PRESS TECH AGRI-PRESS 600 SOLIDS SEPARATOR
AWM-01-01PRESS TECH AGRI-PRESS 600 SOLIDS SEPARATOR PERFORMANCE TEST RESULTS USINGTHE UNIVERSITY OF TENNESSEE TESTING PROTOCOLRobert T. Burns and Lara B. MoodyThe University of TennesseeBiosystems Engineering & Environmental Science Dept.P.O. Box 1071, Knoxville, TN 37901-1071INTRODUCTIONConfined animal production systems utilizing hydraulic-flush manure collection and transport systems usedifferent methods of solids separation to achieve an effluent low enough in total solids to be recycled asflush water. Mechanical solids separators provide one method of solids reduction for flush systems. Theperformance of mechanical manure solids separators can vary dramatically with different total solids inputconcentrations. To properly size and install mechanical manure solids separation units, the separators’performance characteristics must be known for the manure slurry found at the farm in question. The resultsof these performance tests provide information a planner can use to estimate the expected through-put ofmaterial, the resulting mass of solids to be removed and the total solids (TS) content of the recovered solidsexpected from a given manure slurry. This is important information when sizing process sumps and solidsstorage areas; it is critical to selecting a unit that can be operated in the time frame desired by the producer.The nutrient partitioning data can be used by nutrient management planners to estimate the mass ofnutrients remaining with the recovered solids.In an effort to provide comparable performance data with a common basis for the selection of mechanicalseparators, the Biosystems Engineering and Environmental Science Department at The University ofTennessee has developed a standard testing protocol for mechanical manure solids separators. This protocolis designed to provide consultants, engineers and producers with separator performance data across a rangeof manure total solids input concentrations. The University of Tennessee Biosystems Engineering andEnvironmental Science Department has the capability to provide field-scale performance testing of manuresolids separators with either dairy or swine manure slurries at two university experiment station locations.The results of the separator performance testing are a comprehensive analysis of the unit, including; pressliquor flow rates over a range of influent total solids (TS) concentrations and the resulting press-cakemoisture content, dry-mass capture efficiency, and nutrient partitioning of total kjeldahl nitrogen (TKN),total phosphorus (TP), soluble phosphorus (SP), and potassium (K) between the solids and liquid effluentsfrom the separator.UNIT DESCRIPTIONThis report presents the results from testing a PressTech Agri-Press 600 screw-press (Press Technology &Manufacturing, Inc., Springfield, OH) preceded by a Bauer Hydro-sieve static screen (Springfield, OH).The Agri-Press 600 screw-press had a 6-inch diameter continuous flight screw. Two screens were tested onthe Agri-Press, a 0.006” wedge-wire screen and a 0.125” round perforated screen. The Bauer Hydro-sievestatic screen used a 0.060" screen 28" in width and 50 " in length. The static-screen was used to pre-thickenthe input slurry fed to the screw-press. Testing was preformed on June 25 – 27, 2001 at The University ofTennessee Dairy Experiment Station in Lewisburg, TN.1
SEPARATOR TESTINGFor the separator performance tests with dairy waste slurry, raw dairy manure and bedding were collectedand stored for 48 hours prior to testing. Recovered dairy manure solids are used as bedding material at theUT Dairy Experiment Station were the testing was conducted. The manure and bedding mixture wasapproximately 20% TS. Each performance test began with a 500 gal (1890 L) tank containing waste withapproximately 10% TS. To make 10% TS slurry, collected manure and bedding were mixed with dilutionwater for 30 minutes using an electric paddle stirrer. The manure slurry was then pumped from the tank tothe separator system using an air driven diaphragm pump (Model #2150, Graco Husky, Minneapolis, MN).During the testing, the manure slurry storage tank