Large Scale OperationsLarge Scale Operations

Presentation 8:Presentation 8:The Composting ToolkitThe Composting Toolkit

Funded by the Indiana Funded by the Indiana Department of Department of Environmental Environmental Management Recycling Management Recycling Grants ProgramGrants Program

Developed by the Indiana Developed by the Indiana Rural Community Rural Community Assistance Program - Assistance Program - RCAPRCAP

Large Scale OperationsLarge Scale Operations

This section will help you to implement the This section will help you to implement the composting techniques discussed in the earlier composting techniques discussed in the earlier section on aerobic compostingsection on aerobic composting

This section will help you identify the key This section will help you identify the key steps to a large scale operationsteps to a large scale operation

This section will help you identify appropriate This section will help you identify appropriate equipment and appropriately sized equipmentequipment and appropriately sized equipment

Important QuestionsImportant Questions What will you do with the finished product?What will you do with the finished product? How much yard waste is available for you to How much yard waste is available for you to

compost?compost? How much yard waste can you expect to divert?How much yard waste can you expect to divert? Will you utilize only yard waste or also food waste Will you utilize only yard waste or also food waste

and/or biosolids?and/or biosolids? Will it be cost effective?Will it be cost effective? What resources are currently available?What resources are currently available? What type of program will you implement?What type of program will you implement? How are you going to finance the program?How are you going to finance the program?

Key StepsKey Steps

CollectionCollection Particle size reductionParticle size reduction Initial material screening (Front-end)Initial material screening (Front-end) CompostingComposting Regular turningRegular turning Finished product screening (Back-end)Finished product screening (Back-end)

Sections Within This ChapterSections Within This Chapter

Composting Operations EquipmentComposting Operations Equipment Start-up ConsiderationsStart-up Considerations Ongoing Operations are covered in the next Ongoing Operations are covered in the next

chapter . . .chapter . . .

Composting Operation Composting Operation EquipmentEquipment

EquipmentEquipment Many of the pieces of equipment discussed in the Many of the pieces of equipment discussed in the

“woody waste” management presentation are also “woody waste” management presentation are also useful for composting operationsuseful for composting operations

Size Reduction Equipment:Size Reduction Equipment: Chipping and/or Shredding EquipmentChipping and/or Shredding Equipment

Moving Materials / Turning Materials:Moving Materials / Turning Materials: LoaderLoader

Dedicated Turning Equipment:Dedicated Turning Equipment: Windrow TurnerWindrow Turner

Sorting Equipment:Sorting Equipment: Screens Screens

Size Reduction EquipmentSize Reduction Equipment

Size reduction is one of the first critical steps Size reduction is one of the first critical steps in the composting process.in the composting process.

An optimal particle size is 1 to 3 inches. An optimal particle size is 1 to 3 inches. The key is maximizing surface area. The key is maximizing surface area.

Sufficient surface area will give the microbes Sufficient surface area will give the microbes that perform the composting a place to that perform the composting a place to complete their work.complete their work.

Shredding Verses ChippingShredding Verses Chipping

The two primary ways size reduction is The two primary ways size reduction is accomplished is shredding or chippingaccomplished is shredding or chipping

Shredding:Shredding: Shredders grind the waste by employing a hammer Shredders grind the waste by employing a hammer

mill to pound trees into shreds.mill to pound trees into shreds. Chipping:Chipping:

Chippers use sharpened knives on a disc or a drum Chippers use sharpened knives on a disc or a drum to make dimensional chipsto make dimensional chips

Shredding Verses ChippingShredding Verses Chipping The two primary ways size reduction is accomplished is shredding or The two primary ways size reduction is accomplished is shredding or

chippingchipping Shredding:Shredding:

The primary advantage of shredding is that is maximizes surface area which is The primary advantage of shredding is that is maximizes surface area which is optimal for composting. Shredding equipment is also able to handle some optimal for composting. Shredding equipment is also able to handle some contamination from dirt and rocks.contamination from dirt and rocks.

