SOIL BUILDER

Abstract

The present invention relates to an organic soil builder, conditioner and/or biofertilizer, and to the production method thereof, which organic soil conditioner and/or biofertilizer has an organic base that allows the availability of nutrients in the soil to be increased for use when the plant requires, or the recovery of degraded soils. The method of the invention uses any type of animal waste sludges together with dry matter and granulated minerals. This mixture is fermented for 40 to 210 days, thus obtaining the organic soil builder, conditioner and/or biofertilizer of the invention.

Claims

1. A process for obtaining a builder, conditioner and/or organic soil biofertilizer, wherein the process comprises the following stages: a. mixing animal waste sludge with vegetal waste in a biodigester, composting field or mixing piles, where the final mix has between about 35 to about 45% humidity; b. fermenting this mixture for between about 40 and about 210 days; c. incorporating granulated mineral into the mixture; and d. obtaining the resultant builder, conditioner and/or organic soil biofertilizer.

2. The process according to claim 1, wherein the animal waste sludges correspond to primary or secondary sludges of the livestock industry, animal LIWs and faeces.

3. The process according to claim 1, wherein the vegetal waste comprises from about 20 to about 100% of dry vegetal material.

4. The process according to claim 3, wherein the vegetal wastes are chosen among straw, plantation remains, corn waste including corms, rice shells, dry leaves, pine needles, cues, shells and/or sawmill waste.

5. The process according to claim 1, wherein the vegetal material is incorporated in a proportion of between about 30 to about 60% with respect to the sludge used.

6. The process according to claim 1, wherein the granulated mineral is chosen from clay, SIALO flour, slag or ash.

7. The process according to claim 6, wherein the granulated mineral is incorporated in a proportion of between about 15 to about 25% with respect to the mixture of animal waste sludges with vegetal waste.

8. The process according to claim 7, wherein the granulated mineral is incorporated after the fermentation of the animal waste sludge and vegetal waste, and the fermentation is maintained for about 6 additional weeks.

9. The process according to claim 1, wherein the fermentation is anaerobic and is carried out in a closed biodigester or in a hot bed.

10. The process according to claim 9, wherein the fermentation is carried out at a temperature of between about 60 to about 70 C. and a pH between about 7 to about 8.

11. The process according to claim 1, wherein the fermentation step optionally comprises disposing the product in drying piles the last 2 weeks of the process, in order to allow the cooling of the builder, conditioner and organic soil biofertilizer product.

12. A builder, conditioner and organic soil biofertilizer product, wherein the product is obtained by the process described in claim 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0022] As already indicated above, the present invention consists of a reconstituyente, conditioner and/or organic biofertiizante of soils, and its process of elaboration, having an organic base that will allow to increase the availability of nutrients in the soil to be used when the plant require, or the recovery of degraded soils. The process of the invention uses any type of animal waste sludge in conjunction with dry vegetal material and granulated minerals, this mixture is subjected to a fermentation for a period of time of between 40 to 210 days, where the builder, conditioner and/or organic soil biofertilizer of the invention is obtained.

[0023] The process for obtaining a reconstitutant, conditioner and/or organic soil biofertilizer of the invention comprises the following steps:

[0024] a. mixing animal waste sludge with vegetal waste in a biodigester, composting field or mixing piles, where the final mix has between 35 to 45% humidity;

[0025] b. fermenting this mixture for between 40 and 210 days;

[0026] c. incorporating granulated mineral into the mixture;

[0027] d. obtaining the builder, conditioner and/or organic soil biofertilizer.

[0028] Wherein the sludge of animal waste corresponds to primary or secondary sludge of the livestock industry, of LIW and animals faeces. And the vegetal waste comprises 20 to 100% of dry vegetal material. Wherein the vegetal waste are chosen from straw, plantation debris, corn waste including corms, rice shells, dry leaves, pine needles, cues, shells and/or sawmill waste. And the vegetal material is incorporated in a proportion of between 30 to 60% w/v with respect to the sludge used.

