technical and economic study of drying and granulation of ... - Helcom
technical and economic study of drying and granulation of ... - Helcom
technical and economic study of drying and granulation of ... - Helcom
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
BALTHAZAR Pilot Project Report<br />
TECHNICAL AND ECONOMIC STUDY OF<br />
DRYING AND GRANULATION OF CHICKEN<br />
MANURE AT PRIMORSKAYA POULTRY FACTORY<br />
This project is carried out with<br />
funding from the European Union<br />
Towards enhanced protection <strong>of</strong> the Baltic Sea from<br />
mainl<strong>and</strong>-based threats: Reducing agricultural nutrient<br />
loading <strong>and</strong> risk <strong>of</strong> hazardous wastes<br />
Helsinki Commission<br />
(Baltic Marine Environment Protection Commission)<br />
Katajanokanlaituri 6 B, 00160 Helsinki<br />
Phone: +358-207-412 649; Fax: +358-207-412 645<br />
www.helcom.fi<br />
Saint-Petersburg Public Organization<br />
“Ecology <strong>and</strong> Business”<br />
Post <strong>of</strong>fice box 66, RU-197342 St. Petersburg, Russia<br />
Phone: +7-812-430 6860; Fax: +7-812-430 9305;<br />
www.helcom.ru
Baltic Hazardous <strong>and</strong> Agricultural Releases Reduction<br />
BALTHAZAR - project 2009-2012<br />
Towards enhanced protection <strong>of</strong> the Baltic Sea from main l<strong>and</strong>-based threats: reducing<br />
agricultural nutrient loading <strong>and</strong> the risk <strong>of</strong> hazardous wastes<br />
The BALTHAZAR project promotes the protection <strong>of</strong> the Baltic Sea from both hazardous waste <strong>and</strong><br />
agricultural nutrient loading with activities in the Russian Federation. The activities contribute to the<br />
achievement <strong>of</strong> the environmental objectives <strong>of</strong> the HELCOM Baltic Sea Action Plan through providing<br />
assistance to the development <strong>of</strong> national action plans <strong>and</strong> prioritization <strong>of</strong> necessary measures to tackle the<br />
harmful hazardous substances <strong>and</strong> eutrophication segments. In particular, the project aims improving the<br />
management <strong>of</strong> hazardous <strong>and</strong> agricultural wastes focusing exclusively on St. Petersburg, Leningrad <strong>and</strong><br />
Kaliningrad Oblasts <strong>of</strong> the Russian Federation.<br />
The target group includes relevant Russian federal, regional <strong>and</strong> municipal authorities within the above<br />
territories, as well as the stakeholders <strong>of</strong> the territorial departments <strong>and</strong> committees for environmental<br />
protection, agriculture, <strong>and</strong> water resources. Moreover, authorities, industrial (waste-generating <strong>and</strong> waste<br />
management) <strong>and</strong> agricultural companies, scientific organisations, environmental NGOs <strong>and</strong> the general<br />
public awareness are the focal points <strong>of</strong> this project.<br />
The project has been running from February 2009 <strong>and</strong> is expected to finish by March 2012. It is enabled by<br />
a 3.5 Million Euro grant from the European Parliament Pilot Project Facility, through the European<br />
Commission Delegation in Moscow. The Project is managed by the Project Implementation Unit (PIU)<br />
established in the HELCOM Secretariat together with a Russian Partner Ecology <strong>and</strong> Business, the Russian<br />
St. Petersburg Public Organisation with the help <strong>of</strong> individually selected consultant consortiums for specific<br />
tasks in the two thematic areas <strong>of</strong> the project.<br />
As a result <strong>of</strong> the first stage <strong>of</strong> the project, several pilot project proposals were developed for both regions<br />
within the two components. The following 4 pilot projects selected by the Project Steering Group in March<br />
2010 have been carried out in Phase I <strong>of</strong> the Balthazar project:<br />
Agriculture pilots<br />
1. Feasibility <strong>study</strong> <strong>and</strong> detailed plan for investment in technique for conversion <strong>of</strong> chicken manure into<br />
fertilizer products on Poultry Farm Primorskaya, Leningrad Region<br />
2. Manure management strategy in Slavsky District, Kaliningrad Region<br />
Hazardous waste pilots<br />
3. Contamination <strong>and</strong> feasibility <strong>study</strong> <strong>and</strong> development <strong>of</strong> a remediation plan for Ust-Tosno l<strong>and</strong>fill<br />
outside St. Petersburg<br />
4. Enhancement <strong>of</strong> treatment <strong>of</strong> mercury containing waste (fluorescent lamps) in Kaliningrad region<br />
This report relates to the pilot project number 1 on agriculture <strong>and</strong> was prepared by SZNIIMESH. It does<br />
not necessarily reflect the view <strong>of</strong> HELCOM. Other reports related to this pilot project are Lessons learned<br />
<strong>and</strong> future perspectives <strong>of</strong> sustainable manure utilisation at the poultry industry, Case <strong>study</strong> <strong>of</strong> the Poultry<br />
Factory Primorskaya in the Leningrad Region; Preparation <strong>of</strong> manure processing investments on Poultry<br />
Farm Primorskaya; <strong>and</strong> A Comparative <strong>study</strong> <strong>of</strong> the <strong>technical</strong> solutions for conversion <strong>of</strong> chicken manure into<br />
fertilizer products at Poultry Farm Primorskaya in the Leningrad region. For more information on the<br />
project, please see:<br />
