U.S. patent application number 16/020588 was filed with the patent office on 2018-12-20 for organic liquid fertilizer and process of making.
The applicant listed for this patent is Denise Crabtree. Invention is credited to Dennis Crabtree, Bill Love, John Martin.
Application Number | 20180362414 16/020588 |
Document ID | / |
Family ID | 47558759 |
Filed Date | 2018-12-20 |
United States Patent
Application |
20180362414 |
Kind Code |
A1 |
Love; Bill ; et al. |
December 20, 2018 |
ORGANIC LIQUID FERTILIZER AND PROCESS OF MAKING
Abstract
A fertilizer derived from an organic source and a method of
making are provided. The fertilizer of the present invention
advantageously has a Nitrogen content greater than 4%. The method
of making the fertilizer also produces potable water.
Inventors: |
Love; Bill; (Leawood,
KS) ; Crabtree; Dennis; (Leawood, KS) ;
Martin; John; (Leawood, KS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Crabtree; Denise |
Tarpon Springs |
FL |
US |
|
|
Family ID: |
47558759 |
Appl. No.: |
16/020588 |
Filed: |
June 27, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13791442 |
Mar 8, 2013 |
10023501 |
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16020588 |
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13556102 |
Jul 23, 2012 |
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13791442 |
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PCT/US2012/047890 |
Jul 23, 2012 |
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13556102 |
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61572751 |
Jul 21, 2011 |
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61572749 |
Jul 21, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y02P 20/145 20151101;
C05G 5/23 20200201; C05C 11/00 20130101; Y02W 30/40 20150501; C05F
3/00 20130101; C05C 3/00 20130101; Y02A 40/20 20180101 |
International
Class: |
C05F 3/00 20060101
C05F003/00; C05C 3/00 20060101 C05C003/00 |
Claims
1. A liquid fertilizer comprising at least 4% ammoniacal nitrogen,
derived from a liquid organic waste filtrate starting material.
2. The liquid fertilizer of claim 1, wherein the Nitrogen content
is 6%.
3. The liquid fertilizer of claim 1, wherein said liquid fertilizer
is free of pathogens.
4. The liquid fertilizer of claim 1, wherein the liquid fertilizer
contains about 5% potash.
5. The liquid fertilizer of claim 1, wherein the liquid fertilizer
contains about 590,000 ppm dissolved solids.
6. The liquid fertilizer of claim 1, wherein the organic starting
material is animal manure.
7. The liquid fertilizer of claim 6, wherein the animal manure is
poultry manure.
8. The liquid fertilizer of claim 1, wherein the Nitrogen is in a
form available to plants.
9. The liquid fertilizer of claim 1, wherein the liquid fertilizer
meets the criteria for USDA organic certification.
10. A method for making a liquid fertilizer comprising the steps
of: a) obtaining liquid organic waste; b) removing suspended solids
from the liquid organic waste to form a liquid organic waste
filtrate, wherein the nitrogen contained in the liquid organic
waste filtrate is ammoniacal nitrogen; and c) adding an acid to the
liquid organic waste filtrate to adjust the pH to between 5 and 7;
and d) performing an evaporation process on the liquid organic
waste filtrate, to which the acid has been added, to create a
liquid fertilizer that contains nitrogen, wherein the nitrogen is
ammoniacal nitrogen.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Nonprovisional
patent application Ser. No. 13/791,442 which was filed on Mar. 8,
2013, which is a continuation of U.S. Nonprovisional patent
application Ser. No. 13/556,102, which was filed on Jul. 23, 2012,
which relates to and claims priority to U.S. Provisional Patent
Application No. 61/572,751, which was filed on Jul. 21, 2011, and
U.S. Provisional Patent Application No. 61/572,749, which was filed
on Jul. 21, 2011, the contents and teachings of which are
incorporated herein by reference.
BACKGROUND
[0002] Adequate nitrogen in the contents of soil is necessary for a
healthy lawn, plants, and crops. Fertilizers containing nitrogen
are used to enhance the nitrogen levels in the soil to produce
greener, lusher, faster-growing plants, lawns, and crops. Nitrogen
must be available for the plant to use it, meaning that the
nitrogen must be converted to NH.sub.4.sup.+ or NH.sub.3. The
Nitrogen may be readily available or organisms in the soil must
covert the Nitrogen into a usable form.
[0003] Inorganic fertilizers, while inexpensive and easy to apply,
tend to wash the nutrients out of the soil, requiring reapplication
on a regular basis. Additionally, since inorganic fertilizers are
concentrated, they tend to burn plant roots more than organic
materials.
