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Proposal for Recycling Chicken Farm

日期:2014.01.05  来源:阿拉伯信息交流中心

pics

Aerospace Long-March International Trade Co., Ltd.

Chapter 1  General

1.1 Basic Information of the project owner

The project is located in Saudi Arabia.

1.2 Construction plan of the project

1.2.1 Project name, type and site

Project name: Recycling Chicken Farm

Type: new

Site: xx city, Saudi Arabia

1.2.2 Construction scale and Products

●Construction scale:

(1) Standardized and automatic chicken farm with capability of raising 400,000 chickens;

(2) 16,800 tons automatic feed mill;

(3) 1,200 ton eggs (halal) processing workshop;

(4) 340,000 chickens (halal) slaughtering and processing workshops;

(5) 6,000 tons bio-organic fertilizer plant.

●Products: 1,120 tons of fresh eggs; 1,200 metric tons (halal) of protein, egg yolk liquid, egg pulp, albumen powder, yolk powder, and whole egg powder; 6000 tons of bio-organic fertilizer; 320,000 (halal) chickens; 32 tons of feed protein.

1.2.3 Technology, equipment, and buildings (the principal part of the project)

By adopting advanced processing technology and equipment, this project will be in great sanitary condition and has high degree of automation. The quality of the products will conform to the national standards for food and eggs.

25 types of equipment are required for the project with total cost of 11.16 million dollars, Details are as follows (table 1-1).

Table 1-1  Main equipment of the project

 No.

Equipment name

Types

Unit

Quantities

1

Feed mill equipment

 

 

 

2

Cage frame system

 

set

2100

3

 Feeding equipment

 

set

50

4

Cage cleanup equipment

 

set

50

5

Egg collection equipment

 

set

50

6

Feeding water supply equipment

 

set

10

7

Ventilating and cooling equipment

 

set

10

8

Lighting system

 

set

10

9

Electric control equipment

 

set

10

10

Packaging machine and ink-jet printer

 

set

1

11

Egg powder equipment

 

set

1

12

Egg powder dividing equipment

 

 

 

13

Hanging overhead conveyor line

 

set

1

14

High frequency electric stunning machine

 

set

1

15

Stainless steel automatic scalding machine

JTG-1000J

set

1

16

Stainless steel automatic depilator

TYL-32J

set

1

17

Stainless steel evisceration slot

6000×500×800

set

1

18

Stainless steel blood draining slot

 

set

1

19

Spray preheat machine

TYPE

set

1

20

Automatic chicken cleaning machine

NWX768/152

set

1

21

Automatic unloading device

 

set

1

22

Paraffin pool

JL50

set

1

23

Bio-organic fertilizer fermentation equipment

 

 

 

24

Bio-organic fertilizer filter equipment

 

 

 

25

Granulation equipment

 

 

 

  The total area of structure of the project is 38960 square meters. Details of each building are shown in table 1-2.

Table 1-2 Main building of the project

No.

Name

Type

Unit

Quantities

I

Feed Mill

 

 

1160

1

 Production plant

light steel structure

square meters

350

2

Raw materials warehouse

light steel structure

square meters

300

3

Finished products warehouse

light steel structure

square meters

300

4

Packing workshop

light steel structure

square meters

120

5

Testing laboratory

light steel structure

square meters

90

II

Chicken farm for 1 million laying hens

 

 

 

1

Henhouse (25 set)

light steel structure

square meters

22500

2

Henhouse (13 set)

light steel structure

square meters

6960

3

Egg warehouse

light steel structure

square meters

360

4

Packing workshop

light steel structure

square meters

120

5

Testing laboratory

light steel structure

square meters

90

6

Veterinary room

light steel structure

square meters

80

III

Egg powder plant

 

 

 

1

 Production plant

light steel structure

square meters

2400

2

Raw materials warehouse

light steel structure

square meters

300

3

Finished products warehouse

light steel structure

square meters

300

4

Auxiliary workshop

light steel structure

square meters

300

5

Testing laboratory

light steel structure

square meters

80

IV

Chicken slaughtering and processing workshop

 

 

 

1

Production workshop and packing workshop

brick

square meters

1200

2

Refrigeration storage

brick

square meters

180

V

Bio-organic fertilizer plant

 

 

 

1

Fermentation area

 

 

 

⑴    

Fermentation workshop

light steel structure

square meters

1500

⑵    

Ingredients premixed area

 

square meters

300

Secondary fermentation area

 

square meters

450

2

Granulation area

 

 

 

⑴    

 Granulation workshop

light steel structure

square meters

200

⑵    

Fermentation material sorting workshop

light steel structure

square meters

180

⑶    

Finished products warehouse

light steel structure

square meters

300

1.3 Investment structure

The total investment of the project is 29.94 million dollars, including 22.26 million dollars for fixed assets and 7.69 million dollars for working capital.

