Fertilizer Manufacturing Process
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Transcript of Fertilizer Manufacturing Process
Pierce County
Fertilizer Manufacturing ProcessBiosolids Cake to Commercial Fertilizer
A Reality
Chambers Creek Regional Wastewater Treatment PlantFertilizer Manufacturing Facility
September 2010
Pierce County
Digester Failure – Lime StabilizationDecember 2000-March 2001
CostsExcess Hauling $268,917Equipment and Chemicals $213,363Labor $27,085Total Costs $509,365
Pierce County
Fertilizer Manufacturing ProcessThe Facility
Operates 24 hours a day up to 7 days a week depending on operational, maintenance, and distribution strategies
Evaporates 4,400 lbs water/hour
Produces 2,400 tons of fertilizer per year
Final Product: 0.5 - 2.5 mm pellets93% dry solid
Pierce County
Fertilizer Manufacturing ProcessFertilizer Manufacturing Process
Pierce County
Fertilizer
Digesters Centrifuge Wet Materials Bin
Recycle Bin
Mixer
FurnaceDryer Drum
Vibrating Screens
Preseparator/Polycyclone
CrusherTrash
Pellet Cooler
Pneumatic Conveyor
Silo
Bagging
Pierce County
Safety Systems
• Nitrogen Purge SystemActivated when oxygen levels rise too high
Storage silos, recycle solids bin
• Temperature sensors and water spray extinguishing systemActivated when temperature rises too high
Dryer drum
• Operator interfacing with control system
Pierce County
2008/2009 Biogas ProductionChambers Creek Regional Wastewater Treatment Plant
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TOTAL GAS PRODUCED WASTED TO FLARE UTILIZED IN BOILER UTILIZED IN FMF
mill
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of c
u ft/
year
% U
TILI
ZED
2008
2009
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Odor Treatment
Three odor treatment systems:• Venturi Scrubbers• Building Air Scrubbers• Regenerative Thermal
Oxidizer
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Fertilizer Manufacturing Facility2008/2009 Operating Costs
Item 2008 2009Electricity $ 66,958 $68,353Natural Gas $124,867 $149,376Operations and Maintenance Staffing $199,462 $208,258Polymer & Chemicals $316,056 $352,922Miscellaneous (parts, bags, pallets, etc.) $ 87,928 $113,558Total $795,271 $892,467
Digester Gas Value (avoided cost) ($214,331) ($199,789)
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Award Winning Facility
• 2007 - Governors Award for Pollution Prevention & Sustainable Practices
• 2008 - Excellence in Biosolids Management Award, Northwest Biosolids Management Association
• 2009 - Recycler of the Year, Washington State Recycling Association for Public Agency Generator
Pierce County
SoundGRO - The Fertilizer
• Current N-P-K composition 6-7-0
• pH ≈ 7
• Density - 38+ lbs/ft3
• How the nitrogen composition affects the fertilizer’s behavior
• Metals and Micronutrients
• Salt Index
Pierce County
Importance of Pretreatment - MolybdenumOur Experience
• Content exceeding 75 ppm - final product cannot be classified as a Class A or B biosolid
• Content exceeding 10 ppm - a warning must be put on fertilizer label
• Moly is a plant nutrient and can exceed the WSDA loading limit by listing it as a micronutrient
• Pretreatment research identified the source of high Molybdenum discharge source and additional limits were placed on the discharger
• Concentrations have been reduced to well within acceptable levels
Pierce County
Establishing a Fertilizer Marketing Program
• Fertilizer Product Name, Registered Trade Mark, Patent Attorney
• Preliminary Marketing Study
• Biosolids Testing and Agricultural Laboratory Testing
• Product Logo and Bag Design
• University Research Program to Validate Application Rates and NPK Composition
• State Fertilizer Licenses – Washington 2005; Oregon, Idaho, Montana 2007; California 2008
Pierce County
Marketing Plan
Target Markets:
• Fertilizer Blenders, Commercial Agriculture, Golf Courses, Landscapers, Hydroseeders
• Residential users, small farms, pastures, and community gardens
• Competition – Primarily Commercial Fertilizers
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Product Distribution & Sales
• How is the product provided or sold to customers
• How is the product packaged– Individual bags - 50 pound bags;– Pallets - forty 50 pound bags per pallet; – Half and one ton totes; – Bulk - truck trailer transport loaded from silos.
