technical and economic study of drying and granulation of ... - Helcom

BALTHAZAR Pilot Project Report
TECHNICAL AND ECONOMIC STUDY OF
DRYING AND GRANULATION OF CHICKEN
MANURE AT PRIMORSKAYA POULTRY FACTORY
This project is carried out with
funding from the European Union
Towards enhanced protection of the Baltic Sea from
mainland-based threats: Reducing agricultural nutrient
loading and risk of hazardous wastes
Helsinki Commission
(Baltic Marine Environment Protection Commission)
Katajanokanlaituri 6 B, 00160 Helsinki
Phone: +358-207-412 649; Fax: +358-207-412 645
www.helcom.fi
Saint-Petersburg Public Organization
“Ecology and Business”
Post office box 66, RU-197342 St. Petersburg, Russia
Phone: +7-812-430 6860; Fax: +7-812-430 9305;
www.helcom.ru

Baltic Hazardous and Agricultural Releases Reduction
BALTHAZAR - project 2009-2012
Towards enhanced protection of the Baltic Sea from main land-based threats: reducing
agricultural nutrient loading and the risk of hazardous wastes
The BALTHAZAR project promotes the protection of the Baltic Sea from both hazardous waste and
agricultural nutrient loading with activities in the Russian Federation. The activities contribute to the
achievement of the environmental objectives of the HELCOM Baltic Sea Action Plan through providing
assistance to the development of national action plans and prioritization of necessary measures to tackle the
harmful hazardous substances and eutrophication segments. In particular, the project aims improving the
management of hazardous and agricultural wastes focusing exclusively on St. Petersburg, Leningrad and
Kaliningrad Oblasts of the Russian Federation.
The target group includes relevant Russian federal, regional and municipal authorities within the above
territories, as well as the stakeholders of the territorial departments and committees for environmental
protection, agriculture, and water resources. Moreover, authorities, industrial (waste-generating and waste
management) and agricultural companies, scientific organisations, environmental NGOs and the general
public awareness are the focal points of this project.
The project has been running from February 2009 and is expected to finish by March 2012. It is enabled by
a 3.5 Million Euro grant from the European Parliament Pilot Project Facility, through the European
Commission Delegation in Moscow. The Project is managed by the Project Implementation Unit (PIU)
established in the HELCOM Secretariat together with a Russian Partner Ecology and Business, the Russian
St. Petersburg Public Organisation with the help of individually selected consultant consortiums for specific
tasks in the two thematic areas of the project.
As a result of the first stage of the project, several pilot project proposals were developed for both regions
within the two components. The following 4 pilot projects selected by the Project Steering Group in March
2010 have been carried out in Phase I of the Balthazar project:
Agriculture pilots
1. Feasibility study and detailed plan for investment in technique for conversion of chicken manure into
fertilizer products on Poultry Farm Primorskaya, Leningrad Region
2. Manure management strategy in Slavsky District, Kaliningrad Region
Hazardous waste pilots
3. Contamination and feasibility study and development of a remediation plan for Ust-Tosno landfill
outside St. Petersburg
4. Enhancement of treatment of mercury containing waste (fluorescent lamps) in Kaliningrad region
This report relates to the pilot project number 1 on agriculture and was prepared by SZNIIMESH. It does
not necessarily reflect the view of HELCOM. Other reports related to this pilot project are Lessons learned
and future perspectives of sustainable manure utilisation at the poultry industry, Case study of the Poultry
Factory Primorskaya in the Leningrad Region; Preparation of manure processing investments on Poultry
Farm Primorskaya; and A Comparative study of the technical solutions for conversion of chicken manure into
fertilizer products at Poultry Farm Primorskaya in the Leningrad region. For more information on the
project, please see:
http://www.helcom.fi/projects/balthazar/en_GB/BALTHAZAR/

Table of contents
1. Technology of granulated fertilizers production from chicken manure ............................... 3
2. Analysis of existing technical and technological solutions of chicken manure drying and
granulation ........................................................................................................................... 4
2.1. Proposal of “Eco Development” company .......................................................................................... 4
2.2. Proposal of PromTechProject-SPb Ltd. .............................................................................................. 7
3. Technological process of granulated fertilizers production proposed for PF Primorskaya . 8
4. Technical and economic indices of manure processing by drying and granulation .......... 15
Conclusions ............................................................................................................................. 18
Appendix 1. Arrangement and specifications of equipment for chicken manure drying
and granulation
Appendix 2. 3D model of technological line for chicken manure drying and granulation