[0004] Fertilizers that are derived from an organic source are
preferable for a variety of reasons. They have a lower burning
potential and a lower leach potential; and they replenish the soil
with micro-nutrients, essential amino acids, and organic matter
that were consumed by previous agricultural and horticultural
activity. However, most fertilizers derived from an organic source
have a nitrogen content that is less than 3% and the Nitrogen is
usually in a slow release form. The slow release nitrogen in most
fertilizer derived from an organic source must be broken down over
time by microorganisms in the soil in order for that nitrogen to be
converted to a form that is usable by plants and crops. This
element of organic-derived fertilizer pushes many to purchase
synthetic fertilizers that provide a higher level of nitrogen and a
quicker release into the soil and uptake by the plant.
SUMMARY OF THE INVENTION
[0005] The present invention provides for a method of making a
liquid fertilizer. The method for making fertilizer of the present
invention generally includes a) obtaining a liquid organic waste
filtrate; b) adding an acid and c) performing an evaporation
process on the liquid organic waste filtrate. The liquid organic
waste filtrate originates from a liquid organic waste material
wherein the suspended solids have been removed. The method of
making the liquid fertilizer where the method starts from liquid
organic waste would generally include: a) obtaining liquid organic
waste; b) removing the suspended solids from the liquid organic
waste; c) adding an acid; and d) performing an evaporation process
on the liquid organic waste. The liquid organic waste filtrate is
created by obtaining liquid organic waste and removing the
suspended solids. Optionally the method includes a second addition
of an acid to adjust the final pH of the liquid fertilizer. The
liquid organic waste is preferably derived from an organic source.
This liquid organic waste is preferably derived from animal manure,
specifically, poultry manure.
[0006] The present invention also provides for a fertilizer derived
from an organic source with a higher level of nitrogen than other
fertilizers derived from an organic source. The fertilizer of the
present invention advantageously contains at least 4% Nitrogen,
which is greater than previous organic fertilizer compositions. The
Nitrogen in the fertilizer of the present invention is preferably
Ammoniacal Nitrogen. This Ammoniacal Nitrogen is 100% water soluble
and is therefore quickly released into the soil and readily
available for plants. Further, the fertilizer of the present
invention is derived from an organic source. The fertilizer of the
present invention preferably comprises a fertilizer that contains
from about 4% to 10% nitrogen, more preferably from about 4% to 6%
nitrogen. This is a higher nitrogen content than what is presently
available in fertilizers that are derived from organic
materials.
BRIEF DESCRIPTION OF FIGURES
[0007] FIG. 1 is a schematic drawing of one embodiment of the
method of the present invention;
[0008] FIG. 2 is a schematic drawing of an additional embodiment of
the method of the present invention; and
[0009] FIG. 3 is a schematic drawing of an embodiment that
demonstrates the method of obtaining the liquid organic waste
filtrate and the further processing to the ultimate end
product.
DETAILED DESCRIPTION
[0010] A method of making a liquid organic fertilizer is provided.
The method generally comprises the following steps: a) obtaining a
liquid organic waste filtrate; b) adding an acid to the liquid
organic waste filtrate; and c) performing an evaporation process on
the liquid organic waste filtrate.
[0011] A further embodiment provides a method for making fertilizer
that includes the steps of: a) obtaining liquid organic waste; b)
removing suspended solids from the liquid organic waste, forming a
liquid organic waste filtrate; c) adding an acid; and d) performing
an evaporation process on the liquid organic waste filtrate. In an
alternate embodiment, the method further comprises the step of
adding a second acid. Preferably, this second acid is added after
the evaporation process is performed on the liquid organic waste
filtrate.
[0012] The liquid organic waste can be any aqueous solution that
contains a dissolved protein, Ammoniacal Nitrogen, and other
soluble nutrients. If the organic waste is in a solid or semi-solid
form, water is preferably added to the solid or semi-solid material
to form a fluid mixture. For example, in an embodiment where animal
manure is utilized, water is added to form a fluid mixture creating
liquid organic waste. The water preferably creates a fluid mixture
of water and suspended and dissolved solids making up the liquid
organic waste. An effluent discharge from an anaerobic digester is
a preferred liquid organic waste. The suspended and dissolved
solids in the liquid organic waste preferably include, but are not
limited to: nitrogen, phosphate, potash, secondary nutrients,
micro-nutrients and organic matter found in anerobically digested
manure or other agriculturally related organic waste. The
temperature of starting material is preferably between 90.degree.
