A method and a system for recovering nutrients from wet animal manure

Abstract

A method for recovering nutrients from wet animal manure, the method comprising adding acid to wet manure (1) to lower the pH value of the wet manure to provide acidified wet manure; adding a polyelectrolyte to the acidified wet manure to obtain granulated wet acidified manure (5b); conveying the granulated wet acidified manure continuously into a liquid-solids separator (6) to separate a liquid manure fraction (16) and a solid manure fraction (7); providing a water purification apparatus (9) comprising an electrolytic cell (21), and a substantially vertical separator tower (20) arranged in a flow connection with the upper part of the electrolytic cell (21), conveying the liquid manure fraction to the electrolytic cell (21), operating the electrolytic cell (21) to produce an accumulating floc; conveying the raising floc into the separator tower (20), wherein the floc (19) is separated by expelling from the top of the separator tower (15), and conveying the solid manure fraction (7) and the floc (19) to an aerated bio-oxidizer device (8) to provide oxidized manure; discharging the oxidized manure (10) from the bio-oxidizer device. A system for recovering nutrients from wet animal manure. A fertilizer product (12) comprising nitrogen, phosphorus and potassium encapsulated in spores of Thermoactinomyces. Use of Thermoactinomyces for producing organic fertilizer. Use of a water purification apparatus for treating wet animal manure. Use of a continuously operating aerated bio-oxidizer device.

Description

[0001] A method and a system for recovering nutrients from wet animal manure, a fertilizer product, use of Thermoactinomyces for producing organic fertilizer, use of a water purification apparatus and use of a continuously operating aerated bio-oxidizer device

[0002] Field of the application

[0003] The present application relates to a method and a system for recovering nutrients from wet animal manure. The present application also relates to a fertilizer, to use of Thermoactinomyces for producing organic fertilizer, to use of a water purification apparatus and to use of a continuously operating aerated bio-oxidizer device.

[0004] Background

[0005] Today, animal husbandry is highly centralized and animal factory farming increases in size. Large amounts of wet manure are generated locally. Wet manure can be directly applied to cultivation areas, but big amounts result in logistic problems. The wet manure must be spread over a large field area within a short period of time when plants are not growing. Transportation and in spreading equipment are remarkable investment.

[0006] One drawback in using wet manure as fertilizer is the noxious odour, caused mostly by volatile short-chain fatty acids, nitrogen compounds and hydrogen sulphides. Nitrogen loss is mainly caused by the evaporation of ammonia from the wet manure, especially in an anaerobic condition. The total nitrogen loss is typically 80-90% of the original nitrogen concentration of wet manure, before it is spread onto the field.

[0007] In addition, spreading of wet manure onto fields is restricted by legislation in many countries due to the high phosphorus content of the manure. This requires additional synthetic fertilising of nitrogen and potassium to obtain balanced fertilization. Therefore, nutrient losses due to the use of the wet manure, have led to the increasing use of synthetic fertilizers. At the same time fertilizer prices have increased. Tightening environment conservation requirements have caused obstacles to the expansion of livestock farms and a serious problem for the profitability of food production. Further drawbacks of using wet manure are at least that it can be spread only during spring or autumn into thawed soil with heavy machinery compressing the soil. In addition, spreading causes bad odours, leaks to ground waters and to surrounding watersheds causing eutrophication and possible spread of diseases. In several countries where the weather conditions during the wintertime is below zero degree Celsius, manure has to be stored for one year. Fertilization during the high season is labour intensive.

[0008] Conventional synthetic fertilizers require fossil energy for production and transportation. These pollute the environment and heavy machinery compress the cultivation soil. In the compressed soil, oxygen intake is poor during the dry season and rainwater may flus nutrients into the water sheds causing eutrophication. The current factory farming is not a sustainable one.

[0009] There is a need for an improved treatment of wet manure to recover its valuable components for further utilization as organic fertilizer. It is desired to avoid formation of new waste problems when treating the manure, such as formation of greenhouse and / or toxic gases, formation of wastewater, formation of waste sludge, and substantial loss of nutrients.

[0010] Summary

[0011] The present method, system, products and uses enable overcoming drawbacks of prior art and to meet the needs. Problems relating to liquid manure can be solved locally, such as at the site where the wet animal manure is produced.

[0012] The present application provides a method for recovering nutrients from wet animal manure, the method comprising

[0013] (a) providing wet animal manure, preferably in a droppings pit;

[0014] (b) adding acid to the wet animal manure to lower the pH value of the wet animal manure below 6.5, to solubilize nitrogen compounds contained in the wet animal manure and to provide wet acidified animal manure;

[0015] (c) adding a polyelectrolyte to the acidified wet animal manure to obtain granulated wet acidified animal manure;

[0016] (d) preferably continuously measuring and adjusting pH value and conductivity of the granulated wet acidified animal manure, such that the pH value and conductivity value of the granulated wet animal manure meet a predetermined target pH value and a predetermined target conductivity value; (e) conveying, such as pumping, the granulated wet acidified animal manure continuously into a liquid-solids separator to separate a liquid manure fraction and a solid manure fraction;

[0017] (f) providing a water purification apparatus comprising

[0018] • an electrolytic cell comprising a substantially vertical tube connected to a source of DC electric power and comprising one or more first electrode(s) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) having a higher electronegativity compared to the first electrode(s), and

[0019] • a substantially vertical separator tower arranged in a flow connection with the upper part of the electrolytic cell,

[0020] (g) conveying the liquid manure fraction to the electrolytic cell,

[0021] (h) operating the electrolytic cell to produce iron hydroxide and / or aluminum hydroxide acting as molecular sieve capable of trapping soluble substances, such as nutrients and / or minerals, and to produce hydrogen causing the molecular sieve with the trapped substances to raise in the vertical tube as an accumulating floc;

[0022] (i) conveying the raising floc into the separator tower, wherein the floc is separated by expelling from the top of the separator tower, and preferably obtaining first purified water from the separator tower at a point below the raising and / or expelled floc,

[0023] (j) conveying the solid manure fraction to an aerated bio-oxidizer device operating continuously at a temperature of at least 75°C, such as about 80°C, to oxidize the solid manure to provide oxidized manure;

[0024] (k) discharging the oxidized manure from the bio-oxidizer device and providing a spore mass containing the nutrients originally contained in the wet manure;

[0025] (l) preferably controlling feed of the manure and discharge of the spores by measuring the amount of generated heat, water and carbon dioxide and the weight of the reactor;

[0026] (m) preferably capturing the released thermal energy by a heat exchanger used to adjust the air fed into the reactor to a constant temperature.

[0027] The present application also provides a system for recovering nutrients from wet animal manure, the system comprising

[0028] -means for providing wet animal manure and / or a source of wet animal manure, -means for acidifying the wet animal manure, -means for adding a polyelectrolyte to the acidified wet animal manure to obtain granulated wet acidified animal manure,

[0029] -a liquid-solids separator for separating a liquid manure fraction and a solid manure fraction from the granulated wet acidified animal manure,

[0030] -means for continuously conveying, such as pumping, the wet acidified manure and / or the granulated wet acidified manure, preferably into the liquid-solids separator,

[0031] -a water purification apparatus comprising

[0032] • an electrolytic cell comprising a substantially vertical tube connected to a source of DC electric power and comprising one or more first electrode(s) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) having a higher electronegativity compared to the first electrode(s), and

[0033] • a substantially vertical separator tower arranged in a flow connection with the upper part of the electrolytic cell, and comprising an outlet for expelling raising floc at the top of the separator tower, and an outlet for purified water (at a point below the raising and / or expelled floc,

[0034] -means for conveying the liquid manure fraction obtained from the liquid-solids separator to the electrolytic cell,

[0035] -a continuously operating aerated bio-oxidizer device, wherein the solid manure fraction from the liquid-solids separator and the floc from the separator tower are arranged to be conveyed into the bio-oxidizer, wherein the bio-oxidizer is arranged to oxidize the manure to provide oxidized manure.

[0036] The present application also provides a fertilizer product comprising nitrogen, phosphorus and potassium encapsulated in spores of Thermoactinomyces.

[0037] The present application also provides use of Thermoactinomyces for producing organic fertilizer comprising oxidized nutrients comprising nitrogen, phosphorus and potassium encapsulated in spores.

[0038] The present application also provides use of a water purification apparatus comprising

[0039] • an electrolytic cell comprising a substantially vertical tube connected to a source of DC electric power and comprising one or more first electrode(s) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) having a higher electronegativity compared to the first electrode(s), and • a substantially vertical separator tower arranged in a flow connection with the upper part of the electrolytic cell, and comprising an outlet for expelling raising floc at the top of the separator tower, and an outlet for purified water at a point below the raising and / or expelled floc, for treating wet animal manure.

[0040] The present application also provides use of a continuously operating aerated biooxidizer device comprising

[0041] -a reactor comprising spheres, such as ceramic spheres, arranged to receive biomass comprising solid manure,

[0042] -one or more controllable means for providing dried and heated air, preferably at different levels, to the reactor,

[0043] -controllable means for providing the solid manure to the reactor, -controllable means for outputting oxidized manure from the reactor, -controllable means for mixing the solid manure, preferably wherein the means are controlled to obtain and / or maintain constant growth of microbes in the reactor, for treating solid manure and floc to provide oxidized manure.

[0044] The main embodiments are characterized in the independent claims. Various embodiments are disclosed in the dependent claims. The embodiments and examples disclosed herein are mutually freely combinable unless otherwise explicitly stated. The embodiments and examples not in the scope of the claims are embodiments and examples not part of the invention, but useful for understanding the invention.

[0045] The method, system and fertilizer product described herein meet sustainable farming requirements; cause no pollution, creates sellable products, cuts expenses and therefore improves over all farming profits.

[0046] The present system and method enable biochemical conversion of the starting material into organic and chemically, physically and microbiologically stable hygienic natural fertilizer suitable for organic farming without loss into air, water or agricultural land. The method also generates pure air, pure water, emission free heat energy, and carbon dioxide for green houses.

[0047] The present method and system enable processing waste materials or waste streams into valuable materials without substantially providing emissions or discharge of harmful substances or materials. There is no need to transport the waste materials to other locations or store any waste material, but the present system may be implemented on-site in a continuous manner. Further, the present method provides pure water, fertilizers and energy, which can be directly utilized at an agricultural site, plant or environment, even at the same site where the starting material is formed.

[0048] Brief description of the figures

[0049] Figure 1 shows a flowchart of an example of the method,

[0050] Figure 2 shows an example of a setup of the system.

[0051] Figure 3 shows a specific example of a setup of the system.

[0052] Figure 4 shows examples of the electrolytic cell and the separator tower.

[0053] Figure 5 shows a flowchart presenting flow of substances and air in an example of the bio-oxidizing method.

[0054] Figure 6 shows a vertical bio-oxidizer reactor.

[0055] Figure? shows a horizontal bio-oxidizer reactor.

[0056] Detailed description

[0057] In this specification, percentage values, unless specifically indicated otherwise, are based on weight (w / w, by weight, or wt%). In specific examples the embodiments and examples specified with the open term “comprise” may be further limited with a closed term “consisting of”.

[0058] The diameters disclosed herein, unless specifically indicated otherwise, may refer to the smallest diameter, and may be presented as average or number-average diameter. The diameter may be also presented as equivalent spherical diameter. The diameter may be determined by eye, microscopically or by other optical methods, which may comprise using a camera, and / or by sieve analysis. The present method comprises main steps 1 ) pretreatment of manure, 2) solid separation, 3) water purification and 4) bio-oxidation, which produce a fertilizer product. A flowchart of an example of the method is shown in Figure 1 .

[0059] The present disclosure provides a method for recovering nutrients from wet animal manure. The method may also be specified as a continuous method, a zero emission method, and / or a method for recycling and / or recovering all substances of the animal manure. The method may also be a method for production of emission-free stabilized fertilizer and / or an emission-free method for production of stabilized fertilizer. The method may also be a method for converting wet animal manure into pure water and (hygienic) fertilizer product, and preferably for producing heat. The method may also be a method for maintaining and / or recovering original nitrogen content of the animal manure, i.e. a method preventing nitrogen loss in the process. The method can be implemented and the effects thereof can be obtained locally, so the method may be on-site method and / or a method carried out at a site of animal husbandry and / or at an agricultural site or plant.

