Very familiar, but no less relevant for Russia, is the problem of recycling of agricultural waste. Agricultural production produces waste of 250 million tons per year, of which 150 million tons account for livestock and poultry farming, 100 million tons for crop production.

Special attention should be paid to the problem of processing waste from poultry and livestock farms - processing chicken manure and pork manure. A huge number of poultry farms (more than 600 throughout Russia) produce up to 300 tons of manure each day. The timely failure to take compulsory preventive measures to dispose this waste led to the fact that many poultry farms located near big cities and towns began to have a negative effect on the sanitary and ecological state of the environment. There has been a noticeable pollution of the relief of soils, reservoirs, forests and pastures adjacent to poultry farms. In the end, serious economic, environmental and social damage is inflicted not only on agricultural land, but also on residents of nearby communities. Thus, most of the organic raw materials are not processed, they accumulate near the poultry farms, forming "manure lakes" without signs of the life of flora and fauna. Bird droppings, like fertilizer, lose their valuable fertilizing properties and represent a constant threat to the ecological well-being of the population and neighboring farms.

To process manure, a technology that meets the following basic requirements is needed:

- environmental safety of production, i.e. minimization of the degree of impact of processing technology on the environment;

- no need to use absorbing materials and fillers (peat, straw, sawdust, minerals, for example, bischofite, calcium oxide, etc.);

- minimization of the volume of premises for technological equipment;

- comparative manufacturability and payback due to the sale of product processing.

VacuumEcoDry equipment produced by the company "Eco Development" meets all these parameters.

VaccuumEcoDry Equipment

VacuumEcoDry equipment involves solving the problem of waste processing and recycling using vacuum drying technology to obtain a dry organic environmentally friendly product.

Traditional drying is usually based on the principle of multi-stage processing of the source material: mechanical thickening (centrifugation, filtration, squeezing, etc.); evaporation and spraying. The multistage nature of the drying lines used in practice leads to significant investment during the formation of dehydration sites. In addition, the processes of evaporation and spraying, as a rule, are carried out at temperatures from 100 to 400 ° C, which is unacceptable for substances such as vitamins, sugars, some protein compounds, amino acids, etc. It is desirable to process such substances in the temperature range from 40 up to 90 ° C. This temperature range can only be provided when the process is conducted under vacuum.

Therefore, the VacuumEcoDry equipment, which is based on a continuous, environmentally safe, single-stage drying process in vacuum, which allows the processing of the original product in a mode of gentle temperatures while preserving the useful properties of the source material, has become relevant now.

In addition, the flexibility and versatility of VacuumEcoDry equipment makes it possible to use various types of raw materials and any moisture for processing and to ensure the required final product humidity without major structural changes to the installation.

Technology

The basic principle of operation of the equipment is as follows: in order to isolate only water, i.e., without changing the chemical composition of the original product, to reduce its moisture content, it is necessary to maintain a balance of input heat (q), flows required for the process and flow masses of water vapor (M p), released and removed during the drying process.

drying technology1 - Heat exchange installation;

2 - Heater;

3 - Water solution of the original product;

4 - Flow masses of water vapor Mp;

5 - Heat flow Q.

VacuumEcoDry Equipment technology is a separation process in the temperature range from 40 to 90 0С and pressure from 30 to 250 mm Hg. of the source material with the moisture content up to 99% into three components:

1. dry organic fertilizer, feed, fuel, humidity up to 1%, which can be used as fertilizer without any additional processing, to serve as a protein feed additive for livestock and poultry, as fuel.

2. water suitable for further use.

3. environmentally friendly exhaust.

Process Description

The technological process of vacuum drying of substances proceeds in a vacuum volume. As the primary energy source one can use electricity, natural gas, gas obtained as a result of associated biological processes, waste steam, hot water. In connection with these peculiarities of the technological process, the environmental impact occurs only in the case of using gas as an energy carrier, which is burned before heating of the water.

