Method for obtaining organic fertilizer from animal waste

Abstract

FIELD: biotechnology; agriculture.SUBSTANCE: method for obtaining organic fertilizer consists of adding natural zeolite and molasses to animal waste with continuous stirring at a temperature of 105-110 °C for 60 minutes. The following animal wastes are used: horn and hoof meal, or sheep wool, or bird feathers, or blood meal, or a mixture based on horn and hoof meal, bird feathers, sheep wool, and blood meal in a ratio of 1:1:1:1. To obtain granulated fertilizer, crushing and grinding are carried out for 45-60 seconds, using a mini-granulator with a horizontal matrix. The resulting granules are 13.2±5.6 mm in length, diameter 5.74±0.9 mm is brought to a moisture content of 18-20%, and after thermal activation, the granules are intensively cooled to a temperature of at least 75-80 °C and not higher than 145-150 °C.EFFECT: obtaining an organic fertilizer in the form of granules, which has increased efficiency and prolonged action.2 cl, 10 dwg, 1 tbl

Description

[0001] The invention relates to biotechnology and agriculture, in particular to methods for obtaining protein hydrolyzers from waste wool, bird feathers, bone meal, blood meal of slaughtered animals, which can be used in planting agricultural crops, as well as for the reclamation of disturbed lands.

[0002] The meat processing industry produces a large amount of by-product waste, approximately 150 million tons per year, which in turn poses a threat to the environment.

[0003] The issue of waste-free utilization of low-value carcass parts, secondary raw materials, and meat processing waste remains unresolved. Incorporating these processed products into the technological cycle improves the environmental friendliness of production and generates additional profits. These problems can be addressed through biological methods of organic waste disposal.

[0004] Enzymatic decomposition of biological waste transforms it into a valuable, easily digestible product for the soil. Fertilizers made from protein-containing animal waste are claimed to have a positive effect on plant germination and subsequent development, and to have low soil toxicity.

[0005] In the wool processing industry, approximately 10-15% of the wool is considered waste. Wool waste is naturally light, bulky, and protein-rich. Uncleaned sheep's wool is characterized by a high percentage of nitrogen, sulfur, and various microelements (cobalt, copper, iron, manganese, zinc, and molybdenum), which play an important role in plant nutrition.

[0006] Bird feathers are produced in large quantities on poultry farms and in households. Recycling them is a complex and expensive process. To make a feed supplement from them, the feathers are first roasted or processed at elevated temperatures and pressure, and then ground into powder. This process is expensive, and the protein contained in the powder has little nutritional value.

[0007] Horn-hoof meal is one of the organic fertilizers most widely used by Italian farmers. It is used in combination with chemical fertilizers to grow crops. It is known that horn-hoof meal contains approximately 14% nitrogen.

[0008] Blood meal is an organic nitrogen fertilizer containing approximately 10-13% organic nitrogen. Knowledge of the effects of blood meal on soil organic matter and fertility is currently poorly understood.

[0009] Animal by-products are rich in protein and therefore have high potential to be used as nitrogen fertilizer.

[0010] Nitrogen is one of the most important nutrients for plants.

[0011] A complex fertilizer based on activated dehydrated natural zeolites is known, containing a mixture of humic, fulvic acid, and amino acid solutions in the zeolite pores in an amount not exceeding 1000 g per 1 ton of zeolite, as well as a solution of a mixture of nitrogen, phosphorus, and potassium fertilizer in the zeolite pores in an amount not exceeding 20 kg per 1 ton of zeolite. The method for producing this fertilizer involves treating activated dehydrated natural zeolite, crushed to a grain size of 1-7 mm, with an aqueous solution of the active components with vigorous stirring and spraying the solution with a spray bottle, without allowing the zeolite to change its flowability, i.e. saturating the micro- and macropores of the zeolite with this solution (Patent RU No. 2687362, C05G 11 / 02 dated 05 / 13 / 2019).

[0012] The disadvantage of this fertilizer and the method of its production is the low quality of amino acids in the pores of the zeolite, caused, firstly, by the small proportion of amino acids in the total amount of acids used, in addition, humic acids, having very large molecular sizes, do not enter into a synergistic compound with the zeolite, they cannot penetrate into the cavity of the zeolite.

