R&D and manufacturing unit: R&D center of Fudiyuan Engineering Equipment (Henan) Co., Ltd

Scope of application: This manual is applicable to a full range of intelligent organic waste high-temperature liquid fermentation systems from Fudi's main research and development, production and sales, covering equipment technical parameters, structural principles, process flow, control logic, selection specifications, installation and commissioning, operation and maintenance maintenance technical descriptions, which can be used for engineering design, equipment procurement, on-site installation, operation and maintenance operation and technical acceptance.

1. Equipment Overview

This set of intelligent organic waste high-temperature liquid fermentation system is an integrated and efficient treatment equipment independently developed by Fudiyuan R&D Center based on years of experience in environmental protection equipment research and development, combined with the pain points of the organic solid waste recycling industry, and the core is aimed at various types of organic waste such as livestock and poultry manure, kitchen waste, crop straw, tail vegetables, municipal sludge, breeding tailings, etc., to overcome the industry problems such as long degradation cycle, incomplete harmlessness, low degree of intelligence, high energy consumption, and secondary pollution of traditional treatment processes.

The system takes high-temperature aerobic liquid fermentation technology as the core, integrates six core systems: automatic material pretreatment, constant temperature closed fermentation, intelligent closed-loop control, solid-liquid separation, product refining, and waste heat recovery, and runs in a closed and automated manner to achieve integrated treatment of organic waste reduction, harmlessness, and resource utilization, and all technical indicators are better than similar products in China , in line with the "Organic Fertilizer" (NY 525-2021), "Odor Pollutant Emission Standard" (GB 14554-93), "Pollutant Emission Standard for Livestock and Poultry Breeding Industry" (GB 18596-2001It can be widely used in large-scale farms, kitchen waste treatment stations, ecological agriculture parks, township organic solid waste centralized treatment stations, organic fertilizer production plants and other scenarios.

The main body of the equipment is made of food-grade 304 stainless steel, modular integrated design, small footprint, convenient installation, low operation and maintenance cost, stable operation, can be customized according to the needs of user processing volume, taking into account the needs of small and medium-sized distributed processing and large-scale centralized processing.

2. Core structure and system composition

2.1 Division of overall system modules

2.2 Technical structure of core fermentation units

The core fermentation tank is the core component of the system, which adopts a vertical airtight jacket structure, taking into account thermal insulation, anti-corrosion and pressure resistance, and the specific structural parameters are as follows:

1. Tank body: made of 304 stainless steel integral welded molding, the inner wall is finely polished, and the roughness is ≤ Ra0.8, no dead corners, no material residue, corrosion resistance, high temperature resistance, easy to clean, tank design pressure0-0.15MPa, with pressure resistance and anti-deformation performance;

2. Stirring system: top vertical explosion-proof motor driven, with double-layer propeller blades, the paddle is made of corrosion-resistant alloy, the speed is 0-60r/min stepless adjustable, which can realize the all-round uniform stirring of the materials in the tank and avoid material sedimentation and stratification. ensure full contact between microorganisms and materials;

3. Temperature control system: jacketed constant temperature heating structure, supports dual-mode switching of electric heating and steam heating, adopts PID for precise temperature control, and the temperature control accuracy is ± 1°C, which can stably maintain a high-temperature fermentation environment of 55-65°C, with a high-density insulation layer, and the heat loss rate is less than 10%;

4. Monitoring and safety components: the tank integrates temperature sensors, pressure sensors, pH electrodes, dissolved oxygen electrodes, and material level sensors to collect the whole process parameters in real time; Equipped with automatic pressure relief valve and overpressure alarm device to ensure the safety of tank operation.

3. Process flow and core technical parameters

3.1 Whole process route

The system adopts a fully automated closed-loop process, without frequent manual intervention, and the process flow is as follows:

Raw material collection → shear crushing (particle size≤20mm) → screening to remove impurities→ carbon-to-nitrogen ratio/ Moisture content tempering (C/N=20-30:1, moisture content 60-70% → closed transportation→ high temperature constant temperature fermentation (55-65°C). ，7-10 days) →Solid-liquid separation→ liquid organic fertilizer refining/Solid organic fertilizer processing → product storage

The waste heat generated during the fermentation process is recovered to the pretreatment module for preheating of raw materials, and the trace odor generated is discharged to meet the standards after deodorization and purification, and the condensed wastewater is recycled and recycled, with no secondary pollution in the whole process.

3.2 Core technical parameters

4. Core technology advancement and advantages

4.1 Advantages of high-temperature liquid fermentation technology

Compared with traditional composting and ordinary anaerobic fermentation processes, the high-temperature aerobic liquid fermentation technology of this system has subversive advantages: First, it is highly efficient degradation, and the high-temperature environment greatly activates the activity of special microbial strains with high temperature resistance, and the fermentation cycle is shortened by 60% compared with the traditional processAbove, the processing efficiency has been increased by 3 times, and the single-day processing volume has been greatly improved; The second is completely harmless, lasting a constant temperature environment above 55°C, which can completely kill pests such as Escherichia coli, salmonella, parasite eggs, weed seeds, etc., and the harmless compliance rate100%, eliminate the spread of germs; Third, the product quality is excellent, liquid closed fermentation reduces the volatilization and loss of organic matter, and the nutrients of the product are intact, which can be directly processed into high-end liquid organic fertilizer and biological bacterial fertilizer, and the added value far exceeds that of traditional compost products. Fourth, there is no odor diffusion, the whole process of closed fermentation, and the odor purification system completely solves the problem of odor disturbance in traditional treatment processes.