The original product flows through the receiving hopper into the vacuum chamber for drying. The product is supplied by the loading system in volumes strictly coordinated with the equipment capacity. In the process of drying, the original product moves through the conveyors through the heat exchangers. During heating of the processed material it boils, and the separation into 3 components (dry matter, condensate, gas). Next, the dry end product enters the unloading chamber - a reciever for finished products. Then, the finished product is unloaded in a continuous mode by a screw conveyor and fed to the granulation line. After granulation, the finished product is delivered to the packaging line, where it is packed in 50-liter bags or a big-bag.

Technical characteristics of a standard set of equipment

Parameter Unit
Capacity raw materials (humidity 70%) t/day 100
Capacity finished product (humidity 14%) t/day 35
Max. permissible humidity of raw materials % 99
The nature of the workflow Continuous
Operating temperature of the process oС 50 - 90
Electrical installation power kW 300
Thermal installation power kW 2 500
Surface m 2 800
Nutrient loss rate % 0
Volume of wastewater m3/day 0
Required height of the premises m 6
The number of staff in the shift people 2

A set of equipment for a mini-plant

Equipment
  • The system of preparation and grinding of the original product
  • Drying VacuumEcoDry
  • Unloading system of the finished product
  • Control terminal
  • Process surveillance system
  • Granulation line
  • Packaging in bags
The structure of the mini-plant includes duplication of the main supply and discharge units

Space requirements

Premises for the position of the equipment
  • The premises is necessarily insulated,with a roof and walls, the internal temperature is more than +10 ºС, the floors are necessarily concrete, screed height not less than 150 mm.
  • The area of the premises - from 300 до 800 m², width not less than 12m
  • The height of the premises is not less than 6 meters
Storage area for packaged finished goods
  • The premises must be protected from environmental exposure (precipitation, wind), moisture ingress is excluded in any form - from 500 m²
  • The location of the warehouse - in close proximity to the production area.
Building infrastructure
  • Household plumbing.
  • It is desirable to have a gas pipeline.
  • Ceiling height - from 6 m
  • Electric power: from 300kW for the performance of a mini-plant 100 t/day
Location of the premises
  • Ideal if the premises is in close proximity to the source of raw materials.
  • Near the transport infrastructure (railway deadlock, road).


Premises layout

Layout of the organic waste processing department

Drives of loading and unloading units mechanisms
Pos.1 Hydraulic station SG-S-44-170-200-15MOIGP 15kW
Pos.2 Scraping conveyor MT 589-45
Gear motor MBH 100-69,24-20,2-B3-4-1738-380-50 (4P) sf = 1.04
Pos.3 Agitating hopper MT 805.00.00.01.00
Gear motor *: TS-180 SO-200-7-V6-5,5kW. Head No. 733
Pos.4 Screw conveyor (Tatarnikov screw conveyor)
NMRV-110-1-10-3
Pos.5 Drying chamber assembled
Pos.6 Vacuum system (vacuum pump)
Pos.7 (7-1,7-2,7-3) Cooling System (Heat Exchanger)
Pos.8 Pneumatic system
Pos.9-1 Chain conveyor KC-300.00.000 (10m)
NMRV-150-50-28-4
Pos.9-2 Chain conveyor KTS-300.00.000 (10m, 45gr)
NMRV150-50-28-5,5
Pos.10 Butterfly valve KP-300
Pos.11 Chain conveyor KC-300.00.00. (8m)
NMRV130-50-28-3
Pos.12 Mechanized hopper LIT-MB-1
Conic gear motor KA87 / TR57DRS71M4 / AL / DH, 0.55 kW.
Pos.13 Screw conveyor KV-300-3M
Pos.14 Grain elevator NZ-3
Pos.15 Screw agitating hopper BVS-100.000
Pos.16 Granulator Ferotek 480
Granulator Ferotek 480
Pos.17 Scraping belt conveyor CLW 300.000 (2m)
Pos.18 Scraping belt conveyor CLW 300.000 (9m)
Pos.19 Cooling Tower SN-3 00.000
Pos.20 Scraping belt conveyor CLW 300.000 (4m)
Pos.21,22 Packaging and packing

Applications

The flexibility and versatility of VacuumEcoDry equipment allows, without major structural changes to the installation, to use various types of raw materials and of any humidity for processing and to consistently provide the required final humidity of the product.

Waste recycling