Hello! We came to solve your waste problem.
New! The FuelCal® technology – now available for everyone
Sewage sludge and organic waste (post-production biomass) management is a problem to solve by every sewage treatment plant, food processing plant, dairy or abattoir. One of the best ways, recommended by law, is to convert the waste on site into a finished marketable product. Not all of the above entities need large and high performance systems.
Many of them, due to the various constraints and conditions, for example, the small volume of sludge or waste produced, poor infrastructure or limited investment budget, are looking for simpler and more cost-effective solutions. Aiming at the producers with this profile, Evergreen Solutions has developed the containerised FuelCal® Mobile line. We come and process waste and the producer, in addition to having the waste problem solved, can also enjoy the profit from selling the finished and renowned OrCal® series product.
Mobile containerised FuelCal® lines – for whom?
Small sewage treatment plants, biogas plants
The containerised FuelCal® Mobile lines are perfect for small, municipal and industrial sewage treatment plants that produce up to several hundred tonnes of sludge per year, for example, 300 tonnes. With the FuelCal® technology, a treatment plant does not have to cover the costs of sludge transport and disposal outside the production site. A finished product of the OrCal® series is produced in the treatment plant, which can be contracted in advance by local farmers.
Medium and small processing plants
In Poland, there are many small and medium processing companies, for example, packing plants, processed fruit and vegetables manufacturers and wineries.
The waste generated by such entities is most often sent for processing for a fee, for example, to disposal, composting and biogas plants. The use of a mobile FuelCal® line can solve this problem in a simple manner: once a month, a containerised FuelCal® line arrives to convert the waste into the OrCal® series product, which is collected by Evergreen Solutions or sold (may be subject to bartering arrangements) to the farmers that supply agricultural products to the processing plant.
Agricultural production facilities
Agricultural facilities often have highly developed production that generates huge amounts of plant and animal waste. What matters is how they manage it. For example, in large pig farms, the FuelCal® technology solves the slurry management problem without the need to build covered lagoons and creating nuisance in the surrounding area. For farms specialised in plant production, waste processing is only possible in their growth periods, for example, after harvesting, and the generated OrCal® product can be used on the farm itself, to improve the soil quality and yield.
Why choose the containerised FuelCal® Mobile line?
- Low infrastructural investment costs
- No need for additional documentation, for example, an environmental report, a building permit design, a site development project etc. (in most cases)
- Investment without building permit (not applicable to the version with a silo with the capacity above 30m3)
- Can be transported on public roads with conventional equipment, such as truck tractor
- Mobility enabling the support of several branches of the plant producing the waste
- Small footprint for operation on small area sites
- Modular line design for long-term, trouble-free and easy operation
- Control and parameter monitoring from a multifunctional control panel or wireless tablet
- Low labour costs
- Favourable return on investment
- Compact design for easy funding with financial instruments, for example, leasing, rent etc.
FuelCal® Mobile – containerised waste treatment line. How does it work?
Version of the set with a reagent silo (with a silo capacity below 30m3, no building permit is required). Evergreen Solutions’ offer also includes kits with a system for unloading a big bag with reagent (this version also does not require a building permit).
1. Substrate loading
Substrate intake trough
The substrate for pre-shredding is fed into the trough, which consists of the hopper and the two-screw selector. The trough can receive up to 1.5 tonnes of the substrate per hour.The substrate for pre-shredding is fed into the trough, which consists of the hopper and the two-screw selector.
2. Substrate averaging
Buffer tank, homogenisation tank
The substrate, after pre-shredding in the trough, is transported by the conveyor to the buffer tank with the capacity of 1.5m3. It averages substrate particles and provides them with appropriate rheology.
3. Substrate feeding to the reactor
Substrate-to-reactor application system
After averaging, the substrate is fed to the reactor by a special feeding system with the capacity of up to 1.2 tonnes per hour.
4,8. Reagent loading
WapCal® reagent
The WapCal® reagent is fed by manual application to the special hopper, from bags stored on a pallet inside the container or directly from the silo (optionally).
5. Reagent transfer to the reactor
WapCal® reagent-to-reactor feeding system
It is designed to feed the reagent to the substrate mixing chamber in the reactor. After loading, the WapCal® reagent is transported to the reactor by a screw conveyor. Capacity – from 30 to 1000 kg/h.
6. Substrate and reagent mixing
R250 reaction unit
The reaction unit is used to produce organic and mineral products of the OrCal® series. It mixes the substrate with the certified WapCal® (BWR) reagent, compliant with the R.292513 standard. In the reactor, an exothermic chemical reaction takes place, followed by full sanitisation and sterilisation of the product. The entire process is compliant with the patent no. 229206. Reactor capacity – from 80 to 1200 kg/h.
7. Outlet of the finished product
System for extracting the finished product from the reactor
The finished product is collected from the reactor and transported the belt conveyor out of the container, where it will be seasoned and prepared for sale. Capacity – from 1,000 to 1,500 kg/h.
