Extraction and sale of sapropel. Innovative technology for the extraction of lake sapropel with onshore equipment Equipment for the extraction of sapropel in small volumes

New technological developments of the Sapropel Center (Russia, Astrakhan) open up new opportunities in the production of lake sapropels without the use of expensive floating dredgers and floating slurry pipelines, facilitate the transition from seasonal to year-round field development, practically eliminating seasonal equipment downtime and increasing its annual productivity by almost twice.

In 2017-2018, the Center at one of the sapropel fields in the northwestern part of Russia applied innovative production of raw materials necessary for the production of natural environmentally friendly organic fertilizers through inclined wells drilled in the lower part of the productive layer from the shore by self-propelled horizontal drilling equipment.

To conduct pilot tests of the proposed technology for extracting sapropel of natural moisture without involving lake water in the process, an onshore complex was used from a self-propelled HDD device, a mobile diesel hydroelectric power station and downhole pumping and production equipment (SNPO) with an inclined horizontal slurry pipe.

The field has geological reserves of sapropel of 2.36 million tons, the width of the lake is 380 m, the length is 1.3 km, the depth of development is from 4 to 14 m, the thickness of the productive layer is from 3 to 8.7 m.

A technological well was drilled from the east to the west coast along the bottom of the productive layer of sapropel, a slurry pipe with a diameter of 200 mm was laid along the well with a pumping mechanism installed at its end.

The pumping and extraction mechanism is a hydraulic high-pressure submersible dredging pump of the Powerdredging PD3000 type and a forced opening nozzle. It was powered by a mobile diesel hydroelectric power station installed on the shore of the lake. The extraction of sapropel was carried out by a chamber slaughter from the side of the western coast and, as the productive layer was developed, it moved to the east.

The Powerdredging PD3000 dredger is used for various mining operations, incl. for the extraction of sands and ASM, pumping and removal of communal sludge, cleaning of reservoirs. The dredger allows pumping up to 800 m 3 of slurry per hour with a maximum concentration of the pumped materials of 47% water and 53% dry residue. The suction dredger includes a nozzle-grinder for large clay deposits, debris, branches, silt, overgrowth, as well as a ripper for dense layers of sapropel. The characteristics of the dredger are presented below:

** The delivery set includes a pressure slurry line (1.5 m) with a flanged end bundle DN178 mm or 229 mm.

The Powerdredging PD3000 dredger in the technological mode of the development of the lake sapropel field is compatible with the hydraulic diesel station SWAMPKING 32-210, HYDRA-TECH 150DJD / 150DJV, HYDRA-TECH 150DD / 150DV or HYDRA-TECH 200DD / 200DV.

During the pilot industrial development of the sapropel deposit, the bottomhole was advanced by pulling a slurry pipe with a pumping-production mechanism along a previously drilled horizontally inclined well with an onshore HDD device. The completion of the mining process took place at the eastern boundary of the sapropel layer. Pasty liquid sapropel through the slurry discharge pipe entered the coastal warehouse from several bunded receipts, which served as a temporary warehouse of raw materials before processing it into a marketable product.

After the work was completed in one horizontal directional well, the process was repeated in the next one, which had been run parallel to the previous one at a calculated distance from each other.

In the process of operational work, the productivity of sapropel of natural humidity of more than 250 m 3 / hour was achieved. Capital investments, compared to the traditional extraction of sapropel by a dredger, decreased by 42%, energy consumption for the extraction of 1 m 3 of natural moisture sapropel decreased by 28%, and the production cost was less than 52 rubles / m 3.

When geological studies are performed at the field and the calculation of its sapropel reserves, preparation for the launch of production complexes consists of a technological survey of the field, selection of an industrial site for the construction of warehouses for extracted raw materials and processing shops, and preparation of a technical project. It takes no more than 2.5 months in time.

Manufacturing and delivery of downhole and onshore equipment to the work site takes 1.5-2 months. Installation work at the field and preparation of equipment for operation in time lasts no more than 4 hours.