The primary disadvantage of shredding is cost. The equipment to shred is The primary disadvantage of shredding is cost. The equipment to shred is usually much larger than chipping equipment and is significantly more expense usually much larger than chipping equipment and is significantly more expense to purchase and maintain.to purchase and maintain.

Chipping:Chipping: The primary advantage of chipping is that the equipment is smaller, multi-The primary advantage of chipping is that the equipment is smaller, multi-

purpose, faster, and less expensive.purpose, faster, and less expensive. The primary disadvantages to chipping is that the composting process will The primary disadvantages to chipping is that the composting process will

take longer because the chips provide significantly less surface area than take longer because the chips provide significantly less surface area than shredding equipment. A chipper is unable to tolerate contamination from dirt shredding equipment. A chipper is unable to tolerate contamination from dirt and debris.and debris.

ChippersChippers

Variations with ChippersVariations with Chippers

Disc-style chippers are much more common than Disc-style chippers are much more common than drum-style chippers.drum-style chippers.

The disc-style is at this time the “industry standard”The disc-style is at this time the “industry standard” However, at this time there are new developments However, at this time there are new developments

being made in the drum-style arena. Drums have being made in the drum-style arena. Drums have great promise because they are more compact, yet great promise because they are more compact, yet they can have a larger-diameter opening for feeding they can have a larger-diameter opening for feeding materials into the chipper.materials into the chipper.

Variations with Shredders:Variations with Shredders:Tub GrindersTub Grinders

Tub grinders have long been the industry standard in Tub grinders have long been the industry standard in shredding equipment. shredding equipment.

Tub grinders have an opening on the top. Materials Tub grinders have an opening on the top. Materials must be dropped in and rely on gravity to feed the must be dropped in and rely on gravity to feed the hammer mills.hammer mills.

The primary advantage of a tub grinder is it tends to The primary advantage of a tub grinder is it tends to be faster than other shredders with woody wastes.be faster than other shredders with woody wastes.

The primary disadvantage of tub grinders is they tend The primary disadvantage of tub grinders is they tend to “throw-out” materials which is hazardous to to “throw-out” materials which is hazardous to operators as much as within 300 feet of the machine.operators as much as within 300 feet of the machine.

Shredders: Tub GrindersShredders: Tub Grinders

Variations on Shredders:Variations on Shredders:Horizontal GrindersHorizontal Grinders

Horizontal grinders pull in materials to be Horizontal grinders pull in materials to be processed via a conveyor belt of chain track processed via a conveyor belt of chain track which feed materials to be shredded into the which feed materials to be shredded into the hammer mill.hammer mill.

Horizontal grinders do not have the tub Horizontal grinders do not have the tub grinders tendency to “throw-out” materialsgrinders tendency to “throw-out” materials

Shredders: Horizontal GrindersShredders: Horizontal Grinders

Size MattersSize Matters To increase capacity and production, new grinders are getting To increase capacity and production, new grinders are getting

heavier, with bigger hammer mills. The largest models now heavier, with bigger hammer mills. The largest models now approximate the size and weight of a railroad freight car and approximate the size and weight of a railroad freight car and cost well over half a million dollars.cost well over half a million dollars.

Smaller tub-grinders weigh around 80,000 pounds. Larger Smaller tub-grinders weigh around 80,000 pounds. Larger tub-grinders weigh over 110,000 pounds. Horizontal grinders tub-grinders weigh over 110,000 pounds. Horizontal grinders often weigh approximately 100,000 pounds.often weigh approximately 100,000 pounds.

The lighter the machine, the more you will sacrifice longevity The lighter the machine, the more you will sacrifice longevity The thickness of steel determines how soon the machine will The thickness of steel determines how soon the machine will

require welding to remain in one piece. Extra weight reduces require welding to remain in one piece. Extra weight reduces vibrations in turn reducing wear and tear.vibrations in turn reducing wear and tear.

Variations with Shredders:Variations with Shredders:Stump GrindersStump Grinders

These are specialized machines designed These are specialized machines designed specifically to pulverize tree stumps in place specifically to pulverize tree stumps in place down to a specific depth. down to a specific depth.