[0029] Wherein the granulated mineral is chosen between clay, SIALO flour, slag or ash. The granulated mineral is incorporated in a proportion of between 10 to 30% w/w with respect to the mixture of animal waste sludge with vegetal waste. The granulated mineral is incorporated after the fermentation of the animal waste sludge and vegetal waste, and the fermentation is maintained for 6 additional weeks.

[0030] The fermentation is anaerobic and is carried out in a closed biodigester or in a hot bed; at a temperature between 60 to 70 C. and at a pH between 7 to 8.

[0031] The fermentation stage optionally comprises to dispose the product in drying piles the last 2 weeks of the process, in order to allow the cooling of the builder, conditioner and/or organic soil biofertilizer product.

[0032] The invention also aims at the builder, conditioner and organic soil biofertilizer product obtained by the described process.

[0033] The process of the invention consists of a fermentation of animal waste sludge and vegetal material, which varies according to the composition of the sludge, and a second stage of fermentation that includes adding granulated ore. The process of the invention can be carried out in any known anaerobic fermentation medium, including piles, biodigesters, hot bed, etc.

[0034] The animal waste sludges may correspond to primary or secondary sludge from animal fences and/or waste sludge from animal parts, that is to say LIW from livestock, fishing, poultry, aquaculture or other industries. It will be evident to the person skilled in the art that the method of the invention can also employ domestic sewage sludge, composition of which is similar to animal waste sludge. If these sludges have been subjected to a previous fermentation by using a biodigester, they are known as secondary sludge or digestates, and any of them can be used in the method of the present invention.

[0035] For the process of the invention it is required that the mixture of animal waste and vegetal material have a final humidity of 15-50% weight/weight, many times the final sludges does not have this percentage of humidity. In case the sludges are dry, water can be added to the mixture until reaching the desired percentage. In case the sludge is too wet, drier vegetal material is used, or completely dry, to obtain the proper humidity in the final mixture.

[0036] Therefore, the animal waste sludges are mixed with vegetal material, it is special, with waste material from the agricultural industry, in order to solve problems of disposal of these materials that often are even burned by farmers. As vegetal material can be used straw, residues of corn plantations, including corms, rice shells, dry leaves, pine needles, cues, shells, sawmill waste, and ultimately any residues from plantations. Conveniently, at least 20% of the vegetal material must be dry.

[0037] The vegetal material is incorporated in a proportion of between 30 to 60% w/v with respect to the sludge used.

[0038] If the sludges is raw or primary, it will be applied between 35-50% w/v of vegetal material. Of which at least 20% must be dry, wherein the dry matter is essential to accelerate the decomposition and fermentation, facilitating the way to the product of the invention.

[0039] In a preferred embodiment, between 25-40% w/v of vegetal material is applied, maintaining on the mixture a layer of between 30 to 60 cm thick of dry vegetal material on the surface, for example straw. This allows to maintain the mixture at an ideal temperature for the process, of 25-65 C. average.

[0040] In the case of a hot bed (fermentation in situ, in the pen), 50 cm of bed of initial dry vegetal material will be applied on the floor of the livestock production. This hot bed should be maintained with a dry surface between 30 to 60 cm thick.

[0041] The hot bed is a production process, wherein the animals are, in all their stages maintained in pens without slab, with a initial layer of dry matter (straw) preferably of 50 cm. After placing this layer, the animals are entered, which perform all their organic functions on it. Once the in situ fermentation process is initiated by the decomposition of the organic matter and the faeces of the animals, a layer of between 30-50 cm of dry matter is permanently applied to keep them dry and protected from the humidity generated in the fermentation process. This layer is usually applied every 48-76 hours.

[0042] If the sludge is secondary or digestates, it will be applied between 45 to 60% w/v of vegetal material, with at least 20% of dry vegetal material. The additional vegetal material allows to recover the carbon, fiber and other components lost in the generation of methane, and obtain an appropriate product for the reconstitution of soils, the ideal temperature for the process is between 55-65 C. average.

