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The patented NaturTech Composting System uses 40, 50, 80 or 110 cubic yard (yd3) Intermodal or modified roll-off containers, 20 - 30 yd3 biofilter containers, positive fresh air delivery, negative process-air removal, sensors, wiring, computerized process control and data logging, training, and an operations manual. The NaturTech containers can hold one ton per two yd3(1,000 lbs per cubic yard) at 60% moisture.
40 yd3 containers hold 20 tons
50 yd3 containers hold 25 tons
80 yd3 containers hold 40 tons
110 yd3 containers hold 55 tons
With a 20 day retention time, the system is rated at:
one ton per day (TPD) per 40 yd3 container
1.25 TPD per 50 yd3 container
2 TPD per 80 yd3 container
2.75 TPD per 110 yd3 container
With a 15 day retention time, the minimum to meet the US Environmental Protection Agency requirement for vector attraction reduction which is 14 days over 40 C averaging 45 C, the system is rated at:
1.33 TPD per 40 yd3 container
1.67 TPD per 50 yd3 container
2.67 TPD per 80 yd3 container
3.67 TPD per 110 yd3 container
The larger the container, the less capital cost per processed ton for the system up to 1000 tons per day. The cost of air delivery for a container, what we call a "zone" is the same for all sizes of containers. The estimated price per zone for the blowers for positive and negative air, variable frequency drive, manifold, pipe, valves, sensors, wiring, quick couplers, flex hose, leachate collection, condensate collection and actuators is approximately $6,000 per zone for our "better and best" options. For "good", which is a manual control system with only negative air and no computerized process control, the cost is approximately $1,000 per zone.
Composting Containers
Surface - Exterior - corrosion resistant paint -
Interior - corrosion and abrasion resistant liner
Perforated Floor - removable, self-cleaning, coated
perforated steel sheets
Air Sealed - sealed lid with locking mechanism and gaskets
Water Sealed - locking hinged door with watertight gasket,
leachate collection and drain system
Mobile - multi-function roll-off hoist adaptability or
move with trailers to tippers or tipper trailers
Insulation - optional up to R-19
Prices
Optimum sizes for capital efficiency are:
Minimum system sale of 5 - 40 yd3 containers to one biofilter or 4 - 50yd3 containers to one biofilter. For smaller applications, see the CM-Pro line of composting containers.
The first "optimum size" in terms of equipment efficiency, is 20 tons per day, using roll-off trucks and front-end loader on an hourly or "per cycle" basis shared with other operations. Truck with roll-off capability can be integrated with mixer, saving capital cost.
The next cost benchmark is 60 tons per day, resulting in full use of the roll-off truck, front-end loader and full time mixer based upon a 40 hour week.
100-120 tons per day can be accomplished with a second shift or the entry level of larger container systems.
Large container systems are designed in increments of 300 tons per day - large 33 yd3 mixers, automated container filling
The optimization ranges are largely determined by the capitalization of support equipment such as mixer, screener, tipping area, office, process controller, roll-off truck, trailer, tipper trailer, and stationary tipper options. Please fill out a project survey so that we can tailor an estimate that has the best value based upon your site requirements.
Composting System includes software, computer, process controller, system license, air management system, wiring, operations manual, composting containers, biofilters, delivery, installation, and staff training
Prices are as low as $8,000 per 40 yd3 container or curing bins for our modified standard Intermodal bin options up to $19,000 each for 110 yd3 custom containers.
A "good" system could cost as little as $8,000 for the 40 yd3 container plus $1,000 for process control - $9,000 total
A "better" system could cost $8,000 for the 40 yd3 container plus $6,000 for process control - $14,000 total
A "best" system with our largest 110 yd3 containers could cost $19,000 plus $6,000 for process control - $25,000 total
Calculate the capital cost by estimating the tons per day processed, based upon retention time and a seven day week, and you can get an estimate of the number of containers required. You can then calculate both the total cost for the composting portion of the facility and capital cost for each incoming ton of compost on a per ton basis. The operating costs vary depending on location, labor costs, electrical rates, option selected, size of facility, support equipment and should be calculated on a project to project basis.
Generally speaking, operating costs range in the $6.00 per ton range up to $18.00 per ton. Capital costs are in the same range, leading to net costs of $12.00 to $36.00 per ton, depending on retention time, facility size, amortization schedule, interest rate, option selected, and maintenance variables. In developing countries with low labor costs, net costs under $10 per ton can be achieved.
Biofilter Containers
Capacity - 20 - 30 yd3 capacity
Mobile - Intermodal or multi-function roll-off hoist
adaptability
Mixer
The NaturTech Composting System requires a supplemental
industrial duty mixer, either batch or continuous flow,
preferably batch, with a weigh system that provides a controlled
blend of raw materials to achieve porosity, moisture, volatile
solids and carbon to nitrogen ratio specifications established in
the operating plan. A minimum of a 20 yd3 four
auger batch mixer is recommended, although small systems can use
12-15 yd3 mixers. We sell a 54
cubic foot five auger mixer for the CM-Pro system.
Air Control
NaturTech process control regulates air delivery and air
removal from the composting containers. The process is
continuously monitored and can be adjusted by the operator. Air
velocity sensing is one of our patented applications.
Heat Exchange Cycle
Within the container is a temperature probe connected to the
process controller. When the temperature reaches a pre-determined
set point, more air is delivered to the composting containers.
This air acts as a heat exchanger to bring down the temperature
at which time regular air delivery restarts. Optional wintertime
cold climate management configurations, including air
recirculation and oxygen sensing, are available.
Pressure and Volume
Sensors in the air lines adjust air flow according to
predetermined settings. Undetected back pressure leading to
odorous compost is never a problem with NaturTech
Data Logging
The temperature is sampled periodically from the temperature
input and the results sent to a data file. A report is generated
for each batch assuring that the compost has met its time and
temperature requirements for regulatory compliance and compost
quality.
Process Control
The regular air delivery/removal cycles, air flow parameters,
and the temperature data management cycles interact with the
Siemens programmable controller. The various logs and data are
configurable into database files. Files can be retrieved by
communication software and sent to a remote location via modem on
either an automated or manual schedule. Full time process
monitoring through the Internet is available. This remote access
allows for process configuration as well as data retrieval.
Software Ownership
The "NaturTech" Composting Management Program and
operating manuals are copyrighted and are the sole property of
NaturTech Composting Systems, Inc. They are licensed only for the
specified facility and are not transferable without express
written permission of NaturTech Composting Systems, Inc.
Footprint
Assuming a base requirement of appoximately 20,000 square ft.
(ft3)for the mixer, storage, and
initial 4 tons per day (TPD), add up to 500 ft3.
for each additional ton per day capacity. Eg 60 TPD is 50,000 ft3 Add 1,000 ft3
for an additional 60 days of curing in NaturTech Curing Bins, or
110,000 square feet per 60 TPD. Concrete pads under the
containers and in the mixing are recommended. An enclosure or
cover for the mixing area is recommended over 20 tons per day or
in sensitive areas. If the Intermodal option is selected and
equipment capable of stacking containers two-high is included,
the area required can be reduced by 60%.
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Copyright 2003, Renewable Carbon Management LLC