Composter Rotating Drum Technology

 

Composter Rotating Drum Technology is Destined For China

 

This Model 515 BioReactor Composting System (BCS) will be utilized as a Demo Unit For Pilot

Composter Rotating Drum Technology

This BCS offers a “plug and play” opportunity to test various feedstocks and amendments, and blending combinations at the job site.

Projects in all market sectors based in China. It is equipped with the essential components and complete automation features required for most composting facilities….essential that is if the goal is to obtain high quality mature compost in 4 to 7 days!

The Model 515 BioReactor Composter Rotating Drum Technology

The BioReactor is a rotating drum composter that has a load capacity of 70% of the total volume of the drum. This composter is 5’ diameter x 15’ long. It features a fixed, spring-loaded in-feed end with an opening for loading; a fixed, spring-loaded output end with an automated discharge auger or door; a rotating vessel supported by 4 trunnion wheels, a Friction Drive (.75 HP motor), and a negative ventilation fan.

The Mixer

A mixer is needed in order to pre-blend all the feedstocks so that a homogenous mixture of all the materials is obtained. This Mixer is equipped with cutting blades to slash the feedstocks in order to

Composter Rotating Drum Technology

The blades on the rotating vertical auger slash into the organic waste material thus breaking it into smaller pieces. This slashing action is especially critical and necessary when whole vegetables or fruit are present.

reduce the particle size. The capacity of the mixer used on the Model 515 BCS is 50 cubic feet and has a:

The Conveyor

The BCS is equipped with a heavy-duty automated incline conveyor fortified with a cleated belt. The cleated belt prevents the pre-blended organic waste from sliding back down the conveyor as it is being automatically loaded into the BioReactor.

The Control Panel

The control panel monitors the composting process and controls the function of the mixer, the conveyor and the BioReactor. This is accomplished by the Timer/PLC Control on the Control Panel. Complete control of the system is thus at the finger tips of the operator.

 

 

 

 

Rotating Drum Composting Technology

Rotating drum composting technology by XACT Systems is a time saver (and therefore money maker) from start to finish.

Beginning with installation, the XACT BioReactor Composting System is engineered in such a manner that it can be installed in 4 hours.  AND, this quick assembly can be accomplished by average workmen.  In other words, a manufacturer installation specialist is NOT required.  Furthermore, this rotating drum composting technology comes ready for easy electrical hook up followed by east start up…a neat example of “plug and play”!  Click here to see some examples of installations using the BioReactor.  The installation pictured here is at Interstate Septic Sludge in Maine.

Rotating drum composting technology

The BioReactor is engineered in such a manner so that the installation can be done easily and quickly…typically 4 hours will do it!

The most impressive time saving feature of the BioReactor Composting Systems in the length of time it takes to process and transform solid organic waste into compost.  Typically, the processing time is 4 days! What? How?  The BioReactor does so by tightly controlling the factors that are needed for natural decomposition to occur. The rotating drum provides a perfect environment for the decomposition process to occur.  The naturally occurring aerobic bacteria do the actual decomposition work, and the BioReactor provides the perfect setting by controlling all the relevant factors—moisture, oxygen, temperature—within the specific parameters that good composting requires  as per Mother Nature!  The time that the waste remains in the vessel is called retention time and this can vary depending on the type of waste to be composted. Typically, 4 days is sufficient to achieve compost that is about 75% mature (decomposed) and pathogen free, weed seed free, insect larvae free and virtually odorless.

Depending on the intended use of the compost, a final curing period maybe required.  Fortunately, with the BioReactor rotating drum composting technology, the curing period is faster than a “rocket full of monkeys.”  Specifically, upon discharge from the BioReactor, the compost is about 75% mature. In order to obtain maximum maturity (again, this curing period is not required for all uses of compost), the compost should be cured for an additional 14 days or so (the length of time can vary). During this period, the compost should be sheltered and internal pile temperatures controlled within EPA regulation standards.

As any business man/woman can tell you, saving time is equivalent to saving money.

The faster and easier the installation, the less money spent on labour and materials.   The faster the throughput (making compost), the quicker the compost is sold, and the quicker revenue is generated.  There are many other features of the BioReactor rotating drum composting technology that will save composting operations money and create revenue.  Please feel free to contact us directly to learn more.  If you click here, you can send us an outline of your project and we can and will get back to you QUICKLY!