[0013] Methods are known for hydrolyzing protein-containing secondary raw materials and waste using biological methods in order to obtain mixtures of amino acids and peptides intended for various purposes (V.I. Ivashov, A.D. Neklyudov, N.V. Fedorov, R.A. Khromova. Production and use of protein hydrolyzers. Moscow: VgroNIITEI, 1991, 42 p.).

[0014] However, due to the difficulty of carrying out a process that allows preserving all the essential amino acids found in the original raw material, as well as the low yield of the resulting hydrolyzers, waste from the meat processing industry is not used effectively to produce hydrolyzers with a complete amino acid composition.

[0015] Methods are known for producing protein feed additives from keratin- and collagen-containing raw materials (Patent RU No. 2133097, A23K 1 / 10 dated 20.07.1999); Patent RU No. 2229821, A23J 1 / 10, C12S 3 / 00 dated 10.06. 20014) by enzymatic hydrolysis with proteolytic enzymes.

[0016] The disadvantages of these methods are the high energy consumption and duration of the hydrolysis process, as well as the use of scarce and expensive enzyme preparations.

[0017] A known method for obtaining a mixture of amino acids from waste from processing raw materials of animal or plant origin (Patent RU No. 2457689, A23J 3 / 30 dated 10.08.2012) by acid hydrolysis of protein raw materials at a temperature of 115-120 °C for 4-6 hours with continuous stirring and a pressure in the reactor of 1.5 atm., adsorption of non-hydrolyzed products using activated carbon for 1 hour at a temperature of 60-70 °C, removal of the fat part of the mixture by passing it through a Nutsche filter, thickening the hydrolysis products in solution, and drying.

[0018] However, this method cannot be used to obtain protein, lipid and mineral-protein supplements of high biological value, since after acid hydrolysis under these conditions, the released proteins break down into amino acids, and a solution of amino acids in acid is obtained.

[0019] A known method for producing hydrolysates containing protein from plant and animal raw materials is characterized by raw material digestion in an aqueous medium at a temperature ranging from 180 to 220°C for a reaction time of 25 to 45 minutes under a pressure of 50-75 bar. The resulting suspension is then separated into two parts: a sediment containing unsplit components of the raw material and an upper aqueous layer containing dissolved protein hydrolysis products (Patent RU No. 2374893, A23J 3 / 30 dated 10.12.2009).

[0020] However, this method does not allow for the production of additives from recycled materials, as it uses extremely high temperatures and pressure. As a result, the degradation of the raw materials is so profound that virtually all of the molecules disintegrate. Furthermore, the fraction itself has a high acid number and cannot be considered a high-biological-value additive.

[0021] A known method for producing protein hydrolysate by processing poultry farm and livestock waste involves washing the feedstock, grinding it, disinfecting it, and subjecting it to alkaline hydrolysis in an autoclave in the presence of calcium oxide at a temperature of 115-140°C for 2-3 hours with constant stirring. The resulting hydrolysate is purified by filtration or centrifugation, followed by the addition of soda ash until the calcium carbonate is completely precipitated. The purified hydrolysate is neutralized with hydrochloric acid to a pH of 6.7-8.0 and evaporated to a concentration of 35-40% (Patent RU No. 2054840, A23K 1 / 0 dated 20.02.1996).

[0022] However, alkaline hydrolysis of raw materials at a sufficiently high temperature leads to stereochemical racemization of a large number of amino acids, which degrades the quality of the resulting product. The technical process of raw material processing is complicated by the use of a large number of reagents and expensive equipment, which leads to increased costs and higher product costs.

[0023] A known method for obtaining a hydrolyzate from meat and meat-and-bone raw materials of slaughter animals, which involves grinding the raw material, homogenizing with water, degreasing, enzymatic hydrolysis with a complex of proteolytic enzymes with an activity of 6000-9000 PE / g obtained from the pancreas of slaughter animals in an amount of 3 to 5% by weight, and protosubtilin G20x in an amount of 1 to 2% at a temperature of 40-45 ° C and pH 6.5-7.8 and drying (Patent RU No. 2112397, A23J 1 / 10, C12N 9 / 64 dated 10.06.1998).