http://www.helcom.fi/projects/balthazar/en_GB/BALTHAZAR/
Table <strong>of</strong> contents<br />
1. Technology <strong>of</strong> granulated fertilizers production from chicken manure ............................... 3<br />
2. Analysis <strong>of</strong> existing <strong>technical</strong> <strong>and</strong> technological solutions <strong>of</strong> chicken manure <strong>drying</strong> <strong>and</strong><br />
<strong>granulation</strong> ........................................................................................................................... 4<br />
2.1. Proposal <strong>of</strong> “Eco Development” company .......................................................................................... 4<br />
2.2. Proposal <strong>of</strong> PromTechProject-SPb Ltd. .............................................................................................. 7<br />
3. Technological process <strong>of</strong> granulated fertilizers production proposed for PF Primorskaya . 8<br />
4. Technical <strong>and</strong> <strong>economic</strong> indices <strong>of</strong> manure processing by <strong>drying</strong> <strong>and</strong> <strong>granulation</strong> .......... 15<br />
Conclusions ............................................................................................................................. 18<br />
Appendix 1. Arrangement <strong>and</strong> specifications <strong>of</strong> equipment for chicken manure <strong>drying</strong><br />
<strong>and</strong> <strong>granulation</strong><br />
Appendix 2. 3D model <strong>of</strong> technological line for chicken manure <strong>drying</strong> <strong>and</strong> <strong>granulation</strong>
1. Technology <strong>of</strong> granulated fertilizers production from chicken manure<br />
Many companies <strong>of</strong>fer different <strong>drying</strong> <strong>and</strong> granulating technologies <strong>of</strong> chicken manure processing into<br />
organic fertilizers. But currently in Leningrad Oblast there are practically no examples <strong>of</strong> introduced <strong>and</strong><br />
full-scale operating technologies <strong>of</strong> the kind.<br />
The main benefit <strong>and</strong> attractiveness <strong>of</strong> manure <strong>drying</strong> is up to 70 % decrease <strong>of</strong> manure mass. Dried<br />
manure may be used as a fertilizer or fuel. The weak point <strong>of</strong> this technique is high nitrogen loss. Some<br />
companies, however, for example, “Razvitie Eco” (“Eco Development”), <strong>of</strong>fer equipment for <strong>drying</strong> manure<br />
with minimal loss <strong>of</strong> nutrients.<br />
Dried manure has low bulk density <strong>of</strong> 0.25 to 0.3 t/m 3 ; so large closed storages are needed if there are no<br />
steady sales <strong>of</strong> the ready product. Also dry manure h<strong>and</strong>ling involves adverse working conditions because <strong>of</strong><br />
a big amount <strong>of</strong> dust particles. To avoid these weak points the dry manure may be granulated. Today the<br />
market <strong>of</strong>fers a wide range <strong>of</strong> Russian <strong>and</strong> imported machinery for <strong>granulation</strong> <strong>of</strong> organic substances,<br />
including the dry manure. Granulated manure does not have so much dust; its bulk density is from 0.6 to<br />
0.65 t/m 3 ; so nearly twice smaller closed storing area is required.<br />
Granulated manure as an organic fertilizer is more suited for mechanical spot soil application.<br />
Combustion process <strong>of</strong> granulated manure is more efficient. Many poultry factories are interested in manure<br />
combustion because there is practically no stable target market <strong>of</strong> granulated manure, <strong>and</strong> special facilities<br />
are to be in place for its long term storing. But at the same time there are still no processing lines for<br />
industrial scale manure combustion.<br />
Table 1 presents the indices <strong>of</strong> poultry manure mass <strong>and</strong> volume variation during <strong>drying</strong>, <strong>granulation</strong><br />
<strong>and</strong> combustion.<br />
Table 1. Manure mass <strong>and</strong> required storing capacity variation<br />
Mass in % <strong>of</strong> raw manure Capacity needed for storing <strong>of</strong> 1<br />
ton <strong>of</strong> poultry manure, m 3<br />
Raw manure<br />
(70 % moisture content)<br />
100 1.5<br />
Dried manure 35 4<br />
Granulated manure 35 1.5<br />
Ash (after combustion) 3.5 5<br />
According to the above indices Table 2 presents manure mass variation on PF Primorskaya <strong>and</strong> the<br />
capacity <strong>of</strong> additional facilities needed for storing the ready product.<br />
Table 2. Variation <strong>of</strong> manure mass <strong>and</strong> required capacity for 1 month storing on PF Primorskaya<br />
Mass, t Minimal useful storing capacity, m 3 , no<br />
less than<br />
Raw manure<br />
(70 % moisture content)<br />
80 ~3600 (waterpro<strong>of</strong> ground <strong>of</strong> 1600 m 2 )<br />
Dried manure 27 3240 (storehouse)<br />
Granulated manure 27 1215 (storehouse)<br />
Ash (after combustion) 3 450 (storehouse)<br />
According to Table 2, it seems quite reasonable to granulate the poultry manure: the required storehouse<br />
area is 2.5 times lower than that needed for dry non-granulated manure. In terms <strong>of</strong> lowering the chicken<br />
manure mass the combustion seems very promising, but additional detailed examination is needed,<br />
especially for environmental safety reasons (emissions).