4.2 Advanced intelligent control system

The system is equipped with the PLC intelligent control system developed by Fudi to realize the digital control of the whole process: the industrial-grade touch screen human-computer interaction interface is adopted, and the operation is simple and intuitive; Real-time data such as temperature, pressure, pH, dissolved oxygen, and material level are collected through multi-parameter sensors, relying on PIDclosed-loop algorithm, automatically adjust the mixing speed, heating power, ventilation volume, and feeding speed, without manual duty; It has automatic alarm functions for over-temperature, over-pressure, overload, and material shortage, supports automatic shutdown of faults, remote parameter modification, data storage and traceability, and export of production reports, and can be connected to the factory IoT platform to achieve remote operation and maintenance control, greatly reduce manual operation and maintenance costs, and improve operational stability.

4.3 Energy saving and integration advantages

The equipment adopts modular integrated design, and can be put into use after on-site splicing and installation, with a short construction period and a small footprint. Supporting waste heat recovery system, the heat generated by fermentation is recovered for raw material preheating, reducing heating energy consumption, and the energy consumption per unit material treatment is reduced by 20% compared with similar products. condensate and cleaning water are recycled and recycled, and the utilization rate of water resources exceeds 90%; The core components are energy-saving motors, which have low operating power consumption and are much lower than traditional processing equipment.

5. Explanation of electrical control principles

5.1 Control core architecture

The electrical control of this system adopts PLC programmable controller+The industrial touch screen dual-core architecture, the power supply standard is three-phase four-wire 380V/50Hz, equipped with independent power distribution cabinet, with overload protection, short circuit protection, leakage protection, grounding protection multiple electrical safety protections The overall control system is stable and reliable, and is suitable for various industrial working conditions.

5.2 Control logic and principles

1. Signal acquisition: All kinds of sensors convert analog signals such as temperature, pressure, liquid level, pH and other analog signals into electrical signals and transmit them to the PLCcontroller to complete real-time data collection and conversion;

2. Logical operation link: PLC has built-in preset fermentation process program, calculates and analyzes the received signal, compares preset process parameters, and automatically issues control instructions;

3. Execution and control link: PLC command transmits to contactors, frequency converters, relays and other actuator components, controls the start and stop, speed regulation, power adjustment of stirring motors, heating devices, transfer pumps, valves and other equipment, and realizes precise regulation of parameters.

4. Safety and alarm link: When the parameters exceed the preset threshold, the control system immediately starts the sound and light alarm, and cuts off the power supply of the corresponding equipment at the same time to ensure the safety of equipment and personnel.

5. Remote communication link: Through Ethernet and 4G modules, the control system is connected to the cloud and mobile terminal, and supports remote monitoring, parameter debugging, and fault diagnosis.

5.3 Electrical control characteristics

The control system has manual/fully automatic dual modes, and the manual mode is used for equipment debugging and fault repair; Fully automatic mode for normal production operation; The parameters can be flexibly modified according to different raw material categories to meet the needs of various organic waste treatment. The electrical components are all first-line brand industrial-grade products, with strong anti-interference ability, long operating life, and extremely low failure rate.

6. Equipment selection table (standardized selection).

Selection remarks: According to the user's raw material category, site conditions, and processing needs, non-standard models, multi-tank parallel units, and supporting post-processing deep processing equipment can be customized.

7. Installation, commissioning and operation and maintenance specifications

7.1 Installation foundation requirements

The equipment installation needs to use a concrete hardened foundation, with a bearing capacity of ≥ 5t/㎡ and a flatness deviation of ≤3mm/m; The site is equipped with 380V industrial power supply and tap water source, and a simple rainproof shelter needs to be built for outdoor installation; There is no strong corrosive gas or strong electromagnetic interference in the surrounding area, the ambient temperature is 0-40°C, and the relative humidity ≤ 85%.

7.2 Debugging process

1. After the equipment is in place and the pipeline circuit is connected, the overall air tightness test is conducted, and the leakage rate ≤ 0.05MPa/h;

2. No-load test run: start each module equipment, run continuously for 4 hours, check the operation status of the motor, mixing and control modules;

3. Material debugging: Input 50% of the load raw materials, operate according to the process parameters, and monitor various data indicators;

4. Full load acceptance: 72 hours of continuous full load operation, complete commissioning and delivery after all indicators meet the standards.

7.3 Daily operation and maintenance

8. Fault diagnosis and troubleshooting

9. Technical services and prospects

Fudiyuan Engineering Equipment (Henan) Co., Ltd. provides full-process technical services, covering equipment customization, on-site installation, commissioning and training, after-sales maintenance, technology upgrades and other all-round support, and provides lifelong parts supply and technical guidance.