A METHOD OF MANURE DISPOSAL
FOR A BEEF PACKING OPERATION
First Interim Technical Report
by
Procedyne Corporation
221 Somerset Street
New Brunswick, NJ 08903
Project 12060 EOF
Project Officer
Jack L. Witherow
Industrial Treatment & Control-Corvallis
U.S. Environmental Protection Agency
200 S.W. 35th Street
Corvallis, Oregon 97330
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF RESEARCH AND DEVELOPMENT
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
CINCINNATI, OHIO 45268
-------
ABSTRACT
This report contains the preliminary studies, process development,
process calculations, and process design for a system to successfully
handle the paunch manure in a beef slaughtering operation.
These studies resulted in a system in which the paunch manure is
collected from the slaughtering operation and is fed to a screening
device which separates the coarse solids. The screenings are dewatered
to a solids content of 37 percent. This dewatered material is then
sent to a fluid bed incinerator via a screw conveyor. The liquid stream
from the screening is fed to a settler and is combined with the liquid
stream from the dewaterer prior to sand filtering. The filter cake is
fed to the incinerator using a screw conveyor. The filtrate is recycled
back to the settler.
Work was completed as of February 1971.
ii
-------
CONTENTS
Page No.
SECTION I - INTRODUCTION 1
SECTION II - PRELIMINARY STUDIES 5
Paunch Manure Characteristics 5
Present Disposal System 7
Paunch Manure Filtration 14
Studies
SECTION III - PROCESS DEVELOPMENT 23
Dewatering 23
Filtration 37
Sedimentation 36
Incineration 41
SECTION IV - PROCESS CALCULATIONS 55
Paunch Table 55
Paunch Bin 57
Primary Dewatering 58
Dewaterer 59
Settler and Filter 60
Incinerator 62
Material and Heat Balance '62
Fuel and Air 66
Cyclone 6 9
Scrubber 7 0
SECTION V - SUMMARY OF THE PROCESS DESIGN 72
SECTION VI
SECTION VII
Description of the Process 72
Equipment List 7 5
CONCLUSION 78
REFERENCES 7-9
iii
-------
LIST OF FIGURES
Figure No. Title
Page No.
1 PAUNCH MANURE DISPOSAL PROCESS 2
2 PAUNCH PROCESSING AREA 8
-ILLINOIS PACKING COMPANY
3 PRESENT PAUNCH MANURE HANDLING 9
OPERATION
4 PAUNCH PROCESSING AREA 11
-ILLINOIS PACKING COMPANY
5 MATERIAL BALANCE FOR PAUNCH WASH 12
OPERATION
6 FILTRATION THROUGH SAND AND MANURE 15
IN LAYERS
7 FILTRATION THROUGH SAND AND MANURE 16
MIXTURE
8 REGENERATING FILTER 35
9 GRAPH OF % SOLIDS TO SETTLER VS. 37
% OF LAYER SPLIT
10 GRAPH OF % SOLIDS TO SETTLER yS. 38
% SOLID SPLIT INTO LAYERS
H GRAPH OF % SOLIDS TO SETTLER VS.
% LAYER SPLIT
39
12 GRAPH OF % SOLIDS TO SETTLER VS. 4 0
% SOLIDS IN LAYER
13 CONCEPTUAL DRAWING-rPROCEDYNE FLUID 42
BED REACTOR
14 PROCESS SCHEMATIC FOR pILOT PLANT 44
INCINERATOR
15 PROCESS FLOWSHEET (PROCEDYNE CORP. 76
DWG. D-0514 9)
16 MATERIAL BALANCE (PROCEDYNE CORP. 77
DWG. D-05141)
iv
-------
LIST OF TABLES
Table No . Title Page No.
I PAUNCH SOLIDS CONCENTRATION 10
II PAUNCH WASTE STREAM CHARACTERISTICS 13
III FILTRATION TEST RESULTS 17-20
IV CONDITIONS AND RESULTS OF 33-34
FILTRATION EXPERIMENTS
V PAUNCH MANURE INCINERATION 4 6
EXPERIMENTS
VI FEED TO INCINERATION 4 7
EXPERIMENTS
V
-------
SECTION I
INTRODUCTION
This report is concerned with the preconstruction research
and development activities under an FWQA Research
Development and Demonstration Grant, Project Number 12 060 EOF,
to the Illinois Packing Co., Chicago, 111, The objective
of the project is to develop, design, install and
demonstrate a fluidized bed incineration system for the
efficient disposal of paunch manure waste generated in
beef packing operations. The process, shown schematically
in Figure 1, is being engineered and fabricated by
Procedyne Corporation for installation at the Illinois
Packing Co., Chicago, 111.
Paunch Manure is partially digested feed material removed
from the stomach of cattle during preparation for market.
It is the only major portion of the animal with no
practical commercial value. Disposal is costly -- approxi-
mately $12/ton when hauled from the premises for dumping.
In addition, a significant portion of the solid waste is
disposed as sewage and adds a substantial burden to
municipal sewage disposal facilities.
The USDA statistical report on commercial slaughter for the
United States indicates that a total of 35,026,4 00 head
were slaughtered in 1968. When related to the paunch manure
disposal problem of approximately 50 lbs/stock (including
1
-------
PAUNCH WASH
WASTE STREAM
GAS
CLEANING
SYSTEM
CCAUSE SOLIDS
PRIMARY
DEWATERING
i>-
FLUID
BED
FINE
SOLIDS
INCINERATOF
SAND
FILTER
CLARIFIER
AIR
TO SEWER
FUEL
FIGURE 1. PAUNCH MANURE DISPOSAL PROCESS
-------
sack waters), it is seen that 1,751,320,000 lbs. of waste
that must somehow be disposed at minimal cost and with
maximum consideration to the reduction of the pollution
problems resulting from present disposal practice. The
same statistical data indicates that the 1968 slaughter
for the state of Illinois was 1,407,000 head; thus
70,350,00 pounds of paunch manure.
Paunch manure is untreatable in conventional sewage
treatment plants (1) for the following reasons:
1. It has a very high biochemical oxygen demand.
2. Its high solids content tends to mat into
masses which clog bar screens.
3. It settles out in conventional tanks and in time
hardens to the consistency of low density rock.
4. It clogs hopper bottoms, pits and pump suctions.
5. It sets up like concrete in pipe lines, requiring
augering for removal.
6. The cellulose material will not decompose in
digesters and forms straw blankets which clog and
eventually fill digesters.
7. The entrapped moisture in the cellular material
can not be dewatered by vacuum filters.
8. The material has an objectionable odor which
rapidly decomposes into an intolerable stench.
9. Because of its cellular type moisture it cannot
be dried in a flash dryer nor can it be burned in
suspension.
3
-------
For these major reasons and many minor ones, no community
treats paunch manure in sewage treatment plants but
disposes of it separately, usually by land fill.
The research and development activities described in this
report have culminated in a final process design which
is currently being engineered for construction. A
summary of the process design is presented in the last
section of this report, Section V.
4
-------
SECTION II
PRELIMINARY STUDIES
Paunch Manure Characteristics
The quantity and physical-chemical composition of paunch
manure are dependent upon the composition of the animal
feed and the environment in which the animals are held
during the processing period. Due to this fact, it is
difficult to relate existing literature data to the
present problem. Furthermore, data obtained in the past
do not accurately reflect present conditions becau se
of changing feed practices (2) . Physical and chemical data
as required for the present process development were
obtained as presented in this section.
The quantity of paunch manure was established in terms of
pounds of wet paunch waste per animal. A number of
measurements on fresh paunch sacks shows that the average
weight of the paunch contents is approximately 55 lbs./
animal. That number compares to the typical value of
50 lbs/animal reported in the literature.
Simultaneous research conducted by the Federal Water
Quality Office Robert S. Kerr Research Center produced
physical and chemical data on dried paunch material.
BOD analysis on the material established the ultimate first
stage BOD of the soluble material to be 84,000 mg/1 of
paunch content and that of the nonsoluble fraction to be
5
-------
24,000 mg/1 of paunch content. These data suggest that
approximately 8 0% of the total BOD in a paunch wash
stream will be in the form of dissolved paunch solids.
Composition of the dried paunch material was reported
as follows:
Dehydrated paunch Average % of 10 samples
Moisture 15.3
Protein 10.3
Ash 6.7
Fat 4.4
Calcium 0.5
p2°5 1,4
Crude Fiber 21.2
Carbohydrates 42.0**
** Calculated by subtracting the total percentage of
moisture, protein, ash, fat, and crude fiber from 100%.
For purposes of material balance calculations the
combustible fraction of the paunch material was assumed
to be cellulose with the molecular formula(CgHio°5).
In order to establish data for heat balance calculations,
calorimetrie measurements on dried paunch material were
made with Parr Oxygen Bomb Calorimeter. Data on two
samples produced heat of combustion, AH, values of 3890
and 412 0 Cal/gm for an average value of approximately
4000 cal/gm or 7200 Btu/lb.
The data presented above adequately establish the chemical
6
-------
and thermodynamic properties of the paunch material
required for process design purposes. Physical and
chemical characteristics pertinent to the paunch
disposal operation and unit operations in the disposal
system under design are presented in sections which
follow.
Present Disposal System
In the present paunch handling system the unbroken
paunch sacks are conveyed to a table where they are
carefully washed and any excess fat is manually trimmed
before emptying as shown in Figure 2. The empty paunch
sacks are then thoroughly washed and sent on for packaging.
All three streams, the paunch sack preliminary wash, the
paunch manure slurry, and the paunch final wash are
combined and fed through a trough to one of two paunch
manure, drain bins as shown in Figure 3. The solids
content of that manure slurry has been estimated to be
5% solids by weight.
The paunch manure is settled periodically in each of the
drain bins during the day shift by alternating the feed
between the two bins. The bins are unloaded each evening
into a disposal truck which carts the material to a farm
outside of the City of Chicago to be spread on the ground.
The filtrate from the drain bins is discharged at a rate
of approximately 50-6 0 gpm into a plant sanitary sewer line
7
-------
Paunch Processing Area
Illinois Packing.Co.
Constant Water Flow
9
1
CO
Paunch is
Laid on Here
and Scraped
Clean
©
v
n
Paunch Wash
Paunch is
Emotied
Water Line
(not in use)
Water for Table
Q>
>
0
A
<
M
0
0
»H
£
0
u
iw
aj
+>
u
¦<-©
J V
Paunch Viscera
Sluice
"5*"Water Flow Can Be Reversed
Figure 2.
-------
Preliminary
Paunch Wash
Paunch Final
Manure Wash Paunch Wash
Screens
Paunch
Manure
Bin Unload-
ing Doors
^ to Sanitary Sewer
Water+ disolved solids + suspended solids
FIGURE 3. PRESENT PAUNCH MANURE HANDLING OPERATION
-------
which runs from the plant to a Chicago municipal sewer
line and then to the Chicago Sanitary District Treatment
plant.