2. Analysis <strong>of</strong> available <strong>technical</strong> <strong>and</strong> technological solutions <strong>of</strong> poultry<br />
manure <strong>drying</strong> <strong>and</strong> <strong>granulation</strong><br />
SZNIIMESH has been investigating poultry manure <strong>drying</strong> <strong>and</strong> granulating processes since 2000.<br />
Investigation results show that <strong>drying</strong> is a sort <strong>of</strong> challenge in manure processing in terms <strong>of</strong> costs <strong>and</strong><br />
availability <strong>of</strong> suitable equipment. Drying costs may account for above 50 % <strong>of</strong> the final product self cost.<br />
There is no problem in choosing conveyors, granulators, <strong>and</strong> packing machines, which are <strong>of</strong>fered by<br />
different manufacturing companies, while manure <strong>drying</strong> devices are not readily available. That is why<br />
existing methods <strong>and</strong> equipment for manure <strong>drying</strong> have been analyzed in the first place. The processing<br />
line has been designed on the basis <strong>of</strong> available information on machines <strong>and</strong> equipment.<br />
2.1. Proposal <strong>of</strong> Eco Development Company<br />
“Eco Development” Engineering Company was founded in 2006. It is located in Moscow, Ryazanskiy<br />
Avenue, 8-a. Tel: +7 (495) 643-06-81, web-site: www.pometa.net<br />
The company’s pr<strong>of</strong>ile is development <strong>and</strong> introduction <strong>of</strong> VacuumEcoDry technology <strong>of</strong> the vacuum<br />
<strong>drying</strong> <strong>of</strong> organic waste.<br />
Short description <strong>of</strong> the process<br />
VacuumEcoDry is a separation process <strong>of</strong> raw material with up to 99 % moisture content under the<br />
temperature range from 40 to 90 °C <strong>and</strong> the pressure range from 30 to 250 mm Hg. The raw material is first<br />
loaded into the receiving hopper <strong>and</strong> then into the vacuum <strong>drying</strong> chamber. The loading system feeds the<br />
raw material in the quantities, which are strictly adjusted to the productivity <strong>of</strong> equipment. In the process <strong>of</strong><br />
<strong>drying</strong> the raw material moves on the conveyors through the heat exchangers. During the heating the<br />
material boils <strong>and</strong> separates into three fractions:<br />
1. Dry organic substance, which may be used without any additional treatment as a fertilizer, or<br />
protein feed additive for cattle <strong>and</strong> poultry, or fuel.<br />
2. Usable <strong>technical</strong> (recycled) water<br />
3. Environmentally safe emission<br />
The blank drawing <strong>of</strong> the processing line with the VacuumEcoDry technology is shown on Figure<br />
1.
Dry cooling tower Vacuum unit<br />
Loading system<br />
Unloading<br />
complex<br />
Figure 1. Processing line with the VacuumEcoDry technology (top view)<br />
Technical specifications <strong>and</strong> capital costs <strong>of</strong> equipment are presented in Tables 3 <strong>and</strong> 4<br />
Table. 3. Technical specifications (according to the data provided by equipment manufacturer)<br />
Index Unit Value<br />
Throughput t/day 100<br />
Output capacity t/day 35<br />
Operation type Continuous<br />
Operation temperature<br />
Condensate accumulation<br />
tanks, condensate drain<br />
block<br />
Granulation line<br />
(option)<br />
o С 5090<br />
Installed electric power kW 300<br />
Installed heat power kW 2,500<br />
Required space m 2 300<br />
Required building height m 6<br />
Nutrients loss % 0<br />
Run-<strong>of</strong>fs m 3 /day 0<br />
Service employees per shift man 2<br />
Vacuum work<br />
chamber<br />
Packing line
Table. 4. Cost <strong>of</strong> equipment<br />
Equipment Cost, roubles Cost, €<br />
Set <strong>of</strong> equipment for a mini-factory<br />
44,850,000 1,121,250<br />
System for crushing <strong>of</strong> raw material<br />
VacuumEcoDry <strong>drying</strong><br />
System for final product unloading<br />
Management terminal<br />
Video monitoring system<br />
The mini-factory includes back-up devices <strong>of</strong> the product main<br />
loading <strong>and</strong> unloading units.<br />
Granulation <strong>and</strong> packing line<br />
Mixer<br />
Magnetic separator<br />
Granulator<br />
Granules (pellets) cooler<br />
Cyclone separator<br />
Semi-automatic packing unit<br />
Boiler-house<br />
Water conditioning system<br />
Boiler<br />
Burner<br />
Accessories (sensors, fittings)<br />
5,000,000<br />
(the cost varies<br />
with<br />
manufacturers<br />
<strong>and</strong> is agreed<br />
upon in every<br />
particular case)<br />
4,000,000–<br />
6,000,000<br />
(the cost is<br />
agreed upon<br />
separately)<br />
125,000<br />
100,000–<br />
150,000<br />
Total 54,850,000 1,371,250<br />
In February, 2011, A. Bryukhanov, an expert from SZNIIMESH, together with Technical Director <strong>of</strong><br />
PF Primorskaya M. A. Smirnov had negotiations with the head <strong>of</strong> «Eco Development». A trip was<br />
scheduled to the place, where the described technology had been implemented. But further discussions <strong>and</strong><br />
more thorough analysis <strong>of</strong> available information showed that the company <strong>of</strong>fered only the design. They<br />
could show only a demonstration model (Figure 3) with much smaller productivity than required. The<br />
vacuum dryer had no Certificate <strong>of</strong> Compliance.<br />
Figure 3. Demonstration model <strong>of</strong> the vacuum dryer.<br />
Therefore, in spite <strong>of</strong> good characteristics <strong>of</strong> the <strong>of</strong>fered solution, its industrial scale introduction is a<br />
certain risk for PF Primorskaya.
