreading, andutilization characteristics of the material.
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ORGANIC WASTE UTILIZATION -
RECAP
Major Driving Force: Growth!
Demand Side NeedsRising Fertilizer Costs
Trade ImbalancesLocal and Secure Source of Nutrients
Supply Side Needs
Increasing Disposal Problems
Environmental RegulationNeed for safe (and profitable?) means ofNutrient
Recycling
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FERTILIZERS FROM ORGANIC
WASTES
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Granulation Process Approaches
ORGANICS GRANULATION
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ORGANIC GRANULATION SYSTEMS
1. Mixer Drum Dryer Granulation
a. Pin Mixer
b. Paddle Mixer
2. Mixer Pan Pelletizer Drum Dryer
Granulation
3. Dry Pellet Mill & Crumbler
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MIXER DRYER GRANULATION
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MIXER DRYER GRANULATION
Mixer selection based on feedstock analysis
Pin mixer for finely divided particles (chicken
litter, compost, etc.) Pug Mill/Paddle Mixer for sludges, pastes, and
filter cakes.
Dewatered liquid manures from centrifuge, DAF
effluent
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PIN MIXERS
Used as pre-conditioning unit or stand-alone agglomerator
One Rotor with Radial Pins
Multiple Feeds
Fluid Ports in Top Cover
Relatively High Speed Turbulent Mixing Action
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PIN MIXER BASICS
Turbulent action of the mixer provides thorough mixing of
liquid (binder), raw feed, and recycle
Reduces the amount of liquid required for agglomeration
Allows high liquid levels without over-wetting Reduces chances of segregation due to density differences
in feed materials
Reduces the chances of selective agglomeration
Up to 90% of binder liquid can be added in mixer with 10%reserved for finish processing (if necessary)
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PIN MIXER BASICS
Mechanical work compacts the agglomerate through work between
the pins and shell and interaction with each other
Improved crush strength, Less attrition
With a retention time of seconds, the mixer delivers to a finishingpelletizer (if necessary) nuclei that are properly moistened, have
adequate density, and are thoroughly mixed with binders, recycle, and
multiple raw materials
Can increase on-size product up to 95% (when coupled with Pan
Pelletizer)
Can increase capacity of pelletizing disc or drum (nuclei formation in
mixer)
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PIN MIXER BASICS
Mixer may be required for agglomeration to
occur in pelletizing disc or drum:
Chemical reaction (Phosphoric Acid Spray)
Reduce moisture level in sludges by mixing with dry
recycle
Intimately mix liquid with raw feed (compost)
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PIN MIXER
High speed, Multiple feed screws
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PIN MIXER
Internal view, during fabrication
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PADDLE MIXER/PUG MILL
Slower speed, double shaft, mixing paddles
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MIXER DRYER GRANULATION
Advantages:
Mixer offers moisture control of granulation process
Simple, closed system
Minimal waste. Off-spec product recycled in granulation loop
Easy binder addition in mixing step
Optimization includes evaluation of:
Pin arrangement
Pin tip speed
Retention time (function of equipment sizing and mixer speed)
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MIXER DRYER GRANULATION
Disadvantages:
Oftentimes a tight moisture window in pin mixer granulation limits
control
Material handling can be challenging for wet, sticky feed
Require finely divided feedstock pre-grinding/de-lumping may
be necessary
Limitations on achievable granule crush strength (feedstock
specific)
Small diameter granule productionMight be desired for greens grade product
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PAN GRANULATION
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PAN GRANULATION - FUNDAMENTALS
Feed from Pin Mixer fed through
articulating feed chute
Competition betweengravitational and centrifugal
forces resulting segregation by
size in tumbling bed
Small particles at bottom of bed
and travel furthest
Largest particles remain inkidney shaped area on top of
bed
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PAN GRANULATION - FUNDAMENTALS
Trajectories defined
by particle size
Optimization:
Spray locations
Scraper locations
Pan Inclination
Rotational Speed
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PAN GRANULATION
Advantages:
Very good control over granule size
Improved product quality polishing on disc
Flexible with binder addition
Disadvantages:
Open system odor, housekeeping, dust, etc.
Labor intensive
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PELLET MILL PROCESS - OVERVIEW
Raw Manure
Unloading
Manure
Drying
Size
Reduction
Steam
ConditioningPellet Mill Crumbling
ClassifyingFines
On-size
Product
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PELLET MILL PROCESS
Physical Product Differences
Crumble vs. Spherical Product
Energy UsageReduction in drying gas requirements
Increase in electrical requirements (pellet mill)
Reliability & Maintenance
Careful with high silica feedstocks
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BIO-FERTILIZER PLANT - EMISSIONS
Gas Treatment
Feedstock specific
Particulate
Wet scrubbing
Form of Nitrogen in feedstock?
Fuel Source? Biogas may involve SOx scrubbing
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SELECTION OF AGGLOMERATION
EQUIPMENT
Parameters of Particulate Feed
Size and Shape
Moisture Content
Material Characteristics
Material Sensitivities (heat,pressure, reactivity, etc.)
Bulk Characteristics
Binding Characteristics
Parameters of Agglomerated
Product
Size and Shape
Strength
Green Strength
Final (cured) Strength
Structure
Source: Pietsch, Wolfgang Agglomeration in Industry, Vol 2
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Parameters of Agglomeration
Method
Batch or Continuous Operation
Capacity Requirements
Wet or Dry Operation Space and Energy Requirements
Investment and Operating Costs
Site, Supply, Environment,
Infrastructure
Relative location to suppliers and
customers (raw materials,
additives/binders, energy)
Site accessibility and transportation
facilities
Climatic conditions
Availability of skilled and other labor
Availability of support functions
Regulations (EPA, OSHA, etc.)
Source: Pietsch, Wolfgang Agglomeration in Industry, Vol 2
SELECTION OF AGGLOMERATION
EQUIPMENT
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BIO-FERTILIZER PROCESSING
CONSIDERATIONS
Raw Feed Handling Feedstock specific
Dewatering Mechanical (presses, centrifuges, etc.)
Advanced separation with polymers
On-farm or Centralized Plant?
Bio-security concerns
Feed Conditioning
Seed pellets formed in paddle mixer with wet feed and dry recycle Pin or paddle mixer used to blend multiple feed streams
Binder?
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Agglomeration Seed pellets grown on disc pelletizer
Seed pellets grown in rotary drum dryer or agglomerating drum
Binder?
Drying Rotary drum, fluid bed, etc.
Pathogen Reduction (Time & Temperature)
Product cooling & storage
Rotary cooler, dryer cooling hood, fluid bed, etc.
Gas Processing Thermal oxidation, exhaust gas scrubbing, PM capture
BIO-FERTILIZER PROCESSING
CONSIDERATIONS
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OVERALL MASS BALANCE: ADVANCED MANURE
MANAGEMENT
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FEECO BIO-FERTILIZER PROCESS
FLOW
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FEECO BIO-FERTILIZER PROCESS
FLOW
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INORGANIC NUTRIENT
FORTIFICATION
Pipe Reactor
Sulfuric Acid
Phosphoric Acid
Biosolids
Manure
Organic Waste
Ammonia Fortified Granular Product
Benefits of Fortification :
Chemical Heat Release Utilization
Customized grade product
Improved margins, larger markets
Pug Mill
Potash
Drying/Agglomeration
Plant
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FEECO BIO-FERTILIZER PLANT, HOG
MANUREPlant aerial view
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THANK YOU!