Technical Specification for the Intelligent High-Temperature Liquid Fermentation System for Organic Waste

Research and Development and Manufacturing Unit : Fudiyuan Engineering Equipment (Henan) Co., Ltd. Research and Development Center

Scope of Application This manual applies to the entire series of intelligent high-temperature liquid fermentation systems for organic waste independently developed, manufactured, and marketed by Fudiyuan. It provides comprehensive technical documentation covering equipment specifications, structural principles, process flows, control logic, selection criteria, installation and commissioning, as well as operation, maintenance, and upkeep, and is intended for use in engineering design, equipment procurement, on-site installation, operational management, and technical acceptance.

1. Equipment Overview

This intelligent high-temperature liquid fermentation system for organic waste is an integrated, high-efficiency treatment solution independently developed by the Fudiyuan R&D Center. Leveraging years of experience in environmental protection equipment R&D and addressing the key pain points of the organic solid-waste resource utilization industry, the system is specifically designed to handle a wide range of organic wastes, including livestock and poultry manure, food waste, crop straw, vegetable trimmings, municipal sludge, and aquaculture by-products. It effectively overcomes longstanding challenges in conventional treatment processes, such as long degradation cycles, incomplete harmlessness, low levels of automation, high energy consumption, and secondary pollution.

The system is based on High-Temperature Aerobic Liquid Fermentation Technology Centered on six core systems—fully automated material pre-processing, constant-temperature sealed fermentation, intelligent closed-loop control, solid–liquid separation, product purification, and waste heat recovery—the process operates in a fully enclosed, automated manner throughout, achieving integrated treatment that reduces, renders harmless, and recovers resources from organic waste. All technical performance indicators outperform those of comparable domestic products and comply with the “Organic Fertilizer” standard ( NY 525-2021 ）、 “Emission Standard for Odorous Pollutants” ( GB 14554-93 ）、 “Emission Standards for Pollutants from Livestock and Poultry Farming” ( GB 18596-2001 ) and other national and industry standards, can be widely applied in large-scale livestock farms, kitchen waste treatment facilities, eco-agricultural parks, centralized organic solid-waste treatment stations in towns and townships, and organic fertilizer production plants, among other settings.

The equipment body is made of food-grade materials. 304 Made of stainless steel and featuring a modular, integrated design, this system occupies a small footprint, is easy to install, incurs low O&M costs, and delivers stable operation. It can be custom-manufactured to meet specific throughput requirements, seamlessly accommodating both small- and medium-scale distributed treatment as well as large-scale centralized processing needs.

2. Core Structure and System Composition

2.1 Overall System Module Division

2.2 Core Fermentation Unit Technical Structure

The core fermentation vessel is the system’s central component, featuring a vertical, sealed jacketed design that simultaneously provides thermal insulation, corrosion resistance, and pressure resistance. The specific structural parameters are as follows:

1. Tank body : Adopt 304 Stainless steel, integrally welded and formed; inner wall undergoes fine polishing to achieve a specified surface roughness. ≤Ra0.8 , no dead corners, no material residue, corrosion-resistant, high-temperature resistant, easy to clean, and the tank’s design pressure 0-0.15MPa , with pressure-resistant and deformation-proof performance;

2. Mixing System : Top-mounted vertical explosion-proof motor drive, paired with a double-layer propeller; the propeller blades are made of corrosion-resistant alloy, with a rotational speed 0-60r/min Infinitely variable speed control enables omnidirectional, uniform mixing of the material within the tank, preventing sedimentation and stratification and ensuring thorough contact between microorganisms and the material.