1. Technology of granulated fertilizers production from chicken manure
Many companies offer different drying and granulating technologies of chicken manure processing into
organic fertilizers. But currently in Leningrad Oblast there are practically no examples of introduced and
full-scale operating technologies of the kind.
The main benefit and attractiveness of manure drying is up to 70 % decrease of manure mass. Dried
manure may be used as a fertilizer or fuel. The weak point of this technique is high nitrogen loss. Some
companies, however, for example, “Razvitie Eco” (“Eco Development”), offer equipment for drying manure
with minimal loss of nutrients.
Dried manure has low bulk density of 0.25 to 0.3 t/m 3 ; so large closed storages are needed if there are no
steady sales of the ready product. Also dry manure handling involves adverse working conditions because of
a big amount of dust particles. To avoid these weak points the dry manure may be granulated. Today the
market offers a wide range of Russian and imported machinery for granulation of organic substances,
including the dry manure. Granulated manure does not have so much dust; its bulk density is from 0.6 to
0.65 t/m 3 ; so nearly twice smaller closed storing area is required.
Granulated manure as an organic fertilizer is more suited for mechanical spot soil application.
Combustion process of granulated manure is more efficient. Many poultry factories are interested in manure
combustion because there is practically no stable target market of granulated manure, and special facilities
are to be in place for its long term storing. But at the same time there are still no processing lines for
industrial scale manure combustion.
Table 1 presents the indices of poultry manure mass and volume variation during drying, granulation
and combustion.
Table 1. Manure mass and required storing capacity variation
Mass in % of raw manure Capacity needed for storing of 1
ton of poultry manure, m 3
Raw manure
(70 % moisture content)
100 1.5
Dried manure 35 4
Granulated manure 35 1.5
Ash (after combustion) 3.5 5
According to the above indices Table 2 presents manure mass variation on PF Primorskaya and the
capacity of additional facilities needed for storing the ready product.
Table 2. Variation of manure mass and required capacity for 1 month storing on PF Primorskaya
Mass, t Minimal useful storing capacity, m 3 , no
less than
Raw manure
(70 % moisture content)
80 ~3600 (waterproof ground of 1600 m 2 )
Dried manure 27 3240 (storehouse)
Granulated manure 27 1215 (storehouse)
Ash (after combustion) 3 450 (storehouse)
According to Table 2, it seems quite reasonable to granulate the poultry manure: the required storehouse
area is 2.5 times lower than that needed for dry non-granulated manure. In terms of lowering the chicken
manure mass the combustion seems very promising, but additional detailed examination is needed,
especially for environmental safety reasons (emissions).

2. Analysis of available technical and technological solutions of poultry
manure drying and granulation
SZNIIMESH has been investigating poultry manure drying and granulating processes since 2000.
Investigation results show that drying is a sort of challenge in manure processing in terms of costs and
availability of suitable equipment. Drying costs may account for above 50 % of the final product self cost.
There is no problem in choosing conveyors, granulators, and packing machines, which are offered by
different manufacturing companies, while manure drying devices are not readily available. That is why
existing methods and equipment for manure drying have been analyzed in the first place. The processing
line has been designed on the basis of available information on machines and equipment.
2.1. Proposal of Eco Development Company
“Eco Development” Engineering Company was founded in 2006. It is located in Moscow, Ryazanskiy
Avenue, 8-a. Tel: +7 (495) 643-06-81, web-site: www.pometa.net
The company’s profile is development and introduction of VacuumEcoDry technology of the vacuum
drying of organic waste.
Short description of the process
VacuumEcoDry is a separation process of raw material with up to 99 % moisture content under the
temperature range from 40 to 90 °C and the pressure range from 30 to 250 mm Hg. The raw material is first
loaded into the receiving hopper and then into the vacuum drying chamber. The loading system feeds the
raw material in the quantities, which are strictly adjusted to the productivity of equipment. In the process of
drying the raw material moves on the conveyors through the heat exchangers. During the heating the
material boils and separates into three fractions:
1. Dry organic substance, which may be used without any additional treatment as a fertilizer, or
protein feed additive for cattle and poultry, or fuel.
2. Usable technical (recycled) water
3. Environmentally safe emission
The blank drawing of the processing line with the VacuumEcoDry technology is shown on Figure
1.

