Today, Funki Manura provides two alternative technology solutions to processing hog manure in an environmentally friendly manner; they are the:
The MANURA® 2000 and the MANURA® Compact
The two basic differences between the the older MANURA® 2000 option and the newer MANURA® Compact option are described below:
1. The older MANURA® 2000 option seperates out a pure water fraction equivalent to approximately 75% of the raw input thereby reducing the mass balance of the K-Fraction in the above mass balance diagram for the MANURA® Compact, to approximately 13% of the raw input.
2. The cost of the The MANURA® Compact is approximately 45% lower than the MANURA® 2000 and it is anticipated to have lower operational costs with respect to energy requirements. ; the negative is no pure water fraction ; and a corresponding increase in the bulk of the K-fraction.
Generically, the MANURA® process is comprised of two seperate stages. In the first stage a decanter centrifuge performs a mechanical pre-separation with the fiber part being separated from the liquid phase. In the second stage the liquid phase is concentrated by evaporation.
Pressurised boiling pre-separated manure is flashed through a nozzle into a degasser and all
of the CO2 converts from the liquid phase to a gas phase. When the gas phase is cooled in the gas heat exchanger certain chemical reactions take place.
Funki Manura A/S is located in Denmark and is dedicated to the development of processes that enable livestock production without environmental hazards.
Funki Manura is offering processes that convert organic waste and residual products into value added materials.
1000 kg Raw Slurry
5.6 kg N = 100%
1.4 kg P = 100%
3.0 kg K = 100%
100 kg P-Fraction
1.1 kg N = 20%
1.0 kg P = 70%
0.5 kg K = 15%
20 kg N-Fraction
2.8 kg N = 50%
880 kg K-Fraction
1.6 kg N = 30%
0.4 kg P = 30%
2.5 kg K = 85%
Mass Balance Diagram for the MANURA®
MANURA® 2000 Chemical Reactions
First the water vapour condenses and thereafter the NH3 will solute in the water..
(A)H2O (g) ->H2O (l)
(B)NH3 (g) ->NH3 (aq)
Because NH3 has a very high solubility in water and the conversion from gas to an aqueous state takes place very fast, the condensation of water and the solution of NH3 will happen parallel. When NH3 is in solution with water it will act as a weak base.
(C)NH3 (aq) + H2O (l) -> NH4+ (aq) + OH- (aq)
CO2 too will solute in water and hereby act as a weak acid.
(D)CO2 (g) -> CO2 (aq)
(E)CO2 (aq) + H2O (l) -> H2CO3 (aq)
(F)H2CO3 (aq) + OH- (aq) -> HCO3- (aq) + H2O
Present in the liquid is now HCO3- and NH4+
These two molecules will react and make aqueous ammonium hydrogen carbonate (NH4HCO3).
(G)NH4+ (aq) + HCO3- (aq) -> NH4HCO3 (aq)
As a result the N-fraction will be an aqueous solution of ammonia and mainly ammonium hydrogen carbonate.
Chemical Composition - K-Fraction
In effect , the K-Fraction is the residue from the creation of NIT-GRO® and is anticipated to contain:
- 0.18% Nitrogen [N]; and
- 0.05 Phosphorus [P]; and
- 0.28% Potassium [K].(from the MANURA® Compact)
and is anticipated to contain:
- 0.96% Nitrogen [N]; and
- 0.22% Phosphorus [P]; and
- 2.00% Potassium [K].(from the MANURA® 2000 option)
The K and N fractions will always meet the following specific conditions:
- Free of salmonella (absence of salmonella in 25 gram of treated product).
- Free of enterobacteriaceae (aerobic bacteria count < 1,000 cfu per gram).
MANURA® Buyer Supply
The buyer is responsible for:
> Building for dewatering line ( minimum requirement is insulated and heated building).
> Building for the MANURA® (minimum requirement is insulated and heated building of approx 70 m2, not less than 5,3 m high above the evaporator)
- Overall height not less than 4 m;
- Access should be provided through a gate (3.6 m wide by 3.6 m high).
> A covered pre-tank that will ensure homogeneous feeding of the dewatering line.
> A covered buffer tank below ground level for the preseparated thin slurry (ideally
1000 m3 and not less than 350 m3).
> A closed, below-ground-level storage tank for N-fertilizer, 10 m3 pr. desired storage week.
> Tank must be equipped with a trap (siphon) to avoid ammonia emission.
> Storage for the NPK-fertiliser (70 m3 per desired storage week).
> A container or covered storage area for humus (70 tons per desired
desiredstorage week).
> Pumps and control system for storage logistics.
> All onsite piping as described by seller.
> Water supply at a pressure of minimum 2 bar.
> Compressed air supply - 350 l/minute ; peak at 6 bar.
> Power supply including necessary cabling for connection of the MANURA®
component parts.
> A control room (minimun 8 m²) with telephone and ISDN2 dataline.
The above is a general description of the Buyer's Supply for installing a MANURA® system ; it may vary according to the model purchased.
MANURA® Seller Supply
A highly developed and fully tested system for separation af ammonia ensures clean water for recycling, discharge, or irrigation.
Seperated fractions ....
For the older MANURA® 2000, the separated fractions are:
For the MANURA® Compact, the separated fractions are:
- 88% NPK-fertilizer, 10% humus and 2% N-fertilizer.
b
Big capacity ....
The Funki Manura systems have a capacity of 17,500 - 25,000 tons slurry per year, depending on the dry solid matter.
Environmental effect ...
- Utilization percentage of nitrogen in refined slurry approx. 85%
- Exact dosing of N, P and K by way of patented process
- No nitrogen evaporation from slurry tanks
- Large savings on transportation of nutrients
- Volume reduction of 75 to 85%, depending on option
Operation ....
Raw slurry is pumped into a decanter centrifuge where the solid particles in the slurry are separated as humus with a dry matter degree of approx. 30%, thus binding approx. 70% of the phosphorous content in the raw slurry.
The thin part of the slurry is pumped on into the dehydration part of the system where it is heated to approx. 100 degrees Celsius and degassed. The slurry then separates into two fractions - concentrate and nitrogen. Left over is the distilled water.
The dehydration process is based on a number of patented operations ensuring optimum utilization of the heat energy. Energy consumption is consequently kept on a minimum.
Control....
The control technique used allows remote monitoring and adjustment of the system. All operation parameters and adjustment functions can be controlled via modem or Internet.
Compact....
The Funki Manura separation system is very compact. With dimensions of 4x5x4 m the system can be installed in an existing building. In addition to the separation system, only a few tanks are needed for storing the fractions and perhaps the water.
