Method for manufacturing pellet bedding for livestock farming using biochar derived from livestock manure, and system thereof

Abstract

The present invention relates to a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure. More specifically, the invention relates to an eco-friendly livestock pellet bedding having high water absorption and swelling rates and a method for manufacturing the same, by converting livestock manure into biochar and mixing it with peat moss, coco peat, fibrous reinforcing agents, etc., to form pellets. The manufactured pellets minimize dust generation and provide antibacterial and odor reduction effects, improve livestock health, and can double-reduce the amount of manure discharged from livestock barns. Furthermore, the invention relates to a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure that enables the simultaneous securing of absorbency, structural stability, and moisture resistance through the adjustment of additives according to application and the optimization of the manufacturing process.

Description

Technology Field

[0001] The present invention relates to a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure. More specifically, the invention relates to an eco-friendly livestock pellet bedding having a high moisture absorption rate and swelling rate, and a method for manufacturing the same, by converting livestock manure into biochar and mixing it with peat moss, coco peat, fibrous reinforcing agents, etc., to form pellets. Pellet produced by the method according to the present invention minimizes dust generation and provides antibacterial and odor reduction effects, improves livestock health, and can double-reduce the amount of manure discharged from livestock barns. Furthermore, the invention relates to a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure that enables the simultaneous securing of absorbency, structural stability, and moisture resistance through the adjustment of additives according to application and the optimization of the manufacturing process. Background Technology

[0003] Existing bedding materials for livestock have included sawdust, rice hulls, and rice straw, but they had limitations such as adverse effects on the respiratory health of livestock due to dust generation, odor and hygiene management issues due to low moisture absorption rates, and environmental problems caused by the large amount of livestock manure generated during disposal.

[0004] Furthermore, while the resource recovery of livestock manure is an urgent environmental challenge, simple composting limits its use as fertilizer due to issues with salinity and odor. Therefore, it is necessary to develop technologies that convert livestock manure into high-value-added resources, rather than merely treating it.

[0005] As for related prior art, Korean Patent Application No. 10-2022-0109162, "Carbon-neutral livestock manure biochar manufacturing system using power plant waste heat," provides a carbon-neutral livestock manure biochar manufacturing system for manufacturing biochar by treating high-moisture livestock manure using waste heat with low usability from heat-generating facilities such as power plants or various waste incinerators.

[0006] In addition, Korean Patent Application No. 10-2022-0071693, "Smart Decomposition, Elimination, and Reduction Device for High-Moisture Organic Waste Using Biocatalysts," can process high-moisture organic waste, such as food waste, livestock manure, slaughterhouse waste, dead livestock, animal and plant residues, or wastewater sludge, by fermenting and decomposing it using a biocatalyst made by crushing and mixing rice husks, microorganisms, enzymes, and inorganic materials, thereby ultimately producing composting excipients, soil conditioners, and solid fuels for resource recovery.

[0007] In addition, Korean Patent Application No. 10-2022-0137967, "Composition of a Compound Fertilizer with Regulating Nutrient Release Containing Biodegradable Polymer and Biochar and Method for Manufacturing the Same," comprises the steps of: pyrolyzing one or more of livestock manure, agricultural by-products, lignocellulosic biomass, and plant biomass in a temperature range of 200℃ to 1,000℃, allowing a gasification reaction to occur for 5 seconds to 10 hours, and then drying and crushing the biomass that has undergone the gasification reaction to produce biochar; and drying the biomass that has undergone the gasification reaction at 40℃ to 110℃, crushing it, and selecting only biochar consisting of 0.1㎛ to 500㎛ through a sieving method. The present invention relates to a nutrient-releasing compound fertilizer composition comprising biodegradable polymer and biochar, and a method for manufacturing the same, comprising the step of mixing and stirring a mixture of the above biochar, nutrient components, and biodegradable polymer in a certain weight ratio with distilled water to produce a compound fertilizer formed in one of the forms of beads, pellets, or chips.

[0008] In addition, Korean patent application No. 10-2022-0109779, "Method and system for producing solid fuel and biochar from livestock manure using a waste vinyl decomposition system," relates to a method and system for producing solid fuel and biochar from livestock manure using a waste vinyl decomposition system, wherein waste vinyl discharged in large quantities in rural and fishing villages is decomposed to obtain oil, and the obtained oil is used as fuel to produce biochar and solid fuel from livestock manure, and additional heat supply is possible by burning the residue remaining after separating the oil from the waste vinyl, thereby increasing thermal efficiency, and external heat is supplied to produce biochar and solid fuel respectively in preparation for cases where the heat source is insufficient.

[0009] These conventional technologies attempt to manufacture biochar or pellets using livestock manure, but limitations still exist, such as dust generation, low water absorption, issues with salt and odor, and insufficient pellet strength and moisture resistance.

[0010] Accordingly, there is a demand in the relevant technology field for the development of manufacturing technology for livestock pellet bedding that can efficiently utilize livestock manure as a resource while simultaneously ensuring high absorbency, structural stability, and antibacterial properties. Prior art literature

[0012] Republic of Korea Patent Application No. 10-2022-0109162 "Carbon-neutral livestock manure biochar manufacturing system using power plant waste heat" Republic of Korea Patent Application No. 10-2022-0071693 "Smart decomposition, elimination, and reduction device for high-moisture organic waste using a biocatalyst" Republic of Korea Patent Application No. 10-2022-0137967 "Nutrient release-controlled complex fertilizer composition containing biodegradable polymer and biochar and method for manufacturing the same" Republic of Korea Patent Application No. 10-2022-0109779 "Method and system for manufacturing solid fuel and biochar from livestock manure using a waste vinyl decomposition system" The problem to be solved

[0013] The present invention aims to solve the above problems by providing a method and system for manufacturing livestock pellet bedding using livestock manure-derived biochar, which efficiently converts livestock manure into biochar and mixes it with peat moss, coco peat, fibrous reinforcing agents, etc., to form pellets, thereby securing a moisture absorption rate and swelling rate 6 to 8 times higher than that of conventional sawdust.

[0014] Furthermore, the present invention aims to provide a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure, which minimizes dust generation through the pellet bedding to improve the respiratory health of livestock and enables a double reduction in livestock manure discharge—that is, simultaneously achieving a reduction in discharge through the resource utilization of livestock manure and a reduction in manure discharge generated from the pellet bedding after use.

[0015] Furthermore, the present invention aims to provide a method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure, which can contribute to improving the livestock barn environment and enhancing livestock welfare by simultaneously securing a porous structure, high absorbency, structural stability, and moisture resistance through the livestock pellet bedding, thereby increasing the efficiency of livestock barn management and reducing environmental burden, and contributing to the operation of a sustainable livestock industry.

[0016] However, the objectives of the present invention are not limited to those mentioned above, and other unmentioned objectives will be clearly understood by those skilled in the art from the description below. means of solving the problem

[0018] To achieve the above objective, a method for manufacturing a livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention comprises: a first step of introducing livestock manure to perform pretreatment, particle size separation, salt control, and crushing processes; a second step of producing biochar derived from livestock manure by indirectly carbonizing the livestock manure; a third step of forming a pellet composition by mixing the biochar derived from livestock manure with peat moss, coco peat, a fiber reinforcing agent, a binder, and an additive; a fourth step of forming a basic pellet shape by primary pelletizing the pellet composition; a fifth step of re-forming the primary pellet into a final pellet shape for bedding by compressing, molding, and re-mixing the primary pellet; and a sixth step of drying the re-formed pellet and forming an eco-friendly coating layer; wherein conditions including moisture content, mixing ratio, molding pressure, drying pattern, and coating thickness are controlled according to optimal process information received from an AI-based quality prediction and big data server. It is characterized by including

[0019] At this time, the above-mentioned controlling step is linked with a group of administrator terminals and user terminals through a big data server and a network to monitor in real time the quality, absorption rate, volume swelling rate, dust generation rate, and antibacterial properties of the pellets being produced, remotely adjust the formulation of additives for each application, fermentation / maturation conditions, pellet size, and final moisture content, and provide a method for manufacturing livestock pellet bedding using livestock manure-derived biochar, characterized by including a step of feeding back information on manure discharge, livestock health, and livestock barn environment generated after using the pellet bedding and reflecting it in the next manufacturing process.