1.4 Project benefits

1.4.1 Economic benefits

The estimated average annual sales income of this project will be 31.46 million dollars. Considering the investment of 29.96 million dollars, the internal rate of return is 32.57%, the return on investment is 28.60%, and the payback period is 4.88 years (after tax).

1.4.2 Ecological benefits

As a model of recycling economy, the byproducts will be utilized completely and only very limited waste and sewage will be produced. In another word, this project will be an environment friendly project and will cause no ecological problem.


 Chapter 2  Construction Plan

2.1 Product scheme and construction scale

Construction contents and scale:

(1) Standardized and automatic chicken farm with capability of raising 400000 chickens;

(2) Automatic feed mill (16800 tons);

(3) 1200 ton egg (halal) processing workshop

(4) 340000 chickens (halal) slaughtering and processing workshop;

(5) 6000 tons bio-organic fertilizer plant.

●Products: 1120 tons of fresh eggs; 1200 metric tons (halal) of protein, egg yolk liquid, egg pulp, albumen powder, yolk powder, whole egg powder; 6000 tons of bio-organic fertilizer; 320000 (halal) chickens; 32 tons of feed protein.

●Work-flow of the project:

(1) Feed mill: purchasing raw materials for the feed mill and producing feed for chicken;

(2) Chicken farm: feeding chicken to produce eggs and live chickens;

(3) Chickens (halal) slaughtering and processing workshop: Slaughtering and processing live chicken from Chicken Farm;

(4) Egg processing workshop: processing eggs from Chicken Farm into final products;

(5) Organic fertilizer plant: utilizing organic waste from Chicken Farm and other processing department to produce bio-organic fertilizer.

2.2 Construction planning and layout

The total area of the project is about 133 hectares. Feed mill, Chicken farm, Chickens (halal) slaughtering and processing workshop, Egg processing workshop, and Organic fertilizer plant are will settled in the area.

2.3 Construction standards and product standards

All of the constructions are in accordance with Chinese Standards, and details are as follow:

Construction standards:

l  "Food Safety Law"

l  NY/T5043-2001 "The pollution-free food: laying hens breeding management guidelines"

l  DB33 / T531-2005 "The poultry slaughtering operation specification"

l  "Islam poultry slaughtering operation specification"

Product standards:

l  NY 5039 "The pollution-free food: eggs"

l  GB13078-2001 "The standard of feed hygiene"

l  NY 5042 "The pollution-free food: laying hens feed use guidelines"

l  NY 884-2004 "The biological organic fertilizer"

l  NY 5034-2001 "The pollution-free food: chicken

l  GB 2754-2754 "The whole egg powder sanitation standard"

2.4 Process plan, equipment plan, and construction plan for each procedure

2.4.1 Feed mill

2.4.1.1 Process plan

The process is divided into 6 sections, including raw material receiving, cleaning, crushing, mixing, granulating, and finished product packing. Details are as follows:

(1) Raw material receiving section: putting raw materials such as plant material, trace elements, and vitamins into the bin; weighing these materials trough weighing conveyor; pick out moldy material that does not meet the safety requirements .

(2) Cleaning section: conveying raw materials into the dry drum cleaning machine; removing impurities such as dust, weeds and slag by the cleaning machine; convey materials into storage.

(3) Crushing section: conveying materials from storage into the special crusher; crush different materials into the required fineness; re-crushing materials which cannot pass the filter.

(4) Mixing section: after crushing, mixing raw materials straightly according to the formula by automatic processing equipment.

(5) Granulating section: Granulating mixed materials after straightly sterilization.

(6) Cooling and drying section: cooling and drying the granule, and then picking out those unqualified.

(7) Finished product packaging section: packing feed and puting it into the warehouse; purifying and recycling the dust produced during the process.