[0060] The term “nutrients” refer to nutrients naturally contained in the manure, particularly to the combination of phosphorus, nitrogen and potassium, such as wherein the nutrients contain at least phosphorus, nitrogen and potassium.

[0061] In the present method the recovery of nutrients and transformation thereof into stable fertilizer begins already when the wet animal manure is formed, and it is a continuous process. The manure is preferably not collected into storage containers or stored for prolonged time, but the manure can be acidified immediately as it is formed from the animal by dropping into a pre-acidified droppings pit, which may be underneath the animal shelter. The immediate acidifying lowers that pH of the wet animal manure to a value, which prevents nitrogen loss, and can be facilitated by dosing an amount of acid solution in a mixed wet animal manure container.

[0062] Urine, or urea, in wet manure is converted into two ammonia molecules and one carbon dioxide molecule while reacting with water outside the animal. In anaerobic and basic conditions, the ammonia gas molecules evaporate, causing a bad, toxic odour. In the present acidic conditions, ammonia molecules are converted into soluble ammonium ions (such as in ammonium chloride, if hydrogen chloride is used for acidification) and the bad odour will disappear while nitrogen is conserved in the acidified wet manure as soluble ammonium. Also nitrogen oxides will evaporate from the wet animal manure at low oxygen content. These together with ammonia form nitric acid at the atmosphere by the effect of water and sunlight, thus falling down as acid rain also to agricultural land and increasing the acidity of the soil and need for lime application. In the present method the nitrogen compounds form, by the effect of high temperature and extreme thermophiles, nitrate ions, which together with potassium from urine form potassium nitrate KNO3. Thus, no evaporating nitrogen compounds are formed in the present controlled method, and the original nitrogen of the manure can be recovered.

[0063] Phosphates in the sludge manure are mostly in soluble form. The soluble phosphates in the sludge will easily run off with water and cause eutrophication. Phosphates can be precipitated by sulfuric acid-containing iron sulphate as iron phosphates. Such method is widely used in the treatment of municipal sewage, where it is aimed to remove phosphorus from the sewage as much as possible, before partially purified sewage is discharged into natural water bodies. In this process, sulphates, which are released during the precipitation of iron phosphate, enter to the waterways. In an anaerobic condition in lakes and sea, microbes reduce sulphates to hydrogen sulphides. Hydrogen sulphide may permanently destroy aquatic ecosystems. The present method avoids such drawbacks, and the phosphate can be precipitated in the water purification apparatus without added sulphate thus avoiding formation of hydrogen sulphide.

[0064] Pretreatment of manure

[0065] The animal manure may be any suitable animal manure, preferably wet animal manure, which may be directly obtained from an animal farm, such as a cattle farm or a pig farm. The manure may be continuously collected and / or conveyed from an animal shelter, bam or the like.

[0066] The term “wet manure”, which may be also called manure, manure sludge or liquid manure, refers to a slurry of urea and dung collected from the farm, in most cases from cattle (bovine) and / or pig farm. The wet animal manure may be thus obtained without adding water. However, dung in more dry form, such as from poultry farms can also be converted to natural fertilizer although it lacks urine and is not originally in wet form, but it may be added to the wet manure and / or adjusted to contain a suitable moisture content. The same applies also to horse manure. The “animal manure” may be also called as “manure” for simplicity.

[0067] The method comprises (a) providing wet animal manure 1a. A source of wet animal manure, and / or means for providing the wet animal manure 1 may be provided. The wet animal manure may be obtained directly from an animal shelter or the like site, wherein the animals live and produce manure. The wet animal manure may be provided and / or conveyed to a droppings pit, and / or the wet animal manure may be provided to the method from the droppings pit, which may be considered as the source of the wet animal manure and / or means 1 for providing wet animal manure.

[0068] It was found out that when the wet manure was acidified at the early phase with an accurate and a controlled manner, several effects were obtained over the whole process. Adding acid to the wet manure solubilizes nitrogen compounds contained in the wet animal manure. The obtained and / or provided acidified wet animal manure or fractions thereof can be efficiently treated in the further method steps, such as with the water purification apparatus and the bio-oxidizer, while maintaining nitrogen.

[0069] The method comprises (b) adding acid to the wet animal manure, i.e. combining and / or mixing the wet animal manure with acid, to lower the pH value of the wet animal manure to below 6.5. The wet manure may be added to an acid solution, which may be provided to and / or in a droppings pit or the like container or reservoir.

[0070] The wet manure may be subjected to acid, preferably a food grade acid, without delay to prevent urea degradation. When wet manure is acidified, the ammonia is converted to non-volatile, soluble ammonium ion form and nitrogen loss is reduced, i.e. nitrogen is fixed / bound. However acid hydrolysis shall be avoided, as degraded organic compounds would form gases, and even if this would result in a fast flotation, the control of the process would be difficult or impossible. Neutralizing the mixture would cause additional expenses and make the process more complex. Thus, it is preferable not to add strong acid and / or large amount of weak acid, and it is preferable avoid flotation merely by the effect of addition of the acid. Also other gases will not be formed in an uncontrollable manner. The actual flotation is obtained by the combined effect of pH, polyelectrolyte and conductance and therefore nitrogen compounds are not lost. In the present method the addition of acid is carried out in a controlled manner to avoid acid hydrolysis and mainly only the gasification and / or degradation of urea is prevented. The “controlled” may refer to added amount, adding time and / or controlling as feedback to measured pH value(s) and optionally other properties measured and / or detected from the process.

[0071] Acid may be added directly to the droppings pit, for example the droppings pit may already contain acid, so that the dropping manure will be acidified immediately in the pit. The acidified manure may be led to a collection container using a slope of the dropping pit. Alternatively, manure may be collected to a collection container. Said container may have a volume of 1 to 5 m3for a European cattle farm. Organic or inorganic acid may be used. The acid may be diluted to 25% by volume or less, preferably to about 20% by volume. Acid is added until pH of the sludge (set value) is below 6.5, such as about 6.3 or less, for example about 6.0 or less. Preferably the pH is not adjusted below 5.5, as it may cause acid hydrolysis. The pH may be adjusted into a range of 5.5-6.5, such as 5.5-6.4, 5.5-6.3, or 5.5-6, or 5.7-6.5, 5.7-6.4, or 5.7-6.3.

[0072] The acid used in step (b) may comprise or be an organic acid and / or an inorganic acid. Preferably the acid is an organic acid. Formic acid is preferred, but other organic acids or combinations thereof may be used, such as lactic acid, acetic acid and / or citric acid. Oxalic acid is not desired.

[0073] The method may comprise collecting the wet animal manure to an acidic solution in the droppings pit in (b), or combining with the acidic solution in the droppings pit, preferably transferring, such as conveying, to a supply tank and / or a collection container, and subjecting to shearing forces to homogenize the manure.

[0074] The wet manure in collection container may be subjected to intensive mixing with sufficient shear forces to homogenize the manure. A suitable homogenizing device, mixer and / or other device capable of providing suitable shear forces is used and / or provided. The homogenizing device may be in the collection container, in the supply tank, or in a further container. The diameter of grinded particles, if detectable, may be 2 mm or less.

[0075] The pH value of mixed and acidified wet animal manure / sludge is measured continuously and adjusted to a set value in real time. A polyelectrolyte, which may refer to one or more types of polyelectrolytes, preferably a food grade polyelectrolyte, is added to the adjusted sludge.

[0076] The method may comprise conveying / transferring the acidified wet animal manure, such as the homogenized wet animal manure, after step (b) to a pipe system or a pipeline equipped with a mixer, such as a continuously operating flange mixer. The pipe system or pipeline enables carrying out the discussed method steps in a continuous manner. The pipe system may comprise a continuous pipeline from the supply tank, the collection container and / or a mixing container to the liquid-solids separator. The homogenized pre-acidified manure may be introduced / conveyed into the pipe system / pipeline, such as by peristaltic pumps sucking the wet manure into the pipe system / pipeline, equipped with means for measuring and adjusting the necessary parameters, such as pH and conductivity, for creating pH-adjusted and granulated mixture for separating solids and liquid fractions. Then a polyelectrolyte, such as a food grade polyelectrolyte, is added to the acidified slurry in the pipe system. Heavy mixing of the sludge should be avoided to allow flocculation. A floc is obtained. Examples of suitable polyelectrolytes comprise starch-based polyelectrolytes. The granulation of the mixture may be monitored in real time, and adjusted to a set value of granulation level in real time. The aim is to change the physical structure of the sludge to clearly separate liquid and solid fractions.

[0077] The method comprises (c) adding a polyelectrolyte 4g to the acidified wet manure to provide or obtain granulated wet acidified manure. The mixture of acidified wet manure and the polyelectrolyte may be granulated by mechanically treating the mixture. In one example the method comprises adding a polyelectrolyte 4g to the acidified wet manure and granulating the polyelectrolyte-containing acidified wet manure. The system may comprise a granulating means, which may comprise one or more mixing means and / or other mechanical treating means, such as granulator.

[0078] The steps (b) to (e), or (c) to (e), in this order, may be performed in the pipe system.

[0079] The conductivity may be adjusted to 3 mS / cm or less, such as to about 2 mS / cm or less, by adding water. The water may be recycled water, such as the purified water W1 or W2. The maturation of the mixture may be facilitated by gentle mixing, such as with a flange mixer in the vertical pipe. For continuous and accurate measuring, dosing and mixing of the reagents, one or more pumps, such as peristaltic pumps, may be used. Preferably there are no retention times or storages in the process, but continuous flow towards the final products.

[0080] At the pipe system conductivity and pH-value may be continuously monitored, preferably with one or more sensors, and adjusted. If necessary, conductivity is adjusted by diluting with water. Added polyelectrolyte dilutes the manure slurry and thus monitoring and possible adjustment is necessary.

[0081] Conductivity and pH both have effect to stability of the flocs and thereby incorrect conductivity and / or pH may compromise separation of the solid and liquid fractions.

[0082] In vitro, real-time and / or online measurement is / are preferably made for each manure type and used for pre-set / predetermined values for pH, conductivity, amount of polyelectrolyte and preferably residence time in pipe system. The residence time is at least a time required to obtain the desired conditions discussed herein.

[0083] The method preferably comprises (d) continuously measuring and adjusting pH value and conductivity of the wet acidified manure and / or the granulated wet acidified manure, such that the pH value and conductivity value of the wet acidified manure and / or the granulated wet manure meet a predetermined target pH value and a predetermined target conductivity value. The system may comprise one or more means for measuring pH, such as pH sensors, which may be connected to the controlling means. The means for measuring pH are arranged to measure pH at a point of interest, such as at a location or point containing the manure and / or other substance to be measured / monitored.

[0084] Further the floc size may be monitored. This may be done also by following the separation of the solid and liquid fraction when pre-screen and belt dryer are used for separation. The floc size may be monitored by any suitable known method and / or device for particle size analysis, such as by using a particle size analyzer device, and / or by using indirect methods, such as determining viscosity, flow rate, and / or the like. Monitored data can be used to adjust process parameters. Liquid and solids separation

[0085] The granulated sludge is conveyed, such as pumped, into a solid separating device, which may be called as a liquid-solid separator, liquid-solids separator or solid / solids separator, such as into a continuously operating and preferably automated liquid-solids separator, wherein liquid and solid fractions are separated. The separated liquid and / or purified water may be used for continuous washing of the liquid-solids separator. The washing liquids may be conveyed back to the inlet of the liquid-solids separator. The liquid that has passed the liquid-solids separator is conveyed to a water purification apparatus, wherein soluble nutrients and remaining solids are separated as solid floc 19, and separated water is purified into a pure water W1 , W2.

[0086] Separation of the solid and liquid fraction may be done by any known method allowing sufficient scaling. Excess water may be removed by a pre-screen followed by belt dryer. Dry matter of the sludge entering to the separation may be 2 to 15% by weight. Separation should not degrade the flocculated manure / the solid fraction. The liquid-solids separator can be used to obtain a desired dry matter content of the solid fraction. The solid fraction may be obtained as a filter cake, which may be further processed if necessary, such as disintegrated.

[0087] The method comprises (e) conveying, such as pumping, the (adjusted) granulated wet manure continuously into a liquid-solids separator to separate, and preferably recover, a liquid manure fraction and a solid manure fraction. This is carried out by means 2 for continuously conveying the wet acidified manure and / or the granulated wet acidified manure. The means 2 for continuously conveying may comprise any suitable conveying and / or pumping means, such as by using one or more pumps, conveyers and / or the like devices. Peristaltic pump is preferred. One such means 2 may be enough to convey the wet manure from the source to the liquid-solids separator.

