Method for manufacturing organic liquid fertilizer

Abstract

A method for manufacturing a liquid fertilizer product, including the steps of removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and removing water from the converted stream to obtain the liquid fertilizer product, wherein the liquid fertilizer product includes nitrate.

Description

METHOD FOR MANUFACTURING ORGANIC LIQUID FERTILIZERCROSS REFERENCE TO RELATED APPLICATIONSThis application claims the benefit of US Application No. 63 / 599,778, filed on November 16, 2023, which is incorporated herein by reference in its entirety.FIELD

[0001] The present disclosure relates to a fertilizer and to a method for manufacturing a nitrogen-containing liquid fertilizer suitable for use in organic crop production.BACKGROUND

[0002] Nitrogen is an essential nutrient for plants as a major component of chlorophyll, amino acids, adenosine triphosphate (ATP), and nucleic acids, the building blocks of proteins. Plants absorb nitrogen as either ammonium (NH4+) or nitrate (NOT), but it is difficult for producers of organic fruits, vegetables, and crops to find cost-effective and allowed fertilizers comprised of these inorganic, plant- available nitrogen sources.

[0003] A commonly used source of nitrogen for organic farms is manure. However, this fertilizer is typically quite dilute (i.e., less than 1 weight percent total nitrogen), contains a large fraction of organic nitrogen that is not immediately plant-available, and is not economical to haul far distances.

[0004] There is a continuing need for a method of manufacturing a nitrogen-containing fertilizer that is suitable for use in organic agriculture, and which is highly concentrated. Desirably, the resultant fertilizer contains predominantly plant available nitrate, and is economical to produce from natural materials.SUMMARY

[0005] Provided is a method for manufacturing a liquid fertilizer product, including the steps of removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and removing water from the converted stream to obtain the liquid fertilizer product, wherein the liquid fertilizer product includes nitrate.

[0006] The method may further include filtering the converted stream prior to removing water from the converted stream.

[0007] The method may further include separating the filtrate into a first portion and a second portion; wherein converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream includes converting ammonia present in the first portion of the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream; and wherein the method further includes combining the second portion of the filtrate with the converted stream prior to removing water from the converted stream to obtain the liquid fertilizer product.

[0008] Conversion of ammonia present in the filtrate to nitrate using the ammonia oxidizing bacteria and nitrite oxidizing bacteria may directly follow removal of solids from the organic waste to obtain the filtrate.

[0009] The method may further include including a natural mineral to provide a desired level of the natural mineral for bacterial activity in the filtrate.

[0010] The liquid fertilizer product may include greater than or equal to 4 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

[0011] The liquid fertilizer product may include greater than or equal to 6 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

[0012] The liquid fertilizer product may include greater than or equal to 8 weight percent nitrogen, based on a total weight of the liquid fertilizer product.

[0013] The liquid fertilizer product may include greater than or equal to 4 weight percent nitratenitrogen, based on a total weight of the liquid fertilizer product.

[0014] The liquid fertilizer product may include greater than or equal to 6 weight percent nitratenitrogen, based on a total weight of the liquid fertilizer product.

[0015] A total weight of nitrogen in the liquid fertilizer product may include greater than or equal to 70 weight percent nitrate-nitrogen.

[0016] In an embodiment, the method does not include adding an acidic substance.

[0017] The organic waste may include a plant or animal byproduct, food waste, seaweed, dairy product waste, livestock manure, worm castings, peat, guano, compost, blood meal, bone meal, fish meal, decomposing crop residue, cheese whey, wastewater from a meat processing facility, wastewater from a food processing operation, or a combination thereof.

[0018] Converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream may include use of a membrane bio reactor or a moving bed biofilm reactor and aeration to maintain 2 to 6 or 4 to 6 milligrams per liter of dissolved oxygen.

[0019] Removing water from the converted stream may include reverse osmosis and evaporation.

[0020] Provided is a liquid fertilizer product manufactured by the method.

[0021] Provided is a method of practicing organic agriculture including applying the liquid fertilizer product.

[0022] Provided is a method for manufacturing a liquid fertilizer product, including the steps of removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; adding a source of alkalinity during conversion of ammonia present in the filtrate to nitrate to form the converted stream; and removing water from the converted stream to manufacture the liquid fertilizer product, wherein the liquid fertilizer product includes nitrate, and wherein a conversion of ammonia-nitrogen present in the filtrate is greater than or equal to 70 weight percent, based on a total weight of ammonia-nitrogen in the filtrate.