Several field studies were made of the operation of
the paunch table under actual operating conditions.
Flowrates of water were measured and these are shown in
Figure 4. Original estimates of paunch manure weights
were checked and it was found that the contents of
14 sacks weighed an average of 55 lbs. each. Taking the
stated maximum capacity at the paunch table of 95 sacks/
hour, the material balance at the table can be summarized
in the following block diagram Figure 5.
The concentration of solids in paunch manure was determined
at random intervals throughout the preconstruction study
period. Examples of results of these laboratory tests are
presented in Table I.
TABLE I
PAUNCH SOLIDS CONCENTRATION
Sample Number Date
1
Paunch & Fluid 1/3 0/70
% Total Solids
14
2
Paunch
6/15/70
17.0
3
Paunch
10/13/70
18.5
4
Paunch
1.0/22/70
18.4
10
-------
Paunch Processing Area
Illinois Packing Co.
1215 GPH
12.79 gal./cow
Constant Water Flow
0
1
V
Paunch is
Laid Here
and Scraped
Clean
I
X
u
a)
•rl
u
J-t
m
cq
1274 GPH
12.10 gal./cow
Constant Water Flow
Water Lines
(not in use)
Paunch Wash
Paunch is
Emptied
1156 GPH: 12.17 gal/cow
Water for Table
o
a
<
M
O
O
I—I
fa
e
o
n
iw
-------
Table water 1156 GPH
Paunch Wash 1264 GPH
b->
NJ
Sack Rinse 1212 GPH
Table Area
Paunch
55 lbs./sack x 95 sacks/hr,
= 5230 lbs./hr.
To Paunch Tank
5230 #/hr. in 3632 gals./hr. H,0
FIGURE 5. MATERIAL BALANCE FOR PAUNCH WASH OPERATION
-------
Tbp> first result represents a sample of manure and sack
fluids, the others a sample of free drained paunch manure.
Samples of the waste paunch stream running to the sewer
were taken monthly by Illinois Packing personnel during
the four month period - April to July 197 0 and these
samples were sent to Pollution Control Laboratories Inc.
Chicago, 111. Results obtained are shown in Table II.
TABLE II
PAUNCH WASTE STREAM CHARACTERISTICS
Date (1970)
Parameter April 1 May 2 June 3 July 4
BOD (mg/ 1 ) 8,353 5,693 2,990 10,500
COD (mg/ 1 ) 16,334 7,108 11,178 12,534
DO (mg/l ) 0.1 0.1 0.1 0.1
Total Solids
(mg/ 1 ) 18,064 8,274 4,244 2,361
pH 7.40 7.25 6.20 6.55
Nitrogen,
Kjedhal (mg/L ) 238 463 259 291
Except for supplying data regarding ranges of efficient
concentrations, the above information was of little value
in further defining plant design parameters. Because of
the fluctuating stream concentration found, no further
sampling was deemed useful at the time. A scheduled, periodic
sampling program will be initiated six to eight weeks prior
13
-------
to the disposal plant start-up in order to establish
base line measurements for system evaluation purposes.
Paunch Manure Filtration Studies
The first experiments with the filtration of paunch
manure and water mixtures were made to develop
compressibility data for paunch manure on sand beds
using classical techniques (3) . These involve a
determination of filtration rate, filtration volume,
and pressure drop, and then calculating specific cake
resistance at several levels of pressure. The log of cake
resistance is plotted against log of P.; the slope of the
curve is designated as the compressibility S of the cake.
For paunch manure, which produced a mat-like cake because
of the presence of many straw like particles, the
compressibility S, was found to be 0.9 (vs. 1.0 max.).
A second group of experiments involved batch filtration
in a 3 1/2" Plexiglass column with varying static heads of
water above the beds. Results are shown graphically in
Figures 6 and 7 for two conditions of sand and manure in
layers and sand and manure mixed. Filtration rates were
better for mixed material but quite low for both cases.
Several different fluidizing materials are used by
Procedyne in its fluid bed systems. For incineration of
waste materials sand is the economical choice. Two specific
sands were used in the project and these are designated as
Sand MG and Sand P.
14
-------
s
§
s:
w
Eh
§
H
in
1
H
tn
W
o
y
r»
«c
30
25
20
15
10
one layer
two layer
three layers
0.1525
0.134
-P
4-1
•
U<
in
0.1072 1
Cn
M
JH
0.081
§
Cm
0.054
0.0247
WATER HEAD, IN.
FIGURE 6. FILTRATION THROUGH SAND AND MANURE IN LAYERS
15
-------
168
0.91
1" layer
0.78
144
0.65
120
0.52
96
0.391
2" layer
0.26'
3" layer
0.13
24
0
1
2
3
4
WATER MEAD, IN.
FIGURE 7. FILTRATION THROUGH SAND AND MANURE MIXTURE
16
-------
Approximate screen size distribution of these sands is
as follows:
Sand MG Sand P
(%) (%)
+ 30 m. 1 25
-30 + 50 m. 35 60
-50 + 80 " 30 10
- 80 " 34 5
The coarse sand P is somewhat purer and is more stable
as a recycle sand when quenched in the filter circuit. It
was the sand used for the subsequent filtration experiments.
In order to further investigate the filtration properties
of paunch manure-sand mixes, a third program of a group
of 15 fixed bed experiments were performed. These
experiments were performed in 3" and 8" cylindrical chambers
made of both steel and plexiglass depending on the need
for either pressure or visibility in each experiment.
As noted previously, various samples of paunch manure were
used throughout the entire experimental program and these
varied in concentration from 14-18%. Materials used in
Experiments 1 and 2 were from a 14% lot. Materials used for
the other 13 experiments were from a 17.1% lot. Sand to
manure ratios were held at 4:1, a value which permits a
reasonably economical operation of the sand recycle system.
The material itself was first filtered on a Buchner funnel
17
-------
using laboratory filter paper (repeating a procedure develop-
ed during the first group of experiments) in order to
establish a basis for comparison of results when using
sand as a filter medium. Results of those tests are
shown in Table III.
18
-------
TABLE III
FILTRATION TEST RESULTS
Expt. No,
A-l
B-l
M
VD
B-5
B-6
B-7
Technique
Filtration through
Laboratory Buchner
Same as A-l except sand
on an 80 mesh screen is
the filter bed-3" 0
column, 3" deep bed.
Simulation of deep bed
multilayer concept-3"0;
containing three, 4"
deep sand manure layers.
Filtrate removed by
free draining
Same as B-5 except
5 psig pressure use
on filter
Same as B-5 except each
4" layer of manure sand
was well mixed before
adding to filter.
Pressure was increased
to 10 psig.
Filtrate Results
TS(Total Sol.)=5360 mg/liter
T0C(tot. Organic Carbon) =
3 000 ppm
TS(1st. 15 sec.)=1300
TS (after 15 sec.)= 7330
TOC " " " = 5900
TS - 6910
TOC - 5540
TS-8870
TOC-6900
TS-7350
TOC-6060
Other Comments
Eaton-Dikeman
Filter Paper grade
512
Avg. filtration rate
0.91 gpm/sqf Rapid
blinding after 1st
15 sec. used to wet
bed 84% moisture in
cake.
Avg. filtration rate-
.115 gpm/sq.ft.
Avg. filtration rate-
.837 gpm/feq.ft.
Filtration rate average
1.5 gpm/sq.ft.
-------
TABLE III (Ccmt.)
FILTRATION TEST RESULTS
Expt. NO.
B-8
B-12
K>
O
B-13
Technique
Same as B-l except
the 80 mesh screen is
replaced by a sample
of porous stainless
steel belt.
Same as B-5 except
one manure-sand
layer followed by
one sand layer; no
pressure
Same as B-12 except
10 psig pressure
Filtrate Results
TS-7310
TOC-5530
Other Comments
TS-7230
TS-7650
Rate-.363
gpm/sq.ft.
Rate-1.74
gpm/sq.ft.
% moisture in
cake-81%
-------
Thf» following nonrlnsinns wore drawn from the above
series of experiments:—
(a) The basic filtration quality through lab filter
paper on a total solids basis (TS), was 5360
mg/liter and total organic carbon (TGC) was 3000
ppm. This establishes that there will be present
in the feed stock to the process, a fraction
containing certain minimum dissolved or colloidal
volatile solids. These cannot be removed by
normal filtration techniques. The concentration of
these dissolved and colloidal solids will vary
depending on several factors e.g. diet of the cow,
length of time in slaughtering process, age of
paunch manure before processing etc.
(b) Although several different kinds of experiments were
. made using sand as a filter media it was noted that
total solids did not increase much beyond 7 000 to
8 000 mg/liter for any of these experiments.
(c) Batch filtration rates are improved to some extent
with pressure (or vacuum) from under 0.2 gpm/sq. ft.
filter area to approx. 1.75 gpm/sq. ft. at
pressures of 10 psig.
(d) Cake moisture content could not be decreased to
below 81% (or 19% solids) on a sand free basis
during this series of experiments. This value is on
21
-------
the low side for antogenic incineration when
compared with an acceptable level of 2 5-30%.
(e) The most general conclusion reached was that the
filtration rates for paunch manure were dis-
appointing; the dewatering characteristics were
likewise. These results confirmed the work done
on compressibility during the earlier testing
program.
At this point in the process development program it
became necessary to change the process which had a single
dewatering stream to one which would have twos-
(1) A major dewatering stream-which would process
the fibrous and larger particles of paunch manure
to higher than 35% moisture levels.
(2) A minor dewatering stream consisting of the finer
paunch manure particles which would be processed
through the moving bed sand filter.
22
-------
SECTION III
PROCESS DEVELOPMENT
DEWATERING
Preliminary work in the laboratory was directed towards
the investigation to the extent of dewatering that could
be attained by the following treatments:
1) Simple dewatering
2) Pressure dewatering
The preliminary filtration studies indicated that only
the unbound water could be removed. These tests were
carried out using a simple screen and in later cases vacuum
filtration. The maximum attainable solids content was 18.5%.
Pressure dewatering tests were conducted using hand
operated rolls, of the type used for rolling metal in
metal fabrication shops. Three tests were run:
1- Paunch Manure containing 18% solids was put on a
screen and rolled. The solids concentration of the
rolled paunch manure was increased to 23%. The solids
concentration of the liquid extracted was 4%.
2- Paunch Manure (18% solids) was again put on a screen,
but this time was rolled and recycled continuously
through the rollers until no further liquid could be
extracted. The solids content of the material from
this test was 27%.
3- The third experiment was conducted to test the effect
of sand as a dewatering aid. 1/2 part of sand was
23
-------
added to 1 part paunch manure and processed through
the rollers. The solids concentration of the sand-
manure mix was 54%. Correcting for the sand, the
solids concentration of the paunch manure was 23%.
These tests (1 & 2) indicate that the solids content of
the paunch manure can be raised to approach the
autogenic point and thus economic operation.