2.2. Proposal <strong>of</strong> PromTechProject-SPb Ltd.<br />
PromTechProject-SPb Ltd. is located in Saint-Petersburg, Kolpino, Finl<strong>and</strong>skaya street, 34.<br />
Fax: +7 (812) 460-77-67, web-site: www.ptpspb.narod.ru.<br />
The company’s pr<strong>of</strong>ile is engineering solutions <strong>and</strong> development <strong>of</strong> accessories for upgrading the operating<br />
equipment at the enterprises; procurement <strong>of</strong> complete equipment; modernization <strong>of</strong> operating plants <strong>and</strong><br />
industrial enterprises; installation, repair, checkout <strong>and</strong> maintenance <strong>of</strong> processing lines <strong>and</strong> equipment;<br />
development <strong>and</strong> manufacturing <strong>of</strong> non-st<strong>and</strong>ard equipment.<br />
Experts <strong>of</strong> PromTechProject-SPb Ltd. have certain experience in designing, manufacturing <strong>and</strong> introduction<br />
<strong>of</strong> <strong>drying</strong> equipment for organic components (Figure 4).<br />
Figure 4. Drying cylinders manufactured by PromTechProject-SPb Ltd.<br />
For chicken manure <strong>drying</strong> PromTechProject-SPb Ltd. can manufacture a <strong>drying</strong> cylinder with a <strong>technical</strong><strong>and</strong>-operation<br />
data card <strong>and</strong> Certificate <strong>of</strong> Conformity, which are required for the project documentation to<br />
pass the state examination. Experts <strong>of</strong> PromTechProject-SPb Ltd. together with representatives <strong>of</strong> Bioklad<br />
Ltd. Company <strong>and</strong> SZNIIMESH have designed the production scheme <strong>of</strong> granulated poultry manure (Figure<br />
5). Detailed arrangement <strong>of</strong> equipment for PF Primorskaya is presented in Appendix 1. PromTechProject-<br />
SPb Ltd. can also manufacture a prototype model <strong>of</strong> installation for combustion <strong>of</strong> a part <strong>of</strong> produced<br />
granulated manure to lower the <strong>drying</strong> costs. To dry all the amount <strong>of</strong> poultry manure, which is loaded into<br />
the <strong>drying</strong> chamber, about 40 % <strong>of</strong> dry manure is to be combusted.
Drying cylinder<br />
Heat generator<br />
Conveyor to take<br />
granules to combustion<br />
chamber<br />
Mixer hopper<br />
Granules packing<br />
Vibroscreen + granules<br />
cooler<br />
Granulator<br />
Figure 5. Production scheme <strong>of</strong> granulated poultry manure<br />
Some other companies, such as “Chicken Brothers Technology”, “Wood Innovative Technologies”<br />
<strong>and</strong> “Poly-Nom”, <strong>of</strong>fer similar technological <strong>and</strong> <strong>technical</strong> solutions <strong>and</strong> they are also ready to manufacture<br />
<strong>and</strong> supply the equipment for <strong>drying</strong> the chicken manure, for production <strong>and</strong> combustion <strong>of</strong> chicken manure<br />
granules. Description <strong>of</strong> technology is much similar to that <strong>of</strong>fered by PromTechProject-SPb Ltd.<br />
After the <strong>study</strong> <strong>of</strong> the above <strong>of</strong>fers in terms <strong>of</strong> availability <strong>of</strong> required documents, <strong>of</strong>f the shelf<br />
equipment or some parts <strong>of</strong> equipment, the technology <strong>of</strong> manure cylinder <strong>drying</strong> <strong>and</strong> <strong>granulation</strong> was<br />
selected for detailed consideration. The technological, <strong>technical</strong> <strong>and</strong> <strong>economic</strong> indices provided by<br />
PromTechProject-SPb Ltd. were taken as a basis. In industrial facilities <strong>of</strong> this company an experimental<br />
model <strong>of</strong> the technological line for chicken manure processing into organic fertilizers by <strong>drying</strong> <strong>and</strong><br />
<strong>granulation</strong> may be also manufactured.<br />
3. Technological process <strong>of</strong> granulated fertilizers production proposed<br />
for PF Primorskaya<br />
Total manure mass is about 80 t/day. Under the volume density <strong>of</strong> 0.6–0.7 t/m 3 the daily manure<br />
volume is from 114 to 133 m 3 , correspondingly. Manure with 0,6 t/m 3 density <strong>and</strong> the daily output <strong>of</strong> 133<br />
m 3 is taken for technological calculation.<br />
27 t <strong>of</strong> granulated organic fertilizers may be produced from 80 t daily output <strong>of</strong> chicken manure. The<br />
sequence <strong>of</strong> technological operations with corresponding equipment is presented in Appendix 1. The<br />
references to the equipment are given in the text below, for example, pos. 1 - the feeding bin <strong>of</strong> raw manure.<br />
Manure is transported to the asphalted ground in front <strong>of</strong> the building, where <strong>drying</strong> <strong>and</strong> <strong>granulation</strong><br />
takes place, by available vehicles (KamAZ 6250 (6×4) type). ТО-28А “Amkodor” loader equipped with SM<br />
4-23 ALLU bucket transports, crushes <strong>and</strong> loads manure into the feeding bin <strong>of</strong> 9 m 3 capacity (pos. 1),<br />
which is located at the end wall <strong>of</strong> the building. The feeding bin is an upgraded box <strong>of</strong> manure spreader<br />
ПРТ-10 (Appendix 1). Work tools <strong>of</strong> ПРТ-10 are driven by an electrical engine fed from electricity<br />
network.
