GRANULATED WATER TREATMENT PLANT SLUDGE COMPOSITION CONTAINING MINERAL ADDITIVES AND RESPECTIVE PREPARATION PROCESS

Abstract

A granulated formulation formed from ETA (Water Treatment Plant) sludge and minerals from magmatic and/or sedimentary and/or metamorphic rocks, rich in magnesium and potassium silicates in addition to silicon dioxide and other components, representing an innovation in waste recycling processes for environmental purposes, the replacement of animal substrates by the proposed product and soil nutrient recycling process through generation of organomineral fertilizer resulting from exposure of the substrate to waste from creations in which it is used.

Claims

1. A composition of granulated water treatment station sludge with mineral additives, characterized for being granulated and comprising: a. magnesium and potassium silicates; b. of silicon dioxide, with a small organic fraction and silicate aluminum clays from water treatment plants); c. micro and macro-nutrients; and d. sedimentary and/or magmatic and/or metamorphic rocks.

2. The composition according to claim 1, wherein the macronutrients are selected, but not limited to, the group consisting of potassium, phosphorus, magnesium and the like.

3. The composition according to claim 1, wherein the macronutrients are selected, but not limited to, the group consisting of boron, molybdenum, zinc, magnesium and the like.

4. The composition according to claim 1, comprising, in percentages by weight, between 10% and 80% of WTP Sludge and between 90% and 20% of Serpentinite.

5. The composition according to claim 1 comprising 10% to 50%, preferably 30% of ETA Sludge, from 1% to 30%, preferably 10% of Diatomite, from 5% to 50%, preferably 35% Serpentinite, 5% to 40%, preferably 20% Filite and 1% to 15%, preferably 5% Basalt.

6. The composition according to claim 1, comprising, in percentages by weight, between 20% and 80%, preferably 60%, WTP Sludge and between 20% and 80%, preferably 40% of Diatomite.

7. The composition according to claim 1 comprising in weight percentages, 10% to 50%, preferably 30% of WTP Sludge, from 1% to 15%, preferably 5% of Diatomite, from 20% to 60%, preferably 40% Serpentinite, 10% to 30%, preferably 20% Filite and 1% to 15%, preferably 5% Basalt.

8. The composition, according to claim 1, comprising, in weight percentages, 5% to 30%, preferably 20% sludge, 30 to 70%, preferable 50% dehydrated calcium sulphate or anhydrous and 10% to 50%, preferable 30% Serpentinite.

9. The composition according to claim 1, characterized in that wherein the sedimentary rock is chosen from the group consisting of Diatomite, Gypsum, Anhydrite and the like, preferably being Diatomite.

10. The composition according to claim 1, wherein the magmatic rock is chosen from a group of magmatic rocks.

11. The composition according to claim 1, wherein the metamorphic rock is chosen from the group consisting of Serpentinite, Phyllite and the like.

12. A process for preparing a granulated water treatment plant sludge composition with mineral additives, for obtaining a preparation according to claim 1.

13. The composition according to claim 10, wherein the magmatic rock is Basalt.

14. The composition according to claim 11, wherein the metamorphic rock is Serpentinite.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0098] This invention foresees the use of WTP sludge dewatered (in a blast furnace) and granulated (granulator/mixer) with the addition of minerals that have desirable agronomic characteristics, whether chemical or physical. The desirable chemical characteristics in the minerals that can be added are those related to the nutrients needed for the crop. The physical characteristics are those that added to the granule may give it a greater water retention capacity or other advantage, helping the WTP residue in this function and, consequently, the crop when it is used for this purpose.

[0099] The WTP sludge, therefore, leaving the water treatment plant, must undergo drainage, granulation and mixing in the industry.

[0100] It is important to emphasize the technical/logistical non-viability of proceeding with a “pre-mix” of the mineral to be used (sedimentary/metamorphic/magmatic rock) at the sludge production site. Unfeasible due to the large volume of sludge produced per day, the facilities of the treatment plants are compact, as well as it is not the institutional object of the stations (usually public) as this is a different activity from the main one (water production), increasing costs etc.

[0101] Such mixing should, therefore, be done in industry, where the use of blast furnaces/granulators/mixers from a factory that performs such activity is the place for such a process. This action is important for the residue to undergo the necessary discharge, since the in natura residue presents an average of 80% humidity in its composition at the exit of the treatment plant.