was agitated using a centrifugal wastewater pump(Model #N267-F, Zoeller Pump Co., Louisville, KY). The Agri-Press unit input rate was limited by themaximum flow-rate that the static-screen could process. All test runs with the Agri-Press were made withthe static-screen at full capacity. For this test, the Agri-Press 600 screw-press was operated with a screwspeed of 25 rpm. All test runs were made with 33 psi of pressure on the outlet cone. The pressure resultedin a press cake with approximately 70% moisture content, which was the desired press-cake moisturecontent for this test. If a drier press-cake is desired, the Agri-Press unit can be operated with cone outletpressures of up to 100 psi.Samples were collected from the influent and effluent points of each unit. These included side-hill influent,side-hill effluent liquor, side-hill effluent cake (same as screw-press influent), screw-press press-liquor, andscrew-press press-cake. Test duration at each slurry input TS concentration was based on the time requiredto recover approximately 50 gal (190 L) of side-hill effluent liquor or press-liquor from the system.Resulting press-cake and liquor volumes were weighed using a Tru-test load cell (Model #703, Tru-test,Mineral Wells, TX). After testing the system at 10% TS, the manure slurry in the tank was diluted toapproximately 8% TS, and the system tested again. Subsequently, tests were performed with approximately6, 4, 2 and 1% TS influents. Samples were analyzed for total and volatile solids using Standard Method2540. G (Standard Methods, 1998), SP using QuikChem method 12-115-01-1-H (Lachat Instruments,Milwaukee, WI), TP using QuikChem method 13-115-01-1-B (Lachat Instruments, Milwaukee, WI), TKNusing QuikChem method 13-107-06-2-D (Lachat Instruments, Milwaukee, WI).RESULTSPress-Tech provided a manure separation system for testing that utilized a static-screen pre-thickening unitand an Agri-Press 600 screw-press unit. The results presented here are for the overall system performance,not the performance of the screw-press alone. The system was tested with both a 0.006” wedge wire screenand a 0.125" round perforated screen installed in the Agri-Press separator. The static-screen unit precedingthe Agri-Press was equipped with a 0.060" screen for all tests. Information concerning the performance ofthe static-screen or screw-press only can be found in Appendices A & B of this report. Appendix Aprovides the complete data set from the test. Appendix B provides graphs of the data set.System Results with 0.006” wedge wire screen in Agri-Press UnitSystem testing, while the Agri-Press was equipped with a 0.006" screen, was conducted using dairy manureslurries with TS system input concentrations ranging from 1.2 to 8.5%. The press-liquor flow rate throughthe separator system increased as influent TS concentration decreased (Figure 1). In this report, press-liquorflow rate is the sum of the side-hill liquor and the screw-press liquor. For flow rates from each device, seeAppendix A. The press-liquor flow rate of 44.1 gpm occurred at an influent TS concentration of 1.2%. At aslurry influent concentration of 8.5% TS, the system achieved a press-liquor flow rate of 6.4 gpm. Thescrew-press maintained a constant press-cake moisture consistency throughout the test (Figure 1). Theaverage TS concentration of the press cake was approximately 30% ( 5%).The dry-mass capture efficiency of the separator system remained fairly constant over the range of slurryinfluent concentrations tested. The average dry-mass capture efficiency was approximately 32 % ( 8.5%)(Figure 2). Dry-mass capture efficiency was calculated as follows:2