No. Type <strong>of</strong> operation Model<br />
1<br />
Constant volume<br />
supply <strong>of</strong> manure<br />
Table 5. Specifications <strong>of</strong> receiving <strong>and</strong> feeding bin for raw manure<br />
Number<br />
<strong>of</strong> units<br />
Throughput, t/h<br />
Installed power,<br />
kW<br />
ПРТ-10 1 4 7<br />
From the feeding bin the manure is taken by УКВ 106 conveyor (pos. 2) to the <strong>drying</strong> cylinder with<br />
the heat exchanger manufactured by PromTechProject-SPb Ltd., where the moisture is removed. To process<br />
80 t <strong>of</strong> manure two <strong>drying</strong> cylinders are required (pos. 4) with the overall throughput <strong>of</strong> 4 t/h by the raw<br />
manure (2 t/h for every cylinder). Consequently, twenty hours operating mode should be set for this<br />
equipment.<br />
No. Type <strong>of</strong> operation Model<br />
2<br />
Manure loading<br />
from the feeding<br />
bin to the <strong>drying</strong><br />
cylinder<br />
Table 6. Specifications <strong>of</strong> raw manure conveyor<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power,<br />
kW<br />
УКВ-106 2 6 4.4<br />
Table 7. Specifications <strong>of</strong> the <strong>drying</strong> cylinder with the heat exchanger manufactured by<br />
PromTechProject-SPb Ltd.<br />
No. Type <strong>of</strong> operation Model<br />
4<br />
Manure <strong>drying</strong> to<br />
10 to12 % <strong>of</strong><br />
moisture content<br />
АСЗ-5-4 <strong>drying</strong><br />
cylinder<br />
Number <strong>of</strong><br />
units<br />
Throughput,<br />
t/h<br />
Installed power,<br />
kW<br />
2 4 100<br />
To dry the chicken manure the air heated to 200 °C is supplied to the cylinder. Diesel heat-generator<br />
(pos. 3) is used to heat the air as there is no gas supply on the poultry factory.<br />
No. Type <strong>of</strong> operation Model<br />
3<br />
Air heating <strong>and</strong><br />
hot air supply to<br />
the <strong>drying</strong><br />
cylinder<br />
Table 8. Specifications <strong>of</strong> the diesel heat-generator<br />
Number <strong>of</strong><br />
units<br />
Heat<br />
generating<br />
capacity,<br />
MW/h<br />
Diesel fuel consumption,<br />
L/h<br />
2 8 400<br />
The heat is generated by diesel fuel combustion.<br />
Another option is to use granulated manure as a fuel. In this case around 40 % <strong>of</strong> produced granulated<br />
manure is to be combusted. This technology has not been applied in large scale before, <strong>and</strong> additional <strong>study</strong><br />
is needed. The <strong>economic</strong> effect <strong>of</strong> this option may be rather high as shown in Item 4 below.<br />
The manure mass after <strong>drying</strong> m cn with 12 % moisture content that meets technological requirements to<br />
granulated manure is defined by the formula:
( 100 Wn<br />
) mn<br />
mcn<br />
<br />
, kg<br />
100 Wcn<br />
( 100 70)<br />
2000<br />
m cn <br />
681,<br />
81 kg,<br />
100 12<br />
where W n is raw manure moisture, W n = 70 %<br />
Wcn is dried manure moisture, W cn = 12 %.<br />
m is raw manure mass.<br />
n<br />
The output <strong>of</strong> every <strong>drying</strong> cylinder is 0.682 t/h <strong>of</strong> manure with 12 % moisture content. The total<br />
output <strong>of</strong> two cylinders is 1,36 t/h.<br />
After having been dried the chicken manure is taken to the mixer hopper (pos. 5), where other<br />
necessary mineral or biological components are simultaneously supplied by the screw feeder УКП-106 (pos.<br />
6). The components are added to produce the complex organic <strong>and</strong> mineral fertilizers with different<br />
nutrients <strong>and</strong> microelements content required by particular crops.<br />
No. Type <strong>of</strong> operation Model<br />
5<br />
Uniform mixing <strong>of</strong> dry<br />
manure with other<br />
required components<br />
No. Type <strong>of</strong> operation Model<br />
6<br />
Dosed supply <strong>of</strong><br />
required components to<br />
the mixer hopper<br />
Table 9. Specifications <strong>of</strong> mixer hopper<br />
Number<br />
<strong>of</strong> units<br />
Throughput, t/h<br />
Installed power,<br />
kW<br />
1 3 2.2<br />
Table 10. Specifications <strong>of</strong> a screw feeder <strong>of</strong> additives<br />
Number <strong>of</strong><br />
units<br />
Throughput, t/h<br />
Installed power,<br />
kW<br />
УКП-106 1 0,2-3 2.2<br />
In the mixer hopper (pos. 5) the homogeneous substance is produced, which is taken by LM/LG-60<br />
conveyor (pos. 7) to the bin <strong>of</strong> ОГМ-6 press-granulator (pos. 8). The substance is pressed through the holes<br />
<strong>of</strong> the press-granulator matrix <strong>and</strong> then cut <strong>of</strong>f by the shear mechanism. As a result granules with required<br />
physical <strong>and</strong> granulometric parameters (density, length, diameter, etc.) are formed. It is possible to produce<br />
granules with the diameter <strong>of</strong> 6, 8 <strong>and</strong> 10 mm.<br />
No. Type <strong>of</strong> operation Model<br />
7<br />
Supply <strong>of</strong><br />
material from the<br />
mixer hopper to<br />
the pressgranulator<br />
bin<br />
Table 11. Specifications <strong>of</strong> granulator loading conveyor<br />
Number<br />
<strong>of</strong> units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
ЛМ/ЛГ-60 2 6 3
No. Type <strong>of</strong> operation Model<br />
8<br />
Manure<br />
<strong>granulation</strong><br />
Table 12. Specifications ОГМ - 6 press-granulator<br />
Number<br />
<strong>of</strong> units<br />
Throughput,<br />
t/h<br />
Installed power, kW<br />
ОГМ-6 2 3 156<br />
Produced warm granules are taken by the conveyor (pos. 9) to the vibro-screen (pos. 11), where<br />
shapeless granules are sorted out <strong>and</strong> removed by special conveyor (pos. 10).<br />
No. Type <strong>of</strong> operation Model<br />
9<br />
Supply <strong>of</strong> warm<br />
granules from<br />
press-granulator<br />
to vibroscreen<br />
No. Type <strong>of</strong> operation Model<br />
11<br />
Sorting out <strong>of</strong><br />
granules to<br />
comply with<br />
specified<br />
requirements<br />
Table 13. Specifications <strong>of</strong> conveyor<br />
Number<br />
<strong>of</strong> units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
УКВ-106 1 3 2.2<br />
Table 14. Specifications <strong>of</strong> vibroscreen<br />
Number<br />
<strong>of</strong> units<br />
Throughput,<br />
t/h<br />
Installed power, kW<br />
1 3 2.2<br />
After the vibroscreen the granules, which meet the size requirements, are taken by the conveyor (pos. 12) to<br />
the enrichment chamber (pos. 13), where bacteria spores are added. This step is optional for the technology.<br />
No. Type <strong>of</strong> operation Model<br />
12<br />
Transfer <strong>of</strong><br />
granules from the<br />
vibroscreen to the<br />
enrichment<br />
chamber<br />
No. Type <strong>of</strong> operation Model<br />
13<br />
Enrichment <strong>of</strong><br />
granules with<br />
useful bacteria<br />
Table 15. Specifications <strong>of</strong> enrichment chamber conveyor<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
ЛМ/ЛГ-60 1 3 2.2<br />
Table 16. Enrichment chamber specifications<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
1 2 3.6<br />
By the conveyor (pos. 14) the granules are taken to the cooler, where they are cooled by cold air<br />
flow, harden <strong>and</strong> obtain the required strength properties.