F. and 140.degree. F., more preferably from about 132.degree. F. to
136.degree. F. This temperature is preferably achieved using a heat
exchanger. The liquid organic waste for the method of the present
invention is preferably derived from an organic source. The liquid
organic waste is preferably derived from natural sources the
include, but are not limited to, plant and animal-biproducts, rock
powders, seaweed, inoculants, conditioners, dairy product waste,
livestock manure, liquid manure, worm castings, peat, guano,
compost, blood meal, bone meal, fish meal, decomposing crop
residue, cheese whey, dairy product waste, livestock manure, mixed
liquor from food and livestock processing facilities, wastewaters
from a variety of food processing operations, and combinations
thereof. However, the list provided herein is not meant to be
limiting, as any natural source that provides nitrogen, phosphate,
and potash will work for purposes of the present invention.
[0013] The liquid organic waste is preferably filtered to remove
suspended solids. The removal of suspended solids from the liquid
organic waste creates the liquid organic waste filtrate. This
liquid organic waste filtrate preferably contains less than 2,000
parts per million (hereinafter "ppm") suspended solids, more
preferably, less than 1,500 ppm suspended solids, and most
preferably 1,200 ppm suspended solids or less. The liquid organic
waste filtrate preferably contains nitrogen, phosphate, potash,
secondary nutrients, micro-nutrients and organic matter. The
nitrogen is preferably Ammoniacal Nitrogen.
[0014] The step of removing suspended solids can be performed by
any mechanism capable of filtering particles. The suspended solids
are preferably those particles that won't pass through a 270 Dalton
membrane under 500 psi of pressure. The removal of suspended solids
can preferably be completed using at least one, at least two, or at
least three or more filtration steps. The removed suspended solids
can be further processed to produce granular fertilizers. These
filtration steps may utilize the same method of filtration or
different methods of filtration. Preferably, in an embodiment where
three filtration steps are performed, the first step removes large
suspended solids (greater than 24 microns), the second step removes
small suspended solids (less than 24 microns), and the third step
removes any residual solids. Preferably, the suspended solids are
removed using one or more filtration mechanisms including, but not
limited to, mechanical screening, microfiltration, ultrafiltration,
nanofiltration, reverse osmosis, membrane separation, and
electro-coagulation. Preferred machinery for removing suspended
solids include, but are not limited to, BioPulse system provided by
bioprocess H2O (Portsmith, R.I.); Petro Membrane Bioreactor ("MBR")
(Siemens Industry, Inc. USA); PURON MBR (Koch Membrane Systems,
Inc., Wilmington, Mass.); Pall Aria Integrated MF/NF
(microfiltration/nanofiltration) and MF/RO (microfiltration/reverse
osmosis) systems (Pall Corporation, Port Washington, N.Y.); Alfa
Laval Filtration (Alfa Laval, Sweden); and NF (nanofiltration) and
RO (reverse osmosis) Membrane Separation (BKT Co Ltd, Korea). The
filtration step(s) result in the liquid organic waste filtrate.
[0015] In a further embodiment, the step of removing suspended
solids further includes a second filtration step. This second
filtration step preferably removes any material of a size that may
disrupt, impeded, or block an irrigation system. Any filtering
process that removes the material of a size that might disrupt an
irrigation system would work for purposes of the present invention.
Preferred filtering processes include, but are not limited to, the
use of a 500-mesh screen, membrane filters, continuous agitation
through turbulent flow, or reverse osmosis, with or without a
self-cleaning method of filtration.
[0016] In yet a further embodiment, the step of removing suspended
solids includes a third filtration step. The third filtration step
can be any filtration method referenced herein, however, it is
preferred that it is reverse osmosis.
[0017] An acid is preferably added to the liquid organic waste
filtrate. Preferably, the acid is utilized to adjust the pH of the
liquid organic waste filtrate to a pH of 7 or lower. Preferably,
the pH is adjusted to a pH of between pH 3 to pH 7, more preferably
from about pH 5 to pH 7, and most preferably about pH 6.5.