[0020] To achieve the above objective, a manufacturing system for livestock pellet bedding using livestock manure-derived biochar according to an embodiment of the present invention comprises, in the manufacturing system (1) for livestock pellet bedding using livestock manure-derived biochar, a group (10G) of livestock manure-derived biochar manufacturing device modules (10) including a livestock manure-derived biochar manufacturing device module (10), a livestock pellet bedding manufacturing device module (20), a network (30), and a livestock pellet bedding manufacturing server (40); each livestock manure-derived biochar manufacturing device module (10) includes a livestock manure treatment device (11), an indirect carbonization device (12), a raw material input device (13), a first mixing device (14), a first molding device (15), a first drying device (16), and a first control device (17); and the livestock pellet bedding manufacturing device module (20) includes a second mixing device (21), a second molding device (22), a second drying device (23), The livestock pellet bedding manufacturing server (40) may be characterized by including a fixation / coating device (24) and a second control device (25), and by integrating and managing the process through control of each component of the livestock manure-derived biochar manufacturing device module (10) and the livestock pellet bedding manufacturing device module (20), optimizing additive composition, pellet size, moisture content, and quality information for each application by linking with a big data server (50), and communicating with a manager terminal (60) and a user terminal group (70G) to provide production status, quality information, and application information in real time.

[0021] At this time, the first control device (17) can provide a livestock pellet bedding manufacturing system using livestock manure-derived biochar, characterized by performing fermentation and maturation of livestock manure-derived biochar using deep sea water in a fermentation and maturation tank inside a raw material input device (13), and controlling the first mixing device (14), the first molding device (15), and the first drying device (16) based on the optimal fermentation time, temperature, pH, and additive mixing information for each application received from a big data server (50).

[0022] Additionally, the second control device (25) can provide a livestock pellet bedding manufacturing system using livestock manure-derived biochar, characterized by controlling the processes of the second mixing device (21), the second molding device (22), the second drying device (23), and the immobilization / coating device (24), and controlling to predict and optimize the pellet absorption rate, volume expansion rate, dust generation rate, and antibacterial properties in advance using an AI-based quality prediction algorithm. Effects of the invention

[0024] The method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention provide the effect of efficiently converting livestock manure into biochar and pelletizing it by mixing it with peat moss, coco peat, fibrous reinforcing agent, etc., thereby enabling a water absorption rate and swelling rate 6 to 8 times higher than that of conventional sawdust.

[0025] In addition, the method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure according to another embodiment of the present invention provide the effect of improving the respiratory health of livestock by minimizing dust generation through the pellet bedding and doubly reducing the amount of manure discharged from livestock barns, that is, simultaneously achieving a reduction in discharge resulting from the resource utilization of livestock manure and a reduction in manure discharge generated from the pellet bedding after use.

[0026] Furthermore, the method and system for manufacturing livestock pellet bedding using biochar derived from livestock manure according to another embodiment of the present invention can contribute to improving the livestock barn environment and enhancing livestock welfare by simultaneously securing a porous structure, high absorbency, structural stability, and moisture resistance through the livestock pellet bedding. By doing so, it provides the effect of contributing to the sustainable operation of the livestock industry by increasing the efficiency of livestock barn management and reducing the environmental burden. Brief explanation of the drawing

[0028] FIG. 1 is a flowchart illustrating a method for manufacturing livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention. FIG. 2 is a drawing showing a system (1) for manufacturing livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention. FIG. 3 is a block diagram showing the components of a livestock manure-derived biochar manufacturing device module (10) according to an embodiment of the present invention. Specific details for implementing the invention

[0029] Hereinafter, a detailed description of preferred embodiments of the present invention will be given with reference to the accompanying drawings. In describing the present invention below, if it is determined that a detailed description of related known functions or configurations may unnecessarily obscure the essence of the present invention, such detailed description will be omitted.

[0031] FIG. 1 is a flowchart illustrating a method for manufacturing livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention.

[0032] We examine the composite composition used in the method for manufacturing livestock pellet bedding using biochar derived from livestock manure.

[0033] The composite composition may include biochar derived from livestock manure, peat moss, coco peat, a reinforcing agent, zeolite, chitosan, and beneficial microorganisms. Based on 20 to 40 parts by weight of biochar derived from livestock manure, 30 to 50 parts by weight of peat moss, 10 to 30 parts by weight of coco peat, optionally 5 to 15 parts by weight of reinforcing agent, 5 to 10 parts by weight of zeolite, 1 to 5 parts by weight of chitosan, and 0.5 to 5 parts by weight of beneficial microorganisms may be mixed and utilized.

[0034] Therefore, the mixing ratio of each of the above components is not merely a simple mixture, but possesses a critical range essential for achieving a balance of odor suppression, moisture control, mechanical strength, antibacterial properties, and viable microbial stability; if this range is exceeded, performance deteriorates rapidly. By defining this critical mixing range, the present invention can simultaneously ensure the reproducibility of performance and long-term stability of livestock pellet bedding.

[0036] If the biochar derived from livestock manure is less than 20 parts by weight, the adsorption capacity for ammonia and hydrogen sulfide is significantly reduced, resulting in insufficient deodorization effect, and if it exceeds 40 parts by weight, the mechanical strength of the pellets is reduced, causing problems such as easy decomposition.

[0037] The livestock manure-derived biochar used in the present invention can be manufactured using livestock manure by a livestock manure-derived biochar manufacturing device module (10) as shown in FIG. 3.

[0038] When the livestock manure-derived bio used in the present invention is manufactured by the livestock manure-derived biochar manufacturing device module (10), pretreatment, multi-stage pyrolysis, doping, and activation treatment processes may be additionally performed.

[0039] That is, the livestock manure treatment device (11) can collect livestock manure as a pretreatment process, remove impurities, and then inoculate beneficial microorganisms (e.g., Bacillus, nitrifying bacteria, EM, etc.) and ferment for a short period (12 to 48 hours) to decompose the odor-causing components and stabilize the organic structure.

[0040] Subsequently, through a multi-stage pyrolysis process, fermented livestock manure can be first pyrolyzed at a low temperature of 300 to 400°C to remove volatile organic compounds and odor components, and then pyrolyzed at a high temperature of 600 to 700°C to form biochar with a stable carbon structure.

[0041] Subsequently, during the doping and activation process, phosphates, zeolites, metal ions (Fe, Cu, etc.), or clay minerals (bentonite, etc.) may be introduced during or immediately after pyrolysis to form functional catalyst particles and an adsorption correction layer on the surface of the biochar. Additionally, if necessary, an activation treatment to increase porosity by injecting CO2 or water vapor may be performed in parallel.

[0043] In the present invention, the zeolite is not only added as part of the composite composition but is also used separately in subsequent processes (salt washing or adsorption correction, multi-stage salt reduction treatment), thereby combining with biochar in the form of fine powder to optimize odor and salt adsorption.

[0044] When zeolite is used only in subsequent processes rather than being added as part of the composite composition, the process can be simplified by focusing on the primary function of “salt correction and reduction” to serve as a substitute or supplement for washing, and the required amount can be variably adjusted according to process conditions at each stage of biochar manufacturing.

[0045] However, in the present invention, by including zeolite in the composite composition as well as in subsequent processes, it is always formed in a constant ratio within the livestock manure-derived biochar and the final livestock manure-derived biochar used in the livestock pellet bedding, thereby ensuring long-term adsorption performance of ammonia, hydrogen sulfide, and salt. Furthermore, when mixed with peat moss and coco peat, it provides an overall homogenization effect of the livestock manure-derived biochar and, through interaction with chitosan, an antibacterial and adsorption capacity enhancement effect through a chitosan coating on the surface of the zeolite.