Dry cooling tower Vacuum unit
Loading system
Unloading
complex
Figure 1. Processing line with the VacuumEcoDry technology (top view)
Technical specifications and capital costs of equipment are presented in Tables 3 and 4
Table. 3. Technical specifications (according to the data provided by equipment manufacturer)
Index Unit Value
Throughput t/day 100
Output capacity t/day 35
Operation type Continuous
Operation temperature
Condensate accumulation
tanks, condensate drain
block
Granulation line
(option)
o С 5090
Installed electric power kW 300
Installed heat power kW 2,500
Required space m 2 300
Required building height m 6
Nutrients loss % 0
Run-offs m 3 /day 0
Service employees per shift man 2
Vacuum work
chamber
Packing line

Table. 4. Cost of equipment
Equipment Cost, roubles Cost, €
Set of equipment for a mini-factory
44,850,000 1,121,250
System for crushing of raw material
VacuumEcoDry drying
System for final product unloading
Management terminal
Video monitoring system
The mini-factory includes back-up devices of the product main
loading and unloading units.
Granulation and packing line
Mixer
Magnetic separator
Granulator
Granules (pellets) cooler
Cyclone separator
Semi-automatic packing unit
Boiler-house
Water conditioning system
Boiler
Burner
Accessories (sensors, fittings)
5,000,000
(the cost varies
with
manufacturers
and is agreed
upon in every
particular case)
4,000,000–
6,000,000
(the cost is
agreed upon
separately)
125,000
100,000–
150,000
Total 54,850,000 1,371,250
In February, 2011, A. Bryukhanov, an expert from SZNIIMESH, together with Technical Director of
PF Primorskaya M. A. Smirnov had negotiations with the head of «Eco Development». A trip was
scheduled to the place, where the described technology had been implemented. But further discussions and
more thorough analysis of available information showed that the company offered only the design. They
could show only a demonstration model (Figure 3) with much smaller productivity than required. The
vacuum dryer had no Certificate of Compliance.
Figure 3. Demonstration model of the vacuum dryer.
Therefore, in spite of good characteristics of the offered solution, its industrial scale introduction is a
certain risk for PF Primorskaya.

2.2. Proposal of PromTechProject-SPb Ltd.
PromTechProject-SPb Ltd. is located in Saint-Petersburg, Kolpino, Finlandskaya street, 34.
Fax: +7 (812) 460-77-67, web-site: www.ptpspb.narod.ru.
The company’s profile is engineering solutions and development of accessories for upgrading the operating
equipment at the enterprises; procurement of complete equipment; modernization of operating plants and
industrial enterprises; installation, repair, checkout and maintenance of processing lines and equipment;
development and manufacturing of non-standard equipment.
Experts of PromTechProject-SPb Ltd. have certain experience in designing, manufacturing and introduction
of drying equipment for organic components (Figure 4).
Figure 4. Drying cylinders manufactured by PromTechProject-SPb Ltd.
For chicken manure drying PromTechProject-SPb Ltd. can manufacture a drying cylinder with a technicaland-operation
data card and Certificate of Conformity, which are required for the project documentation to
pass the state examination. Experts of PromTechProject-SPb Ltd. together with representatives of Bioklad
Ltd. Company and SZNIIMESH have designed the production scheme of granulated poultry manure (Figure
5). Detailed arrangement of equipment for PF Primorskaya is presented in Appendix 1. PromTechProject-
SPb Ltd. can also manufacture a prototype model of installation for combustion of a part of produced
granulated manure to lower the drying costs. To dry all the amount of poultry manure, which is loaded into
the drying chamber, about 40 % of dry manure is to be combusted.

