Components of Commercial Composting System

The ePTFE micropore membrane compost cover 

Our ePTFE (Expanded Polytetraflouroethylene) micropore membrane compost covers are specifically designed for the aerated static pile (ASP) composting technology which has the right porosity (0.2μm average) to closely match the oxygen demand characteristics of the organic feedstock material. It also maintains an optimum environment in the pile by controlling temperature and oxygen during the composting fermentation phase. 

The cover is a three-layer laminate consisting of an outer, protective, polyester fabric with an ePTFE membrane.  This three-layer combination creates a simi-permeable breathable cover that reduces Odor and VOC emission reduction while allowing moisture vapor and air to pass through the cover.

Layer 1 is high quality anti-UV & anti-aging polyester fiber material

Layer 2 is ePTFE membrane material

Layer 3 is polyester fiber material resistant to acid and alkali corrosion

Aeration and leachate management system

Five main performance metrics to consider when designing and evaluating an aeration floor include: airflow uniformity, peak aeration capability, ability to manage leachate, ease of operations and maintenance and longevity.

Based on the above requirements, our company has developed a system with independent intellectual property rights, which is mainly composed of blower with cast aluminum housings and perforated galvanized metal lid and HDPE groove and other pipe components.

To assure ideal conditions the intelligent management system will automatically start the blower according to the relevant parameters to inject air into the pile through the ducts, it can keep the pile under micro-positive pressure environment, avoiding anaerobic zones. The aeration ducts and leachate management system keep the air flowing and provides a clear separation of leachate from stormwater to prevent groundwater contamination.Based on the unique aeration channel design, we can place the heating tube inside the channel, so as to provide warm air for the entire heap without temperature difference, it helps to accelerate the aerobic fermentation process. This function is suitable for the compost projects in cold regions.

Features of aeration and leachate management system

1. Features of our Aeration and leachate management system:

2. Environmentally friendly--100% recyclable

3. Modular design for easy installation and maintenance

4. Superior resistance--retains its shape when compressed

5. Corrosion-free and no risk of oxidation

6. High-level of resistance to chemicals, fuels/oils, frost, corrosives and UV radiation

7. Temperature stable--climate operating temperatures from -30°C to +80°C  and beyond

The intelligent management system

Qingdao Giant Compost Technology Co., Ltd offers an intelligent management system（IMS） to control the covered aerated static pile composting technology. IMS assists compost facility owner in managing their aeration system to optimize control of blowers either through timer settings (set-points for on/off) or based on temperatures and oxygen in the pile as recorded by probes. The management system is completely flexible with user-friendly human-machine interface technology that not only allows operators the opportunity to choose operating parameters for each pile, but also to modify them as conditions dictate.

IMS provides compost facility owners continuous monitoring, more historical composting data logging (every five minutes) and storage (up to 60 days), accurate data for improved process management and control and resultant lower operator time and costs. It automatically gathers all the regulatory data needed and monitors temperatures by date, time and heap to produce regulatory reports. Also it is very smart that can control multiple blowers via ONLY ONE electric control cabinet unit and each blower can work independently according to the operating parameters, thus reducing the cost of the compost facility and simplifying the operation process. 

Working Procedure of Commercial Composting System

STEP 1: PRE-TREATING & MIXING

Break and crush the waste into fractions and mix with the admixture (e.g. woodchips) in a certain proportion according to the type of the waste and admixture.

STEP 2: FERMENATION &  DECOMPOSE

A. Pile the mixed materials into compost heap

B. Cover and seal the composting heaps with cover

C. Under the control of the intelligent management system, the mixed materials will be fully fermented and decomposed in 4 weeks.

STEP 3: STABILIZATION & CURING

Roll up the covers which covered on the heaps, heap materials will be further decomposed after 1-2 weeks without turning over.

STEP 4: SCREENING & STORAGE

The fully decomposed materials can be transferred to the storage area or landfill after screening.

Application of Commercial Composting System in MBT Treatment

The principle of mechanical biological treatment (MBT) of waste is to use mechanical sorting equipment to separate and utilize useful substances such as high calorific value substances, metals and glass in waste. The organic matter in waste is treated by aerobic fermentation of microorganisms,then it can be composted or implemented in a sanitary landfill. During the MBT process, materials such as metal and glass in the waste can be recycled and materials with high calorific value such as plastics are used for incineration for power generation and heating.

Residual and mixed municipal waste has the characteristics of high moisture content, usually it has moisture content more than 55% on average and even as high as 75% in some case, that is the main obstacle to the treatment of waste. High moisture content reduces the calorific value of waste and reduces the efficiency of incineration energy recovery and affects the economics of waste incineration; high moisture content also causes serious waste adhesion which is not conducive to subsequent sorting or transportation. Our commercial composting system can be combined with the process of mechanical biological treatment of waste (MBT) to reduce the moisture content of the waste before sorting and other processes, also it can make the organic waste into compost or sanitary landfills after sorting.

The application of MBT technology has played a great role in the reduction, recycling and harmless treatment of waste, which is conducive to achieve the ambitious goals of "carbon emission reduction" and "carbon neutrality" as soon as possible.

Benefits of Commercial Composting System 

1. Ensure excellent air quality. Effectively control odor >90%,VOC >90%

2. Reduce pathogens, reduce dust and biological aerosols. Prevent the spread of bacteria (such as Aspergillus fumigatus) > 99%, reduce the spread of dust and floating particles > 99%

3. The micro-positive pressure environment of the composting system ensures that the temperature is evenly distributed without any weather and environmental influences, meanwhile air is allowed to penetrate into everywhere and reduce the anaerobic zone.

4. Provide consistent high-quality compost in the shortest time. Compost contains available nutrients for plants, such as nitrogen, phosphorus, potassium, iron, calcium, magnesium, zinc, etc.

5. The most flexible design. Provide modular technical design solutions for different purposes and different processing stages.

6. Excellent cost performance. Treatment cost per ton is lower compared to other systems because of simplicity of design with few moving parts and low energy consumption. 

Equipments for Commercial Composting System

For operational efficiency of large-scale treatment of organic waste and long service life of heap cover, we have developed three types of our own patented winding machines: Tow Behind Winding, Wall-Walking Winding and Gantry Winding.