[0047] Biochar derived from livestock manure (20 to 40 parts by weight) can secure a porous structure favorable for microbial activity by applying a low-temperature (350 to 450°C) carbonization process.

[0048] In one embodiment of the present invention, a carbonization process can be performed by an indirect carbonization device (12) between the multi-stage pyrolysis process and the doping and activation treatment process.

[0049] More specifically, when producing biochar derived from livestock manure, indirect carbonization of livestock manure with separated particle sizes is performed by an indirect carbonization device (12), and a low-temperature carbonization process is applied as a subsequent process after the biochar derived from livestock manure is produced to secure a porous structure favorable for microbial activity.

[0051] In another embodiment of the present invention, by introducing a medium-temperature carbonization process immediately before activation, precise control of the micropore / medium pore ratio is possible compared to the same activation conditions, and thermal fixation of heteroatom functional groups is promoted, thereby improving the simultaneous removal capacity of ammonia and hydrogen sulfide by more than 30% and increasing the capacity retention rate after 10 regeneration cycles to more than 80%.

[0052] More specifically, after multi-stage pyrolysis (medium-low temperature) and before activation, a 'medium-temperature carbonization process' can be performed sequentially after pretreatment, including (1st) low-temperature pyrolysis at 300 to 380°C, (2nd) medium-temperature pyrolysis at 420 to 520°C, medium-temperature carbonization at 600 to 750°C, doping (or simultaneous execution), and activation (steam / CO₂ at 780 to 900°C).

[0053] Through this process, volatile components are first removed by pyrolysis to reduce the risk of pore collapse, and by accelerating aromaticization and condensation in medium-temperature carbonization to lock the carbon matrix, followed by an activation process, it is possible to simultaneously suppress over-etching of micropores and secure high specific surface area and durability.

[0054] In addition, N / P / K doping stabilization is achieved, and after substitution / complexion of the intrinsic minerals derived from livestock manure and the external doping agent during medium-temperature carbonization, the thermal fixation of functional groups such as pyridine-type N and phosphate ester bonds can be enhanced.

[0055] In addition, the fine dispersion and fixation of ash can reduce heavy metal leaching and enhance ammonia / hydrogen sulfide adsorption performance.

[0056] According to another embodiment of the present invention, the indirect carbonization device (12) can perform a double carbonization process in which hydrothermal carbonization (HTC) is performed upstream. Specifically, after undergoing hydrothermal treatment (HTC) and drying processes under conditions of 180 to 220°C and 1 to 3 MPa, primary and secondary pyrolysis, medium-temperature carbonization, doping, and activation steps are performed sequentially, thereby enabling compositional homogenization and inorganic rearrangement for raw materials with high moisture and salt content. Accordingly, the micropore structure and heteroatom fixation can be precisely controlled in subsequent steps, thereby reducing process variability and improving performance reproducibility.

[0058] Livestock manure-derived biochar can be utilized after salt washing or adsorption correction treatments have been applied not only during production but also after production. For example, this can be achieved through the mixing of zeolite or loess.

[0059] Livestock manure (especially pig and cattle manure, etc.) contains sodium (Na + ), chloride (Cl - It contains a large amount of salt components, and if this is incorporated directly into biochar, it can lead to reduced fertilizer usability, deterioration in the quality of livestock pellets and bedding made from livestock manure-derived biochar, and cause odor and microbial problems; therefore, a preliminary purification process may be required. In other words, when producing livestock manure-derived biochar, it is desirable to reduce the salt content or correct the effects of the salt using an adsorbent.

[0060] In the present invention, during the "Washing Treatment" process, the biochar derived from livestock manure can be washed with distilled water or a weak acid (e.g., 0.1M acetic acid) after production to dissolve and remove water-soluble salts such as NaCl and KCl, and then dried again to reduce the salt concentration. Through such washing treatment, the salt content can be reduced by 30 to 50%, preventing salt damage when used in soil, and improving pellet molding stability.

[0061] In other words, the process of removing soluble salts through primary distilled water washing and weak acid treatment must be performed immediately after the production of biochar. If livestock manure biochar is pelletized while retaining salts, water-soluble inorganic salts, and alkaline components, it will cause salt leaching corrosion, odors, and the proliferation of pathogenic microorganisms within the livestock barn. Therefore, washing and acid treatment must be performed during the pretreatment stage for pelletization.

[0062] Meanwhile, during the "Adsorption Compensation" process, salt is not washed directly; instead, adsorbents such as zeolite, bentonite, and activated carbon are mixed, and this adsorbent Na + , Cl - It supports the back, which can compensate for the negative effects of salt in livestock bedding.

[0063] That is, adsorption correction is performed by adding a second zeolite / bentonite fine powder, and this process may be optimally carried out by the second mixing device (21) during the mixing stage immediately before pellet molding.

[0064] In other words, zeolite and bentonite must be uniformly dispersed within the pellets to maintain long-term adsorption of ammonia, hydrogen sulfide, and moisture during use in livestock barns; otherwise, if processed immediately after biochar production, there is a risk of uneven mixing or partial loss during the subsequent mixing and molding processes.

[0065] Accordingly, it is possible to alleviate salt problems without additional washing, enhance the odor and ammonia adsorption performance within livestock pellet bedding, and simplify the process.

[0066] In other words, salt washing or adsorption correction treatment of livestock manure-derived biochar can be performed by directly removing salt physically and chemically through salt washing, or by mitigating side effects through adsorption materials without completely removing salt through adsorption correction treatment.

[0067] In another embodiment of the present invention, a manufacturing system (1) for livestock pellet bedding using biochar derived from livestock manure is constructed as a multi-stage salt reduction and adsorption optimization system, thereby reducing salt (Na+, Cl-) in the biochar derived from livestock manure by more than 50% and minimizing the deterioration of pellet quality and the generation of odors caused by salt.

[0068] To this end, the process may consist of the above-mentioned first step of removing soluble salts through washing with distilled water and weak acid treatment, the second step of performing adsorption correction treatment by adding zeolite and bentonite fine powder, and the third step of improving adsorption capacity and antibacterial properties by coating the surface of the biochar with chitosan.

[0069] That is, the improvement in adsorption capacity and antibacterial properties due to the third chitosan coating can be maximized by placing it as a final surface treatment after pellet molding by the second molding device (22). Since chitosan has antibacterial and cationic polymer properties, it must be coated on the surface of the pellet to directly contribute to bacterial inhibition and odor adsorption. Therefore, if it is added before molding, there is a concern that it may decompose or lose functionality during the high temperature and compression process. Thus, spray coating or dip coating after pellet molding may be the most ideal method.

[0070] By constructing such a multi-stage salt reduction and adsorption optimization system, it is possible to achieve a 30-50% reduction in salt concentration, improved pellet molding stability, and enhanced adsorption of ammonia and hydrogen sulfide, which can be achieved by the second control device (25) of the livestock pellet bedding manufacturing device module (20) in FIG. 2.

[0072] Peat moss (30 to 50 parts by weight) can be used as a high-moisture absorbent.

[0073] If the peat moss is less than 30 parts by weight, the moisture retention capacity is insufficient, which lowers the comfort of the livestock environment, and if it exceeds 50 parts by weight, mold growth and odor may increase due to excessive moisture accumulation.

[0074] To explain the peat moss used in the present invention, the peat moss is moss ( Sphagnum moss It is preferable to use materials that have been accumulated and decomposed over a long period of time to improve the moisture retention capacity of the bedding, and to use materials produced by drying the peat moss to a moisture content of 35-40%.

[0075] The peat moss used in the present invention refers to organic matter that has been deposited over a long period of time in an anaerobic state by plants such as aquatic plants, reeds, and mosses in swamps approximately 3,000 years ago due to elevated groundwater levels. The peat moss has the following characteristics.

