Disposal of Layer Manure

Big Dutchman has acquired considerable expertise in the design and operation of composting systems capable of processing poultry manure. Installations are capable of reducing the moisture content of waste containing 65 percent water from high-rise houses or from belt and aviary systems with 45 percent moisture. The Big Dutchman CompoTower applies microbial degradation to convert layer manure into a valuable pathogen-free, organic product marketed as an acceptable high-value fertilizer for domestic and institutional applications.

Direct spreading of raw manure onto farmland will be subject to increasing restrictions as the nitrogen component percolates through the soil and contaminates groundwater and wells. Runoff entering streams and waterways from concentrated animal feeding operations (CAFOs) is subject to increased scrutiny from both state and federal regulators, irrespective of ongoing relaxation of environmental regulations. Future environmental restraints may require on-farm or remote processing of manure before field application.

The CompoTower system reduces odor and eliminates complaints and lawsuits. With belt manure housing, fly populations are effectively eliminated, reducing expenditure on insecticides.

Operation of the CompoTower

The Big Dutchman CompoTower is available in a range of capacities, handling the output from farms housing 5,000 to 250,000 hens. For a modern U.S. in-line aviary complex with one million hens, four units can be clustered to maintain continuous processing of approximately 100 tons of manure daily. The processing cycle ranges from 5 to 15 days, depending on moisture content. Complete composting of waste from a belt-collection aviary system averages 10 days. The microflora of the tank functions in an anaerobic environment with sequential daily filling. The corresponding off-take of sterile, organic nutrient-rich product with a moisture content of 15 percent is gathered daily.

Each CompoTower can receive raw manure using a skid steer loader to transfer material from a storage area to a loading bucket in one-ton or larger increments, depending on the model. Manure is elevated to the input hopper on top of the tower. Designated quantities of manure appropriate to the capacity of the CompoTower are added to the insulated reaction vessel to undergo composting. Mixing blades with perforated holes agitate the product continually during composting. The insulated vessel is equipped with power ventilation, and the composting process is controlled by integrated circuitry located in a control panel. The screen provides appropriate readouts of temperature and other operational details. The composting process is continuously monitored with automated responses to ensure optimal function, eliminating the need for observation or intervention. CompoTower installations require 380-volt three-phase connections.

Application of CompoTower Installations

The CompoTower was designed by Big Dutchman’s agricultural engineers for ease of shipping. Assembly on-site is expedited by modular and bolt-together features. As with all Big Dutchman products, durability is ensured by incorporating stainless steel components that contribute to a long service life.

For farms of small capacity, the CompoTower is self-contained with respect to loading manure and the discharge of the composted product. For large in-line U.S. complexes, clusters of more than one CompoTower can be erected. These units will require elevators and conveyors that are designed and installed in accordance with the farm layout, including the number, size, and configuration of houses and the location of the central manure storage facility. Given the volume of product from large complexes, pelleting and bagging equipment is recommended to facilitate dust-free handling, marketing, and transport.

Big Dutchman has installed CompoTower units in the E.U. and Asian nations to comply with environmental regulations and is providing farmers with an additional cash stream from composted product.

Big Dutchman Air Scrubber

In areas with rigorous restrictions on the emission of compounds, including ammonia and greenhouse gases, Big Dutchman can supply a two-stage Air Scrubber. Each unit is designed to moderate the emissions of two CompoTowers. The Air Scrubber achieves a high separation rate, removing 99% of ammonia and 90% of dust.

Exhaust air is drawn from the CompoTower into the Scrubber and is filtered. Water is sprayed over the filter to separate dust. Water containing sulfuric acid is passed over the filter package to inactivate ammonia and other compounds. Water is recirculated, and the level of acidity and nitrogen is automatically monitored and adjusted. The Scrubber ensures that only clean, dry air is released from the CompoTower manure processing system.

Additional Information

Big Dutchman sales personnel and authorized agents can prepare feasibility studies to calculate the return on investment and payback from CompoTower installations. Actual return will depend on specific details relating to an operation, including the prevailing interest rate, depreciation provision, cost of power, and value of product.

For further information, access the Big Dutchman website www.bigdutchman.com.