Swine Manure Processing Systems

Swine Manure Processing Systems
engineering for a better world
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Maximizing the Value of Swine Manure
Once viewed as simply a waste product, manure
is now recognized as a valuable source of plant
nutrients. But like any farm asset, from livestock
to land, this resource requires smart management.
To maximize the benefit on your operation it is
necessary to properly integrate the manure into
the natural nutrient cycle. This requires knowledge
of topography and soil characteristics as well as
an understanding of the nutrient composition of
swine manure.
The dry matter and nutrient content of manure
is impacted by animal diet, age and other factors.
For example, the nutrient content of manure
from a farrowing operation is different from a
growing/finishing facility. In a growing/finishing
operation, raw manure consists of approximately
6-10% dry solids. Further, each ton of this manure
offers 15.9 lb of nitrogen, 9.3 lb of phosphate
and 15.9 lb of potassium. Considering that hogs
produce approximately 63 pounds of manure per
day for every 1,000 pounds of live animal, there
are significant amounts of nutrients available
to harvest.
The aim is to process the raw manure so that
nutrient surpluses are minimized and the products
that result can be effectively put back to use on the
farm and in the fields.
Farrowing Operations
GEA Houle Liquid Manure Spreader
Of the three major nutrients (N, P, K) present
in manure, nitrogen and phosphorus are often
the most difficult to manage and can have
the largest environmental impact. A decanter
centrifuge can significantly improve the balance of
these nutrients in both the solid and liquid portion
of the processed manure product. Figures 1 and
2 show the composition of both fractions of the
manure, including its nutrients, once it has passed
through this process.
Growing/Finishing Operations
After Processing
Raw
Solid
Manure fraction
Liquid
fraction
Dry solids (%)
4-7
>27
<2.5
Nitrogen (lb/ton)
9.7
17.4
(25%)
Phosphate (lb/ton)
6.6
Potassium (lb/ton)
9.9
After Processing
Raw
Solid
Manure fraction
Liquid
fraction
Dry solids (%)
6-10
>30
<2.5
7.9
(75%)
Nitrogen (lb/ton)
15.9
32.0
(35%)
12.6
(65%)
30.0
(60%)
3.1
(40%)
Phosphate (lb/ton)
9.3
40.1
(75%)
2.9
(25%)
3.5
(5%)
10.4
(95%)
Potassium (lb/ton)
15.9
13.7
(15%)
16.3
(85%)
Fig. 1 - Nutrient composition of manure from a farrowing
operation
Fig. 2 - Nutrient composition of manure from a growing/finishing
operation
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The Nutrient Management Process
The separation system shown
in figure 3 can be used with
or without a digester. The process
begins by pumping the manure
slurry to a GEA Westfalia Separator
AGM decanter centrifuge. This
rugged, high speed machine has
been built to handle mixtures with
high solids content. It automatically
adjusts to different flow rates and
solid levels. After passing through
t h e d e c a n t e r, r e m o ve d s o l i d s
contain higher levels of nitrogen
and phosphorus and can be used
to fertilize fields or for composting.
Additional nutrients are recovered
in liquid form and can be stored
for transport to nutrient deficient
locations or applied to fields.
Additionally, recovered liquid
can be further processed using
ultrafiltration and reverse osmosis
and then reused in the barn as
potable water.
Fig. 3
GEA Houle Electric Pumps
High performance centrifugal pumps to transfer liquid manure
The diversity of applications for transfer pumps is as varied as the factors to be considered in order to
maximize its use. GEA has developed a complete and diversified range of pumps that provides maximum
performance and efficiency. The line of electric pumps, as shown on page 4, is available for various
pressures and flow rates.
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GEA Houle Pump Models
Manure
Consistency Range
8“ Flush Pump
Low RPM pump offering a high flow rate and remarkable
performance to feed a flush system.
4“ Agi-Pompe
Available on pontoon
Compact
Economical
Agitation
High Pressure
High Flow
1/2’’
3/8’’
1/4’’
1/8’’
Description
Water
Pump Models
Key Features
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Stands out from the other pumps because of its ability to provide
both high performance pumping and high efficiency agitation.
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4“ High Pressure
Pump
Reaches its full potential when responding to high head pressures
or when used to transfer relatively long distances.
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4“ Dairy Manure
Pump
The perfect balance between pressure, flow rate and
agitation quality for efficient and optimal results.
4“ Hog Manure
Pump
An ideal pump to transfer low consistency liquid
when high flow rate and high pressure are needed.
3“ High Pressure
Pump
The most powerfull of the 3’’ pumps, it will respond to
high head pressures while remaining economical.
3“ Pump
3“ Compact Pump
Excellent
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Offers sufficient power and flow rate to transfer
hog manure or dairy waste water.
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As reliable as the 3’’ Pump, this compact version offers
performance and efficiency where space is limited.
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Optional
GEA Houle Power Take-off Pumps
Powerful PTO pumps to handle liquid manure
For decades, GEA has been offering PTO pumps designed to agitate and facilitate the evacuation of
manure from the main storage pit.
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GEA strives to provide solutions that support
proper manure management by offering
products that aid in manure transfer from
pits to lagoons and spreaders. Agi-Pompe and
Super Pump come in three models to be suitable
for any type of storage:
⋅ Vertical pumps allow easy installation and
removal from concrete pits.
⋅ Lagoon pumps which are specially designed to
facilitate the approach, agitation and transfer of
manure from lagoons.
⋅ Far-reaching articulated pumps, secured solidly
with a 3-point hitch, are designed to mix and
transfer manure from larger concrete pits.