[0076] ① Containing approximately 0.6–1.4% nitrogen, it can supply a significant amount of nitrogen to crops. ② It has a water absorption capacity of about 16 to 24 times its dry weight, thereby increasing the soil's water retention capacity. ③ It possesses excellent nutrient retention capabilities, which are the ability to adsorb fertilizer components, due to its high Cation Exchange Capacity (CEC). ④ As it exists in the form of organic carbon that is stable against soil decomposition, its physicochemical properties can be maintained for a long period. ⑤ Produced in humid areas of cold regions, it is free from filamentous fungi, bacteria, pests, and weed seeds, and is lightweight, making it easy to handle. ⑥ It prevents soil hardening and is free from toxicity and unpleasant odors.

[0077] Peat moss is mainly found in cold regions such as North America (including Canada), Northern Europe, Siberia, and Alaska, and is widely used as a raw material for organic fertilizers and potting soil.

[0079] Coco peat (10 to 30 parts by weight) can improve the mechanical strength and water retention capacity of the pellets. If the amount of coco peat is less than 10 parts by weight, the effect of improving the air permeability of the pellets is limited, and if it exceeds 30 parts by weight, the compression formation of the pellets becomes unstable due to the excessive fibrous structure.

[0081] If the reinforcing agent (e.g., starch-based or lignin-based binder) is less than 5 parts by weight, the compressive strength and wear resistance of the pellets cannot be secured, and if it exceeds 15 parts by weight, the dispersibility of the pellets is reduced due to excessive binding.

[0082] In another embodiment of the present invention, a reinforcing agent (optional 5 to 15 parts by weight) may be formed from a PLA (PolyLactic Acid)-based composite resin. Specifically, the PLA-based composite resin may be prepared by extruding and kneading 20 parts by weight of polyethylene and 5 to 6 parts by weight of polyurethane based on 100 parts by weight of PLA resin, and then adding a waterproofing agent, a surface protective agent, a PHA (PolyHydroxyAlkanoate) resin, and a flame retardant in appropriate proportions.

[0083] These PLA-based composite resins go beyond simple bonding functions and play a role in reinforcing strength, enhancing moisture resistance, and imparting antibacterial and flame retardant properties within the pellet structure. In particular, when mixed in a weight ratio of PLA-based composite resin : waterproofing agent : surface protection agent : PHA resin : flame retardant = A : B : C : D : E, it was confirmed that the tensile strength, fracture strength, and burst strength test results improved by more than 20–40% compared to the use of PLA alone.

[0084] Here, the recommended weight parts (e.g., g or parts by weight) may be A : B : C : D : E = 6.5 : 0.8 : 0.8 : 0.5 : 1.0, and when converted to mass percentages (converting the sum of the PLA-based composite resin matrix and additives to 100), A (PLA base) may be approximately 78~80 wt%, B 9~10 wt%, C 9~10 wt%, D 5~6 wt%, and 12 wt% (slightly variable depending on rounding to the nearest decimal point).

[0085] More specifically, the PLA-based composite resin (A) is preferably composed in a weight ratio range of 6.0 to 7.0. If this range is exceeded, either the mechanical strength or the deodorization / adsorption performance of the pellets is compromised. The waterproofing agent (B) should be controlled within a range of 0.5 to 1.0, with a recommended value of 0.8. Exceeding this range results in performance degradation due to excessive coating or insufficient waterproofing. The surface protection agent (C) is added within a range of 0.5 to 1.0 to ensure the wear resistance and long-term durability of the pellets. PHA (D) is limited to a range of 0.25 to 0.75, with a recommended value of 0.5 that balances biodegradability and physical property reinforcement. The flame retardant (E) should be maintained within a range of 0.75 to 1.25, with a recommended value of 1.0.

[0086] Through this composition and weight ratio, mechanical properties, moisture resistance and shape stability, maintenance of deodorization and adsorption performance, and antibacterial properties can be improved. Regarding the improvement of mechanical properties, pellet bedding manufactured with the above recommended ratios (A to E) showed a 20-35% increase in tensile strength, a 25-40% increase in fracture strength, and a 15-25% increase in burst strength compared to PLA alone (control group) (tensile test: TAPPI T 404 om-87; fracture strength: TAPPI T 511 om-83; burst: TAPPI T 403 om-85). Regarding moisture resistance and shape stability, the residual strength after exposure to 90% RH and 30°C for 14 days was 85% or more (comparative example 60-70%). In terms of maintaining deodorization and adsorption performance, more than 90% of the initial NH3 adsorption capacity is maintained for 30 days (group containing the complex agent), whereas the group with excessive repellent (e.g., B > 1.0) drops sharply to less than 60% of the initial value. In terms of antibacterial properties, the reduction rate of E. coli and S. aureus on the pellet surface is 1-log or higher (chitosan and PHA combination group).

[0087] In other words, the PLA-based composite resin used as a reinforcing agent performs moisture barrier and surface protection functions within the pellets, thereby suppressing the easy collapse or decay of the pellets even under the high humidity and ammonia concentrations of livestock environments. Furthermore, the combined use of PHA resin, chitosan, and beneficial microorganisms enhances antibacterial and deodorizing performance on the pellet surface, allowing the pellets to maintain stable physical properties for a long period even under friction and compression caused by livestock hooving.

[0088] Therefore, the composite composition containing the PLA-based composite resin of the present embodiment as a reinforcing agent provides a significant effect in that it can simultaneously secure mechanical strength, durability, antibacterial properties, and deodorizing performance, unlike the manufacture of a floor mat through simple mixing of absorbent materials.

[0090] Zeolite (5 to 10 parts by weight) is a natural aluminosilicate mineral with a microporous structure that selectively adsorbs odor components such as ammonia (NH3) and hydrogen sulfide (H2S), and when used together with biochar, it can enhance the odor and salt reduction effects.

[0091] When zeolite is included in the range of 5 to 10 parts by weight, it creates a synergistic effect with the micropores of biochar, ammonium ions (NH4 + ) Exchange and adsorption capabilities are maximized, and if less than 5 parts by weight, the effect is insufficient, and if more than 10 parts by weight, the uniformity of the pellet structure is reduced due to excessive mineral content.

[0093] Chitosan (1 to 5 parts by weight) is a natural polymer derived from crustacean shells and has excellent antibacterial properties, binder function, and moisture adsorption capacity, and can inhibit microbial growth and improve structural strength within pellets.

[0094] When chitosan is included in an amount of 1 to 5 parts by weight, the antibacterial and binding power are optimized, and if it is less than 1 part by weight, the antibacterial properties are weak, and if it exceeds 5 parts by weight, clogging may occur during the pellet extrusion process due to excessive viscosity.

[0096] Beneficial microorganisms (0.5 to 5 parts by weight) may be optionally added depending on the application and may include Bacillus, Lactobacillus, Rhodopseudomonas, etc. When beneficial microorganisms are used in livestock pellet bedding, they can reduce odors and promote fermentation.

[0097] When beneficial microorganisms are added in an amount of 0.5 to 5 parts by weight, they attach to the surface of the biochar and the peat moss / coco peat fibers, stabilizing the viable cell retention rate and maximizing the effects of odor reduction and pathogen inhibition. If the amount is less than 0.5 parts by weight, it is difficult to secure an effective number of viable cells, and if it exceeds 5 parts by weight, quality degradation occurs due to over-fermentation and heat generation during storage.

[0099] A method for manufacturing a livestock pellet bedding using the above-described composite composition, that is, a method for manufacturing a livestock pellet bedding using biochar derived from livestock manure, may include a raw material preparation step (S11), a mixing step (S12), a molding step (S13), and a drying / fixation step (S14) as shown in FIG. 1.

[0100] In the raw material preparation step (S11), livestock manure can be carbonized at 350 to 450°C to produce porous biochar derived from livestock manure.

[0101] According to one embodiment of the present invention, the biochar that is primarily carbonized in the livestock manure-derived biochar manufacturing device module (10) can be re-carbonized in the range of 350 to 450°C in the raw material preparation step (S11) for manufacturing livestock pellet bedding. Compared to a single carbonization process, this double carbonization process provides effects such as (i) homogenization of the pore structure, (ii) stabilization of surface functional groups, (iii) improvement of microbial loading efficiency and deodorization performance, and (iv) increase in pathogen removal rate, so that the durability, hygiene, and functionality of the livestock pellet bedding can be greatly improved.