2.4.1.2 Equipment plan

The main equipment for the feed mill includes raw material receiving system, crushing system mixing system, granulating and cooling system, packing system and liquid adding system. Details of these systems are as follows:

Table 2-1 Feed processing workshop equipment

Complete sets of equipment for the feed mill

Raw material receiving system

Include: initial filter, bucket, deduster, etc.

Crushing system

Include feeding, crushing, bucket elevator, etc.

Mixing system

Include: mixing machine, conveyor, etc.

Granulating and cooling system

Include: granulating machine, classification machine, cooling machine, etc.

Packaging system

Include: finished goods warehouse, gate, etc.

Liquid adding system

Include: oil adding machine, pipeline, etc.

2.4.1.2 Equipment solutions

Feed processing workshop equipment mainly used is the set of feed processing equipment, including the receiving system, mixing system, pelletizing feed cooling systems, packaging systems and liquid adding system. Equipment for each system is detailed in the following table

Table 2-1 Feed processing workshop equipment

Complete sets of feed processing equipment

Raw material receiving system

including the initial screen. Bucket. Filter, etc

Crushing system

 including feeding. Pieces. Bucket machine, etc

Hybrid system

including mixing machine, conveyor, etc

Granulating cooling system

including particle machine. Classification. Cooling, etc

Packaging system

including finished goods warehouse. Gate, etc

Liquid adding system

including the oil added. Pipeline, etc

2.4.1.3 Construction scheme

Feed processing plant construction projects including production workshop, auxiliary facilities (lab), warehouse, form a complete set of engineering (fluctuation and landscaping, etc.), living facilities (employee bathhouse), total construction area of 1160 square meters, the main body of light steel structure workshop, warehouse, fast construction, beautiful shape, low maintenance cost and strong vibration resistance.

The investment and details of civil engineering for feed processing plant are as follows:

Table 5-2 The investment subsidiary of main building for feed processing plant

No.

Name of Project(equipment)

Types

Units

Quantities

1

Production plant

light steel structure

square meters

350

2

Raw materials warehouse

light steel structure

square meters

300

3

 Finished goods warehouse

light steel structure

square meters

300

4

Packing workshop

light steel structure

square meters

120

5

Laboratory

light steel structure

square meters

90

2.4.2 Healthy breeding

2.4.2.1 Briefly technology proposal

For the purpose of healthy breeding, the three key technical aspects are feeding conditions, the environment, feeding control management. This process for healthy breeding is mainly shown in the figure below:

Figure 2-2 The aquaculture process flow diagram of healthy breeding

pics

2.4.2.2 Equipment scheme

The laying hens’ farm adopted automated equipment, including incubation equipment, laying hens brood, breeding and feeding equipment of egg production, the details list as follows:

Table 2-3 The list of aquaculture workshop equipment

No.

Name of device

Specifications

Unit

Quantity

mark

1

Automation equipment

9CLXD-4240,four cascading

Ton

25

Including incubation shed

1.1

Cage frame

50000 / cage

 

 

 

1.1.1

Cage

L=2280,42sets 5 columns

Group

210

1building.the following the same

1.2

Feeding system

 

 

 

 

1.2.1

The head and tail frame

 

Set

5

 

1.2.2

Lateral transporting device

Φ125 L=21m

Set

1

 

1.2.3

Towers (15t)

Φ2.75m,H=6.892m

1

 

1.2.4

Electronic says feeder

FD4004A   6foot

Set

1

 

1.2.5

Stainless steel wire rope

Φ6,L=200m

5

 

1.2.6

Wire rope supporting wheel

 

60

 

1.3

Night soil clean up system

 

 

 

 

1.3.1

Vertical transport dung and power transmission device

 

Set

5

 

1.3.2

Longitudinal lost dung bracket

4lays/set

Group

210

 

1.3.3

Longitudinal lost dung

δ=1,L200m,B1110

Strip

20

 

1.3.4

lateral device

B600,L15+9m

Set

1

 

1.4

set system

 

 

 

 

1.4.1

 egg machine

 

Set

5

 

1.4.2

egg belt

L=200m   B=100

Strip

40

 

1.4.3

 eggs with supporting

 

Piece

3380

 

1.5

 Feeding water supply system

Aerospace JB2.9-30

 

 

 

1.5.1

pipes, nipples, etc

contain voltage regulator

Building

1

 