[0023] The source of alkalinity may include potassium carbonate, potassium dicarbonate, potassium oxide, potassium hydroxide, calcium carbonate, calcium oxide, calcium hydroxide, sodium hydroxide, sodium carbonate, sodium bicarbonate, magnesium hydroxide, magnesium bicarbonate, or a combination thereof.

[0024] A total weight of nitrogen in the liquid fertilizer product may include greater than or equal to 70 weight percent nitrate-nitrogen.

[0025] Provided is a system for manufacturing a liquid fertilizer including a waste tank configured to hold organic waste; a filter in fluid communication with the waste tank, the filter being configured to remove solids from the organic waste to obtain a filtrate; a nitrification reactor in fluid communication with the filter, the nitrification reactor configured to converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and a concentrator in fluid communication with the nitrification reactor, the concentrator configured to remove water in the converted stream to manufacture a liquid fertilizer product including nitrate.

[0026] The system may further include a second filter between the nitrification reactor and the concentrator.

[0027] Any combination or permutation of embodiments is envisioned. Additional advantageous features, functions and applications of the disclosed fertilizer manufacturing process and methods of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.DRAWINGS

[0028] The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art from the following detailed description, particularly when considered in the light of the drawings described hereafter.

[0029] Exemplary embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps, and combinations of features / steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure. To assist those of ordinary skill in the art in making and using the disclosed facial masks, assemblies and methods, reference is made to the appended figures, wherein:

[0030] FIG. 1 is a schematic diagram illustrating a system for manufacturing a liquid fertilizer product, according to an embodiment.DETAILED DESCRIPTION

[0031] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding pails and features. In respect of the methods disclosed, the order of the steps presented is exemplary in nature, and thus, is not necessary or critical unless otherwise disclosed.

[0032] Throughout the description, various dimensions, units of measure, volumes, and quantities are also disclosed; however, it should be appreciated that these features are being provided for purposes of illustrating various examples, and one of ordinary skill in the ail mayselect other suitable dimensions, units of measure, volumes, and quantities within the scope of the instant disclosure.

[0033] The present disclosure includes systems and methods for manufacturing a liquid fertilizer product, as shown in FIG. 1. The contemplated systems and methods are configured to treat waste from a natural source, such as animal manure or food waste, in order to produce the liquid fertilizer product. The liquid fertilizer product is, for example, an aqueous solution containing nitrogen mainly in the nitrate form, e.g., a total weight of nitrogen in the liquid fertilizer product may include greater than or equal to 70 weight percent nitrate-nitrogen. In an embodiment, the method includes removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; removing water from the converted stream to obtain the liquid fertilizer product, wherein the liquid fertilizer product includes nitrate. The liquid fertilizer product can be compliant with the Organic Foods Production Act of 1990, U.S. Department of Agriculture Organic Regulations (also referred to as the National Organic Program or NOP) or other agency standards for use in organic farming.

[0034] In an embodiment, the waste is a liquid waste that may be derived from a plant or animal source. For example, the liquid organic waste may be derived from a natural source including, but not limited to, a plant or animal byproduct, a fresh or anaerobically digested source-separated organic waste (e.g., food waste, including fats, oils, greases (FOG)), seaweed, dairy product waste, livestock manure in a wet or dry form (e.g., dairy manure, chicken manure or litter, swine manure, horse manure), worm castings, peat, guano, compost, blood meal, bone meal, fish meal, decomposing crop residue, cheese whey, wastewater from a meat processing facility, wastewater from a food processing operation, or a combination thereof. The source may be any suitable natural source that contains ammoniacal nitrogen.

[0035] Certain additional natural materials, e.g., from a natural source, may be added or blended with the waste to provide specific nutrients to help ensure the efficient metabolism of the ammonia oxidizing bacteria, nitrite oxidizing bacteria, or a combination thereof. In an embodiment, a natural mineral or natural mineral product containing nutrients such as molybdenum, selenium, cobalt, or a combination thereof may be added to provide a desired level of the natural mineral or nutrients in the feedstock or filtrate, to help ensure stable operation of the ammonia oxidizing bacteria, nitrite oxidizing bacteria, or a combination thereof, whichconvert ammonia present in the filtrate to nitrate. The natural mineral may be ground to a fine powder or otherwise naturally processed to increase a solubility thereof in water.

