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Design Variations in Aerated Static Pile Composting Systems

Scott Gamble, P.Eng.


Compost Council of Canada 2014 Annual Conference
Halifax, Nova Scotia
What are Aerated Static Piles?
ASP composting originated at the USDA
research facility in Beltsville, MD in the
early 1970s.
ASPs have remained a mainstay for
composting dewatered biosolids.
There were many departures in SSO
composting technologies in the 1980s and
1990s.
ASP systems are the building block from
which many of the common higher tech
systems have evolved (e.g. channels,
tunnels, static containers).
During the past ten years we have seen a
revival of ASP systems.
Beltsville ASP circa 1975

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Where Do ASPs Fit in the
Technology Spectrum?
Passively Aerated Systems Actively Aerated Systems

Passively Aerated Static Piles Aerated Static Piles


(uncovered and covered)
Passively Aerated Windrows
Bunker Tunnels
Static Containers
Windrow
Agitated Containers
Turned mass bed
Channels
Agitated beds
Rotating drum

Environment Canada Technical Document on MSW


Organic Processing, 2013

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Advantages Disadvantages

Pile configurations and height reduce Capital cost of forced-aeration


the space requirements of the facility. equipment.
This can translate into lower land costs
and civil development costs. Over-aeration can remove moisture and
slow biological decomposition process.
Positive aeration provides better odour
control than passively aerated systems. Feedstock preprocessing requires a
Negative aeration with biofilters higher degree of care; feedstocks must
provides even better odour control. be properly sized, well mixed, and
moistened.
Smaller surface area (relative to
windrows) reduces the impacts of cold More operator skill is required to
weather and rain infiltration. manage the aeration systems.

Significantly shorter active composting Aeration systems generally require


times than passively aerated systems. three-phase electrical supply.

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What Feedstocks can be Handled?

Leaf and yard waste (Harvest


Power pre 2008)

Food waste (Jepson Prairie)

Biosolids (Clearwater, Kelowna)

Digestate (Harvest Power)

Abattoir waste (Spa Hills)

Specified Risk Materials


(Lethbridge Research Station)

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Basic ASP Components

Biocover (e.g. compost, screening overs)


or Fabric Cover

Centrifugal Fan

Aeration Header Aeration Lateral

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Common ASP Design Variations
Pile Configurations
Aeration Laterals
Fan Controls
Aeration Method
(air direction)
Aeration Zoning

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Pile Configurations
Discrete Piles Pile heights typically
range from 6 to 11
feet high.

Extended Piles.

Bunker Systems

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Aeration Laterals - Above Grade
Aeration Laterals - Below Grade
Fan Control Intermittent Aeration
The simplest way to controls aeration fans is
on an intermittent basis using a timer. A typical
timer cycle involves 2 to 5 minutes of run time
during each 15 to 20 minute cycle.

Fans can also be operated on an intermittent


basis using temperature feedback. Fans turn
on when temperatures reach a high level set
point, and off when a low level set point is
reached

Fans can also be operated on an intermittent


basis using temperature feedback. Fans turn
on when oxygen reaches a low level set point,
and off when a high level set point is reached.

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Fan Control Continuous Aeration
Aeration fans operated on a
continuous basis are normally
controlled using a VFD.

The fan speed can be set


manually on the VFD keypad,
or remotely via a PLC.

Fans/VFDs wired to a PLC can


also be programmed to ramp
up and down automagically in
response to temperature or
oxygen readings.

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Basic Aeration Methods

Negative Aeration

Positive Aeration
Bidirectional Aeration
Control Dampers

Single Fan System

Dual Fan System


Aeration Zoning
In a multi-zone system, each
aeration fan supplies air to two or
more compost piles or zones.
Fans typically operate continuously
and air flow to/from each zone is
controlled with dampers.
Dampers can be controlled
manually or automagically with a
PLC.
Systems can be positively or It is important for operators to
negatively aerated, or bidirectional. understand the air flow limits of
their fans/ ducting system, and
how their PLC logic distributes
air between zones.

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Basic Multi-zone Aeration

Positive Aeration

Negative Aeration
Bidirectional Multi-Zone Aeration
ASP Size Considerations
Pile configuration (length, width) is a balance between
available space and site traffic/layout, duct and fitting
costs (for headers and laterals) and fan costs.
Pile sizing should also consider daily/weekly feedstock
quantities, delivery schedules, and site operational
schedules.
In bunker systems, end wall vs side wall lengths should
be optimized. Roof truss lengths and column locations
are a factor when enclosing ASP piles in buildings or
pole barns.
Longer piles (e.g. > 100ft) may require a special lateral
designs (e.g. varying diameter and/or perforation
pattern).

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Aeration Design Considerations
Ducting materials must match the anticipated air temperatures. Ducting
designs must account for expansion/contraction, fan vibration, and
construction tolerances.
Duct sizes, fittings and transitions must be appropriate to the air volumes
so that system pressures are reduced.
Condensate and leachate drainage must be considered in the ducting
design and aeration fan selection. The ducting design should also allow
for easy maintenance and cleanout of ducting runs.
Ducting and fans in negative and bidirectional aeration systems must be
designed to resist corrosion.
Aeration fans must provide appropriate aeration rates and meet pressure
requirements of the system.

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Thank you!
Scott Gamble, P.Eng.
CH2M HILL (Edmonton)

tel: 780-628-4496
email: scott.gamble@ch2m.com

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