The cost of the mining complex with technical project designed for a productivity of up to 250 m 3 of natural moisture sapropel per hour with a lake deposit width of up to 400 m, a layer depth of up to 14 m and a range of feedstock supply to warehouses at a distance of no more than 450 m does not exceed 18 million rubles.

From the sapropel extracted in this way, the technology provides for the production of organic, environmentally friendly fertilizers in pasty, granular, tableted and free-flowing form, soil formers and recultivators, going to the needs of agricultural producers in Russia and for export to the countries of Central, South-East Asia, the Middle East, as a material, able to recreate farmland in poorly humid desert areas, transform depleted land into soils with a high humus content. Some types of sapropel are used for the production of medical and cosmetic preparations, potassium and sodium humates, feed additives for poultry, cattle and pigs.

Workshop processing sapropel in commercial products, consists of a set of equipment for dehydration, grinding, screening, mixing, drying and packaging of the finished product in various types of containers.

The market wholesale price of bulk fertilizers made from sapropel in accordance with GOST R 54000-2010 with an organic content of more than 30% is at least 5800 rubles / m3 in the domestic market, $ 380 in the external market, and 34 thousand rubles for pasty cosmetic mud. and $ 870 US, respectively.

To date, the Sapropel Center conducts prospecting and appraisal of productive bottom silts and sapropel and prepares technological solutions on their development using innovative production technology not only in Russia and the post-Soviet space, but also in countries such as Vietnam, Poland, Ethiopia, Georgia, Estonia, Lithuania.

The proposal for organizing the production of sapropel fertilizers is especially important for areas rich in fresh water bodies: lakes, swamps, artificial rates, estuaries, etc. Demand for products is constant, business profitability is high and there is always an opportunity for development in more large enterprise since there is global problem deterioration and depletion of fertile land.

Investments of about 12,000 USD;
More than 100% profitability;
Payback period 6-12 months

To develop a sapropel deposit, there is no need to rent a section of a reservoir, on the contrary, it can bring additional income... Extraction of sapropel purifies the water, which contributes to fish farming, therefore, farms that breed fish at their rates always meet entrepreneurs halfway and pay for their services by agreement. On an industrial scale, government subsidies are possible.

Sapropel is a silt from the remains of microorganisms (plankton), aquatic plants and their decay products, formed under the influence of complex biochemical processes. Sapropel contains a complex of mineral, organic and biologically active substances.
Application and potential customers.

The main area of ​​use is agriculture, as organic fertilizers and additives in animal feed.

The advantage of sapropel over other fertilizers:
- high concentration of nitrogen and organic matter;
- ecological cleanliness and naturalness;
- absence of impurities and weeds;
- storage resistance;
- long-term action (15 kg per 1 m kW, gives an effect for 10-14 years);
- increases productivity up to 50%, quality of soil and plant products.

Also sapropel is used in medicine for mud therapy and in construction, for the production building materials and solutions.

Potential clients are private farms and agricultural enterprises, enterprises that process sapropel into dry and granular fertilizers, mud baths and sanatoriums, factories for the manufacture of construction enterprises.

Production and fixed assets of production.

Sapropel is extracted by hydromechanical method, a mini dredger is working on the reservoir, which sucks in the sapropel and transfers it through a pipeline to land or a pontoon for further processing and packaging.

Production stages:
1. Preparation of the place for work:
- trees and shrubs are removed;
- the entrance for transport is being cleared;
- temporary structures are being built for storing equipment and fuels and lubricants, a warehouse and a place for recreation, electricity and, if possible, communications are supplied.
2. Installation and assembly of equipment.
3. Extraction and processing of sapropel into a finished product.

The production is completely organized on the shore of the reservoir, from where it is transported to the place of sale or to the warehouse.
The main means of production is a mini dredger, which is a self-propelled watercraft with a pump powered by one or more engines. Minimum requirements for a dredger, productivity of at least 50-70 cubic meters of silt per hour at a depth of up to 5 meters and transfer of sapropel through a pipeline at a distance of 50-100 meters through a pipeline.
It is possible to produce and sell sapropel with natural moisture content up to 85% in soft polymer packaging.
The greatest demand is for bulk and granular sapropel; for its production, a more serious set of equipment from drying chambers and granulators is required.