[0088] Solid matter separator 6 may be based on any known method for separation of the liquid and solid phases without disrupting the granules of manure and polyelectrolyte. A liquid-solids separator (solid separator) as discussed here may be based on industrial belt press filters and may benefit three permeable wire screens to compress granulated manure for separation of the liquid and solid fraction. The pre-screen is used to remove excess water. Solid fraction and liquid fraction are separately recovered and / or conveyed to further processing / devices. The solid manure fraction 7 and the liquid manure fraction 16 may be separated from each other using sieves, such as a pre-screen 6a and a belt dryer 6b. In one example the liquid-solids separator comprises a pre-screen 6a for removing excess water and then a belt dryer 6b.

[0089] The dry matter content of the solid manure fraction, either when obtained from the liquid-solids separator and / or when providing to the next step, may be in the range of 20-40% by weight, preferably in the range of 25-35% by weight, such as in the range of 25-30% by weight. The dry matter content of the solid manure may be adjusted to such range by using one or more suitable means, such as disclosed herein. pH of the liquid manure fraction 16 may be adjusted according to cell type used in the water purification apparatus 9.

[0090] Water purification

[0091] Liquid fraction typically has a dry matter content of 5% by weight or less. It is led to a water purification system / step to recover remaining nutrients, which may be solid and / or soluble, and which can be then returned to the process and combined with the solid fraction. The remaining water is purified in the water purification step, and it may be even further purified to make it suitable for household or drinking water.

[0092] The method comprises (f) providing a water purification apparatus 9 comprising

[0093] • an electrolytic cell 21 comprising a substantially vertical tube connected to a source of DC electric power 23 and comprising one or more first electrode(s) 32 comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) 34 having a higher electronegativity compared to the first electrode(s), and

[0094] • a substantially vertical separator tower 20 arranged in a flow connection with the upper part of the electrolytic cell 21 .

[0095] The method using the water purification apparatus may be called as Molecular sieve separation (MSS-method), wherein iron ions and / or aluminum ions and water ions associate and combine into a macromolecular net of ferric and / or aluminum hydroxide, which forms a sieve of sub-molecular pore size that is floated by water-originated hydrogen gas. The present water purification apparatus, which may be also called as a water purification device, refers to a system where a molecular network of metal hydroxides and hydrogen gas is formed within reactor cells by direct current and ionic separation. A system that may be controlled remotely and / or automatically and / or semiautomatically is preferred. Ionic separation as used herein means that elementary iron and water molecules are ionized, i.e., dissociated into positive and negative ions, in the electric field of a reactor cell.

[0096] The method comprises (g) conveying the liquid manure fraction to the electrolytic cell 21. This can be obtained by pumping immediately before the electrolytic cell, or the liquid may be conveyed to the electrolytic cell by a pressured formed in a previous pumping or the like conveying step. The liquid manure fraction may be considered as wastewater which is to be purified with the water purification apparatus / step.

[0097] The electrolytic cell 21 may be installed in a substantially vertical position, wherein the first end of the electrolytic cell points down and the second end points up. The first end comprises an inlet 31 for incoming liquid (pretreated wastewater), such as an aperture and / or a connector for the liquid, preferably for a tube or pipeline for the liquid. The second end comprises an outlet for outgoing liquid and floc 19, and the second end / outlet is in a flow connection with the separator tower, for example the electrolytic cell 21 and the separator tower 20 are connected together at their ends as shown in Figure 4, of the flow from the electrolytic cell 21 is conveyed to a point in the separator tower 20 between the ends of the separator tower, such as substantially at the center of the separator tower, or at the lower part of the separator tower. In general, the outcoming liquid and floc from the electrolytic cell 21 are provided to the separator tower at a point between the ends of the separator tower so that pure water can be obtained below the point and the floc can be expelled above the point. In this way the floc and the purified water can be efficiently separated.

[0098] The one or more first electrode(s) 32 comprising one or more iron and / or aluminum electrode(s) are preferably in a form of cylinder, which defines a flow channel for the solution. The first electrode(s) 32 is / are worn in the process.

[0099] The one or more inert second electrode(s) 34 are preferably inner electrode(s), which preferably is / are in a form of cylinder inside the cylinder of the first electrode. Therefore, between the first electrode 32 and the second electrode 34 a channel is formed, whereto the pretreated wastewater may be conveyed. The cylinder of the second electrode 34 may be longer than the cylinder of the first electrode 32, which enables for example using the second electrode 34 as a pipeline for conveying treated flow from the electrolytic cell 21 to a next step and / or to a specific point / level in the separator tower 20.

[0100] In one example an apparatus 9 or a system comprising the apparatus is provided comprising, as disclosed in Figure 4, an electrolytic cell 21 comprising a vertical tube connected to a source of DC electric power 23 and comprising a first electrode 32 comprising a cylindrical outer iron electrode, and a cylindrical inner inert second electrode 34 comprising precious metal, such as platinum, having a higher electronegativity compared to the first electrode. A vertical separator tower 20 is connected to the upper part of the electrolytic cell so that the flow raising from the cell is conveyed to the separator tower substantially at the middle of the separator tower. The total height h of the combination disclosed in Figure 4 may be in the range of 2-10 meter, for example about 4 meters. Each of the electrolytic cell 21 and the separator tower 20 may have a height in the range of 1-6 meters, for example. The system may comprise one or more of electrolytic cells 21 and one or more of separator towers 20, or combinations thereof, which may be arranged in series and / or in parallel, and / or as a cascade.

[0101] The liquid manure fraction 16 in Figure 4 is pumped into the electrolytic cell 21 with a suitable flow rate via inlet 31 at the first end of the electrolytic cell to between the first electrode 32 and the second electrode 34. In the example of Figure 4 the electrodes 32, 34 are in the form of cylinders, but electrodes in other forms may be applied as well.

[0102] In general, the first electrode is fed with positive current releasing iron ions and electrons. The electrons are conducted to the second electrode. The iron ions react with hydroxides from the water making iron hydroxide 33. Iron hydroxide forms a molecular sieve that captures impurities from the water but allows water molecules to pass through. A floc begins to evolve. The electrons react with hydrogen ions from water creating hydrogen gas. This lifts the iron hydroxide with trapped impurities, i.e. the floc, up to the separating tower. The situation would be similar if aluminum electrode was used, in which case aluminum ions would react with hydroxides from the water making aluminum hydroxide, which forms similar molecular sieve. However, the molecular sieve formed by iron hydroxide is substantially denser and can bind substances more efficiently. Especially the produced iron can precipitate phosphates without added sulphate, thus avoiding the formation of hydrogen sulfide. The formed iron phosphate can be separated from other solids at a later phase, if necessary.

[0103] In one example the second cylindrical electrode of precious metal 34 conducts the electrons from the cylindrical iron electrode 32 by negative current. The precious metal cylinder comprises a plurality of small holes or apertures. Jetting water from the holes, by the effect of electrolytic reactions, cleans the surface of the iron cylinder so iron ions can form readily. Wash water 22d may be provided to the electrolytic cell, such as inside the second cylindrical electrode, to facilitate the jetting flow shown by arrows in Figure 4.

[0104] The second electrode 34 may be cylindrical and it may form a tube which is connected to the separator tower, as shown in Figure 5. The raising impurities in the forming floc, and the purifying water, raise inside the cylinder 34. The second electrode may comprise (larger) holes or apertures 26, which allow impurities and clean water to enter and escape up in the system. The cylinder 34 may continue inside the separator tower 20, and purified water may be separated from the tower 20 below the level / point of the second end of the cylinder 34, or an end of a tube continuing from the second end of the cylinder 34. This will ensure that the floc is properly separated from the purified water.

[0105] The method comprises (h) operating the electrolytic cell (21 ) to produce iron hydroxide and / or aluminum hydroxide (33) acting as molecular sieve capable of trapping soluble substances, such as nutrients and / or minerals, and to produce hydrogen causing the molecular sieve with the trapped substances to raise in the vertical tube as an accumulating floc. The electric current can be controlled to obtain desired reaction rate, such as desired degree of formation of the floc. The flow rate of the pretreated wastewater may be also controlled so that a desired reaction efficiency can be obtained. The controlling can be carried out by the electronic controlling means 24, which may be operatively connected to the pump controlling the flow rate and to the source of electric current 23.

[0106] Typically, the electrolytic cell may be operated or run with a direct current (DC) in the range of 10-100 A and a voltage in the range of 10-100 V. In one example the voltage may be about 10 V and the current may be about 40-50 A. In another example, the voltage may be about 50 V and the current may be about 20-30 A. These parameters can be controlled by the electronic controlling means 24 to obtain desired reaction rate and for example adjust the electrolytic reactions to adapt to the currently used wastewater content and / or flow rate.

[0107] The network of metal hydroxides tends to self-set as globular or spherical structures. The metal hydroxides are oxidized by the oxygen present in the solution into oxides, i.e. iron oxides and / or aluminum oxides 33, which are solid minerals containing no water. During the formation thereof a solid shell is formed in the floc, which holds everything inside, except water. Thus, when the floc spheres raise at accelerating speed up while the hydrostatic pressure decreases, the gas inside the spheres expands thus forming buoyant force, which in turn accelerates the separation of the floc thus resulting in very efficient separation of the floc / im purities from the purified water.

[0108] The floc comprising the iron hydroxide with impurities is lifted up towards the surface and / or the top / upper part 15 of the separator tower 20. The top of the separator tower, which may refer to the upper part and / or second end thereof, comprises an outlet 15 for the expelled or separated floc, which may comprise a pipe or chute sloping downwards, as shown in Figure 4. The floc, which is selfdrying, falls from the outlet to a decanter by gravity.

[0109] The method comprises (i) conveying the raising floc into the separator tower 20, wherein the floc 19 is separated by expelling, i.e. discharging, from the top the top / upper part of the separator tower 20, and / or from an outlet 15 for the floc.

[0110] The separated floc can be collected to a container positioned below the outlet or chute. The floc may be allowed to dry, or it may be dried. The floc may be further processed, such as disposed and / or it may be treated to recover any valuable substances, such as metals.

[0111] Preferably the floc 19 is conveyed to the bio-oxidizer device 8, wherein it may be processed together with the solid manure from the solid manure fraction 7. The solid manure and the floc can be oxidized to provide oxidized material 10, which may be called as oxidized manure and / or oxidized biomass. In one embodiment the floc 19 obtained in step (i) is combined with the solid manure fraction 7 obtained in step (e), such as before conveying to the bio-oxidizer device, to obtain combined biomass 50. The solid manure fraction may be conveyed by using a suitable conveying means, such as a conveyer belt or a screw conveyor. The method comprises obtaining first purified water W1 from the separator tower 20 from below the raising floc and / or from below the end of the tube or pipe connecting the electrolytic cell 21 with the separator tower 20. The point of withdrawing the water shall be selected in such way that the forming and raising floc cannot be included to the separated water fraction. In general, the floc and the purified water move to opposite directions, which facilitates the separation of purified water, especially when the purified water is withdrawn below the level of the raising floc. The first purified water W1 is separated at a point, position or level, such as via an outlet 18, which is below the aperture of the outlet 15 for expelled floc 19 in the separator tower 20, as shown in Figure 4. The first purified water W1 is withdrawn from an outlet 18 for the first purified water W1 , which may be at the bottom (first end) of the separator tower 20, or at any other suitable point / level. The first purified water W1 may be conveyed to a buffer tank 25 and / or for other use and / or treatment from the outlet 18. The flow of the first purified water W1 may be controlled by controlling means, such as wherein the means comprise a valve. The pump controlling the flow rate of incoming pretreated wastewater may also control the flow rate of the whole apparatus, such as the flow rate of outcoming purified water.

[0112] The method may comprise using the purified water W1 as washing water and / or as diluent. The method may comprise treating the recovered purified water W1 with active carbon. The apparatus or the system may comprise an active carbon filter or the like flow-through container or column comprising active carbon, through which the purified water W1 may be conveyed.

