Continuous Fermentation Shaft for Fruit Pomace Fertilizer
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Solution Overview
Problem
Existing organic fertilizer production processes are batch-type, leading to long durations, lack of control over conditions, and limited availability, with potential for environmental pollution from odors and inefficiencies in raw material utilization.
Innovation Solution
A continuous process for organic fertilizer production using a fermentation shaft with a microbial consortium, where fruit pomace is used as a waste, and a mixing process, which includes controlled temperature and oxygen addition, allowing for continuous production and adjustment of fertilizer composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batch-type processes are used for organic fertilizer production, then the process is simple to operate, but the production duration is long and productivity is low
Solution Approach 1:
The patent implements a continuous fermentation process where raw materials are continuously fed into the fermentation reactor and fertilizer is continuously discharged, eliminating the start-stop nature of batch processes. This continuous operation maintains constant microbial activity and metabolic processes, significantly increasing productivity while keeping the system relatively simple to operate through automated continuous feeding and discharge mechanisms
2Device complexity
If batch-type processes are used, then the system design is simple, but control over fermentation conditions is poor
Solution Approach 1:
The patent incorporates automated control systems that continuously monitor fermentation parameters such as temperature, moisture content, and oxygen levels. Sensors detect these parameters and feed information back to the control system, which automatically adjusts aeration rates, heating/cooling, and moisture addition to maintain optimal fermentation conditions throughout the continuous process, achieving precise control without excessive system complexity
Solution Approach 2:
The continuous fermentation process allows dynamic adjustment of operational parameters including temperature, aeration rate, moisture content, and retention time. By continuously varying these parameters according to the fermentation stage and material composition, the system achieves precise control over the fermentation process while maintaining relatively simple equipment design
3Productivity
If batch processes are used to ensure continuous availability of fertilizer, then multiple systems are required, but device complexity and cost increase
Solution Approach 1:
The patent employs a single continuous fermentation system that operates without interruption, with continuous material input and fertilizer output. This eliminates the need for multiple batch systems running in parallel or sequence, reducing overall system complexity and cost while ensuring continuous fertilizer availability through the uninterrupted fermentation process
4Ease of operation
If traditional composting is used, then the process is simple, but unpleasant odors are generated causing environmental pollution
Solution Approach 1:
The patent utilizes controlled aeration and forced oxidation during the continuous fermentation process to rapidly decompose organic matter and eliminate odor-causing compounds. By maintaining adequate oxygen levels and promoting aerobic decomposition, the system prevents the formation of anaerobic conditions that generate foul odors, while the continuous flow regime ensures rapid processing and minimization of harmful emissions
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
The process enables efficient, cost-effective, and environmentally friendly production of organic fertilizer, enhancing control and flexibility in fertilizer composition and reducing waste.
Implementation Method 1
a continuous process for preparation of fertilizers... comprising two steps: a) optionally preparation of a fermentation agent comprising a mixture of fruit pomace and a microbial consortium comprising at least fungi, actinomycetes, thermophilic microorganisms and acidophilic bacteria
Implementation Method 2
mixing every 1 to 3 days, so that addition of oxygen during mixing maintains high temperature around 70-80 °C
Data Source
Figure 1
AI summary
The present invention belongs to the field of fertilizers, particularly organic fertilizers, and to the field of processes for preparation of fertilizers, which comprise biological or biochemical steps, such as composting or fermentation. The invention relates to a process and a system for continuous production of organic fertilizer and organic fertilizer produced with said process. The process comprises preparing or providing a fermentation agent, which comprises inoculation of fruit pomace with a microbial community comprising at least fungi, actinomycetes, thermophilic microorganisms and acidophilic bacteria, and preparing a fertilizer by mixing the fermentation agent and the raw material. In the process, acidophilic bacteria are sequentially activated, which break down fats and proteins in the input raw material, then the decomposition of cellulose and the activation of thermophilic microorganisms occur due to the increase in temperature. This is followed by the mineralization and formation of humates from the humic acids formed in the previous steps, the optional addition of nitrogen, phosphorus, and/or potassium to form organic-mineral complexes, and a drop in temperature to room temperature or ambient temperature, which is a sign that the fertilizer preparation process is finished. Raw material is added at the first end of the fermentation shaft, and with mixing the entire mass moves due to mixing towards the second end of the fermentation shaft, where the final fertilizer with humates is present, while at the first end fresh raw materials and fermentation agent can be added.