U.S. patent application number 14/760837 was filed with the patent office on 2015-12-10 for method of aerobic treatment of poultry manure and apparatus for producing organic fertilizer.
The applicant listed for this patent is 1867239 ONTARIO CORP.. Invention is credited to Damira Shaimukhambetova.
Application Number | 20150353436 14/760837 |
Document ID | / |
Family ID | 51164133 |
Filed Date | 2015-12-10 |
United States Patent
Application |
20150353436 |
Kind Code |
A1 |
Shaimukhambetova; Damira |
December 10, 2015 |
Method of Aerobic Treatment of Poultry Manure and Apparatus for
Producing Organic Fertilizer
Abstract
A bio-chamber and a method of making organic fertilizer from
poultry manure. The bio- chamber has a chamber body that defines a
receiving chamber and an aeration chamber. The aeration chamber
underlies the receiving chamber and is divided therefrom by a
partition. The partition has a plurality of holes formed therein.
An oxygen probe and a temperature probe are positioned inside the
receiving chamber. An air blower is connected to the aeration
chamber and is operable to blow air therein. The method comprises:
mixing the poultry manure with a carbon carrier; loading the
mixture into the receiving chamber; monitoring the temperature and
the oxygen concentration of the mixture; aerating the mixture; and
regulating the temperature and the oxygen concentration by
adjusting the operation of the air blower. The temperature and
oxygen concentration are regulated to provide conditions that
permit aerobic bacteria to propagate and biodegrade the
mixture.
Inventors: |
Shaimukhambetova; Damira;
(Richmond Hill, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
1867239 ONTARIO CORP. |
Maple |
|
CA |
|
|
Family ID: |
51164133 |
Appl. No.: |
14/760837 |
Filed: |
December 23, 2013 |
PCT Filed: |
December 23, 2013 |
PCT NO: |
PCT/CA2013/001082 |
371 Date: |
July 14, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61752021 |
Jan 14, 2013 |
|
|
|
Current U.S.
Class: |
53/111RC ;
435/290.1; 71/9 |
Current CPC
Class: |
C05F 17/964 20200101;
Y02A 40/20 20180101; Y02A 40/205 20180101; C05F 17/70 20200101;
C05F 17/971 20200101; Y02W 30/40 20150501; C05F 3/00 20130101; C05B
17/00 20130101; Y02A 40/208 20180101; C05F 17/979 20200101; Y02P
20/145 20151101; C05F 17/914 20200101; C05F 17/993 20200101; C05F
3/06 20130101; Y02W 30/43 20150501 |
International
Class: |
C05F 17/02 20060101
C05F017/02; C05B 17/00 20060101 C05B017/00; C05F 3/00 20060101
C05F003/00 |
Claims
1. A bio-chamber made of an acid resistant material for producing
organic fertilizer from poultry manure, the bio-chamber comprising:
a chamber body defining a receiving chamber and an aeration
chamber, the aeration chamber underlying the receiving chamber and
being divided therefrom by a flat partition, the partition being
divided into a grid pattern of about 10 cm grids defining a
plurality of square cells, each cell having a plurality of nodes
and having a plurality of holes or slits formed therein, one of
said holes or slits being positioned at each node of the grid
pattern and one hole or slit being positioned at a centre of each
of said cells, each of said holes or slits having a width of
between 4 and 5 mm; a plurality of oxygen probes, at least one of
said oxygen probes being positioned in each of a lower region, a
middle region, and an upper region of said receiving chamber; a
plurality of temperature probes, at least one of said temperature
probes being positioned in each of the lower region, the middle
region, and the upper region of said receiving chamber; and at
least one high pressure air blower connected to the aeration
chamber and operable to blow ambient air therein and a volumetric
flow rate of at least 9.5 cubic metres per minute for each 2.2
m.sup.3 and a pressure of at least 4200 Pa for each 2.2 m.sup.3 of
a mass contained in the receiving chamber, said mass having height
about 1.5 m.
2. The bio-chamber according to claim 1, further comprising: a
plurality of said oxygen probes, at least one of said oxygen probes
being positioned in each of a lower region, a middle region, and an
upper region of said receiving chamber; and a plurality of said
temperature probes, at least one of said temperature probes being
positioned in each of the lower region, the middle region, and the
upper region of said receiving chamber.