 

 

 

Filed under: Uncategorized — Doreen on May 22, 2017

Composter Automates Rotating Drum Operation

Composter automates rotating drum operation with the newly automated PLC Control Panel with Soft Touch Screen by XACT Systems.  The user friendly soft touch screen on the front of the control panel was designed for the BioReactor Composting System in order to give the operator easy access to a wide variety of critical data.  Data which is vital to the successful composting of solid organic waste.

Although composting is not a complicated process it is a fairly precise process in terms of balancing the few factors that impact it.  The control panel has been developed to provide more accurate monitoring of these factors to ensure the best results.  A quick reminder as to what those few factors are:  Carbon-Nitrogen ratio, moisture content, oxygen, operating temperatures, and particle size.  For a more detailed description of the parameters for successful composting, please follow this link to the XACT Composting System website page describing them.

In addition, the data collected from the monitoring can be sent to the operator’s cell phone or computer 24/7.  By making the data “portable”, the operator can be tracking the BioReactor’s operation while eating lunch!

These added features compound the benefits that the XACT BioReactor System already has.

  1. The BioReactor has the fastest decomposition time—it can compost organic waste in as little as 4 days. Compare this to traditional methods that can take upwards of a year!
  2. Odor control is also ensured by the continual rotation of the drum, which causes the organic material to tumble around inside.  This tumbling action ensures all the particles of the waste are exposed to oxygen at all times which is vital to a highly aerobic composting process and therefore an odor-free process.
  3. Pathogen and virus destruction are the foundations of our composting system. XACT In-Vessel Organics Composting follows the guidelines set down by the EPA to ensure pathogen and virus kill.
  4. Less manpower is required because the rotating vessel does all the work—one man can operate the entire process especially when the composter automates rotating drum operation.
  5. The XACT BioReactor uses a very, very low horsepower electric motor to operate.
  6. The vessel can be insulated which helps retain the high operating temperatures of 130°F+ (55°C+) required (this is the EPA standard for pathogen kill—3 days at 130°F). Because of the insulation, the XACT vessel does not need to be housed in a building, but the compost should be stored under cover.
  7. The process is natural and typically requires no added heat.
  8. Less land is required with the BioReactor rotating drum because the decomposition process occurs within the vessel, and less feedstock piles are required because material is processed so fast.
  9. Site requirements are minimal because of the compact size of the system, and because what little condensates are present are completely captured.
  10. Fantastic compost is the result because changeable weather conditions are not a consideration, and all the factors needed for great decomposition are optimized and controlled.

To learn more about how the composter automates rotating drum operation with the new control panel is super easy.  Just contact us by Cell: 613-391-1445 or email info@xactsystemscomposting.com.  Many many thanks!  D

composter automates rotating drum operation with control panel and soft screen

The Soft Touch Screen on the PLC Control Panel allows for easy access to data such as processing temperature, starting/stopping, correct loading (capacity), door opening/closing and more!

Solid Organic Waste Management Facility

XACT Systems’ BioReactors will compost tons of solid organics daily at this new state-of-the-art solid organic waste management facility located in Goa, India.  In the final stages of completion, this massive facility will treat the solid organics waste of just the north half of the city.  The waste material coming into the plant is classified as MSW.

Solid organic waste mangement facility in Goa, India

These are the administration buildings of the North Goa facility.

Solid Organice Waste Management Facility

These 3 BioReactors are part of a comprehensive solid organic processing facility. The BioReactor Composting System by XACT Systems Inc. handles all the composting portion of the waste management treatment.

The treatments of the organics coming into the plant consist of fermentation processing (digester), and compost processing by the BioReactor Composting System.  In addition, the facility features bio-filters, transport truck weigh scales, bag openers, screeners, sorting stations, magnetic separators, balers, conveying systems and shredders.