Primary Dewatering
In the development of the flow sheet for this process the
need for simple (primary) dewatering became apparent.
This step was required to:
(a) Remove free draining liquid to reduce the load on
main dewatering equipment.
(b) Provide a constant feed stream to the main dewatering
equipment i.e. to eliminate any effect of large water
inputs upstream of the dewatering system.
Preliminary investigation into equipment for this service
indicated that it could be broken down into two broad
categories a) simple screens and b) vibrating screens.
The use of either of these two approaches for this duty
is classical in the chemical and mineral processing industries.
Simple screens are not normally used in dilute slurry
processing service. Their use is normally restricted
to the handling of- dry or near-dry solids. However,
recent developments in this equipment have been made by
24
-------
companies active in the meat packing, domestic sewage,
and pulp and paper industries. These screens, set at
predetermined varying angles, using patented screen
configurations, have the ability to dewater low solid
content slurries and discharge the dewatered solids
without clogging the screens. Screens of this type
are the Bauer Bros. Inc. "Hydrosieve" and the Dorr-Oliver
"DSM Screen".
The second category of screen available is the vibrating
type. There are many of this type available, the vibra-
tion to the screen being induced electro-magnetically,
by unbalanced fly-wheels or eccentric shafts. in this
type of machine, the vibration induced to the screen
ensures discharge of the solids deposited on it.
In an effort to provide a plant whose operation would be
ecoiiomic as well as simple, and based on the experience
of screen manufacturers in dewatering paunch manure, the
angle screen described above was given primary consideration.
The Hatfield Packing Co., Hatfield, Pa. and Wilson
Packing Co., Cedar Rapids, Iowa were visited to obser
this equipment in operation. Those operations supported
manufacturers claims that paunch manure could be dewatered
to 18% solids on this equipment.
Mechanical Dewatering
As described elsewhere in this report, the solids in
25
-------
paunch manure are a mixture of hay, straw,- gr^ir* anr)
corn. These materials are fibrous and cellular in
nature and contain, when dewatered of all surface
moisture, approximately 8 0% water.
The laboratory investigation conducted on this material
has shown that mechanical dewatering would be necessary
in order to reduce the quantity of water in this
material.
The investigation of the types of equipment available
to dewater this material uncovered the following:
1- The substantial work done previously in the dewater-
ing of this material was discouraging in that only
one device could be found to dewater this material
to the extent required.
2- No information was available as to the quality of
the liquid stream exiting from this dewatering device.
The solids concentration in this stream was not
available from previous tests.
3- The advancements made in dewatering equipment spurred
by recent interest in ecology would require investigation
for applicability to paunch manure dewatering.
4- Developmental work would be required to provide a
machine suitable for paunch manure dewatering.
5- Due to the inexperience of some equipment manufacturers
on paunch manure, actual operating tests would be
26
-------
required to judge the suitability of the various
machines offered.
Equipment Investigated
The following types of dewatering equipment were
investigated:
1- Screw Presses
2- Disc Presses
3- Rollers
4- Miscellaneous
Screw Presses
a) Conventional Design
This press is essentially a screw conveyor with the
cross-sectional area decreasing with the length of
the conveyor. This reduction is accomplished by
'either changing pitch of the screw or shaft diameter.
The exit is usually restricted so that the material
to be discharged is further subjected to compression,
usually by means of a pressurized cone.
Manufacturers of this type of equipment were contacted
and invited to quote on this application. Two
declined to quote and those quotations that were
received indicated that this type of equipment is
generally more expensive than the other types of
equipment available.
27
-------
It has been reported(1) that paunch manure particles,
after compression, tend to swell. This action in
a screw press tends to overload the drive, causing
the machine to stall.
A field test was conducted on a screw press and the
machine failed before any dewatered paunch manure
was discharged. Failure was due to an overloaded
motor.
Most screw presses are of the conventional design
described above. The quotations received showed
them to be expensive, no doubt due to the heavy duty
drives and motors required to accomplish dewatering
of this material.
Improved Screw Press
An improved design of screw press has recently been made
stvailable. It improves on the basic design of a conventional
screw press in that it incorporates an expansion zone to
compensate for swelling after compression. This reduces
the drive and motor requirement.
A device of this type was tested on paunch manure .(18% solids)
The test proceeded'smoothly with the paunch manure dewatered
to 38 weight percent solids. The liquid underflow stream
contained 3.5% solids.
Disc Presses
During the search for suitable equipment for the dewatering
28
-------
of paunch manure, it was found that extensive testing
had been done with this type of equipment.
This press consists of a pair of inclined screened discs
that rotate very slowly. The paunch manure is fed in the
top and is squeezed as it passes through the reducing
area caused by the incline of the discs.
The manufacturer reported that paunch manure could be
dewatered to 4 0% solids. Subsequent .investigation in an
effort to arrange for field testing showed that 1) presses
were not being used for paunch manure dewatering at the
present time 2) presses were not available on which to
test the material 3) data for the solids content, of the
liquid stream were not available.
Rollers
The application of rollers for dewatering operations is
old. It is the classical method for the removal of syrup
from sugar cane. Despite this, most roller manufacturers
are not inclined to quote on, or are disinterested in the
application of roller machinery to dewatering applications.
A3,though five manufacturers of roller equipment were
contacted, only one was interested in this application.
A developmental program was initiated and executed for
four months. After a discouraging start, machine development;
has progressed to the pojnt where the solids stream from
the rollers is 37%. This has been confirmed in two tests.
29
-------
"The liquid discharge from this equipment contains 6% solids,
the highest concentration of solids in the liquid stream of
any of the machines tested. Further development no doubt
could decrease this concentration of solids.
Miscellaneous
Investigation into the various types of dewatering equip-
ment available uncovered several miscellaneous machines
available for dewatering service.
a) Roller Type Hydraulic Press
This machine consisted of two rolls separated by a
floating ring. It had been used primarily in the
wood and pulp industry. Its main disadvantage was
the high hydraulic pressures required for its oper-
ation. This machine has been out of production for
some time.
b) Multiple Roller Presses
These units are a fairly new development finding
application in the sanitary field. It consists of
a porous belt that travels through several stages of
compression and shear rolls. The material to be
dewatered is placed on the belt and travels through
the rolls. Sufficient information was not available
nor units available for field testing with paunch
manure.
30
-------
Summary
The actual operating tests run in the field on paunch
manure showed that this material could be dewatered to a
solids content approaching 4 0%. This was accomplished
on both the three roll mill and the newer design of
screw presses.
Manufacturers of other equipment, namely the disc press
and conventional design of screw press, state their
equipment is also capable of attaining this solids com-
position.
In addition to the solids concentration of the solids
stream exiting from the dewatering equipment, it is
important that the solids in the liquid stream be held
to a minimum. This is a necessary requirement for the
process design of the disposal plant.
Thus,, in the selection of dewatering equipment, the con-
servation of solids is a prime requirement. Those solids
discharged in the liquid stream must be removed in addition-
al processing steps, and it is these streams which dictate
the quality of water leaving the process.
FILTRATION
It was found that liquid streams from the mechanical
dewatering devices could contain up to 4-5% solids in the
form of fines, colloidal materials and solubles. A fourth
group of filtration experiments were then conducted using
31
-------
feed streams having concentrations ranging from 0.7% to
4.85% solids. During the course of these experiments, it
was noted that the fines could be concentrated to some
extent by settling. Work on settling is described in a
later section of this report.
In addition to the use of classical techniques (Buchner
funnel & filter leaf) the Procedyne bench scale
regenerating filter was also used. This filter and its
auxiliaries are described schematically in Figure 8.
Typical results from that program are shown in Table IV.
From this last series of experiments it was concluded that
filtration rates up to 0.5 gpm/sq.ft. could be obtained.
In all of the batch or semi-continuous experiments during
Part I and Part II rapid blinding of the filtration area
took place with the formation of a thin manure cake.
This of course resulted in a rapid increase in pressure
drop and decrease in filter rate.
Only a continuous removal of sand and the manure layers
prevents blinding. This removal is accomplished while
dewatering takes place in a moving bed filter. Filtrate
qualities varied from 0.35 to 0.48% solids compared with .31%
solids . in soluble or colloidal form and represents material
which cannot be removed without additional treatment of the
water using tertiary treatment devices.
32
-------
TABLE IV CONDITIONS AND RESULTS OF EXPERIMENTS
EXPT. NO.
EXPERIMENT DESCRIPTION
FILTRATION
RATE
GPM/SQ.FT.
FILTRATE SAND QUALITY CAKE QUALITY
QUALITY %H20 %SOL. %SAND %SOL. %K20
CO
CO
Vacuum filtration with 0.215
sand, 0.7% solution
(initial) Buchner Lab
filter paper
Vacuum filtration 0.51
through Buchner
funnel without any
sand through lab filter
paper, feed concen-
tration C.7%, 11"
Hg vacuum.
Vacuum filtration 0.595
through 170 mesh
screen, 11" Hg. , 0.7%
initial solution,
Buchner Funnel.
Hot vacuum filtration 1.35
through 170 mesh
screen, temp. 165°F,
27" Hg., No sand,
initial conc. 0.7%.
0.41'
0.48%
0.464
0.342
initial
26.3% 1.67%
in the
sand
resev.
23
21.7 —
17.3 —
14.65
?rocedyne truncated
filter, P=IQ psi
sample is collected
on the screen, 0.7%
0.5
37
15
sol,
-------
TABLE IV CONDITIONS AND RESULTS OF EXPERIMENTS (contd.)
EXPT. NO. EXPERIMENT DESCRIPTION FILTRATION FILTRATE SAND QUALITY CAKE QUALITY
RATE QUALITY %H20 %SOL. %SAND %SOL. fel^O
GPM/SQ.FT.
7 Filtration through
truncated filter,
continuous feed of
0.7% sol. and sand
Sand rate 450 gins./
5 min.
0.44 0.494%
solid
38.7 9.3 —
Mixed Sand
Sand from screw
Truncated Procedyne
Filter, vacuum 14"
w.g. feed, 6400 gms
of 6.8% sol., 3,200
gms sand, 0.5 psi back
pressure.
86.73 1.84 11.4
87.6 0.31 12.1
0.5
0.9%
24%
3.7%
-------
16
Air
12
12
12
Vacuum
¦*5j—:
Pump
i*
A. sand and manure receiver
B. Sight glass
C. Pressure gauge
D. Pipe containing 1 3/4" diameter screw feeder
E. Filter chamber
F. Two 6" x 14" screens on both sides
G. Feed Hopper
H. Screw drive system
I. Filtrate receiver
FIGURE 8. REGENERATING FILTER
35
-------
SEDIMENTATION
As in the case with all commonly used dewatering devices
in which the solid stream is concentrated; the liquid
stream contains water soluble and colloidal solids and a
quantity of small particles in the form of fines. The
production of fines in the two streams from the two
dewatering devices has been described above.
