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Manure Separators by Agpro,®Inc. A full line of separation solutions!
Where there are problems, there are solutions. More stringent regulations and permit requirements make waste management a top concern at dairies and other livestock operations. Agpro® Inc. is the solution. From design to installation and service, we have the knowledge and experience to bring you the most complete selection of separation systems.
As regulations get tougher, so do separation systems from Agpro® Inc. Our separators are able to remove more solids and phosphorous than ever. No matter what type of bedding, feed or housing conditions are present, separator systems from Agpro® Inc. can be configured or modified to achieve ultimate performance that will give any inspector or regulator a “clear” idea of your waste management program.
Agpro® has a wide range of separating equipment, including ultra-fine double screening or standard single-screen systems, static-screen, conveyor and screw-press designs, models in multiple shapes and sizes to fit existing spaces and specific needs, removable screens and stationary spray nozzles for easy cleaning, stainless steel and hot-dipped galvanized construction. The list goes on.
Agpro’s® Mark IV line of static screen separator units is designed to separate properly diluted and agitated liquid waste slurries delivered by pump. Split screen design affords both flexibility in selection of weir spacing and enhanced clean ability. Stainless steel construction includes body, rear entry chamber and screens. All units are provided with hot dip galvanized support structure, two access stairways and under screen spray nozzles to facilitate clean up.
The Agpro Mark IV and Mark V manure separators are designed to separate the excess water from manure-water slurries and provide the operator with more manageable components.
Adequately diluted slurries run over a clean, properly installed separator, will result in separated solids with moisture contents down to 90% or less, and the separated water will normally contain no solids larger than the selected screen spacing. The materials should be stored on a properly constructed and drained floor.
All manure slurries are not alike. The make-up of slurries is affected by these factors and probably others.
• Dilution from rainfall.
• Dilution from other water.
• Evaporation from heat and sunshine.
• Changes in feed ration ingredients.
• Method of cleanup.
• Age of slurry.
• Reuse of cleanup water.
• Introduction of ingredients such as detergents, disinfectants, bedding, waste hay, and waste silage.
• Frequency of cleanup and processing.
With this many variables, it is easy to see that the make-up of manure slurry will vary greatly from one farm to another and, in fact, may vary significantly on the same farm from one day to the next or even from one hour to the next. These separators are best suited to slurries with 4% or less solids contents. Because of this the flow to the separator must be controlled. Provide a pump that has provisions for flow rate control.
Refer to assembly drawing for aid in parts identification. Note: Do not tighten bolts until assembly is complete. The unit is shipped partially assembled. Remove all crating and protecting material. Use caution when working around the separator screens. The stainless steel screens are virtually indestructible with normal use; however can be easily damaged by blows from hammers or falling tools.
1. Raise the top end of the separator body allowing the rear leg assembly to pivot out. The separator should now stand with minimal support. The rear leg assembly should be vertical.
2. Attach two horizontal leg-to-body supports(1/2”x 55 7/8” flat) to the tabs on the underside of the body and to the rear leg using (2) ½” X 5” hex bolts to legs & ½” x 1 ¾ on body tab, (8) washers and (4) nuts provided.
3. Install stairs on each side. Insert (3) 1½” square X 46” long tubes into 2” square tubes located horizontally along the back of the separator. These tubes should be inserted with the two sets of stairs mount plates positioned on top and approximately parallel to the back of the separator. Position the stair platform in place. Re-secure nuts to clamp stairs to body. Join the eight stair mount plates (four on ladder, four on 1½” tubes) using (8) 1/2” X 1½” hex bolts, (16) washers and (8) hex nuts provided. Position and attach the side and end handrails to plates located on the outside of the stairs using (8) ½” X 3” hex bolts, (16) washers and (8) hex nuts provided. Attach upper end diagonal strap from lower outside end handrail hole (hardware already installed) to hole at top of separator entry chamber using (1) ½” X 1¼” hex bolt, (2) washers and (1) hex nut provided (shipped already in hole). Finally snap outside corner cap into position to connect side and end handrails.
4. Check to see that all components are assembled and positioned properly. Tighten all bolts and nuts. Note: Do not tighten the bolts retaining the screens to the body.
Normal installation includes the positioning of the separator on a tower or other platform.
If possible, the separator tower should be constructed so that the screen area of the separator can be seen from the manure collection pit. This will allow the operator to adjust a flow control device positioned at the manure pump to effectively match the pump and separator capacities.
The pump supplier must account for all elevation differentials from bottom of pit to weir distribution of separator in calculating head to adequately size delivery pump. Dimensions will vary at each installation.
The platform should be approximately 10 to 12 feet above the floor where the manure solids are to be accumulated and sturdily constructed to support a minimum of 4,000 pounds. The platform floor will require a slot 20″ wide by the width of the separator across the front of the unit for solids to fall through. The platform should be fitted with a good safe access ladder or stair and totally enclose the separator with safety rails.
In areas where very cold weather is anticipated, an insulated building to house the separator may be needed. The concrete floor below the platform should be sloped to drain away from a push wall and to the manure collection sump or the waste retention pond.