[0102] That is, the primary purpose of primary carbonization by the livestock manure-derived biochar manufacturing device module (10) is to remove a large amount of moisture and form basic porosity, and is carried out at a relatively low temperature (e.g., 300~400℃) or in a short time, with the primary effects being the removal of impurities, securing basic porosity, and removing odor components. Meanwhile, the secondary carbonization (post-carbonization, re-carbonization) in the pellet manufacturing raw material stage (S11) has the primary purpose of refining the structure and optimizing surface characteristics, and is carried out through precise control at a temperature of 350~450℃ (medium temperature range), with the primary effects being improved adsorption performance (deodorization, ammonia capture capacity) by controlling the pore diameter distribution, improved affinity with zeolite, chitosan, and microorganisms by controlling surface oxygen functional groups, and imparting antibacterial properties and improving durability due to high-temperature carbonization.

[0104] The mixing step (S12) may uniformly mix biochar derived from livestock manure, peat moss, and coco peat in the weight ratios described above. Additionally, zeolite and chitosan may also be uniformly mixed in the weight ratios described above. Furthermore, reinforcing agents and microorganisms may be optionally added.

[0105] Here, zeolite is added after being finely ground (200 mesh or less) and combined with biochar derived from livestock manure to increase adsorption capacity. In addition, when chitosan is mixed, it is prepared as a 1% solution and sprayed into the mixture to provide a binder function and antibacterial function during molding.

[0106] When livestock manure-derived biochar and zeolite are mixed, the adsorption capabilities of their porous structures overlap, maximizing the effect of reducing ammonia and salt.

[0107] In addition, when livestock manure-derived biochar and chitosan are mixed, the chitosan is coated on the surface of the livestock manure-derived biochar, which can simultaneously enhance antibacterial and adsorption properties.

[0108] In addition, when zeolite and chitosan are mixed, chitosan adheres to the surface of the zeolite, which can increase structural stability and provide the effect of reducing dust generation.

[0109] Overall, it can provide the effect of enhancing absorption, deodorization, antibacterial, and durability performance compared to existing peat moss and coco peat compositions.

[0110] The molding step (S13) can be formed by feeding the composite composition, which is the mixture prepared in the mixing step (S12), into a pellet molding machine to form cylindrical, spherical, or porous pellets.

[0111] The drying / fixation step (S14) can be performed by drying with hot air at 60~80℃ or by natural drying to maintain the moisture content at 10% or less. As an additional fixation, an eco-friendly binder can be used to apply a coating that prevents decomposition and scattering.

[0113] By utilizing a manufacturing method and system for livestock pellet bedding using biochar derived from livestock manure, moisture absorption and swelling rates 6 to 8 times higher than those of sawdust can be secured, thereby maximizing moisture absorption. Furthermore, dust generation is suppressed; provided in pellet form, dust is minimized, which can improve the respiratory health of livestock. In terms of environmental benefits, the conversion of livestock manure into biochar reduces the primary amount generated, and the amount of manure discharged after the use of pellets can be reduced secondarily. Additionally, regarding hygiene and odor improvement, odors such as ammonia and hydrogen sulfide can be reduced through the adsorption capacity of biochar and the fermentation action of microorganisms. Moreover, regarding ease of management, the pellet form facilitates packaging, transportation, and spreading, enabling intensive collection during cleaning. Finally, regarding policy compliance, it enables the resource utilization of livestock manure and compliance with environmental regulations.

[0115] FIG. 2 is a drawing showing a system (1) for manufacturing livestock pellet bedding using biochar derived from livestock manure according to an embodiment of the present invention. Referring to FIG. 2, the system (1) for manufacturing livestock pellet bedding using biochar derived from livestock manure may include a group (10G) of livestock manure-derived biochar manufacturing device modules (10) composed of a plurality of livestock manure-derived biochar manufacturing device modules, a livestock pellet bedding manufacturing device module (20), a network (30), a livestock pellet bedding manufacturing server (40), a big data server (50), an administrator terminal (60), and a group (70G) of user terminals (70) composed of a plurality of user terminals.

[0116] Here, the network (30) is a high-speed communication network capable of high-capacity, long-distance voice and data services, and may include the Internet or mobile communication networks such as 5G, LTE, WCDMA, etc., and serves to mutually transmit signals and data between a group of livestock manure-derived biochar manufacturing device modules (10G) consisting of a plurality of livestock manure-derived biochar manufacturing device modules (10), a livestock pellet bedding manufacturing device module (20), a livestock pellet bedding manufacturing server (40), a big data server (50), a manager terminal (60), and a group of user terminals (70G) consisting of a plurality of user terminals (70).

[0117] As shown in FIG. 3, the livestock manure-derived biochar manufacturing device module (10) includes a livestock manure treatment device (11), an indirect carbonization device (12), a raw material input device (13), a first mixing device (14), a first molding device (15), a first drying device (16), and a first control device (17). Meanwhile, the livestock pellet bedding manufacturing device module (20) includes a second mixing device (21), a second molding device (22), a second drying device (23), a fixation / coating device (24), and a second control device (25).

[0118] The livestock pellet bedding manufacturing server (40) integrates and controls the entire process of the livestock manure-derived biochar manufacturing device module (10) and the livestock pellet bedding manufacturing device module (20), and transmits and receives real-time data with each control device through the network (30). Through this, it manages the entire manufacturing process, including raw material characteristics, additive blending, moisture content, temperature, pellet strength, cracking degree, and fermentation status. In addition, the livestock pellet bedding manufacturing server (40) links with the big data server (50) through the network (30) to perform AI analysis based on past production data and environmental data, and provides optimal process conditions and composition guides for each application to each device module, thereby minimizing variations in production quality.

[0119] The first control device (17) feeds livestock manure and additives (peat moss, coco peat, binder, moisture regulator, etc.) indirectly carbonized inside the raw material input device (13) into the first mixing device (14), and performs mixing, first pellet molding, and second drying. In this process, the first control device (17) utilizes the optimal drying pattern, cooling / heat dissipation cross-control information, and composition information for each application provided by the big data server (50) to precisely control the moisture content, cracking degree, and strength of the pellets, and controls the automatic feeding of compositions optimized for each of the agricultural byproduct reinforced type, inorganic reinforced / strength type, and functional super-absorbent type pellets.

[0120] The second control device (25) manages the entire process from the second mixing device (21) to the immobilization / coating device (24) in an integrated manner, and utilizes multi-axis stirring, vacuum-pressure stirring, an ultrasonic dispersion module, high-frequency vibration compression technology, and temperature and humidity sensors to provide real-time feedback control of the pellet's internal uniformity, mechanical strength, porous structure, and coating layer thickness. In addition, by applying an AI-based quality prediction algorithm, it learns from past production data to predict key quality indicators such as pellet absorption rate, volume expansion rate, dust generation rate, and antibacterial properties in advance, and automatically calculates optimal process conditions.

[0121] The livestock pellet bedding manufacturing server (40) is linked with the manager terminal (60) and the user terminal group (70G) to provide real-time information such as production status, quality data, pellet usage, additive composition, absorption rate, and foaming characteristics. The manager terminal (60) enables the production manager to remotely monitor the entire process, adjust process control parameters, and perform quality certification and production history tracking functions. The user terminal group (70G) and each user terminal (70) allow the end user to check the quality, usage, usage guide, and replacement timing information of the pellet product in real-time, thereby contributing to the management of residual livestock manure after pellet use and the improvement of the hygienic environment.

[0122] As such, the livestock pellet bedding manufacturing system (1) of the present invention integrates and controls the entire process from the production of biochar derived from livestock manure to the final pellet molding and coating in a server-centric manner, and automatically produces optimal pellets for each application by utilizing big data-based AI analysis, thereby simultaneously securing a high moisture absorption rate, volume expansion, uniform internal structure, antibacterial properties, dust suppression, and environmental friendliness compared to existing technologies. In addition, by linking the manager terminal and the user terminal to monitor the entire process of production and use in real time and guarantee quality, it can contribute to improving hygiene in livestock barns and promoting livestock health.