The fines from the primary dewatering device were principally
small strawlike particles and tended to settle rapidly.
That stream was also fairly dilute. The fines from the
secondary device were somewhat more concentrated and
tended to settle more poorly.
Two specific sets of settling experiments were carried
out with the two types of particles px-oducedi The results
of these are described in the graphs presented in figi^res
9 thru 12.
As shown in the flowsheet developed for the process, the
concentrated, more difficult to settle fines are taken
through the filter directly and the easily settlable
materials from the primary dewatering device are settled
first before feeding to the filter. Filtrate from the
filter is recycled through the settler before sewering to
take advantage of the settler's capacity and residence
time.
36
-------
80
70
60
50
40
30
20
10
0
temperature 165 P
expected feed stream
from dewaterer. —
^ - Top Layer
0 - Bottom Layer
1.2
2.0
2.8
3.6
% SOLIDS TO SETTLER
3. 9 GRAPH OF % SOLIDS TO SETTLER vs. % OF LAYER
-------
80
70
60
50
40
30
20
10
0
CONDITIONS:
1) temperature 165°f
2) expected stream
from primary dewatercr,
O Top Layer
/\ Bottom Layer
0.4
1.2
2.0
2.8
3.6
4.
% SOLIDS TO SET'i'J.ER
FIG. 10 GRAPH OF % SOLIDS TO SETTLER vs. % SOLID SI
INTO LAYiWS
38
-------
80
A
70
60
50
40
30
x>
20
o
10
& - Top Layer
0 - Bottom Layer
0
1.
0.4
1
-1™
1.6
^'viv "¦ i
2.0
FIG. 11
0.8 1.2
% SOLIDS TO SETTLER
GRAPH OF % SOLIDS TO SETTLER VS. % LAYER SPLIT
2.4
39
-------
80
70
60
50
40
30
20
10
0
CONDITIONS:
1) Room temperature
2) Expected stream
from Bauer Hydro
Seive
/\ - In bottom layer
O ~ In top layer
0.4 0.6 1.2 1.6 2.0 2.
% SOLIDS TO SETTLOR
;,IG. 12 GRAPH OF % COLDS TO SETTLER vs. % SOLIDS IN TAYF.RS
40
-------
INCINERATION
A recently developed technique for disposing of sludge
from municipal waste treatment plants involves the use
of fluidized bed reactors. In this device, sludge con-
taining 25-30% organic solids is fed into a fluidized
bed of inert material at approximately 1400°F. The
reactor is capable of completely oxidizing (incinerating)
all of the organic material. This operating technique
is based on the principle long used for processing in
the chemical industry, that when solids are suspended
in an upward moving stream of gases, the mixture posseses
the characteristics of a liquid. The properties of this
fluidized bed, in terms of mixing, result in good heat
transfer which can be utilized effectively to incinerate
manure. Incineration of paunch manure in a fluid bed
reactor has not been attempted commercially. Incineration
studies were performed on a 6" bench scale fluid bed
reactor in order to establish the incineration character-
istics of paunch manure.
Description of Laboratory Apparatus
The experimental unit used for these studies consists of
a 6" diameter reactor made up of four sections. Each
section is made up of type 33 0 Stainless Steel. The
bottom section A (Refer Fig. 13) of the unit is called
the plenum chamber where the plenum burner is mounted.
41
-------
Free Board Section
(E)
Sand Over Flow
Section (D)
Radiant Barrier
Exhaust-Tangent
^Exit
Refractory Materia1
Reaction Zone
Annular Combustion
Zone of Radiant Bu^1'
Radiant Burner
Fired Tangentia.lly
into Annular (c)
Section \
Feed Zone
(B)
Feed Screw
Distribution Plate
Plenum (A)
Propane Burner
FIGUiCii 13. Conceptual Drawing - Proccdyne Fluid Bed Reactor
42
-------
There are provisions for a relief valve and for
excess air in the plenum- The plenum chamber is lined
with 3" of castable refractory. A metal distributor is
placed above the plenum chamber. This plate is similar
to a bubble cap distributor plate.
The section B above this distributor plate is called the
feed section into which the feed is conveyed by screw.
A radiant section C of 8" height is placed over this
4" feed section. The radiant section consists of an 8"
reactor section, surrounding which is an annular 2" space
around this 6" by 8" cylinder. Gas is fired through
this annular space tangentially by means of a North American
Burner. Castable refractory of 1" thickness is used
around the 2" annular section to protect the metal jacket
surrounding the radiant section. This metal jacket holds
the inside 1" thick refractory. The next higher reactor
section is a 4" refractory lined section which is accessi-
ble for refractory evaluation purposes.
The sand overflow section sits on top of this, and is also
a 4" section. The free board and expanded section (E)
completes the fluidized bed reactor. Detailed schematic
diagram are shown in Fig. 14.
General Test Procedure
The bed is initially heated to 14 00°F by means of both the
plenum burner and the radiant burner. When the steady
state temperature is attained, propane gas to the plenum
43
-------
T.\ATER IN
COMBUSTION
PRODUCTS
PROPANE
DC
i
o
r
i
e.
n
I EXHAUST GAS
A-2 | SCRUBBER
I
A
—[X}
r
S7
L\
WATER
OUT
! Vy
A - 1
| AIR j Cp>
'O'
-//-
1
¥
ZSFEBD |
SCREW
\
M-l
FEED
BIN
_J
!
t
i;
OPERATE
i i
! )
REACTION
j ZONE
{BED)
*L
_ ^, , BURNERS V1
fFiN vWVWW\AA/\/VTOj
STARTUP BURNER j ~
// j ^ IStr IBUT IC^I
] PLATE
N © D"j ;PLENUM
TT
€)
ir
^Tr
N.C.
CYCLONE
CARBON SAND
M-2^ PRODUCT
-------
and radiant burner and the air requirements are adjusted
according to the heat requirement of the material being
burned. Combustion air for paunch manure combustion
was supplied at 4% excess oxygen in the exit gases.
When the flow rates of air and gas are adjusted, sand in
the feed screw hopper is blown initially with air and the
screw is started. Sand, which is initially present in the
hopper, is fed to the incinerator slowly and then the
actual feed is started. The speed of the screw is
adjusted to give precalculated feed rates. Gas samples,
temperature and pressure measurements at various points
are taken when the feed rate and off-gas rate were uniform.
Several types of experiments were run during the early
part of the work on paunch manure. From a feedstock point
of view these could be divided into three general
catagories:
(1) Paunch manure at 18% dry solids plus sand in ratios
of 1 part manure to 4 parts sand.
(2) Paunch manure in the 28-31% dry solids range as
produced from squeezing in Procedyne's bench scale
rollers.
(3) Paunch manure-sand mixtures from early bench scale
filtration studies.
45
-------
Results from this experimental program were used in the
incineration scaleup calculations described elsewhere
in this report.
Data from one each of the three experimental catagories
are shown in the Table V.
TABLE V
PAUNCH MANURE INCINERATION EXPERIMENTS
Expt. Number
1
2
3
Feed Stock
Paunch Manure
31% Solids
Paunch Manure
18% Solids +
Sand
Filter Mix
3.36% solids
12.0% H20
84.64% Sand
Feed Rate
16.5 lbs/hr
11.0 lbs/hr
11.5 lbs/hr
Plenum Temp.
1500°F
143 0°F
1500°F
Bed Temp.
1300-1410°F
1465-1510
1590-1260
Fluid Bed Height
12"
12"
12"
Main Air Flow
3.5 Scfm
3.0
3.0
Heat input
23,2 00 Btu/hr
27,2 00 Btu/hr
18,200
Calc. Heat Loss
15,000 "
-
-
% CO in exit
.02%
tr.
tr.
On the basis of the low levels of CO present in the off-gas,
it was concluded that the residence time in the reactor
was too short. It was decided to increase the height
of the bed and another 4" high x 6" diameter section was
46
-------
added to the laboratory fluid bed reactor.
The experimental program was then continued. Feedstocks
for the program were chosen to simulate feeds from the
dewatering system being developed in the other
preconstruction studies connected with the project.
As before, one set of results from each of the three
types of feedstock experiments are described in Table VI.
TABLE VI
Expt. Number
1
2
3
Peed
Paunch Manure
37%
Solids
% Sol. 4.4 6
% H20 22.66
% Sand 72.70
% Sol. 13.15
% H20 31.40
% Sand 55.4 5
Rate
6.7 5 lbs/hr
12.6 lbs/hr
12.4 lbs/hr
Air for Combustion
3.9 Scfm
3.75 Scfm
2.89 Scfm
Plenum Temperature
1540-1480
1500
14 00°F
Bed'Temperature
1332
1300
14 00°F
Heat Supplied
17,3 00 But/hr
15,900 But/hr
17,3 90 Btu/hr
Radiation Losses
18,200
12,000
14,000
CO in exit gas
.04%
0.0%
0.05%
The general conclusions reached were that feeding of the
various feeds was very satisfactory, no major mechanical
problems were encountered and that paunch manure could be
burned satisfactorily, although 16" bed heights at this
47
-------
scale would be considered an absolute minimum.
Incinerator Design Considerations
The steps used in the basic design of the incinerator are
as follows:
(a) Calculate minimum fluidization velocity for the sand
to be used.
(b) Determine an operating velocity (based in part on
experimental results).
(c) Perform a mass balance on the system. Inputs are;
paunch manure + moisture, sand, fuel and air. Outputs
are products of combustion, excess air and ash.
(d) Perform a heat balance on the system. Heat inputs
are heat of combustion from paunch manure and heat
of combustion from fuel. Outputs are heat loss by
radiation and in exhaust cases.
(e) . -Gas flows in the fluidized system are the sum of
fluidizing and oxidizing gas required plus products
of combustion.
(f) The diameter of the reactor is determined from (b)
and (e)
(g) The height of the fluidized bed is determined em-
pirically from experimental results.
Fluid bed incinerators contain a distributer plate through
which fluidizing gas passes and which holds up the fluid
bed material.
48
-------
Tn designing the plate and its holes, calculations are
based on the following considerations:
(a) Hole spacing must permit uniform distribution
of the fluidizing gas.
(b) Bubble coalescence should not take place right at
the plate, otherwise channeling and spouting takes
place.
(c) Slugging of the bed should be avoided. This places
a restriction on maximum bubble size.
(d) Pressure drop across the bed cannot exceed 10% of the
total pressure drop.
(e) Limits are placed on the ratio of orifice diameter
to particle diameter.
One then proceeds with the following generalized approach:
(a) List fluidization \elocity, reactor diameter, height
..and inert material size.
(b) Assume a number of holes n and calculate bubble flow
per hole, hole spacing L^, bubble volume and bubble
diameter.
(c) Calculate maximum bubble diameter d and new
max
bubble diameter d^ resulting from the coalescence
between two adjacent bubbles.
(d) di Li estimated bubble volume is acceptable .