1.6

ventilation cooling system

 

 

 

 

1.6.1

damp curtain

δ=150,in total 3 set

square meters

126

 

1.6.2

water circulation device including spray

 including spray, return water

set

1

 

1.6.3

 energy-saving fan

9FJ125

18

 

1.6.4

side wall ventilation window

 

48

 

1.6.5

ventilation window linkage

 

set

2

 

1.7

lighting system

 

 

 

 

1.7.1

energy-saving lamps and lead

9W lamps 220,

building

1

 

1.8

 electric control system

 of material findan scenery, etc

 

 

 

1.8.1

System control cabinet France schneider

France

set

1

 

1.9

other

 

 

 

equipment above 15%discout

1.9.1

installation building fee

 

building

1

 

1.9.2

 transport and insurance premium

 

car

4

 

1.9.3

other building sporadic

 

building

1

 

2

upgrading equipment

 

 

 

 

2.1

update equipment

 

building

13

13 buildings

2.1.1

common  chicken coop

 

set

800

 

2.1.2

water nipple manger

 

set

800

 

2.1.3

fan

 

set

70

 

2.1.4

nightsoil equipment

 

set

26

 

2.2

equipment

 

 

 

 

2.2.1

packaging printing machine

 

2

 

2.2.2

Weighing equipment

 

set

2

 

2.2.3

transport vehicles

 

8

 

2.2.4

poultry disease diagnosis equipment

 

set

3

 

2.2.5

test equipment

 

set

3

 

2.2.6

other item

 

1

 

2.4.2.3 Construction scheme

Broiler and laying hens plant covers an area of 266,800 square meters and the main building such as hen house, warehouse and other housing are all north-south directional and the light steel structure. The distance between each of the ten laying hens breeding points is no less than 500 meters.

According to the regulations of the NY/T5043-2001 pollution-free food laying hens breeding management guidelines, the hen house structure, the distribution location of each unit of broiler and laying hens plants conform to the  bellowed requirements:

Hen house building is single laying and semi-recycling roof bearing, and the cornice height is no less than 2.5 meters. A large fan on the east side of the plant is built to make it easy to air convection. Rain-proof windows in the south and north wall are set to ensure ventilation. The wall is brick structure, with inside surface coated with mixed ash to control moisture. The inner ground is concrete to ensure the ground to be smooth, seamless, permeable, and resistant to corrosion.

According to the live characteristics and breeding requirements of the broilers and laying hens, combined with the local dominant wind direction and the status quo of the production site, the brood house should be built in the right position, and bred up house should be built close to the hen house. Poultry medical room and sick chicken isolation room should be located in downwind position to avoid influence of the course. Living quarters and production should be strictly separated. The entrance of the production area is equipped with disinfection room, and the roads gateway should set sterilization tank.

Around the plant should set green area.

The detail of construction and investment for Aquaculture workshop are listed in the following table, including the major projects, such as the henhouse, fresh eggs plant, packaging workshop, laboratory and poultry disease diagnosis room, employee bathhouse and heating, water supply etc.

Table 2-4 The investment subsidiary of main building for aquaculture workshop

No.

Name of project(equipment)

type

unit

quantities

1

New sheds (25 buildings)

light steel structure

square meters

22500

2

New sheds (13 buildings)

light steel structure

square meters

6960

3

Fresh egg sheds

light steel structure

square meters

360

4

Packing workshop

light steel structure

square meters

120

5

Laboratory

light steel structure

square meters

90

6

Poultry disease diagnostic room

light steel structure

square meters

80

2.4.3 Halal egg powder and eggshell powder processing

2.4.3.1 Briefly technology scheme

The processing workshop take fresh eggs through the collection, transmission, cleaning, egg and egg, separation, filtration, sterilization, drying, packing and so on several process to product the egg powder, eggshell powder, and provide fresh eggs byproduct for eggs package processing, Main production process is briefly as follows:
(1) egg collection section:, using egg farming workshop equipment, transporting the egg directly through the egg belt to egg powder processing workshops.

(2) egg chosen section: using testing instruments to choose blood egg, etc to ensure product quality.
(3) egg cleaning section: spraying and disinfection the selected eggs to reduce the affection of eggshells bacteria to the quality of the products, and drying these eggs after the above disinfection process.
(4)egg screening section: choosing eggs according the appearance, shape, size, if the appearance or the size is not in conformity with the requirements, then bring these eggs to the egg powder processing plant for processing. Other qualified eggs are mainly supply for fresh eggs packaging link and egg powder processing workshops.
(5)egg breaking section: making the egg shell and egg liquid separation.