Using Cranes, Skytrack, or other similar equipment place the assembled separator on the platform. Use caution during this process to avoid injury or equipment damage.
Position the separator in place with the solids discharge edge of the unit 2″ beyond the edge of the slot. As required, adjust the separator with shims under the support legs so the top distribution weir pipe is perfectly level. Bolt the separator down to the platform floor.
Plumb from the pump to the separator inlet located at the rear of the unit. This line should be sized by the pump supplier and connected to the pump by installing a flexible rubber hose coupling (minimum 12″ long) to absorb vibrations. An adapter may be needed to connect to separator inlet. For best results, a flow rate control valve should be installed in this line near the discharge of the manure pump. Install a tee where the inflow line enters the separator and cap the down leg to provide a cleanout. It is best if slopes allow this line to completely drain out following processing session; this will avoid settling in line. If freezing weather is anticipated, the lines should be insulated or drained.
Plumb from the separator drain (bottom of separator) to the retention pond or secondary setting tank. This pipe should be at least the size of the separator drain. This drain will start with a head of 10′ to 12′ so it is generally possible to gravity flow the drain line for a long distance. If this line is run on a continually descending grade, it will drain out after each use and will not require insulation for freezing weather. A minimum uniform slope of 1% is required in the drain line to assure proper separator discharge.
Install a 1″ water line, hose bibb, and hose on the separator platform for cleaning the stainless steel screen. Insulate or provide for draining this line if freezing weather is anticipated. The easiest time to clean the screen is immediately after use before any material dries to the surface.
After each use, be sure all lines drain completely or flush all lines with clear water to prevent solids build-up and possible plugging. Regularly hose the screens thoroughly to prevent solids buildup. If the screens should loose efficiency in separation, algae may have formed on the underside. First clean loose debris from face of screens. Pivot all screens to expose underside. Clean by spraying the entire screen area with household strength chlorine solution (one part Clorox and two parts water) and allow to set 10-15 minutes. If fresh water supply is available, hose the solution off the screen, otherwise run the pump to remove the solution and algae.
In some instances a calcium type build-up may occur between the screen bars (sometimes called struvite). It may appear as white, light gray or even black in color. It is very hard and may be difficult to see. It normally may be removed by the soaking method described above utilizing milk line cleaner (acid) or muratic acid instead of chlorine. Always wear proper protective clothing and eyewear and exercise extreme care during the cleaning procedure.
Upper screen should appear similar to MKIV. Solids from Upper screen falling on lower screen should prevent “streamers” on lower screen from entering stack.
Normal MKIV Separation Operation – Note free water disappearing in upper half.
Static Screen Separators are one of the most reliable and maintenance free manure separators available today. Since they have no moving parts they simply do not wear out. Agpro has produced this type of separator for over 30 years and some of the early units are still in operation! However, they are not totally maintenance free.
This type of separator will require periodic cleaning. They utilize a stainless steel ‘wedge wire screen’ with a specific bar size and opening size. The performance of the screen is dependent on the water passing through screen openings; if the screen is dirty, the openings will be restricted.
The wedge wire screen can be fouled by two methods: 1) dirt and algae growth or 2) mineral deposit.
Dirt and Algae Growth
A brown slimy scum will build up on the back of the wedge wire screen. Often you cannot see this build up from the topside of the screen! Eventually this will build up and degrade the performance of the screen. The amount of time between cleaning is affected by the following factors.
1. Warm humid weather encourages this growth.
2. Heavily recycled flush water encourages growth.
3. Water quality and the amount of chlorine in the fresh water supply.
4. Fine screen openings will require more frequent cleaning.
5. Fresh water rinse after separation cycle will encourage less frequent cleaning.
Agpro Static Screen Separators are built with the ability to be easily cleaned. The cleaning procedure is as follows.
1. Remove manure and rinse the top of the screens.
2. Raise the screens. Be sure screens are secure in the raised position, safety tie the screen if needed.
3. Apply chlorine solution to the bottom of the screen with hand pump spray machine. Household bleach will work. Allow to soak for 10 to 15 minutes then spray clean the screen with a hose or pressure washer.
TAKE SAFETY PRECAUTIONS TO ENSURE SKIN AND EYES ARE PROTECTED FROM THE CHEMICAL. ALSO, BE CERTAIN THAT THE AREA IS WELL VENTILATED SO THAT CHEMICAL FUMES WILL NOT BE HARMFUL.
Minerals may build up on the back of the wedge wire screen. Often you cannot see this build up from the topside of the screen! The deposits are nearly clear when wet and are difficult to see from the bottom of the screen. You may feel a roughness on the bottom of the normally smooth stainless steel screen wire. Eventually this will build up and degrade the performance of the screen. The amount of time between cleaning is affected by the following factors.
1. Heavily recycled flush water encourages the mineral deposit (sometimes called struvite).
2. Water quality and the amount of minerals in the fresh water supply.
3. Fine screen openings will require more frequent cleaning.
4. Fresh water rinse after separation cycle will encourage less frequent cleaning.
There are various products available to deal with these mineral deposits. Contact your local supplier for a product that will be suitable for your application.