[0113] The water purification apparatus 9 may comprise or be connected to an iron oxidizing device 17, wherein the first purified water W1 is arranged to be conveyed to the iron oxidizing device 17 to oxidize and to separate iron from the first purified water W1 to obtain second purified water W2 (Figure 2). The iron oxidizing device may comprise an outlet for the second purified water W2, which outlet may be controlled by controlling means to obtain desired flow of the second purified water W2.

[0114] In one example an iron oxidizing device 17 comprises one or more pressurized containers, such as cylinders, such as made form stainless steel. The container(s) may be arranged in series. The container(s) is / are filled with limestone, which set pH of the water to about 8.3, which is the pH value wherein iron will be oxidized in optimal way into iron trioxide (hematite). The device is operated at an elevated pressure, such as at a pressure in the range of 3-5 bar, wherein the increased partial pressure of oxygen accelerates the oxidizing reactions. The container(s) may be pressurized with means for pressurizing the containers, such as a pump. On the limestone there are layers of silica sand, such as first a layer with a rough grain size, and subsequently layers having increasing liner grain sizes towards the surface. As the silica sand is piezoelectric, i.e. there is a voltage between the ends of crystals, electrolysis is obtained in the water. The silica sand thus catalyzes the oxidation of iron compounds into non-soluble form hematite. Hematite is bright red mineral, which will be precipitated on the surface of the silica sand layer, wherefrom it is washed / rinsed by backwash method and is conveyed back to feed container and / or out from the process as harmless mineral. While oxidizing, the iron coprecipitates oxidizing minerals such as arsenic, manganese and the like, if present in the first purified water W1. Aluminum hydroxide will be oxidized into aluminum trioxide (bauxite) and can be removed in similar manner by backwash. If drinking water is to be prepared, the purified water W1 , W2 can be treated with active carbon. The precipitates comprising Fe2Os and / or AI2O3 and possible coprecipitates thereof obtained from the iron oxidizing device may be conveyed to the bio-oxidizer.

[0115] The method may comprise treating the recovered first purified water W1 by oxidizing iron and removing oxidized iron to obtain second purified water W2. This can be done by using the iron oxidizing device 17.

[0116] The system may comprise means for conveying the first purified water W1 and / or the second purified water W2 to one or more points and / or uses in the system, preferably in a controlled manner, such as wherein the means comprise suitable conveying means, such as pipes, tubes and the like, and preferably one or more pumping means, valves, and / or the like means operatively connected to the controlling means. The points where the purified water W1 , W2 may be conveyed may be any points where pure water is needed, such as for diluting and / or for washing.

[0117] The method may comprise adding one or more polyelectrolytic polymers to the formed floc 19 to stabilize the floc, preferably after the electrolytic cell 21 and / or before the separator tower 20. The apparatus and related parts may be made of material(s), which can tolerate the conditions, such as used pressures, temperatures, liquids and reagents, such as stainless steel, plastic, glass, and / or silicone. Parts of the apparatus may be made transparent, such as the separator tower or part thereof may comprise a transparent tube and / or a transparent tube may be connected to the electrolytic cell, which enable monitoring the process visually, for example the formation of the floc.

[0118] One or more of the devices / apparatuses, or the system, may be electronically controllable, thus comprising one or more electronic controlling means 24, herein also called controlling means, which may comprise one or more electronic control unit(s). The whole system may be controlled by one controlling means, and / or one or more, such as two or more, of the devices / apparatuses may comprise a specific controlling means, which may be optionally controlled by and / or connected to a main controlling means. The devices / apparatuses or the system may be automated or semi-automated. The controlling means, or the control unit(s), may be programmable, preferably comprising one or more processors, memory, and software configured, when executed with a processor in the controlling means / control unit, to carry out one or more operations to implement the method or part thereof, for example dosing of one or more reagent(s), feeding of substances, such as reagents, wet manure, liquid fraction, solids fraction, biomass, and / or final products, diluting water, and / or flow of air and / or liquids or other substances disclosed herein; and / or to adjust pH, voltage, current, temperature, pressure, and / or the like features, by controlling and / or adjusting any of the operating components of the apparatus or the system. The controlling means may be arranged to maintain one or more of parameters in a desired range, preferably as feedback to one or more properties detected / measured from the system / device / apparatus and / or other means of location in the system. The controlling means may be arranged to maintain, adjust and / or control the operation of the controlled device, apparatus and / or means. For example the electronic controlling means 24 may be arranged to control the flow and / or dosing of liquids and / or chemicals in the system to carry out the method or any part thereof. Flow may include flow rate and / or setting the flow on and off. Dosing may include amount of a substance dosed to a target, which may be controlled by operating one or more valves, pumps and / or other actuators or means.

[0119] The controlling means may be arranged, such as programmed, to monitor, detect and / or measure one or more properties from the means, devices and / or apparatuses of the system, and / or from the system, for example as a function of time, and as feedback to the monitored properties to carry out one or more control actions in the means, devices and / or apparatuses or the system to adjust the function of the means, devices and / or apparatuses or system to carry out the present method or a part thereof. Any means, such as sensors, for detecting, monitoring and / or measuring one or more properties and / or parameters of the system may be connected to the controlling means to allow control of the system, device, apparatus or one or more of the means disclosed herein, such as to maintain one or more measured parameters at a predetermined range by carrying out one or more controlling actions, such as by adjusting and / or operating the mentioned controllable means. Examples of means for detecting, monitoring and / or measuring one or more features or parameters include temperature sensors, pH sensors, flow rate sensors, weight sensors, conductivity sensors, optical sensors, and / or any other applicable means for detecting or monitoring one or more properties disclosed herein.

[0120] In one example the controlling means is arranged to monitor one or more properties from the means for acidifying 1 b the wet animal manure and / or the means for adding a polyelectrolyte 4g, and / or from the pipe system or part thereof, and as feedback to the monitored properties to carry out one or more control actions in the means for acidifying 1 b the wet animal manure and / or the means for adding a polyelectrolyte 4g, and / or in the pipe system to carry out the pH adjusting / acidifying and / or the adding of polyelectrolyte(s) of the present method.

[0121] In one example the controlling means is arranged to monitor one or more properties from the water purification apparatus and as feedback to the monitored properties to carry out one or more control actions in applicable means in the apparatus and / or at other point of the system. In one example the controlling means is arranged to monitor one or more properties from the bio-oxidizing device, and as feedback to the monitored properties to carry out one or more control actions in the means for mixing, means for rotating, means for providing air, means for inletting material, means for discharging material, any of the conveyors, temperature controlling means, and / or other applicable means and / or at other point of the system.

[0122] Any of applicable devices, apparatuses, means and / or parts thereof or other means of the system may be operatively connected to the controlling means, which may be arranged to control the operating of the devices, apparatuses and / or parts thereof or other means. Applicable means include for example actuators, such as electric motors, valves for controlling flow of liquid, solids and / or air, conveying means such as conveyors and / or pumps, pumping means such as pumps, temperature controlling means such as heating means and / or cooling means, pH controlling means, conveying, providing and / or dosing means of liquid, solids and / or air, electrical current controlling means and any other applicable means disclosed herein. The pumps used herein may be selected according to needs, and may comprise peristaltic pumps, progressive cavity pumps, and / or other types of pumps suitable for pumping sludges, liquids and / or any other pumpable material. Solid materials may be conveyed by using suitable conveyers, such as a screw conveyer, a belt conveyer and / or a scraper conveyor.

[0123] “Conveying”, which may be also called “transferring”, in general as used herein refers to a suitable transferring of material, such as by using suitable conveying / transferring / pumping means, which are usually dependent of the nature of the material, such as solid, sludge, liquid and / or gas, such as disclosed herein. For example, liquid and sludge may be conveying by pumping, i.e. by using pumping means and / or by using pipes or tubes. Conveying may be active and / or passive.

[0124] The present method involves controlled oxidation of the obtained organic material, which oxidation can produce natural organic fertilizers. Transforming waste into usable material is extremely profitable. It creates clean air, water and nutrition and provides no harmful emissions. Balance of oxygen and carbon dioxide controls global warming. The process provides a positive material balance with very small nutritional losses. Nitrogen is fixed and phosphorous does not dissolve into water system. Exothermic reactions produce more energy than is consumed, and obtained heat energy can be completely used for example for heating buildings.

[0125] Bio-oxidization

[0126] Solid fractions recovered from steps (i) and / or (j) may be transferred to another vessel allowing aeration and mixing. Such vessel may be a bio-oxidizer or chemostat, and may be a part of the bio-oxidizer. A horizontal rotating drum or vertical cylinder may be used / provided / included. The solid fraction or biomass is subjected to an elevated temperature and aeration. Usually, air with a constant temperature of about 15-25°C is introduced to said solid fraction (biomass). Air may be obtained and / or provided with an air pump from outside, and conveyed through a continuous pipeline through the air purifier, heat exchanger and the biooxidizer device. The bio-oxidizer device may have one or more compressors and / or fans to facilitate flow-through of air.

[0127] The method comprises (j) providing an oxidizer device or apparatus 8, such as a bio-oxidizer device or the like bioreactor capable of carrying out the corresponding method steps, especially the oxidation and related actions, and conveying the solid manure fraction 7 and / or the floc 19 to the oxidizer device 8. The oxidizer device is preferably an aerated bio-oxidizer device operating continuously at a temperature of about 80°C to oxidize the solid manure to provide oxidized manure. The temperature of the reactor, or the biomass in the reactor, may rise, as a result of microbial action, up to about 85°C. A target temperature of the biomass may be in the range of 75-85°C, such as in the range of 80-85°C. Aim is to create optimal conditions for growth of thermophilic microbes, especially Thermoactinomyces mold. Thermoactinomyces spores are present in nature as well as in wet manure. In optimal conditions they will start growing, propagating and form filaments. The growth of the thermophilic microbes is controlled into end phase of exponential growth. The exponential (logarithmic) growth is maintained by controlling the growth parameters such as mixing, aeration, temperature, biomass feed and outtake with moist content (chemostasis).

[0128] The bio-oxidizer device may be based on and / or implementing a chemostat principle providing continuous growth. In general, a chemostat is a bioreactor to which fresh medium is continuously added, while culture liquid containing left over nutrients, metabolic end products and microorganisms is continuously removed substantially at the same rate to keep the culture volume constant. By changing the rate with which medium is added to the bioreactor the specific growth rate of the microorganism can be easily controlled within limits. However, unlike in common chemostats based on liquid medias, in the present bio-oxidizer reactor the process is carried out as a solid phase process, more particularly in the absence of added water and at a certain dry matter content. The present chemostat bio-oxidized operates with the same principle as the liquid phase chemostats, until Thermoactinomyces sp mould have formed almost a pure culture. The term “bio-oxidizer” may refer to a device facilitating biological oxidation of biomass by microbes contained in the biomass. In a continuous culture system, the overflow maintains the culture in the growth chamber of the bio-oxidizer at a fixed volume, V liter. Fresh medium that enters at a flow rate of w / V, will be termed D.

[0129] In the growth chamber, two opposing factors influence the size of the population. The population increases continuously as a result of growth; At the same time, it is continuously diminished by washing out through the overflow. The rate of these two opposing processes can be described mathematically.

[0130] By derivation from the growth equation

[0131] Nt= eptN (equation 1 : growth equation)

[0132] The instantaneous growth rate of the population is dN / dt=MN (equation 2: population increases) the rate of loss of cell by overflow (12) can be expressed as dN / dt=DN (equation 3: population decreases) where N is the initial population size and D the dilution rate.

[0133] The net rate of change of population size in the growth chamber is accordingly determined by the algebraic sum of these two partial derivatives: dN / dt=MN - DN = (M- D)N (equation 4: when p becomes equal to D, the size of the population in the growth chamber becomes constant and the growth is self-regulating).

[0134] It may be considered how N, the population size, will vary with time. For any given microorganism growing under a fixed set of environmental conditions, the growthrate constant, p, cannot exceed a certain maximal value, which is called pmax. If the dilution rate, D is greater than pmax, the expression dN / dt has a negative value. Under these circumstances, the population in the growth chamber will diminish until it has been completely washed out.