Number of staff 1 - 2 people:
- dredger operator;
- an assistant in charge of sapropel packing.

Type of ownership.

To conduct business, it is enough to organize private or individual entrepreneurship on a simplified taxation system. An unregistered enterprise will not be able to work on water bodies and sell untested products. You also need to get the package permits from a number of authorities and environmental inspections.

Expenses.

Capital costs to start production are calculated based on the availability of transport.
1. Registration of the company and collection of documents 2000 c.u.
2. Mini dredger 7,000 USD
3. Temporary collapsible structures 1000 USD
4. Other costs, including transportation to the sapropel deposit and packing 2,000 USD.
5. Total $ 12,000
Variable costs, depending on the volume of production, amount to 8-12 USD. per unit of production (1 ton):
- fuels and lubricants for dredger engines and pumps;
- transportation to the place of storage or sale;
- packaging costs;
- electricity;
- other costs.

Fixed costs:
- wages to employees;

Taxes and contributions to the pension fund;
- equipment depreciation;
- sales and advertising costs.

The cost of services and products.

1. Services of a dredger, for washing up the coast, cleaning reservoirs, deepening the bottom, etc. 6-8 USD. for 1 sq.m.
2. Sapropel of natural moisture, 1 ton of raw materials 60-80 USD

Profit.
The production of liquid sapropel per month, with a dredger capacity of 50-70 cubic meters of raw materials per hour, will be about 35-37 tons
35 tons x 80 USD = 2800 USD

Additional income for the services of the dredger 600-800 USD
Total revenue for the month 2800 + 600 = 3400 c.u.
Variable costs per month (average) $ 350
Fixed costs per month (average, including wages) 1200 USD
Total costs 350 + 1200 = 1550 USD / month.
Profit 3400 - 1550 = 1850 USD / month
Production profitability of about 119%

Technological progress in foreign countries in the field of manufacturing compact and mobile equipment for cleaning reservoirs from siltation and utilization of recoverable sludge makes it possible to use it by analogy in the extraction and processing of sapropel as raw materials for the production of environmentally friendly fertilizers, feed additives, cosmetic and medicinal raw materials.

Conducted tests of the universal amphibious dredger Truksor DM 4700V of the Swedish company Dorotea Mekaniska AB together with a set attachments gives grounds for its effective use on lake deposits of sapropels, dense and viscous bottom silts with a depth of occurrence of up to 1.6 m. The company's efforts to maintain its superiority in this direction are now focused on increasing the extraction depth to 2.4 m and more. The first machines of this class with an increased depth of sludge intake were produced in 2009. With a diesel engine power of 27.2 hp. A pump suspension of the Dredgepump 2500 type on Truxor DM 4700V equipment allows to extract up to 30 m3 of sapropel per hour and move it along a floating flexible pipeline over a distance of more than 50 m. One person controls the mining process. The equipment is certified by the European committee. The interest in this technique among Russian small businesses and farmers is not accidental: the dredger is easy to operate, mobile, and moves by itself on water, land, and swamps. Does not require assembly and disassembly when moving from one lake to another. In Russia, there is a representative of the company, ensuring its timely delivery, customs clearance, provision of the necessary components and repair units. No special skills or permits are required to operate the equipment. The cycle of preparation of the lake sapropel deposit for development includes coastal fortification, construction of entrances and berths on the water, cleaning algae and grass, cleaning the water surface from branches, roots and trunks of fallen trees, etc. The change of attachments for such operations is carried out by one person in no more than 20 minutes. The cost is affordable for entrepreneurs and farmers. So in 2009 the basic set of equipment did not exceed 81 thousand euros in value. The payback period for Truxor DM 4700V in production schemes for the extraction and processing of sapropel for fertilizers is no more than 3, 5 years. To work at the sapropel lake deposit, a technological regulation or a project is required. The project is coordinated with local authorities, environmental management, etc. On its basis, a permit for water use is issued and the profitability of the entire business is ensured from the start of production to processing and packaging. Designs areas for the production of fertilizers from sapropel and supplies equipment to the Sapropel Center. The usual terms for a complex of works are from 1.5 to 2.5 months. Projects for small-scale production include a description of the technology of work and an economic calculation part with data on the specification of equipment, the cost of a unit of manufactured products, the payback period of the enterprise, its profitability, energy intensity, staffing. Excellent results are shown by the Truxor DM 4700V complex with the TenCate geotube coastal sludge dewatering containers, especially in the production of sapropel for granular fertilizers and cosmetic sapropel raw materials. Such a complex excludes settling warehouses for freezing raw materials, mechanical dehydrators (separators, centrifuges, decanters). Similar Russian equipment is not produced. The project + equipment set does not exceed 4 million rubles at a cost and is supplied by the Sapropel Center within 3 months. Products manufactured by a farm using this equipment and materials: granular and bulk fertilizers, feed additives, sapropel-vitamin supplements, viscous therapeutic mud, medical and veterinary applications, cosmetic cheese.