Drying cylinder
Heat generator
Conveyor to take
granules to combustion
chamber
Mixer hopper
Granules packing
Vibroscreen + granules
cooler
Granulator
Figure 5. Production scheme of granulated poultry manure
Some other companies, such as “Chicken Brothers Technology”, “Wood Innovative Technologies”
and “Poly-Nom”, offer similar technological and technical solutions and they are also ready to manufacture
and supply the equipment for drying the chicken manure, for production and combustion of chicken manure
granules. Description of technology is much similar to that offered by PromTechProject-SPb Ltd.
After the study of the above offers in terms of availability of required documents, off the shelf
equipment or some parts of equipment, the technology of manure cylinder drying and granulation was
selected for detailed consideration. The technological, technical and economic indices provided by
PromTechProject-SPb Ltd. were taken as a basis. In industrial facilities of this company an experimental
model of the technological line for chicken manure processing into organic fertilizers by drying and
granulation may be also manufactured.
3. Technological process of granulated fertilizers production proposed
for PF Primorskaya
Total manure mass is about 80 t/day. Under the volume density of 0.6–0.7 t/m 3 the daily manure
volume is from 114 to 133 m 3 , correspondingly. Manure with 0,6 t/m 3 density and the daily output of 133
m 3 is taken for technological calculation.
27 t of granulated organic fertilizers may be produced from 80 t daily output of chicken manure. The
sequence of technological operations with corresponding equipment is presented in Appendix 1. The
references to the equipment are given in the text below, for example, pos. 1 - the feeding bin of raw manure.
Manure is transported to the asphalted ground in front of the building, where drying and granulation
takes place, by available vehicles (KamAZ 6250 (6×4) type). ТО-28А “Amkodor” loader equipped with SM
4-23 ALLU bucket transports, crushes and loads manure into the feeding bin of 9 m 3 capacity (pos. 1),
which is located at the end wall of the building. The feeding bin is an upgraded box of manure spreader
ПРТ-10 (Appendix 1). Work tools of ПРТ-10 are driven by an electrical engine fed from electricity
network.

No. Type of operation Model
1
Constant volume
supply of manure
Table 5. Specifications of receiving and feeding bin for raw manure
Number
of units
Throughput, t/h
Installed power,
kW
ПРТ-10 1 4 7
From the feeding bin the manure is taken by УКВ 106 conveyor (pos. 2) to the drying cylinder with
the heat exchanger manufactured by PromTechProject-SPb Ltd., where the moisture is removed. To process
80 t of manure two drying cylinders are required (pos. 4) with the overall throughput of 4 t/h by the raw
manure (2 t/h for every cylinder). Consequently, twenty hours operating mode should be set for this
equipment.
No. Type of operation Model
2
Manure loading
from the feeding
bin to the drying
cylinder
Table 6. Specifications of raw manure conveyor
Number of
units
Productivity,
t/h
Installed power,
kW
УКВ-106 2 6 4.4
Table 7. Specifications of the drying cylinder with the heat exchanger manufactured by
PromTechProject-SPb Ltd.
No. Type of operation Model
4
Manure drying to
10 to12 % of
moisture content
АСЗ-5-4 drying
cylinder
Number of
units
Throughput,
t/h
Installed power,
kW
2 4 100
To dry the chicken manure the air heated to 200 °C is supplied to the cylinder. Diesel heat-generator
(pos. 3) is used to heat the air as there is no gas supply on the poultry factory.
No. Type of operation Model
3
Air heating and
hot air supply to
the drying
cylinder
Table 8. Specifications of the diesel heat-generator
Number of
units
Heat
generating
capacity,
MW/h
Diesel fuel consumption,
L/h
2 8 400
The heat is generated by diesel fuel combustion.
Another option is to use granulated manure as a fuel. In this case around 40 % of produced granulated
manure is to be combusted. This technology has not been applied in large scale before, and additional study
is needed. The economic effect of this option may be rather high as shown in Item 4 below.
The manure mass after drying m cn with 12 % moisture content that meets technological requirements to
granulated manure is defined by the formula:

( 100 Wn
) mn
mcn
, kg
100 Wcn
( 100 70)
2000
m cn
681,
81 kg,
100 12
where W n is raw manure moisture, W n = 70 %
Wcn is dried manure moisture, W cn = 12 %.
m is raw manure mass.
n
The output of every drying cylinder is 0.682 t/h of manure with 12 % moisture content. The total
output of two cylinders is 1,36 t/h.
After having been dried the chicken manure is taken to the mixer hopper (pos. 5), where other
necessary mineral or biological components are simultaneously supplied by the screw feeder УКП-106 (pos.
6). The components are added to produce the complex organic and mineral fertilizers with different
nutrients and microelements content required by particular crops.
No. Type of operation Model
5
Uniform mixing of dry
manure with other
required components
No. Type of operation Model
6
Dosed supply of
required components to
the mixer hopper
Table 9. Specifications of mixer hopper
Number
of units
Throughput, t/h
Installed power,
kW
1 3 2.2
Table 10. Specifications of a screw feeder of additives
Number of
units
Throughput, t/h
Installed power,
kW
УКП-106 1 0,2-3 2.2
In the mixer hopper (pos. 5) the homogeneous substance is produced, which is taken by LM/LG-60
conveyor (pos. 7) to the bin of ОГМ-6 press-granulator (pos. 8). The substance is pressed through the holes
of the press-granulator matrix and then cut off by the shear mechanism. As a result granules with required
physical and granulometric parameters (density, length, diameter, etc.) are formed. It is possible to produce
granules with the diameter of 6, 8 and 10 mm.
No. Type of operation Model
7
Supply of
material from the
mixer hopper to
the pressgranulator
bin
Table 11. Specifications of granulator loading conveyor
Number
of units
Productivity,
t/h
Installed power, kW
ЛМ/ЛГ-60 2 6 3