3. The bio-chamber according to claim 1 or claim 2, wherein said
plurality of holes are arranged in a grid pattern, the grid pattern
defining a plurality of square cells, with one said hole being
positioned at each node of the grid pattern, and one said hole
being positioned at a center of each of said cells.
4. The bio-chamber according to claim 3, wherein the cells are
approximately 10 cm by 10 cm.
5. (canceled) The bio-chamber according to any one of claims 1 to
4, wherein the holes have a width of 4 mm to 5 mm.
6. The bio-chamber according to claim 1, further including an
exhaust fan connected to the receiving chamber to exhaust the odour
and excessive moisture from the bio-chamber.
7. The bio-chamber according to any one of claims 1 to 6: wherein
said removable cover is made of a material selected from the group
consisting of plastic, metal and tarpaulin; a cover for the
receiving chamber that is at least partially removable.
8. The bio-chamber according to claim 1, wherein the chamber body
comprises a sea container or a shipping container wherein the walls
and the partition are at least partially covered with an acid
resistant material.
9. The bio-chamber according to 1, wherein the [sea container or
shipping container has] walls and the partition are covered by
stainless steel sheets or plastic panels and the partition is a
stainless steel sheet.
10. The bio-chamber according to any one of claims 1 to 9, wherein
the at least one air blower has a motor power of at least 0.75 kW,
a pressure of at least 4200 Pa , and a volumetric flow rate of at
least 9.5 cubic metres per minute for each 2.2 m.sup.3 of a mass
contained in the receiving chamber, the mass having a height of 1.5
m.
11. A method of making organic fertilizer having more than 50%
organic matter from poultry manure mixed with a carbon carrier, the
method comprising: crushing the poultry manure to a particle size
of from 5 mm to 10 mm; mixing the poultry manure with the carbon
carrier wherein said mixture has a C:N ratio from 23:1 to 26:1 and
a moisture content from 49% to 54%; loading the poultry manure and
the carbon carrier into the receiving chamber of a bio-chamber
defined in claim 1; monitoring a temperature of the mixture and
maintaining the temperature of said mixture below 90 degrees
Celsius; permitting the temperature of the mixture to rise to
75.degree. C., and then maintaining the temperature of the mixture
at 75.degree. C. to 85.degree. C. until the biodegradation is
complete; permitting the oxygen concentration of the mixture to
fall to 6%, and then maintaining the oxygen concentration at 5% to
13% until the biodegradation is complete; and regulating the
temperature of the mixture and the oxygen concentration of the
mixture by adjusting the operation of the at least one air blower,
to provide conditions that permit aerobic bacteria to propagate and
biodegrade the mixture.
12. The method according to claim 11, further comprising: crushing
the poultry manure to a particle size of 5 mm to 10 mm before the
poultry manure is mixed with the carbon carrier.
13. The method according to claim 11, wherein the carbon carrier is
sawdust.
14. The method according to claim 11, wherein a pH value of the
mixture is from 6 to 8.
15. The method according to any one of claims 11 to 14, wherein a
C:N ratio of the mixture is from 23:1 to 26:1.
16. The method according to any one of claims 11 to 15, wherein a
moisture content of the mixture is from 49% to 54%.
17. The method according to any one of claims 11 to 16, wherein the
oxygen concentration of the mixture is maintained above 5%.
18. The method according to any one of claims 11 to 17, wherein the
temperature of the mixture is maintained below 90.degree. C.
19. The method according to any one of claims 11 to 18, wherein the
temperature of the mixture is permitted to rise to 75.degree. C.,
and is then maintained at 75.degree. C. to 85.degree. C. until the
biodegradation is complete.
20. The method according to any one of claims 11 to 19, wherein the
oxygen concentration of the mixture is permitted to fall to 6%, and
is then maintained at 5% to 13% until the biodegradation is
complete.
21. The method according to any one of claims 11 to 20, wherein the
organic fertilizer has more than 50% organic matter.
22. The method according to claim 11, wherein the organic
fertilizer has a nitrogen: phosphorus: potassium ratio from
2-2.5-2.5 up to 2.7-3.0-3.0.
23. The method according to claim 11, wherein the organic
fertilizer is free of pathogens, salmonella, and weed seeds.