Details with the content of production projects different types products in farms using this technique on shallow lakes can be found in the annexes to www.saprex.ru

The invention relates to agriculture and can be used in the extraction of environmentally friendly organic fertilizer - sapropel. The method includes preliminary loosening of sapropel, suction through a pipeline to a previously prepared site on the coastal surface and subsequent freezing of excess moisture. Loosening and suction is carried out using a buoyant undercarriage of an armored personnel carrier on caterpillar, on which the pump and ripper are hung. The device contains a suction pipe with a screw installed on the shaft, a pump and a drive. A loosening cutter with spiral knives is mounted coaxially with the auger shaft, and a grate is installed at the inlet of the suction pipe. The auger shaft and ripper cutter are mounted on bearings with the ability to rotate in opposite directions. The invention will reduce labor costs in the extraction of sapropel, improve maneuverability and mobility in work. 2 c.p. f-crystals, 8 ill.

The invention relates to agriculture, in particular to the production (growing) of environmentally friendly food. At present, in Russia, as a result of the use of chemical fertilizers, the amount of phosphates and nitrates has sharply increased. The desire to increase yields through the application of chemical fertilizers and the use of herbicides, as a rule, leads to a deterioration in the quality of land and food. It is necessary to stop further saturation of the soil with harmful elements as soon as possible. Therefore, despite the deteriorating state of nature, priority attention should be directed to the creation of environmentally friendly technologies-methods for growing food. At present, the fight against nitrates is carried out by the method of washing and cooking products, as a result of which the amount of nitrates is reduced by 20 - 40%. For table beets, for example, the upper and lower parts of the root crop are cut off, in cabbage, the upper covering foliage and stubs are cleaned, for squash, the upper part adjacent to the stalk is cut off, for zucchini, the skin is removed, for cucumbers it is better to peel the skin and cut off the tail. If potatoes are soaked for a day in a 1% solution of sodium chloride and ascorbic acid, then the level of nitrates and tubers will decrease by almost 90% (1). The disadvantage of the above fight against nitrates is that when cooking, it is necessary to additionally spend labor on cutting off parts of root crops, soaking in the required percentage solution. Most of the grown product goes to waste, and the waste itself, once again falling into the ground, is again contaminated with nitrates. A global struggle for a purely environmentally friendly product is needed - to exclude the use of chemicals in agriculture, replacing them with organic fertilizers, including sapropel. It is known that more than 2 million freshwater lakes are located on the territory of Russia. These lakes are rich in diverse life. Perennial plants such as reeds, peas, etc., by the way, containing starch, penetrate the entire water column and accumulate at the bottom. Billions of living organisms live in the soil of lakes and water. Every autumn, a significant part of plants and animals dies, sinks to the bottom, drifts from the shores also fall here, therefore organic matter, called sapropel, accumulates at the bottom of the lakes. As a result of a complex and long-term biological process, a most valuable product is formed - a natural concentrate of sapropel. This is not bottom silt, these deposits are different in origin and composition with soil composition. Sapropel is formed in stagnant lakes, silt sediments of flowing lakes contain up to 15% of organic matter, and sapropel - up to 96%. The physical properties are also different. Dried bottom sludge crumbles into powder, dried sapropel turns into stone. If wet sapropel is frozen and then dried, it becomes crumbly. According to forecasts of scientists in the lakes Russian Federation accumulated 230 billion cubic meters of sapropel (of which 50 in the Non-Black Earth Region). It has been proven