No. Type of operation Model
8
Manure
granulation
Table 12. Specifications ОГМ - 6 press-granulator
Number
of units
Throughput,
t/h
Installed power, kW
ОГМ-6 2 3 156
Produced warm granules are taken by the conveyor (pos. 9) to the vibro-screen (pos. 11), where
shapeless granules are sorted out and removed by special conveyor (pos. 10).
No. Type of operation Model
9
Supply of warm
granules from
press-granulator
to vibroscreen
No. Type of operation Model
11
Sorting out of
granules to
comply with
specified
requirements
Table 13. Specifications of conveyor
Number
of units
Productivity,
t/h
Installed power, kW
УКВ-106 1 3 2.2
Table 14. Specifications of vibroscreen
Number
of units
Throughput,
t/h
Installed power, kW
1 3 2.2
After the vibroscreen the granules, which meet the size requirements, are taken by the conveyor (pos. 12) to
the enrichment chamber (pos. 13), where bacteria spores are added. This step is optional for the technology.
No. Type of operation Model
12
Transfer of
granules from the
vibroscreen to the
enrichment
chamber
No. Type of operation Model
13
Enrichment of
granules with
useful bacteria
Table 15. Specifications of enrichment chamber conveyor
Number of
units
Productivity,
t/h
Installed power, kW
ЛМ/ЛГ-60 1 3 2.2
Table 16. Enrichment chamber specifications
Number of
units
Productivity,
t/h
Installed power, kW
1 2 3.6
By the conveyor (pos. 14) the granules are taken to the cooler, where they are cooled by cold air
flow, harden and obtain the required strength properties.

Table 17. Specifications of the conveyor for granules supply to the cooling chamber
No. Type of operation Model
14
Granules supply
to the cooling
chamber
Number of
units
Productivity,
t/h
Installed power, kW
ЛМ/ЛГ-60 1 3 2.2
Table 18. Cooling chamber specifications
No. Type of operation Model
Number of
units
Productivity,
t/h
Installed power, kW
15 Granules cooling 1 3 2.2
Conveyor (pos. 16) transfers the dry (11 to 20 % moisture content) and enriched with bacteria product
from the cooling chamber to the final product bin. After that the product is packed into bags of different
volume.
Table 19. Specifications of the loading conveyor to the final product bin
No. Type of operation Model
18
Granules supply
from the cooling
chamber to the
final product bin
No. Type of operation Model
19
The final product
storage and
packing
Number of
units
Productivity,
t/h
Installed power, kW
ЛМ/ЛГ-60 1 3 2.2
Table 20. Specifications of the final product bin
Number of
units
Productivity,
t/h
Installed power, kW
«Delta-С» 1 2 2.2
The full set of equipment is presented in Summary Table 21.