9. Recovery of macro- and micro-elements
Central condensate neutralisation system (CUNS1)
During the entire production process, the central condensate neutralization system (CUNS1) reduces all emissions, recovers the micro- and macro-elements content, and guarantees the safety of the entire process of biomass conversion into OrCal series products.
OrCal® – the resulting product of the FuelCal® line
Deacidification, fertilisation, nourishment
The FuelCal® process results in organic and mineral products with active calcium hydrate of the OrCal® and OrCal® pHregulator® series. Their characteristics are a perfect match for the problem of degradation of agricultural land in Poland. Much of it is highly acidic and poor in humus layer. OrCal® products dissolve in water almost 100 times better than traditional calcium carbonates, for example, chalk or dolomite. As a result, they increase the soil pH efficiently and quickly by up to 1 pH point in three months, which is a revolutionary result. In addition, with their organic matter content, they are excellent in soil fertilisation and plant nourishment. The application results are already visible in the first crop. This has been recognised by Polish farmers, thousands of whom have already decided to purchase OrCal® products.
Established market position
The unique characteristics of OrCal® products cause the demand for them to increase every year. Evergreen Solutions prioritises their quality, so the production sites follow a strictly defined technological regime. In addition, periodical control tests in science and certification centres are conducted, as well as field tests in the agricultural advisory centres. This appreciated by the farmers, who use OrCal® not only to improve the soil quality, but also to obtain tangible farming gains. The reputation of the OrCal® brand is also a major selling point and profit for production sites.
Winner of numerous industry awards
The investment in quality and reputation pays off. OrCal® products have been repeatedly recognised by farmers and experts, as evidenced by the industry awards, for example, Złoty Żuraw Rolnictwa – an award won at the Central Agricultural Trade Fair in 2016, the Cup of the Managing Director of the National Support Centre for Agriculture in 2019.
Process requirements of the FuelCal® Mobile line
| Description of the substrate | The shredded biomass from the agricultural and food industry and biodegradable waste shredded below 6mm, waste selected from Cat. II, i.e. milk, old digestive tract content separated from the digestive tract (excluding fallen stock) and Cat. III. With a veterinary medicinal product decision, it is permissible to process Cat. II. NOTE: By-products of animal origin shredded below 6mm and/or waste shredded below 6mm, agricultural and food biomass and post-production biomass fed to the FuelCal® Mobile system contribute to the end result, that is the production of the OrCal® fertiliser or OrCal® pHregulator® soil conditioner. The input substrate and the reagent/ground calcium lime in use have an impact on the type of the decision issued by the Minister of Agriculture and Rural Development and the composition, rheology and performance of the end product. |
| Waste composition | In the range of 17-22% of dry matter, 22% indication NOTE: It is required to feed the FuelCal® Mobile system with by products of animal origin/waste/sludge/ agricultural and food biomass/post-process biomass below 6mm at the level of 17-22%, with the qualitative, quantitative and composition parameters enabling the production of the rCal® pHregulator® soil conditioner or OrCal® fertiliser in accordance with the provisions the Fertilisers and Fertilisation Act of 10 July 2007. |
| Reagent consumption | 25-35%, with an average of 27%/tonne of waste fed to the FuelCal® Mobile system at the dry matter level of 17-22%, temperature of 20°C and pH of 6.5. NOTE: In the production process of OrCal® organic-mineral fertilizers or improving agents soil properties OrCal® pHregulator® only quicklime can be used as a reagent ground with very high reactivity, in accordance with the factory standard No. R.292513 for the WapCal® reagent, available at www.evergreen-solutions.pl. A necessary condition for proper conduct processing process, operation of production lines and creation of products from the OrCal® series strict use and ensuring automatic administration of controlled amounts of reagent with parameters no worse than those specified in the R.292513 standard. |
| Substrate feeding method | Discharge to the external intake trough (hopper) |
| Processing capacity kg/h | From 80kg/h to 1200kg/h (depending on the settings, temperatures, retention time in the RCal250m reactor and the rheology and pH of the waste |
| Possible operation hours per day | 1-15 hours/day, maintenance – 1 hour for the specified capacity |
| End product | Semi-granulate, OrCal® or OrCal® pHregulator® series product |
| Projected paving area | W/L/H – 20m/25m/5m over the trough |
| End product storage | Open covered warehouse or covered shed with fill height up to 2.5m |
| Media | Water – min. diameter 20mm, capacity 0.4m3/h Sewage system Ø100mm, water effluent approx. 480l/h Dry compressed air, Ø10mm, min. capacity 14m3/h Permanent Internet access via LAN RJ45 cable |
| Operation | 2 people |
| Other requirements | Required – ventilation and dust extraction system integrated into the facility system Required – telehandler required for co-packing, product/waste loading Recommended – forklift truck with the load capacity of min. 1.5t Line sold without truck tractor and semi-trailer |
