31st Conference of the Institute for Briquetting and Agglomeration
San Antonio, Texas, USA
September 29th, 2009
Presented by:
Brett Rittenhouse, FEECO International
[email protected]
(920) 468-1000
ORGANICS GRANULATION
BIO-FERTILIZER & VALUE-ADDED WASTE STREAMS
Principles of Organics Granulation
A Technical Overview of Fertilizer Production from Waste Streams
FEECO INTERNATIONAL
FEECO – OVERVIEW
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
became FEECO International.
Privately held company with about 80 employees
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
STRENGTHS OF OUR TEAM
Engineering Staff from all major disciplines:
Chemical/Process
Mechanical
Civil/Structural
Environmental
Electrical
Customer-focused Project Management
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
The 30,000’ View
ORGANICS RECYCLING
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 water pollution, and lower
greenhouse gas emissions.” – Wikipedia, September,
2009.
ORGANIC WASTE STREAMS
Agricultural Waste (Manures, Composts)
Industrial Waste
DAF Sludge, Food Waste, Restaurant Waste
Municipal Waste (Biosolids, Composts)
THE AG-WASTE DILEMMA
Economic pressure pushing towards herd growth
Prohibitively high land costs lead to herd growth
without adequate land to dispose of waste
Nutrient levels saturated on fields where it is
economically viable to spread
Excess nutrient run-off leads to surface and ground
water pollution
Nutrient value of manure does not get fully realized
THE AG-WASTE OPPORTUNITY
Source of macro and micro nutrients
Nitrogen, Phosphorus, Potassium, Sulfur, Boron
Source of Bio-Energy Production – Anaerobic
Digestion
Organic industry as a growth market
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.)
THE ORGANIC FOOD INDUSTRY
U.S. sales of organic food and beverages have
grown 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
FERTILIZERS FROM ORGANIC WASTES
Generally considered a low-analysis fertilizer
Macronutrient content < 10% by weight.
Wide range of feedstocks:
Slurries (<10% solids) – Relatively dry, composted material (>80%
solids)
The drier feed material can be finely divided and relatively
dusty
Limits application in the field.
Traditional granulation approaches can be implemented to
improve the handling, storage, spreading, and utilization
characteristics of the material.
ORGANIC WASTE UTILIZATION - RECAP
Major Driving Force: Growth!
Demand Side Needs
Rising Fertilizer Costs
Trade Imbalances
Local and Secure Source of Nutrients
Supply Side Needs
Increasing Disposal Problems
Environmental Regulation
Need for safe (and profitable?) means of “Nutrient
Recycling”
FERTILIZERS FROM ORGANIC WASTES
Granulation Process Approaches
ORGANICS GRANULATION
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
MIXER – DRYER GRANULATION
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
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
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)
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 finishing
pelletizer (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)
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)
Click icon to add picture
PIN MIXER
High speed, Multiple feed screws
Click icon to add picture
PIN MIXER
Internal view, during fabrication
Click icon to add picture
PADDLE MIXER/PUG MILL
Slower speed, double shaft, mixing paddles
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)
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 production
Might be desired for “greens” grade product
PAN GRANULATION
PAN GRANULATION - FUNDAMENTALS
Feed from Pin Mixer fed through Small particles at bottom of bed
articulating feed chute and travel furthest
Largest particles remain in
kidney shaped area on top of
bed
Competition between
gravitational and centrifugal
forces resulting segregation by
size in tumbling bed
PAN GRANULATION - FUNDAMENTALS
Trajectories defined
by particle size
Optimization:
• Spray locations
• Scraper locations
• Pan Inclination
• Rotational Speed
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
PELLET MILL PROCESS - OVERVIEW
Raw Manure Manure Size
Unloading Drying Reduction
Steam
Pellet Mill Crumbling
Conditioning
Fines
Classifying
On-size
Product
PELLET MILL PROCESS
Physical Product Differences
Crumble vs. Spherical Product
Energy Usage
Reduction in drying gas requirements
Increase in electrical requirements (pellet mill)
Reliability & Maintenance
Careful with high silica feedstocks
BIO-FERTILIZER PLANT - EMISSIONS
Gas Treatment
Feedstock specific
Particulate
Wet scrubbing
Form of Nitrogen in feedstock?
Fuel Source? Biogas may involve SOx scrubbing
SELECTION OF AGGLOMERATION EQUIPMENT
Parameters of Particulate Feed Parameters of Agglomerated Product
Size and Shape Size and Shape
Moisture Content Strength
Material Characteristics Green Strength
Final (cured) Strength
Material Sensitivities (heat, pressure,
reactivity, etc.)
Structure
Bulk Characteristics
Binding Characteristics
Source: Pietsch, Wolfgang Agglomeration in Industry, Vol 2
SELECTION OF AGGLOMERATION EQUIPMENT
Parameters of Agglomeration Site, Supply, Environment,
Method Infrastructure
Batch or Continuous Operation Relative location to suppliers and
Capacity Requirements customers (raw materials,
Wet or Dry Operation additives/binders, energy)
Space and Energy Requirements
Site accessibility and transportation
facilities
Investment and Operating Costs
Climatic conditions
Availability of skilled and other labor
Availability of support functions
Regulations (EPA, OSHA, etc.)
Source: Pietsch, Wolfgang Agglomeration in Industry, Vol 2
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?
BIO-FERTILIZER PROCESSING CONSIDERATIONS
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
OVERALL MASS BALANCE: ADVANCED MANURE MANAGEMENT
FEECO BIO-FERTILIZER PROCESS FLOW
FEECO BIO-FERTILIZER PROCESS FLOW
INORGANIC NUTRIENT FORTIFICATION
• Biosolids
• Sulfuric Acid • Manure
• Phosphoric Acid • Organic Waste
Pipe Reactor
Drying/Agglomeration
Pug Mill
Plant
Ammonia Fortified Granular Product
Benefits of Fortification :
Potash • Chemical Heat Release Utilization
• Customized grade product
• Improved margins, larger markets
FEECO BIO-FERTILIZER PLANT, HOG MANURE
Plant aerial view
THANK YOU!