[0043] Finally, granulated mineral is added to these mixtures, the mineral can be clay, SIALO flour, which is obtained by crushing igneous rock, slag or even ashes. The maximum granulation of the mineral to be used is 200 nm, and the mineral is added in a proportion of 10 to 30% weight/weight to the previous mixture.

[0044] The inventors have found that the granulated mineral can be added after the beginning of the fermentation of sludge and vegetal material, however, the preferred embodiment comprises incorporating it in the final stage of the process, which determines the last 8 final weeks thereof.

[0045] Once the mixture of the invention is obtained it is subjected to anaerobic fermentation, for example, in Hot bed, or in fermentation reactors. (Biodigesters)

[0046] It is important that the processes are protected from rain, either indoors or covered with impermeable material, such as plastic.

[0047] Digestion in biodigesters produces methane gas, so the digesters or reactors must be closed and have a system for capturing the gas produced. Additionally, the fermentation is carried out at a temperature of between 60 to 70 C. and a pH between 6.5 to 8.5, especially between 7 and 8.

[0048] During fermentation the pathogen microorganisms die due to anaerobic conditions and high temperatures reached, up to 70 C., while the organic matter is degraded to appropriate nutrients for crops. The increase in temperature occurs naturally by fermentation.

[0049] In the second stage the granulated material is added to the fermented mixture in a proportion of 10 to 30% weight/weight, initiating the second stage of the process. This second stage of maturation lasts 6 weeks, at a pH between 6 and 7.5, wherein if the pH decreases it is increased by adding lime to the fermented material. Finally, the stabilized mixture is allowed to cool for 2 weeks, thus ending the process.

[0050] Surprisingly, after a very short period of time, between 80 and 210 days, the process has already been completed and the organic soil reconstitutant, conditioner and/or biofertilizer has been formed.

[0051] If the final product has between 35 and 48% humidity, it is used as a builder substrate and or organic soil conditioner. If in default, its humidity is between 10 and 20% it is used as an organic biofertilizer. This product can be used directly on agricultural soil at the end of the process.

[0052] Once the process of the invention is finished, the soil builder substrate and/or biofertilizer of the invention having the nutritional characteristics described in Table 1 is obtained; and chemical composition, % compound in mass and % element in mass indicated in Table 2, included below.

TABLE-US-00001 TABLE N1 Nutritional composition for soil reconstitution Compound Mass percentage Dry matter 55-54% Nitrogen (N) 1.56-4.60% Phosphorous (P) 0.78-10.0% Potassium (k) 0.38-2.5% Calcium (Ca) <3.08% Magnesium (Mg) <4.0% Organic matter 80-85% Sodium 10-3.48% Manganese <580 ppm mg/kg <1000 Sulfur <322% mg/kg1 <0.32% (SO4) Iron <5600 ppm mg/kg <7000 Boron <17 ppm mg/kg <7000 Zinc (Zn) <17 ppm mg/kg <120 Organic carbon 5-19.25% Moisture 36-45% Total humic extract <5.39 Humic acids <4.46 Fulvic acids <0.93 C/N ratio <17.08 pH 5.5-3.6 Electric Conduciivity dS/m2-10 Copper mg/kg<2.500 ppm 80 Lead mg/kg 4-8 Cadmium mg/kg <0.01 Arsenic mg/kg <0.05 Mercury mg/kg <0.005 Density kg/m3 520-750 g/cm3 0.52-0.80 Carbon 1-160 parts of C/1 part of N Organic carbon % average Organic carbon (g/kg) Ct 10.81% 108.0 Cext 4.06% 4.3 Cha 48.91% 2 Cfa 51.09% 2.3 CaO 12.50-13.31% SiO2 38.060-43.04% Al2O3 12.60-14.630% Fe2O3 10.480-13.380% MgO 10.380-10.740% SO3 0.101-0.330% K2O 1.670-1.940% Na2O 2.65-4.690% Cr2O3 0.070-0.072% NiO 0.090-0.095% SrO 0.100-0.107% MnO 0.170-0.176% P2O5 1.500-1.630% TiO2 2.750-2.765% P.F. 2.800-2.870% SiO2R 27.680-27.690%