• Commercial distributors for product
• Product price - the product has value - it should be sold, not given away
Pierce County
SoundGRO Sales and Storage
2008
2009
Jan Feb Apr
Mar Sep May Aug Oct June Dec
July Nov
800*
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Feb Jan Mar May
Apr July
June Aug Sep
Oct Nov
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Sales Storage *In tons
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SoundGRO Marketing & Revenue (Excludes Labor)
Marketing Costs 2008 2009- State Fertilizer Licenses $330 $500- State Tonnage Fees $622 $732- Tradeshow Booth Fees $2,750 $2,465
Total $3,702 $3,697
Revenue 2008 2009- Individual Sales $34,199 $32,783- Commercial Sales $56,652 $86,633- Sales Taxes Collected $3,103 $3,703- Sales Taxes Paid $3,082 $3,716
Total $90,872 $119,403
Pierce County
Asset Management Program Utilize BCE process to determine best solution for optimizing operations, maintenance, and distributions
Pierce County
Alternatives Analysis
Alternative Description Capital costs 10-year NPVMeets
regulatory requirement
Optimizes practices
Allows for RTO
drying
1 Existing operating practices
$15M ($24.975M)
2 Redundant facilities $15M ($26.564M)
3 Optimized operations schedule
$15M ($25.142M)
4 Existing maintenance practices
($1.366M)
5 Optimized maintenance practices
($666K)
6 Existing distribution ($1.565M) 7 Automated bagging $1M ($2.086M) 8 New storage $2M ($3.566M) 9 Automated bagging
and new storage$3M ($4.086M)
Pierce County
Fertilizer Manufacturing Facility Maintenance Requirements
• Total Assets in Fertilizer Manufacturing Facility300 pieces of equipment
• Manufacturer Recommended Maintenance Labor3,047 hours annually
• Business Case Evaluation by Consultant Recommended 1,651 hours annually
• Work Orders by Trade Mechanical – 1,122; Electrical – 222; Instrumentation – 205; Operations 116; and Miscellaneous – 24
Pierce County
Fertilizer Manufacturing Facility Optimization
• Operations– Operational practices do not leave sufficient time for
maintenance
• Maintenance– Tasks based on manufacturer’s recommendation and a review to
determine if bundling, delaying or removal was applicable had not been performed
• Distribution– Excess product in winter requires storage, currently using
Collection’s garage which displaces Collections vehicle fleet
Pierce County
Since the BCE
Operations adopted a modified schedule for planned shutdownsMaintenance work orders and costs significantly reduced
2006 2007 2008 2009 2010ytd
2006 2007 2008 2009 2010ytd
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Total Work Order Count
Total Preventative Maintenance WO’s
Total Corrective Maintenance WO’s
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Distribution Overview
• Bulk customers– Golf courses, farmers,
fertilizer blenders• Bag customers
– Residential, distributors, lawn and landscape
• Cost $450/ton to produce (2009)
• Sold at – $58.40/ton ($1.46/bag) for
bulk bagged product– $38.80/ton for loose bulk– $3.20/bag for individual bags
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Distribution Trends Analyzed Better Understanding of Customer Buying Patterns
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Distribution Customer Profile Developing a Reliable Commercial Customer Base
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BCE Conclusions and Recommendations
• Operations – Optimize with 10 day on/5 day off schedule
• Maintenance– Optimize by going from 3,175, maintenance tasks to 1,610
• Distribution– Continue with current practice– Expand market research and determine new winter customers
Pierce County
Questions