It is easier to pulverize a stump in the ground It is easier to pulverize a stump in the ground than to pull it out and grind it.than to pull it out and grind it.

This would more commonly be used in on-site This would more commonly be used in on-site wood waste management than in composting wood waste management than in composting operations separate from where the woody operations separate from where the woody waste is generated. waste is generated.

LoadersLoaders

LoadersLoaders

The front-end loader is the single most The front-end loader is the single most important piece of equipment for large scale important piece of equipment for large scale composting facilities.composting facilities.

It may be the only piece of equipment needed It may be the only piece of equipment needed for operations for smaller communities.for operations for smaller communities.

The loader moves materials around the site The loader moves materials around the site and can be used as the turning equipment for and can be used as the turning equipment for windrows as well.windrows as well.

Windrow TurnerWindrow Turner

Windrow TurnersWindrow Turners Windrow turners are designed specifically to turn and Windrow turners are designed specifically to turn and

aerate compost in a windrow.aerate compost in a windrow. There are both self-propelled models and models that There are both self-propelled models and models that

require a tractor to pull them.require a tractor to pull them. The advantage of windrow turners is they thoroughly The advantage of windrow turners is they thoroughly

turn and mix materials and do so more quickly than turn and mix materials and do so more quickly than front end loaders can. front end loaders can.

This superior mixing produces a superior compost This superior mixing produces a superior compost product.product.

Their primary disadvantage is the added cost of Their primary disadvantage is the added cost of purchasing an additional piece of equipment for a purchasing an additional piece of equipment for a composting operation.composting operation.

ScreensScreens

ScreensScreens

Plastic, cloth, wire mesh, deck (flat), disc, Plastic, cloth, wire mesh, deck (flat), disc, grizzly, orbital, star, and trommel screen. grizzly, orbital, star, and trommel screen. The The many varieties of screens.many varieties of screens.

ScreeningScreening

Large scale composting facilities will nearly always Large scale composting facilities will nearly always employ some form of screening.employ some form of screening.

If your facility plans to SELL finished compost a If your facility plans to SELL finished compost a screen is essential. When paying for the finished screen is essential. When paying for the finished compost, people demand a quality of finished product compost, people demand a quality of finished product that simply can’t be obtained without screening.that simply can’t be obtained without screening.

If a community has strong controls on the front end If a community has strong controls on the front end of their process such as strong litter control, strong of their process such as strong litter control, strong compliance on not allowing plastic bags, then the compliance on not allowing plastic bags, then the community may be able to get by without a screen if community may be able to get by without a screen if the end product is given away. the end product is given away.

ScreeningScreening

Removal of contaminationRemoval of contamination Proper sizing of starting and finished productProper sizing of starting and finished product Material passing through a screen is generally Material passing through a screen is generally

referred to as “undersize”referred to as “undersize” Material that remains on the screen surface is Material that remains on the screen surface is

generally referred to as “oversize”generally referred to as “oversize”

Cost Effectiveness ofCost Effectiveness ofWindrow CompostingWindrow Composting

That equipment looks expensive! I thought That equipment looks expensive! I thought you said this was cost effective!you said this was cost effective!

First, compare these to the costs of landfill First, compare these to the costs of landfill equipment or MRF equipment.equipment or MRF equipment.

Second, select equipment appropriate to your Second, select equipment appropriate to your size operation.size operation.

Third, form partnerships!Third, form partnerships!

Form PartnershipsForm Partnerships

Bartholomew County SWMD contracts with a Bartholomew County SWMD contracts with a private contractor who provides tub grinder private contractor who provides tub grinder services. The District pays an hourly rate for the services. The District pays an hourly rate for the equipment. The contractor maintains the equipment. The contractor maintains the equipment and Bartholomew is simply one of equipment and Bartholomew is simply one of many clients for the contractor.many clients for the contractor.

Northeast Indiana SWMD owns a tub grinder and Northeast Indiana SWMD owns a tub grinder and uses it at five composting sites over a four county uses it at five composting sites over a four county area. area.

