Organic containing sludge to fertilizer alkaline conversion process

• US 9,233,882 B2
• Filed: 10/08/2014
• Issued: 01/12/2016
• Est. Priority Date: 09/15/2005
• Status: Active Grant

• Current Assignee: Profile Products LLC
• Original Assignee: Anuvia Plant Nutrients Corporation
• Inventors: Burnham, Jeffrey C.
• Primary Examiner(s): LANGEL, WAYNE A
• Application Number:
  US14/509,223
• Publication Number:
  US 20150020560A1
• Time in Patent Office: 461 Days
• US Class Current: 1/1
• 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 for treating organic-containing sludges and converting such sludges to high value fertilizers containing both inorganic and organic fertilizer components, which creates an inorganically-augmented bioorganic fertilizer. The invention describes methods to create a thixotropic or paste-like material via the application of mixing energy to the organic sludge followed by an alkaline treatment and a subsequent ammoniation. The invention further describes a method to increase the plant nutrient content in the organic containing product to a level which permits the finished granular fertilizer product to compete in the commercial agricultural fertilizer marketplace. Further, the invention reduces odors associated with said organic-containing sludges.

Claims

1. An inorganically-enhanced, bioorganic fertilizer with reduced bioorganic odor, comprising:

dried granules of one or more organic materials containing disinfected biosolids and a nutrient mixture;

wherein the dried granules have a dryness of greater than 90%, and are coated with a material to reduce dust formation;

wherein the fertilizer contains no active pathogens and organisms, and odors have been substantially reduced or eliminated during processing with the nutrient mixture;

wherein the nutrient mixture is comprised of nitrogen and one or more of calcium, phosphorous, potassium, sulfur, or iron; and

wherein the nutrient mixture is reacted with chemical components of the organic materials such that the fertilizer does not require further modification or supplementation before use.

2. The fertilizer of claim 1, wherein the one or more organic materials are from municipal sewage.

3. The fertilizer of claim 1, wherein the dried granules have an average diameter of 2.7 mm.

4. The fertilizer of claim 1, wherein the concentration of one or more of calcium, nitrogen, phosphorous, iron, or potassium in the fertilizer is greater than the respective concentration of calcium, nitrogen, phosphorous, iron, or potassium in an all organic fertilizer.

5. The fertilizer of claim 1, which comprises, by weight, from 6% to 16% nitrogen, 20% or more organic components and from 4% to 14% phosphorous, from 6% to 10% potassium, or up to 1% iron.

6. The fertilizer of claim 1, wherein the water-holding capacity of the fertilizer is greater than the water-holding capacity of a synthetic fertilizer.

7. The fertilizer of claim 1, further comprising an oxidant.

8. The fertilizer of claim 7, wherein the oxidant is selected from the group consisting of calcium ferrate, potassium ferrate, sodium ferrate, hydrogen peroxide, oxygen, sodium hypochlorite, calcium hypochlorite, chlorine dioxide, and combinations thereof.

9. The fertilizer of claim 1, which has a pH of from 4 to 7.5, from 5 to 7, or from 5.8 to 6.8.

10. The fertilizer of claim 1, which comprises a granulating or binding agent.

11. The fertilizer of claim 10, wherein the granulating or binding agent is industrial molasses.

12. The fertilizer of claim 1, wherein the pathogens and organisms are selected from the group consisting of microorganisms, bacteria, spores, pharmaceutical compounds, and waste material.

13. The fertilizer of claim 1, wherein the one or more organic materials are subjected to heat or a concentration of ammonia.

14. The fertilizer of claim 13, wherein the heat is a temperature of greater than 80°

C., greater that 100°

C., or greater than 121°

C.

15. The fertilizer of claim 13, wherein the concentration of ammonia is from 2,000 ppm to 20,000 ppm.

16. The fertilizer of claim 1, which meets USEPA biosolid Class A standards.

17. The fertilizer of claim 1, wherein the dried granules have a diameter of 2 mm to 3.5 mm.

18. The fertilizer of claim 1, wherein the nitrogen content of the fertilizer is from 6-16%.

19. The fertilizer of claim 1, wherein the nitrogen content of the fertilizer is over 8%.

20. An inorganically-enhanced, bioorganic fertilizer with reduced bioorganic odor, comprising:

dried granules of one or more organic materials containing disinfected biosolids, a binding or granulating agent, and a nutrient mixture;

wherein the dried granules have a dryness of greater than 90%, and are coated with a material to reduce dust formation;

wherein the fertilizer contains no active pathogens and organisms, and odors have been substantially reduced or eliminated during processing with the nutrient mixture;

wherein the nutrient mixture is comprised of nitrogen and one or more of calcium, phosphorous, potassium, sulfur, or iron; and

wherein the nutrient mixture is reacted with chemical components of the organic materials such that the fertilizer does not require further modification or supplementation before use as a USEPA Class A biosolid.

21. The fertilizer of claim 20, wherein the binding or granulating agent is industrial molasses.

22. The fertilizer of claim 21, wherein the one or more organic materials are subjected to heat at a temperature of greater than 80°

C., greater that 100°

C., or greater than 121°

C., and a concentration of ammonia of from 2,000 ppm to 20,000 ppm.

23. The fertilizer of claim 20, wherein the dried granules have a diameter of 2 mm to 3.5 mm.

24. The fertilizer of claim 20, wherein the nitrogen content of the fertilizer is from 6-16%.

25. The fertilizer of claim 20, wherein the nitrogen content of the fertilizer is over 8%.

26. An inorganically-enhanced, bioorganic fertilizer with reduced bioorganic odor, comprising:

one or more organic materials containing disinfected biosolids, a binding or granulating agent, and a nutrient mixture;

wherein the fertilizer contains no active pathogens and organisms, and odors have been substantially reduced or eliminated during processing with the nutrient mixture;

wherein the nutrient mixture is comprised of nitrogen and one or more of calcium, phosphorous, potassium, sulfur, or iron;

wherein the nutrient mixture is reacted with chemical components of the organic materials such that the fertilizer does not require further modification or supplementation before use as a USEPA Class A biosolid; and

wherein the fertilizer comprises, by weight, from 6% to 16% nitrogen, 20% or more organic components and from 4% to 14% phosphorous, from 6% to 10% potassium or up to 1% iron.

27. The fertilizer of claim 26, wherein the dried granules have a diameter of 2 mm to 3.5 mm.