[0036] For example, the liquid organic waste may be any suitable aqueous solution that contains a dissolved protein, ammoniacal nitrogen, and other soluble nutrients derived from natural sources. If the organic waste is in a solid or semi-solid form, water may be added to the solid or semi-solid material beforehand to form the fluid mixture. For example, in an embodiment in which dry or semi-dry animal manure is utilized, water may be added to form a fluid mixture creating the liquid organic waste. The water thereby creates the fluid mixture of water and suspended plus dissolved solids to form the liquid organic waste.

[0037] In an embodiment, a method for manufacturing the liquid fertilizer product may generate the liquid fertilizer product from a solid organic waste. For example, the method may utilize the system, as described herein, to form the liquid fertilizer product. As used herein, the term “solid organic waste” is defined to include both completely solid and semi-solid wastes including, for example, wet chicken manure may be 20 to 30 weight percent dry matter and 70 to 80 weight percent moisture.

[0038] The liquid organic waste may be pre-treated through an anaerobic digestion or other microbial fermentation process to provide an effluent discharge as the liquid organic waste, or the liquid organic waste may be used in a raw form in the system and method, as desired.

[0039] In an embodiment, as shown in FIG. 1, a system 1000 for manufacturing the liquid fertilizer product may produce the liquid fertilizer product from a liquid organic waste that contains ammoniacal nitrogen. The system 1000 may include a waste tank 100, a filter 200, a nitrification reactor 300, and a concentrator 400, each of which may be placed in selective communication via conducts such as pipes, pumps, motors, valves, and the like.

[0040] The system 1000 may also be provided with a controller and sensors that will permit a user to monitor and regulate an operation of the system 1000, as desired. The controller can include a processor and a memory having tangible and non-transitory processor-executable instructions that are embodied thereon. The controller may also be in communication with a user interface such as a screen, a keyboard, a dial, a button, and the like, which permit the user to interact with and regulate the operation of the system 1000 in accordance with the method described further herein. Other suitable types of controllers, sensors, and user interfaces may also be employed, as desired.

[0041] The waste tank 100 may be configured to hold the liquid organic waste 1 . For example, the liquid organic waste may be derived from livestock manure, such as dairy manure or pig manure, or food waste. In an embodiment, the waste tank may include a manure holding tank that receives and maintains, for example, with an optional heating and mixing equipment, the liquid organic waste at 95-105°F (35-40.6°C). The waste tank 100 may be other suitable holding containers for the liquid organic waste, such as an above ground mixed tank, in-ground covered lagoon or pit, or a combination thereof. To maximize the conversion of nitrogen contained in complex organic compounds (e.g., proteins) into ammonia, as well as generate biogas for renewable energy production, the waste tank 100 may be sized to retain the waste for about 10 to 30 days on average.

[0042] The filter 200 may be in communication, e.g., in fluid communication, with the waste tank 100. The filter 200 may be configured to filter the organic waste 1 to obtain a clarified liquid organic waste. For example, the filter 200 may be configured to remove suspended solids from the liquid organic waste. The suspended and dissolved solids in the liquid waste may include, but are not limited to nitrogen, phosphorus, potash, secondary nutrients, micro-nutrients and organic matter found in anaerobically digested manure or other agriculturally related organic waste. Adjusting the temperature of the organic waste may facilitate filtration as well as the dissolution of particulate organic waste into the aqueous solution. Advantageously, the removal of the suspended solids from the liquid organic waste may mitigate against undesirable clogging in the system 1000 in operation as well as the presence of undesirable particulate matter in the final fertilizer product.

[0043] The suspended solids may be removed by the filter 200 via a filtration mechanism including, but not limited to, mechanical screening and pressing (e.g., sloped screen, vibratory screen, brush screen, screw-press), microfiltration, ultrafiltration, nanofiltration, other membrane separation equipment, high-speed mixing (e.g., hydrocyclone), centrifugation, ultrasound, electro-coagulation, polymer flocculation, dissolved air flotation, or a combination thereof. A combination of separation mechanisms may be employed for the filter 200. Natural settling, such as may occur in a lagoon, pond, or tank, is also envisioned as a mechanism to create a clarified liquid organic waste with lower amounts of suspended solids. The liquid organic waste may also be electrified or magnetized to crystalize minerals and reduce scaling on process equipment. Suitable types of filtration or separation equipment will be selected, for example, depending onconditions and desired processing considerations within the scope of the present disclosure. For wastes with very low levels of suspended solids, no filtration may be required.

