Process and apparatus for manufacture of fertilizer products from manure and sewage

Abstract

This invention discloses systems and methods for conversion of manure to novel fertilizer and/or soil builder products useful as input for organic farming operations. The equipment systems comprise a gas turbine generator unit (preferred heat source), a dryer vessel and a processing unit, wherein the connection between the gas turbine and the dryer vessel directs substantially all the gas turbine exhaust into the dryer vessel and substantially precludes the introduction of air into the dryer vessel. The dryer vessel receives the manure for contact with the turbine exhaust gases to convert the manure to a dry material, which is passed to the processing unit where it is formed into granules, pellets or other desired form for the final dry fertilizer product. The method comprises drying, heating and converting the manure to form novel self binding fertilizer and soil builder type products for organic farming and other uses.

1 . A method of making a fertilizer material from manure feedstocks comprising:
 operating a gas turbine generator to produce electricity and exhaust gases having a temperature greater than 1,000° F.;   contacting the exhaust gases having a temperature greater than 1,000° F. with manure feedstock having a moisture content of at least about 30% by weight in a dryer vessel for a contact time sufficient to produce without significant oxidation of the manure feedstock a dried fertilizer material having a moisture content of less than about 20% by weight.   
     
     
         2 . A method according to  claim 1  wherein the exhaust gases contacting the manure feedstock is at an initial temperature between about 1,100° F. and about 1,600° F. 
     
     
         3 . A method according to  claim 1  wherein the manure feedstock comprises at least about 50% by weight moisture. 
     
     
         4 . A method according to  claim 3  further comprising the steps of granulating, pelletizing or prilling the fertilizer material to produce a fertilizer product suitable for conventional dry fertilizer application in a crop growing operation. 
     
     
         5 . A method of making a fertilizer material from manure feedstocks comprising:
 operating a gas turbine generator to produce electricity and exhaust gases;   contacting the exhaust gases with the manure feedstock having a moisture content of at least about 30% by weight, in a dryer vessel for a contact time sufficient to produce, without significant oxidation of the manure feedstock, a dried fertilizer material having a moisture content of less than about 20% by weight; and   processing and forming the fertilizer material into a granular, pellet or prill form or fertilizer product suitable for conventional dry fertilizer application in a crop growing operation.   
     
     
         6 . A method according to  claim 5  wherein the manure feedstock comprises a moisture content of at least about 50% by weight. 
     
     
         7 . A method according to  claim 6  wherein the manure feedstock is at least about 70% by weight. 
     
     
         8 . A method according to  claim 5  wherein the fertilizer material comprises a moisture content of less than about 15% by weight. 
     
     
         9 . A method according to  claim 5  wherein the fertilizer material comprises a moisture content of less than about 10% by weight. 
     
     
         10 . A method according to  claim 5  wherein the feedstock comprises agricultural animal waste. 
     
     
         11 . A method according to  claim 5  wherein the feedstock comprises municipal sewage. 
     
     
         12 .- 61 . (canceled)