[0102] The idea is that during dewatering, the water contained is largely eliminated, and as such waste is basically composed of clay and silt, its water retention capacity is later resumed, this capacity will be maximized with the ore to be added.

[0103] The physical uniformity of the residue (granulation/mixture) is important, taking into account the animals' need for comfort. Greater comfort, greater effectiveness in production and subsequent use.

[0104] Such step (draining/granulation/mixing), as already said, is the appropriate time for the addition of other mineral elements/fertilizers in the granule, such minerals to be added will be defined largely according to the need/use that will be given later, the chicken/poultry litter, as it will depend on the type of crop (coffee, corn, soy, pasture, etc.) always in line with the soil analysis of the place where such fertilizer will be applied and with the current legislation regarding metal indices heavy tolerated.

[0105] Bearing in mind the possibility of adding minerals to the ETA sludge granule, in order to improve its chemical and/or physical qualities for its subsequent use in agriculture, we have as examples the possibility of using sedimentary and/or magmatic and/or metamorphic rocks.

[0106] Sedimentary rocks: sedimentary rocks can be used to supplement the agricultural soil with nutrients, since, taking as an example the granulation with Diatomite (and not limited to this sedimentary rock), we have Diatomite as a good source of Si and Mg which, in addition, increases the moisture adsorption capacity. Other sedimentary rocks may be, but are not limited to, suitable Gypsum, Anhydrite and the like.

[0107] Magmatic rocks: aiming to supplement the agricultural soil with nutrients, magmatic rocks are also a good option. From magmatic rocks, taking as an example the granulation with Basalt (and not limited to just this magmatic rock, it could be another suitable similar chosen from the group of magmatic rocks), we will have Basalt as a good source of Si (presence of 45 to 50% in the rock), as well as more of 60 micro and macro other nutrients.

[0108] Metamorphic rocks: aiming to correct soil acidity, the use of metamorphic rocks is an excellent option, in addition to providing other nutrients for the agricultural culture. Of the metamorphic rocks, taking as an example the granulation with Serpentinite (and not limited to this metamorphic rock), in addition to the correction of acidity, we also have the input of Ca and Mg into the soil. Other metamorphic rocks may be, but are not limited to, suitable Phyllite and the like.

[0109] In addition, we also have the possibility of powder mixtures from rocks of different classes (metamorphic/sedimentary/magmatic), or even more than one rock powder of the same class.

[0110] As a non-limiting example of rock powder mixtures of different classes (metamorphic/sedimentary/magmatic), according to the invention, we can mention, in percentages by weight, a composition comprising between 10% and 80% of ETA Sludge and between 90% and 20% Serpentinite.

[0111] In a preferred embodiment not limiting the scope of the present invention, the composition comprises from 10% to 50%, preferably 30% of ETA Sludge, from 1% to 30%, preferably 10% of Diatomite, from 5% to 50%, preferably 35% Serpentinite, 5% to 40%, preferably 20% Filite and 1% to 15%, preferably 5% Basalt.

[0112] In another preferred embodiment not limiting the scope of the present invention, the composition comprises between 20% and 80%, preferably 60% of ETA Sludge and between 20% and 80%, preferably 40% of Diatomite.

[0113] In a preferred embodiment not limiting the scope of the present invention, the composition comprises from 10% to 50%, preferably 30% of ETA Sludge, from 1% to 15%, preferably 5% of Diatomite, from 20% to 60%, preferably 40% Serpentinite, 10% to 30%, preferably 20% Filite and finally 1% to 15%, preferably 5% Basalt.

[0114] In yet another preferred mode not limiting the scope of this invention, the composition comprises 5% to 30%, preferably 20% sludge, 30 to 70%, preferably 50% dehydrated calcium sulphate or Anhydrous and 10% to 50%, preferably 30% Serpentinite.

[0115] The composition according to the invention therefore comprises a granulated compound made of different silicates of magnesium and potassium and silicon dioxide, with a small organic fraction and silicate aluminum clays from the WTP (Water Treatment Plant), in addition to micro and macronutrients in different proportions, always obeying the parameters dictated by the composition of the residues or analysis of the WTP sludge to be used.

[0116] Macronutrients can be selected from, but not limited to, the group consisting of suitable potassium, phosphorus, magnesium, and the like.

[0117] Macronutrients can be selected from, but not limited to, the group consisting of suitable boron, molybdenum, zinc, magnesium, and the like.

