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Manure Granulation Testing

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FEECO International, Inc.
FEECO International, Inc.

As the granulation of manure into a premium fertilizer or soil amendment product becomes more popular, testing is needed to confirm feasibility and develop a process around the unique manure sample to be processed. This presentation goes over why testing is important, and details the testing process that occurs in the FEECO Innovation Center, including the phases of testing, how testing works, and what particle characteristics can be targeted.

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Manure Granulation Testing Experts in process design and material processing for over 65 years.
As the granulation of manure into a fertilizer or soil amendment product becomes increasingly popular, so too does research and development around manure granulation systems.
With significant variation between manure types and even amongst the same type, testing is a key component to the success of a manure granulation process. The following is an overview on testing in the FEECO Innovation Center.
Why Testing is Important
In addition to the significant variation among manure types, many on-farm practices will also influence the consistency and make-up of manure. This might include the type of feed, the separation system used, handling practices, farm location, and even barn type.
With so many variables, the unending matrix of manure outcome possibilities makes testing an absolute necessity to the success of the overall process and the end product.
There are a few different approaches to granulation, and it may not be clear at the onset of testing which method will suit the unique manure source best and be able to produce the desired end product characteristics.
Mixer-dryer granulation works by first mixing the pre-treated manure in an industrial mixer, typically either a pin mixer or pug mill. FEECO Pug Mill
Once a homogenous mixture of the material and any additional inputs has been created, the newly-formed pellets are discharged and carried to a rotary dryer, where they are dried into their final form. A cooling step after drying is also common. FEECO Rotary Dryer
The pelletizing approach is similar, but with the addition of a disc pelletizer after the mixer. This approach increases process efficiency, overall throughput, and also adds an element of fine- tuning, ultimately improving the quality of the end product. FEECO Disc Pelletizer
Drum granulation is similar to the pelletizing method, but with a rotary drum replacing the disc. This approach allows for higher capacities, and offers a closed system, unlike the disc pelletizer, which is considered an open system. FEECO Granulation Drum
Extrusion, a pressure agglomeration approach in which materials are forced through a die to create a cylindrical pellet, is also an option and is often chosen for smaller operations that do not have the volume to support the capacities required by a non-pressure granulation system. Pellets created via extrusion are considered a lower-grade product. FEECO does not offer this approach.
How Testing Works
Testing in the FEECO Innovation Center typically happens in four stages: •  Feasibility/Proof of Concept •  Proof of Product •  Proof of Process •  Process/Product Optimization
Feasibility/Proof of Concept In this initial phase of testing, process experts run batch scale tests to determine if the specific source of manure will agglomerate. Small sample sizes can be produced for use in lab or grow room trials.
Proof of Product This next phase is a more in-depth batch testing phase, where more time is spent determining if the specific manure sample can be made to exact specifications. Additional binders and formulations may also be tested.
Proof of Process Building off of step two, this phase uses a continuous setup to determine if the process is viable on a continuous scale, as well as what process variables will need to be for continuous production.
Process/Product Optimization This stage works on fine-tuning the end product and the process itself, providing a recipe for scale-up. Samples produced can be used in field trials.
As with any testing, it is critical that the manure sample be as representative as possible, to ensure testing simulates on-farm conditions.
The first step in testing manure is to determine if a pre-conditioning step is needed to optimize the feedstock for granulation. This centers around ensuring ideal particle size distribution, moisture content, and material composition for granulation.
It may be obvious from the start whether a material will require pre-conditioning, or this conclusion may be reached through the testing process itself.
The type of mixer chosen for the process is commonly dictated by the consistency of the manure, with pin mixers favoring more dry, finely divided solids such as chicken litter, and pug mills favoring cakes such as separated dairy manure.
If the mixer alone produces suitable results, process experts can move on to fine-tuning the process and testing it as a continuous process loop.
If the end product requires more refinement, or if the process is struggling to produce on-size product, process experts will likely try a different approach, possibly adding a disc pelletizer to the process, or utilizing a different mixer.
Product Customization
Producers are most often looking to target a specific set of particle characteristics. This might include any of the following: •  Bulk Density •  Crush Strength •  Solubility •  Attrition •  Compression •  Particle Size Distribution •  Flowability •  Moisture Content •  Physical/Surface Quality •  Green/Wet Strength
Throughout testing, process experts work with a number of variables to produce these targeted parameters. Depending on the setup, this might include any of the following…
• Material Feed Rate • Amount of Recycle • Binder Feed Rate • Type of Binder • Mixer Speed • Type of Mixer • Mixer Pin/Paddle Arrangement • Disc Speed • Disc Angle • Dryer Temperature • Dryer Air Flow • Dryer Flight Design and/or Pattern
Additionally, while the product can be 100% manure-based, granulation can also accommodate the addition of other beneficial materials such as macro or micronutrients to improve the quality of the product or create a fortified nutrient blend customized to a specific application.
Automation
Throughout testing in the Innovation Center, FEECO process experts utilize our state-of-the-art automation system from Rockwell Automation to gather, trend, and report on data, even adjusting variables in real-time. This provides customers with complete process transparency and data visualization and analysis. In addition, FEECO can provide Rockwell Automation systems as part of a system purchase.
Conclusion Testing is a critical component in the success of a manure granulation process. The FEECO Innovation Center offers comprehensive testing services at both batch and pilot scale and can help to develop a process around your unique manure sample and process goals.
has been a leader in transforming wastes into value-added products since 1951. In addition to feasibility testing, process design, and custom equipment, we offer complete systems for the granulation of manure into a premium product.
Want to learn more? Download our Organics Granulation Handbook Download Now The Organics Granulation Handbook Granulation as a Solution Systems and Equipment Considerations Outlook

