DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
AND
The Patents Rules, 2003

COMPLETE SPECIFICATION
(Section 10 and Rule 13)

TITLE
A Process for the Preparation of Organic Fertilizer

APPLICANT
(a)Patanjali Organic Research Institute Pvt. Ltd,
(b)An Indian Research Institute,
(c)Patanjali Food and Herbal Park, Village - Padartha,
Laksar Road, Haridwar, Uttarakhand, INDIA

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is be performed.

FIELD OF THE INVENTION
This invention relates to a process for the preparation of organic fertilizer. Particularly this invention relates to the process for the preparation of organic fertilizer obtained from sewage sludge which is a byproduct created by the treatment of the water of residential households, municipal wastewater, etc.
BACKGROUND OF THE INVENTION
Fertilizers especially chemical fertilizers are, nowadays, used in agricultural fields for growing crops. However, it is presumed that use of the chemical fertilizers to grow crops is one of the main causes of different kinds of diseases. Therefore, consumers prefer to use organic good items / eatables. Therefore, farmers are now willing to use organic fertilizers, but the organic fertilizer is not available in the market. Some organic fertilizers are available in the market, but they are too costly and poor farmers cannot afford such organic fertilizers. Even the compost khad (fertilizer) is now a days not available in the villages as the people have stopped keeping caws, buffaloes and ox, etc. However, there is a demand for organic food in the market.
US patent (US5125951A) teaches about a process, for producing a dried material suitable for use as fertilizer, consisting essentially of;
(A) obtaining a starting sewage sludge including principally water and a minor amount of solids containing nitrogen as ammonia; and then
(B) mechanically dewatering the material to provide a sludge having about 20% to about 30%, by weight, solids; and then
(C) adding to the dewatered sludge, before its exposure to any temperature as high as about 70° C., an amount of acid selected from the group consisting of nitric acid, phosphoric acid, and mixtures thereof, sufficient to produce a treated material with a pH of about 7 or less, comprising fixed nitrogen in thermally stable compounds which do not volatilize until temperatures over 100° C. are reached selected from the group consisting of ammonium nitrates, ammonium phosphates, and mixtures thereof; and then
(D) thermally drying at temperatures up to about 100° C. to remove water from the treated material, to produce a thermally dried material with a solid concentration of about 70% to about 90%, by weight, where substantially all of the nitrogen of the original sludge remains.
Chinese patent (CN101962302B) teaches about a kind of process to prepare fertilizer with the WWT excess sludge, it is characterized in that: (1) the mud acidifying is sized mixing: get the excess sludge that sewage work handles through mechanical dehydration; The ratio that adds 0.5~3L water in the 1Kg excess sludge adds entry; Add the ratio adding technical grade acetic acid that mass concentration is 95%~98% technical grade acetic acid, 0.01~0.1L in the 1Kg excess sludge; After stirring, process the mud slurry;
(2) heat treated: the mud slurry is heated to 45 ?~65 ?, in the process of heating, stirs 10min~90min;
(3) filtration washing: the slurry of the mud after the heat treated is carried out mechanical filter and uses water washing, get mud cake and filtrating, the washing water consumption is in the ratio of 1Kg excess sludge with 1~4L washing water, and filtrating gets into Waste Water Treatment as waste water;
(4) neutralizing treatment of mud cake: join in the mud cake lime powder and mixing, make the pH value of mud cake arrive 6.5~7.5;
(5) mud cake prepares fertilizer: with mud cake granulation, drying and packing, process fertilizer.
WIPO (PCT) application (WO2008067524A2) teaches about a method of producing a wastewater sludge-based fertilizer comprising: obtaining wastewater sludge; testing the sludge obtained for heavy metal organic compounds and pathogens; drying the sludge to a predetermined water to solids ratio; and mixing the sludge with micro and macronutrients to achieve an equivalent to a desired grade of fertilizer.
US patent (US7662206B2) teaches about a process of fertilizer manufacture comprising: creating a thixotropic paste from a composition containing biosolids;
adding an oxidizing agent to the paste;
adding an alkaline agent to the paste to produce a pH of 10 or higher;
exposing the paste to ammonia at a concentration of at least 1,000 ppm;
adding an acid to the paste to produce heat and a pH 7.0 or less;
adding a granulating agent to the paste;
extruding or granulating the paste; and
drying the extruded or granulated paste to a dryness of 90% or more of solids.
Chinese patent (CN101648831B) teaches about an organic fertilizer produced from sludge generated in sewage treatment is characterized in that being made up of the raw material of following ratio of weight and number:
100 parts of organism, nitrogen phosphorus potassium raw materials, wherein organic matter raw material is 30 parts, 70 parts of nitrogen phosphorus potassium raw materials;
Residual mud 8 -15 part after the sanitary sewage disposal;
98% vitriol oil 2.5 - 3.5 part;
Liquefied ammonia 1.5 - 2.5 part.
Chinese patent application (CN100457690C) teaches about the method for producing agriculture fertilizer by sludge in water treatment plant characterized in that:
The first step: add iron sulphide in concentrated pretreated sewage factory mud, it is 0.3% of sludge quality that iron sulphide adds quality, enters then in the aerobic digestion device, carry out aerobic digestion, the dissolved oxygen of digestive process is controlled at 2.0-1.5mg/l, and digestion time 6d obtains digested sludge;
Second step: above-mentioned digested sludge pumped in the whizzer dewater, the centrifugation controlling factors is between 1800-2200, and the mud cake of obtain dewatering liquid and dehydration is separated in the dehydration back;
The 3rd step: the dehydration liquid pump that will go up the step is gone into by filtration in flyash and the filtration neutralizer that rubble mixings filtrate is formed and is neutralized; Make liquid effluent pH remain on the scope of 8-9; When liquid effluent pH still cannot remain on 8-9 when the long-pending ratio of liquid effluent flow and filter cross-section drops to 0.01m/s, stop to filter, restart again to filter and neutralization after changing filtrate; The filtrate of more changing is delivered to brick making from fly-ash factory, mixes back powder process coal-dust brick with other flyash; Liquid effluent after the neutralization is back to the anoxic denitrogenation section of Sewage Plant, and the dissolved organic matter that wherein contains is utilized and removes as the carbon source of denitrification denitrogenation;
The 4th step: the dehydrated sludge cake in second step is mixed with flyash, make the water ratio of mixture reach 55%-58%; Enter overturning slot type composting device again, the degree of depth of banking up 1.5m; Preceding 8 days, to 80t mud cake and 36t mixture of fly ash, with 1500m 3The vent flow of/h, the 15min that per hour ventilates, and every overturning in 1 day 1 time; Back 22 days, with identical vent flow, per 2 hours ventilation 15min, and every overturning in 2 days 1 time, carry out 30 days composting altogether after, it is fertile promptly to obtain farming, N, P, K content that after testing should farming fertilizer reach 8%-10%, and is similar to the dried poultrymanure in the fertilizer.
European Patent (EP2444382A1) teaches about the method used to produce mineral organic fertilizer mixture that involves mixing of municipal wastewater sludges with detoxicant, characterized in that highly dispersed sodium humate with particles not larger than 100 µm and in quantity of not less than 10 % of the sludge mass is used as the detoxicant.
There are disadvantages associated with the known organic fertilizer and the process for the preparation thereof. One of the disadvantages is that the conventional fertilizer and process are not environment friendly.
Another disadvantage, associated with the known organic fertilizer and the process for the preparation thereof, is that known fertilizer costly and poor farmers of India cannot afford it.
Yet another disadvantage, associated with the known organic fertilizer and the process for the preparation thereof, is that known fertilizer disseminate pathogenic coliform bacteria to the Agriculture Land as it contains these coliform bacteria are not eliminated during the know process.
Still another disadvantage, associated with the known organic fertilizer and the process for the preparation thereof, is that known fertilizer contains harmful chemicals and heavy metals and thus are toxic to the soil.
A further disadvantage, associated with the known organic fertilizer and the process for the preparation thereof, is that known organic fertilizers are a threat to the Ecosystem.
Another disadvantage, associated with the known organic fertilizer and the process for the preparation thereof, is that known organic fertilizers are a threat to the groundwater Ecosystem.
OBJECTS OF THE INVENTION
Therefore, an object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge, which obviates the disadvantages associated with the soil testing methods and systems known in the prior art.
Another object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is environment friendly and recycle the sewage sludge to produce organic fertilizer which reduces pollution.
Yet another object of the present invention is to a process for the preparation of organic fertilizer from sewage sludge which is a cheap and affordable process that is capable to produce cheap and affordable organic fertilizer.
Still another object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is provide a free of pathogenic coliform bacteria organic fertilizer and therefore does not disseminate these bacteria in the agricultural land.
A further object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is produced a chemicals free and heavy metals free organic fertilizer.
Another object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is not a threat to the Ecosystem.
Yet another object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is not a threat to the groundwater Ecosystem.
Still another object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is produced a Nitrogen and Phosphorus rich organic fertilizer in large quantities.
