There are many factors to consider when developing a manure granulation process. While not an exhaustive list, this presentation goes over some of the main factors to consider, including return on investment, spatial needs and storage, emissions, fuel source, product off-take, automation, engineering, and more.

1. Considerations in
Manure Granulation
Experts in process design and material
processing for over 65 years.

2. As the granulation of manure into a fertilizer
product draws increasing interest, many
questions have arisen around the systems and
the many factors that should be taken into
consideration.

3. While not an exhaustive list, the following
provides an overview of some of the key
factors to consider when starting a manure
granulation facility.

4. Return on
Investment

5. Return on investment is typically the first
factor to consider.
In general, the more the quantity of
manure, the shorter the payback
period.
This is true for a few reasons…

6. Labor costs are likely to stay the same
whether the operation is producing 1
TPH or 10 TPH.
Similarly, the incremental capital costs
are lower at larger size plants. For
example, to double production
capacity, the capital cost will typically
go up by 40-50%, allowing for twice the
amount of saleable product to be
produced, for about 1.5 times the
capital.

7. Emissions

8. The unique source of manure,
combined with state and local
regulations, will determine how much
exhaust gas treatment will be needed.

9. A typical treatment system might consist
of a cyclone or baghouse for
particulate capture.
Additional treatment such as a wet
scrubber or thermal oxidizer may be
necessary if pollutants are present in the
off gas.

10. If a scrubbing system is employed, the
resulting liquid waste will also require
disposal or treatment in accordance
with regulations.

11. Spatial Needs &
Storage

12. The space required, along with potential
storage needs is also an important
consideration.
If the operation will be located on-farm,
modifications will be needed to
accommodate the new operation.

13. Not including storage/bagging, a
typical granulation process alone may
require a space 100’ x 100’ x 50’ tall.
Storage and/or bagging can require a
significantly larger space, particularly if
a large receiving operation will be
needed to accommodate additional
additives or minerals.

14. Space will also be needed for the pre-
treatment stages as well (nutrient
separation, pre-drying, crushing, etc.).
This varies, but in general, usually
requires about half the space that the
granulation portion requires.
An area for cake storage can be useful
as well, because it can act as a buffer in
the event that something goes down for
a period of time.

15. A typical layout for
on-farm granulation
and supporting
facilities.
ANAEROBIC
DIGESTION
FARM
STORAGE BAYS
GRANULATION
PLANT
CAKE
RECEIVING
LOAD OUT
BAGGING
SOLID-LIQUID SEPARATION
& NUTRIENT CAPTURE

16. Fuel Source

17. Fuel source also needs to be considered.
Natural gas is typically used because of
its cost effectiveness and availability, but
other options are available as well,
including propane, fuel oil, and diesel.
Biogas and waste heat from other
on-farm operations can provide
supplemental fuel sources as well.

18. Electricity should also be considered.
When a reliable source of electricity is not
available, alternative options such as
large-scale generators may be needed.

19. Product Off-take

20. How product will be handled after
granulation also requires consideration.
Will the product require storage in silos,
open bins, or super sacs?
Will a loadout system be needed for
product to leave the facility?
Will the product be taken away in bulk
by truck or rail, or will a packaging
facility be needed?

21. All of these are important
considerations, with many options
available depending on the needs of
the system.

22. Additional
Considerations

23. System Engineering
System engineering includes a number
of other items that will affect the overall
success of the project, such as layout
drawings, Process & Instrumentation
Diagrams (P&ID’s), commissioning and
start-up assistance, as well as overall
project management.
These items will need to be layed out at
the onset of the project for clear
direction.

24. Material Handling
Material handling brings together all the
pieces of the process, moving material
from one area to the next in seamless
fluidity.
Various material handling equipment is
available to suit the needs of a
granulation facility, including bucket
elevators, belt conveyors, and belt
trippers and plows.

25. Automation
An automation control system such as a
Programmable Logic Controller (PLC) is
also something to consider.
Depending on the system, this can offer
many benefits, such as the ability for
operators to view and adjust various
data points in real-time from a single
screen.
This is helpful in both troubleshooting
and process optimization applications.

26. Conclusion
There are many factors to take into
consideration when developing a granulation
facility for manure and other organics.
Working with a company that is well-versed in
the process will provide the best results.

27. has been a leader in transforming wastes into
value-added products since 1951. In addition to
feasibility testing, process design, and custom
equipment, we offer complete systems for the
granulation of manure into a premium product.

28. Want to learn more?
Download our
Organics Granulation
Handbook
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The Organics Granulation Handbook
Granulation as a Solution
Systems and Equipment
Considerations
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