24. A production line for producing organic fertilizer using the
method as comprising mixing poultry manure with a carbon carrier;
loading the poultry manure and the carbon carrier into a receiving
chamber of a biochamber; monitoring a temperature of the mixture
and an oxygen concentration of the mixture; evenly and fully
aerating all layers of the mixture with at least one air blower;
regulating the temperature of the mixture and the oxygen
concentration of the mixture by adjusting the operation of the at
least one air blower, to provide conditions that permit aerobic
bacteria to propagate, the production line comprising a manure
crusher, a mixer having a weighing scale, a bio-chamber, a packing
and packaging machine, and several belt or screw conveyors.
25. The production line according to claim 24, further comprising a
dryer and a machine for making granules.
26. The production line according to claim 24, wherein the
production line is automated.
27. The production line according to claim 24, wherein the
production line is scalable, flexible and mobile.
28. The production line according to any one of claims 24 to 26,
wherein the production line is scalable.
29. The production line according to any one of claims 24 to 26,
wherein the production line is flexible.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. 119(e)
of U.S. Provisional Patent Application Ser. No. 61/752,021, filed
Jan. 14, 2013, which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of processing and
treatment of poultry wastes, especially chicken manure/excrements
and to the field of making organic fertilizers. The invention can
be used for the industrial production of organic fertilizer from
chicken manure, which can be applied to restore depleted and eroded
soils and increase agricultural crop yields grown on them.
BACKGROUND OF THE INVENTION
[0003] Poultry production operations generate significant
quantities of animal waste, mainly manure. Vegetation chemically
burns from direct contact with excrements containing ammonia.
Poultry manure can contaminate the surface or groundwater resources
through leaching and runoff of contaminants. Runoff from factory
farms can go into nearby rivers, lakes and results in fish-kills,
dead-zones, closed beaches, and long-term damage to
fisheries/ecosystems. In many areas manure causes dangerous
contamination of the drinking water due to nitrates. Poultry manure
also contains bacteria and pathogens which may also potentially
affect soil, water, and food resources. Lack of appropriate
treating methods and the bad odor of chicken excrements has created
a social problem. Due to increased pressures from society to reduce
the impact on the environment, several methods of manure management
were developed. Most of them are not efficient, not scalable and
not economical.
[0004] Composting requires several months, a significant amount of
land or other space, and a lot labor for managing compost piles
such as mixing, turning etc. which leads to high labor costs. Loss
of ammonia occurs during the composting. Some nutrients may be
leached due to exposure to rainfall. Furthermore, compost can
attract insects, and disease-producing organisms may not be
adequately controlled. Another problem with composting is odor
nuisances.
[0005] Treating chicken manure with high temperatures requires
significant power consumption and results in loss of organic
matter. Furthermore, because dried chicken excrements have not gone
through the biological decomposition stage, they cannot contribute
to humus. It is known that humus is the organic matter that has
broken down into a stable substance that resists further
decomposition.
[0006] Other methods require either additional components such as
different acids, ferments, enzymes, bio-catalysts, accelerating
agents, worms etc. or sophisticated and expensive equipment, which
must be specially designed and constructed. Often additional
actions such as elevated pressure, mechanical compression, extra
heating, agitation, exposure to radiation (including but not
limited to super high frequency) etc. of raw materials is
required.
[0007] In many methods aeration is uneven. Some parts of the mass
are excessively aerated and some parts are not aerated enough. Both
conditions cannot provide the optimum development of aerobic
bacteria. Also some known methods use plastic pipes or metal tubes
with holes for aeration. The maintenance for such a construction is
not easy. If the holes are clogged by the mass then it becomes
difficult to clean them.
[0008] The population of the world is consuming more and more food.
But despite the increasing use of chemical fertilizers,
agricultural crop yield is gradually and constantly decreasing. It
has been found that the exclusive and prolonged use of chemical
fertilizer is harmful to the soil's ability to restore its
fertility due to depleted humus. For good soil conditions the
organic matter should be retained. Organic fertilizers contribute
to the fertility of the soil by adding organic matter and
nutrients. Chemical fertilizer does not have this organic
matter.