If not, a new diameter d2 is calculated and a distance
L2 between adjacent bubble tracks is taken as equal
49
-------
to 2*1.^. That diameter &2 i-s then coiapdreu with
L2 and the procedure repeated until d is less than
L/2.
(e) That bubble diameter d is the estimated maximum
diameter which must agree with dm_v in section (c).
IIlclX
(f) For the particular number of holes n and the
spacing, calculate pressure drop across the place
considering each opening as an orifice. This is
compared with an empirically determined acceptable
number.
(g) Each hole in the plate in an orifice and the
diameter of each orifice dQr can be determined, number
of holes n and mass flow.
(h) The ratio of the orifice diameter to particle diameter
is compared and must fall into an acceptable range
with pressure drop and weepage of particles through
the plate controlling parameters.
(i) This generally implies that several calculations are
made for various n's (number of holes) until a
satisfactory value of dQr is found.
(j) Thickness and detailed construction of the plate
will depend on weight of bed and temperature consider-
ations .
The free board in fluidized bed systems permits disen-
gaging of the solids from the fluidizing gas stream.
50
-------
The gas, in the form of bubbles, erupts on the surface
of the fluidized bed. These erupting gas bubbles can
and do intermittently splash solids into the free board
region above the surface of the bed. This intermittent
bursting action of bubbles causes velocity fluctuations
and these fluctuations smooth to an average velocity
at a certain height. If the gas exit is situated immed-
iately above the top of the bed, a considerable amount
of solids will be entrained by gas. With higher gas
exit, the amount of entrainment is smaller, and finally
a level is reached above which entrainment becomes approx-
imately constant and this height is called transport
disengaging height (T D H).
It has been found that the entrainment from a bed closely
sized solids is not significant until a superficial
velocity UQ considerably in excess of terminal velocity,
U^_ is reached. Under these conditions, free board acts
like a penumatic conveying tube. Thus, according to Zenz
and Weil, the solids that are conveyed become constant
and is termed as saturation carrying capacity of the gas
stream under pneumatic transport conditions initially
present.
Several investigations (4,5,6) have shown that elutrication
rates increase sharply with rising superficial gas velocity
51
-------
decrease with inurcasiny diameter of fines, and
decrease with increasing free board up to a limiting
value of the free board beyond which no further
entrainment occurs. However, T D H is not as sensitive
to gas velocity; it increases by about 70% for a doubling
in gas velocity. Hence, it is advisable to design
the free board of a fluidized bed very near to T D H.
In spite of the importance of T D H in fluid bed design,
there is very little information available on T D H except
for the work of Zenz and Weil on FCC Catalyst.
Virtually all the reported work on entrainment from
fluidized beds has been carried out with either of two
simplifications: Singly, closely sized fractions or a
mixture of two such fractions in a small laboratory units.
It was felt that these results may not establish a correct
criterion for elutriation since that column diameter,
particle diameter, particle density, density of gas, viscosity
of gas are effecting entrainment eitherway, depending on
the specific conditions.
Hence, for engineering design of free board for Procedyne's
fluidized bed reactor,T D H is calculated from the basic
concept of bubble theory and checked by using the correla-
tion developed by Zenz and Weil and as reported in a recent
oublication, (7)
As already pointed out the bursting action of the bubbles
52
-------
on thf> surface of a fluidized bed projects agglomerates
of particles into the space above the bed. These particles
(depending on size) will be carried by the gas into the
free board. Practically all the gas that is in excess of
minimum fluidizing conditions passes through the bed in
the form of bubbles. These bubbles grow in size as they
pass through the bed with a velocity that is higher than
superficial velocity of gas. While the bubbles travel
through the bed, they collide with other bubbles and trap
some solids in the bubble and wake. These solids that are
in the wake are also carried along with the bubble. When
these bubbles reach the surface of the fluidized bed they
burst, thus throwing the solids in the bubble in the
free board. At this stage, some of the solids will be
having a velocity equal to bubble velocity. When this
phenomenon occurs, some particles will be carried av;ay
in the free board by gas depending on the terminal velocity
of gases. Some of them will fall back into the bed.
The following generalized approach was therefore used in
calculating T D 11.
(a) Small bubbles form at the distributor, coalesce, grow
and speed up as they rise through the bed.
(b) The velocity of rise of a crowd of bubbles is related
to the velocity of rise of a single bubble in a bed.
The absolute rise velocity of bubbles in bubbling bed
is calculated by Davidson's (D) model.
53
-------
(c) Bubbles are assumed to be spherical anrl t^pir
diameter are calculated by Davidson's(8) model.
(d) When a bubble bursts, the particles in the wake and
bubble are thrown up. The particles whose Ut-dUj-,,
are carried in the free board.
(e) The frequency of bubbles at the surface of bed is
calculated from n = 1.5 (UQ - Umf)
(f) The voidage of the wake in the bubble is equal to
the voidage @ .
(g) Ratio of volume of wake to bubble is taken to be 0.2,
for irregular sand from the data of Rowe and Partridge
(h) The basic eqauation for entrainment is came as that
used by. Lewis et al (10) .
(i) The entrainment rate is maximum 1% of the total sand
.in the bed per day.
54
-------
IV PROCESS CALCULATIONS
Basis for Design:(1)
95 cattle x 55# paunch manure = 5225# paunch manure
hour cattle hour
Now, paunch manure as removed from the sack is 14% (wt) dry-
solids, this is equivalent to:
5225# paunch manure x 14_ = 731# Dry solids
hour 100 hour
Paunch Table Operation
The paunch manure, after removal from the sack is free
drained, draining to 17% Dry solids, the water drained
containing dissolved and very fine solids.
731 = 4310# paunch manure (after draining)
.17 hour
5225 #/hour - 4310 #/hour = 915#/Hr. Total material
drained away.
Solids in drainage is 3000 ppm
915 #/hr. x .003 = 3#/Hr. solids in drainings.
Based on the calculations above, stream OA is composed of
the following.
Paunch Manure Total Dry solids Water %Solids
(As Rec'd) 5225 731 4494 14
Paunch Manure(drained) 4310 728 3582 17
Paunch Manure Drainings 915 3 912 0.3 •
Water is added for the following:
STREAM FUNCTION
OC Table Rinse
OD Sack Wash
OE Sack Rinse
55
-------
At present, at Illinois Packing Co., these three streams are
continuous, each approximately 20 gpm, or a total of 60 gpm.
Significant improvements in the disposal plant efficiency
will be realized by installing foot pedal valves OC and OD.
This will result in significant water savings, estimated at 2/3
of the present water usage. The new water rate is assumed to
be 20 gpm. This figure is designated stream OB. Stream OE,
the sack rinse, will be sewered directly.
P re sent System
' ' OC
OE
A
OE
..-"T
OB
Present Water Flow - 60 gpm (20 gpm each flow)
Pedal Controlled System
OB
1—[XI—
A 00
—[X3—
-"<3—
OC
56
-------
Under this system, OB will flow at rate of 20 gpm.
20 gallons x 6 0 minutes x 8.33# = 10,000 #_
minutes hour gallon hr
It is assumed that this water will extract fine particles
of paunch manure in range of 3000 ppm.
10,000# x 0.003 = 30# fine solids
hour
Stream 1, exiting from the paunch table is composed of
streams OA and OB and is as follows:
OA OB Total Stream 1
Free Water 912 10,000 10,912
Bound Water 3582 3,582
Dry solids 731* 731*
15,225
*of this 731# of Dry solids, 33# is estimated to be dissolved
or very fine solids.
PAUNCH BIN
This stream (1), is fed to the paunch bin which functions
as both surge bin and feed tank to the remainder of the pro-
cess. The plant design is based on a 16-hour per day operation,
or an hourly rate of 365.5 of paunch manure on a dry basis.
Feed to process: (Stream 2A)
Free water 5456.0
Bound water 1791.0
Dry solids 365.5
7612.5
57
-------
Primary Dewatering
Dewatering
7247
Solids
Water
3A
1.
2.
3.
The expected yeilds in streams 3A and 3B are as follows
a. 3A = .8 of total solids in 2A = 292 #/hr.
b. 3B - .2 of total solids in 2A = 73 #/hr.
c. Solids in stream 3A = 18%
Water in Stream 3A:
= 1625 #/hr. - total weight stream 3A
29 2 ,_4
"Tl"8~
1625 - 292 - 1333rr/hr. water in stream 3A
Water in Stream 3B:
Total water - water in 3A = water in 3B
7247 - 1333- 5914 #/hr. (8)
4. Determination of Bound Water - Stream 3B only:
Total water - free water = bound water
5914 - 5456.0 = 458 #/hr.
5. Solids Concentration in 3B:
7_3_
7 3 " + "5914
X 100
1.22%
58
-------
6. Thus, balance about the primary dewaterer:
Dewaterer
Solids 365#
Water 7247#
% Solids 4.8%
Solids
Water
% Solids
3A
292#
1333#
18%
Solids 73#
Water 5914#
% Solids 1.2%
Stream 3A, the solids rich stream, goes forward to the
dewaterer, stream 3B, relatively weak in solids, goes to
the settler for thickening.
Dewaterer
Stream 3A is fed directly to the dewaterer, yielding 2 streams;
4A, high in solids content and 4B, a liquid rich stream.
3A
v>,
Solids
Water
% Solids
292#
1333#
18%
4A
1. The expected compositions of 4A and 4B are as follows:
a. 4A has a composition of 40% dry solids
b. 4B has a composition of 5% dry solids
c. 82.5% of entering solids in stream 3A will be recov-
ered in stream 4A
59
-------
Let stream 4A - X and 4B = Y
Total weight of stream 3A = 1625 #/hr.
Therefore X + Y = 1625#
and
Simultaneous solution of these equations yields the
following:
Stream 4A + 4B = ' 3A
Water
Solids
Total
364
241
969
51
605 #/hr. 1020 #/hr.
Thus, balance about the dewaterer:
1333
292
1625 #/hr.
3A
Liquids = 1333
Solids - 29 2
% Solids
1%
Dewaterer
4A
Solids
Liquid
% Solids
= 241
- 364
= .4 0%
Y
4B
Solids
Liquid -
% Solids
51
- 969
5%
Settler and Filter
Stream 4A is fed directly to the incinerator, Stream 4B is
sent directly to the sand filter where combining with Stream
6A (from the settler), it is filtered, the solids Stream 7A
going to the incinerator, and the filtrate 7B going back to
the settler for further treatment. This is shown schematically
on the following page.
60
-------
2A
3A
-£>»
3B
4B
7A
-JNji
6A
— ——
I
Dewaterer
Primary
Dewaterer
Settler
Filter
Incinerator
It can be shown that those streams indicated by the dashed
lines (6A, 6B, 7A, 7B) are dependent on the settler and filter
performance. Stream 7B is recycled, effecting both stream 6A
and stream 6B which in turn effects stream 7A and 7B, and so
forth. By a series of consecutive, iterative calculations,
these streams are determined to be:
Stream
6A
6B
7A
7B
Dry Solids
69
37
87
33
Water
1625
6453
430
2164
% Solids 4.1% 0.58% 0.17% 1.57%
Stream 4B, the required sand for filtration is also arrived at
by these calculations. This value is 1352# sand/hour.