Start-up ConsiderationsStart-up Considerations

Start-up ConsiderationsStart-up Considerations

Facility LocationFacility Location Facility TypeFacility Type Site CharacteristicsSite Characteristics Customer AccessCustomer Access

Collection OptionsCollection Options Drop-offDrop-off CurbsideCurbside Out-of-system UsersOut-of-system Users

Operational ConsiderationsOperational Considerations

Hours of OperationHours of Operation StaffingStaffing EquipmentEquipment Site RequirementsSite Requirements Fee ScheduleFee Schedule Program BudgetProgram Budget

Site LayoutSite Layout

OfficeOffice Drop-off AreaDrop-off Area Chipping/Shredding AreaChipping/Shredding Area Mulch / Woody Waste Storage AreaMulch / Woody Waste Storage Area Composting AreaComposting Area Screening AreaScreening Area Equipment Service and Storage AreaEquipment Service and Storage Area

Operation Plan and ProceduresOperation Plan and Procedures

Composting RegistrationComposting Registration Site and Traffic PlanSite and Traffic Plan Administrative ProceduresAdministrative Procedures Safety ProceduresSafety Procedures Materials Processing ProceduresMaterials Processing Procedures Testing RequirementsTesting Requirements Maintenance ProceduresMaintenance Procedures Marketing Plan Marketing Plan

Example Site LayoutExample Site Layout

Compost Facility RegistrationCompost Facility Registration

Compost facilities that process more than Compost facilities that process more than 2,000 pounds of vegetative matter during a 2,000 pounds of vegetative matter during a year are required to register with IDEM.year are required to register with IDEM.

Registered facilities must then submit an Registered facilities must then submit an annual report to IDEM in regard to the volume annual report to IDEM in regard to the volume of materials processed in the previous year.of materials processed in the previous year.

Registration is valid for five years and may be Registration is valid for five years and may be renewed.renewed.

Compost Facility RegistrationCompost Facility Registration The registration must include the following components:The registration must include the following components:

A legal description of the siteA legal description of the site A topographic map of the siteA topographic map of the site A description of the composting facility and who it will serveA description of the composting facility and who it will serve An estimate of the yearly volume to be processedAn estimate of the yearly volume to be processed

A registered Indiana compost facility may not:A registered Indiana compost facility may not: Be located within 200 feet of a potable water supplyBe located within 200 feet of a potable water supply Be located within 200 feet of a existing residential structureBe located within 200 feet of a existing residential structure Be located within a 10-year floodplainBe located within a 10-year floodplain

A registered Indiana composting facility must:A registered Indiana composting facility must: Keep compost five feet from the water tableKeep compost five feet from the water table Manage leachate and runoff generated by the compost siteManage leachate and runoff generated by the compost site Control dust, odor, and noiseControl dust, odor, and noise

White PapersWhite Papers

Don’t reinvent the wheel (or the compost pile in this Don’t reinvent the wheel (or the compost pile in this case)case)

Composting tool-kit white paper topics include:Composting tool-kit white paper topics include: Facility Siting GuidelinesFacility Siting Guidelines ““How to” for Navigating Compost Facility Registration How to” for Navigating Compost Facility Registration

ProcessProcess Start-up and operation logistics recommendationsStart-up and operation logistics recommendations Guidelines for identifying appropriately sized equipmentGuidelines for identifying appropriately sized equipment

QUESTIONS?QUESTIONS?

Thank You!Thank You!

Additional Questions, Comments, or You Additional Questions, Comments, or You Think You Have A Potential Pilot CommunityThink You Have A Potential Pilot Community Please Feel Free to Contact Me:Please Feel Free to Contact Me:

Mark W. DavisMark W. Davis

Technical Assistance ProviderTechnical Assistance Provider

Rural Community Assistance ProgramRural Community Assistance Program

Office: 1-800-382-9895Office: 1-800-382-9895

Wireless: (812) 320-0720Wireless: (812) 320-0720

E-mail: mdavis@incap.orgE-mail: mdavis@incap.org