[0044] In an embodiment, the filter 200 may be capable of removing suspending solids that are 0.02 to 1 micrometer. In an embodiment, the filter 200 may be a microfilter. The microfilter may be capable of removing suspended solids that are 0.1 to 0.5 micrometers. In an embodiment, the filter 200 may be an ultrafilter. The ultrafilter may be capable of removing solids that are 0.01 to 0.05 micrometers. The microfilter and ultrafilter membrane may be comprised of, e.g., include, poly vinylidene fluoride (PVDF), polyethersulfone (PES), ceramics, titania-coated porous stainless steel, stainless steel, or other materials known to those skilled in the art of filtration. The membranes may be tubular, hollow fiber, spiral- wound or plate and frame as dictated by the material being filtered.

[0045] The filter 200 produces a retentate 2 and a filtrate 3. The filtrate 3 may be a clarified liquid organic waste. The clarified liquid organic waste may have a low suspended solids (for example, less than 500 milligrams per liter (mg / L) total suspended solids (TSS)) content and a high concentration of ammonia (for example, greater than 1,000 mg / L).

[0046] Following filtration, ammonia present in the filtrate 3 is converted to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream 4. In an embodiment, the nitrification reactor 300 includes a membrane bio reactor or a moving bed biofilm reactor. In an embodiment, the nitrification reactor 300 includes a membrane bio reactor or a moving bed biofilm reactor and removing water from the converted stream includes reverse osmosis and evaporation. A membrane bio reactor may include an ultrafilter for ultrafiltration and output from the membrane bio reactor and ultrafilter may be called a filtered converted stream. In an embodiment, the filter 200 may be present in or directly attached to the nitrification reactor 300 and concentrate from the filter 200 may be circulated within the nitrification reactor.

[0047] The nitrification may include adding plastic media pieces to the reactor to fill the moving bed biofilm reactor 30 to 60% by volume, and aerating to maintain 2 to 6 or 4 to 6 mg / L of dissolved oxygen. Nitrification is a two-step process carried out by aerobic bacteria in which ammonium (NH4+) is converted to nitrate (NCL-). Ammonia is oxidized to nitrite by ammoniaoxidizing bacteria (AOB), such as Proteobacteria, Nitrosomonas, and Nitrosococcus, and nitrite is oxidized to nitrate by nitrate-oxidizing bacteria (NOB), such as Nitrobacter and Nitrospira.The reactions are as follows:NH4++ 1 .5 02- N02“ + 2 H++ H20 Equation 1NOC + O.5 02> NOr Equation 2The formed nitrate is stable and the nitrification process consumes alkalinity present in the filtrate, thereby lowering the pH of the solution. Typically the organic waste filtrate will have a pH greater than 7 (typically 7.5 to 8.5) and the converted stream 4 will have a pH less than or equal to 7 (typically 6 to 6.5). No addition of an acidic substance is necessary to affect this pH change and hence a significant cost of stabilizing nitrogen solutions containing ammonianitrogen can be avoided with the disclosed method.

[0048] In an embodiment, ammonia present in the filtrate is converted to nitrate using the ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream directly following filtration. Stated otherwise, in an embodiment, the filtrate is not diluted or subject to other processing prior to converting ammonia present in the filtrate to nitrate.

[0049] In an embodiment, a source of alkalinity may be added during conversion of ammonia present in the filtrate to nitrate to form the converted stream. The source of alkalinity may help drive the nitrification towards completion. For example, a source of carbonate alkalinity may influence the metabolism of the ammonia oxidizing bacteria, nitrite oxidizing bacteria, or a combination thereof by providing inorganic carbon, which may impact the activity of the ammonia oxidizing bacteria, nitrite oxidizing bacteria, or a combination thereof. Examples of the source of alkalinity include, for example, potassium carbonate, potassium dicarbonate, potassium oxide, potassium hydroxide, calcium carbonate, calcium oxide, calcium hydroxide (e.g., as lime slurry), sodium hydroxide (caustic soda), sodium carbonate (soda ash), sodium bicarbonate, magnesium hydroxide, magnesium bicarbonate, or a combination thereof.

[0050] Conversion of ammonia- nitrogen present in the filtrate may be greater than or equal to 70 weight percent, or greater than or equal to 80 weight percent, or greater than or equal to 90 weight percent, or greater than or equal to 95 weight percent, or greater than or equal to 99 weight percent, or 100 weight percent, based on a total weight of ammonia-nitrogen in the filtrate. Without addition of extra alkalinity, conversion of ammonia-nitrogen present in the filtrate may be, for example, less than 70 weight percent, based on a total weight of ammonia- nitrogen in the filtrate.