[0124] FIG. 3 is a block diagram showing the components of a livestock manure-derived biochar manufacturing device module (10) according to an embodiment of the present invention. Referring to FIG. 3, the livestock manure-derived biochar manufacturing device module (10) may be equipped with a livestock manure treatment device (11), an indirect carbonization device (12), a raw material input device (13), a first mixing device (14), a first molding device (15), a first drying device (16), and a first control device (17).

[0125] FIG. 3 is a drawing showing a livestock manure-derived biochar manufacturing device module (10) of a livestock pellet bedding manufacturing system (1) using livestock manure-derived biochar according to an embodiment of the present invention. Referring to FIG. 3, the livestock manure-derived biochar manufacturing device module (10) may include a livestock manure treatment device (11), an indirect carbonization device (12), a raw material input device (13), a first mixing device (14), a first molding device (15), a first drying device (16), and a first control device (17).

[0126] Livestock manure has problems with soil and water pollution and odor generation, and the livestock manure-derived biochar manufacturing device module (10) in the present invention aims to alleviate environmental problems by converting livestock manure into biochar through such a configuration.

[0127] The livestock manure-derived biochar produced by the livestock manure-derived biochar manufacturing device module (10) can be mixed with peat moss, coco peat, sawdust, etc. by the livestock pellet bedding manufacturing device module (20) to produce it in the form of pellets, and due to its high moisture absorption rate and volume expansion effect, it provides sufficient effectiveness as livestock barn bedding even when using only a small amount. In addition, the salt content can be reduced through a salt washing or adsorption correction treatment process to improve the usability of the soil and livestock bedding.

[0128] Next, we will examine each component constituting the livestock manure-derived biochar manufacturing device module (10).

[0129] The livestock manure treatment device (11) can perform the processes of removing foreign substances, crushing, and particle size separation when livestock manure is introduced. The livestock manure treatment device (11) can control the salt concentration by performing salt washing (water washing) or adsorption correction treatment (mixing zeolite and bentonite) as needed.

[0130] More specifically, the livestock manure treatment device (11) can additionally perform pretreatment, multi-stage pyrolysis, doping, and activation treatment processes, and can perform treatment by requesting a carbonization process for the indirect carbonization device (12) between the multi-stage pyrolysis process and the doping and activation treatment process through linkage with the indirect carbonization device (12) under the control of the first control device (17).

[0131] In an embodiment of the present invention, the indirect carbonization device (12) performs indirect carbonization of livestock manure with separated particle sizes and can transfer the generated heat and combustion gas to the first drying device (16) to enable secondary energy utilization. In another embodiment of the present invention, the indirect carbonization device (12) performs indirect carbonization of livestock manure with separated particle sizes and can also transfer the generated heat and combustion gas to the second drying device (23).

[0132] The raw material input device (13) can input indirectly carbonized livestock manure, biochar additives (e.g., peat moss, coco peat), moisture regulators, and binders into the first mixing device (14).

[0133] The first mixing device (14) can prepare a uniform biochar composition derived from livestock manure through a mixing and kneading process with respect to the input raw materials.

[0134] The first molding device (15) can compress the mixed composition to form a primary pellet. The first molding device (15) can optimize the absorption rate and volume expansion of the final product by adjusting the primary pellet size, density, and moisture content in consideration of the mat shape finally manufactured by the livestock pellet mat manufacturing device module (20).

[0135] The first drying device (16) can utilize not only waste heat generated during the indirect carbonization process, but also waste heat from a waste incinerator or a combined heat and power plant.

[0136] Here, the first control device (17) controls the moisture content, cracking degree, and pellet strength through secondary drying using a plurality of Peltier elements for the first drying device (16), and can utilize drying pattern and cooling / heat dissipation cross-control information provided from the big data server (50). The first control device (17) preferably controls the target moisture content to be 15 to 20% or less, preferably around 18%, and the cracking degree to be within the 15% range.

[0137] The raw material input device (13) can input components other than indirectly carbonized livestock manure into the first mixing device (14).

[0138] In addition, the additive composition that can be additionally introduced into the first mixing device (14) through the raw material input device (13) in the present invention may include a basic additive (moisture regulator, wetting agent, pH regulator) and an auxiliary additive (foaming agent, stearic acid, silica). Here, the foaming agent controls the volume expansion and moisture absorption rate of the pellets, and the stearic acid controls the foaming rate after pellet molding to induce uniform diffusion. Silica can prevent dust generation.

[0139] Depending on the use of the livestock manure-derived biochar, such as an agricultural byproduct reinforced type, an inorganic reinforced / strength type, or a functional high-absorbency type, the first control device (17) receives use category information from a livestock pellet bedding manufacturing server (40) connected to a network (30), and can limit the composition to be fed into the first mixing device (14). Here, the livestock pellet bedding manufacturing server (40) can remotely receive use category information from an administrator terminal (60) or a user terminal (70) and transmit the received information to the first control device (17) through the network (30).

[0140] First, the agricultural byproduct-reinforced livestock manure-derived biochar composition comprises 25 parts by weight of rice straw powder, 15 parts by weight of SMS (waste mushroom substrate), 10 parts by weight of binder (starch-based or PLA reinforcing agent), and 10 parts by weight of zeolite, based on 40 parts by weight of indirectly carbonized livestock manure, thereby enhancing porosity and microbial affinity, and simultaneously improving odor reduction and absorption rate.

[0141] In addition, 1 to 3 parts by weight of a moisture regulator, 0.5 to 2 parts by weight of a wetting agent, 1 to 3 parts by weight of a foaming agent, and 0.5 to 1 part by weight of silica may be optionally mixed as additives.

[0142] Here, the mixing of rice straw powder and SMS maximizes the internal porosity and microbial affinity of the pellets, enabling simultaneous improvement in odor reduction and absorption rate, and the zeolite is NH4 +The soil and odor control functions can be enhanced by strengthening the exchange capacity.

[0143] By selectively adding and mixing moisture regulators, wetting agents, foaming agents, and silica as additives, it can be used when stabilization of absorption performance due to homogenization of moisture on the surface and inside of the pellets when moisture regulators are added, improvement of fermentation uniformity due to promotion of initial water absorption of agricultural by-products when wetting agents are added, improvement of instantaneous absorption capacity due to expansion of internal porosity of the pellets when foaming agents are added, and suppression of dust generation and assistance in molding stability when silica is added.

[0144] Since agricultural byproduct-based pellets have relatively low structural strength, the appropriate use of foaming agents and wetting agents can balance the absorption rate and volume expansion.

[0145] Next, the inorganic reinforced, strength-type livestock manure-derived biochar composition can focus on increasing strength, increasing moisture retention, and minimizing dust generation by including 20 parts by weight of diatomaceous earth, 10 parts by weight of bentonite, 5 parts by weight of a binder (chitosan-based), and 20 parts by weight of coco peat based on 45 parts by weight of indirectly carbonized livestock manure.

[0146] As additives, at least one of 0.2 to 1 part by weight of a pH adjuster, 0.5 to 2 parts by weight of stearic acid, 0.5 to 1 part by weight of silica, and 1 to 2 parts by weight of a moisture regulator may be optionally mixed.

[0147] Here, through the inorganic filling of diatomaceous earth and bentonite, the pellet strength and moisture resistance are improved and dust generation is minimized, and coco peat can play a role in absorbing moisture and assisting in binding strength.

[0148] By selectively adding and mixing pH regulators, stearic acid, silica, and moisture regulators as additional additives, the addition of a pH regulator ensures material stability by controlling pH deviation when using inorganic reinforcing materials, the addition of stearic acid protects the pellet surface and maintains a uniform shape after extrusion and molding, the addition of silica improves the working environment by minimizing dust, and the addition of a moisture regulator can be used when strength maintenance is required in high-humidity environments.

[0149] Since structural stability is key to inorganic reinforcement and strength-type compositions, unpredictable performance improvements can be achieved by selecting additives focused on shape stability, dust suppression, and pH homogenization.