Table 17. Specifications <strong>of</strong> the conveyor for granules supply to the cooling chamber<br />
No. Type <strong>of</strong> operation Model<br />
14<br />
Granules supply<br />
to the cooling<br />
chamber<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
ЛМ/ЛГ-60 1 3 2.2<br />
Table 18. Cooling chamber specifications<br />
No. Type <strong>of</strong> operation Model<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
15 Granules cooling 1 3 2.2<br />
Conveyor (pos. 16) transfers the dry (11 to 20 % moisture content) <strong>and</strong> enriched with bacteria product<br />
from the cooling chamber to the final product bin. After that the product is packed into bags <strong>of</strong> different<br />
volume.<br />
Table 19. Specifications <strong>of</strong> the loading conveyor to the final product bin<br />
No. Type <strong>of</strong> operation Model<br />
18<br />
Granules supply<br />
from the cooling<br />
chamber to the<br />
final product bin<br />
No. Type <strong>of</strong> operation Model<br />
19<br />
The final product<br />
storage <strong>and</strong><br />
packing<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
ЛМ/ЛГ-60 1 3 2.2<br />
Table 20. Specifications <strong>of</strong> the final product bin<br />
Number <strong>of</strong><br />
units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
«Delta-С» 1 2 2.2<br />
The full set <strong>of</strong> equipment is presented in Summary Table 21.
Summary Table 21<br />
No Technical device Operation Model<br />
1<br />
Receiving <strong>and</strong> feeding bin for raw<br />
manure<br />
Number<br />
<strong>of</strong> units<br />
Productivity,<br />
t/h<br />
Installed power, kW<br />
Constant volume supply <strong>of</strong> manure ПРТ – 10 1 4 7<br />
2 Raw manure conveyor<br />
Manure loading from the feeding bin to the <strong>drying</strong><br />
cylinder<br />
УКВ-106 2 6 4.4<br />
3 Heat generator Air heating <strong>and</strong> hot air supply to the <strong>drying</strong> cylinder 2 2<br />
4<br />
Drying cylinder with a heat<br />
exchanger<br />
Manure <strong>drying</strong> to 10 to12 % moisture content<br />
АСЗ-5-4 <strong>drying</strong><br />
cylinder<br />
2 4 100<br />
5 Mixer hopper Uniform mixing <strong>of</strong> dry manure with required components 1 3 2.2<br />
6 Screw feeder <strong>of</strong> additives<br />
Dosed supply <strong>of</strong> required components to the mixer<br />
hopper<br />
УКП-106 1 0.2–3 2.2<br />
7 Granulator loading conveyor<br />
Supply <strong>of</strong> material from the mixer hopper to the<br />
press-granulator bin<br />
ЛМ/ЛГ-60 2 6 3<br />
8 Press-granulator Manure <strong>granulation</strong> ОГМ – 6 2 3 156<br />
9<br />
Conveyor to take the granules to the<br />
vibroscreen<br />
Supply <strong>of</strong> warm granules from press-granulator to<br />
vibroscreen<br />
УКВ-106 1 3 2.2<br />
10<br />
Conveyor to remove the shapeless<br />
granules<br />
To remove the shapeless granules from vibroscreen УКП-106 1 0.2–3 2.2<br />
11 Vibroscreen<br />
Sorting out <strong>of</strong> granules to comply with specified<br />
requirements<br />
1 3 2.2<br />
12 Enrichment chamber conveyor<br />
Transfer <strong>of</strong> granules from the vibroscreen to the<br />
enrichment chamber<br />
ЛМ/ЛГ-60 1 3 2.2<br />
13 Enrichment chamber Enrichments <strong>of</strong> granules with useful bacteria 1 3 2.2<br />
14<br />
Loading conveyor <strong>of</strong> the cooling<br />
chamber<br />
Supply <strong>of</strong> granules from the enrichment chamber to<br />
the cooling chamber<br />
ЛМ/ЛГ-60 1 3 3.6<br />
15 Granules cooler Granules cooling 1 2 2.2<br />
16<br />
Conveyor <strong>of</strong> the accumulation bin <strong>of</strong><br />
the final product packing<br />
Supply the granules from the cooler to the<br />
accumulation bin <strong>of</strong> the final product packing<br />
ЛМ/ЛГ-60 1 3 2.2<br />
17<br />
The final product bin + packing<br />
machine<br />
Final product storing <strong>and</strong> packing<br />
“Delta-С” 1 2 2.2<br />
18 Tipping truck<br />
Transportation <strong>of</strong> manure from the chicken house to<br />
the temporary storing ground<br />
KamAZ 6250<br />
(6×4)<br />
ТО-28А<br />
1 16<br />
19 Loader<br />
Manure crushing <strong>and</strong> loading from the temporary<br />
storing ground to the feeding bin<br />
“Amkodor” loader<br />
equipped with SM<br />
4-23 ALLU busket<br />
1 25<br />
Total 298
No. Technological<br />
operation<br />
1 Manure<br />
transportation<br />
to the<br />
mixing place<br />
3 Organic<br />
components<br />
crushing <strong>and</strong><br />
loading to<br />
the mixer<br />
hopper<br />
Table 22. Required number <strong>of</strong> mobile machinery<br />
Type <strong>of</strong> machinery Productivi<br />
Tractor Teamed ty, t/h<br />
(vehicle) unit<br />
KamAZ<br />
6520<br />
(6х4)<br />
ТО-28А<br />
loader<br />
equipped<br />
with SM<br />
4-23<br />
busket<br />
Output at<br />
8/10hours<br />
shift, t<br />
Number<br />