[0024] The disadvantage of this method is low protein conversion (up to 50%), low yield of amino acid and peptide mixture, formation of a significant amount of unused technical fat (up to 25-30% of the weight of loaded meat and bone raw materials), as well as the use of an expensive enzyme preparation in the technology.

[0025] Also known is a method for producing a mixture of amino acids from waste from the processing of raw materials of animal or plant origin (Patent RU No. 2457689, A23J 3 / 30 dated 10.08.2012), as well as a method for producing an additive for farm animals and poultry (Patent RU No. 2649896, A23K 10 / 26 dated 05.04.2018). However, these methods require significant energy consumption for heating the raw materials and drying the final product, which leads to environmental pollution.

[0026] The closest method in technical essence and achieved effect is a method for producing protein hydrolysate, including the enzymatic hydrolysis of crushed raw materials. Protein-containing products (split skins of mammals, internal organs of birds) are used as raw materials. Enzymatic hydrolysis is carried out in the presence of chloroform (1.5-2.0 vol.%) in the alkaline zone of pH 7.8-8.0 with proteolytic enzymes (porcine pancreatic enzymes in the amount of 15-20 vol.%, poultry intestinal enzymes) at a temperature of 42-48 °C for 7-12 hours. Then the resulting mass is heated at a temperature of 80-95 °C, cooled, filtered using depth filters and dried by spraying in a stream of hot air. Accepted as a prototype.

[0027] The disadvantages of this method include the multi-stage process cycle, the use of chemical reagents for raw material treatment, and the significant energy costs of heating the raw materials and drying the final product, which leads to environmental pollution. Furthermore, this method does not take into account the amino acid content in the zeolite pores and does not describe the use of a synergistic combination of raw materials with zeolite when mixed with nitrogen-containing waste. There is no development of an effective technology for using these wastes as fertilizer in crop production.

[0028] The technical challenge is to develop a method for the rapid and safe processing of animal waste: horn and hoof meal, or sheep wool, or bird feathers, or blood meal, or a mixture based on horn and hoof meal, feather meal, sheep wool, blood meal when mixed with zeolite-containing rock and molasses.

[0029] The technical result of the claimed technical solution is the rapid disinfection with continuous processing of waste into a finished fertilizer from the above-mentioned by-products of animal origin, rich in protein and, therefore, having a high potential for use as a nitrogen fertilizer. The resulting granules can be applied both separately to the soil, and in the form of composite mixtures. The creation and use of nitrogen fertilizer makes it possible to obtain an economically viable harvest of spring wheat.

[0030] The technical result is achieved in that the method for obtaining organic fertilizer from waste of animal origin, characterized in that waste of animal origin is used as raw material: horn and hoof meal or sheep wool, or bird feathers, or blood meal, or a mixture based on horn and hoof meal, bird feathers, sheep wool, blood meal in a ratio of 1: 1: 1: 1, and then natural zeolite and molasses are added at a ratio of 0.1: 0.1 with continuous stirring at a temperature of 105-110 ° C for 60 minutes, while to obtain granulated fertilizer, crushing and grinding are used for 45-60 seconds and a granulator with a horizontal matrix is ​​used, the resulting granules are 13.2 ± 5.6 mm long, 5.74 ± 0.9 mm in diameter, bringing to a moisture content of 18-20%, and after thermal activation, intensive cooling of the granules is carried out to a temperature of no lower than 75-80°C and no higher than 145-150°C.

[0031] In addition, they use a mini-granulator of the GU-5 brand.

[0032] Zeolites have a structure consisting of a framework of tetrahedrons ((Si, Al)O4), where the negative charges, primarily Ca, Na, and K, are balanced. The framework contains large cavities and channels containing water molecules. Cations and water molecules are weakly bound to the framework and can be partially or completely replaced (removed) by ion exchange and dehydration, without destroying the zeolite framework. A zeolite dehydrated from water is a microporous crystalline "sponge," the pore volume of which accounts for up to 50% of the zeolite framework volume. Dehydrated zeolites can adsorb other substances instead of water: ammonium, alcohol, NO2, H2S, amino acids, etc.

[0033] But in order to make the zeolite work in the desired direction, it is necessary to modify it, which includes mechanical and thermal activation.