[0150] In addition, the functional superabsorbent biochar composition derived from livestock manure is composed of 35 parts by weight of indirectly carbonized livestock manure, 25 parts by weight of peat moss, 10 parts by weight of biodegradable SAP, 3 parts by weight of nanocellulose, 7 parts by weight of binder (PLA-based composite resin), 10 parts by weight of zeolite, 2 parts by weight of chitosan, and 3 parts by weight of microorganisms (Bacillus / yeast), thereby focusing on simultaneously securing instantaneous absorption capacity, structural stability, and antibacterial properties.

[0151] As additional additives, at least one of 0.5 to 2 parts by weight of a foaming agent, 0.5 to 1.5 parts by weight of a wetting agent, 0.5 to 1 part by weight of silica, and 0.2 to 0.8 parts by weight of a pH adjuster may be optionally mixed.

[0152] Here, it can be used when instantaneous absorption capacity and volume expansion are maximized by adding SAP, structural stability is secured with nanocellulose, and antibacterial, odor reduction, and soil compatibility are simultaneously secured by zeolite, chitosan, and microorganisms.

[0153] By selectively adding and mixing a foaming agent, a wetting agent, silica, and a pH regulator as additional additives, the foaming agent can be used to control the absorption rate and achieve uniform volume expansion by combining with SAP expansion, the wetting agent can be used to improve absorption efficiency by promoting SAP activation inside the pellet, the silica can be used to suppress dust and enhance surface protection, and the pH regulator can be used to optimize microbial activity and ensure SAP stability when necessary.

[0154] Since the key to instantaneous absorption compositions is achieving both volume expansion and structural stability simultaneously, the selection of additives allows for unexpected control of absorption rates and enhanced antibacterial properties.

[0156] In another embodiment of the present invention, the raw material input device (13) can perform fermentation and aging using deep sea water in an internal fermentation and aging tank, and it is preferable to maintain the temperature in the range of 27 to 32°C. The uniformity of the fermented biochar is improved, which can increase the efficiency of final pellet manufacturing and drying.

[0158] Next, we will examine the second mixing device (21), second molding device (22), second drying device (23), immobilization / coating device (24), and second control device (25) of the livestock pellet bedding manufacturing device module (20) that manufactures livestock pellet bedding using biochar derived from livestock manure.

[0159] The second mixing device (21) can ensure uniformity by mixing livestock manure-derived biochar, peat moss, coco peat, zeolite, chitosan, reinforcing agent, and useful microorganisms in a multi-stage and multi-axis stirring manner.

[0160] The second mixing device (21) combines a multi-axis stirring impeller and an ultrasonic dispersion module to uniformly disperse fine particles (zeolite 200 mesh or less, chitosan spray liquid, etc.).

[0161] The second mixing device (21) is equipped with a temperature sensor and a humidity sensor during the mixing process, so that the internal moisture content and temperature can be controlled in real time, thereby maintaining the quality of the mixture without inhibiting the activity of the fermentation microorganisms.

[0162] In another embodiment, the second mixing device (21) adopts a vacuum-pressure stirring method to allow the additive to penetrate into the voids, thereby maximizing the uniformity of the internal structure after pellet molding.

[0163] The second molding device (22) is a device for compressing and molding a composite composition into a pellet shape, and is equipped with a multi-mold replacement system to automatically convert and produce various pellet shapes such as cylindrical, spherical, porous structure, and multi-layer structure.

[0164] The second molding device (22) applies high-frequency vibration compression technology during the molding process, thereby enabling high density and strength with lower energy compared to the same pressure.

[0165] In another embodiment, the second molding device (22) performs a two-stage extrusion process to form an internal porous core and an external high-strength shell structure. Accordingly, the water absorption rate and mechanical strength of the livestock pellets using biochar derived from livestock manure can be improved simultaneously.

[0166] In another embodiment, the second molding device (22) can perform a primary pelletizing and a secondary pelletizing (or re-molding) method.

[0167] In the first pelletization, the second molding device (22) molds a composite composition mixed with livestock manure-derived biochar and additives (peat moss, coco peat, zeolite, chitosan, etc.) into a basic pellet shape. Here, the pellets for bedding are molded to be suitable for a diameter of 5 to 15 mm and a length of 10 to 30 mm, thereby ensuring pellet strength, basic moisture absorption, and maintaining a porous structure, which simplifies the production process, homogenizes raw materials, and facilitates primary storage and transportation.

[0168] Meanwhile, it is preferable that the livestock manure-derived biochar produced by the livestock manure-derived biochar manufacturing device module (10) be formed with a diameter of about 3 to 12 mm and a pellet length of about 7 to 25 mm.

[0169] Afterwards, in the secondary pelletization (re-molding for matting), the second molding device (22) performs re-molding of the primary pellets to optimize the structure and functionality for matting, by feeding the primary pellets into a compression mold / mold and molding them into a mat block or sheet of a desired size / area.

[0170] In other words, the primary pelletization is performed separately for the purpose of “raw material stabilization and production efficiency,” and the secondary pelletization is performed for the purpose of “optimization of bedding function.”

[0171] The second drying device (23) is a device for controlling the moisture content of livestock pellets made of molded livestock manure-derived biochar to 10% or less, and adopts a hybrid drying system (hot air drying + infrared drying + Peltier cooling drying) to achieve uniform drying without internal cracks.

[0172] The second drying device (23) is equipped with a gas sensor (NH3, H2S) during the drying process to collect and recycle odor components released during drying or to remove them through a zeolite filter.

[0173] In another embodiment, the second drying device (23) is equipped with an AI-based drying pattern optimization algorithm so that the drying curve can be automatically adjusted according to the diameter, initial moisture content, and mixing ratio of livestock pellets using livestock manure-derived biochar in pellet form.

[0174] The immobilization / coating device (24) is a device that forms an eco-friendly coating layer on the surface of a dried pellet to prevent dust, enhance antibacterial properties, and increase mechanical stability. It can uniformly spray a chitosan solution, natural resin, starch-based binder, nanosilica, etc. onto the surface of the pellet and then dry and immobilize it through a spray-dry coating method.

[0175] In another embodiment, the immobilization / coating device (24) can implement a multilayer coating structure. For example, among the multilayer coatings, the first coating layer is a chitosan antibacterial coating to inhibit bacteria and fungi, the second coating layer is a silica / diatomaceous earth coating to inhibit dust and enhance durability, and the third coating layer is an eco-friendly foaming coating to control the moisture absorption rate when using pellets.

[0176] Through this coating process, livestock manure-derived biochar can simultaneously secure antibacterial, dustproof, durable, and foam control functions.

[0177] The second control device (25) is a core module that integrates and manages the entire process from the second mixing device (21) to the fixation / coating device (24) described above, and can monitor and provide feedback control of mixing uniformity, molding pressure, drying temperature, coating thickness, etc. in real time through an IoT sensor network.

[0178] In another embodiment, the second control device (25) can apply an AI-based quality prediction algorithm to learn past production data (temperature, humidity, fermentation state, salt concentration, etc.) from a big data server (50), predict the absorption rate, strength, and dust generation rate of livestock pellets using biochar derived from livestock manure in advance, and automatically calculate optimal process conditions.

[0179] In addition, the second control device (25) is equipped with remote control and quality certification functions, so that the production status and quality can be checked and controlled from the manager terminal (60) or user terminal (70), and a QR code-based quality tracking system can be applied to the produced pellets.

[0181] In another embodiment of the present invention, a system (1) for manufacturing livestock pellet bedding using biochar derived from livestock manure can maximize the fermentation activity of beneficial microorganisms (Bacillus, Lactobacillus, Rhodopseudomonas, etc.) in the pellets by manufacturing livestock pellet bedding using biochar derived from livestock manure so as to perform AI-based fermentation optimization and beneficial microorganism activity management.

[0182] That is, the first control device (17) can perform automatic temperature control and pH monitoring in the range of 27 to 32°C by utilizing deep sea water in the fermentation and aging tank inside the raw material input device (13).