(6)egg separation section: according to the requirements of production line, separating egg to get a egg cream, egg yolk, or protein liquid for different product line for raw material.
(7)egg filtering section: respectively filtering the egg cream, egg yolk, egg whites, and removing impurities such as all kinds of material in the eggshell.
(8)homogeneous, mixing section : mixing the egg cream, egg yolk liquid, make products to achieve homogeneous.
(9)sterilization, disinfection section: pasteurizing the egg cream, egg yolk liquid in a fully sealed environment.
(10)protein liquid filling and frozen section: according to different requirements, filling or quick-frozen the filtered protein liquid to make the egg whites satisfies the requirement of frozen liquid protein processing and manufacturing products needed for the protein powder.
(11)egg whites modulation, fermentation section: fermenting sugar, acid, etc from the quick-frozen protein liquid.
(12)cooling and drying section: cooling the egg cream, protein, egg yolk, spraying for drying, and screening the powder products to test the product.
(13)packaging section: weighing and packaging egg cream, protein powder, egg yolk powder according to the needs of packaging.
2.4.3.2 Equipment scheme
The equipment of Halal egg powder processing workshop including eggs automatic cleaning, sorting, disinfection, packaging production line, laboratory for raw eggs, 1200 tons (halal) egg processing equipment and technology. Specific equipment and investment for the workshop are listed in the following table.

Table 2-5 The equipment and investment details of egg powder processing workshop

NO.

Name of Project (equipment)

Model

Unit

Quantity

1

whole set of import equipments

set

1

1.1

Automatic beat egg machine

 

set

1

1.2

Egg washing machine

 

set

1

1.3

Automatic filling machine

 

set

1

1.4

Recovery of residual liquid protein machine

 

set

1

1.5

Other devices

 

set

1

2

Domestic exchange equipment

 

 

 

2.1

Receiving tank

100L

 

8

2.2

Tank

1000L

 

4

2.3

Mixing tank

3000L

 

2

2.4

Miller insulation groove

3000L

 

4

2.5

Miller desugar tank

15000L

 

3

2.6

Acid tank

250L

 

1

2.7

Horizontal drier

550KG-H

 

1

2.8

The cleaning crew

CIP225A

 

3

2.9

Pasteurization machine

1500LL/H

 

1

2.10

Homogenizer

1000KG/H

 

1

2.11

Shell processor

10M-250

 

1

2.12

High pressure cleaning pump

NM031SYOIL06B

 

1

2.13

Hinge conveyor

 

 

2

2.14

Connection technology of stainless steel pipe

3″21/2″2″11/2″

 

The whole line

3

Auxiliary equipment

 

 

 

3.1

Power supply equipment (transformer)

10KV.630kVA

set

 

3.2

Water supply and drainage equipment (pump)

50m3/h

set

 

3.3

Heating equipment (boiler)

4t/h.16kg/c

set

 

3.4

Refrigeration equipment (chiller etc.)

21kcal.

set

 

3.5

Compressed air equipment (air compressor)

8Nm3/m.8kg/c square meter

set

 

3.6

Laboratory equipment (gas chromatograph, spectrophotometer, pH, viscosity etc.)

 

set

 

3.7

Transport equipment (egg car, refrigerator car, forklift truck, flatbed tricycle, belt machine, etc.

 

set

 

2.4.3.3 The construction scheme

The halal egg powder processing factory building mainly including raw materials warehouse, finished products warehouse, workshop, auxiliary workshop inspection laboratory and employee bathhouse, and the above projects adopt the light steel structure, other projects including roads, green area, water supply, the details are listed as follows:

Table 2-6 The main building investment details of egg powder processing workshop

NO.