<strong>of</strong> shifts<br />
per day<br />
Volume <strong>of</strong><br />
work,<br />
t/day<br />
Transportationdistance,<br />
km<br />
Number<br />
<strong>of</strong><br />
required<br />
machinery<br />
(under<br />
8/10hours<br />
shift)<br />
- 16 112/144 2 80 0.5 0.71/0.55<br />
- 25 175/225 2 80 - 0.91/0.71<br />
4. Technical <strong>and</strong> <strong>economic</strong> indices<br />
<strong>of</strong> manure processing by <strong>drying</strong> <strong>and</strong> <strong>granulation</strong><br />
Technical <strong>and</strong> <strong>economic</strong> indices <strong>of</strong> manure processing by <strong>drying</strong> <strong>and</strong> <strong>granulation</strong> are presented in<br />
Table 23.<br />
Table 23. Technical <strong>and</strong> <strong>economic</strong> indices <strong>of</strong> manure processing by <strong>drying</strong> <strong>and</strong> <strong>granulation</strong><br />
per 1 ton <strong>of</strong> granulated manure<br />
No<br />
.<br />
Technical <strong>and</strong> <strong>economic</strong> indices Units Value Cost,<br />
rouble/t<br />
1. Production capacity t/year 9855<br />
2. Time to process 4 t <strong>of</strong> raw manure min 60<br />
3. Daily production output t 27<br />
4. Final production output for 1 hour cycle t 1.36<br />
5. Inputs per 1 ton <strong>of</strong> granulated manure<br />
- labor<br />
- electric power (with due account <strong>of</strong><br />
actual operation <strong>of</strong> equipment)<br />
- diesel fuel for vehicles<br />
- diesel fuel for a diesel generator<br />
6. Required electric power supply<br />
network capacity<br />
5. Number <strong>of</strong> drivers <strong>and</strong> operators per<br />
shift<br />
man-hour/t<br />
kWh/t<br />
L/t<br />
L/t<br />
1.4<br />
49.7<br />
4.4<br />
296<br />
kW ~300<br />
man 4<br />
140<br />
198<br />
88<br />
5920<br />
Cost,<br />
€/t<br />
Following per unit indicators were used in calculations: staff compensation – 2.5 €/h; price <strong>of</strong> electric<br />
energy – 0.1 €/kWh; price <strong>of</strong> diesel fuel – 0.5 €/L.<br />
3.5<br />
4.95<br />
4.4<br />
148
Capital costs have been calculated on the basis <strong>of</strong> the preliminary quotation <strong>of</strong> PromTechProject-SPb<br />
Ltd. <strong>and</strong> information on the similar equipment from other manufacturers.<br />
Table 24. Capital costs <strong>of</strong> equipment <strong>and</strong> machinery<br />
Price with Price, €<br />
No. Technical device Model Number <strong>of</strong> units<br />
VAT,<br />
thous<strong>and</strong><br />
roubles<br />
1<br />
Receiving <strong>and</strong> feeding bin for raw<br />
manure<br />
ПРТ – 10 1<br />
380 9500<br />
2<br />
Raw manure conveyor (to load the <strong>drying</strong><br />
cylinder)<br />
УКВ-106 2<br />
700 17500<br />
3 Heat generator 2 1760 44000<br />
4 Drying cylinder with a heat exchanger<br />
АСЗ-5-4 <strong>drying</strong><br />
cylinder<br />
2<br />
3400 85000<br />
5 Mixer hopper 1 485 12125<br />
6 Screw feeder <strong>of</strong> additives УКП-106 1 375 9375<br />
7 Granulator loading conveyor ЛМ/ЛГ-60 2 500 12500<br />
8 Press-granulator ОГМ – 6 2 3080 77000<br />
9<br />
Conveyor to take the granules to the<br />
vibroscreen<br />
УКВ-106<br />
(shortened)<br />
1<br />
245 6125<br />
10<br />
Conveyor to remove the shapeless<br />
granules<br />
УКП-106<br />
(shortened)<br />
1<br />
220 5500<br />
11 Vibroscreen 1 160 4000<br />
12 Enrichment chamber conveyor ЛМ/ЛГ-60 1 250 6250<br />
13 Enrichment chamber 1 200 5000<br />
14 Cooling chamber loading conveyor ЛМ/ЛГ-60 1 250 6250<br />
15 Granules cooler 1 290 7250<br />
16<br />
Conveyor <strong>of</strong> the accumulation bin <strong>of</strong> the<br />
final product packing<br />
ЛМ/ЛГ-60 1<br />
250 6250<br />
17 Final product bin + packing machine «Delta-С» 1 340 8500<br />
18<br />
KamAZ 6520 (6×4) vehicle KamAZ 6250<br />
(6×4)<br />
1<br />
2300 57500<br />
ТО-28А loader + SM 4-23 busket ТО-28А<br />
“Amkodor”<br />
19<br />
loader equipped<br />
with SM 4-23<br />
1<br />
“Allu” busket<br />
6100 152500<br />
TOTAL 21285 532125<br />
To accommodate the processing line a facility with the area <strong>of</strong> 300 m 2 <strong>and</strong> the height <strong>of</strong> 5 m is<br />
required. Accommodation cost will be about 5,250,000 roubles or € 131,250.<br />
The storehouse cost for the month’s output <strong>of</strong> granulated manure will be around 4,000,000<br />
roubles or € 100,000.<br />
Total capital costs will amount to:<br />
construction € 231 250<br />
Equipment <strong>and</strong> machinery € 532 125<br />
When calculating the self cost, the following charges should be taken into account: 2 %<br />
depreciation for construction part <strong>and</strong> 10 % depreciation for equipment <strong>and</strong> machinery; equipment<br />
maintenance <strong>and</strong> service – 9.3 %. Calculation <strong>of</strong> the granulated manure self cost is presented in Table<br />
25.