SUMMARY OF THE INVENTION
[0009] Chicken excrements consist of raw organic matter in a large
fraction, which in combination with other nutrients is a major
component of the fertility of a vegetative layer of soil. If it is
properly treated and decomposed it becomes good fertilizer. The
present invention is a simplified method of aerobic treatment of
poultry manure mixed with a carbon carrier such as sawdust under
controlled conditions. It is well known that for rapid development
and vital activity of aerobic bacteria, and hence for rapid aerobic
decomposition of the mass, oxygen supply is needed. This invention
is about how to provide adequate oxygen supply (i.e. a method of
proper, even aeration) for optimum development and propagation of
aerobic bacteria. This is achieved by monitoring temperature and
oxygen concentration, which provide a good indication of proper
aeration and development of the decomposition process. A short
decomposition time, such as only 3-5 days, can be achieved by this
method.
[0010] The invention also provides an inexpensive and simple
apparatus for making the fertilizer. The main element in the
production line is a specially designed bio-chamber where the
biodegradation occurs. The constructive design of the bio-chamber
allows for even and uniform distribution of the air and very simple
maintenance of the bio-chamber itself. Furthermore, the bio-chamber
does not require any actions such as turning over, spinning or
agitating, which significantly simplifies the production process
and reduces costs. Preferably an open top twenty or forty foot sea
container or shipping container can be repurposed for use as the
main component of the bio-chamber. These are inexpensive and easy
to obtain. Their dimensions can slightly vary, but are
approximately height 2.3 m, width 2.3 m and length 6 m or 12 m.
[0011] Properly mixed raw materials are placed into a bio-chamber
equipped with temperature and oxygen probes. Airflow is supplied by
a high pressure air blower. Uniform distribution of the air is
provided by a specially designed double bottom of the bio-chamber
and by the pressurized (forced) airflow. Air penetrates all layers,
and there is no need to agitate or turn the mass. There is no need
to treat the mass with mechanical compression, friction, exposure
to rays or radiation (including but not limited to super high
frequency radiation). Also there is no need to pre-heat the air.
Intermittent (pulse) air supply reduces power consumption. There is
furthermore no need to add additional substances such as acids,
ferments, enzymes, bio-catalysts, accelerating agents, worms, etc.
Furthermore, the process requires significantly less time and space
than composting.
[0012] The optimal temperature of the process is
75.degree.-85.degree. C., which ensures that all pathogens and
salmonella are killed, and all weed seeds are eliminated. The best
oxygen concentration is 5%-13%.
[0013] Using this method, high quality organic fertilizer can be
produced within only 3-5 days in an inexpensive production line
that can be easily built with existing machinery. As there is no
need for specially developed or sophisticated equipment, and no
additives are required, the invention provides a cheaper production
process. Only the bio-chamber where the process of biological
decomposition of organic matter will occur needs to be constructed.
This does not require a lot of work or materials. Furthermore, the
production process is environmentally friendly and waste-free, and
the production line is scalable and flexible.
[0014] Accordingly, in one aspect the present invention resides in
a bio-chamber for producing organic fertilizer, the bio-chamber
comprising: a chamber body defining a receiving chamber and an
aeration chamber, the aeration chamber underlying the receiving
chamber and being divided therefrom by a partition, the partition
having a plurality of holes formed therein; at least one oxygen
probe positioned inside the receiving chamber; at least one
temperature probe positioned inside the receiving chamber; and at
least one air blower connected to the aeration chamber and operable
to blow air therein.
[0015] Preferably, the bio-chamber further comprises a plurality of
said oxygen probes, at least one of said oxygen probes being
positioned in each of a lower region, a middle region, and an upper
region of said receiving chamber; and a plurality of said
temperature probes, at least one of said temperature probes being
positioned in each of the lower region, the middle region, and the
upper region of said receiving chamber.
[0016] In a preferred embodiment, said plurality of holes are
arranged in a grid pattern, the grid pattern defining a plurality
of square cells, with one said hole being positioned at each node
of the grid pattern, and one said hole being positioned at a center
of each of said cells. Preferably, the cells are approximately 10
cm by 10 cm, and the holes have a width of 4 mm to 5 mm.
[0017] Optionally, the bio-chamber further comprises an exhaust fan
connected to the receiving chamber.
[0018] In a preferred embodiment, the bio-chamber further comprises
a cover for the receiving chamber that is at least partially
removable.
[0019] In an especially preferred embodiment, the chamber body
comprises a sea container or a shipping container. The sea
container or shipping container can have walls that are at least
partially covered with stainless steel sheets; and the partition
can comprise at least one stainless steel sheet.
