Vulcan Systems – Drying System
INTERNATIONAL LEADER IN THERMAL TECHNOLOGY SPECIALIZING IN ENGINEERING AND MANUFACTURING EQUIPMENT FOR DRYING ANIMAL FEED AND MANURE
About the Company:
Vulcan® Systems, headquartered in Moberly, Missouri, serves clients on six continents and in more than 80 countries, utilizing vast experience and know-how to create safe, efficient, and reliable thermal systems for a wide variety of processes, including animal feed, animal manure, automotive shredder residue, biomass, coal fines, fly ash, minerals and spent catalyst drying, as well as drill cuttings and tank bottom remediation, and RCRA waste processing.
Vulcan® Systems also provides additional services for clients, ranging from thermal testing and training to commissioning and maintenance support.
About the Solution:
Animal Manure Drying
Vulcan® Systems’ Technology was developed to address the growing problems produced by the oldest and most natural fertilizer in the world…manure. Historically, animal manures have been handled as a solid and were either directly deposited to pastures or collected along with animal shelter bedding and applied to land as a crop nutrient. As the concentration of animals on farms increased, the need for more efficient methods of manure management developed. Hauling nutrients to cropland in raw form became very expensive compared to hauling the same amount of nitrogen or phosphorus in the form of a commercial dry fertilizer.
Until recently, despite the negative environmental impact, manure has not been strictly regulated. Now, amidst the conflicts over who is responsible for pollution caused by manures, new and more stringent regulations have been introduced. Vulcan® Systems’ Animal Manure Drying Equipment consists of a base system, and seven optional additions to meet each client’s specifications.
Base System: Includes all the components necessary to feed and dry animal manure to a granular end-product, including air pollution control equipment. For a low cost quick solution, the base system is all you need.
Feed Conditioning System: Often referred to as a debris removal system, the feed conditioning system is used to separate manure from unwanted products. After the material is fed into a feed hopper, the material travels up a conveyor and enters a trommel. The trommel does all the heavy lifting by sorting the valuable manure from unwanted debris. The debris will make its way to a bin for disposal.
Weight Monitoring Feed Hoppers: Additional feed hoppers can be added to the beginning of the process, which include weight cells and constant feed weight monitoring. This addition allows for streamlined control and highly accurate recordkeeping of feed processing rates.
Fertilizer Additive Dosing System: Customer specified additives are stored in the dosing equipment above the mixer. Dosers release precise amounts of each into the mixer where it will be combined with the wet feed material before it is conveyed into the dryer. Any number of fertilizer ingredients can be added to meet the requirements of various end-product specifications.
End-Product Sizing System: After exiting the dual knife gate valve at the end of the rotary drum, all dry manure material enters a screen shaker to separate the dried end-product according to size.
Dry Storage Silo and Elevator Conveyor: The elevator conveyor brings off-spec granules from the screen shaker to be stored in the dry storage silo. The silo allows material, that does not meet required sizing specifications, to be stored and then recirculated back into the feed as seed material to produce the specified granules.
Frac Water Tank with Mixer: The frac water tank serves as a storage solution for those without a lagoon or other source of water. The water can be stored for a period of time before being discharged in a field as a liquid fertilizer.
Ammonia Scrubber: By utilizing the second stage ammonia scrubber, ammonia is extracted from the vapor stream and ammonium sulfate is recovered for use as a liquid fertilizer.
Solution Strengths, Weaknesses and Critical Indicators
Active Drying Technologies:
- Produce a marketable product, dry manure solids, and reduce transportation costs
- Require energy to reduce water content and dry manure solids, purchased energy cost are an issue
- Require operator attention in excess of other systems due to the risk of combustion
- Other compounds are released with the water (i.e. ammonia, hydrogen sulfide), and require additional treatment
- Potential loss of ammonia nitrogen due to volatilization
- Proven technology for storage reduction, odor control, GHG reduction and pathogen reduction
Evaporation and Drying Technologies:
- Uses heat to produce either manure with less water or dried manure solids
- Systems that reduce water in manure use a series of evaporators to sequentially evaporate water from liquid slurries—energy is supplied either by purchased fuel and/or waste heat from other processes
- Systems that dry separated solids use either a belt or drum to evaporate water from separated solids—energy is supplied either by purchased fuel, electricity and/or waste heat from other processes
- Chemicals are released with the water (i.e. ammonia, hydrogen sulfide), and this often requires additional treatment such as condensation of the water and/or scrubbing of the chemicals
- The requirement for purchased energy and costs are a significant concern leading to a tradeoff between input costs and gains in liquid concentration and transportation/market of by-products
1. OPERATIONAL HISTORY