More Related Content

Manure Granulation Testing

  • 1. Manure Granulation Testing Experts in process design and material processing for over 65 years.
  • 2. As the granulation of manure into a fertilizer or soil amendment product becomes increasingly popular, so too does research and development around manure granulation systems.
  • 3. With significant variation between manure types and even amongst the same type, testing is a key component to the success of a manure granulation process. The following is an overview on testing in the FEECO Innovation Center.
  • 5. In addition to the significant variation among manure types, many on-farm practices will also influence the consistency and make-up of manure. This might include the type of feed, the separation system used, handling practices, farm location, and even barn type.
  • 6. With so many variables, the unending matrix of manure outcome possibilities makes testing an absolute necessity to the success of the overall process and the end product.
  • 7. There are a few different approaches to granulation, and it may not be clear at the onset of testing which method will suit the unique manure source best and be able to produce the desired end product characteristics.
  • 8. Mixer-dryer granulation works by first mixing the pre-treated manure in an industrial mixer, typically either a pin mixer or pug mill. FEECO Pug Mill
  • 9. Once a homogenous mixture of the material and any additional inputs has been created, the newly-formed pellets are discharged and carried to a rotary dryer, where they are dried into their final form. A cooling step after drying is also common. FEECO Rotary Dryer
  • 10. The pelletizing approach is similar, but with the addition of a disc pelletizer after the mixer. This approach increases process efficiency, overall throughput, and also adds an element of fine- tuning, ultimately improving the quality of the end product. FEECO Disc Pelletizer
  • 11. Drum granulation is similar to the pelletizing method, but with a rotary drum replacing the disc. This approach allows for higher capacities, and offers a closed system, unlike the disc pelletizer, which is considered an open system. FEECO Granulation Drum
  • 12. Extrusion, a pressure agglomeration approach in which materials are forced through a die to create a cylindrical pellet, is also an option and is often chosen for smaller operations that do not have the volume to support the capacities required by a non-pressure granulation system. Pellets created via extrusion are considered a lower-grade product. FEECO does not offer this approach.
  • 14. Testing in the FEECO Innovation Center typically happens in four stages: •  Feasibility/Proof of Concept •  Proof of Product •  Proof of Process •  Process/Product Optimization
  • 15. Feasibility/Proof of Concept In this initial phase of testing, process experts run batch scale tests to determine if the specific source of manure will agglomerate. Small sample sizes can be produced for use in lab or grow room trials.
  • 16. Proof of Product This next phase is a more in-depth batch testing phase, where more time is spent determining if the specific manure sample can be made to exact specifications. Additional binders and formulations may also be tested.
  • 17. Proof of Process Building off of step two, this phase uses a continuous setup to determine if the process is viable on a continuous scale, as well as what process variables will need to be for continuous production.
  • 18. Process/Product Optimization This stage works on fine-tuning the end product and the process itself, providing a recipe for scale-up. Samples produced can be used in field trials.
  • 19. As with any testing, it is critical that the manure sample be as representative as possible, to ensure testing simulates on-farm conditions.
  • 20. The first step in testing manure is to determine if a pre-conditioning step is needed to optimize the feedstock for granulation. This centers around ensuring ideal particle size distribution, moisture content, and material composition for granulation.
  • 21. It may be obvious from the start whether a material will require pre-conditioning, or this conclusion may be reached through the testing process itself.
  • 22. The type of mixer chosen for the process is commonly dictated by the consistency of the manure, with pin mixers favoring more dry, finely divided solids such as chicken litter, and pug mills favoring cakes such as separated dairy manure.
  • 23. If the mixer alone produces suitable results, process experts can move on to fine-tuning the process and testing it as a continuous process loop.
  • 24. If the end product requires more refinement, or if the process is struggling to produce on-size product, process experts will likely try a different approach, possibly adding a disc pelletizer to the process, or utilizing a different mixer.
  • 26. Producers are most often looking to target a specific set of particle characteristics. This might include any of the following: •  Bulk Density •  Crush Strength •  Solubility •  Attrition •  Compression •  Particle Size Distribution •  Flowability •  Moisture Content •  Physical/Surface Quality •  Green/Wet Strength
  • 27. Throughout testing, process experts work with a number of variables to produce these targeted parameters. Depending on the setup, this might include any of the following…
  • 28. • Material Feed Rate • Amount of Recycle • Binder Feed Rate • Type of Binder • Mixer Speed • Type of Mixer • Mixer Pin/Paddle Arrangement • Disc Speed • Disc Angle • Dryer Temperature • Dryer Air Flow • Dryer Flight Design and/or Pattern
  • 29. Additionally, while the product can be 100% manure-based, granulation can also accommodate the addition of other beneficial materials such as macro or micronutrients to improve the quality of the product or create a fortified nutrient blend customized to a specific application.
  • 31. Throughout testing in the Innovation Center, FEECO process experts utilize our state-of-the-art automation system from Rockwell Automation to gather, trend, and report on data, even adjusting variables in real-time. This provides customers with complete process transparency and data visualization and analysis. In addition, FEECO can provide Rockwell Automation systems as part of a system purchase.
  • 32. Conclusion Testing is a critical component in the success of a manure granulation process. The FEECO Innovation Center offers comprehensive testing services at both batch and pilot scale and can help to develop a process around your unique manure sample and process goals.
  • 33. has been a leader in transforming wastes into value-added products since 1951. In addition to feasibility testing, process design, and custom equipment, we offer complete systems for the granulation of manure into a premium product.
  • 34. Want to learn more? Download our Organics Granulation Handbook Download Now The Organics Granulation Handbook Granulation as a Solution Systems and Equipment Considerations Outlook