[0020] Preferably, the at least one air blower has a motor power of
at least 0.75 kW, a pressure of at least 4200 Pa, and a volumetric
flow rate of at least 9.5 cubic metres per minute for each 2.2
m.sup.3 of a mass contained in the receiving chamber, the mass
having a height of 1.5 m.
[0021] In another aspect, the present invention resides in a method
of making organic fertilizer from poultry manure mixed with a
carbon carrier, the method comprising: mixing the poultry manure
with the carbon carrier; loading the poultry manure and the carbon
carrier into the receiving chamber of the bio-chamber; monitoring a
temperature of the mixture and an oxygen concentration of the
mixture; evenly and fully aerating all layers of the mixture with
the at least one air blower; and regulating the temperature of the
mixture and the oxygen concentration of the mixture by adjusting
the operation of the at least one air blower, to provide conditions
that permit aerobic bacteria to propagate and biodegrade the
mixture.
[0022] The poultry manure should be crushed to a particle size of 5
mm to 10 mm before the poultry manure is mixed with the carbon
carrier.
[0023] Preferably, the carbon carrier is sawdust.
[0024] In preferred embodiments, a pH value of the mixture is from
6 to 8, a C:N ratio of the mixture is from 23:1 to 26:1, a moisture
content of the mixture is from 49% to 54%, the oxygen concentration
of the mixture is maintained above 5%, and the temperature of the
mixture is maintained below 90.degree. C.
[0025] In especially preferred embodiments, the temperature of the
mixture is permitted to rise to 75.degree. C., and is then
maintained at 75.degree. C. to 85.degree. C. until the
biodegradation is complete, and the oxygen concentration of the
mixture is permitted to fall to 6%, and is then maintained at 5% to
13% until the biodegradation is complete.
[0026] The organic fertilizer produced by this method can have more
than 50% organic material, a nitrogen : phosphorus : potassium
ratio from 2-2.5-2.5 up to 2.7-3.0-3.0, and be free of pathogens,
salmonella, and weed seeds.
[0027] In a further aspect, the present invention resides in a
production line for producing organic fertilizer using the
aforementioned method, the production line comprising a manure
crusher, a mixer having a weighing scale, the aforementioned
bio-chamber, a packing and packaging machine, and several belt
conveyors.
[0028] Optionally, the production line further comprises a dryer
and a machine for making granules.
[0029] In preferred embodiments, the production line is automated
and mobile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Reference may now be made to the following detailed
description taken together with the accompanying drawings in
which:
[0031] FIG. 1 shows a complete production line;
[0032] FIG. 2 is an enlarged and detailed side view of the
bio-chamber (9) from the production line of FIG. 1;
[0033] FIG. 3 is a detailed perspective view of the bio-chamber (9)
from the production line of FIG. 1;
[0034] FIG. 4 is a detailed view of stainless steel sheets from
which the partition (19) of the bio-chamber (9) of FIG. 2 and FIG.
3 are made; and
[0035] FIG. 5 is an alternate embodiment of the partition (19)
formed from profiled sheeting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Reference may first be had to FIG. 1, which depicts a
complete production line according to a preferred embodiment of the
invention. At the beginning of the process the raw materials,
chicken manure (excrements) and sawdust, are inside hoppers (1) and
(5), respectively. Although sawdust is preferably used as the
carbon carrier, other suitable sources of organic carbon such as
peat, crushed wood chips, hay or straw could be used instead. The
raw materials should be properly mixed to give a homogenized
structure, as this will shorten the decomposition time. The best
particle size is 5 mm-10 mm. Usually the sawdust particles are
already this size and do not need to be crushed. For the sawdust it
is preferable to mix deciduous and coniferous sawdust to give a pH
value within the range 6-8.
[0037] The chicken manure should be crushed because more
homogenized pieces will speed up the decomposition process. The
chicken manure is delivered by belt conveyor (2) into the manure
crusher (3). After crushing, the manure is delivered by belt
conveyor (4) to the mixer (7), which is equipped with a weighing
scale. Sawdust is delivered by belt conveyor (6) to the mixer (7)
as well. Both components are delivered to the mixer (7) in proper
proportions. Proportions are identified by the ratio C:N for the
mixture. The best value for this ratio is between 23:1 and 26:1. It
is easy to identify the proper proportions of each component using
the ratio C:N for each component. The ratio C:N of each component
should be analyzed by a laboratory.
