Feather Fertilizer Extrusion with Roller Cooling
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Solution Overview
Problem
The existing methods for manufacturing organic fertilizers from feathers face challenges such as high energy consumption, complex and time-consuming sanitization processes, and issues with granulation due to the use of sugar-based binders, leading to fouling and clogging in extruders, which hinder industrial-scale production.
Innovation Solution
A process involving direct grinding of feathers with a mixture of a sugar-based release agent, keratin binder, and a filler, followed by extrusion through a roller extruder with controlled temperature and cooling to prevent carbonization, and using a decompression tunnel to manage water vapor, allowing for continuous industrial production of sanitized fertilizer granules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If feathers are steamed for sanitization before grinding, then sanitization is achieved, but energy consumption increases and processing time is extended
Solution Approach 1:
The patent performs sanitization during the grinding process itself rather than as a separate preliminary step. The grinding operation generates heat that raises the temperature of feathers to sanitization levels (above 70°C), thereby achieving sanitization as a byproduct of the necessary grinding operation, eliminating the need for separate steaming equipment and energy input.
Solution Approach 2:
The patent combines the sanitization function with the grinding function into a single integrated process. The mechanical energy input for grinding simultaneously provides the thermal energy needed for sanitization, merging two separate operations into one that reduces both equipment requirements and energy consumption.
2Ease of manufacture
If sugar-based binders are used for granulation, then granule formation is achieved, but fouling and clogging of extruder die occurs rapidly
Solution Approach 1:
The patent modifies the temperature parameter during extrusion by implementing rapid cooling of the die. This temperature control prevents the sugar-based binder from carbonizing and clogging the die, allowing continuous production. The die is cooled to maintain temperatures below the carbonization point of sugars while still enabling granule formation.
Solution Approach 2:
The patent introduces a cooling system as an intermediary between the extrusion process and the die. This cooling mechanism acts as a mediator that allows the use of sugar-based binders (which provide good granulation) without suffering from their tendency to carbonize and clog the die, thus enabling continuous production.
3Object-generated harmful factors
If water is added to prevent extruder die clogging, then fouling is reduced, but lignin sulphonate reacts with water and loses adhesion capability
Solution Approach 1:
The patent changes the temperature parameter by implementing rapid cooling of the die during extrusion. This temperature control prevents carbonization of the sugar-based binder, eliminating the need to add water for fouling prevention. The controlled temperature maintains the adhesion capability of lignin sulphonate while preventing die clogging.
4Loss of energy
If heat is not evacuated quickly from feathers, then energy is saved, but temperature increases cause carbonization of the raw material
Solution Approach 1:
The patent extracts heat from the extrusion process by implementing a cooling system for the die. This removal of excess heat prevents carbonization of the feather material while maintaining the energy efficiency of the process, as the cooling is localized and targeted only where necessary to prevent degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy consumption, prevents fouling, and enables the production of high-quality, purely organic NPK fertilizer granules with controlled nitrogen, phosphorus, and potassium dosages, facilitating industrial-scale and continuous production while maintaining product quality.
Implementation Method 1
The temperature rises above 73° C. so as to ensure sanitation by destroying pathogenic organisms
Implementation Method 2
If this heat is not evacuated quickly, it contributes to the increase in temperature, which leads to carbonization of the raw material
Implementation Method 3
there remains another problem to be solved, namely the evacuation of the water vapor liable to accumulate in the enclosure 34 due to the evaporation by heating of the composition extruded in the form of granules
Data Source
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AI summary
The object of the invention is a process for manufacturing a fertilizer based on ground feathers, comprising the following steps: - preparation of an intermediate composition comprising: ground feathers, a lignin sulfonate-based binder, an anti-stick agent, a filler, and water; - mixing of the intermediate composition; - extrusion/granulation of the intermediate composition in an extruder/granulator; and - extraction of excess water to obtain organic fertilizer granules. Another object of the invention is the device for implementing the process, characterized in that it comprises extrusion/granulation means including a thick, disc-shaped plate (72) with holes, a roller train rotating about a central axis relative to the thick plate, and a conveyor delivering the composition directly onto said thick plate.