3. Temperature control system : Jacketed constant-temperature heating structure, supporting dual-mode switching between electric heating and steam heating, employing PID Precise temperature control, temperature control accuracy ±1℃ , can be stably maintained 55-65°C High-temperature fermentation environment, combined with a high-density insulation layer, results in a heat loss rate of less than 10%；

4. Monitoring and Security Components : The tank body is integrated with a temperature sensor and a pressure sensor, pH Equipped with pH electrodes, dissolved oxygen electrodes, and level sensors to collect process parameters in real time; paired with fully automatic pressure-relief valves and overpressure alarm systems to ensure the safe operation of the vessel.

3. Process Flow and Core Technical Parameters

3.1 End-to-end process route

The system employs a fully automated closed-loop process that requires no frequent manual intervention. The process flow is as follows:

Raw Material Collection → Cutting and crushing (particle size ≤20mm ) → Screening and impurity removal → Carbon-to-nitrogen ratio / Moisture content conditioning ( C/N=20-30:1 , moisture content 60-70% ) → Closed-Loop Conveying → High-temperature constant-temperature fermentation ( 55-65°C ， 7-10 days) → Solid-liquid separation → Refined Liquid Organic Fertilizer / Solid Organic Fertilizer Processing → Product warehousing

Waste heat generated during the fermentation process is recovered and fed back to the pretreatment module for feedstock preheating; trace odorous emissions are treated and purified to meet regulatory standards before discharge; condensed wastewater is collected and recycled; and the entire process is free from secondary pollution.

3.2 Core Technical Parameter Metrics

4. Advanced Core Technology and Its Advantages

4.1 Advantages of High-Temperature Liquid Fermentation Technology

Compared with conventional composting and standard anaerobic fermentation processes, this system’s high-temperature aerobic liquid fermentation technology offers disruptive advantages: first, Efficient degradation , High-temperature conditions significantly activate the activity of heat-resistant specialized microbial strains, shortening the fermentation cycle compared with conventional processes. 60% Above, processing efficiency has improved. 3 times, with a substantial increase in daily processing capacity; second, Complete harmlessness , continuous 55°C The above-mentioned constant-temperature environment can completely eliminate harmful organisms such as Escherichia coli, Salmonella, parasite eggs, and weed seeds, achieving compliance with harmlessness standards. 100% , to prevent the spread of pathogens; third, Excellent product quality , liquid closed fermentation reduces the volatilization and loss of organic matter, ensuring that the nutrient content of the product remains intact; the resulting material can be directly processed into high-end liquid organic fertilizers and bio-organic fertilizers, with added value far exceeding that of traditional compost products; fourth, No odor diffusion The entire process is conducted in a fully sealed fermentation system, coupled with an odor purification system, thoroughly resolving the issue of odor nuisance to residents that plagues conventional treatment processes.

4.2 Advanced Nature of the Intelligent Control System

The system is equipped with Fudiyuan’s independently developed Programmable Logic Controller Intelligent control system for end-to-end digital monitoring and management: features an industrial-grade touchscreen HMI for simple, intuitive operation; utilizes multi-parameter sensors to collect temperature, pressure, pH , dissolved oxygen, material level, and other data, relying on PID The closed-loop algorithm automatically adjusts the agitator speed, heating power, ventilation rate, and feed rate, eliminating the need for manual supervision. It features automatic alarm functions for over-temperature, over-pressure, overload, and material shortage, and supports automatic shutdown in case of faults, remote parameter modification, data storage and traceability, and export of production reports. The system can also be integrated with the plant’s IoT platform to enable remote operation and maintenance management, significantly reducing labor costs and enhancing operational stability.

4.3 Energy-saving and Integration Advantages

The equipment features a modular, integrated design that allows for on-site assembly and immediate commissioning, resulting in a short construction period and a small footprint. It is also equipped with a waste-heat recovery system that captures the heat generated during fermentation to preheat raw materials, thereby reducing heating energy consumption and lowering the specific energy consumption per unit of material processed compared with similar products. 20% ; Condensate and wash water are recovered and recycled, with a water utilization rate exceeding 90% ; The core components utilize energy-efficient motors, resulting in low operating power consumption and significantly lower overall operation and maintenance costs compared with conventional treatment equipment.