US proiM.-i\
Corvaihe Environments] Hessarch
200 S.W. 35ib Street
Corraili®, Oregon 07330
-------
Incinerator
The feed to the incinerator has been determined to be:
Stream 4A 7A Total
Dry solids 241
(#/hr) * B/ 328
Water (#/hr) 364 430 794
Sand (#/hr) - 1352 1352
This is 90% of the total dry solids entering the process,
being fed to the incinerator as 29.4% solids (sand free basis).
The following process design criteria have been determined:
a. % ash in dry solids - 8% ^
b. Heat of combustion of paunch manure - 7200 Btu/hr. >
z f
c. Excess Air (dry basis) 4%
d. Paunch manure taken to be cellulose.
Material and Heat Balance Calculations:
1. Feed to Incinerator
a. Pounds of combustibles present:
329.4 (.92) = 303 #/hr
b. Pounds-moles of combustibles present (as cellulose):
(M.W. Cellulose = 162 #/hr-mole)
303 = 1.87 #-moles
162 hour
c. Combustion equation:
C6H10°5 + 602 6C02 + 5 H2°
c.l. Stochiometrie quantity of Oxygen required for
complete combustion:
(1.87) (6) = 11.22 # - moles/hr.
62
-------
c.2. Amount of Nitrogen, (a)-above provided by air.
11.22 #-moles C>2 x 3.76 # moles N2 = 42.2 # moles N2
HR. # mole 02 HR.
d. Water present in the feed.
793.6 # H20 x 1 # mole H20 = 44.1 .# moles H20
Hr. 18 # H20 Hr.
From combustion of paunch manure
a. C02 from combustion of paunch, from combustion equation
1. 87 x 6 = 11.22 # moles CC>2
b. H20 from combustion of paunch, from combustion equation
1.87 x 5 = 9.35 # moles H„0
" ¦ — ' ' " £
HR.
c. Nitrogen present (l-c-2) above
42.2 # moles N2
hr.
d.- Water present in feed (1-d) above
44.1 # moles H?0
hr.
Heat from Combustion of manure
303 #/hr x 7200 Btu/# = 2,181,600 Btu/hr.
O
Heat Output (All Discharged at 1400 F)
a. Heat required to heat water in feed: to 1400°F
793.6 x 1700 = 1,345,000 Btu/hr.
b. Heat required by CO2
NCPA T = Q
11.22 x 1328 x 11.48 Btu = 170,800 Btu
hr.
63
-------
c. Heat required by H20 formed.
(9.35) (18) (1700) = 286,000 Btu/hr
d. Heat required by N2 present
(42.2) (7.35) (1328) = 412,000 Btu/hr
e. Heat required by excess 02 present:
Let X represent # moles of excess 0^
X (7175) (1328) = 10,280 X Btu/hr
f. Heat required by excess N2 present:
excess N2 = 3.76 x
3.76 (x) (7.35) (1328) = 36,700x Btu/hr
5. Heat losses from System
a. Incinerator - 9.5' O.D. x 23.75' high
b. Area of shell - II D H
(3.14) (9.5) (23.75) = 710 ft2
7
c. Area of Heads = II D
4
. • 3.14 (90) (2) = 142 ft2
4
d. Total exposed area of incinerator = 852 ft2
e. Total heat losses;
852 ft2 x 4 40 Btun = 375,000 Btu/hr
ft £
6. Heat Loss From Recirculating Sand:
1362 x .25 x 1328 = 450,000 Btu
hr
7. Summation of Heat Losses
Water in Feed 1,345,000
CO2 formed 170,000
64
-------
E^O formed
N2 present
Excess 02
Excess
412,000
286,000
10,280x
36,700X
Surface Heat losses
375,000
Recirculating Sand
450,000
Total Heat Losses (Btu/hr)3,038,800 + 46,980x
8. Total heat requirement
Heat losses - Heat supplied by combustion of paunch =
heat required.
3,038, 800 + 46,980x - 2,184, 600 = 857, 200 + 46,980x(Btu/hr)
65
-------
Calculation of Fuel and Air Requirements:
The calculations are based on a fuel oil composition of
87% Carbon, 12% Hydrogen and 1% Sulfur, and exit gases from
the incinerator at 1500°F. The basic equations used are
common to the combustion literature (ll)and calculations
are developed as follows.
1. Heat available; .87 #Carbon 66 BTU
1# combustible" Scf air
2. Air required (Scf) = Btu/hr required
66
3. Air required (lb.-moles) = BTU/hr. required
23.694
4. 0^ in this air (lb-moles) = BTU/hr. required
113,000
5. N2 in this air (lb-moles) = BTU/hr required
30,000
Air required for combustion:
6* Air required (Scf) = % C(1.514)+ %H (4.54)+%S(. 568)
• ' #Fuel
- 188 Scf or .525 lb.-moles
#Fuel #Fuel
7* C0o formed (Scf) __ . 315(%C) = 27.4 Scf
#Fuel # Fuei
or .076 lb-moles CC>2
# Fuel
8. H00 formed (Scf)
_± = 1.89 (%H) = 22. 68 Scf
#Fuel ~~FGil~
or .06 3 lb.-moles H^O
l~Fuel
66
-------
From equation (3) and (6) above:
9. .525 lb.-moles Air x N# Fuel _ BTU/hr required
#Fuel . 23,694
or* N=Fuel required = BTU required
12.500
Rewriting equations (7) and (8) above:
10. lb.-moles CO« formed = .076(BTU required)
1 ( 12,500 )
=5.2 + .284x
11. lb.-moles H00 formed = .063 (BTU Req'd)
A 12,500
=4.32 + .236x
Summation of Products
co2 h2o n2 O
A 11.22 9.35 42.2
B — 44.1
C (5.2 + .284x) (4.32 + .236X (28.5 + 1.56X
D — — 3,76x
Where:
A = Products of combustion of paunch manure.
B - Water in paunch manure.
C =Products of combustion of additional fuel.
D = Excess Air
Thus:
C02 = 16.42 + .2 84X
H20 = 57.77 + .236X
N2 = 70.70 + 5.32 X
o2 - X
67
-------
Calculation of excess oxygen on a dry basis:
Total moles of dry gas = 87.12 + 6.60x
= . x X = 4.76 lb.-mole
100 87.12+6.604x Hr
Composition of Flue Gases (lb.-moles/hr.)
CO<2 17.77
H2° 58.89
n2 95.90
°2 4.75
177.31 lb.-moles/hr.
Additional heat required:
BTU (required) = 857,200 + 46.980 x
hr
= 1,080,000 BTU ^
Hr.
Fuel oil required:
N = BTU/hr required 86.5 #/hr. -
127500
Air requirement (lb.-moles/hr.) :
For manure combustion 53.4
For fuel combustion 45 5
For excess air requirement 22.7
121.6 lb.-moles/h
or:
121.6 3^.-mol£s x 359^ _ 727 SCFM
60
Effect of sulfur content of fuel; sulfur content is
assumed at 1%.
68
-------
86.5 (.01) = .027 lb.-moles sulfur
32
S + o2 so2
O
2 requirement for sulfur = .027 lb.-moles.
SC>2 in stack = 0.027 lb.-moles/hr.
Composition of stack gases:
C02 17.77
H20 58.89
N2 95.90
O, 4.75
S02 0.027
177.337 lb.-moles/hr. (1064 SCFM)
Solids content of incinerator exit gases. This stream is
based on the following 1) solids discharge is composed of
ash and sand, 2) all ash is carried over, and 3) sand carry
over is equal to 1% of bed capacity per 24 hrs. of operation,
Ash content 26 #/hr.
Sand content 10 #/hr
Loading to cyclone _233 grains
Scf.
Cyclone
Gases to cyclone (lb.-moles/hr.)
C02 17.77 •
O, 4.75
N2 95.90
H20 58.89
S02 0*03
177.34 lb.-moles/hr.
69
-------
The solids to the cyclone as shown above are 26 lb./hr
of ash and 10 lb./hr. of sand. Based oil a soliuy collection
efficiency of 90% of all particles above the 5 micron size
and a particle size analysis as follows:
Sand - All above 5 micron size
Ash - 32% 0-5 micron
36% > 5-10 micron
23% >10-20 micron
8% >20-40 micron
1% >40-80 micron
On this basis it is assumed that 100% of the sand and 60% of
the ash entering the cyclone will be collected.
Collected in cyclone:
Sand 10#
Ash (26)(.6) 15#
Solids loading to scrubber:
Ash - 11# or 72 grains/ scf.
Scrubber
The stream fed to the scrubber is a s follows:
Gases (lb.-moles/hr)
C02 17.77
°2 4*75
N2 95.90
«20 58.89
S02 _ 0.0 3
177.34 lb.-moles/hr.
70
-------
Solids
Ash ll#/hr (72 grains/scf.) This stream entering the
scrubber will be at 1400°F. The gases exiting from the
scrubber will be saturated and leaving at 185°F. The
water evaporated in the scrubber is 15 85 #/hr.
Composition of gases leaving scrubber (lb.-moles/hr.):
C02 17.77
02 4.75
N2 95.90
H20 146.90
S°2 0.03
265.35 lb.-moles/hr.
Solids from Scrubber
Scrubber is to be sized on 1/2 the maximum allowable
particulate emission (City of Chicago Environmental Control
Ordinance, Chapter 17)of 0.2 grains/scf. at 50% excess
air. The allowable emission under this code is 4.1 #/hr,
the design criteria is 2.0 #/hr. or 0.1 grains/scf.
71
-------
Solids
Ash llfc/hr (72 gr?.i ns/scf. ) This stream entering the
scrubber will be at 1400°F. The gases exiting from the
scrubber will be saturated and leaving at 185°F. The
water evaporated in the scrubber is 1585 #/hr.
Composition of gases leaving scrubber (Ib.-moles/hr.):
C02 17.77
02 4.75
N2 95.90
H20 145.90
S02 0.03
265.35 lb.-moles/hr.
Sold,ds _f rom_ Scr ubbc r
Scrubber is to be sized on 1/2 the maximum allowable
particulate emission (City of Chicago Environmental Control
Ordinance, Chapter 17)of 0.2 grains/ccf. at 50% excess
air. The allowable emission under this code is 4.1 if/hr,
the design criteria is 2.0 #/hr. or 0.1 grains/scf.
7 1 a
-------
ECONOMICS OF AN AIR PREHEATER INSTALLATION
The temperature which the air is heated to will be 1200°F.
This provides a maximum -amount of heat transferred to the
air, while not pinching in the warm end temperature difference
in the heat exchanger to too low a value (200°F).
