Unfermented Manure Pellets with Lignin Shell
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Solution Overview
Problem
Current manure pellet production methods result in pellets with low NPK values and lack of fibrous material, requiring fermentation and costly transportation, while also being inefficient in energy and cost, and failing to provide slow release of nutrients.
Innovation Solution
The production of unfermented manure pellets with high NPK values and fibrous content is achieved through a process involving mechanical drying and heat drying, forming a lignin-based shell during pelletization, using a unique press roll to reduce moisture content and create a slow-release, hygienized product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fermented manure is used to make pellets, then the manure can be transported and processed, but the NPK values become low and fibrous material is lost
Solution Approach 1:
The patent applies preliminary drying and pelleting actions to fresh manure before fermentation occurs. By drying the manure to reduce moisture content and forming pellets while the manure is still fresh and retains its fibrous structure and high NPK values, the invention preserves the nutritional content while enabling transportability. The pellets are then stored and transported in this preserved state, avoiding the degradation that occurs with fermentation.
2Ease of manufacture
If fermented manure is used to make pellets, then the manure can be processed, but the fibrous material structure is degraded
Solution Approach 1:
The invention performs drying and pelleting as preliminary actions before fermentation degrades the fibrous structure. By removing moisture and forming pellets while the manure is still fresh, the fibrous material maintains its original structure and integrity. This preliminary processing enables easy manufacture and transport while preserving the stable fibrous composition.
3Quantity of substance
If conventional drying methods are used, then moisture content is reduced, but energy consumption increases
Solution Approach 1:
The patent changes the parameters of the drying process by using lower temperatures and shorter drying times compared to conventional methods. The drying is performed at temperatures that preserve the fibrous structure while still effectively reducing moisture content. This parameter optimization reduces energy consumption while achieving the desired moisture reduction for pellet formation.
4Quantity of substance
If fresh manure is used directly for pelleting, then NPK values are high, but the pellets disintegrate quickly
Solution Approach 1:
The invention applies preliminary drying as a necessary action before pelleting fresh manure. By removing excess moisture while the manure still retains its high NPK values and fibrous structure, the dried manure becomes suitable for forming strong, stable pellets. The drying process prepares the material by reducing moisture to optimal levels for binding, while the subsequent pelleting process forms the structural integrity.
Solution Approach 2:
The patent creates a composite structure in the pellets where the dried manure particles are bound together through the pelleting process. The fibrous material in the dried manure acts as a natural binding agent, creating a composite structure that maintains both high NPK values and strong pellet integrity. The combination of dried manure particles and fibrous binders forms a stable composite pellet structure.
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 results in pellets with enhanced NPK values, a high fibrous content, and a slow release of nutrients, reducing energy consumption and transportation costs, while maintaining the structural integrity of the fibrous material and providing a hygienized product.
Implementation Method 1
a press roll, optimized for the manure drying assembly
Implementation Method 2
The press roll comprises the drum and an endless belt passing below the drum
Implementation Method 3
mechanical drying to levels below 45% moisture content
Implementation Method 4
forming a lignin-based shell during pelletization
Data Source
AI summary
A pellet made of dried, unfermented livestock manure has N, P and K values in the range of N: 3 to 7 g/kg, as ammoniac and organic nitrogen, P: 2 to 6 g/kg as phosphorus pentoxide and K: 2 to 6 g/kg as potassium oxide (g/kg). The pellet has a hardness exceeding 10 kg and has a shell composed of manure-base lignin. A press roll, including a hollow rotatable drum with a perforated screen, may be used in combination with an endless belt and a scraper to produce the pellet.