Additionally, the acid preferably acts to bind the ammonium
molecules so that they are able to release free ammonia, preferably
without producing suspended solids. In an embodiment where an acid
is utilized, the acid can be any organic or inorganic acid that
will adjust the pH of the liquid organic waste filtrate to a pH of
7 or less, more preferably a pH of 6.5. The type and amount of acid
will vary depending on the given situation, but the amount and type
of acid is enough to lower the pH of the liquid organic waste
filtrate to a pH of 7 or less. The acid is preferably selected
from, but is not limited to, citric acid, lactic acid, L-malic
acid, vinegar (acetic acid), phosphoric acid, sulfuric acid,
hydrochloric acid, nitric acid, and combinations thereof. Most
preferably, the acid is citric acid. In a most preferred
embodiment, the acid utilized is an organic acid. Any organic acid
will work for purposes of the present invention. Preferred organic
acids include, but are not limited to, lactic acid, acetic acid,
formic acid, citric acid, oxalic acid, and uric acid. Inorganic
acids may also be utilized for purposes of the present invention.
Inorganic acids include, but are not limited to, hydrochloric acid,
nitric acid, phosphoric acid, sulfuric acid, hydrofluoric acid,
hydrobromic acid, perchloric acid, and combinations thereof. The
acid is preferably added in an amount that is sufficient to change
the pH of the liquid organic waste filtrate to a pH of 7 or lower.
The amount of acid added depends on the type of acid used, starting
pH of the liquid organic waste filtrate, the buffering capacity of
the liquid organic waste filtrate, and the Nitrogen content of the
liquid organic waste filtrate. In a preferred embodiment the acid
is added in an amount of from about 0.1 lb/gallon to 2.0 lb/gallon,
more preferably from about 0.2 lb/gallon to 1.5 lb/gallon, still
more preferably from about 0.4 lb/gallon to 1.0 lb/gallon, and most
preferably, the acid is added in an amount of about 0.6
lb/gallon.
[0018] The liquid organic waste filtrate and acid are preferably
exposed to an evaporation process. The evaporation process may be
any process suitable for removing water from the composition. In a
preferred embodiment, the composition is in a liquid form following
the evaporation step. Preferably, a vacuum evaporation is utilized.
A most preferred vacuum evaporator is the Turbo CAST.RTM. vacuum
evaporator (ThermoEnergy Inc., Worcester, Mass.). Other possible
vacuum evaporators include, but are not limited to, the vacuum
evaporators made by Veolia Water Solutions and Technologies (Cary,
N.C.), HF Pure Water (Compton, Calif.), Mech-Chem Associates
(Norfolk, Mass.), and Econ Industries (Starnberg, Germany). The
evaporation process requires heat to remove water from the
composition. The temperature range of the evaporation process is
preferably from about 90-110.degree. F., more preferably from about
100-105.degree. F. In an embodiment that includes a vacuum
evaporation process, the vacuum range is preferably from about
26-28 inches of mercury, with the preferred range being from about
27-28 inches of mercury. The time the evaporator is used depends on
the temperature and pressure utilized and can be determined in line
with industry standards. A non-limiting example includes a Turbo
Cast MVR 21000 system (ThermoEnergy, Inc., Worcester, Mass.),
operating at 100.degree. F. and 28 inches of mercury, will
concentrate 155,000 gallons of solution to 21,000 gallons by
removing water at a rate of 46,565 pounds per hour.
[0019] Preferably, the evaporation process creates water vapor that
can be captured and transformed into potable water. Advantageously,
during the evaporation step, water vapor is created. This water
vapor is then cooler condensed into liquid water. The water that
results from the method of the present invention is clean and
suitable for drinking.
[0020] An alternate embodiment of the present invention is
described in the next several paragraphs. The alternate embodiment
starts with an anerobic digester discharge (herinafter
"digestate"). This digestate can be any fluid mixture of water and
suspended and/or dissolved solids. The suspended and dissolved
solids in the digestate preferably include, but are not limited to
nitrogen, phosphate, potash, secondary nutrients, micro-nutrients
and organic matter found in anerobically digested manure or other
agriculturally related organic waste. Preferably, the digestate is
at a temperature of between 80.degree. F. and 132.degree.
Fahrenheit.
[0021] The digestate is preferably then processed by a filtering
mechanism to remove and capture the large suspended solids,
hereinafter called "recovered solids". These large suspended solids
are preferably greater than 24 microns in size. The recovered
solids preferably have a moisture content of from about 70% to 90%
moisture, more preferably about 80% moisture. The recovered solids
are then preferably processed in a twin-screw helical heat
exchanger to produce granular fertilizer with a moisture content of
10% or less, more preferably 5% or less. The heat utilized to
process the recovered solids is preferably from an indirect source,
such as, but not limited to hot oil flowing around the ducts.