Vertical Agi-Pompe
The Agi-Pompe physically
distinguishes itself from the
others by its large and powerful
propeller. At the same time it
gives a powerful and constant
agitation when in loading or
agitation mode.
Vertical Super-Pump
All the power of the Super
Pump is concentrated in its
exceptional transfer capacity. It
allows homogenizing and fast
transfer of hog slurry.
Liquid Manure Spreaders and Tool Bars
For spreading all types of liquid manure
Well known for their performance and their
reliability for over 20 years, liquid manure
spreaders offered by GEA are equipped to
combine efficiency with safety so tasks can
be completed with confidence.
Steerable Series Spreaders
The directional spreader offers excellent maneuverability
and control on all types of terrain. Its agility results in
less ground compaction when turning. Additionally, its
exclusive power-steering and superior quality suspension
provide more resistance to obstacles.
Tandem Series Spreaders
Combining lightness and strength, the tandem spreader
remains an economical choice. The GEA tandem
axle is closed by a full length central tube, providing
more resistance to twisting than conventional open
tandem axles.
Tool Bars
Land application of manure is a standard practice. No
matter how it is applied – broadcast with no incorporation,
broadcast and incorporated or injected – GEA offers
spreading tool bars that can do the job efficiently.
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GEA Westfalia Separator AGM Centrifuge
The AGM decanter centrifuge from GEA Westfalia
Separator is a continuously operating centrifuge
with a horizontal solid-wall bowl developed
specifically to dewater liquid manure and digestate
that results from biogas production. Centrifuges
are available in a range of sizes and can be
built on a mobile unit, complete with pumps
and other equipment, to allow for transport to
different locations.
• Removes particles as small as 40 microns
• No need for added chemicals
• No filtration system, therefore no blockages
• Compact design
• Easy installation, operation and maintenance
• PLC automated controls for unattended
operation
• Automatic adjustment to changing feed streams
Benefits of centrifugal technology:
•H
ighest separation efficiency of N (up to
40%) and P (up to 70%) through centrifugal
or g-forces
22
• Low energy requirement
Secondarymotor
motor
11Secondary
33 44
Mainmotor
motor
22Main
55
6
7
8
99
Scrolldrive
drive
33Scroll
Bowldrive
drive
44Bowl
Frame
55Frame
66Distributor
Distributor
77Feed
FeedTube
Tube
88Scroll
Scrollbearings
bearings
99Feed
Feed
10
10Bowl
Bowlbearings
bearings
11
11Regulating
Regulatingplates
plates
11
12
12Gravity
Gravitydischarge
dischargeofof
the
theClarified
Clarifiedliquid
liquid
13
13Bowl
Bowl
14
14Separation
Separationchamber
chamber
15
15Conveyor
Conveyorscrew
screw
16
16Solids
Solidsdischarge
discharge
18 17
17
19 18
19
16
16
15 14
14
15
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13
13 12
12
11
11 10
10
17
17Gearbox
Gearbox
18
18Vibration
Vibrationabsorbers
absorbers
19
19Coupling
Coupling
Ensuring Maximum Process Efficiency,
Availability and Budget Security with
serv&care from GEA Westfalia Separator
Wherever separating technology tasks have
to be carried out, our serv&care program
assures comprehensive services right from the
very beginning.
Customers benefit not only from traditional
services such as inspection, maintenance,
original spare parts and repair work provided
by the original manufacturer, but also
from pro-active solutions which avoid risk,
e.g., online and offline monitoring with
our GEA Westfalia Separator wewatch®.
Modernization or upgrading to state-of-the-art
technology also provides the opportunity to
boost services as required.
Training provided on site or in our modern
training center ensure that our customer‘s
employees receive training in the proper
handling of our installations. This provides
additional safety.
Our serv&care program provides for maximum
process efficiency and installation availability
as well as budget security. And these benefits
are provided throughout the entire lifecycle of
the entire installation.
Services performed by specialists
When normal equipment use results in wear and
tear, we stand behind the quality of our repair
services. GEA Westfalia Separator has trained
mechanics on staff that have the proprietary
knowledge to make the necessary repairs. In
true emergencies, a response team can be
quickly deployed to your farm. Spare bowl
and scroll assemblies are readily available for
your use, so you can use your equipment while
repairs are underway. And when equipment
needs to be repaired off-site, we offer two full
service locations here in North America. Our
facility in Patterson, California was specifically
developed to service customers based in the
western United States and Canada. Here,
decanter and separators of all sizes can be
repaired. There is also a large parts inventory
and a specially designed training facility.
Service from the original manufacturer:
• Service engineers move quickly to the site
• Extensive service network
• Risk avoided by service provided
by the original manufacturer
• Pro-active solutions which avoid risk
• Upgrading to boost performance
• Staff training
serv care
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We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Farm Technologies, Inc.
GEA Farm Technologies
Headquarters:
1880 Country Farm Drive
Naperville, IL 60563
630-369-8100
www.gea-farmtechnologies.com
GEA Farm Technologies Canada Inc.
GEA Houle Division
Manufacturing Plant:
4591, boul. St-Joseph
Drummondville, QC, Canada, J2A 0C6
819-477-7444
www.gea-farmtechnologies.com/houle/en
www.gea.com
Westfalia and Westfalia Separator are registered trademarks of GEA Westfalia Separator GmbH.
2561
GEA Group is a global engineering company with ­multi-billion euro sales and ­operations in more
than 50 countries. Founded in 1881, the company is one of the largest providers of ­innovative
equipment and ­process technology. GEA Group is listed in the STOXX® Europe 600 Index.