[0051] The concentrator 400 removes water 5 from the converted stream 4 to obtain the liquid fertilizer product 6. The concentrator 400 may include an evaporator. The evaporator may beconfigured to receive the converted stream. For example, the evaporator may be in communication, c.g., in fluid communication, with the nitrification reactor 300. The evaporator may further be configured to heat the converted stream to a temperature greater than 100°F (37.8°C). For example, the evaporator may be configured to heat the converted stream to a temperature of greater than or equal to 140°F (60°C) or greater than or equal to 165°F (73.9°C), for example, in order to comply with regulatory requirements for pathogen kill for manure- derived and food waste-derived products. The evaporator may be operated at atmospheric pressure or under vacuum. The evaporator may be configured to raise the temperature of the converted stream to a predetermined temperature that facilitates the removal of water vapor and volatile compounds from the converted stream.

[0052] In an embodiment, the concentrator 400 may use reverse osmosis, forward osmosis or a combination thereof. The concentrator 400 may be configured to perform a reverse osmosis process, a forward osmosis process, or a combination thereof. Reverse osmosis is a water purification process that uses a partially permeable membrane to remove ions, unwanted molecules and larger particles from water. Forward osmosis is an osmotic process that, like reverse osmosis, uses a semi-permeable membrane to separate water from dissolved solutes. The driving force for this separation is an osmotic pressure gradient, such that a “draw” solution of high concentration (relative to that of the feed solution), is used to induce a net flow of water through the membrane into the draw solution, thus effectively separating the water from the solutes. In reverse osmosis, an applied pressure is used to overcome osmotic pressure.

[0053] In an embodiment, removing water from the converted stream includes both reverse osmosis and evaporation. Reverse osmosis may remove water more energy-efficiently than evaporation. About 70 to 80 weight percent of water present in the converted stream, based on a total amount of water in the converted stream, may be removed with reverse osmosis and the remainder of water removed from the converted stream may be removed by evaporation.

[0054] A collection tank may be in communication, e.g., in fluid communication, with the concentrator 400. The collection tank may receive effluent(s) from the concentrator 400 for storage, mixing, and later transport until a desired end use.

[0055] The system 1000 is configured to treat liquid organic waste to form the liquid fertilizer product, which is likewise organic in nature. The resultant liquid fertilizer product may be a water solution including ammonia and nitrate. The liquid fertilizer product may include greaterthan or equal to 4 weight percent total nitrogen, or greater than or equal to 6 weight percent total nitrogen, or greater than or equal to 8 weight percent total nitrogen, based on a total weight of the liquid fertilizer product. The liquid fertilizer product may include greater than or equal to 4 weight percent nitrate-nitrogen, or greater than or equal to 6 weight percent nitrate-nitrogen, or greater than or equal to 8 weight percent nitrate-nitrogen, based on a total weight of the liquid fertilizer product. The liquid fertilizer product may include less than or equal to 12 weight percent total nitrogen, or less than or equal to 10 weight percent total nitrogen, based on a total weight of the liquid fertilizer product. The total weight of nitrogen in the liquid fertilizer product may include greater than or equal to 70 weight percent nitrate-nitrogen (i.e., nitrate-nitrogen portion of the total nitrogen in the liquid fertilizer product). Stated otherwise, the liquid fertilizer product may include less than or equal to 30 weight percent ammonia, based on a total weight of the liquid fertilizer product.

[0056] In an embodiment, the method may further include separating the filtrate 3 from the filter 200 into a first portion 3a and a second portion 3b. Ammonia present in the first portion 3a of the filtrate may be converted to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream 4. The second portion 3b of the filtrate may be combined with the converted stream 4 prior to removing water 5 from the converted stream to obtain the liquid fertilizer product 6.

[0057] The first portion 3a of the filtrate may include, for example, 50 to 100 weight percent, or 55 to 90 weight percent or 60 to 80 weight percent or 65 to 75 weight percent, of the filtrate, based on a total weight of the filtrate, and the second portion 3b of the filtrate may include, for example, 0 to 50 weight percent, or 10 to 45 weight percent or 20 to 40 weight percent or 25 to 35 weight percent, of the filtrate, based on the total weight of the filtrate. The first portion 3a of the filtrate may include, for example, 70 weight percent of the filtrate, based on a total weight of the filtrate, and conversion of ammonia-nitrogen present in the first portion 3a of the filtrate may be, for example, 100 weight percent, based on a total weight of ammonia-nitrogen in the filtrate. All of the filtrate may be fed to the nitrification reactor, and conversion of ammonia-nitrogen present in the filtrate may be, for example, 70 weight percent, based on a total weight of ammonia-nitrogen in the filtrate.