[0135] If the dilution rate D, is less than the maximal growth rate, p max, the value of dN / dt is positive, and the size of the population will increase. This increase will continue until the rate of growth begins to be limited by the concentration of the limiting nutrient in the inflowing medium. At this point, the growth rate, p, falls to a lower value. When p becomes equal to D, the size of the population in the growth chamber becomes constant. Under these circumstances, accordingly, growth is self-regulating. This is the principle of the continuous culture device known as the chemostat. The oxidizer device 8 comprises one or more reactors, which is / are arranged to receive the material to be oxidized, which may be called biomass, and which may comprise solid manure, such as obtained from solid manure fraction 7 and / or from the floc 19. Other precipitates may be also provided, such as precipitates from an iron oxidizer and / or precipitates from an air purifier. These may be combined, such as mixed, to obtain the material / biomass 50 to be oxidized, preferably in a continuous manner, before applying and / or conveying to the oxidizer device, and / or in the oxidizer device. The reactor(s) may comprise a vertical cylinder or a rotating drum arranged to receive the material and wherein the material is arranged to be mixed. The cylinder may be elongated in the direction of the axis thereof. The rotating drum may be elongated in the direction of the rotating axis.

[0136] The oxidizer device, or the reactor thereof, comprises in inlet for air, an outlet for air, an inlet for the solid material to be oxidized (biomass), an outlet for oxidized biomass, and mixing means for mixing the content of the reactor, such as the biomass. The outlet for oxidized biomass may comprise or be connected to conveying means for conveying the oxidized biomass, such as wherein the conveying means comprises a screw conveyor or other suitable conveyor. The oxidizer device preferably comprises one or more sensors for detecting / monitoring temperature, moisture, carbon dioxide and / or the like property of the biomass, reactor air, and / or inlet / incoming air and / or outlet / outgoing air. The reactor may also comprise means for measuring the mass of the reactor and / or content of the reactor, such as a scale, which may be used for determining the moisture content of the biomass and / or the state of the process, for example need for inletting / inputting and / or outletting / discharging material, i.e. to maintain balance of the continuous process. The detecting / monitoring means may be connected to the controlling means.

[0137] The term bio-oxidizer as used here refers to an instrument, which provides optimal propagating condition for a viable microbe population. Bio-oxidizers may be constructed with either a horizontal or a vertical orientation. Operating principle of the bio-oxidizer is based on oxidation of manure at a high temperature, such as at or above about 80°C, wherein only thermophilic microbes can survive. The microbes oxidize the nutrients contained in the manure and encapsulate the nutrients into spores. The rate of oxidation may be measured using Rottegard scale, where value 5 indicates a complete oxidation when the biomass does not consume any more oxygen. What is discussed herein for the bio-oxidizer may apply also to other suitable oxidizing devices or reactors. The thermophilic microbes are originated from the manure material. A desired microbe for the present purposes is or comprise Thermoactinomyces mold, which was found to survive and proliferate in the conditions of the bio-oxidizer and which was found to encapsulate desired nutrient into a form that can be used as or in a fertilizer. The endospores of Thermoactinomyces are produced in surface soil, self-heating composts, and overheated fodders. They are beneficial to plant growth, e.g., by nitrogen fixation, phosphorus solubilization, and their biocontrol properties.

[0138] The bio-oxidizer is strongly aerated, wherein one or more aerating means are provided and operated to obtain desired aeration. “Aerating” or “aerated” as used herein may refer to active aerating, wherein active aerating means are used. Preferably the aerating means are controllable, and the aerating means may comprise one or more aerator device, such as fans and / or other means for providing air, such as a source of pressurized air. The aerating means may be operatively connected to the controlling means.

[0139] The content of the bio-oxidizer is mixed, so the bio-oxidizer may comprise one or more mixing means, such as one or more mixers, for example comprising one or more mixing blades of the like operated by an actuator, such as an electric motor arranged to operate / rotate / move the blades or the like, which actuator or mixing means may be operatively connected to the controlling means. The mixing means may also comprise a rotating / rotatable drum.

[0140] In embodiments the bio-oxidizer device comprises one or more of:

[0141] -a reactor comprising spheres and / or arranged to receive spheres, such as ceramic spheres, arranged to receive the material to be oxidized, such as biomass comprising the solid manure fraction,

[0142] -one or more controllable means for providing dried and heated air, preferably at different levels, to the reactor,

[0143] -controllable means for providing the solid manure to the reactor,

[0144] -controllable means for outputting the oxidized manure from the reactor, -controllable means for mixing the solid manure, preferably wherein the means are controlled to obtain and / or maintain constant growth of microbes in the reactor.

[0145] The reactor preferably comprises a plurality of spheres 54 and / or the spheres may be applied and / or added to the reactor. A reactor arranged to receive spheres may be connected to a source of spheres, which may comprise a conveyor for providing spheres to the reactor, such as recycled spheres and / or clean spheres 54a. The spheres may be provided to the reactor, such as from a reservoir, and / or in suitable amounts, such as having a volume larger than the biomass 50 applied to the reactor. The “spheres” as used herein may refer to any applicable beads or bodies, which may have a variety of shapes. The spheres may have a fully spherical and / or substantially spherical shape, and / or they may have other applicable shapes as well, which may not be spherical. A term “bodies” may be also used to refer to the spheres discussed herein. The spheres can act as carrier material for the biomass material to be oxidized, and they facilitate implementing the solid-phase chemostat reactor with the present manure-based solid materials. The spheres may comprise or consist of suitable material, which may be inert and / or which are mechanically suitable for the present process and present biomass. The spheres preferably comprise hard material, which can tolerate the high temperatures in the reactor, such as ceramic material, temperature tolerant plastics, and / or composite materials. In one example the spheres comprise titanium oxide mixed with polyethylene, whereby the specific gravity of the spheres can be altered using titanium oxide.

[0146] The spheres may have a diameter in the range of 1-5 cm, such as 2-4 cm, and they may have a surface that is roughened and / or otherwise treated, such as coated, for enhancing the adherence of the manure material / biomass to the surface. The spheres may be made of a homogeneous material, and while wearing, the spheres may develop continuously the same effective gripping surface which is highly adhesive for the material. The spheres, and / or surfaces thereof, may comprise biologically non-oxidizing material. The spheres do not need to include catalytic material and / or surface.

[0147] When the solid manure material, i.e. biomass, is provided to the reactor and contacted and mixed with the spheres, the biomass forms a thin layer attached or bound to the surfaces of the spheres. The layer on the surfaces of the spheres shall be thin enough to allow air / oxygen to enter the layer, such as a layer of about 2 mm or less. This results in a substantially increased oxidation area. Further, the inter-sphere air space is larger than the volume of the biomass to be oxidized. These properties substantially enhance the oxidation efficiency of the reactor. The surface of the spheres may or may not act catalytically to enhance the oxidation of the biomass. The spheres 54 may be circulated in the bio-oxidizer device and / or in the reactor thereof. The used spheres, after the oxidized biomass / spore mass has been detached, may be conveyed back to the reactor as cleaned spheres 54a, for example to another end or location of the reactor, preferably by using suitable conveying means. The clean spheres 54a are controllably combined with the biomass 50, preferably with (controllable) means for conveying and / or combining the biomass and / or the spheres.

[0148] Feeding fresh biomass (new solid fraction) and removal of bio-oxidized biomass may be controlled by following the weight of the bio-oxidizer.

[0149] In one embodiment the bio-oxidizer device comprises a rotating / rolling drum arranged to receive the biomass equipped with means for mixing the biomass, and preferably means for monitoring weight, means for monitoring outlet gases, and / or means for monitoring temperature; inlet and outlet for the biomass; inlet for supplying air and / or outlet for gas. In one embodiment the bio-oxidizer device comprises a horizontally rotatable drum, and / or a cylinder or a reactor arranged in a horizontal position, arranged to receive the material (biomass) to be oxidized. The directions and orientations discussed herein are defined for devices installed for operating.

[0150] The inlet for the biomass may comprise inletting and / or conveying means, which may be controllable, and preferably operatively connected to controlling means. The inletting and / or conveying means may be arranged to controllably combine the incoming biomass with spheres.

[0151] The outlet for the oxidized biomass may comprise an outlet arrangement and / or separating means for separating spheres and oxidized biomass / formed spore mass. The separating means may also comprise vibrating means, such as a vibrator, which may be arranged to vibrate one or more parts of outlet arrangement. The outlet may comprise or be connected to outlet means for oxidized biomass / spore mass 10, which may comprise one or more chutes, pipes, conveyors and / or the like means, which can enable conveying and / or outputting oxidized biomass / spore mass 10 to a target, such as to a container or a collecting location.

[0152] The bio-oxidizer, such as the reactor or a rotating / rotatable drum thereof, may be arranged to provide a flow of the spheres, such as with a mechanical means, such as a conveyor, for example a screw conveyor, blade mixer, and / or the like means connected to an actuator for operating the means, which actuator may be operatively connected to controlling means. The mechanical means may also provide mixing of the biomass, and they may be mixing means. The flow of spheres may be in the reactor and it may be outside the reactor for circulating used spheres back to the reactor. This may be obtained by using separate mechanical means, such as a conveyor 55, 68 for circulating the spheres 54, preferably cleaned spheres 54a.

[0153] As the rotating / rotatable drum rotates, the spheres are mixed in the drum and the surfaces thereof comprising the material to be oxidized are efficiently exposed in the reactor / drum to conditions facilitating the oxidation. A rotating drum prevents the spheres and the material to accumulate, but the spheres and the material tends to rise on the inner surface of the drum to a certain level, until they fall down to the bottom of the drum thus efficiently mixing and aerating / oxidating the material. The drum is connected to rotating means, such as an actuator, for example comprising an electric motor arranged to rotate the drum, which may be operatively connected to controlling means.

[0154] In one embodiment the bio-oxidizer device comprises a vertical cylinder arranged to receive the biomass 50 equipped with means for mixing the biomass, and preferably means for monitoring weight, means for monitoring outlet gases, and / or means for monitoring temperature; inlet and outlet for the biomass; inlet for supplying air and / or outlet for gas. In one example the bio-oxidizer device comprises a vertically rotatable drum arranged to receive the material to be oxidized.

[0155] A vertical bio-oxidizer device, such as shown in Figure 6, may comprise as a reactor an upright cylinder, preferably having a height which exceeds its diameter. In the middle of the reactor there may be a rotatable shaft 51 , which is connected to an actuator 52 for operating the shaft 51 , for example which shaft is driven by an electric motor at a variable speed through the intermediary of a reduction gear. A manifold or distributor plate, comprising pipe rings and radial tubular members interconnecting the same, may be arranged to disperse the biomass 50 evenly across the reactor in its top end. The biomass 50 is delivered by means of a pipe into the manifold or plate. The shaft may be fitted with one or more vane-like stirring elements 53 extending towards inner wall of the reactor. Spheres 54, 54a may be provided by a conveyor 55, such as a screw conveyor or a scraper conveyor, from the bottom to the top of the reactor to obtain in the reactor a flow of spheres which is directed downwards. As the spheres 54 are generally lighter than the biomass 50, having for example a specific gravity of about 0.5 kg / dm3or less, the spheres, which are coated with biomass having a density higher than that of the spheres, strive to descend faster than cleaner spheres, with the result that substantially all the spheres receive a coating from the biomass. The spheres are returned by way of a cover of the reactor and the oxidized biomass is passed below to prevent formation of aerosols.

[0156] Regulated oxidation air is blown into the reactor, generally from below its middle section. The reactor may have its inner wall fitted with a pipe frame including orifices and having air supplied therein by means of a pump through a duct, preferably from a heat exchanger 40. The pipe frame may comprise annular and radial pipes. Condense water 45 from the heat exchanger 40 may be conveyed to the water purification apparatus 9, such as in combination with liquid manure fraction 16.

[0157] The reactor may have its height adjustable by adding or removing cylindrical blocks, which can be placed on top of each other for assembling the reactor in modular manner.

[0158] The reactor may have one or more detecting means 56, such as sensors, for detecting and / or measuring temperature, moisture and / or carbon dioxide. The reactor may comprise several detecting means applied at a distance from each other, such as about 50 cm, so that conditions along the length of the reactor can be monitored.