Summary Table 21
No Technical device Operation Model
1
Receiving and feeding bin for raw
manure
Number
of units
Productivity,
t/h
Installed power, kW
Constant volume supply of manure ПРТ – 10 1 4 7
2 Raw manure conveyor
Manure loading from the feeding bin to the drying
cylinder
УКВ-106 2 6 4.4
3 Heat generator Air heating and hot air supply to the drying cylinder 2 2
4
Drying cylinder with a heat
exchanger
Manure drying to 10 to12 % moisture content
АСЗ-5-4 drying
cylinder
2 4 100
5 Mixer hopper Uniform mixing of dry manure with required components 1 3 2.2
6 Screw feeder of additives
Dosed supply of required components to the mixer
hopper
УКП-106 1 0.2–3 2.2
7 Granulator loading conveyor
Supply of material from the mixer hopper to the
press-granulator bin
ЛМ/ЛГ-60 2 6 3
8 Press-granulator Manure granulation ОГМ – 6 2 3 156
9
Conveyor to take the granules to the
vibroscreen
Supply of warm granules from press-granulator to
vibroscreen
УКВ-106 1 3 2.2
10
Conveyor to remove the shapeless
granules
To remove the shapeless granules from vibroscreen УКП-106 1 0.2–3 2.2
11 Vibroscreen
Sorting out of granules to comply with specified
requirements
1 3 2.2
12 Enrichment chamber conveyor
Transfer of granules from the vibroscreen to the
enrichment chamber
ЛМ/ЛГ-60 1 3 2.2
13 Enrichment chamber Enrichments of granules with useful bacteria 1 3 2.2
14
Loading conveyor of the cooling
chamber
Supply of granules from the enrichment chamber to
the cooling chamber
ЛМ/ЛГ-60 1 3 3.6
15 Granules cooler Granules cooling 1 2 2.2
16
Conveyor of the accumulation bin of
the final product packing
Supply the granules from the cooler to the
accumulation bin of the final product packing
ЛМ/ЛГ-60 1 3 2.2
17
The final product bin + packing
machine
Final product storing and packing
“Delta-С” 1 2 2.2
18 Tipping truck
Transportation of manure from the chicken house to
the temporary storing ground
KamAZ 6250
(6×4)
ТО-28А
1 16
19 Loader
Manure crushing and loading from the temporary
storing ground to the feeding bin
“Amkodor” loader
equipped with SM
4-23 ALLU busket
1 25
Total 298

No. Technological
operation
1 Manure
transportation
to the
mixing place
3 Organic
components
crushing and
loading to
the mixer
hopper
Table 22. Required number of mobile machinery
Type of machinery Productivi
Tractor Teamed ty, t/h
(vehicle) unit
KamAZ
6520
(6х4)
ТО-28А
loader
equipped
with SM
4-23
busket
Output at
8/10hours
shift, t
Number
of shifts
per day
Volume of
work,
t/day
Transportationdistance,
km
Number
of
required
machinery
(under
8/10hours
shift)
- 16 112/144 2 80 0.5 0.71/0.55
- 25 175/225 2 80 - 0.91/0.71
4. Technical and economic indices
of manure processing by drying and granulation
Technical and economic indices of manure processing by drying and granulation are presented in
Table 23.
Table 23. Technical and economic indices of manure processing by drying and granulation
per 1 ton of granulated manure
No
.
Technical and economic indices Units Value Cost,
rouble/t
1. Production capacity t/year 9855
2. Time to process 4 t of raw manure min 60
3. Daily production output t 27
4. Final production output for 1 hour cycle t 1.36
5. Inputs per 1 ton of granulated manure
- labor
- electric power (with due account of
actual operation of equipment)
- diesel fuel for vehicles
- diesel fuel for a diesel generator
6. Required electric power supply
network capacity
5. Number of drivers and operators per
shift
man-hour/t
kWh/t
L/t
L/t
1.4
49.7
4.4
296
kW ~300
man 4
140
198
88
5920
Cost,
€/t
Following per unit indicators were used in calculations: staff compensation – 2.5 €/h; price of electric
energy – 0.1 €/kWh; price of diesel fuel – 0.5 €/L.
3.5
4.95
4.4
148