[0058] Following nitrification and prior to treatment in concentrator 400, the converted stream may optionally be filtered, e.g., a second filter may be present between the nitrification reactorand the concentrator. Filtration may be accomplished in accordance with the description provided herein with respect to the filter 200.

[0059] The liquid fertilizer product may be combined with additional ingredients to manufacture additional fertilizer products. The additional ingredients may advantageously be natural or organic. For example, the liquid fertilizer product may be combined with other fertilizers, nitrate, Chilean nitrate, microbial products, bacteria, fungus, yeast, mushrooms, minerals, vitamins, guano, dried and powdered blood, ground bone, crushed shells, finely pulverized fish, phosphate rock, coffee grounds, and seaweed.

[0060] The following example is provided to illustrate the present disclosure. The example is merely illustrative and are not intended to limit devices made in accordance with the disclosure to the materials, conditions, or process parameters set forth therein.Example

[0061] Swine manure was anaerobically digested in a covered lagoon to produce biogas and liquid organic waste (i.e., digestate). The digestate was pumped from the lagoon to an ultrafiltration system comprised of porous stainless steel tubular’ membranes (0.02 micrometer average pore size). A 1,000 gallon (3,785 liter (L)) batch of digestate was processed into 500 gallons (1,893 L) of filtrate and 500 gallons (1,893 L) of concentrate. The digestate contained about 2,100 milligrams per liter (mg / L) ammonia-N. The filtrate was nitrified using a 250-gallon (946 L) moving bed bioreactor being aerated to maintain 4 mg / L dissolved oxygen. The average hydraulic residence time was approximately 3 days (approximately 83 gallons (314 L) of filtrate was fed per day to the reactor). About 500 gallons (1,893 L) of nitrified effluent were collected and then ultrafiltered; the volume of the second filtrate was approximately 450 gallons (1,703 L). This second filtrate was concentrated using a combination of reverse osmosis and evaporation. The reverse osmosis process was run as a batch starting at about 350 psi (2.41 megapascals (MPa)) and ending at 950 psi (6.55 MPa) and resulted in the removal of about 360 gallons (1,363 L) of reverse osmosis permeate (water). The remaining 90 gallons (341 L) of reverse osmosis concentrate were processed in the evaporator to remove about of 75 gallons (284 L) of condensate. The resulting approximately 15 gallons (57 L) of evaporator residue are the final fertilizer product containing about 6 weight percent total nitrogen.

[0062] Table 1 provides analysis of the product.Table 1

[0063] Set forth below are non-limiting aspects of this disclosure.

[0064] Aspect 1 : A method for manufacturing a liquid fertilizer product, comprising the steps of removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and removing water from the converted stream to obtain the liquid fertilizer product, wherein the liquid fertilizer product comprises nitrate.

[0065] Aspect 2: The method of aspect 1, further comprising filtering the converted stream prior to removing water from the converted stream.

[0066] Aspect 3: The method of aspect 1 or 2, further comprising separating the filtrate into a first portion and a second portion; wherein converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream comprises converting ammonia present in the first portion of the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream; and wherein the method further comprises combining the second portion of the filtrate with the converted stream prior to removing water from the converted stream to obtain the liquid fertilizer product.

[0067] Aspect 4: The method of any one of the preceding aspects, wherein conversion of ammonia present in the filtrate to nitrate using the ammonia oxidizing bacteria and nitriteoxidizing bacteria directly follows removal of solids from the organic waste to obtain the filtrate.

[0068] Aspect 5: The method of any one of the preceding aspects, further comprising including a natural mineral 1 to provide a desired level of the natural mineral for bacterial activity in the filtrate.

[0069] Aspect 6: The method of any one of the preceding aspects, wherein the liquid fertilizer product comprises greater than or equal to 4 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

[0070] Aspect 7: The method of any one of the preceding aspects, wherein the liquid fertilizer product comprises greater than or equal to 6 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

[0071] Aspect 8: The method of any one of the preceding aspects, wherein the liquid fertilizer product comprises greater than or equal to 8 weight percent nitrogen, based on a total weight of the liquid fertilizer product.

[0072] Aspect 9: The method of any one of the preceding aspects, wherein the liquid fertilizer product comprises greater than or equal to 4 weight percent nitrate-nitrogen, based on a total weight of the liquid fertilizer product.