[0118] The object of this patent can be considered a soil remineralizer, as it uses natural silicates in the form of serpentinite, phyllite, diatomaceous earth, gypsum/anhydrite of recognized agronomic effect, together with the WTP sludge that served as its base.

[0119] In terms of process, the best way of carrying out according to the invention comprises the processing of WTP sludge in ovens with high temperature that allow its efficient dewatering, passing these residues, as a result of the production process, through granulators/mixers with different systems (cylinder/rotating drum, inclined discs, tray, plate), with uniformity being the most important of particle size/mixture. After this step, the product can be sent to places of intermediate use (bed/corral/animal house), and, later, to farming.

[0120] The process starts with mixing the WPT sludge with one or more of the selected minerals. Such mixture will take place in the industry that will produce/granulate the product. It is unfeasible, but not technically impossible, to carry out such a mixture in the sludge production unit. The proportions of minerals vary according to several factors, including the cost of the raw material(s), the need of the aviculturist/farmer etc.

[0121] The raw materials will be received in lung silos with adequate capacity, and their supply will be carried out by a loader, where the material will be duly weighed according to the production order and then deposited in a horizontal paddle mixer. After the residence time for the mixture has elapsed, it goes by conveyor belt to the storage location in the manufacturing sector, in a duly identified box.

[0122] The granulation of the products will be carried out with a granulating plate and a starch solution will be used as an adhesive to agglomerate the particles in the granulation, giving physical stability to the finished product.

[0123] In the manufacturing sector, raw materials feed a lung silo that supplies the conveyor belt, which in turn feeds the granulating plates, where the granulation process will be carried out. In the granulating dishes, the raw material receives a spray of starch solution through a fan nozzle. After a period of residence of the material in the granulating plate, accompanied by the operator, the granules are formed.

[0124] The formed granules are unloaded on a conveyor and taken to the dryer cylinder, which carries out the drying process through high temperature, close to 700° C. at the dryer inlet and 150° C. at the dry material outlet. It is important to point out that, at this stage, due to the thermal process described above, pathogenic agents such as bacteria, fungi, viruses, as well as weed seeds are eliminated. Product sterilization occurs.

[0125] In the dryer cylinder, the drying process is carried out, in which the moisture content of the material should be approximately 1%, thus maintaining its physical stability and hardness level above 2 kgf.

[0126] When drying the material, the vapors generated in the dryer are suctioned by the exhaust system, formed by the hood, cyclone, exhaust ducts and particle washer, returning to production, forming a closed circuit.

[0127] The dry material is discharged into the hood by gravity and through ducts, to a bucket elevator, later transported to a rotating classification sieve. In the rotary sieve, the material is classified into stainless steel sieves with openings between 2.00 and 4.00 mm. After the classification process, the material goes through a conveyor belt to the finished product storage box, duly identified. Granules below 2.00 mm are returned to the granulating plates, with a return to drying and classification. Granules over 4.5 mm are fed to a hammer mill and returned for classification on the rotary sieve. The particulate material generated in the particle washing process is collected in specific bays and returned to production, as it is a simple mineral fertilizer production, not interfering with the quality of the product.

[0128] The effluent generated in the particle washer and decanted in the concreted bays is used as a water source and reused in the production system, thus forming a closed production circuit, without generation environmental liabilities of solid and liquid residues. Only water vapor is generated by the gas washer, coming from the washing process. The prevention of production failures is detected by collecting samples in the production at a pre-established frequency, where the granulometry and the degree of hardness will be analyzed. With these results, it is possible to evaluate how the process of granulation, drying and starch concentration is going. If necessary, flaws in the process can be immediately corrected, generating information to meet the technical indexes, embodied in the production process spreadsheet, aiming at dynamic adjustments to the production process.

[0129] The production will be monitored by collecting information from technical indexes, preferably with the items quantity produced per hour, consumption of raw materials, energy consumption, consumption of starch solution and temperature in the hood, amount of return in the production cycle. All these data will be noted in a production spreadsheet by work shift. The information from the technical indexes will generate information that makes it possible to track all material consumption in the production cycle and form a standard method for production. All occurrences in the production period will be reported in the “Production Report”, with the following information: date, batch number, product name, minimum guarantees, list of team components, collection of technical index information, occurrence of problems in production, time of occurrences and production stops, quantity produced, hours worked, etc.

[0130] It is important to consider that after the industrial mixing/granulation process, a certain amount of Diatomite can be used as QSP (sufficient amount to) improve the granules in the anti-caking aspect of the mixture, a property inherent to this mineral.