Let X = lb. moles/hr of excess
then 53.4 + 10OX is the lb moles/hr of air, following the
21
calculation procedure already established. This does not
include air for combustion of supplementary fuel. The total
heat losses with no air preheating, as previously computed are:
857,200 + 46,980 X Btu/hr
Heat added to the system by preheating the air with flue gases
is: (53.4 + lQQX) (7.3) (1200-72) = 439,000 + 39f200X Btu/hr
21
Therefore the heat losses are reduced to:
418,200 + 7,780X
For supplementary fuel with flue gases leaving at 14O0°F.
66 Btu of heat are available for every scf of air used in
supplying supplementary heat.
Using the same equation numbers as in the master calculation:
3. Air required (lb moles) = Btu/hr required
hr 23,694
4. 0^ in this air = Btu/hr required
113,000
5. n2 in this air .= Btu/hr required
30,000
6. Air required for combustion of 1 lb. of fuel, oil is
0.525 lb. moles as computed previously
7. CO2 formed = 0.076 lb moles/lb fuel
8. K^O formed = 0.06 3 lb moles/lb. fuel
From (3) and (6)
N = no. of lbs. of fuel oil/hr = Btu/hr required
12,500
Rewriting equation (7) and (8) above =
71 b
-------
10. lb moles CO„ formed = 0.076 (Btu
^ ,r—— required
hr l££
12,500
=»_ 2.543 + 0.0473X
11. lb moles H_0 formed « 0.0631 (Btu
* tEr~ recluirec3
12,500
= 2.11 + 0.0392X
SUMMATION OF PRODUCTS
C02 H2Q n2 02
11.22 9.35 42.2 ~—
B- —— 44.1
C. (2.543+0.0473X) (2.11+0.0392X) (13.94+0.259x;
D. 3.76X X
Where:
A. = Products of combustion of paunch manure
B. = Water in paunch manure
C. = Products of combustion of additional fuel
D. = Excess Air
C02 = 13.76 -*• 0.0473X
H2° = 55.6 + 0.0392X
N2 = 56.1 + 4.02X
°2 - *
Calculation of excess 02 on a dry basis = 1%
4 X
100 69.86 + 5.067X
X = 3.50 lb moles 02/hr
Composition of f gases
C02 13.96 lb molas/'hr
H20 55.74
N2 70,2
07 ...
2 -1 3.40
Addit.-lov. ;.:.rsd - 4." • -"CO + 7 r 780.: -- 445 ,400 Ecu
P uoJ. o:.¦' '' •; o o - 3S. '• • /v -
-------
Air requirement (lb mole/hr)
For manure combustion 53.4
For fuel combustion 18.7
For excess air 16.7
88.8 or. 531 SCFM
Fuel Oil Required Air Required
lb/hr SCFM
No preheater 86.5 727
Preheater 35.7 531
Annual savings in fuel (4000 hrs/yr operation)
50.8 lb x ga_l x $0. 10 x 4000 hr = $2730.
Kr 7.4 4 lb gal yr
Annual savings in blower electricity (based on centrifugal
blower performance)
14.4 BIIP x (727-531) SCFM = 4.7 BHP
600 SCFM
4.7 BHP x kw x 1 x 400 0 hr x $0.02 = $331'.
TT34 HP UT85 yr Ewh
Capital expense of additional blower capacity - $300.
Btu/hr transferred in preheater
Air goes from 130°F to 1200°F
531 SCFM x 60 Min x 7.3 BTU x (1200-130) °F = 694,000 BTU
359 Kr lb mole °F j7r"~
Heat released by cooling products to 500°F (computed for
determination of heat capacity of this stream)
co?
13.96
[ (1400-77)
11.45 -
(500-77)
9.9]
=
153,100
HO
55.74
[ (140C-77)
8.92 -
(500-77)
8.2]
=
46 5,000
«2
70.2
[.(1400-/7)
7.35 -
(500-77)
7.1]
=
472,500
CM
O
3. 50
[ (1400-77)
7.75 -
(500-77)
7.2]
=
25,300
Total Heat Released
1,
115 ,900
-------
1,200,000
1G00
temperature. "
F:CHRE
\r
Pr
-------
Using the attached graph, a stream with this heat capacity would
only be cooled to 900CF.
Based on a previous quotation for a heat exchanger in similar
service, the purchase price of this heat exchanger is estimated
at $16,400 plus $3600 for installation. A cyclone would have
to be added to protect the preheater from erosion. Because the
incinerator itself could be smaller due to lesser air requirements,
the savings in incinerator cost is estimated at $3000; however the
plenum chamber and distributor would have to be designs for high
temperature. The extra cost incurred for this would be about
$6000. Net increase in incinerator cost is then $3000.
Net change in operating cost after preheater addition =
Fuel $2730/yr
Electricity 331
$3061/yr savings
Net change in investment after preheater addition =
Cyclone (refractory lined) $ 5,000
Preheater 20,000
Elov/er - 300
Incinerator 3,000
$ 27,000 increase
Return on investment before taxes = 3061 „ 10Q _
$ 27,000
This is the minimum ROI most companies would consider. The
fact that the corrosion and erosion problems have been severe
with known operating units would dissuade all companies from
this investment for this particular plant.
71f
-------
ECONOMICS _OF_ A WASTE HEAT BOILER INSTALLATION
Heat available when flue gases, as shown in the master calculation,
are cooled to 500°F.
C02 17.77 lb moles 195,000 BTU/hr
H2° 58. 89 Frf 491,000
N2 95.90 645,000
°2 4-75 34,000
1,365,000 BTU
Kr~
This would be equivalent to
*
1,365,000 = 11.6 gal/hr fuel for steam generation
118,000
or 11.6 gal $0.10 „ 4000 hr as a credit
1 X * Jl 1 • - - •• X ¦ —
hr gal yr
A conventional industrial waste heat boiler could be purchased
for about $10,000. The erosion problem resulting from the
carryover from fluid bed incinerators would require installation
of a hot, refractory-lined cyclone at about $5000.
Special corrosion problems known to exist from trace components
with off gas from incinerators may raise this to $25,000. Piping
and installation, tying into the existing steam system, and
instrumentation could bring this to $35,000.
Operation of a boiler in accordance with local codes usually
requires an operator or part of an operator if the boiler is
located m the pov/erhouse. ¦ Assume the effective labor rate for
boiler attendance is $0.50/'hour - This is a very optimistic rate
and depends on the waste heat boiler be.'.ng part of an installation
of several standard boilers.
The estimated return on investment before taxes would than be
(4000 hr/yr operation) :
$4640/yr - $2000/yr x 100 = 7.5% which is extremely unactract
$35,000
72 a
-------
V SUMMARY OF THE PROCESS DESIGN
Description of the Process
The process equipment flowsheet for the processing of
paunch manure is shown in Figure 14 (Procedyne Corporation
Drawing D-05149).
Paunch manure and fluid from the paunch sack (OA), plus
water from the table and from sack washing operations (OB),
currently runs by gravity to an existing paunch storage bin.
A new screw conveyor (2700) will be installed in the bin to
feed paunch to the slurry transfer pump (1100).
Stream 2A, from the transfer pump (1100), is fed to the
primary dewaterer (1200), a screening device which separates
the coarse solids in the paunch manure stream (stream 3A)
from the free water and fines (stream 3B). That stream is
fed into a dewaterer (1300) which discharges material with
solids content raised to approximately 37% (stream 4A).
Stream 4A is fed into the fluid bed incinerator (0100) via
screw conveyor system (1400). Stream 4A contains approxi-
mately 2/3 of the solids to be incinerated.
Returning to the screening device (1200) , the liquid streaw
3B is fed into a settler (1500) where it is settled before
becoming part of a feed stream to sand filter (1700). That
feed stream (6A) is combined with the liquid,stream (4B) from
the dewaterer and transferred via transfer pump 1600 to fil-
ter 1700. Solids content of stream 6A + 4B is estimated to
be approximately 4.5% and contains approximately 1/3 of the
72
-------
solids to be incinerated by the fluid bed incinerator 0100.
Filter 1700 is also fed with clean recycle sand overflowing
from incinerator 0100 (stream 5B). Product stream 7A from
the filter, containing approximately 15% solids (on a sand
free basis) is fed to incinerator 0100 using screw conveyor
system 1800. Makeup sand (stream 5A) is also added via con-
veyor 1800. Filtrate from the filter (stream 7B) is recycled
back to settler 1500 and combines with other streams from
the dewatering part of the process before entering the sewer
system as overflow from the settler 1500 (stream 6B).
Fluidizing air (stream 5C), which also supplies oxygen for
combustion, is fed to incinerator 0100 from blower 2400. Com-
bined feed streams 4A and 7A are expected to contain 25-30%
solids on a sand free basis, as well as the recycling sand
used for filtration.
The system is expected to be self incinerating at approxi-
mately 30% solids content. Burner system 1000 is used to burn
a small amount of oil (5D) to maintain the incinerator tempera-
ture at approximately 1500°F during periods of high moisture
feed. A burner-fuel system is also required to start up the
system, bringing the temperature of the incinerator to to at
least 1300°F before starting a feed stream.
Stream 5A contains the products of combustion, cc>2 and water
and excess air required by the process, as well as a trace
of fluidizing sand carried away from the incinerator by the
73
-------
combustion gases. That stream flows through a cyclone
separator (1900) which removes a high proportion of the
solids from the combustion gases, dropping them into port-
able ash bin (2000) via stream 8B.
Exit gases leave the cyclone (1900) as stream 8A and are
fed to a water scrubber (2300) for cooling and final removal
of particulates before entering the atmosphere via stack
9A. Scrubber (2300) is part of a system which includes tank
(2100) to which makeup water is added via stream 9B. Circu-
lating pump 2200 circulates scrubbing water over scrubber
(2 300). Overflow water from tank (2 300) enters the sewer
via stream 9C. Solids, which accumulate by settling in tank
(2100) , are removed periodically as a wet ash.
74
-------
Major Equipment List & Material Balance
The ma]or equipment list tor the process is as follows:
ITEM
DESCRIPTION
0100
Procedyne Fluid Bed Incinerator
1000
Burner
1100
Slurry Transfer Pump
1200
Primary Dewaterer
1300
Dewaterer
1400
Paunch Conveyor
1500
Settling Tank (Procedyne)
1600
Filter Feed Pump
1700
Procedyne Sand Filter
1800
Sand Conveyor
1900
Cyclone
2000
Ash Bin (portable)
2100
Scrubber Feed Tank
2200
Scrubber Feed Pump
2300
Scrubber
2400
Blower
2500
Panel Board (Procedyne)
2600
Settler Feed Pump
2700
Paunch Bin Conveyor
Figure 16 (Procedyne Drawing D-05141) gives the results of
all calculations made on process flows. Streams described
above and illustrated in Figure 15 are all defined in terms
of flow rate. Data used for the calculations are described
in Section II and calculations presented in Section IV.