[0038] Proper blending of carbon and nitrogen is important so that
the bacteria are supplied with the required nutrients and sources
of energy to be able to work effectively, and to ensure the
temperature of the process is high enough. Calculation of the
moisture content of the mixture can be done using the moisture
content of each component and their proportions in the raw mass. If
needed, water can be added to provide optimum moisture content
values of 49%-54%.
[0039] Properly mixed raw materials are placed by the belt conveyor
(8) into the bio-chamber (9) in loosened form. Preferably, the
mixture has a height of 120 cm-150 cm in the bio-chamber (9). If
the height is too high, the mixture of materials will be compressed
by its own weight, thus reducing air space between particles that
is needed for rapid aerobic decomposition. Also, if the height of
the mixture is too high, the airflow may not reach the top layer of
the mass due to insufficient pressure of the air blower (20).
[0040] The bio-chamber (9) is shown in detail in FIG. 2 and FIG. 3.
The bio-chamber (9) should be made of material that is resistant to
aggressive and corrosive substances such as chicken manure.
Stainless steel is preferred. Other materials can optionally be
used such as different types of plastic, glass, wood, etc. It is
most preferable to use either a twenty or forty foot used sea
container or shipping container. If a regular shipping container is
used, rather than an open topped sea container, hatches can be
installed at the top of the container for loading the mixture. The
walls and a door (16) of the container should be covered with
stainless steel sheets up to a height of 160 cm.
[0041] The bio-chamber (9) has a double bottomed structure, with a
partition (19) that divides the bio-chamber (9) into a receiving
chamber (33) and an aeration chamber (34) as shown in FIG. 2 and
FIG. 3. The partition (19) consists of stainless steel sheets (30)
with drilled holes (32) of diameter 4 mm-5 mm. Alternatively,
instead of holes (32), slits (31) of 4 mm-5 mm width can be drilled
in the partition (19). These holes (32) (or slits (31)) are less
likely to become clogged because the size of the holes (32) is less
than the size of most of the particles of the mixture.
[0042] These stainless steel sheets (30) should be screwed on
channel bars welded to the bottom of the bio-chamber (9). Holes
(32) in the partition (19) are preferably positioned on nodes of a
10 cm grid, and in the center of each square of the grid, as shown
in FIG. 3 and FIG. 4. The distance between the nodes can differ
depending on the air flow generated by the high pressure air
blowers (20). Different size grids and different size and/or shape
of holes (32) can be used if they ensure even and sufficient
aeration. Furthermore, instead of stainless steel sheets (30),
profiled sheeting (35) can be used as the partition (19) as shown
in FIG. 5. The profiled sheeting (35) has the same configuration of
holes (32) or slits (31) drilled in it. The holes (32) provide even
aeration and uniform distribution of the air, and the pressure from
the air blowers (20) ensures that air penetrates all layers of the
mass. This ensures that all of the mass is able to undergo rapid
aerobic decomposition.
[0043] It is easy to clean the holes (32). All stuck particles can
be pushed through the holes (32). During regular maintenance, which
preferably occurs once in a year, the partition (19) can be
unscrewed and the aeration chamber (34) can be cleaned. If needed,
the aeration chamber (34) can be cleaned at any time by
disconnecting the high pressure air blower (20) from the sleeve
(21), which tightly fits into hole (22), and inserting a vacuum
cleaner hose into the sleeve (21) to suck out any small
particles.
[0044] The partition (19) should be placed apart from the bottom of
the bio-chamber (9) at a distance greater than the diameter of the
sleeve (21). A distance of 20 cm is enough. One or two high
pressure air blowers (20) are required for each bio-chamber (9) to
blow air into the aeration chamber (34). Forced airflow will go
through the holes (32) and penetrate the mass from underneath.
[0045] Spent air, excessive moisture, and generated gases can be
withdrawn from the bio-chamber (9) with the help of an exhaust fan
(26) and chimney stack (27). Excessive moisture and steam
condensate goes through the joining part (23) and is collected in
elbow part (24), which has a tap (25) to drain the water. The
bio-chamber (9) can be covered preferably with a light plastic
cover (18), which can be folded, or with any other suitable
materials such as metal, tarpaulin or similar. An advantage of this
construction is that odor can be significantly reduced.