Final Considerations

[0131] This invention describes a new and inventive composition used as an absorbent in its initial use in agriculture as a substrate disposed in breeding floors to absorb moisture from excreta and other waste in order to maintain comfort and animal health.

[0132] After using this material, it is transformed into fertilizer or as a filler or additive for mixing other complex fertilizers, especially when it has previously served for raising livestock and poultry.

[0133] The invention relates to a composition and a process for the preparation of a granular compound made of different silicates of magnesium and potassium and silicon dioxide, with a small organic fraction and silicate aluminum clays from WTP. (Water Treatment Station), in addition to micro and macro nutrients in varying proportions, all depending on the composition of waste or analysis of the WTP sludge that was used.

[0134] The object of this patent can be considered a soil remineralizer, as it uses natural silicates in the form of serpentinite, phyllite, diatomaceous earth, dehydrated calcium sulphate/anhydrous of recognized agronomic effect, together with the WTP sludge that served as its base.

[0135] In current technique, there is nothing similar to the invention, which is environmentally correct and gives flow to the volume of WTP generated, transforming an environmental liability into an environmental asset.

[0136] With the use of WTP sludge mixed with minerals in chicken litter/corral/vivarium, the problem in these activities is minimized.

[0137] The use of traditional waste (shavings, straw, sawdust, etc.) brings a series of health problems to the activities, such as the proliferation of bacteria, rodents (and their transmissible diseases), small husks, etc.

[0138] In the case of bacteria/fungi/viruses, the use of a mixture of minerals (WTP sludge+other minerals), as it is not an organic substrate, obviously minimizes the proliferation of such pathogens. Less pathogens, lower costs.

[0139] The minimization of pathogens will be largely due to the physical and chemical aspect of the finished product object of this patent, since wood shavings, straw, sawdust, etc. they have rough surfaces and insets and, thus, greater capacity to fix bacteria, fungi, etc. Such health advantages can certainly be computed as additional gains, by minimizing the use of insecticides, bactericides, etc.

[0140] In the case of cascudinho its proliferation is also minimized for the same reason mentioned above;

[0141] The moisture retention capacity will be given by the intrinsic characteristic of the residue (high clay/silt content), added to the capacity of the added mineral. It is also important to emphasize that there will be a percolation of moisture through the gaps between the granules;

[0142] In the case of rodents, their infestation tends to decrease, as they will have less food available. The organic substrate leaves and the mineral enters.

[0143] With the standardization of the chicken litter/corral/vivarium, with the granules, there will be greater comfort for the animals. Greater comfort, greater productivity.

[0144] Litter management is facilitated, since the movement of a chicken litter/pen with traditional waste (shavings/straw), has its difficulties increased, since the material intertwines with each other, worsening with deposition of the waste;

[0145] With such use, the sanitary problem is minimized and the handling of the substrate is improved.

[0146] With the use of WTP sludge+minerals in litter, the use of this substrate in chicken litter/pen/biotery as fertilizer for agriculture is improved.

[0147] The possibility of adding minerals (which add chemical and/or physical benefits to the soil) to the ETA sludge, when it is granulated, brings advantages in its use as a fertilizer. Since they fill fertility and/or physical gaps in the crop where they will be used;

[0148] The possibility of adding minerals in traditional beds is less efficient than the solution presented here;

[0149] The inclusion of interesting minerals for agriculture, whether by chemical or physical aspect of these, is shown as an advantage that must be computed. It is in the granulation/mixing that we can correct nutritional deficiencies in the soil where the chicken/barn/animal litter will be used as fertilizer.

[0150] The advantage of dispersion in the crop is facilitated, for the same reason listed above.

[0151] If the breeder is not a farmer, he can, even so, sell the substrate at more interesting values, since it is enriched by minerals useful for agriculture.

[0152] Greater retention of ammonia, compared to waste traditionally used and substantial gain in the cost/benefit ratio of the fertilizer resulting from the industrial process and after its use as a substrate.

CONCLUSION

[0153] It will be easily understood by those skilled in the art that modifications can be made to the present invention without thereby departing from the concepts set out in the above description. Such modifications are to be considered within the scope of the present invention. Consequently, the particular embodiments described in detail above are only illustrative and exemplary and not limiting the scope of the present invention, which must be given the full extent of the appended claims and any and all equivalents thereof.