Preferably, the rotation of helical ducts severs to cause the
solids to bind together to form fertilizer granules. Amonia-rich
exhaust gas is preferably created by this process that can be
cooled and added to the liquid filtrate and further processed. The
formation of granular fertilizer is an optional part of the method
of the present invention and is not a required element. In an
alternate embodiment, the recovered solids are discarded.
[0022] In one embodiment, the liquid filtrate remaining after the
suspended solids are removed is pH adjusted with an acid to produce
a pH of approximately 7.0. The acid added can be any acid capable
of adjusting the pH of the liquid filtrate. Preferably an organic
acid is used, more preferably citric acid is utilized. The liquid
filtrate is preferably then filtered at least one additional time,
more preferably at least two additional times. The first additional
filtration step preferably removes the remaining small suspended
solids. The small suspended solids are preferably less than or
equal to 24 microns. This first additional filtration step is
preferably completed using membrane filters, however, any
filtration system capable of removing small suspended solids will
work. Other filtration methods contemplated by the present
invention are discussed herein. The second additional filtration
step preferably removes molecular dissolved solids. This second
additional filtration step is preferably completed using a
nano-filter, however, any filtration system capable of removing
molecular dissolved solids, such as those filtration methods
discussed herein.
[0023] The liquid organic waste filtrate resulting from the above
process is a liquid fertilizer product with unique solids and
nutrient content of exceptional value for soil conditioning,
replacement of exhausted nutrients, and restoration of soil health.
The second filtration step is a semi-continuous process that
produces reject in quantifiable batch volumes. After a programmed
interval, the valve of the extruder is opened to release the
accumulated reject. This accumulated reject is isolated and removed
to storage. At this point, the next batch of liquid organic waste
is filtered. This cycle repeats indefinitely. Citric acid is
preferably added to the resulting liquid filtrate from the second
filtration step to adjust the pH. This pH adjustment preferably
stabilizes the ammonium nitrogen contained in the permeate and
produces entrained carbon dioxide. The carbon dioxide gas is
liberated from the liquid filtrate and then the acidified liquid
filtrate is filtered again in the third additional filtration step.
The concentrated stream produced by the third filtration step is
then concentrated by vacuum evaporation. This vacuum evaporation
further concentrates the liquid organic waste filtrate from the
second filtration step and produces the phosphate-free liquid
organic fertilizer of the present invention. The water vapor
produced during this process is preferably condensed and combined
with permeate obtained from the final filtration step. The
resultant solution is clean water of such quality required to meet
the NPDES discharge permit requirements established by the USEPA
Clean Water Act of 1972.
[0024] The final products of this alternate embodiment of the
method of the present invention are preferably a liquid fertilizer
and water. The liquid fertilizer preferably has a high Nitrogen
content, where the Nitrogen is Ammoniacal Nitrogen, which is 100%
water soluble and readily available to the soil. Additionally, the
water produced is potable water.
[0025] A liquid fertilizer derived from an organic source is also
provided by the present invention. The organic source preferably
includes, but is not limited to, plant and animal-bi-products, rock
powders, seaweed, inoculants, conditioners, dairy product waste,
livestock manure, liquid manure, worm castings, peat, guano,
compost, blood meal, bone meal, fish meal, decomposing crop
residue, cheese whey, dairy product waste, livestock manure, mixed
liquor from food and livestock processing facilities, wastewaters
from a variety of food processing operations, and combinations
thereof. However, the list provided herein is not meant to be
limiting, as any natural source that provides nitrogen, phosphate,
and potash will work for purposes of the present invention. In a
most preferred embodiment, the organic source is animal manure,
most preferably, poultry manure.
[0026] The liquid fertilizer of the present invention preferably
contains Ammoniacal Nitrogen derived from an organic source. The
Ammoniacal Nitrogen provided by the fertilizer of the present
invention is derived from anerobically digested waste. The
Ammoniacal Nitrogen in the liquid fertilizer of the present
invention is preferably soluble Ammoniacal Nitrogen (N-NH4) that is
immediately available to the plant. The Ammoniacal Nitrogen is
preferably present in the liquid organic waste and thus, still
present in the liquid organic waste filtrate. The Ammoniacal
Nitrogen is preferably concentrated by the method of the present
invention and the addition of the acid in the method also binds the
ammonium (NH.sub.4) molecules very tightly, thus restricting their
conversion to free ammonia (NH.sub.3) and subsequent loss through
volatilization.