AGAIN, AS WITH ANY CLEANING AGENT, IT IS IMPORTANT THAT ALL RECOMMENDED SAFETY PRECAUTIONS BE FOLLOWED
RAISING THE SCREENS IS ESSENTIAL FOR EFFECTIVE CLEANING.
Some cleaning can be achieved by washing from the front side of the screen and should precede the thorough cleaning.
Trouble Shooting Guide
FAILURE OF THE SEPARATOR TO OPERATE PROPERLY CAN BE CAUSED BY ANY ONE OR A COMBINATION OF THE FOLLOWING FACTORS.
Condition: Visible water flowing 2/3 of the way down the screen with streams flowing all the way down. Cause: Excessive inflow rate. Solution: Reduce the inflow rate. Water should disappear between 1/4 and 1/2 way down the screen. Flow rate is crucial for proper separation.
Condition: Uneven flow across the distribution weir causing a stream of water to flow all the way down the screen. Cause: The separator is not level. Solution: Level the separator.
Condition: Thick manure resulting in entire mass sliding down the face of the separator with very little water separation. Cause: Inadequate dilution. Solution: Add more water. The slurry needs to be very thin for proper separation. In cases where water is in short supply, the plumbing can be arranged so that a portion of the separated liquid from the separator goes back into the slurry collection pit at the pump to provide extra dilution.
Condition: A thin slurry flows over the screen without separation. Cuase: This condition is usually caused by dirty or partially plugged screens. Material from the last use may have dried on the face of the screens or a growth of algae may have partially plugged the screen opening. The algae problem occurs more frequently in warm weather. Solution: Clean the screens after each use. This is most efficiently done by brooming the face horizontally followed by a clear water rinse. In case of algae growth, a household strength chlorine solution should be spread on the screen, allowed to set several minutes, and then washed off thoroughly with clean water. In warm summer weather, this treatment may be needed quite frequently (daily); in cool weather, weekly or not at all.
Condition: Foaming at the separation point with excess foam trapped in the solids. When the foam turns back to liquid you have a higher than normal moisture content in the separated solids. Cause: The exact cause of this phenomenon is not known. It may be related to temperature, dilution, or the presence of certain bacteria or detergents. It has been observed most frequently in systems where the flush water is being recycled to clean up the facilities. Solution: Slowing down the flow rate over the separator and/or the addition of fresh water to the slurry will help. In the case of recycled water, it will be necessary to replace the water with fresh more frequently.
Condition: Foaming from excess agitation resulting in excessive air in the liquid slurry. Cause: This occurs when an agitator (Propeller type) becomes exposed to the air and you get a mixing of air and slurry at the same time you are pumping over the separator. Solution: Don’t pump the slurry collection tank down low enough to expose the propeller agitator.
Condition: Thick manure slurries at or near the minimum dilution for separation not separating properly immediately after mixing with water. Cause: Short mixing time. With adequate time, the added dilution water gradually dissolves mucus and other thick soluble portions of the manure. Solution: Wait several hours after mixing before separation. One of the most efficient management programs is to accumulate the manure and mix with water in the afternoon and separate the next morning after a brief agitation period.
Agpro, Inc. Mark IV Screen Separator Leg Extensions
Leg Extensions must be installed before the Roller Press
Lift MKIV Separator to attach leg extensions required for the roller press
Install cross bracing while the Separator is still suspended
Lower Separator to the ground and begin installing Roller Press
Agpro Inc.’s® Mark V line of static screen separator units is designed to separate properly diluted and agitated liquid waste slurries delivered by pump. Top screen has split screen design to enhance clean ability. Bottom screen is bolted in. All are stainless steel body and rear entry chamber. All units are provided with hot dip galvanized support, two access stairways and bottom screen spray nozzles.
The Agpro® stacking separator is designed to provide up to a 20′ stack of reclaimed solids when used in conjunction with our Static Screen Separators. By utilizing this unit tower height mounting of separators is reduced substantially. Additionally, the added length of separating components greatly enhances the overall dryness of the reclaimed solids. Unit comes complete with reception chamber and support system. PARTS OF THE DRIVE PACKAGE ARE HOT DIP GALVANIZED. Desired power requirements ( phase and voltage) must be specified by customer.
Agpro’s® Extractor line of separators is designed to mate with flush operations and provide separation of waste solids without the use of manure pumps, agitators, collection pits or towers. The unit comes with required motors and controls including an automatic on/off switch. Desired power requirements (phase and voltage) must be specified by customer.
Agpro, Inc.’s® HS-II Stainless Steel 36″ wide Conveyor Separator. Unibody construction with perforated or wedge wire screen. Motor & gearbox are euro-style rated for variable speed use. The unit has integral spray bars under the screen to facilitate cleaning. Unit has inflow bypass and includes a dual roller combination with adjustable tension springs to control bypass. Mount frames, catwalk and other minor parts are hot dip galvanized. Electrical controls are included -Verify phase and voltage.
Individual applications and desired results will dictate screen spacing combinations.