5. Explanation of Electrical Control Principles

5.1 Control Core Architecture

This system employs electrical control. Programmable Logic Controller Programmable Controller + Industrial Touch Screen Dual-core architecture, with a three-phase four-wire power supply standard. 380V/50Hz It is equipped with a dedicated distribution cabinet that provides multiple layers of electrical safety protection, including overload protection, short-circuit protection, leakage protection, and grounding protection. The overall control system is stable and reliable, making it suitable for a wide range of industrial operating conditions.

5.2 Control Logic and Principles

1. Signal Acquisition Stage : Various sensors will measure temperature, pressure, liquid level, pH After the analog signal is converted into an electrical signal, it is transmitted to Programmable Logic Controller The controller performs real-time data acquisition and conversion.

2. Logic Operation Stage ： Programmable Logic Controller It features built-in preset fermentation process programs that perform computational analysis on received signals, compare them with the preset process parameters, and automatically issue control commands.

3. Execute the regulation and control phase ： Programmable Logic Controller The control commands are transmitted to actuating elements such as contactors, variable-frequency drives, and relays, enabling the start/stop, speed regulation, and power adjustment of equipment like agitator motors, heating units, transfer pumps, and valves, thereby achieving precise parameter control.

4. Security and Alarm Section : When a parameter exceeds the preset threshold, the control system immediately activates an audible and visual alarm and simultaneously cuts power to the corresponding equipment, thereby ensuring the safety of both the equipment and personnel;

5. Remote communication link : via Ethernet, 4G A module that enables connectivity between the control system and the cloud and mobile devices, supporting remote monitoring, parameter tuning, and fault diagnosis.

5.3 Characteristics of Electrical Control

The control system features manual operation. / The system features fully automatic dual-mode operation: manual mode is used for equipment commissioning and troubleshooting, while fully automatic mode is employed for routine production. Parameters can be flexibly adjusted to accommodate different types of feedstock, ensuring optimal performance for a wide range of organic waste treatment applications. All electrical components are sourced from leading industrial-grade brands, offering strong anti-interference capabilities, long service life, and an exceptionally low failure rate.

6. Equipment Selection Table (Standardized Selection)

Selection Notes : Custom non-standard models, multi-tank parallel units, and accompanying advanced post-processing equipment can be tailored to meet users’ specific raw-material categories, site conditions, and processing requirements.

7. Installation, Commissioning, and Operation & Maintenance Specifications

7.1 Basic Installation Requirements

Equipment installation requires a concrete hardened foundation with adequate load-bearing capacity. ≥5t/ ㎡, flatness deviation ≤3mm/m ; On-site equipped with 380V Industrial power supply and municipal water source; for outdoor installation, a simple rain shelter must be erected; the surrounding environment should be free of highly corrosive gases and strong electromagnetic interference, with an ambient temperature of 0–40°C , relative humidity ≤85%。

7.2 Debugging Process

1. After the equipment is in place and the piping and electrical circuits are connected, perform a comprehensive air-tightness test, with a leakage rate of ≤0.05 MPa/h ；

2. No-load trial run: Start all module equipment and operate continuously. 4h , check the operating status of the motor, agitator, and control module;

3. Material-in-place commissioning: Initiate 50% Load the feedstock, operate according to process parameters, and monitor all relevant data metrics.

4. Full-load acceptance: continuous 72h Operate at full load and complete commissioning and handover upon verification that all performance indicators meet the required standards.

7.3 Daily Operations and Maintenance

8. Fault Diagnosis and Troubleshooting

9. Technical Services and Prospects

Fudiyuan Engineering Equipment (Henan) Co., Ltd. provides end-to-end technical services, including equipment customization, on-site installation, commissioning and training, after-sales maintenance and repair, and technological upgrades, along with lifetime supply of spare parts and ongoing technical support.