Capital costs have been calculated on the basis of the preliminary quotation of PromTechProject-SPb
Ltd. and information on the similar equipment from other manufacturers.
Table 24. Capital costs of equipment and machinery
Price with Price, €
No. Technical device Model Number of units
VAT,
thousand
roubles
1
Receiving and feeding bin for raw
manure
ПРТ – 10 1
380 9500
2
Raw manure conveyor (to load the drying
cylinder)
УКВ-106 2
700 17500
3 Heat generator 2 1760 44000
4 Drying cylinder with a heat exchanger
АСЗ-5-4 drying
cylinder
2
3400 85000
5 Mixer hopper 1 485 12125
6 Screw feeder of additives УКП-106 1 375 9375
7 Granulator loading conveyor ЛМ/ЛГ-60 2 500 12500
8 Press-granulator ОГМ – 6 2 3080 77000
9
Conveyor to take the granules to the
vibroscreen
УКВ-106
(shortened)
1
245 6125
10
Conveyor to remove the shapeless
granules
УКП-106
(shortened)
1
220 5500
11 Vibroscreen 1 160 4000
12 Enrichment chamber conveyor ЛМ/ЛГ-60 1 250 6250
13 Enrichment chamber 1 200 5000
14 Cooling chamber loading conveyor ЛМ/ЛГ-60 1 250 6250
15 Granules cooler 1 290 7250
16
Conveyor of the accumulation bin of the
final product packing
ЛМ/ЛГ-60 1
250 6250
17 Final product bin + packing machine «Delta-С» 1 340 8500
18
KamAZ 6520 (6×4) vehicle KamAZ 6250
(6×4)
1
2300 57500
ТО-28А loader + SM 4-23 busket ТО-28А
“Amkodor”
19
loader equipped
with SM 4-23
1
“Allu” busket
6100 152500
TOTAL 21285 532125
To accommodate the processing line a facility with the area of 300 m 2 and the height of 5 m is
required. Accommodation cost will be about 5,250,000 roubles or € 131,250.
The storehouse cost for the month’s output of granulated manure will be around 4,000,000
roubles or € 100,000.
Total capital costs will amount to:
construction € 231 250
Equipment and machinery € 532 125
When calculating the self cost, the following charges should be taken into account: 2 %
depreciation for construction part and 10 % depreciation for equipment and machinery; equipment
maintenance and service – 9.3 %. Calculation of the granulated manure self cost is presented in Table
25.

Table 25. Calculation of the granulated manure self cost under production capacity of 9855 tons
per year
No. Cost elements Value, €/y
1 Allowance for depreciation:
construction part
equipment and machinery
4625
53,212.5
2 Maintenance and service 49,487.6
3 Labor 48,000
4 Electricity 49,275
5 Diesel fuel 1,480,221
6 Total of operating costs 1,626,983.6
7 Self cost of 1 ton of granulated manure 171
As stated above the self cost may be cut by combustion of a part of granulated manure to produce
the heat for raw manure drying. To provide the heat for the drying cylinder, 40 % of the dry granulated
manure should be burned.
In spite of somewhat higher total capital costs:
Construction part € 256 250
Equipment and machinery € 607 125
the granulated manure self cost will be four times lower (Table 26).
Table 26. Calculation of granulated manure self cost under production capacity
of 5913 tons per year
No. Cost elements Value, € / y
1 Allowance for depreciation:
construction part
equipment and machinery
5125
60712
2 Maintenance and service 56463
3 Labor 60000
4 Electricity 49 275
5 Diesel fuel 22000
6 Total of operating costs 187738
7 Self cost of 1 ton of granulated manure 43

Conclusions
1. Manure drying and granulation technologies appeared more than 10 years ago and now it is
possible to find many different options. But this technology has not been applied in an industrial
scale because of high costs, operational ones in the first place. For poultry factories the main
benefit of drying and granulation technology is in substantial decrease of produced manure
mass and in production of a marketable product – a “presentable” odorless organic fertilizer. It
should be understood, however, that it is manure mass, which decreases during the drying and
not the volume. That is why in case of poor year-round sales the facilities for dried manure
storing should be provided. Different technical and technological innovations are offered to
increase the efficiency of manure processing technology and decrease the power inputs. But few
proposals have been developed on the adequate technical, engineering and economic level and
actually introduced in large-scale production.
2. The most cost-intensive part of the technology under consideration is manure drying prior to
granulation. Investigations show that currently only cylinder-type drying installations are
available on the market to be applied in large-scale animal and poultry production.
3. Drying costs depend on the sources of heat for drying cylinders. Calculations have shown that
in case of a diesel heat generator, the drying costs account for 85 % of the total operating costs.
The drying costs may be twice lower in case of a heat generator on natural gas and almost four
times lower in case a part of granulated manure is used as fuel.
4. Manure processing into the granules is most reasonable if they are (1) further used for spot
organic fertilizing (this is especially topical in the southern areas of the country, where vast
arable lands are found); (2) sold through commercial network (in view of their “attractive”
appearance); (3) used as fuel in boilers.
5. The above calculations should be regarded as approximate. By preliminary estimates the overall
capital costs may grow up twice, first of all, because all the required documents concerning the
technology should be prepared to be included in the design and estimate documentation for the
state examination. Besides the costs of required service media have not been included in the
calculations.