[0073] Aspect 10: The method of any one of the preceding aspects, wherein the liquid fertilizer product comprises greater than or equal to 6 weight percent nitrate-nitrogen, based on a total weight of the liquid fertilizer product.

[0074] Aspect 11: The method of any one of the preceding aspects, wherein a total weight of nitrogen in the liquid fertilizer product comprises greater than or equal to 70 weight percent nitrate-nitrogen.

[0075] Aspect 12: The method of any one of the preceding aspects, wherein the method does not comprise adding an acidic substance.

[0076] Aspect 13: The method of any one of the preceding aspects, wherein the organic waste comprises a plant or animal byproduct, food waste, seaweed, dairy product waste, livestock manure, worm castings, peat, guano, compost, blood meal, bone meal, fish meal, decomposing crop residue, cheese whey, wastewater from a meat processing facility, wastewater from a food processing operation, or a combination thereof.

[0077] Aspect 14: The method of any one of the preceding aspects, wherein converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream comprises use of a membrane bio reactor or a moving bed biofilm reactor and aeration to maintain 2 to 6 milligrams per liter of dissolved oxygen.

[0078] Aspect 15: The method of any one of the preceding aspects, wherein removing water from the converted stream comprises reverse osmosis and evaporation.

[0079] Aspect 16: The liquid fertilizer product manufactured by the method of any one of the preceding aspects.

[0080] Aspect 17: A method of practicing organic agriculture comprising applying the liquid fertilizer product of aspect 16.

[0081] Aspect 18: A method for manufacturing a liquid fertilizer product, comprising the steps of removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; adding a source of alkalinity during conversion of ammonia present in the filtrate to nitrate to form the converted stream; and removing water from the converted stream to manufacture the liquid fertilizer product, wherein the liquid fertilizer product comprises nitrate, and wherein a conversion of ammonia-nitrogen present in the filtrate is greater than or equal to 70 weight percent, based on a total weight of ammonia-nitrogen in the filtrate.

[0082] Aspect 19: The method of aspect 18, wherein the source of alkalinity comprises potassium carbonate, potassium dicarbonate, potassium oxide, potassium hydroxide, calcium carbonate, calcium oxide, calcium hydroxide, sodium hydroxide, sodium carbonate, sodium bicarbonate, magnesium hydroxide, magnesium bicarbonate, or a combination thereof.

[0083] Aspect 20: The method of aspect 18 or 19, wherein a total weight of nitrogen in the liquid fertilizer product comprises greater than or equal to 70 weight percent nitrate-nitrogen.

[0084] Aspect 21: A system for manufacturing a liquid fertilizer comprising a waste tank configured to hold organic waste; a filter in fluid communication with the waste tank, the filter being configured to remove solids from the organic waste to obtain a filtrate; a nitrification reactor in fluid communication with the filter, the nitrification reactor configured to converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and a concentrator in fluid communication with the nitrification reactor, the concentrator configured to remove water in the converted stream to manufacture a liquid fertilizer product comprising nitrate.

[0085] Aspect 22: The system of aspect 21, further comprising a second filter between the nitrification reactor and the concentrator.

[0086] While certain representative embodiments and details have been shown for purposes of illustrating the present disclosure, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is furtherdescribed in the following appended claims.

[0087] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

[0088] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, “a,” “an,” “the,” and “at least one” do not denote a limitation of quantity, and are intended to include both the singular and plural, unless the context clearly indicates otherwise. For example, “an element” has the same meaning as “at least one element,” unless the context clearly indicates otherwise. Thus, reference to “an” element in a claim followed by reference to “the” element is inclusive of one element and a plurality of the elements. It will be further understood that the terms “comprises” and / or “comprising,” or “includes” and / or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and / or groups thereof.

[0089] " About" or "approximately" as used herein is inclusive of the stated value and means within an acceptable range of deviation for the particular value as determined by one of ordinary skill in the art, considering the measurement in question and the error associated with measurement of the particular quantity (i.e., the limitations of the measurement system). For example, "about" can mean within one or more standard deviations, or within ± 30%, 20%, 10% or 5% of the stated value.

[0090] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used, e.g., non-technical, dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0091] Although the systems and methods of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited to suchexemplary embodiments and / or implementations. Rather, the systems and methods of the present disclosure arc susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and / or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, and substitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A method for manufacturing a liquid fertilizer product, comprising the steps of: removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and removing water from the converted stream to obtain the liquid fertilizer product, wherein the liquid fertilizer product comprises nitrate.