[0046] It has been found that 12 seconds of working time of an air
blower (20) with a motor power of 0.75 kW, pressure of 4200 Pa, and
volumetric flow rate of 9.5 cubic meters per minute is enough for
the blown air to penetrate the top layer of 2.2 m.sup.3 (with a
height of 1.5 m) of the mass. For a 40 ft container, two air
blowers (20) with motor power of 3 kW, pressure of 8600 Pa or
greater, and volumetric flow rate of 26 m.sup.3/min (or greater) is
enough. If a less powerful air blower (20) (or less pressure or
less volumetric flow rate) is used, then longer working periods
will be needed for air penetration. Operating periods of the blower
(20) will depend also on the porosity of the raw mass.
[0047] The bio-chamber (9) is equipped with oxygen and temperature
probes (36) which are positioned inside the bio-chamber (9) through
holes (28) at three levels--lower, middle and upper as shown in
FIG. 2. This permits monitoring of three different layers of the
decomposing manure, so that the conditions of the entire mass can
be assessed. Initially the mixed raw materials contain enough air
with an oxygen concentration of about 18% for the decomposition to
start. During the first couple of hours the air blower (20) should
not turned on while the process starts. The signal for the air
blower (20) to be turned on is a drop of the oxygen concentration
to 6%-8%. The best oxygen concentration is 5%-13%. Also, the
decision to turn on the blower (20) depends on the temperature as
well. If the oxygen concentration is in the middle of the range but
the temperature is not going up fast enough, then turning on the
blower (20) can be postponed until oxygen decreases further.
Anaerobic processes must be avoided, and so oxygen levels less than
2%-3% are unacceptable. If the oxygen concentration is in the
middle of the range and the temperature is going up too fast, then
the blower (20) can be turned on more often to slow down the
heating of the mass. The exhaust fan (26) should also be turned on
simultaneously with the air blower (20), as this will remove
excessive heat (hot air) more quickly. For this reason, it is
preferable to use a contruction with an exhaust fan (26) and
chimney stack (27), rather than having to open the cover (18) of
the bio-chamber (9).
[0048] The operating time of the air blower (20) can be exactly
identified by measuring oxygen concentration in all three layers.
Usually several seconds, such as 8 sec-12 sec, is enough to
saturate all layers with sufficient oxygen. The idle time (pause)
is 20-30 minutes. The idle time also can be identified by the
oxygen concentration. If the oxygen concentration goes below 5%,
the air blower (20) should be turned on. The air will penetrate the
lower and middle layers first before reaching the upper layer. To
provide air to the upper layer, the air blower (20) should work
several seconds more than for the lower or middle layers. The exact
number of seconds can be identified experimentally using readings
from the oxygen and temperature analyzers (36). The process can be
easily adjusted for different sized bio-chambers (9) and different
types of air blowers (20) by relying on these temperature and
oxygen readings.
[0049] A short operating time of the air blower (20) is energy and
cost saving. Excessive air will cool down the mass and slow the
process. Also it may cause a loss of too much carbon dioxide
(CO.sub.2) and prevent the slight accumulation of CO.sub.2 that is
needed by the bacteria. If the initial temperature of the mass is
less than 20.degree. C. then it will take time for the
psychrophylic bacteria, which are active in lower temperatures from
below zero up to 20.degree. C., to start the process and generate
heat. It was found that the duration of this stage is not very
important for the quality of the end product, and if time is
critical then air can be heated to shorten the duration of the
biodegradation. However, there is no requirement to actively heat
the mass, as the biodegradation process will itself generate heat.
Once the temperature of the mass reaches 20.degree.-23.degree. C.,
mesophilic bacteria continue the biodegradation and further
increase the temperature inside the decomposing materials. It is
best if the mesophilic stage lasts not less than 3 hours and not
more than 7 hours. Next, thermophyllic bacteria take up the
process. It was found that during this stage the maximum air
consumption occurred and the air blower (20) worked more often.
Idle time decreased to 3-4 minutes. The temperature should reach
75.degree.-85.degree. C. within 9-15 hours.
[0050] The temperature should not be allowed to go higher than
85.degree. C. A temperature higher than 90.degree. C. is not
acceptable. If the temperature is too high the quality of the
fertilizer will be poor. If the temperature gets close to
85.degree. C., then the air blower (20) and the exhaust fan (26)
should be turned on for cooling the mass. During the thermophyllic
stage, which lasts several days (3-4), pathogens, eggs of
helminthes, salmonella, and weed seeds are killed. Inside the
decomposing organic matter of the mass the humus is being formed.