Dry-mass capture efficiency (%) min (%TS in ) m PL (%TS PL )m (%TS PC ) 100 PC 100min (%TS in )min (%TS in )Where min is mass influent, mPL is mass press-liquor and mPC is mass press-cake.80%4060%3040%2020%100Press Cake TS50Press Liquor Flow Rate(gpm)100%60Press Liquor Flow Rate(gpm)Press-Liquor Flow RatePress Cake TS0%0%5%Influent TSDry-Mass Capture Efficiency60100%5080%4060%3040%2020%10010%0%FIGURE 1. Press-Liquor Flow Rate (gpm) andPress-cake Total Solids (TS, %) from the SideHill / Screw-press Separator System (0.006”screen) as a Function of Influent TS (%)Concentration.2%4% 6% 8%Influent TS (%)Dry-Mass CaptureEfficiencyPress Liquor Flow Rate0%10% 12%FIGURE 2. Dry-Mass Capture Efficiency by theSide Hill / Screw-press System (0.006” screen)as A Function of Influent Total Solids (%)Concentration.At an influent TS concentration of 8.5%, 11% of the influent manure mass was recovered in the press-cake,on a wet-weight basis. However, 16.6% of the influent SP, 20.9% of the influent TP and 22.3% of theinfluent TKN were recovered in the press-cake on a wet-weight basis (Figure 3). Because the percentage ofnutrients recovered in the press-cake was greater than the percentage of mass recovered in the press-cake,nutrients were being partitioned into the press-cake. As the influent TS concentration decreases, theprevious statement is true for all but one case. At 5.2% influent TS, the percentage of recovered SP isslightly less than the percentage of recovered manure mass. This data point may be attributed to samplehandling or analyses error. Percentage of influent constituent recovered in the press-cake was calculated asfollows:Percentage in press cake Percentage in Press-CakeManure massm PC constituent 100min luent TS2.4%1.2%FIGURE 3. Nutrient Partitioning: Percentage of InfluentConstituent Recovered in the Press-Cake, on a Wet Basis.3
System Results with 0.125” round perforated screen in Agri-Press UnitWhile the screw-press contained the 0.125” screen, the system was tested with TS influent concentrationsranging from 1.3 to 11.8%. The separator system press-liquor flow rate increased as influent TSconcentration decreased (Figure 4). The maximum press-liquor flow rate of 34.8 gpm occurred at aninfluent TS concentration of 1.3%. At an influent concentration of 11.8% TS, the system achieved a pressliquor flow rate of 3.9 gpm. The system maintained a press-cake with a TS concentration of 34% ( 2.4%)while the influent TS range was between 1.3 and 11% (Figure 4). However, at an influent TS of 11.8% thepress-cake TS dropped to 16.6%; this was likely the result of an unsatisfactory cake being built after themachine purged during a previous test.Generally, the dry-mass capture efficiency of the separator system increased with an increasing influent TSconcentration. With a 1.3% TS influent, the dry-mass capture efficiency was 18%, while at 11.8% TSinfluent the dry-mass capture efficiency was 32% (Figure 5).Press-Liquor Flow Rate100.0%5080.0%4060.0%3040.0%2020.0%1000%2%4% 6% 8%Influent TS60100%5080%4060%3040%2020%1000.0%10% 12%0%FIGURE 4. Press-liquor Flow Rate (gpm) andPress-cake Total Solids (TS, %) from the SideHill / Screw-press Separator System (0.125”screen) as a Function of Influent TS (%)Concentration.Dry Mass Capture Efficiency2%4% 6% 8%Influent TS (%)Dry Mass CaptureEfficiency60Press-Liquor Flow Rate,gpmPress-Cake TSPress Cake TSPress Liquor Flow Rate(gpm)Press-Liquor Flow rate0%10% 12%FIGURE 5. Dry-Mass Capture Efficiency by theSide Hill / Screw-press System (0.125” screen)as a Function of Influent Total Solids (%)Concentration.When the influent TS concentration was 11.8%, SP and TKN were not preferentially partitioned into thepress cake. As indicated above, abnormalities in this run may have been the result of the screw-presspurging during a previous test. In all other data sets taken using the 0.125” screen, SP, TP and TKN werepreferentially partitioned into the press-cake, as shown in Figure 6.Percentage in Press-CakeManure massSPTPTKN50%40%30%20%10%0%11.8%11.0%4.8%Influent TS2.9%1.3%FIGURE 6. Nutrient Partitioning: Percentage of InfluentConstituent Recovered in the Press-Cake, on a Wet Basis.4