Name of project (equipment)

Model

Unit

Quantity

1

Production plant

Light steel structure

Square meter

2400

2

Raw material warehouse

Light steel structure

Square meter

300

3

Finished products warehouse

Light steel structure

Square meter

300

4

Plant auxiliary workshop

Light steel structure

Square meter

300

5

Inspection laboratory

Light steel structure

Square meter

80

2.4.4 Halal chicken slaughtering and processing

2.4.4.1 Brief description of process technology scheme

The poultry will go through several process including quarantine, stun, slaughter, cleaning, packing, storage and other production process, operation process as shown in the following: pics

The main production process is described as follows:

(1)Acceptance process: making a clinical examination of health for the live poultry in the aquaculture workshop to judge the acceptance or negative to next stage.

(2)Electric hemp section: hanging the poultry lightly, and fixing the feet of poultry firmly. Setting electric parameters of the electric hemp process: voltage is not more than 70V, electric current is less than 0.75A, and hemp time is between 2 to 3 seconds.

(3)The slaughter blood section: the implementation of slaughter should be neck cutting, but should not cut off the cervical vertebra. The bled tool should be regular disinfection, which the interval is not more than 250 chickens, and the time of phlebotomy is not less than 3min.

(4)Scalding and depilation section: after phlebotomy, spraying the body with shower, cleaning the blood, dung and other contaminants. Controlling the scalding water temperature at 55 ℃ ~68 ℃, scalding time is 2min, and using water shower to wash clean after mechanical fur removal.

(5)Paraffin, dewaxing section: putting the head hanging to make the body convey automatically into paraffin to dip wax. After wax dipping, enter into the cooling tank for cooling to make good condensation. The distance between wax liquid paraffin bath and the notch edge should be 1.5 ~ 2 cm, the wax laying has a thickness not less than 30cm, wax temperature should be controlled at 65 ~ 70 ℃, and wax dipping time at 18s. Water cooling tank should be able to change the water flow, and water temperature is not more than 20 ℃ in cooling tank. When the body passing by the cooling tank, it should be keep the bird body wholly submerged into the water for 30min.

(6)Unloading section: adjust the unloading device according to the avian body size, and ensure the automatic hanging rate reached 100%. If any dropped, then place in special containers, which could make the animal quarantine officer easily do pollution treatment and then incorporated into the processing.

(7)Ripper, the cleaning section: cut the neck skin along the throat, pull apart the trachea and esophagus, use tools to cut out all around the anus, visceral and esophagus, cleaning the carcass, and classify the eviscerat after the cleaning, at last storage and packaging.

(8)Packaging: package and test.

2.4.4.2 Equipment scheme

Equipment includes transportation, slaughter, hair removal, cleaning, cooking, refrigeration andfreezing, packing facilities required for halal chicken slaughtering and processing workshop,specific equipment and investment are as follows:

Table 2-7 The investment details of equipment for halal chicken slaughter workshop

NO.

name (equipment)

Model

Unit

Quantity

1

Hanging overhead transmission line

6 inch

Set

1

2

High frequency electric shock halo

 

Set

1

3

Stainless steel automatic scalding machine

JTG-1000J

Set

1

4

Stainless steel automatic dehairing machine

TYL-32J

Set

1

5

Stainless steel digging bore groove

6000×500×800

Set

1

6

Stainless steel blood slot

 

Set

1

7

Spray pre pressing machine

TYPE

Set

1

8

Carcass and automatic cleaning machine

NWX768/152

Set

1

9

Automatic unloading device

 

Set

1

10

Paraffin pool

JL50

Set

1

11

The bird cage automatic cleaning machine

LC×60

Set

1

13

Packer

 

Set

2

14

Cold storage and freezing facilities

 

Set

1

15

QCHS fan (fan)

 

Set

8

16

Distribution facilities

 

Set

1

17

SC1022BB13D refrigerator car

 

Set

2

18

Other

 

Set

1

2.4.4.3 The construction scheme

The Halal chicken factory building including: closed workshop, cold storage and slaughter and processing. The main project for this part including: the slaughter plant and cold storage, which the total area is 1380 square meters, and other projects including the guard room, clean pool, cesspool, etc. Specific details are list as follows:

Table 2-8 The investment details of chicken slaughtering and processing workshop

NO.

name (equipment)

model

Unit

quantity

1

The production workshop and packaging workshop

brick and concrete

square meter

1200

2

Cold storage

brick and concrete

square meter

180

2.4.5 Organic fertilizer processing

2.4.5.1 Brief description of process technology scheme

The production process includes process of composting fermentation, two times of aging, screening, mixing, granulation, drying, cooling, screening, spray coating, packing and other processes.