[0027] This Ammoniacal Nitrogen is preferably present in the liquid
fertilizer in an amount of greater than 4%, more preferably from
about 4% to 10% Nitrogen, more preferably from about 4% to 6%
Nitrogen, and most preferably about 6% Nitrogen. Water is
preferably present in the liquid fertilizer in an amount of from
about 10% to 90%, more preferably from about 20% to 80%, more
preferably from about 30% to about 60%, and most preferably from
about 35% to 45%. Advantageously, the liquid fertilizer contains
dissolved solids. Preferably, the liquid fertilizer contains at
least 40,000 ppm to about 750,000 ppm dissolved solids, more
preferably from about 100,000 ppm to about 700,000 ppm dissolved
solids, preferably from about 200,000 ppm to 690,000 ppm dissolved
solids, more preferably from about 300,000 ppm to about 680,000 ppm
dissolved solids, and most preferably from about 550,000
ppm-650,000 ppm dissolved solids. It is generally preferred that
the liquid fertilizer contain at least 40,000 ppm of dissolved
solids. A preferred embodiment contains about 590,000 ppm dissolved
solids.
[0028] In a preferred embodiment, the liquid fertilizer has little
to no suspended solids in the composition. Preferably, the liquid
fertilizer has from 0 ppm to 20,000 ppm suspended solids, more
preferably less than 15,000 ppm, more preferably less than 13,000
ppm and most preferably less than 12,000 ppm, more preferably less
than 10,000 ppm, still more preferably less than 5,000 ppm, still
more preferably less than 3,000 ppm, and most preferably about
1,200 ppm. In a most preferred embodiment the liquid fertilizer has
no suspended solids. The liquid fertilizer of the present invention
may also contain potash. The potash is preferably soluble potash.
The potash is preferably present in an amount from about 1% to 10%,
most preferably about 5%. Sulfur may also be present in the liquid
fertilizer. Sulfur is preferably present in the liquid fertilizer
in an amount less than 10%, more preferably less than 8%, and most
preferably 4% or less.
[0029] The fertilizer of the present invention preferably has a pH
of between pH 3 to pH 7, more preferably from about pH 5 to pH 7,
and most preferably about pH 6.5. Additionally, the fertilizer of
the present invention is preferably free of pathogens. In a
preferred embodiment, pathogens die within 24 hours of being
introduced into the fertilizer.
[0030] Additionally, the fertilizer of the present invention may be
certified by the United States Department of Agriculture ("USDA")
as "USDA organic." The USDA has a program called the National
Organic Program ("NOP") which specifically describes the synthetic
materials that are allowed in fertilizer (www.ams.usda.gov/nop).
Specifically, the list of acceptable ingredients is provided in the
National Organics Program List in section 205.605. In a preferred
embodiment, the method of the present invention produces a liquid
fertilizer eligible for USDA organic certification. However, this
is not a required element of the present invention. The method of
the present invention producing a fertilizer of the present
invention can be derived from an organic source without meeting the
requirements of being certified USDA organic.
Definitions
[0031] "Organic" or "Organically derived", for purposes of the
present invention refer to the natural source of the starting
material for the fertilizer of the present invention. While not
meant to be limiting, a starting material for the fertilizer may
include, but is not limited to plant and animal bi-products, rock
powders, seaweed, inoculants, conditioners, dairy product waste,
livestock manure, liquid manure, worm castings, peat, guano,
compost, blood meal, bone meal, fish meal, decomposing crop
residue, cheese whey, dairy product waste, livestock manure, mixed
liquor from food and livestock processing facilities, wastewaters
from a variety of food processing operations, and combinations
thereof. However, the list provided herein is not meant to be
limiting, as any natural source that provides nitrogen, phosphate,
and potash will work for purposes of the present invention.
[0032] "USDA organic" refers to a fertilizer or components that
meet the guidelines as set forth by the USDA requirements to
certify something as "organic."
[0033] "Ammoniacal Nitrogen" for purposes of the present invention
refers to Nitrogen that is provided to the plant in a water soluble
form, where the Ammoniacal Nitrogen includes ammonium
(NH.sub.4.sup.+) and ammonia (NH.sub.3). The Ammoniacal Nitrogen is
readily plant available.
[0034] "Liquid organic waste," for purposes of the present
invention refers to any aqueous solution that contains a dissolved
protein, Ammoniacal Nitrogen, and other soluble nutrients. If the
waste is in a solid or semi-solid form, water is preferably added
to the solid or semi-solid material to form liquid organic waste,
creating a fluid mixture of water and suspended and dissolved
solids. The liquid organic waste can come from any organically
derived source, as detailed in the definition for "organic" or
"organically derived."