A further object of the present invention is to provide a process for the preparation of organic fertilizer from sewage sludge which is capable to increase the fertility of the soil.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a process for the preparation of organic fertilizer comprising: taking sewage sludge from a sewage treatment plant; dewatering the sewage sludge and thickening the same, blending the thickened sewage with dried recycled sewage, drying the blended sewage sludge and crushing the same to obtain semisolid cake, heating semisolid cake by passing hot air having a temperature of 400 - 800 0C for 2 - 12 seconds so as to obtain organic fertilizer.
Yet, according to the present invention, the dewatering process is done by a mechanical process, for example, a filter press process, centrifugal process, or by a chemical process.
Still, according to the present invention, the thickening process is done by trickling the sewage sludge over a filter,
Further, according to the present invention, the blending of the thickened sewage is done with 65 – 75 % by weight-dried recycled sewage.
Yet, according to the present invention, 25 – 35 % by weight obtained heated sludge is converted into the organic fertilizer, and the remaining heated sludge is recycled with thick sewage sludge.
BRIEF DESCRIPTION OF THE DRAWINGS
A process for the preparation of organic fertilizer in a preferred embodiment is illustrated in the accompanying examples
DETAILED DESCRIPTION OF THE INVENTION
A process for the preparation of organic fertilizer is herein described and illustrated with numerous specific details so as to provide a complete understanding of the invention. However, these specific details are exemplary details and should not be treated as the limitation to the scope of the invention. The invention may be performed with slight modifications. Throughout this specification the word “comprise” or variations such as “comprises or comprising”, will be understood to imply the inclusions of a stated element, integer or step, or group of elements, integers or steps, but not the exclusions of any other element, integer or step or group of elements, integers or steps.
The process for the preparation of organic fertilizer comprises sewage sludge obtained by treatment of the wastewater of residential households, municipal wastewater, etc which is taken from a sewage treatment plant. The sewage sludge is dewatered and thickened the same. The thickened sewage is blended with 65 – 75 % by weight dried recycled sewage. The blended sewage sludge is dried by passing hot air having a temperature of 400 - 800 0C for 2 - 12 seconds and crushed the same to obtain semisolid cake. The semisolid cake is heated by passing hot air having a temperature of 400 - 800 0C for 2 - 12 seconds. 25 – 35 % by weight obtained heated sludge is converted into the organic fertilizer and the remaining heated sludge (65 – 75 % by weight) is recycled with the thick sewage sludge.
In one embodiment, the sludge mixture is continuously blended during the drying and heating processes.
The dewatering process is done by a mechanical process, for example, a filter press process, a centrifugal process, or by a chemical process and the thickening process is done by trickling the sewage sludge over a filter.
EXAMPLE 1
Sewage sludge of wastewater of residential households was taken from a sewage treatment plant. The sewage sludge was dewatered by a filter press process and thickened the same by tickling the sewage sludge over a filter. 200 kg thickened sewage was blended. The blended sewage sludge was dried by passing hot air having a temperature of 600 0C for 6 seconds and crushed the same to obtain semisolid cake. The semisolid cake was heated by passing hot air having a temperature of 700 0C for 5 seconds. Further, 68 kg of heated sludge was taken with 32 kg of thickened sewage and blended the same. The blended sewage sludge was dried by passing hot air having a temperature of 500 0C for 10 seconds and crushed the same to obtain a semisolid cake. The semisolid cake was heated by passing hot air having a temperature of 650 0C for 10 seconds. The obtained 28 kg obtained dried sludge was converted into organic fertilizer and the remaining was kept for recycling with the thick sewage sludge.
EXAMPLE 2
Sewage sludge of wastewater of municipal was taken from a sewage treatment plant. The sewage sludge was dewatered by a centrifugal process and thickened the same by tickling the sewage sludge over a filter. 30 kg of thickened sewage was taken with 70 kg of heated sludge and blended the same. The blended sewage sludge was dried by passing hot air having a temperature of 500 0C for 10 seconds and crushed the same to obtain a semisolid cake. The semisolid cake was heated by passing hot air having a temperature of 650 0C for 10 seconds. The obtained 30 % by weight dried sludge was converted into organic fertilizer and the remaining was kept for recycling with the thick sewage sludge.
The obtained organic fertilizer from the sewage sludge was tested by the Patanjali Organic Research Pvt. Ltd. The testing reports are provided as follows.
Test Report - 1
Product Name STP SLUDGE GRN No. NA
Material Code NA Vehicle No. UK08AS4095
Batch Qty. NA Sample Qty. 500 GM
Invoice No. NA Analysis Date: 08-05-2022
Receiving Date 08-05-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result Variation
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 28.360 3.360
3 pH (Max 7.5, Min 6.5) 7.5 Percent 7.908 0.408
4 C:N Ratio (Max) 20.0 Percent 26.961 6.961
5 Total Organic Carbon 14.0 Percent 15.880 I .880
6 Total Nitrogen (N) 0.5 Percent 0.589 0.089
7 Total Phosphates as P205 (P) 0.5 Percent 0.600 0.100
8 Total Potassium as 1<20 (K) 0.5 Percent 3.200 2.700
9 Total NPK Nutrient (Min) 3.0 Percent 4.389 I .389

