technology of obtaining granulated phosphate fertilizers...

TECHNOLOGY OF OBTAINING GRANULATED

PHOSPHATE FERTILIZERS BASED ON MUNICIPAL

SEWAGE SLUDGE ASHES AND BACTERIA

BACILLUS MEGATERIUM

M A C I E J R O L E W I C Z , P I O T R R U S E K , K R Z Y S Z T O F B O R O W I K , N E W C H E M I C A L S Y N T H E S E S I N S T I T U T E I N P U Ł A W Y , P O L A N D

THE WORLD’S FERTILIZERS DEMAND

Compound 2012 2013 2014 2015 2016

N 109.9 111.6 113.1 114.5 116.0

P2O5 41.5 42.7 43.5 44.3 45.0

K2O 28.6 29.5 30.9 32.2 33.2

Total 180.0 183.8 187.5 191.0 194.2

The world’s fertilizers demand in the years of 2012-2016 (millions tones ofthe component)

Phosphate rock is not a renewable raw material

More fertilizers will be need in future

WHERE WE LOST THE PHOSPHORUS?

• municipal sewage

• industry sewage

• livestock's excrement

• phosphogypsum

• leaching from soil

BIO-FERT-P PROJECT

• 2013-2017

• The project aim is to develop new technology of phosphatefertilizers based on renewable raw materials and microbialsolubilization

• bones or meat and bone meal• ashes from incineration of sewage sludges• Bacillus megaterium

• Product with fast and slow release of fertilizers nutrients

• Study in laboratory scale and pilot scale

• Obtaining parts of products for field experiments

• Field experiments for assessing properties of obtained product

BIO-FERT-P PROJECT CONSORTIUM

Wrocław University of Technology

New Chemical Syntheses Institute in Puławy

University of Warmia and Mazury in Olsztyn

THE SCOPE OF WORK

• Verification of technology concept at pilot plant scale

• a kind of granulating agent

• an amount of granulating agent

• a selection of the phosphorus raw material mixture

• Obtaining the product for the field experiments

• Designing of installation

• Preliminary economic analysis

OBTAINING OF THE GRANULATED FERTILIZERS

• Grinding of the raw materials

• Adding the lyophilisate

• Mixing of the raw materials

• Granulation

• Drying

• Classification

• Granulating agent: dried blood• Raw materials: Ash from incineration of municipal sewage sludge

(MSSA)

QUALITY OF GRANULES

• Compressive strength• min. 10-15 N

• Abrasion resistance• > 99 % for best market products

• Granulating liquid consumption• need to evaporate

• Efficiency

• Concetration of P2O5• SSP – 18 %• DAP – 46 %• NPK – 10-20 %

RAW MATERIALS

Compound Unit MSSA

P2O5 % mass 24.7

Cd

ppm

1.23

Cr 140

Hg 0.03

Ni 64

Pb 40

The composition of the raw materials

Concentration of metals are below the Polish fertilizers standards

MSSA - municipal sewage sludge ash

A PILOT PLANT FOR FERTILIZER GRANULATION RESEARCH

A GRANULATION NODE

A GRANULATION NODE

A COMPACTOR

RESULTS – PAN GRANULATOR

Parameter Unit MSSA+ bloodMSSA + blood +

bacteria

Compressivestrength

N 92.1 99.1

Abrasionresistance

% 98.1 98.8

Consumption ofgranulating liquid

% 49 50

P2O5 total % mass 20.3 20.1

Efficiency % 88.1 87.5

Quality of obtained granules and consumption of granulating liquid

Long time of drying

MSSA - municipal sewage sludge ash

RESULTS – DRUM GRANULATOR

Parameter Unit MSSA+ bloodMSSA + blood +

bacteria

Compressivestrength

N 42.3 41.1

Abrasionresistance

% 95.7 95.8

Consumption ofgranulating liquid

% 47 46

P2O5 total % mass 20.2 20,2

Efficiency % 48.3 47.9

Quality of obtained granules and consumption of granulating liquid

Long time of drying

MSSA - municipal sewage sludge ash

INFLUENCE OF DRYING

Two types of dryer

• Belt dryer

• Drum dryer

Percent of active population of Bacillus megaterium• 105°C – 50%

• 80°C – 90%

• 60°C – 100%

RESULTS – COMPACTOR

Parameter Unit MSSA+ bloodMSSA + blood +

bacteria

Compressivestrength

N 36.5 36.4

Abrasionresistance

% 75.6 75.2

Consumption ofgranulating liquid

% 6 6

P2O5 total % mass 22.5 22,1

Efficiency % 28.9 27.6

Quality of obtained granules and consumption of granulating liquid

MSSA - municipal sewage sludge ash

High pressure decrease the population of bacteria

CONCLUSIONS

Fertilizers obtained by plate granulation process are characterized by higher

compressive strength and abrasion resistance comparing to fertilizers

obtained by compaction and drum granulation. However, this is at the

expense of decreased P2O5 content in a product and significant water

consumption during granulation process that generate the costs of drying

process.

Drying in temperature over 80°C leads to decrease of the active population

of Bacillus megaterium in fertilizer.

ACKNOWLEDGEMENTS

This project is financed in the framework of grant PBS 2/A1/11/2013 entitled: „Phosphorus renewable raw

materials - aresource base for new generation of fertilizers”attributed by the National Center for Research

and Development.