[0183] Here, the first control device (17) can perform fermentation using deep sea water in the fermentation and aging tank inside the raw material input device (13) by receiving information on the optimal fermentation time / conditions calculated through AI analysis based on the big data server (500) after accessing the big data server (30) through the network (30).

[0184] Accordingly, when using livestock pellet bedding made from biochar derived from livestock manure, it is possible to provide increased odor reduction, improved pellet uniformity and quality, and effects such as inhibition of microbial growth and enhanced antimicrobial properties.

[0186] In another embodiment of the present invention, a manufacturing system (1) for livestock pellet bedding using biochar derived from livestock manure can achieve maximum moisture absorption and minimize dust through a multi-layered pellet structure and a three-stage drying system.

[0187] That is, when manufacturing biochar derived from livestock manure using the livestock manure-derived biochar manufacturing device module (10), a porous internal structure and an external eco-friendly binder coating are formed, so that drying at 60~80℃ is achieved first by waste heat or hot air from the first drying device (16), and second by second precision drying using a Peltier element, and cracking is maintained at 15% or less.

[0188] Afterwards, the moisture content can be maintained at 10% or less by drying / fixing in the drying / fixing step (S14) by the second drying device (23) of the livestock pellet bedding manufacturing device module (20) using hot air drying at 60~80℃ or natural drying, and an anti-decomposition and anti-dusting coating can be applied using an eco-friendly binder as an additional fixation.

[0189] Through this process, a moisture absorption rate 6 to 8 times higher than that of conventionally used sawdust can be secured, livestock respiratory health can be improved by minimizing dust generation, and pellet strength and durability can be enhanced.

[0191] In another embodiment of the present invention, the manufacturing system (1) for livestock pellet bedding using biochar derived from livestock manure is configured as a smart integrated management system, thereby enabling integrated control and quality tracking of all stages of the manufacturing process.

[0192] To this end, for each component of a plurality of livestock manure-derived biochar manufacturing device modules (10) and each component of a livestock pellet bedding manufacturing device module (20), the livestock pellet bedding manufacturing server (40) performs network settings through access via the network (30), and the livestock pellet bedding manufacturing server (40) can perform real-time temperature, moisture, salinity, mixing ratio, and fermentation status monitoring through linkage with an AI-based big data server (500), and in addition, the administrator terminal (60) and user terminal (70) can access the livestock pellet bedding manufacturing server (40) via the network (30) to check the status and quality of the livestock manure-derived biochar and livestock pellet bedding, and perform remote control.

[0193] This enables enhanced policy compliance through process automation and optimization, maximization of environmental and hygienic performance, and securing pellet quality stability.

[0195] In another embodiment of the present invention, a manufacturing system (1) for livestock pellet bedding using biochar derived from livestock manure can respond to livestock manure resource utilization and environmental regulations by establishing an environmental and resource-circulating process system.

[0196] To this end, the process of livestock manure → biochar by the livestock manure-derived biochar manufacturing device module (10) and the process of biochar → pellet bedding by the livestock pellet bedding manufacturing device module (20) are performed sequentially, and by utilizing waste heat, deep sea water, and an eco-friendly binder in an eco-friendly manner, a secondary reduction in the amount of manure discharged after use can be achieved.

[0197] In other words, a sustainable livestock farming environment can be realized by reducing manure production and mitigating odors and environmental pollution.

[0198] The livestock pellets using biochar derived from livestock manure produced by the above method in the present invention may be used alone in the form of pellets themselves, or may be used in a mixed form with powder.

[0200] As described above, preferred embodiments of the present invention have been disclosed in this specification and drawings. Although specific terms have been used, they are used merely in a general sense to facilitate the explanation of the technical content of the invention and to aid in understanding the invention, and are not intended to limit the scope of the invention. It is obvious to those skilled in the art that, in addition to the embodiments disclosed herein, other variations based on the technical concept of the present invention may be implemented. Explanation of the symbols

[0202] 1: Manufacturing system for livestock pellet bedding using livestock manure-derived biochar 10: Livestock manure-derived biochar manufacturing device module 10G: Livestock manure-derived biochar manufacturing device module group 11: Livestock manure treatment device 12: Indirect carbonization device 13: Raw material input device 14: First mixing device 15: 1st molding device 16: 1st drying device 17: First control unit 20: Livestock pellet bedding manufacturing device module 21: Second mixing device 22: Second molding device 23: Second drying device 24: Immobilization / coating device 25: Second control unit 30: Network 40 : Livestock pellet bedding manufacturing server 50 : Big Data Server 60 : Administrator Terminal 70 : User terminal 70G : User terminal group

Claims

Claim 1 A method for manufacturing a livestock pellet bedding using biochar derived from livestock manure, comprising: a first step of introducing livestock manure to perform pretreatment, particle size separation, salt control, and crushing processes; a second step of indirectly carbonizing the livestock manure to produce biochar derived from livestock manure; a third step of mixing the biochar derived from livestock manure with peat moss, coco peat, a fiber reinforcing agent, a binder, and an additive to form a pellet composition; a fourth step of primary pelletizing the pellet composition to form a basic pellet shape; a fifth step of compressing, molding, and remixing the primary pellets to re-form them into a final pellet shape for bedding; and a sixth step of drying the re-formed pellets and forming an eco-friendly coating layer; wherein the conditions including moisture content, mixing ratio, molding pressure, drying pattern, and coating thickness are controlled according to optimal process information received from an AI-based quality prediction and big data server. Claim 2 A method for manufacturing livestock pellet bedding using livestock manure-derived biochar according to claim 1, wherein the controlling step comprises linking with a group of administrator terminals and user terminals via a big data server and a network to monitor in real time the quality, absorption rate, volume swelling rate, dust generation rate, and antibacterial properties of the pellets being produced, remotely adjusting the formulation of additives for each application, fermentation / maturation conditions, pellet size, and final moisture content, and feeding back information on manure discharge, livestock health, and livestock barn environment generated after using the pellet bedding to reflect in the next manufacturing process. Claim 3 A livestock pellet bedding manufacturing system (1) using livestock manure-derived biochar comprises a group of livestock manure-derived biochar manufacturing device modules (10G) including a veterinary livestock manure-derived biochar manufacturing device module (10), a livestock pellet bedding manufacturing device module (20), a network (30), and a livestock pellet bedding manufacturing server (40). Each livestock manure-derived biochar manufacturing device module (10) comprises a livestock manure treatment device (11), an indirect carbonization device (12), a raw material input device (13), a first mixing device (14), a first molding device (15), a first drying device (16), and a first control device (17). The livestock pellet bedding manufacturing device module (20) comprises a second mixing device (21), a second molding device (22), a second drying device (23), a fixation / coating device (24), and a second control device (25). A livestock pellet bedding manufacturing system using livestock manure-derived biochar, characterized in that the pellet bedding manufacturing server (40) integrates and manages the process through control of each component of the livestock manure-derived biochar manufacturing device module (10) and the livestock pellet bedding manufacturing device module (20), optimizes additive composition, pellet size, moisture content, and quality information for each application by linking with the big data server (50), and communicates with the manager terminal (60) and user terminal group (70G) to provide production status, quality information, and application information in real time. Claim 4 A livestock pellet bedding manufacturing system using livestock manure-derived biochar according to claim 3, wherein the first control device (17) performs fermentation and maturation of livestock manure-derived biochar using deep sea water in a fermentation and maturation tank inside a raw material input device (13), and controls the first mixing device (14), the first molding device (15), and the first drying device (16) based on optimal fermentation time, temperature, pH, and additive mixing information for each application received from a big data server (50). Claim 5 A livestock pellet bedding manufacturing system using livestock manure-derived biochar according to claim 4, wherein the second control device (25) controls the processes of the second mixing device (21), the second molding device (22), the second drying device (23), and the immobilization / coating device (24) in an integrated manner, and controls the pellet absorption rate, volume expansion rate, dust generation rate, and antibacterial properties in advance by utilizing an AI-based quality prediction algorithm.

Images