Test Report - 2
Product Name STP SLUDGE GRN No. GR002
Material Code NA Vehicle No. NA
Batch Qty. NA Sample Qty. 500 GM
Invoice No. NA Analysis Date: 22-11-2022
Receiving Date 22-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 88,470
3 Bulk Density (Min.) 1.0 g/mL I .020
4 pH (Max 7.5, Min 6.5) 7.5 6.780
5 Total Organic Carbon (Min.) 14.0 Percent 19.910
6 Total Nitrogen (N) (Min.) 0.5 Percent I .540
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent 0.750
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.690
9 Total NPK Nutrient (Min) 3.0 Percent 4.440

Test Report - 3
Product Name STP SLUDGE GRN No. GR001
Material Code NA Vehicle No. NA
Batch Qty. NA Sample Qty. 500 GM
Invoice No. NA Analysis Date: 22-11-2022
Receiving Date 22-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 78.910
3 Bulk Density (Min.) 1.0 g/mL 0.890
4 pH (Max 7.5, Min 6.5) 7.5 6.670
5 Total Organic Carbon (Min.) 14.0 Percent 27.350
6 Total Nitrogen (N) (Min.) 0.5 Percent 1.100
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent 1.990
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 4.100
9 Total NPK Nutrient (Min) 3.0 Percent 7.190

Test Report - 4
Product Name STP SLUDGE (300 deg cel)
Material Code NA GRN No. GR003
Batch Qty. NA Vehicle No. NA
Invoice No. NA Sample Qty. 500 GM
Receiving Date 23-11-2022 Analysis Date: 23-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 51.210
3 Bulk Density (Min.) 1.0 g/mL 0.720
4 pH (Max 7.5, Min 6.5) 7.5 7.820
5 Total Organic Carbon (Min.) 14.0 Percent 24.600
6 Total Nitrogen (N) (Min.) 0.5 Percent 2.170
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent I .050
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.230
9 Total NPK Nutrient (Min) 3.0 Percent 3.450

Test Report - 5
Product Name STP SLUDGE (300 deg cel)
Material Code NA GRN No. GR004
Batch Qty. NA Vehicle No. NA
Invoice No. NA Sample Qty. 500 GM
Receiving Date 23-11-2022 Analysis Date: 23-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 60.570
3 Bulk Density (Min.) 1.0 g/mL 0.750
4 pH (Max 7.5, Min 6.5) 7.5 7.810
5 Total Organic Carbon (Min.) 14.0 Percent 24.260
6 Total Nitrogen (N) (Min.) 0.5 Percent 2.1 1 0
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.240
9 Total NPK Nutrient (Min) 3.0 Percent 4.020