[0159] The discharge of air from the bottom end of the reactor is precluded, for example in such a way that a receiving space for oxidized biomass 10 has a bottom, which is otherwise solid except for a gap connecting the space with a conveyor which can be connected, if necessary, by way of a shut-off feeder with another conveyor for delivering a finished product into a container. Thus, the air is forced to flow in the reactor up towards the top end of the reactor. The reactor may have its top end provided with an exhaust fan for drawing out the air fed inside the reactor and for guiding it out through an air purifier and a heat exchanger. The spheres constitute a dense homogeneous system of flow channels distributed all over the reactor, having in association therewith a large surface area of the substance to be oxidized. At the mid-height section of the reaction vessel is established a so- called oxidizing zone, wherein moisture and oxygen conditions, as well as temperature, are especially suitable for the microbial activity. The oxidizing microbial activity will be particularly effective as the entire amount of air proceeds continuously through the entire oxidizing zone and the material to be oxidized. The air heated in biological oxidation and the dry hot air supplied, if necessary, into the reactor’s top section are capable of drying the biomass in the reactor's top section. The residence or dwell time of the material to be oxidized can be regulated by means of the sphere conveyor and the reactor's top end may be supplied with just enough biomass to provide a suitable biomass layer on the spherical surfaces.

[0160] The reactor may be provided with a perforated floor or other part or means, which has an aperture size substantially smaller than the diameter of the spheres and below which is the receiving space or part, such as a chute, for oxidized biomass 10. A scraper blade driven by a shaft may be arranged to scrape the perforated floor, and to push the oxidized biomass through the apertures, and to prevent blocking of the floor apertures and simultaneously advances cleaned spheres 54a by way of a shut-off feeder onto a conveyor 55. Thus, the perforated floor constitutes a screen. The oxidized biomass 12 may be conveyed from the bottom of the reactor by a conveyor 57, such as a screw conveyor.

[0161] As air is flown into the reactor and from the reactor, and the spheres are covered with the layer of biomass, the oxidation reactions cause the reactor to “ignite” thus providing efficient oxidation process, for example as a zone in the reactor, which causes the microbes to form the spores and encapsulate the nutrients, as discussed herein. The globular spores formed from the ribbon-like microbe cells will detach from the surfaces of the spheres at a lower part and / or at an end of the reactor as the binding ability thereof is lowered, preferably facilitated by cooling or allowing to cool. The detached spores may fall from the reactor / drum and may be recovered and / or conveyed to another location and / or collecting means / container. Preferably there is no need to facilitate the removal of the oxidized biomass from the spheres by additional scrapers or the like mechanical manipulating means / devices. After the spores are detached from the spheres, the cleaned spheres can be recirculated back to the reactor. A horizontal bio-oxidizer reactor 8 may comprise a horizontal rotating drum 60, as shown in Figure 7, preferably wherein the length of the drum exceeds its diameter. At a first end, which is an inlet end comprising an inlet, conveying or inletting means 62, such as a conveyor, preferably a screw conveyor, chute and / or a pipe, is arranged to provide biomass 50 into the drum, wherein the biomass is controllably combined with clean spheres 54a. The conveying or inletting means 62 may be operatively connected to the controlling means. As the drum 60 rolls, the spheres 54 are mixed and coated with the biomass 50. The drum may be filled up to about 2 / 3 by volume with the spheres, wherein the spheres fill the space evenly. The spheres coated with the biomass proceed in the drum cylinder to the direction of a second end (shown by an arrow), and may be conveyed out from a lower part of the second end of the cylinder from an outlet and / or by using conveying and / or discharging means 64, such as a conveyer, preferably a screw conveyor. The spheres may be conveyed / expelled into a funnel and / or into separating means 65 for separating spheres and oxidized biomass / formed spore mass. The separating means may comprise a perforated part, such as a wire / mesh, which has an aperture size substantially smaller than the diameter of the spheres, so the spheres do not pass but the oxidized biomass / spore mass does pass. The separating means may also comprise vibrating means, such as a vibrator, which may be arranged to vibrate one or more parts of outlet arrangement 65, such as the funnel, the perforated part and / or any conveying parts thereof. From the separating means 65 the separated and cleaned spheres 54a are conveyed with conveying means 68, such as a conveyor, back to the first end of the rotating drum 60 with the conveying and / or inletting means 62, wherein the spheres 54a are reused and will be contacted with incoming biomass 50 in a controlled manner to obtain desired and / or suitable ratio of biomass and spheres, as well as a desired and / or suitable flow rate. The separated oxidized biomass / spore mass 10 is conveyed through suitable conveying means, such as comprising a chute, and optionally with active conveying means and / or mechanical manipulating means, to be recovered and / or further processed. The horizontal biooxidizer reactor 8 may comprise the inlets, outlets, controlling means and other parts discussed herein in an applicable manner, which are not shown in the simplified Figure 7.

[0162] The biomass is mixed, such as by mixing means and / or when a drum is rotated, and the conditions in the reactor / bio-oxidizer are controlled to obtain and / or maintain conditions suitable for obtaining the desired oxidation conditions. The desired conditions provide a dry matter chemostat. Therefore, the dry matter content of the material to be oxidized, i.e. the biomass / solid manure material, shall be maintained at suitable range, such as in the range of 20-40% by weight, preferably in the range of 25-35% by weight, such as in the range of 25-30% by weight. The temperature shall be maintained at high level, such as at a temperature of at least 75°C, such as about 80°C, for example in the range of 75- 90°C, such as 75-85°C. The upper limit is restricted by the ability of the thermophilic microbes to tolerate high temperatures, i.e. to survive. The absence of free water, and the presence of high temperature, in general selective conditions, cause the desired microbes to dominate and grow as the main species in the reactor. Non-thermophilic microbes are killed / inactivated. Thermoactinomyces will be preferably the main or substantially only viable microbe at the high temperature. The conditions also cause the microbes to be at the exponential growth phase and the nutrients in the biomass to be encapsulated by the microbes. If free water would be present, for example if the dry matter content would be lowered and / or if water would be added, the desired microbes would die and / or be inactivated.

[0163] Therefore, the conditions and / or properties in the reactor shall be monitored and controlled, such as adjusted as feedback to one or more properties detected from the reactor / drum / biomass to maintain one or more property of the reactor / drum / biomass at a predetermined level and / or range. Controllable properties may include one or more of temperature of the biomass, temperature of inlet air, dry matter content of the biomass, rotating speed of the drum, inlet air flow and / or content, outlet air flow and / or content, inflow (rate) of the solid manure material and / or other biomass, outflow (rate) of the oxidized manure material / biomass, and / or the like. Pure, dried and heated air may be provided to the reactor / drum at different levels and / or from different source, which may be controllable, so that the efficiency of the oxidation may be controlled and / or adjusted. Hot, moist and carbon dioxide rich (pure) air, which is formed when the microbes oxidize the biomass, can be discharged, outputted or expelled at the top or higher part of the reactor, and preferably conveyed into a heat exchanger and / or to suitable use, such as into a greenhouse. Warm / hot, dry and pure air may be conveyed through heat exchanger to heat houses and / or buildings, and / or grain, and subsequently the pure and odour free air can be conveyed outside.

[0164] The system may comprise means for purifying the inlet air, which may be outside and / or ambient air. The purified inlet air may be conveyed to the heat exchanger to heat the air, and it may be used for controlling the moisture content of the biomass in the reactor / bio-oxidizer. Air may be also cooled with a heat exchanger, and the cooled air may be used for cooling the spore mass / biomass obtained from the biooxidizer.

[0165] The method comprises (k) discharging the oxidized manure / biomass from the biooxidizer and providing a spore mass containing the nutrients originally contained in the wet manure. The oxidized manure / biomass may comprise the spore mass, which can be discharged from an outlet, such as from the outlet for oxidized biomass and / or with the conveying means for conveying the oxidized biomass. The oxidized manure / biomass / spores / spore mass is / are recovered.

[0166] The feed and discharging of the solid phase can be controlled by mixing and by measuring the amount of heat formed in the reactor, the amount of water and / or the amount of carbon dioxide, the weight of the reactor or part thereof, and / or the amount of the microbial spores. After the secured retention time, the bio-oxidized biomass is removed from the bio-oxidizing reactor and the temperature naturally decreases. A temperature of less than 55-65°C, such as less than 60°C, initiates sporulation of the Thermoactinomyces. The reactor expels microbe mass, which forms spores and / or release the spores when the temperature lowers below a set value, which is typically 60°C or less, such as 55°C or less, or 50°C or less. Even lower temperature down to room or ambient temperature may be used and / or desired. At the lowered temperature the released spores will fall from the reactor, such as at an end, at a bottom, and / or a site of the reactor, which is cooled or allowed to cool and which preferably comprises one or more apertures for the released spores.

[0167] The method may comprise allowing the temperature of the spore mass / biomass to decrease, for example to allow or facilitate formation and / or release of spores encapsulating the nutrients and / or to cool the spore mass. The temperature may be decreased to 60°C or less, to 50°C or less, to 40°C or less, such as to 30°C or less, preferably to about ambient temperature and / or to about room temperature, such as to 20-25°C.

[0168] The released heat energy is recovered with a heat exchanger 40, 8e and can be used for adjusting the temperature of incoming air, preferably to constant temperature to control and / or stabilize oxidizing reactions. The rest of the heat energy can be used for heating buildings, greenhouses and the like, and for drying grain and / or the like. The heat production is substantial, and for example 6000 tons of sludge can produce about 403 MWh / year. If necessary, part of the heat energy can be transformed into electrical energy, which can be used in the present system, in households, in agricultural plants and the like.

[0169] The method may comprise (I) controlling feed of the manure and discharge of the spores by measuring the amount of generated heat, water and carbon dioxide and the weight of the reactor. This may be implemented by controlling one or more means capable of adjusting the reaction conditions and / or capable of operating the system, and may be controlled by a controlling means operatively connected to the means. The conditions may be measured by using one or more sensors connected to the controlling means.

[0170] The method may comprise (m) capturing the released thermal energy by a heat exchanger 40, 8e, which may have been used to adjust the air fed into the reactor to a constant temperature.

[0171] The spores encapsulate the nutrients of the bio oxidized solid fraction (biomass). Spores carrying the nutrients are ready to be used as an organic fertilizer or they may be compressed to a granule.

[0172] In one embodiment Thermoactinomyces is the main viable microbe at temperature of about 80°C in steps (j) and / or (k). The method may comprise (j) encapsulating the nutrients to spores of the Thermoactinomyces, or allowing the Thermoactinomyces to form spores encapsulating the nutrients.

[0173] The temperature and / or the reaction where Thermoactinomyces is in strong growth is sufficient to kill possible parasites, enterobacteria, viruses and seed of weeds of the solid fraction. Thus, resulting fertilizer is safe to use for food production. For every type of solids, depending on animal and feed, the retention time in optimal condition will be determined experimentally (in vitro).

[0174] The flowchart of Figure 5 shows an example of flow of substances and air / heat in a setup comprising the bio-oxidizing device / apparatus. Flow of pure air is shown with dashed arrow lines. The solid fraction 7 obtained from the liquid-solids separator 6 and the floc 19 from the water purification apparatus 9, optionally supplemented with precipitates 41 from air purifier 43 and Fe-oxy oxidizing device (iron oxidizing device) 17, is dosed as combined biomass 50 into the bio-oxidizing device 8. Incoming pure air A1 from outside atmosphere is purified 27 and drawn through a heat exchanger 40 and mass moisture control 28 into a bio-oxidizer 8.

[0175] The oxidized biomass and / or the spore mass 10 produced by the bio-oxidizer 8 is cooled with the pure, dry and cool air produced by the heat exchanger 40. The dry spore mass 11 , which may have an average dry mater content of about 50% by weight, can be formed into a fertilizer product 12, for example by pelletizing and packing.

[0176] The heat formed in the cooling of the spore mass is conveyed to the hot (over 60°C) and moist air 42 produced by the bio-oxidizer 8, wherefrom the combined hot air is conveyed through an air purifier 43 as pure moist and hot air 44 into the heat exchanger 40. The condense water thereof 45 is conveyed with a liquid fraction 16 of the liquid-solids separator to the water purification apparatus 9.

[0177] The hot, moist and carbon-dioxide rich air 42 from the bio-oxidizer 8 may also be conveyed through the air purifier 43 to heating of greenhouses 48 throughout year. The warm, dry and pure air 46 may be conveyed from the heat exchanger 40 to heating of buildings 47 and subsequently the pure and odourless air A2 may be conveyed outside.

[0178] The present disclosure provides a system for recovering nutrients from wet animal manure and / or for carrying out any other method disclosed herein. The system may be also called as a device arrangement, and it may comprise the devices, means and / or parts specified herein in an operational combination, such as connected to each other to obtain a system capable of carrying out the method described herein. The system may comprise at least means for collecting and acidifying wet manure; means for granulating wet manure, a liquid-solids separator, a water purifier, a bio-oxidizer and preferably a heat-exchanger and an air purifier, more preferably an ion blast purifier.