[0034] This technological process is aimed at producing a modified zeolite that can form a synergistic compound with amino acids. In this process, the zeolite is activated by zeolite-modifying biostimulants. When specially prepared, these biostimulants freely penetrate the cavities and are retained there for a specified period. When the fertilizer enters the soil, the zeolite, as a carrier of amino acids, begins to interact with soil microorganisms. Through weak bonds with the zeolite molecules, the amino acids, together with the zeolite's macro- and microelements, form a complex structure and easily reach the root system.

[0035] Before the experiments, samples of crushed waste were analyzed for the content of macro- and microelements.

[0036] An analysis of animal by-products for macronutrient content showed that sheep's wool contained the highest amount of nitrogen at 18.3%. Horn and hoof meal contained 1.7% less nitrogen, poultry feathers 3.1% less, and blood meal 4.4%.

[0037] Sheep wool waste had high phosphorus levels (1.1%). In other by-products, this element ranged from 0.7-0.85%.

[0038] The results of macroelement content in animal waste are shown (Fig. 1).

[0039] Potassium content was found in all waste products (0.09-1.1%). High levels of this element were found in poultry feathers (1.1%). Slightly lower levels were found in wool and horn and hoof meal. The lowest content was found in blood meal (0.09%).

[0040] The chromatogram results for samples of horn and hoof meal and poultry feathers are shown (Fig. 2). The graph clearly shows the presence of elements such as iron, zinc, calcium, magnesium, sulfur, and copper.

[0041] It should be noted that the content of toxic metals such as arsenic, cadmium, chromium, mercury, nickel and lead was not detected.

[0042] The results of studies on the content of iron (Fe) and zinc (Zn) in by-products in all studied fertilizer samples are shown (Fig. 3).

[0043] It was also found that zinc exceeded the maximum permissible concentration (MPC) for this element in soil in all samples. The exception was the blood meal sample. However, this type of waste was characterized by a high iron content.

[0044] Thus, it can be concluded that all types of animal by-products had a high macro- and microelement composition. However, the content of individual elements exceeded maximum permissible concentrations. Therefore, their direct application to the soil should be excluded and the above-mentioned elements should first be reduced to obtain and ensure the desired final fertilizer product in granular form. The granule size allows for the fertilizer to be applied during seeding of grain crops.

[0045] It has been established that zeolite-containing rock has a high sorption capacity for many elements due to its highly porous structure (the basis of the zeolite structure is described above).

[0046] Figure 4 shows the structure of a zeolite-containing rock. Microscopic imaging was used to determine the presence and number of pores in the natural zeolite sample.

[0047] The method allows to obtain a safe organic fertilizer based on animal waste, corresponding in the presence of nutrients, in the absence of toxic metals, with the possibility of using a practically freely available raw material base.

[0048] The zeolite porosity in the proposed invention was studied as a function of the medium's pH and sorption time. For the pH study, solutions were prepared, and the exposure times for each experiment were determined, which amounted to 7, 12, and 24 hours. The water absorption porosity of the zeolite was determined at a rate of 2 g / 500 ml.

[0049] The experiment was repeated three times. The experiments were conducted to fix iron (Fe) and zinc (Zn) metals in solution using liquid chromatography.

[0050] It should be noted that the experiments conducted revealed that 100% of the metals (Fe) and (Zn) were sorbed within 12 hours in the pH range of 5.0-7.0. Therefore, by including zeolite-containing rock in a mixture of animal waste such as horn and hoof meal, blood meal, sheep wool, and bird feathers, it is possible to utilize this mechanism of action on soils with a pH of 5.0-7.0 in the Lipetsk region of Russia, which are represented by leached chernozem with a pH of 5.0-6.0.

[0051] Below are examples confirming the effectiveness of using the technology of the method for producing organic fertilizer of animal origin.

[0052] Example 1. The proposed method for producing organic fertilizer from animal waste consists of five stages:

[0053] Stage 1. Raw material preparation. This stage was carried out using laboratory soil sieves to obtain a homogeneous mass.

[0054] Stage 2. Sterilization. The sterilization process was carried out in a SNOL 58 / 350 drying oven. The oven temperature was 105-110°C, with an exposure time of 60 minutes, ensuring complete sterilization of the waste materials. The raw materials were then cooled on a conveyor with a ventilated duct.