that when sapropel is introduced as a fertilizer, the fertility of the land is sharply improved. (2). The addition of sapropel significantly increases the yield of almost any agricultural crops, both grain and garden crops. You can add it without any dosage restrictions. There is a known method of extracting sapropel from the bottom of dying lakes, including its preliminary loosening with a ripper, suction by a pump through a pipeline using dredgers to a prepared site on the coastal surface and subsequent freezing of excess moisture (3). The known method has disadvantages - low efficiency of pumping water, there is little sapropel in it, and therefore the use of dredgers has not received proper development, mainly due to the lack of sufficient mobility of equipment, which makes it possible to extract sapropel in any lake. It is known that the thickness of the deposit ranges from 2 - 5 meters to 40 meters. There are lakes, the water layer in which is literally a few centimeters, almost the entire bowl is occupied by sediments. The deeper the sapropel, the higher its quality. Therefore, in order to obtain the necessary pulp for the suction dredger, the sapropel must be loosened, it is necessary to set up sedimentation tanks for freezing the sapropel, followed by loosening, drying and packaging in an appropriate container for sale to warehouses, outlets etc. A device for sapropel extraction is known, comprising a suction pipe with a screw mounted on the shaft, a pump and a drive (4). The known device does not provide sufficient efficiency and productivity of sapropel extraction. The objective of the invention is to increase the profitability of sapropel mining, reduce labor costs, improve maneuverability and mobility in work. The problem is solved by the fact that during the extraction of sapropel, its loosening and suction is carried out using a buoyant undercarriage of an armored personnel carrier on a caterpillar track, on which a pump and a ripper are hung, and the device for sapropel extraction is equipped with a loosening cutter mounted coaxially with the auger shaft with spiral blades and installed on inlet of the suction pipe with a grate, and the auger shaft and the loosening cutter are mounted on bearings with the possibility of rotation in opposite directions. At the same time, it is planned to create a minimum complex of machines with mobility and maximum versatility, good stability during transportation over relief terrain, ease of control and operation. FIG. 1 (a) shows a schematic general form a special machine equipped with a sapropel ripper to a depth of at least 4 meters, a screw elevator for feeding after loosening the pulp to a centrifugal pump, equipped with hoses of any length and diameter. To drive the specified equipment, the machine is equipped with a power plant up to 100 kW. FIG. 1 (b) shows a section along AA in FIG. (a); in fig. 1 (c) is a view along arrow "B" in FIG. 1 (a). FIG. 2 schematically shows a bulldozer-excavator, which has a large cross-country ability, which makes it possible to prepare a special site for sapropel washing and, after freezing and drying, loading into a dump truck. FIG. 3 (a) shows a schematic diagram of a heavy-duty dump truck on the same interchangeability of an armored personnel carrier base for transporting sapropel to fields or a place of packaging and packaging for sale to the public. The body of the dump truck is equipped with an adjustable tailgate, which creates a gap of up to 15 cm, which makes it possible to deliver (pour, sprinkle) sapropel to the fields with a predetermined layer. FIG. 3 (b) shows the installation of a counterweight for stability in rough terrain. FIG. 4 shows a schematic of a trailer trailer transported by a dump truck for working personnel for the extraction of sapropel, equipped with the necessary instruments that can analyze sapropel and work at any time of the year. FIG. 5 shows a schematic general view of the proposed device for the extraction of sapropel, made in the form of a hinged mechanism. Loosening milling cutter 1 with spiral knives 2, having a helical inclination (like a spiral of a drill) towards the slurry discharge in the center of the suction pipe 