Test Report - 6
Product Name STP SLUDGE (400 deg cel)
Material Code NA GRN No. GR005
Batch Qty. NA Vehicle No. NA
Invoice No. NA Sample Qty. 500 GM
Receiving Date 23-11-2022 Analysis Date: 23-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 57.610
3 Bulk Density (Min.) 1.0 g/mL 0.780
4 pH (Max 7.5, Min 6.5) 7.5 8.030
5 Total Organic Carbon (Min.) 14.0 Percent 28.750
6 Total Nitrogen (N) (Min.) 0.5 Percent 2.410
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent 1.140
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.290
9 Total NPK Nutrient (Min) 3.0 Percent 3.840

Test Report - 7
Product Name STP SLUDGE (550 deg cel)
Material Code NA GRN No. GR006
Batch Qty. NA Vehicle No. NA
Invoice No. NA Sample Qty. 500 GM
Receiving Date 23-11-2022 Analysis Date: 23-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 8.840
3 Bulk Density (Min.) 1.0 g/mL 0.890
4 pH (Max 7.5, Min 6.5) 7.5 5.980
5 Total Organic Carbon (Min.) 14.0 Percent 28.820
6 Total Nitrogen (N) (Min.) 0.5 Percent 2.590
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent 2.320
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.200
9 Total NPK Nutrient (Min) 3.0 Percent 5.110

Test Report - 8
Product Name STP SLUDGE (550 deg cel)
Material Code NA GRN No. GR007
Batch Qty. NA Vehicle No. NA
Invoice No. NA Sample Qty. 500 GM
Receiving Date 23-11-2022 Analysis Date: 23-11-2022
Supplier Name NA
Sr. No. Parameters Specification Unit Test Result
1 Physical State Powder Complies
2 Moisture Content (Max) 25.0 Percent 23.330
3 Bulk Density (Min.) 1.0 g/mL 0.820
4 pH (Max 7.5, Min 6.5) 7.5 7.790
5 Total Organic Carbon (Min.) 14.0 Percent 21.640
6 Total Nitrogen (N) (Min.) 0.5 Percent 2.090
7 Total Phosphates as P205 (P) (Min.) 0.5 Percent 2.390
8 Total Potassium as K20 (K) (Min.) 0.5 Percent 0.190
9 Total NPK Nutrient (Min) 3.0 Percent 4.670

Certain features of the invention have been described with reference to the example embodiments. However, the description is not intended to be construed in a limiting sense. Various modifications of the example embodiments as well as other embodiments of the invention, which are apparent to the persons skilled in the art to which the invention pertains, are deemed to lie within the spirit and scope of the invention. ,CLAIMS:WE CLAIM
1.A process for the preparation of organic fertilizer comprising:
I.Taking sewage sludge from a sewage treatment plant;
II.Dewatering the sewage sludge and thickening the same,
III.Blending the thickened sewage with dried recycled sewage,
IV.Drying the blended sewage sludge and crushing the same to obtain semisolid cake,
V.Heating semisolid cake by passing hot air having a temperature of 400 - 800 0C for 2 - 12 seconds so as to obtain organic fertilizer.
2.The process for the preparation of organic fertilizer as claimed in claim 1, wherein the dewatering process is done by a mechanical process, for example, a filter press process, centrifugal process, or by a chemical process.
3.The process for the preparation of organic fertilizer as claimed in claim 1, wherein the thickening process is done by trickling the sewage sludge over a filter,
4.The process for the preparation of organic fertilizer as claimed in claim 1, wherein the blending of the thickened sewage is done with 65 – 75 % by weight dried recycled sewage.
5.The process for the preparation of organic fertilizer as claimed in claim 1, wherein the drying of the sewage sludge is done by passing hot air having a temperature of 400 - 800 0C for 2 - 12 seconds.
6.The process for the preparation of organic fertilizer as claimed in claim 1, wherein 25 – 35 % by weight obtained heated sludge is converted into the organic fertilizer, and the remaining heated sludge is recycled with the thick sewage sludge.
7.The process for the preparation of organic fertilizer as claimed in claim 1, wherein the sludge mixture is continuously blended during the drying and heating processes.