[0035] "Liquid organic waste filtrate," for purposes of the present
invention, is the liquid organic waste, described above, where the
suspended solids have been removed. Preferably, the suspended
solids are removed by a filtration process.
[0036] "Suspended solids," for purposes of the present invention
refer to those particles that won't pass through a 270 Dalton
membrane under 500 psi of pressure.
[0037] "Dissolved solids," for purposes of the present invention
refer to those particles that are smaller than the suspended
solids, or those particles that will pass through a 270 Dalton
membrane under 500 psi of pressure.
EXAMPLES
Example 1
[0038] This example illustrates one embodiment of the method and
fertilizer of the present invention.
[0039] Materials and Methods
[0040] Poultry manure was obtained and water was added to the
poultry manure to form an aqueous mixture for the liquid starting
material. A nanofiltration and reverse osmosis filtration system
were used to remove the suspended solids. Once the suspended solids
were removed, citric acid was added to the liquid starting
material. Next, a vacuum evaporator was utilized at between
100-105.degree. F. at a pressure of 26-28 inches of mercury. After
the evaporation process was complete, an additional amount of
citric acid was added to adjust the pH of the solution to around pH
6.5. The water vapor from the evaporation process was captured.
[0041] Results and Conclusions
[0042] The resulting liquid fertilizer contained a soluble and
rapid-acting nitrogen source, where the amount of nitrogen in the
fertilizer was 6%. The potassium content of the fertilizer was 5%
and the fertilizer did not contain any phosphorus. The potash
content was about 5% and the fertilizer contained 4% sulfur.
Suspended solids were present in the fertilizer at about 1,200 ppm
and the fertilizer contained about 590,000 suspended solids. The
organic matter present in the fertilizer was about 75% and it was
about 11 pounds per gallon at 68.degree. F. The liquid fertilizer
was also pathogen free.
[0043] Additionally, the water vapor was recovered as potable
water, suitable for drinking.
Example 2
[0044] This example illustrates use of the fertilizer for
crops.
[0045] Materials and Methods
[0046] Using the fertilizer resulting from Example 1, crops may be
fertilized. The crops may be fertilized at 10 lbs N/acre pre-plant
or at planting; 25-35 lbs N/acre at thinning; and 10-15 lbs N/acre
at pre-harvest.
[0047] Results and Conclusions
[0048] The total nitrogen in the fertilizer will be 45-60 lbs
N/acre, where the fertilizer of the present invention has 0.66 lbs
N/gallon, which equals 75-100 gallons/acre.
Example 3
[0049] This example illustrates the pathogen-free aspect of the
fertilizer of the present invention.
[0050] Materials and Methods
[0051] Pathogens may be introduced into the liquid fertilizer of
the present invention.
[0052] Results and Conclusions
[0053] After 24 hours, none of the pathogens introduced into the
liquid fertilizer will be alive.
Example 4
[0054] This example illustrates the removal of suspended
solids.
[0055] Materials and Methods
[0056] The solid separation and nutrient recovery process began
with the effluent discharge from an anaerobic digester, hereafter
referenced as "digestate". Digestate is a fluid mixture of water
and suspended and dissolved solids including, but not limited to:
nitrogen, phosphate, potash, secondary nutrients, micro-nutrients
and organic matter found in anaerobically digested manure or other
agriculturally related organic waste. The temperature of digestate
was between 80.degree. F. and 132.degree. Fahrenheit.
[0057] The digestate was processed by a filtration mechanism to
remove and capture large (>24 microns) suspended solids,
hereafter referenced as "recovered solids". The recovered solids
were separated from the digestate by the filtration mechanism have
a moisture content of approximately 80 percent. These wet solids
were then processed in a twin-screw helical heat exchanger to
produce granular fertilizer with a moisture content of 5% or less.
The wet recovered solids were then introduced into a series of
rotating helical ducts. Hot oil flowing around through the ducts
provided indirect heat. The constant motion and heat applied to the
solids functioned to remove latent moisture from the solids.
Rotation of the helical ducts served to cause the solids to bind to
each other and form granules of solid fertilizer. These fertilizer
granules may be later screened to size as desired. The evaporated
moisture consisted of an ammonia-rich exhaust gas. This warm gas
may be cooled to produce condensate that can be added to the
filtrate from the filtering mechanism and further processed.
Example 5
[0058] This example illustrates the filtration process of the
present invention.