TABLE-US-00002 TABLE 2 Compound Mass percentage Element Mass percentage SiO.sub.2 49.50% 38.06 Si 25.40-17.49 TiO.sub.2 2.10% 2.76 Ti 1.650-2.760 Al.sub.2O.sub.3 14.95% 12.6 Al 8.00-7.40 Fe.sub.2O.sub.3 3.70% 14.8 Fe 3.70-7.33 FeO 8.70% MnO 0.19% 0.176 Mn 0.136-0.176 MgO 6.80% 10.38 Mg 6.26-6.80 CaO 9.60% 13.1 Ca 5.60-9.51 Na.sub.2O 0.35% 4.69 Na 3.48 K.sub.2O 1.15% 1.94 K 1.150-1.610 P.sub.2O.sub.5 0.38% 1.53 Px 0.350-0.666 SO.sub.3 0.33% 0.101 Sx 0.04 PF 2.870% 2.800 SiO.sub.2R 27.690% 27.680 MnO 1500 ppm Mn 0.136-0.176 Cu 87 ppm Zn 105 ppm B 5 ppm Mo 1.5 ppm Cr 220 ppm 0.072 Cr 0.049 Co 48 ppm Ni 200 ppm 0.095 Ni 0.075 Sr 465 ppm 0.107 Sr 0.091 Ba 330 ppm

[0053] The stabilization of secondary sludge in normal composting, currently carried out in composting fields, takes between 210 and 360 days. This will depend on the climate and environmental humidity where this process is carried out, so that the method of the invention allows a very significant acceleration of the stabilization of the sludge.

[0054] The scope of the invention can be better understood in the examples included below.

EMBODIMENTS EXAMPLES

[0055] Different embodiments of the process of the invention are described below.

[0056] a) Process in Biodigester.

[0057] Primary waste sludges from the livestock industry (LIW, faeces and wastewater) were placed in a biodigester (10 m.sup.3) 10000 L of sludge, with approximately 70% humidity (in this example an approximate humidity is indicated because the mixture does not have a homogeneous humidity, however, the measurement registered 71%). The result of this is the generation of methane gas, generator of caloric and electric energy. The methane gas produced in the process was collected and recovered.

[0058] The product obtained has a pH of 7.80, slightly alkaline; an electrical conductivity (EC) in microohms of 20.91. A sample of 100 grams was analyzed and the following values were found: [0059] MO (organic matter) 34%; [0060] CO (organic carbon) 19.72%; [0061] N 1.70%; [0062] The Carbon/Nitrogen C/N ratio is 11.60; [0063] P 0.13%; [0064] Na 0.015%; [0065] K 0.135%; [0066] Ca 0.19%; [0067] Mg 0.18%; [0068] Fe 839 ppm; [0069] Mn 56.3 ppm; [0070] Zn 51.5 ppm and [0071] Cu 5.5 ppm

[0072] These residual sludge or biodigestates were mixed in closed containers, with straw, from dry bales in proportions of 50% dry matter and 50% biodigestates, which is equivalent to a 50% w/v mixture. Both components were mixed, where the final mixture had 40% humidity. This mixture was coated with dry straw in order to preserve the heat. The fermentation was allowed for 12 weeks, controlling that the pH were maintained over 8, if the pH was lowered, lime was added in order to increase it. The temperature was controlled, which naturally, by the fermentation process, was around 65 C. On the third month, 20% of SIALO flour was added, which was mixed with the fermentation already obtained and the mixture was continued in stabilization for 6 more weeks. Finally, the compost obtained was placed in drying piles for an 2 additional weeks, in order to allow the cooling of the Builder, conditioner and organic soil biofertilizer product, thus completing the 8 additional weeks of the process.