[0179] The system comprises, such as shown in Figure 2,

[0180] -means 1 for providing wet animal manure, such as comprising the droppings pit and / or any other suitable manure collecting and / or conveying means, and / or a source of wet animal manure, -means for acidifying 1 b the wet animal manure, such as one or more (controllable) sources of one or more acids, including an amount of acid arranged in the droppings pit or any other container,

[0181] -means for adding a polyelectrolyte 4g to the acidified wet animal manure to obtain granulated wet acidified animal manure, such as one or more controllable sources of one or more polyelectrolytes,

[0182] -a liquid-solids separator 6 for separating a liquid manure fraction 16 and a solid manure fraction 7 from the granulated wet acidified animal manure,

[0183] -means 2 for continuously conveying and / or providing the wet acidified animal manure and / or the granulated wet acidified animal manure,

[0184] -a water purification apparatus 9 comprising

[0185] • an electrolytic cell 21 comprising a substantially vertical tube connected to a source of DC electric power 23 and comprising one or more first electrode(s) 32 comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) 34 having a higher electronegativity compared to the first electrode(s), and

[0186] • a substantially vertical separator tower 20 arranged in a flow connection with the upper part of the electrolytic cell 21 ,

[0187] -means for conveying the liquid manure fraction 16 obtained from the liquid-solids separator 6 to the electrolytic cell 21 ,

[0188] -a continuously operating aerated bio-oxidizer device 8, wherein the solid manure fraction 7 from the liquid-solids separator, and preferably the floc 19 from the separator tower 20, is / are arranged to be conveyed into the bio-oxidizer 8, wherein the bio-oxidizer is arranged to oxidize the solids manure, preferably also the floc material 19, which may be combined into combined biomass 50, to provide oxidized manure / biomass 10. The bio-oxidizer may be arranged to expel the oxidized manure / biomass 10, such as from an outlet for the oxidized manure / biomass 10. The solid manure fraction 7 and the floc 19 may be arranged to be conveyed into the bio-oxidizer 8 with suitable conveying means, such as conveyors.

[0189] The means 2 for continuously conveying and / or providing the wet acidified animal manure and / or the granulated wet acidified animal manure comprises one or more conveying means, such as pumping means, preferably with one or more pumps. The conveying means may be controllable and may be arranged to convey the wet acidified manure from the means for providing wet animal manure and / or from the source of wet animal manure. The conveying means may be arranged to convey the granulated wet acidified animal manure to the liquid-solids separator 6. In general, any conveying means 2 located before the liquid-solids separator will cause the wet manure material to be conveyed forward, finally to the liquid-solids separator. The conveying means 2 may be located for example before and / or after a point of addition of the polyelectrolyte, immediately before conveying to the liquid-solids separator 6 and / or after the liquid-solids separator to convey separated liquid fraction 16. The conveying means 2 may be used to control the flow rate in the system or in a part thereof.

[0190] The means for acidifying 1 b the wet animal manure may be controllable and comprise means for adding acid, such as comprising a source of the acid, such as a container, wherefrom the acid may be arranged to be dosed. The means for acidifying 1 b to the wet animal manure may also comprise means for monitoring pH of the wet animal manure, and preferably the means are arranged to controllably add acid as feedback to the monitored pH. The means for adding a polyelectrolyte 4g may comprise a source of the polyelectrolyte, such as a container, wherefrom the polyelectrolyte may be arranged to be dosed. The means for a polyelectrolyte 4g to the wet animal manure may also comprise means for monitoring the properties of the wet animal manure, and preferably the means are arranged to controllably add polyelectrolyte as feedback to the monitored properties and / or to add polyelectrolyte in predetermined amounts. The wet animal manure is arranged to be mixed with the polyelectrolyte to facilitate granulating of the wet acidified animal manure. The means 1 b, 4g may comprise a pump and / or a valve, which are controlled, such as operatively connected to controlling means, and preferably arranged to dose liquid.

[0191] The controlling means 24 may be arranged to control and / or monitor the water purification apparatus 9, the bio-oxidizer 8 and / or other devices and / or means of the system, such as controllable means, for example pumping means 2, or detecting / monitoring means.

[0192] The system may further comprise a heat exchanger 40 arranged to capture the released thermal energy, preferably (at least) from the bio-oxidizer 8. The heat exchanger may be arranged to adjust and / or maintain the temperature of the air fed into the reactor, preferably to a constant temperature.

[0193] The system may further comprise an air purifier, such as an ion blast purifier. The air purifier may utilize SOG technology for purifying the air and to transfer heat. The system may further comprise one or more of:

[0194] -a collection container for wet manure;

[0195] -means for homogenizing the wet manure, such as a homogenizer providing shear forces;

[0196] -a pipe system with a flange mixer, means for monitoring pH and conductivity and inlets for acid and polyelectrolyte;

[0197] -means for leading the homogenized manure to the pipe system;

[0198] -means for separating solid fraction and liquid fraction.

[0199] Fertilizer

[0200] The present disclosure also relates to an organic fertilizer comprising oxidized nutrients encapsulated in Thermoactinomyces spores. The fertilizer may be obtained with the present method. The amount of encapsulated nutrients is the same as in the wet manure taken to the process. The process and the arrangement for obtaining such encapsulated nutrients is discussed above. The spores may be compressed into granules applicable with a sowing machine. As the spores are not soluble and thus do not contaminate waters, they can be applied simultaneously with sowing without harming sprouting and the nutrients are released slowly during the whole growing season. The application to the soil can be made with any equipment, and in any time of the year without risk of over fertilization and eutrophication. Application may be done on sowing, thereby minimizing compression of the soil. Practically all the nutrients of the wet manure are encapsulated. The fertilizer is free of parasites, enterobacteria viruses and seeds of weeds. Only the plant micro roots can penetrate the spores thus providing encapsulated nutrients to the plants.

[0201] The present application provides a fertilizer product 12 comprising (at least) nitrogen, phosphorus and potassium encapsulated, such as at least partially encapsulated, in spores of Thermoactinomyces. The fertilizer product may be obtained with the method disclosed herein. The fertilizer product is obtained from the oxidized biomass / manure 10, or the oxidized biomass may be provided as a fertilizer product, either as such or as further processes. The oxidized biomass 10 obtained directly from the bio-oxidized device may be cooled.

[0202] To obtain the fertilizer product the oxidized biomass 10 may be combined with one or more further agents, such as fertilizers, carrier agents, modifiers and / or the like, and / or packed in one or more packages, such as containers, bags, boxes or the like. The oxidized biomass 10 may be pelletized or granulated by using a suitable pelletizing device or granulating device.

[0203] In one embodiment the nitrogen, phosphorus and potassium encapsulated in spores of Thermoactinomyces are derived from acid-treated wet manure, such as disclosed herein.

[0204] The present disclosure also relates to use of Thermoactinomyces for producing organic fertilizer comprising oxidized nutrients encapsulated in spores, preferably with the methods disclosed herein. The “organic” as used herein refers to ecological and biological methods, products and principles. The present organic fertilizers are of organic origin, as an opposite to “synthetic”, i.e. the used starting material and the obtained products are non-synthetic, and the present fertilisers are suitable for organic farming.

[0205] The present application provides use of Thermoactinomyces for encapsulating oxidised nutrients comprising at least nitrogen phosphorus and potassium for fertilizer use, preferably with the methods disclosed herein.

[0206] The present application provides use of a water purification apparatus 9 comprising

[0207] • an electrolytic cell 21 comprising a substantially vertical tube connected to a source of DC electric power 23 and comprising one or more first electrode(s) 32 comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) 34 having a higher electronegativity compared to the first electrode(s), and

[0208] • a substantially vertical separator tower 20 arranged in a flow connection with the upper part of the electrolytic cell 21 , and comprising an outlet 15 for expelling raising floc 19 at the top of the separator tower, and an outlet 18 for purified water W1 at a point below the raising and / or expelled floc, for treating wet animal manure with the method and / or system disclosed herein.

[0209] The present application also provides use of the continuously operating aerated bio-oxidizer device 8 comprising

[0210] -a reactor comprising spheres arranged to receive biomass comprising solid manure, -one or more controllable means for providing dried and heated air, preferably at different levels, to the reactor,

[0211] -controllable means for providing the solid manure to the reactor,

[0212] -controllable means for outputting oxidized manure from the reactor,

[0213] -controllable means for mixing the solid manure, preferably wherein the means are controlled to obtain and / or maintain constant growth of microbes in the reactor, for treating solid manure 7 and floc 19, such as biomass 50, to provide oxidized manure 10 with the method and / or system disclosed herein.

[0214] Examples

[0215] Example 1

[0216] In the example shown in Figure 3, and presented in the flowchart of Figure 1 , the wet manure 1a is first provided with means for providing the wet animal manure 1 , collected and acidified, such as with means for collecting and preferably (pre)acidifying wet manure, which includes droppings pit wherein the wet manure 1a is combined with an acid solution 1 b. Immediate acidification was found to prevent nitrogen loss. The acidified wet manure flowed to a collection container 1c passively via a slope. The collection container was equipped with a mixer 1d able to homogenize the manure and e.g. straw withing it.

[0217] Homogenized (pre)acidified wet manure 1e) was led to a system for granulating wet manure 4 using peristaltic pump 2 and via a connection 3.

[0218] The system for granulating wet manure comprises a pipeline 4, typically a vertical pipe, equipped with means for mixing 4a, such as a flange mixer and means for measuring, dosing reagents to adjust pH and conductivity. First, pH is measured with a pH sensor 4b. If necessary, acid is added via acid inlet 4d. Then a polyelectrolyte 4g is added via an inlet for said polyelectrolyte. The material may be mixed with the mixer 4a after addition of a reagent. Polyelectrolyte dilutes the acidified wet manure and thus it is necessary to measure both pH and conductivity and adjust, if necessary, to ensure that polyelectrolyte will form granules with the homogenized manure. Conductance is measured using conductance sensor 4e. If the value exceeds 3 mS / cm, water is added via inlet for water 4c to lower the conductance. Then pH is measured again with another pH sensor 4h located after added polyelectrolyte. The sensors provide data for adjusting the acid and water feed, feedback loops 4f, 4i are shown using a dashed line. A gentle mixing is continued over the length of the pipeline. The residence time and exact parameters are measured in advance in vitro.

[0219] The end of the pipeline is open 5a and there are means to transfer the granulated wet acidified manure 5b to a solid matter separator 6, which may comprise a conveyor belt. The pump 2 can transfer the manure material to the solid matter separator.

[0220] Solid matter separator 6 comprises a pre-screen 6a for removing excess water and then a belt dryer 6b.

[0221] Dry matter (dry manure fraction) 7 is lead with a screw conveyor to a vessel for bio-oxidation 8, which may comprise a rotating drum or vertical cylinder, via a connection and / or conveying means 7a. This may be carried out for example with a conveyer belt.

[0222] Vessel (reactor) for bio-oxidation 8 comprises an inlet for biomass feed 8a, means for mixing 8b. The means for mixing may include means for rotating the drum as well as various blades and active mixers inside the vessel. Gentle mixing is used. The dry solid manure 7 is oxidized to provide oxidized manure / biomass 10.

[0223] Means for aeration 8c comprise at least one inlet and outlet for the gases. Heat exchanger(s) 8e is / are used to recover heat from the moist exiting gas and to dry and heat the air A1 supplied to the biomass via the heat exchanger 8e. The exhaust gas may be cleaned by using ionizing particle separators and a singlet oxygen generator (not shown) to obtain outcoming air A2, which may be conveyed to heat buildings and / or other applicable targets, and finally released. In addition, the vessel may have sensors for temperature measurement 8d. The biomass feed and intake must be in balance, this can be followed by monitoring the weight of the vessel e.g. using strain gauges (not shown). Naturally, there is also an outlet 8g for oxidized manure at the bottom / lower part of the reactor. After removing the oxidized manure / biomass 10 from the reactor, the temperature will automatically decrease thereby initiating and / or facilitating sporulation of the Thermoactinomyces. Nutrients of the oxidized manure are encapsulated to the spores and can be used as fertilizers as such or after compressing to bigger granules. Liquid matter (liquid manure fraction) 16 from the solid matter separator 6 is conveyed by pumping to a water purification apparatus 9 (Must Pure Water Technology, Applied Physics Instruments API Oy) according to Figure 4 comprising an electrolytic cell 21 comprising a substantially vertical tube connected to a source of DC electric power 23 and comprising one or more first electrode(s) 32 comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) 34 having a higher electronegativity compared to the first electrode(s); and a substantially vertical separator tower 20 arranged in a flow connection with the upper part of the electrolytic cell 21 .