This solid organic waste management facility design will be duplicated time and again.  The next facility to be built will be located in the south of Goa, India

SFC Environmental Technologies PVT Ltd. is the engineering firm behind this impressive facility.  They chose XACT Systems’ to be the supplier of the composting equipment.  Because of the heavy-duty and 24/7 performance redundancy design of the BioReactor, it was

Solid Organic Waste Management Facility

SFC designed and engineered this modern compost processing plant. It is but one portion of the entire solid organic waste management facility. At the end of the building, the ends of the 3 BioReactors are visible.

an obvious choice.  Plus, the accelerated processing, cleanliness and 70% fill capacity of this composter pushed the invessel rotating drum BioReactor to the top of SFC’s composter list.  It is very exciting for both XACT Systems and SFC Environmental Technologies to see this project nearing completion.  The next time we show pictures of this site, all the brown clay earth showing will be covered in green vegetation because the finished compost will applied to the grounds.  Compost makes as an excellent soil amendment and supports plant growth in harsh, dry conditions in a remarkable way.

For those of you who cannot get to Goa India to see this site, XACT Systems has many BioReactors working in North America and elsewhere.  Please feel free to contact us at anytime if you wish to arrange for a site visit.

If you want to meet with us, consider going to the US Composting Council Conference in Los Angeles, California, USA, on January 23-25.  You can find us at Booth 514. (Click on the link below to get more details about the conference venue etc).   Please feel free to stop by or call ahead (call
Glenn McConkey at 6123-391-1445) and arrange a private meeting to discuss you particular project.  Many thanks,  Doreen

www.uscompostingcouncil.org

 

 

Compost Slaughterhouse Renderings & Carcasses

Compost Slaughterhouse Renderings & Carcasses completely using the BioReactor by XACT Systems.  It makes sense for an organic beef operation to choose to compost the renderings from its slaughter house because this method of organic waste management jives with the overall objectives and philosophy of the organic meat industry.

This BioReactor Composting System is designed to compost slaughterhouse renderings & carcasses. (The carcasses have to be small or cut up) It can also handle other organic wastes such as manure, spoiled feed etc.

This site layout illustrates the complete composting process of the organic waste material from the mixer, the BioReactor to the short term curing piles.

This type of composting system (using multiple rotating vessels) can be scaled to any size to handle any volume of waste material/amendments.  The BioReactor is available in many sizes.  The smallest BioReactor is 5′ diameter x 10′ long while the largest is 10′ diameter x 60′ long (1.5 m diameter x 3m long) to 3m diameter x 18 m long).

Site Layout Description

In this particular scenario, the entire operation is inside (this is not always necessary for all facilities).  In order to compost slaughterhouse renderings & carcasses, the waste/amendments are loaded into a mixer.  The purpose of this initial step is to blend the various waste materials into a homogenous mixture.  This mixture is then discharged onto a conveyor and conveyed up to the infeed opening which is located in the upper quadrant of the end of the BioReactor.  The BioReactor has fixed ends.  A consequence of this unique feature allows the vessel to big filled to 70% capacity.

Another unique feature of the BioReactor are the Blending Bars.  The rotating drum turns SLOWLY and this rotation with the help of the Blending Bars causes the mixture to tumble inside.  This tumbling action greatly facilitates the aerobic composting process.  There is ample oxygen available to the naturally occurring aerobic bacteria and they thrive–multiplying their population exponentially–and decomposing the waste material at a phenomenal speed.

In addition, the high temperatures (thermophilic) required to compost any waste successfully are easily maintained by the BioReactor using the Negative Ventilation Fan.  This fan is located at the discharge end of the BioReactor and can be ducted into a BioFilter if odour control is an issue.

When ready for discharge, the discharge door/auger opens/unloads the compost onto an incline conveyor.  Then the compost is piled and stored for a short term curing period.  Skid steers are used to handle the piles as needed.

Typically, the length of time from start to finish is under 30 days.  To learn more about various possibilities of a composting operation check out www.xactsystemscomposting.com

 

Are You Attending the International Poultry Expo in Atlanta This Week?

Are You Attending the International Poultry Expo in Atlanta This Week?

If so, stop in at the Farmer Automatic booth in Hall C booth number C13007 and learn how to successfully compost all poultry waste.   There, you will find us, XACT Systems Inc. and the awesome BioReactor.

Compost poultry litter and much more with the BioReactor composting technology by XACT

BioReactor Composting System with In-feed and Discharge Conveyors, BioFilter & Future Expansion Capability.

When you compost poultry litter and all your other poultry waste with the BioReactor, you will realize economic benefits (always a good thing),  and environmental benefits.  Converting waste into quality compost allows you to capitalize on the nutrient value of the waste.  Because traditional methods of managing these wastes are incurring high costs, are creating health hazards and odor problems in the surrounding communities, and are causing damage to the environment, there is a need to treat these huge volumes of organic waste with technological innovation.