[0073] b) Process in Pile

[0074] Primary waste sludges from the intensive livestock industry, (LIWs, faeces, guanos, slurries and sewage), coming from a decanter pool or directly from a pen, were disposed in a drying pile (50 m.sup.3) 50000 L of sludge, with a 70% initial humidity.

[0075] It was added 35% of vegetal material with 75% dry matter, producing a compost in fermentation, stirring and mixing for 120 days. As result of this mixture in fermentation process, a temperature between 55 C. and 65 C. is reached naturally (specifically in the example was 60 C.), pathogens are removed, leached and percolated. It was possible to lower the humidity to 37%, producing a compost of nutritious characteristics similar to an organic bio-stabilized. To this mixture, 20% SIALO flour was added, which was mixed with the fermentation already obtained and was coated with dry straw in order to preserve the heat. The maturation was allowed for 6 weeks, controlling that the pH was maintained over 8, if the pH dropped, lime was added in order to increase it to the desired value. Finally, the fermentation product was allowed to cool for 2 weeks, totaling 8 weeks, with a total process time of 180 days.

[0076] c) Hot Bed Process.

[0077] Organic composts from hot beds were placed in mixing piles (50 m.sup.3) 32.5 MT (metric ton) of stabilized, with 40% initial humidity. The indicated product is a stabilization of pre-dry organic matter, producing a compost in fermentation in situ, which is achieved in livestock production pens, stirring and mixing with the bustle of the animals for 200 days (it can be a range of 150 to 210 days) the organic sludge generated by these with dry matter. The result of this mixture in controlled process with average temperatures of approximately 55 C. during the fermentation, was lowered to 40 C. inside the bed. With an initial process humidity of between 25-85% (in the example was 40%) in the lower layer of the pen and permanently maintaining a layer of not less than 30 cm of superior dry matter, it was obtained in the indicated time, a final mix of organic compost with a humidity of about 40% and a surface temperature of about 31 C. The composition of the hot bed is in Table 3.

TABLE-US-00003 TABLE 3 Nutritional composition of the hot bed during fermentation Moisture 72.1-80.73% Raw protein 14.69-26.92% Ether extract 3.85-10.9% Ashes 9.25-20.34% FND 28.42-68.65% FAD 7.95-29.93% CNE 4.86-23.26% Ca 2.51-5.01% P 0.19-0.29% Cu 427.64-1160.5 mg/kg

[0078] Manure contribution, calculation corresponds to 400 animals at 180 days average.

[0079] 360,000 kg-3,600,000 kg. The post-fermentation nutritional composition, hot bed compost is described in Table 4.

TABLE-US-00004 TABLE 4 O.M 40-60% pH 7-8.6% E.C. 3-10.0 dS/m N 3-4.5% P2O5 6-10.0% K2O 1.5-2.5% CaO 5-6.5% MgO 2-4.0% Cu 1000-2000 mg/kg Zn 2000-3500 mg/kg Mn 800-1000 mg/kg Fe 4000-7000 mg/kg B 80-120 mg/kg Lead 4-8 mg/kg Cadmium <0.01 mg/kg Arsenic <0.05 mg/kg Mercury <0.005 mg/kg Density 600-750 kg/m3

[0080] To this mixture, 20% SIALO flour was added, which was mixed with the fermentation already obtained and was coated with dry straw in order to preserve the heat. Maturation was allowed for 6 weeks, controlling that the pH was maintained over 8, if the pH drop, lime is added in order to increase it. Finally, the product of the fermentation was allowed to cool for 2 weeks, for a total of 8 weeks.

[0081] The final product of any of the processes described has the appearance of earth, and its constitution is included in what is described in Tables 1 and 2 of the description.