Table 25. Calculation <strong>of</strong> the granulated manure self cost under production capacity <strong>of</strong> 9855 tons<br />
per year<br />
No. Cost elements Value, €/y<br />
1 Allowance for depreciation:<br />
construction part<br />
equipment <strong>and</strong> machinery<br />
4625<br />
53,212.5<br />
2 Maintenance <strong>and</strong> service 49,487.6<br />
3 Labor 48,000<br />
4 Electricity 49,275<br />
5 Diesel fuel 1,480,221<br />
6 Total <strong>of</strong> operating costs 1,626,983.6<br />
7 Self cost <strong>of</strong> 1 ton <strong>of</strong> granulated manure 171<br />
As stated above the self cost may be cut by combustion <strong>of</strong> a part <strong>of</strong> granulated manure to produce<br />
the heat for raw manure <strong>drying</strong>. To provide the heat for the <strong>drying</strong> cylinder, 40 % <strong>of</strong> the dry granulated<br />
manure should be burned.<br />
In spite <strong>of</strong> somewhat higher total capital costs:<br />
Construction part € 256 250<br />
Equipment <strong>and</strong> machinery € 607 125<br />
the granulated manure self cost will be four times lower (Table 26).<br />
Table 26. Calculation <strong>of</strong> granulated manure self cost under production capacity<br />
<strong>of</strong> 5913 tons per year<br />
No. Cost elements Value, € / y<br />
1 Allowance for depreciation:<br />
construction part<br />
equipment <strong>and</strong> machinery<br />
5125<br />
60712<br />
2 Maintenance <strong>and</strong> service 56463<br />
3 Labor 60000<br />
4 Electricity 49 275<br />
5 Diesel fuel 22000<br />
6 Total <strong>of</strong> operating costs 187738<br />
7 Self cost <strong>of</strong> 1 ton <strong>of</strong> granulated manure 43
Conclusions<br />
1. Manure <strong>drying</strong> <strong>and</strong> <strong>granulation</strong> technologies appeared more than 10 years ago <strong>and</strong> now it is<br />
possible to find many different options. But this technology has not been applied in an industrial<br />
scale because <strong>of</strong> high costs, operational ones in the first place. For poultry factories the main<br />
benefit <strong>of</strong> <strong>drying</strong> <strong>and</strong> <strong>granulation</strong> technology is in substantial decrease <strong>of</strong> produced manure<br />
mass <strong>and</strong> in production <strong>of</strong> a marketable product – a “presentable” odorless organic fertilizer. It<br />
should be understood, however, that it is manure mass, which decreases during the <strong>drying</strong> <strong>and</strong><br />
not the volume. That is why in case <strong>of</strong> poor year-round sales the facilities for dried manure<br />
storing should be provided. Different <strong>technical</strong> <strong>and</strong> technological innovations are <strong>of</strong>fered to<br />
increase the efficiency <strong>of</strong> manure processing technology <strong>and</strong> decrease the power inputs. But few<br />
proposals have been developed on the adequate <strong>technical</strong>, engineering <strong>and</strong> <strong>economic</strong> level <strong>and</strong><br />
actually introduced in large-scale production.<br />
2. The most cost-intensive part <strong>of</strong> the technology under consideration is manure <strong>drying</strong> prior to<br />
<strong>granulation</strong>. Investigations show that currently only cylinder-type <strong>drying</strong> installations are<br />
available on the market to be applied in large-scale animal <strong>and</strong> poultry production.<br />
3. Drying costs depend on the sources <strong>of</strong> heat for <strong>drying</strong> cylinders. Calculations have shown that<br />
in case <strong>of</strong> a diesel heat generator, the <strong>drying</strong> costs account for 85 % <strong>of</strong> the total operating costs.<br />
The <strong>drying</strong> costs may be twice lower in case <strong>of</strong> a heat generator on natural gas <strong>and</strong> almost four<br />
times lower in case a part <strong>of</strong> granulated manure is used as fuel.<br />
4. Manure processing into the granules is most reasonable if they are (1) further used for spot<br />
organic fertilizing (this is especially topical in the southern areas <strong>of</strong> the country, where vast<br />
arable l<strong>and</strong>s are found); (2) sold through commercial network (in view <strong>of</strong> their “attractive”<br />
appearance); (3) used as fuel in boilers.<br />
5. The above calculations should be regarded as approximate. By preliminary estimates the overall<br />
capital costs may grow up twice, first <strong>of</strong> all, because all the required documents concerning the<br />
technology should be prepared to be included in the design <strong>and</strong> estimate documentation for the<br />
state examination. Besides the costs <strong>of</strong> required service media have not been included in the<br />
calculations.