The main production process are described as follows:

(1) Ingredients, fermentation process: according to the requirements of health feed ingredients, put the organic wastes, microbial fermentation, auxiliary materials together as ingredients, put the complete ingredients into the distributor, after the mixing fermentation in the fermentation tank for about 7-8 days, then age 10-15 days. The last process is screen the large debris as the raw materials of production, and other spare parts could return to fermentation process.

(2) Screening section: package the fine material which passing the screen as the powder fertilizer for storage; other ingredients, through the elevator, could transport to the efficient mixing machine, for the preparation of making fertilizer.

(3) Granulation system: use the feeding machine delivery the mixed ingredients to the extrusion granulator to granulation.

(4) Cooling and drying section: dry and cool of the ingredients and crush, screen the particles.

(5)Packing section: seal and package the organic fertilizer, and storage in warehousing; recovery and purify the dust.

2.4.5.2 Equipment scheme

The equipment of organic fertilizer processing workshop including: fermentation equipment, screening and processing equipment, granulating equipment and other test equipment, specifications and quantity are listed in the following table:

Table 2-9 The investment details of equipment for bio-organic fertilizer processing workshop

NO.

Name of project(equipment)

Model

Unit

Quantity

1

Fermentation equipment

 

 

 

Shallow pool type continuous fermentation upender

FPJ25 10kw

set

5

Mixed cloth machine

HB750

set

5

Light rail

12 #

m

500

Small forklift

40 hores power

set

2

2

Screening and processing equipment

 

 

 

The charger

2m3

set

1

Magnetic belt feeder

DCT500

set

1

Belt feeding machine

DT500

set

1

Roller screen

GS12×25

set

1

Vertical crusher

LP60

set

1

Electric control system

 

set

1

3

Granulation equipment

 

 

Compound feed system

PJ300

set

1

Organic fertilizer extrusion granulating machine

FLY37

set

1

Recycling particle polishing shaping machine

KZ1200

set

1

Dryer

Φ1.6*16

set

1

Cooling, screening machine

HL12*100

set

1

Belt conveyor

DT500

set

2

Dedusting system

4-72No8C

set

1

Electric control system

 

set

1

4

Other equipment

 

 

 

Laboratory equipment

 

set

1

Other equipment

 

set

1

2.4.5.3 The construction scheme

The construction of organic fertilizer factory mainly includes fermentation workshop and granulation workshop, which are of the light steel structure both. Auxiliary facility includes road and afforestation. The construction detail is as follows.

Table 2-10 Main Building of Organic Fertilizer Processing Workshop

NO.

Project (Equipment)

Model

Unit

Quantity

1

Fermentation Area

 

 

 

Fermentation Workshop

Light Steel Structure

M2

1500

Premixed Site of Raw material and Burden

 

M2

300

Stacking Site for

Secondary Fermentation

 

M2

450

2

Granulation Area

 

 

 

Granulation Workshop

Light Steel Structure

M2

200

Sorting Workshop for

the Fermented Material

Light Steel Structure

M2

180

The Warehouse for

 Finished Product

Light Steel Structure

M2

300

2.5 Measures of Energy Saving and Emission Reduction

a. In the whole process, feed processing, breeding, chicken slaughtering and processing, egg powder processing and organic fertilizer processing depend on each other, forming a complete product chain of egg chicken deep processing. Processing of organic fertilizer makes the waste from the breeding workshop into valuable stuff, of which the annual income will be CNY14, 400,000.

b. All equipment in workshop is under automation and standardization management, with high efficiency and good energy-saving performance.

c. The related electrical equipment is operated by professional, which can meet the requirement of using and saving.

d. In water supply system high-qualified piping material and valve products are adopted. The pipe mainly buried in the ground, and the exposed pipe should be considered to avoid stepping and rolling on.

e. Energy saving design is taken in the workshop. In order to save lighting power, the sun lighting area can be increased or the sun lighting plate can be adopted. Energy-saving capacitor, light source and lamp can be adopted.

f. Water-saving sanitation apparatus is adopted.

After the completion of the project, the main pollutants are chicken feces and sewage. Chicken feces have been utilized by the organic fertilizer workshop. Pay attention to environmental protection and sustainable development in the construction design; separate the production area from the living area, clean area from non-clean area. The sewage from breeding workshop and slaughtering workshop will be processed through grating, oil-sorting, precipitating, fermenting, and filtering. The solid waste will be precipitated and fermented in feces storage bin, and the sewage will be bio-filtered in the filter bin and then discharged.