[0055] Stage 3. Grinding. This was performed using an IPP-1N laboratory soil sample grinder. The raw material was loaded into the grinding bin; the grinding time was 45-60 seconds.

[0056] Stage 4. Granulation. After grinding, the raw materials were sent to a GU-5 mini-granulator (shown in Fig. 5).

[0057] Technical data of the device:

[0058] 1. Type - stationary.

[0059] 2. Electric drive - motor 7.5 kW, 750 rpm, 380 V.

[0060] 3. The productivity of organic granule production is up to 100 kg / hour.

[0061] Overall dimensions: 900x500x950 mm. Die diameters: 6 mm and 8 mm.

[0062] The general diagram of the mini-granulator brand GU-5 (Fig. 5) includes: 1 - Flat matrix; 2 - Rollers or punch; 3 - Shaft transmitting rotation from the worm to the punch; 4 - Coupling; 5 - Worm mechanism; 6 - Electric motor; 7 - Loading opening; 8 - Unloading window; 9 - Bearings with seal; 10 - Press legs; 11 - Body.

[0063] Under pressure, the raw material was pressed into granules using an additional component for viscosity - beet molasses, which contributed to the formation of the fertilizer shell.

[0064] Stage 5. Drying. After granulation, the resulting granules are brought to a moisture content of 18-20%, and after thermal activation, the granules are intensively cooled to a temperature of no lower than 75-80°C and no higher than 145-150°C.

[0065] The final product is organic fertilizer based on the production of a single-component granular fertilizer, which included one type of animal waste, and a multi-component fertilizer, which included a complex of waste, while zeolite and molasses were added to all types of waste.

[0066] The experimental design included the following options:

[0067] 1. Blood meal-based fertilizer.

[0068] 2. Wool-based fertilizer.

[0069] 3. Feather-based fertilizer.

[0070] 4. Fertilizer based on horn and hoof meal.

[0071] 5. Fertilizer based on: horn and hoof meal + feather + sheep wool + blood meal with a ratio of 1:1:1:1, respectively.

[0072] Zeolite and molasses were added in a ratio of 0.1:0.1.

[0073] The results of obtaining a sample of horn and hoof meal and blood meal are shown (Fig. 6).

[0074] Fig. 7 shows the flow chart of granular fertilizer production.

[0075] The cooled pellets are packaged after leaving the finished product bin. The filled bags are labeled and transported to the finished product warehouse.

[0076] It should be noted that increasing the amount of powdered material increases its density and decreases porosity. This process is irreversible, as it involves structural deformations.

[0077] Research has shown that the surface of the multi-component granules was highly durable and the granules had a smooth, glossy surface.

[0078] Granules based on single-component waste were less durable and had a rough, porous structure.

[0079] Figure 8 shows granulated fertilizers of finished products consisting of horn and hoof meal and horn and hoof meal + feathers + sheep wool + blood meal. The granule surfaces were visualized using a microscope for better visual inspection.

[0080] In the experiments, an additional component, molasses, was added to the samples together with the zeolite-containing rock.

[0081] Example 2. Five types of granules, as noted above, were produced in a laboratory. Granule parameters were measured for length and diameter (accuracy ±0.01 mm). Granule mass was estimated using a KERN ABJ balance (accuracy ±0.001 g). The length, diameter, and weight were calculated for each sample type using 10 granules to obtain the average error. Granule volume was calculated based on granule size (diameter and length).

[0082] Thus, we obtained granules with an optimal length of 13.2±5.6 mm and a diameter of 5.7±0.9 mm.

[0083] Moisture content was determined using a standard method. Samples were weighed and dried for 2 hours at 105-110°C, yielding a final moisture content of 18-20%.

[0084] The finished pallets were subjected to sanitary and bacteriological tests.

[0085] The test results for all samples were consistent with the microbiological indicators:

[0086] - Proteus not detected 1.0 g.

[0087] - Salmanella was not detected in 2.5 g.

[0088] - E.Coli not detected in 1.0 g.

[0089] Fig. 9 shows samples of wheat plants obtained under control and using granules based on sheep wool.