The BioReactor Composting System

The BioReactor Composting System is a rotating drum that converts any solid organic waste into compost.  It complies with the fundamentals of composting* regulations by tightly controlling the parameters of the composting process. The BioReactor makes an ideal environment for the oxygen-loving bacteria to thrive and decompose the material. The BioReactor will process large volumes of organic waste quickly, and will do so without the occurrence of hazardous leachates.

On Wednesday, January 28th, XACT Systems will make a presentation  describing 2 separate pilot projects that were conducted on poultry farms composting various types of poultry waste. One test took place in Brazil and the other in New York State. The test results proved that the BioReactor composting system will compost organic poultry waste in 7 days (or less), and will produce a light fluffy compost that is pathogen-free (including salmonella and coliforms), odor-free, weed-seed free, insect larvae-fee and mature. Indeed, the compost bears no resemblance to the waste from which it was produced.

This compost has tremendous value if sold in bags or bulk because it makes an excellent soil amendment due to its organic matter and nutrient content. Indeed, the compost no longer has harmful bacteria in it to cause disease so can be spread on land close to water sources. Because the BioReactor is situated on site, the cost of hauling poultry waste is eliminated. Depending on the facility’s situation, the compost can be used on site or sold to others.

* Composting is defined as a process of biological decomposition of biodegradable organic fraction of the waste, carried out by a diverse population of organisms under controlled aerobic conditions and other parameters (ratio of carbon: nitrogen, moisture, temperature, pH, particle size, porosity, homogeneity of the mixture).

If you are planning to go to the International Poultry Expo (IPPE) in Atlanta January 27-29, 2015, please consider attending the presentation and visiting us at booth C13007.  We will be at the Farmer Automatic booth in Hall C…again the booth number is C13007.  Hope to see you there!

In-Vessel Composters to Compost Palm Fruit Bundles

These in-vessel composters of XACT Systems are being manufactured in our Mexico plant, and will be composting the spent fruit bundles from palm oil production.  After the oil has been extracted from the fruit, the tons and tons of fruit bundle waste will be loaded into the XACT in-vessel composter and converted into rich earthy compost.  The compost will be a terrific soil amendment because it adds organic matter and nutrients back into the soil.  The soil is healthier thus the crops are healthier, more resistant to disease, and will produce higher yields.  So, not only will the XACT BioReactor solve the organic waste problem, it is also improving  crop production.

This link will take you to a document describing research done in 2006 regarding palm oil production and composting the spent fruit bundles.

http://www.biomass-asia-workshop.jp/biomassws/03workshop/material/tanaka.pdf

Actually, the in-vessel composter by XACT can compost any solid organic waste.  In this case, fruit bundles will be composted, but the BioReactor can also compost other agricultural waste such as green waste, spoiled feed, manure and mortalities.  In the  commercial sector, the BioReactor quickly composts food waste, fish waste, paper, leaf and yard waste, grass clippings and so on.

Composting palm fruit bundles

The production of palm oil creates tons of fruit bundle waste which needs to be sustainably managed. The operation where these 2 BioReactors by XACT will be going have wisely chosen to compost their waste. The finished compost can then be spread on the land to enhance future crop production.

Composting agricultural waste.

In-Vessel composters engineered by XACT Systems are ruggedly built to handle tons and tons of waste. The BioReactors turn slowly and in a 4 to 7 day period will compost raw organic waste into rich fluffy compost. These 2 composters are going to a palm oil production facility. They will be used to compost the spent fruit bundles from which the oil is extracted.

 

 

Each BioReactor is 10′ diameter x 40′ long.  The drum turns very slowly while the ends of the drum remain stationary.  This allows for the filling capacity to reach 70% of the volume of the vessel. The typical daily operation of a BioReactor begins by unloading a specific portion of the compost using the discharge door followed by loading the daily volume of waste material in to the BioReactor at the in-feed end.  The waste material remains in the BioReactor 3 to 7 days depending on the properties of the waste material.

Once this installation gets up and running, I will get pictures and post them so that you can see how well the operation is working.  Until then…check out our website for more information on some of our other installations.  Many thanks for your interest today!