3, mounted coaxially with the shaft 4 of the screw 5, installed in the suction pipe 3. At the inlet of the latter, there is a grate 6. Shaft 4 is installed in in the suction pipe 3 with the help of bearings 7, and the loosening cutter 1 - on the suction pipe 3 with the bearings 8. The auger 5 and the loosening milling cutter 1 are driven in opposite directions by an electric motor 9 with a gearbox. The suction pipe 3 has slots 10 for the suction of the slurry by a centrifugal pump 11 with its supply through a pipeline-hose 12 to a previously prepared site on the coastal surface. The described device is hung on a special carriage (Fig. 1 (a)), which makes it possible to turn the intake mechanism by 180 o. FIG. 1 shows a tracked vehicle, for which an armored personnel carrier undercarriage is used, which has buoyancy, on which an alternating current diesel generator is installed with a power that provides electric drives for the intake mechanism and lighting, allowing it to work at night. FIG. 1 (b) shows a sectional view of the intake mechanism along AA in FIG. 1 (a). 1 - Knives in the form of a helical spiral, 4 - shaft, 3 - pipe and 5 - auger. FIG. 1 (c) shows the same element, but in a different plane. To fix the entire machine on the water, there are two screw clamps, which are a drilling rig for determining the thickness of sapropel deposits and taking samples for analysis, and a simple corkscrew screwed into the ground. In order to ensure the preparation of sites for reclaimed pulp, for raking, freezing sapropel and loading onto a dump truck, an excavator, a grader and a bulldozer, shown in Fig. 2, which is also created on the basis of the chassis of the armored personnel carrier and has buoyancy. Such a mechanism makes it possible to dig trenches for water drainage, make embankments, prepare approaches to the lake, rake and load sapropel onto dump trucks. The same complex of machines makes it possible for the widespread extraction of sapropel in lakes located throughout Russia. In this case, billions of dollars in costs for the production of granular chemical fertilizers are excluded; they can be replaced with nitrate-free sapropel. The use of the proposed method for obtaining and extracting sapropel and the design of the intake device, in comparison with the known one, sharply reduces the labor costs for the extraction of sapropel, there is maneuverability, mobility in work, efficiency in terms of the costs of organizing these works. There is no need to use a dredger (the approximate price of one dredger is 900 million rubles). Vehicles based on armored personnel carriers are easily converted into vehicles for Agriculture... Great mobility and maneuverability makes it possible to effectively use them throughout Russia. There is an opportunity to use the accumulated military vehicles of the army without any special restructuring of production, to load production capacities without spending additional resources on it, to find jobs for most of the unemployed population of the country. Sources of information 1. Rural machine operator, N 5, 1990, p. 38. 2. Fomin A.I. Sapropel mining. - Science and Life, N 11, 1991. 3. Fomin A.I. Technology for the extraction of local fertilizers (sapropel). - M .: Higher school, 1969., p. 100 - 116. 4. USSR author's certificate N 870719, class. E 21 C 50/00, 07.10.81.

Claim

1. A method of extracting sapropel from the bottom of dying lakes, including its preliminary loosening with a ripper, suction by a pump through a pipeline to a previously prepared site on the coastal surface and subsequent freezing of excess moisture, characterized in that loosening and suction of sapropel is carried out using a buoyant undercarriage an armored personnel carrier on a caterpillar track, on which a pump and a ripper are hung. 2. A device for the extraction of sapropel, containing a suction pipe with a screw installed on the shaft, a pump and a drive, characterized in that it is equipped with a loosening cutter mounted coaxially with the screw shaft with spiral knives and a grid installed at the inlet of the suction pipe, and the screw shaft and the loosening cutter is mounted on bearings with the ability to rotate in opposite directions.