75
-------
o*
i
9A
0103
5£
To;
,go
'OC
KOO
e ?;
5C
75
EQUIP?/
EM LIST
0100
INCINERATOR
tooo
6URN£R
1 (00
slurry t«an:tcr puwp
1200
PRlVARY Dt A'ATEPER
1100
S£tt'AT£SER
1400
PAUNCH CONVEYOR
1500
SETTU\G TANK
1600
filter teed pu«p
iroo
SAnO FfLTER
1600
SAr:o conveyor
1900
C*Cc.Or;E
??CC
ASM S^N IP0*7A=LE)
Zioo
SC«JC.2I* FEcD tank
2200
SCF.osSER fZZZ PJ\'.P
23C0
SC«-j9jER
2«00
SLOWER
25C0
rAT.'cL &GA5D
ZZ03
SETTLE^ feeJ Pjyp
270?
r'A'J%C*• S:\ CON'VErCR
-------
¦*1 f"-
A4
MHCM
TA6LI
CYCLO^C
tana
ZA
<*!&?///*
3A
PtWATLRCR
' ie
t*
,r AS
*A
IHat/UtXTOSf
'*e
SB
fn tea
se
94
$CRi)£B£X
"IwL
1
STRtAM
UMTS O* I 00
1 B.D.I
2 \ V*AT£R fBOUHQ)
3 '. WATftt (Tft££}
4 water (total)
5 [ SAW _
6 ASH
7 "imil S7/&AM
7 i; Z4I SI 1 - j -
•~*r 73^ - rJi ; xj< m
OUt'iaz - ' iset\n9i\i'n3-'ist i 3« - ') - / - ,' - ;- -- , -
I I-- t • - t ; • 1" 1" ' ';
*/m ft tjoea ic'ii .us*.' - jf«i - - , - j - j -. . " : " . *" .
#/}*{ 44*4 /$0M *t,4*4 7&f\t3S3 jSfl* -344 *»* - - i - j - - K>ts HO IK*
- | -- w nsi -
fA* - — —
1/& - - -
«» *p*> efts
o fuct arc
»! MR
JO FLUE GASES
//icoi "
tr\<>z
"""
*\n{o
a\s°2
1/6 TOTAL
2A I 3A
~y
33 • 4A ' tB ¦ SA 58 I SC SDH 6A 60 . Ta 70 M .03 i 9A | 93 j ?C
.... U'W ¦¦«« I !¦'¦' .mi ^ . i... ... i ¦ - I j —¦
..-¦69
37
ST \ 3 3
/ 0
- t35Z
¦ - - ; i» * - :
7mi \/&t5 jSSv (OS reia I 3* /3Sl'.
*f*m
—S? ~ !
sax - , — i. — I —
i&jjT- u—'
!
•M*a _ _ i _ | -
"Tf .
I
~* ' i
Wlffj — | — —
; - : -
•^5. - ! - . -
sc" - \ - - A
//
10 1/57 //
- 37S0
' /0 I — —
_/5j 4 7
15
3150 tm
- - ill - j - I - - . - -
- I
I
- I
y?/.6 [
»7 -
.. i.. i . : .
nt.ii] ]
- -i
— ; — i5?o; 1 -
— ¦ — 388>
O.tt)
/0401 — ; — ' — —I
•f-
- 1
i
1. | i
2SS1S
- rt?7 - ; -
~ " <"-
- : 95 so — -
- W» — ; -
- 0.OJ —
~ ts^c — 4 -
//orts
*' /~ ASSL/A1FO 7~0 ££ # Z F"t/£L G/4.-/XMAX SULflR /*£/? CM/CSSO
ro^'.r^i (CMfPr&V /7) - CjTY or CxtCAGO.
Z-8ASCD 0-Z.F4*Tirl;Ljrt \ . C,\/,fCKW/.7SL
Ct.., *wl O^ClNAtiCZ - Cc fA.TtZ ,7) - C'-)' cr Cf
-------
VI CONCLUSIONS
The results of the preliminary studies have led to a process
design more complex than that originally proposed. The
principal departure from the proposed process being the
breakdown of the dewatering operation into two distinct
steps. This split in the dewatering operation was necessi-
tated by the radically differing properties of the course
and fine fractions of the paunch material.
The project is presently in the engineering design phase for
which the material presented herein forms the design basis.
Results of the design phase will be presented in a subsequent
interim technical report.
78
-------
SECTION VII
REFERENCES
1. Henningson, Durham & Richardson, "Report on the
Processing and Disposition of Paunch Manure", prepared
for the City of Omaha, Nebraska, (1964).
2. Taiganides, E.P., and Hazen, T.E., "Properties of Farm
Animal Excreta," Transactions of the ASAE, Vol. 9, No. 1,
pp 374-376 (1966).
3. Perry, Chilton & Fitzpatrick, "Perry's Chemical Engineers'
Handbook", 4th Edition, McGraw-Hill, New York (1963).
4. Jolly, L., and Stantan, J.E., Journal of Applied
Chemistry (London), 2. 562 (1952).
5. Leva, M., "Elutriation of Fines from Fluidized Systems",
Chemical Engineering Progress, 47, 39, (1951).
6. Wen, C.Y. and Hashinger, R.F., American Institute of
Chemical Engineering Journal, 6, 220, (1960).
7. Zenz, F.A. and Weil, N.A., "A Theoretical-Empirical
Approach to the Mechanism of Particle Entrainment
from Fluidized Beds." AICHE Journal, 4, 472, (1958).
Dewiclson, J.F., and Harison, D. , "Fluidized Particles,"
Cambridge University Press, New York, (1963) .
9. Rowe, P»N. and Partridge, B.A., "X-Ray Study of Bubbles
in Fluid Beds , Transactions of the Institute of Chemical
Engineers, 43, T157, (19 65).
10. Lewis, W.K., Gilliland, E.R., and Lang, P.M.,
"Entrainment from Fluidized Solids," Chemical Engineering
Progress Symposium Series, Vol. 58, 65, (1962).
11. North American Manufacturing Co., "North American
Combustion Handbook" First Edition, North American Mfg.
Co., Cleveland, Ohio (1965).
79
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
2.
3. RECIPIENT'S ACCESSIOI*NO.
4. TITLE AND SUBTITLE
A METHOD OF MANURE DISPOSAL FOR A BEEF PACKING
OPERATION
5. REPORT DATE
06/75
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Anon
8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Procedyne Corporation
221 Somerset Street
New Brunswick, NJ 08903
10. PROGRAM ELEMENT NO.
1BB037
11. CONTRACT/GRANT NO.
12060 EOF
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Pacific NW Environmental Research Laboratory
Industrial Wastes Branch
200 SW 35th Street
Corvallis, OR 97330
13. TYPE OF REPORT AND PERIOD COVERED
Interim
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The report contains the preliminary studies, process development, process
calculations, and process design for a system to successfully handle the paunch
manure in a beef slaughtering operation.
These studies resulted in a system in which the paunch manure is collected
from the slaughtering operation and is fed to a screening device which separates
the coarse solids. The screenings are dewatered to a solids content of 37 percent,
This dewatered material is then sent to a fluid bed incinerator via a screw conveyor
The liquid stream from the screening is fed to a settler and is combined with the
liquid stream from, the dewaterer prior to sand filtering. The filter cake is
fed to the incinerator using a screw conveyor. The filtrate is recycled back to
the settler.
Work was completed as of February 1971.
17.
KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
b. IDENTI FIE RS/OPEN ENDED TERMS
c. COSATI Field/Group
Industrial Wastes, Industrial Waste
Treatment, Incinerators, Dewatering
Filtration, Meat
Meat Packing Industry,
Paunch Manure Disposal,
Fluid Bed Incineration
13B
IB. DISTRIBUTION STATEMENT
Unlimited; Available from NTIS, U.S.
Dept. of Commerce, 5285 Port Royal Rd.
Sorinafleld. VA 22151
19. SECURITY CLASS (ThisReport)'
21. NO. OF PAGES
91
20. SECURITY CLASS (Thispage)
22. PRICE
CPA Form 2220-1 (9-73)
-------
INSTRUCTIONS
1. REPORT NUMBER
Insert the EPA report number as it appears on the cover of the publication.
2. LEAVE BLANK
3. RECIPIENTS ACCESSION NUMBER
Reserved for use by each report recipient.
4. TITLE AND SUBTITLE
Title should indicate clearly and briefly the subject coverage of the report, ana be displayed prominently. Set subtitle, if used, in smaller
type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary title, add volume
number and include subtitle for the specific title.
5. REPORT DATE
Each report shall carry a date indicating at least month and year. Indicate the basis on which it was selected (e.g., date of issue, date of
approval, date of preparation, etc.).
6. PERFORMING ORGANIZATION CODE
Leave blank.
7. AUTHOR(S)
Give name(s) in conventional order (John R. Doe, J. Robert Doe, etc.). List author's affiliation if it differs from the performing organi-
zation.
8. PERFORMING ORGANIZATION REPORT NUMBER
Insert if performing organization wishes to assign this number.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Give name, street, city, state, and ZIP code. List no more than two levels of an organizational hirearchy.
10. PROGRAM ELEMENT NUMBER
Use the program element number under which the report was prepared. Subordinate numbers may be included in parentheses.
11. CONTRACT/GRANT NUMBER
Insert contract or grant number under which report was prepared.
12. SPONSORING AGENCY NAME AND ADDRESS
Include ZIP code.
13. TYPE OF REPORT AND PERIOD COVERED
Indicate interim final, etc., and if applicable, dates covered.
14. SPONSORING AGENCY CODE
Leave blank.
15. SUPPLEMENTARY NOTES
Enter information not included elsewhere but useful, such as: Prepared in cooperation with, Translation of, Presented at conference of,
To be published in, Supersedes, Supplements, etc.
16. ABSTRACT
Include a brief (200 words or less) factual summary of the most significant information contained in the report. If the report contains a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper authorized terms that identify the major
concept of the research and are sufficiently specific and precise to be used as index entries for cataloging,
(b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc Use open-
ended terms written in descriptor form for those subjects for which no descriptor exists.
(c) COSAT1 FIELD GROUP - Field and group assignments are to be taken from the 1965 COSATI Subject Category List. Since the ma-
jority of documents are multidisciplinary in nature, the Primary Field/Group assignment(s) will be specific discipline, area of human
endeavor, or type of physical object. The application(s) will be cross-referenced with secondary Field/Group assignments that will follow
the primary posting(s).
18. DISTRIBUTION STATEMENT
Denote releasability to the public or limitation for reasons other than security for example "Release Unlimited." Cite any availability to
the public, with address and price.
19. & 20. SECURITY CLASSIFICATION
DO NOT submit classified reports to the National Technical Information service.
21. NUMBER OF PAGES ^ j , , ,
Insert the total number of pages, including this one and unnumbered pages, but exclude distribution list, if any.
22. PRICE
Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
EPA Form 2220-1 (S-73) (R»vtr>«)
------- |