[0224] Electronic controlling means 24 comprising a control unit is connected to the devices and programmed to monitor and to control the operation of the devices, such as to the water purification apparatus 9 and to the bio-oxidizing device 8. However also the liquid-solids separator 6 and the pipeline system 4 can be controlled with the controlling means 24.

[0225] Example 2

[0226] The system according to Example 1 was run at a dairy farm located in eastern Finland. Milk produced in the farm was 1 500 000 liters / year. Amount of produced wet manure was 4080 tons / year resulting 4000 m3of pure water and 480 tons of natural fertilizer. The manure contained 48 tons I year of nitrogen, 5.3 tons / year of phosphor and 27.4 tons / year of potassium.

[0227] The treatment system was as explained in previous as an exemplary embodiment. Adjustment of pH by adding formic acid, adjustment of conductance and addition of polyelectrolyte were controlled as explained in the specification.

[0228] Collection contained used was 2 m3, capacity of liquid-solids separator 2 m3 / hour and water purifier 1 000 litre / hour. Bio-oxidizer (chemostat) had a capacity of 300 kg / hour.

[0229] Liquid recovered was subjected to water purification using Must Pure Water Technology (Applied Physics Instruments API Oy), which was according to the definition of the water purification apparatus 9.

[0230] The bio-oxidation was carried out in a rolling horizontal drum system comprising a plurality of ceramic spheres, and operating in a solid phase chemostat principle. The spheres were recirculated as pure spheres 54a after the oxidized biomass was separated, and the pure spheres 54a were conveyed with a conveyer to the inlet of the reactor, wherein they were controllably combined with newly added biomass.

[0231] Amount of the liquid isolated from the wet manure was 6000 tons / year. It was subjected to water purification with flow of 0.5 m3 / hour. Oxygen from air was used 1 587 200 m3 / year. The outside temperatures varied between about -25 to +25 °C. Amount of air lead to the heat exchange was 26 Mm31 year; 3 000 m3 / hour and T > 20 °C, RH <10 %, < 5 g H2O / m3

[0232] 1920 tn I year of solid matter (about 25 wt.-% dry matter content) separated from the wet manure was led to the bio-oxidizer at feeding rate of 55 kg / hours, 110 litre / hour.

[0233] The resulting spores were tested for both amount of main nutrients (NPK) and microbiological purity. It was shown that the amount of NPK encapsulated in the spores corresponded to the amount of the same nutrients in the wet manure. However, the nutrients are concentrated in the fertilizer. The NPK contents in the raw manure are typically N=0.8%, P=0.09% and K=0.46%. The corresponding contents in the obtained fertilizer were N=10%, P=1.1 % and K=5.7%.

[0234] Spores were used for fertilization during sowing, and crop yields were comparable to yields with artificial fertilizers. It was found out that there is no upper limit to the dosing of the present fertilizers. The plants take the oxidized nutrients as much as they need from the encapsulated spores.

Claims

46Claims1. A method for recovering nutrients from wet animal manure, the method comprising(a) providing wet animal manure (1a), preferably in a droppings pit;(b) adding acid (1b) to the wet animal manure (1a) to lower the pH value of the wet animal manure below 6.5, to solubilize nitrogen compounds contained in the wet animal manure and to provide wet acidified animal manure (1e);(c) adding a polyelectrolyte (4g) to the wet acidified animal manure (1e) to obtain granulated wet acidified animal manure (5b);(d) preferably continuously measuring and adjusting pH value and conductivity of the wet acidified manure and / or the granulated wet acidified animal manure, such that the pH value and conductivity value of the wet acidified manure and / or the granulated wet animal manure meet a predetermined target pH value and a predetermined target conductivity value;(e) conveying the granulated wet acidified animal manure (5b) continuously into a liquid-solids separator (6) to separate a liquid manure fraction (16) and a solid manure fraction (7);(f) providing a water purification apparatus (9) comprising• an electrolytic cell (21 ) comprising a substantially vertical tube connected to a source of DC electric power (23) and comprising one or more first electrode(s) (32) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) (34) having a higher electronegativity compared to the first electrode(s), and• a substantially vertical separator tower (20) arranged in a flow connection with the upper part of the electrolytic cell (21 ),(g) conveying the liquid manure fraction (16) to the electrolytic cell (21 ),(h) operating the electrolytic cell (21 ) to produce iron hydroxide and / or aluminum hydroxide (33) acting as molecular sieve capable of trapping soluble substances, such as nutrients and / or minerals, and to produce hydrogen causing the molecular sieve with the trapped substances to raise in the vertical tube as an accumulating floc;(i) conveying the raising floc into the separator tower (20), wherein the floc (19) is separated by expelling from the top of the separator tower (15), and preferably obtaining first purified water (W1 ) from the separator tower (20) at a point below the raising and / or expelled floc,(j) conveying the solid manure fraction (7) and the floc (19) from the separator tower (20) to an aerated bio-oxidizer device (8) operating continuously47 at a temperature of at least 75°C, such as about 80°C, to oxidize the solid manure (7) and the floc (19) to provide oxidized manure (10);(k) discharging the oxidized manure (10) from the bio-oxidizer device (8) and providing a spore mass containing the nutrients originally contained in the wet animal manure;(l) preferably controlling feed of the manure and discharge of the spores by measuring the amount of generated heat, water and carbon dioxide and the weight of the reactor;(m) preferably capturing the released thermal energy by a heat exchanger used to adjust the air fed into the reactor to a constant temperature.

2. The method of claim 1 , wherein the acid in (b) is an organic acid or an inorganic acid, preferably wherein the acid is an organic acid, more preferably formic acid.

3. The method of claim 1 or 2, comprising collecting the wet animal manure to an acidic solution in the droppings pit in (b), conveying to a supply tank and subjecting to shearing forces to homogenize the manure.

4. The method of any of preceding claims, comprising conveying the acidified wet animal manure or the homogenized wet animal manure after (b) to a pipe system equipped with mixer, such as a continuously operating flange mixer, preferably wherein (b) to (e), or (c) to (e), in this order are performed in the pipe system.

5. The method of any of preceding claims, wherein the conductivity is adjusted to 3 mS / cm or less by adding water.

6. The method of any of preceding claims, wherein the dry matter content of the solid manure fraction is in the range of 20-40% by weight, preferably in the range of 25-35% by weight, such as in the range of 25-30% by weight7. The method of any of preceding claims, wherein the floc (19) obtained in step (i) is combined with the solid manure fraction (7) obtained in step (e).

488. The method of any of preceding claims, wherein Thermoactinomyces is the main viable microbe at temperature of about 80°C in steps (j) and / or (k), the method comprising(j) encapsulating the nutrients to spores of the Thermoactinomyces.

9. A system for recovering nutrients from wet animal manure, the system comprising-means for providing wet animal manure (1 ), and / or a source of wet animal manure,-means for acidifying (1b) the wet animal manure,-means for adding a polyelectrolyte (4g) to the acidified wet animal manure to obtain granulated wet acidified animal manure (5b),-a liquid-solids separator (6) for separating a liquid manure fraction (16) and a solid manure fraction (7) from the granulated wet acidified manure,-means for continuously conveying (2), such as pumping, the wet acidified manure and / or the granulated wet acidified manure,-a water purification apparatus (9) comprising• an electrolytic cell (21 ) comprising a substantially vertical tube connected to a source of DC electric power (23) and comprising one or more first electrode(s) (32) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) (34) having a higher electronegativity compared to the first electrode(s), and• a substantially vertical separator tower (20) arranged in a flow connection with the upper part of the electrolytic cell (21 ), and comprising an outlet (15) for expelling raising floc (19) at the top of the separator tower, and an outlet (18) for first purified water (W1 ) at a point below the raising and / or expelled floc,-means for conveying the liquid manure fraction (16) obtained from the liquidsolids separator to the electrolytic cell (21 ),-a continuously operating aerated bio-oxidizer device (8), wherein the solid manure fraction (7) from the liquid-solids separator (6) and the floc (19) from the separator tower (20) are arranged to be conveyed into the bio-oxidizer (8), wherein the bio-oxidizer is arranged to oxidize the solid manure (7) and the floc (19) to provide oxidized manure (10).

10. The system of claim 9, further comprising-a heat exchanger (40) arranged to capture the released thermal energy from the bioreactor (8), preferably wherein the heat exchanger is arranged to adjust the air fed into the reactor to a constant temperature.11 . The system of claim 9 or 10, further comprising one or more of: -a collection container for wet manure;-means for homogenizing the wet manure, such as a homogenizer providing shear forces;-a pipe system (4) with a flange mixer (4a), means for monitoring pH and conductivity and inlets for acid and polyelectrolyte;-means for leading the homogenized manure to the pipe system;-means for separating solid fraction and liquid fraction, -an air purifier, preferably an ion blast purifier.

12. The method of any of claims 1-8 or the system of any of claims 9-11 , wherein the bio-oxidizer device comprises a rotating drum arranged to receive biomass comprising the solid manure, equipped with means for mixing the solid manure, and preferably means for monitoring weight, means for monitoring outlet gases, and / or means for monitoring temperature; inlet and outlet for the biomass; inlet for supplying air and / or outlet for gas.

13. The method of any of claims 1-8 or the system of any of claims 9-12, wherein the bio-oxidizer device comprises-a reactor comprising spheres, such as ceramic spheres, arranged to receive biomass comprising the solid manure,-one or more controllable means for providing dried and heated air, preferably at different levels, to the reactor,-controllable means for providing the solid manure to the reactor,-controllable means for outputting the oxidized manure from the reactor, -controllable means for mixing the solid manure, preferably wherein the means are controlled to obtain and / or maintain constant growth of microbes in the reactor.

14. The system of any of claims 9-13, comprising one or more electronic controlling means 24 arranged to monitor one or more properties from the means, devices and / or apparatuses of the system, and / or from the system and as feedback to the monitored properties to carry out one or more control actions in the means, devices and / or apparatuses or the system to adjust the function of themeans, devices and / or apparatuses or system to carry out the method of any of claims 1-8 or a part thereof15. A fertilizer product (12) comprising nitrogen, phosphorus and potassium encapsulated in spores of Thermoactinomyces, preferably wherein said fertilizer product is free of parasites, enterobacteria viruses and seeds of weeds.

16. The fertilizer product of claim 15, wherein said nitrogen, phosphorus and potassium encapsulated in spores of Thermoactinomyces are derived from acid-treated wet manure.

17. Use of Thermoactinomyces for producing organic fertilizer comprising oxidized nutrients comprising nitrogen, phosphorus and potassium encapsulated in spores, preferably with the method of any of claims 1-8.

18. Use of a water purification apparatus (9) comprising• an electrolytic cell (21 ) comprising a substantially vertical tube connected to a source of DC electric power (23) and comprising one or more first electrode(s) (32) comprising one or more iron and / or aluminum electrode(s), and one or more inert second electrode(s) (34) having a higher electronegativity compared to the first electrode(s), and• a substantially vertical separator tower (20) arranged in a flow connection with the upper part of the electrolytic cell (21 ), and comprising an outlet (15) for expelling raising floc (19) at the top of the separator tower, and an outlet (18) for first purified water (W1 ) at a point below the raising and / or expelled floc, for treating wet animal manure with the method of any of claims 1-8.

19. Use of a continuously operating aerated bio-oxidizer device (8) comprising-a reactor comprising spheres, such as ceramic spheres, arranged to receive biomass comprising solid manure,-one or more controllable means for providing dried and heated air, preferably at different levels, to the reactor,-controllable means for providing the solid manure to the reactor,-controllable means for outputting oxidized manure from the reactor,-controllable means for mixing the solid manure, preferably wherein the means are controlled to obtain and / or maintain constant growth of microbes in the reactor,for treating solid manure (7) and floc (19) to provide oxidized manure (10) with the method of any of claims 1-8.

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