[0059] Materials and Methods
[0060] The filtrate from the filtration mechanism was pH adjusted
with citric acid to produce a pH of approximately 7.0 and then fed
through a series of membrane filters hereafter referenced as
"filtration steps". The first filtration step (nano-filtration)
removed the remaining small (.ltoreq.24 microns) suspended solids
that were not initially captured. The second filtration step
(reverse osmosis) removed molecular dissolved solids that pass
through the nano-filter.
[0061] The material that passed through each filtration step,
hereafter referenced as "permeate", was the feed stream to the
subsequent filtration step. The concentrated product produced at
each filtration step, hereafter referenced as "reject", was a
high-value fertilizer product of unique solids and nutrient
content. After a programmed time interval, a valve was opened to
release the accumulated reject. The valve was then closed to allow
the concentration of additional feed stream. This cycle repeated
several times. The filtration method utilized continuous agitation
through turbulent flow forced the filtrate against the membrane
filters of a cylindrical mechanism. As the mechanism rotated,
specially designed blades created vortices which removed foulants
from the membrane surface and dramatically decreased boundary layer
effects. Both reject and permeate were obtained and processed as
previously disclosed.
[0062] Citric acid was added to the reject from the second
filtration step (reverse osmosis) to produce approximately 6.0 pH.
This pH adjustment stabilized the ammonium nitrogen contained in
the reject and, in doing so, produced entrained gaseous carbon
dioxide. Entrained gas was liberated from the reject by applying
ultrasonic vibration and mechanical agitation. The acidified,
de-gassed reject was further concentrated by vacuum
evaporation.
[0063] The vacuum evaporation process was operated under vacuum of
approximately 28 inches mercury and at a temperature of
approximately 100.degree. Fahrenheit. This process further
concentrated the reject solution and produced a phosphate-free
liquid organic fertilizer. Nitrogen and potash concentrations may
be adjusted as required by controlling the volume of water removed
through evaporation. The water vapor produced by evaporation was
condensed and combined with permeate obtained from the final
filtration step. The resultant solution was then processed by
spiral reverse osmosis which removes any remaining solids and any
pathogens not destroyed in the digestion process.
[0064] Results and Conclusions
[0065] The final products of the filtrate processing consisted of:
at least two high-value liquid fertilizer products with uniquely
different nutrient contents and agronomic uses, including a
concentrated phosphate-free liquid organic fertilizer, and potable
water.
Example 6
[0066] This example provides another embodiment of the present
invention.
[0067] Materials and Methods
[0068] A typical pilot process demonstration included the
collection of 300 gallons of digestate from the anaerobic digestion
of poultry waste at 132.degree. Fahrenheit. This stream had a total
nitrogen content of 14 percent (dry weight basis) including an
ammonium concentration of approximately 3,000 ppm. This stream was
mechanically screened to remove large (>24 microns) suspended
solids. The underflow from the mechanical screen was approximately
294 gallons with an ammonium concentration of approximately 2,800
ppm.
[0069] The 294 gallons was then filtered to remove the residual
suspended solids greater in size than will pass through a 270
Dalton membrane under 500 psi pressure. This filtration step
produced approximately 44 gallons of reject and 250 gallons of
permeate. The ammonium concentration of the permeate stream was
approximately 2,000 ppm.
[0070] The 250 gallons of permeate were pH adjusted with citric
acid to 6.5 and then filtered by reverse osmosis. The reverse
osmosis process produced approximately 37 gallons of reject and 213
gallons of permeate (liquid organic waste filtrate). Approximately
0.6 pounds of citric acid were added per gallon of reject produced.
The ammonium concentration of the reject stream was approximately
15,000 ppm.
[0071] The 37 gallons of reject from the reverse osmosis process
were then concentrated to approximately 6 gallons of finished
product by the use of vacuum evaporation.
[0072] Results and Conclusions
[0073] The fertilizer of the present invention was produced. The
ammonium concentration of the finished product was 60,000 ppm or
six percent by weight.
[0074] All of the compositions and methods disclosed and claimed
herein can be made and executed without undue experimentation in
light of the present disclosure. While the compositions and methods
of this invention have been described in terms of preferred
embodiments, it will be apparent to those of skill in the art that
variations may be applied to the compositions and methods and in
the steps or in the sequence of steps of the method described
herein without departing from the concept, spirit and scope of the
invention. More specifically, it will be apparent that certain
agents which are both chemically and physiologically related may be
substituted for the agents described herein while the same or
similar results would be achieved. All such similar substitutes and
modifications apparent to those skilled in the art are deemed to be
within the spirit, scope and concept of the invention as defined by
the following claims.
* * * * *