In-Vessel Composting System is Put Through Its Paces and Performs Well

Our In-Vessel Composting System Is Being Put Through Its Paces and Performs Well

XACT’s in-vessel composting system is being put to the test in a pilot project using various solid organic materials and amendments.  One of the tests included small animal/bird mortalities as a feedstock.  Recently, one of the superb composts produced used the following feedstocks:

Composting food waste and other organic solid waste with the Compact BioReactor.

In-Vessel Composting System Using XACT Systems’ BioReactor for a
Pilot Project to Test Various Organic Waste Including Food Waste.

This project has been implemented  to confirm the BioReactor’s performance and to determine best practises for the composting process protocols  and feedstocks.  This in-vessel composting system is comprised of a 5′ diameter  x 10′ long vessel, a mixer and conveyor and is situated in a hoop building.  It has been running tests for approximately 6 months trouble free.  Satisfied with the pilot project results, this company is ready to take on the full “meal deal” and   get started commercially on a large scale with a 1060 BioReactor.

The Value of Pilot Projects

Pilot projects allow a facility to:

An in-vessel composting system, such as the Compact BioReactor, lend itself perfectly for pilot projects:

  1. The system is totally self-contained.  Typically, a mixer and conveyor come with the rotating drum in order to facilitate blending and loading.
  2. The BioReactor composting system comes completely wired and ready to go….just plug and play! (3 phase or single phase options)
  3. This composting system comes equipped with variable speed return air fan.
  4. The friction drive systems has extremely low energy requirements.
  5. The system is very quiet and pristine.
  6. The Compact composting system can be place on a flat bed trailer and moved from site to site.

 

 

 

The BioReactor Makes Ecological and Economical Sustainability Possible.

The BioReactor Makes Ecological and Economical Sustainability Possible.

Sustainable organic waste management–in the real world–has to converge 2 notions of sustainability.  The 1st is ecological sustainability and the 2nd is economic sustainability.  With XACT’s BioReactor composting technology, this dual purpose sustainability is not only possible but profitable!

Superb Green Roof Design

Superb Green Roof Design

Let’s consider, for example, the green roof industry.  A building owner chooses to have a green roof installed.  Construction begins using a soil substrate for the plants.  What if the soil substrate included compost made from organic waste which was generated by the occupants and/or operations of the building itself?   Now that is an exciting sustainable concept!

This is where the BioReactor enters the picture.  The BioReactor is ideally suited to an urban setting.  because the:

• Waste is quickly processed with automatic feeders and off loaded with no on-site peripheral contamination.

• Equipment meets OSHA Safety Standards.

• Remarkably small electric motors power the drive(s) so that the operation is quiet.

• The BioReactor has a professional finish and the installation is pristine in appearance.

By composting solid organic waste (food waste, paper, leaf and yard waste etc.) with the help of the BioReactor, you can turn raw waste into rich pathogen-free, sanitized compost in 4 to 7 days.

Plus, soil amended with good quality compost produces healthier plants. This picture compares 2

Plantings in soil amended with compost!

Plantings in soil amended with compost!

types of plantings.  The 3 rows of plants on the left were placed in pots in soil that had been amended with compost and the single row of plants on the right were placed in pots with soil only.  The difference in the health of the plantings is clearly visible, and there is much scientific study and data to prove the benefits of compost for plant better growth, and better resistance to pests and drought to be true time and time again.

No doubt by now, you have figured out  the economics/cost savings with respect to the:

Typically, the BioReactor will pay for itself in under 3 years which is better than industry standard.

This is just one example of how the BioReactor can make sustainable organic waste management both ecological and economical. Please feel free to get in touch with us to explore these opportunites for your next project. Many thanks, D.

 

XACT Systems Exhibits Latest Innovations of the BioReactor in Orlando Trade Show

The latest technological innovations to XACT’s BioReactor will be highlighted at the upcoming US Composting Council Conference and Trade Show in Orlando,  Florida.   With the latest advancements to the BioReactor Composting System, installation is easier and faster then ever.  The implications of this, of course, is lower costs!  (Always a good thing). If you are not able to come to the show, then just get in touch to learn more about the XACT  System BioReactor.  Many thanks, D

 

Tel: 1-613-399-5686   •   Or: 1-613-391-1445   •   Email: info@xactsystemscomposting.com