[0090] It should also be noted that after receiving the finished product in the form of granules, the amount of macronutrients in animal waste increased, but not significantly.

[0091] The maximum amount of nitrogen, phosphorus and potassium were found in multi-component granules.

[0092] Composition of the finished fertilizer:

[0093] 1. Blood meal-based fertilizer: N-14.4%: P-0.08%: K-0.2%.

[0094] 2. Wool-based fertilizer: N - 18.6%: P - 1.5%: K - 1.0%.

[0095] 3. Feather-based fertilizer: N -16.1%: P - 0.9%: K - 1.2%.

[0096] 4. Fertilizer based on horn and hoof meal: N - 17.1%: P - 0.9%: K - 1.0%.

[0097] 5. Fertilizer based on: horn and hoof meal + feather + sheep wool + blood meal: N - 19.2%: P - 1.7%: K - 1.4%.

[0098] The research objective also included studying the effect of granular fertilizer on plant development. Field preparation included plowing, incorporation of crop residues, loosening of the topsoil, and cultivation, with simultaneous harrowing and sowing of spring wheat seeds of the Aquilon variety, sown in the early second half of May. Sowing was carried out at a depth of 3 cm with a row spacing of 20 cm and a seeding rate of 400 spring wheat seeds per m. 2 The predecessor is potatoes.

[0099] Example 3. A vegetation experiment with the Aquilon spring wheat variety under laboratory conditions. A 15-liter container was used, then filled with soil substrate and fertilizer was added.

[0100] The experimental design included:

[0101] 1. Control (without fertilizer application).

[0102] 2. Blood meal granules 5g.

[0103] 3. Wool-based granules 5g.

[0104] 4. Feather-based granules 5g.

[0105] 5. Granules based on: horn and hoof meal + feather + sheep wool + blood meal 5 g (complex fertilizer).

[0106] The use of nitrogen-containing fertilizers contributed to an increase in the height and vegetative mass of wheat plants in all study variants. Results for biometric indicators at various stages of development are presented in Table 1.

[0107] Plant height reflects the intensity of its nutrition, which enhances growth and development. In the control group, plant height across the stages was recorded at the lowest values, in contrast to plants in the treatments with nitrogen-containing fertilizers. Research shows that productive tillering of wheat increased, due to the formation of additional stems during the tillering stage. With nitrogen-containing fertilizers, the plant formed a more vigorous and spreading bush (Fig. 10).

[0108] The results obtained in the experiments showed a positive effect of zeolite on the preparation of finished fertilizer based on all the studied animal waste at a ratio of 1:1:1:1, respectively. The inclusion in all experiments of zeolite and molasses in a ratio of 0.1:0.1 when mixing to obtain granules had a positive effect on the passage of the reproductive phases of plant development (Table 1). It was noted that with a granule moisture content of no more than 18-20 % ensures their stability during long-term storage.

[0109] The resulting fertilizer from animal waste is convenient for packaging, storage, transportation, and the size of the granules allows them to be applied along with the sowing of grain crops.

[0110] The resulting organic fertilizer is highly effective. It has a prolonged effect, disinfects the soil, absorbs heavy metals, aerates the soil, and saturates it with moisture, allowing plants to thrive during dry periods.

Claims

1. A method for producing organic fertilizer from animal waste, characterized by the fact that animal waste is used as raw material: horn and hoof meal, or sheep wool, or bird feathers, or blood meal, or a mixture based on horn and hoof meal, bird feathers, sheep wool, blood meal in a ratio of 1:1:1:1, respectively, to which natural zeolite and molasses are added in a ratio of 0.1:0.1 with continuous stirring at a temperature of 105-110 ° C for 60 minutes, to obtain granulated fertilizer, crushing and grinding are carried out for 45-60 s, and a mini-granulator with a horizontal matrix is ​​used, the resulting granules with a length of 13.2 ± 5.6 mm, a diameter of 5.74 ± 0.9 mm are brought to a moisture content of 18-20%, and after thermal activation, intensive cooling of the granules to a temperature of not below 75-80°C and not higher than 145-150°C.

2. The method according to paragraph 1, characterized by the fact that a mini-granulator of the GU-5 brand is used.

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