Process to beneficiate heat-dried biosolid pellets

• US 8,491,693 B2
• Filed: 05/16/2012
• Issued: 07/23/2013
• Est. Priority Date: 09/15/2005
• Status: Active Grant

• Current Assignee: Profile Products LLC
• Original Assignee: Vitag Corporation
• Inventors: Burnham, Jeffrey C.
• Primary Examiner(s): LANGEL, WAYNE A
• Application Number:
  US13/472,828
• Publication Number:
  US 20120234063A1
• Time in Patent Office: 433 Days
• Field of Search: 71 11- 63
• US Class Current: 71/11
• CPC Class Codes: A45D 20/18 Flexible caps with provision for hot air supply
• CPC Class Codes: C02F 11/06 by oxidation incinerators for burning waste liquors, e.g. sulfite liquor from paper-making plant F23G7/04
• CPC Class Codes: C05B 17/00 Other phosphatic fertilisers, e.g. soft rock phosphates, bone meal
• CPC Class Codes: C05C 11/00 Other nitrogenous fertilisers
• CPC Class Codes: C05C 3/00 Fertilisers containing other salts of ammonia or ammonia itself, e.g. gas liquor
• CPC Class Codes: C05C 7/00 Fertilisers containing calcium or other cyanamides
• CPC Class Codes: C05D 3/02 from limestone, calcium carbonate, calcium hydrate, slaked lime, calcium oxide, waste calcium products
• CPC Class Codes: C05F 11/00 Other organic fertilisers
• CPC Class Codes: C05F 3/00 Fertilisers from human or animal excrements, e.g. manure
• CPC Class Codes: C05F 5/008 Waste from biochemical processing of material, e.g. fermentation, breweries
• CPC Class Codes: C05F 7/00 Fertilisers from waste water, sewage sludge, sea slime, ooze or similar masses
• CPC Class Codes: C05F 9/00 Fertilisers from household or town refuse
• CPC Class Codes: C05G 3/20 for preventing the fertilisers being reduced to powder; Anti-dusting additives
• CPC Class Codes: Y02P 20/145 the feedstock being materials of biological origin
• CPC Class Codes: Y02W 30/40 Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Abstract

This invention is directed to systems, devices and methods to beneficiate heat-dried biosolids or sludge pellets or granules as presently manufactured by municipalities or companies from a) dewatered municipal wastewater biosolids or sludges within the municipal wastewater treatment plant heat-dried biosolids production facility or from b) finished dry heat dried biosolids pellets or granules in a separate manufacturing facility from the municipal wastewater treatment plant to produce a fertilizer containing sufficient organic and inorganic plant nutrients to be valuable and saleable into the commercial agricultural industry. The present invention describes beneficiation methods to increase the plant nutrient content of the fertilizer and also to reduce the odors associated with traditionally-produced heat dried biosolids.

Claims

1. A method for the manufacture of a fertilizer comprising:

mixing an oxidant with dewatered biosolids to control odor;

acidifying the oxidized and dewatered biosolids with concentrated acid to disinfect the biosolids;

blending the acidified biosolids into a thixotropic mixture;

subjecting the thixotropic mixture to an increased atmospheric pressure;

adding an inorganic plant nutrient to the thixotropic mixture;

mixing granulating agents into the mixture; and

drying the mixture to greater than 90% solids to produce a beneficiated, dried-biosolids fertilizer.

2. The method of claim 1, wherein the oxidant is selected from the group consisting of ferrates, chlorine dioxide, hydrogen peroxide, oxygen, ozone and combinations thereof.

3. The method of claim 1, wherein the beneficiated, dried-biosolids fertilizer has an inorganic plant nutrient value of 8% to 22% nitrogen.

4. The method of claim 1, wherein the beneficiated, dried-biosolids fertilizer has little to no detectable odor as compared to the dewatered biosolids.

5. The method of claim 1, further comprising adjusting the pH of the thixotropic mixture to a pH of between pH 4.5 and pH 7.0.

6. The method of claim 5, wherein the inorganic plant nutrient is selected from the group consisting of solid fertilizers, iron, nitrogen, potassium, sulfur, ammonium salts, ammonium sulfate, ammonium nitrate, mono-ammonium phosphate, di-ammonium phosphate, potash, urea, methylene urea, sulfur-coated urea, liquid fertilizers, urea ammonium nitrate (“

UAN”

), liquid urea, liquid N-P-K fertilizers 16-4-8, 10-8-8 or 6-14-6, and combinations thereof.

7. The method of claim 1, further comprising adding a hardener to the thixotropic mixture.

8. The method of claim 1, further comprising forming pellets or granules.

9. The method of claim 8, wherein the pellets or granules are coated with an agent to reduce dust and abrasion.

10. The method of claim 9, wherein the coated pellets or granules are cooled to less than 55°

C.

11. The method of claim 1, which is conducted entirely within a single heat-drying facility.

12. The method of claim 1, further comprising adding a chemical additive directly to the dewatered biosolids to produce a thixotropic mixture prior to drying.

13. The method of claim 12, wherein the chemical additive is added to the dewatered biosolids without making a slurry.

14. The method of claim 1, wherein the concentrated acid reacts with aqueous or anhydrous ammonia to produce ammonium salts.

15. The method of claim 14, wherein the concentrated acid is phosphoric acid, sulfuric acid, or both.

16. The method of claim 1, further comprising adding a plant nutrient to the mix to enhance fertilizer value.

17. The method of claim 1, wherein the atmospheric pressure is increased in a pressure vessel.

18. The method of claim 1, wherein the atmospheric pressure is increased to at least 1.5 atmospheres.

19. A method for the manufacture of a fertilizer comprising:

mixing an oxidant with dried biosolids to control odor;

acidifying the oxidized and dried biosolids with concentrated acid;

blending the acidified biosolids into a thixotropic mixture;

subjecting the thixotropic mixture to an increased atmospheric pressure;

adding an inorganic plant nutrient to the thixotropic mixture; and

producing a beneficiated, dried-biosolids fertilizer.

20. The method of claim 19, wherein the dried biosolids are greater than 90% solids.

21. The method of claim 19, wherein the dried biosolids comprise pellets or granules.