CONCLUSIONSThe University of Tennessee testing protocol developed for mechanical manure solids separators was usedto quantify the performance of a manure solids separation system consisting of a Bauer Hydro-sieve staticscreen followed by a PressTech Agri-Press 600, using both a 0.006” wedge wire screen and a 0.125” roundperforated screen. The 0.125" perforated screen produced higher press-liquor flow rates than did the 0.006”wedge-wire screen with the exception of the lowest total solids (TS) influent ( 1% TS). Press-liquor flowrates for this system vary with influent TS concentration and screen size. The flow rates ranged from 3.9 to44.1 gpm at influent TS concentrations of 11.8 and 1.2%, respectively. The 0.125” screen maintained ahigher TS concentration press cake than the 0.006” screen. The average press-cake TS concentration was34% from the 0.125” screen and 30% from the 0.006” screen. The dry-mass capture efficiency was greaterand more consistent when the Agri-Press had the 0.006” screen in place; the average capture efficiency was32% throughout the testing. When the 0.125” screen was in place the dry-mass capture efficiency variedwith influent TS concentration. At 1.3% TS influent, the dry-mass capture efficiency was 18%, while at11.8% TS influent the dry-mass capture efficiency was 32% The Agri-Press preferentially partitionednutrients into the press cake using both screens. The percentages of nutrients recovered from the press-cakeduring the tests were greater than the percentage of solids recovered in the press-cake.VENDER CONTACT INFORMATIONPress Technology & Manufacturing2300 Columbus AvenueSpringfield, OH 45503Phone: 937-327-0755Fax: ard Methods for the Examination of Waste and Wastewater Treatment, 20th Edition. 1998. ClesceriL.S., A.E. Greenberg, A.D. Eaton eds. United Book Press Inc., Baltimore, Maryland.Disclaimer StatementUse of trade or brand names or companies in this publication is for clarity and information; itdoes not imply approval of the product or the vendor to the exclusion of others that may be ofsimilar, suitable composition, nor does it guarantee or warrant the standard of the product.A State Partner in the Cooperative Extension ServiceThe Agricultural Extension Service offers its programs to all eligible personsregardless of race, color, age, national origin, sex or disability and is an Equal Opportunity Employer.COOPERATIVE EXTENSION WORK IN AGRICULTURE AND HOME ECONOMICSThe University of Tennessee Institute of Agriculture, U.S. Department of Agriculture,and county governments cooperating in furtherance of Acts of May 8 and June 30, 1914.Agricultural Extension ServiceCharles L. Norman, Dean5
APPENDIX A6
Wet Wt. mass in PCdry massof eff.wet basis Dry Wt. of Eff. capture eff.(lb)%(lb)%Sample Identification#Screen Sizeinches1116212631Side Hill inSide Hill inSide Hill inSide Hill inSide Hill in0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 2.681317222732Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill liquor0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 0.009.388.5215.408.653.971218232833Side Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 22.683.8913.9012.645.441.971419242934Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press liquor0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 .593.312.270.830.251520253035Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 .005.748.606.922.582.20Initial TS .49%24.06%21.77%38.84%Vol of eff.(gal)Run time(min)Flow .441.57SystemFlow Rate6.449.5115.2928.7644.06
SPTKPTKNmass % removedgin PCconc.mg/Lmassg% removedin PCconc.mg/Lmassg%removedin 22.7%13.4%30.2%0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 56192043329061298690Side Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 42593411351686719561419242934Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press liquor0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 4660616102031520253035Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 2758885914926261701Sample Identification#Screen Sizeinches1116212631Side Hill inSide Hill inSide Hill inSide Hill inSide Hill in0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire1317222732Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill liquor1218232833conc.mg/L16.6%23.7%4.0%4.2%8.7%8