The difference in temperature in the center of the decomposing
organic mass and at the edges is 5.degree. C.-7.degree. C. The
design of the bio-chamber (9) allows the temperature to be
regulated such that all parts of the mass are exposed to high
temperatures. This ensures that all pathogens, eggs of helminthes,
salmonella, and weed seeds are killed.
[0051] When oxygen is no longer being consumed and the temperature
is steadily decreasing, this means the process is finished and the
end product is ready to be unloaded. It is not necessary to wait
until the temperature of the product goes down to the ambient
temperature. At the moment when the temperature constantly goes
down at a rate of several degrees per hour, the air blower (20) can
be turned on to cool down and dry the mass. The product may be
unloaded at a temperature of 65.degree.-68.degree. C. or lower. The
end product is delivered by the belt conveyor (10) from the
bio-chamber (9) to the dryer (11) to be dried if necessary to a
moisture content of 20%-25%.
[0052] To simplify the process of unloading the fertilizer from the
bio-chamber (9), a hydraulic lift (29) can be put underneath of the
end of the bio-chamber (9) opposite to the door (16). Another way
of lifting the opposite end is to use a winch connected to the
frame above. Also a hydraulic lift (29) or winch can be used for
cleaning the aeration chamber (34) by lifting the bio-chamber (9)
on one side (opposite to the door (16)), opening the small door
(17) between the partition (19) and the bottom of the bio-chamber
(9), and turning on the high pressure air blower (20). All stuck
particles will be eliminated through the door (17).
[0053] The unloading can alternatively be done with a similar
method of inclination implemented not to the opposite side of the
door (16), but to one of the long sides of the bio-chamber (9). In
this case hatches are positioned along the other long side of the
bio-chamber (9), from which the fertilizer can be unloaded. Another
method of unloading is to use an air discharge system (vacuum
suction system or pneumatic conveying system).
[0054] After that the fertilizer is ready for sale. It is free of
harmful substances and can have more than 50% organic matter. This
organic matter distinguishes organic fertilizer from chemical
fertilizer. The organic matter contributes to the restoration of
the humus and to the fertility of the soil. Also, the fertilizer
has good nitrogen: phosphorus: potassium ratios compared to other
organic fertilizers (2-2.5-2.5, even up to 2.7-3.0-3.0). If
desired, the end product can be granulated or pelletized in the
granules/pellet making machine (13), where the product is delivered
by the belt conveyor (12). Belt conveyor (14) delivers the
fertilizer to the packing and packaging line (15).
[0055] This process can be easily automated using existing
technical resources such as computers, software, data acquisition
units, automatic relays/switches, etc. All formulas for calculating
the ratio of C:N, and moisture content of the raw materials mix is
known. Using these, the proper proportions of the components can be
calculated.
[0056] The process is simplified because it is a batch process.
Only one operator is required to supervise it. All equipment and
parts can be found on the market. The crusher (3), mixer (7) and
used sea containers for the bio-chamber (9) can be cheaply
purchased, for example in China. The production line can easily be
adjusted for any production volume by adding more bio-chambers (9),
belt conveyors and other units if necessary. If desired any unit
can be replaced with a more modern or efficient unit without
affecting other parts of the whole line. It is expected that this
method would work with any type of poultry manure, and with a mix
of poultry manure with pig and cattle manure. The bio-chamber (9)
could furthermore be used for other processes or products where
even aeration is required.
[0057] The production line itself is mobile, flexible, scalable and
cost effective. It does not require a lot of maintenance or a big
space.
[0058] It will be understood that, although various features of the
invention have been described with respect to one or another of the
embodiments of the invention, the various features and embodiments
of the invention may be combined or used in conjunction with other
features and embodiments of the invention as described and
illustrated herein.
[0059] Although this disclosure has described and illustrated
certain preferred embodiments of the invention, it is to be
understood that the invention is not restricted to these particular
embodiments. Rather, the invention includes all embodiments which
are functional, chemical or mechanical equivalents of the specific
embodiments and features that have been described and illustrated
herein.
[0060] The production line can be variously modified within the
scope of the claims.
* * * * *