iba 2009 distribution

8/9/2019 IBA 2009 Distribution

1/47

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

[email protected]

(920) 468-1000


2/47

Principles of Organics Granulation

A Technical Overview of Fertilizer Production from Waste Streams

FEECO INTERNATIONAL


3/47

FEECO OVERVIEW


4/47

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


5/47

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


6/47

STRENGTHS OF OUR TEAM

Engineering Staff from all major disciplines:

Chemical/Process

Mechanical

Civil/Structural

Environmental

Electrical

Customer-focused Project Management


7/47

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


8/47

The 30,000 View

ORGANICS RECYCLING


9/47

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.


10/47

ORGANIC WASTE STREAMS

Agricultural Waste (Manures, Composts)

Industrial Waste

DAF Sludge, Food Waste, Restaurant Waste

Municipal Waste (Biosolids, Composts)


11/47

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


12/47

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


13/47

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.)


14/47

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


15/47

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.


16/47

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


17/47

FERTILIZERS FROM ORGANIC

WASTES


18/47

Granulation Process Approaches

ORGANICS GRANULATION


19/47

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


20/47

MIXER DRYER GRANULATION


21/47


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


22/47

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


23/47

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)


24/47

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)


25/47

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)


26/47

PIN MIXER

High speed, Multiple feed screws


27/47

PIN MIXER

Internal view, during fabrication


28/47

PADDLE MIXER/PUG MILL

Slower speed, double shaft, mixing paddles


29/47


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)


30/47


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


31/47

PAN GRANULATION


32/47

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


33/47

PAN GRANULATION - FUNDAMENTALS

Trajectories defined

by particle size

Optimization:

Spray locations

Scraper locations

Pan Inclination

Rotational Speed


34/47

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


35/47

PELLET MILL PROCESS - OVERVIEW

Raw Manure

Unloading

Manure

Drying

Size

Reduction

Steam

ConditioningPellet Mill Crumbling

ClassifyingFines

On-size

Product


36/47

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


37/47

BIO-FERTILIZER PLANT - EMISSIONS

Gas Treatment

Feedstock specific

Particulate

Wet scrubbing

Form of Nitrogen in feedstock?

Fuel Source? Biogas may involve SOx scrubbing


38/47

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


39/47

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


40/47

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?


41/47

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


42/47

OVERALL MASS BALANCE: ADVANCED MANURE

MANAGEMENT


43/47

FEECO BIO-FERTILIZER PROCESS

FLOW


44/47

FEECO BIO-FERTILIZER PROCESS

FLOW


45/47

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


46/47

FEECO BIO-FERTILIZER PLANT, HOG

MANUREPlant aerial view


47/47

THANK YOU!

iba 2009 distribution

Documents