2. The method of claim 1, further comprising filtering the converted stream prior to removing water from the converted stream.

3. The method of claim 1 or 2, further comprising separating the filtrate into a first portion and a second portion; wherein converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream comprises converting ammonia present in the first portion of the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream; and wherein the method further comprises combining the second portion of the filtrate with the converted stream prior to removing water from the converted stream to obtain the liquid fertilizer product.

4. The method of any one of the preceding claims, wherein conversion of ammonia present in the filtrate to nitrate using the ammonia oxidizing bacteria and nitrite oxidizing bacteria directly follows removal of solids from the organic waste to obtain the filtrate.

5. The method of any one of the preceding claims, further comprising including a natural mineral 1 to provide a desired level of the natural mineral for bacterial activity in the filtrate.

6. The method of any one of the preceding claims, wherein the liquid fertilizer product comprises greater than or equal to 4 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

7. The method of any one of the preceding claims, wherein the liquid fertilizer product comprises greater than or equal to 6 weight percent total nitrogen, based on a total weight of the liquid fertilizer product.

8. The method of any one of the preceding claims, wherein the liquid fertilizer product comprises greater than or equal to 8 weight percent nitrogen, based on a total weight of the liquid fertilizer product.

9. The method of any one of the preceding claims, wherein the liquid fertilizer product comprises greater than or equal to 4 weight percent nitrate-nitrogen, based on a total weight of the liquid fertilizer product.

10. The method of any one of the preceding claims, wherein the liquid fertilizer product comprises greater than or equal to 6 weight percent nitrate-nitrogen, based on a total weight of the liquid fertilizer product.

11. The method of any one of the preceding claims, wherein a total weight of nitrogen in the liquid fertilizer product comprises greater than or equal to 70 weight percent nitrate-nitrogen.

12. The method of any one of the preceding claims, wherein the method does not comprise adding an acidic substance.

13. The method of any one of the preceding claims, wherein the organic waste comprises a plant or animal byproduct, food waste, seaweed, dairy product waste, livestock manure, worm castings, peat, guano, compost, blood meal, bone meal, fish meal, decomposing crop residue, cheese whey, wastewater from a meat processing facility, wastewater from a food processing operation, or a combination thereof.

14. The method of any one of the preceding claims, wherein converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form the converted stream comprises use of a membrane bio reactor or a moving bed biofilm reactor and aeration to maintain 2 to 6 milligrams per liter of dissolved oxygen.

15. The method of any one of the preceding claims, wherein removing water from the converted stream comprises reverse osmosis and evaporation.

16. The liquid fertilizer product manufactured by the method of any one of the preceding claims.

17. A method of practicing organic agriculture comprising applying the liquid fertilizer product of claim 16.

18. A method for manufacturing a liquid fertilizer product, comprising the steps of: removing solids from organic waste to obtain a filtrate; converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; adding a source of alkalinity during conversion of ammonia present in the filtrate to nitrate to form the converted stream; and removing water from the converted stream to manufacture the liquid fertilizer product, wherein the liquid fertilizer product comprises nitrate, and wherein a conversion of ammonia-nitrogen present in the filtrate is greater than or equal to 70 weight percent, based on a total weight of ammonia-nitrogen in the filtrate.

19. The method of claim 18, wherein the source of alkalinity comprises potassium carbonate, potassium dicarbonate, potassium oxide, potassium hydroxide, calcium carbonate, calcium oxide, calcium hydroxide, sodium hydroxide, sodium carbonate, sodium bicarbonate, magnesium hydroxide, magnesium bicarbonate, or a combination thereof.

20. The method of claim 18 or 19, wherein a total weight of nitrogen in the liquid fertilizer product comprises greater than or equal to 70 weight percent nitratc-nitrogcn.

21. A system for manufacturing a liquid fertilizer comprising: a waste tank configured to hold organic waste; a filter in fluid communication with the waste tank, the filter being configured to remove solids from the organic waste to obtain a filtrate; a nitrification reactor in fluid communication with the filter, the nitrification reactor configured to converting ammonia present in the filtrate to nitrate using ammonia oxidizing bacteria and nitrite oxidizing bacteria to form a converted stream; and a concentrator in fluid communication with the nitrification reactor, the concentrator configured to remove water in the converted stream to manufacture a liquid fertilizer product comprising nitrate.

22. The system of claim 21, further comprising a second filter between the nitrification reactor and the concentrator.

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