Sample Identification#Screen Sizeinchesconc.mg/LKmassg% remin PCconc.mg/LNH3massg% removedin PC1116212631Side Hill inSide Hill inSide Hill inSide Hill inSide Hill in0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 7496044239119.3%7.8%8.8%5.0%6.7%1317222732Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill liquor0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 e Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 429427333465171538507935608275321419242934Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press liquor0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 8714213026510873615302452001520253035Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press cake0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 wedgewire0.006 531836601587110818779493001609
Sample Identification#Screen SizeinchesInitial TS3646515661Side Hill inSide Hill inSide Hill inSide Hill inSide Hill in0.01250.01250.01250.01250.01253747525762Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill liquor3848535863Wet wt. mass in PCof eff. wet basis Dry Wt. of 73.6%74.6%58.5%Side Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill 9%1.3%17.8%13.9%13.1%12.0%10.0%3949545964Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press 2.9%1.3%4050556065Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press 9%1.3%Flow 881.49SystemFlow Rate3.8815.0629.3529.6934.751023%8%5%1%1%dry masscapture eff. Vol of eff. Run Time%(gal)(min)32%23%34%16%18%
SPmass % removedgin PCconc.mg/LTKPmassg% removedin PCconc.mg/LTKNmassg% removedin 30376103254461Side Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill 3949545964Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press 6065Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press mple Identification#Screen Sizeinches3646515661Side Hill inSide Hill inSide Hill inSide Hill inSide Hill in0.01250.01250.01250.01250.01253747525762Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill liquor3848535863conc.mg/L19.4%12.4%14.7%7.5%9.8%11
Sample Identification#36Side Hill in46Side Hill in51Side Hill in56Side Hill in61Side Hill inScreen 8392825138970556408Kmass % removedgin 1333747525762Side Hill liquorSide Hill liquorSide Hill liquorSide Hill liquorSide Hill 41237489186824673848535863Side Hill cakeSide Hill cakeSide Hill cakeSide Hill cakeSide Hill 1718916702743949545964Screw Press liquorScrew Press liquorScrew Press liquorScrew Press liquorScrew Press 7111001584050556065Screw Press cakeScrew Press cakeScrew Press cakeScrew Press cakeScrew Press 37412% removedin PC5.0%7.6%27.3%1.9%6.5%
APPENDIX B13
Percentage of Total Solids (TS) in Press Cake fromBauer Side Hill and Agri-Press (0.006" screen)60100%Press Liquor Flow RatePress Cake TS80%4060%3040%2020%1000%2%4%6%Influent TS148%10%0%12%Press Cake TSPress Liquor Flow Rate (gpm)50
Percentage of Total Solids (TS) in Press Cakefrom Bauer Side Hill and PressTech AgriPress (0.125" screen)100.0%60Press-Liquor Flow ratePress-Cake TS80.0%4060.0%3040.0%2020.0%1000%2%4%6%Influent TS158%10%0.0%12%Press Cake TSPress Liquor Flow Rate (gpm)50
Dry Mass Capture Efficiency byBauer Side Hill and PressTech Agri-Press (0.006" screen)60100%Dry-Mass Capture EfficiencyPress Liquor Flow Rate (gpm)5080%4060%3040%2020%1000%2%4%6%Influent TS (%)168%10%0%12%Dry-Mass Capture EfficiencyPress-Liquor Flow Rate
Dry Mass Capture Efficiency fromBauer Side Hill and PressTech Agri-Press (0.125" screen)Press-Liquor Flow RateDry Mass Capture Efficiency60Press-Liquor Flow Rate, gpm5080%4060%3040%2020%1000%2%4%6%Influent TS (%)178%10%0%12%Dry Mass Capture Efficiency100%
Total Solids (TS) in Press Liquor vs. Influent with use of 0.006" ScreenScrew Press LiquorSide Hill Liquor9.0%8.0%Press Liquor Influent TS188.0%10.0%12.0%
Total Solids (TS) in Press Liquor vs. Influent with use of 0.125" ScreenScrew Press LiquorSide Hill Liquor9.0%8.0%Press Liquor 8.0%Influent TS1910.0%12.0%14.0%
Nutrient Partitioning in Agri-Press Using 0.006" Screen:Percentage of Influent Constituent in the Press-CakeManure massSPTPTKN50%Percentage in Influent TS202.4%1.2%
Nutrient Partitioning in Agri-Press Using 0.125" Screen:Percentage of Influent Constituent in the Press-CakeManure massSPTPTKN80%Percentage in luent TS212.9%1.3%
(Model #N267-F, Zoeller Pump Co., Louisville, KY). The Agri-Press unit input rate was limited by the maximum flow-rate that the static-screen could process. All test runs with the Agri-Press were made with the static-screen at full capacity. For this test, the Agri-Press 6
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