Chapter 3 Environmental Impact Assessment

3.1 Environmental Impact

In the construction process, the various environmental protection measures will be implemented. Make sure that all kinds of pollutants such as wastewater, waste gas, waste residue, dust and noise conform to related standard.

In the production process of egg powder, chicken, and eggs, the material does not contact toxic substances. The whole process does not produce toxic substances.

3.2 Environment Protection and Treatment Measures

3.2.1 The Main Pollution Sources

This food processing project will not cause damage to the environment. But sewage, waste residue and noise are unavoidable, which affect the local environment to some extent.

The main pollution source of the project is sewage, waste residue, waste gas, and noise.

3.2.2 The main pollutants

a. Waste water coming from the production process in egg powder workshop,  slaughter workshop, and processing workshop. The main pollutants in wastewater are COD, BOD5, ammonia nitrogen, SS, animal and vegetable oils and coliform bacteria.

b. Chicken feces, chicken giblets, chicken feather, and egg shell.

c. High-noise equipment of the project mainly includes fur removal machine, cutting machine, compressor in refrigeration system, fan, and feed grinding machine. The noise volume is about 80-100dB (A).

3.2.3 Pollutant Treatment

a. Wastewater Treatment

The treatment system of hydrolysis acidification cyclic activated sludge is adopted in this project. Oil regulation pool is used for the recovery of the oil slick, to balance water quantity and quality, which ensures the normal operation of subsequent processing facilities. In the hydrolysis and acidification pool, through the control of hydraulic retention time, using anaerobic fermentation hydrolysis and acidification reaction stage to the large molecules, long key ring material into small molecular, short chain of biochemical, the macromolecule organic matter is degraded into low molecular organic compounds, can improve the health of. CAST is a cyclic activated sludge system, the reactor is provided with a combined biological selector, aeration and non-aeration in the manner of operation, processing function complete biodegradation of organic pollutants and water separation in a reactor, the whole system flow to push operation, but the reaction zone to completely mixed mode, synchronization of carbonization and the function of nitrogen and phosphorus removal.

b. Waste Residue Treatment and Recycling

(1) Chicken feces will be processed by fermentation, granulation, and drying, and changed into organic fertilizer, for surrounding peasant household use.

(2) Chicken giblets, feather and other ingredients will be processed by concentrating, drying and changed into protein feed, for internal use and external sales.

(3) The egg shell will be processed by crushing, drying, and sorting, and changed into eggshell powder for sales.

3. Noise Pollution Prevention and Control Measures

All the high-noise equipment of the project will be equipped with the damping apparatus, and the fan will be equipped with muffler.

 Chapter 4  Project Organization and Management

4.1 Organization and Function Division

The basic principle of enterprise organization is the general manager responsibility system under the leadership of the board of directors. Board of supervisors is set up. The board of directors appoints the general manager, and the general manager appoints the deputy general manager. A 3-level management system consist of Company, workshop, and work section is implemented.

4.2 Labor Quota

Table 4-2 Enterprise Structure of Labor

Production Staff

Auxiliary Person

Sale Personnel

Administrative Staff

100

12

10

10

4.3 Labor safety, health and fire control

4.3.1 Design Reference (Chinese standard)

4.3.2 Design Specification (Chinese Standard)

(1)   Hygienic standard for the design of industrial enterprises (TJ36-79)

(2)   Noise standard for industrial enterprise

(3)   Code for fire protection design of buildings (GBJl6-87)

(4)   Transport safety regulations in industrial enterprises (GB4387-84)

(5)   Code for noise control design of industrial enterprises (GBJ87-85)

4.3.3 The Project Characteristics

This food processing project will not cause damage to the environment. It is important to focus on industrial hygiene.

4.3.4 Building and Site Layout

 (1) To ensure the safety and smooth traffic, the main roads have two lanes, and a shunting space in the loading and unloading sites, to meet transportation and shunting requirements.

(2) There is enough space among the buildings in the plant in accordance with the firefighting design standard, to ensure that the firefighting safety.

(3) Each production workshop has toilets, dressing rooms, rest rooms.

(4) There are adequate emergency exits and staircases. The safety training of new employees must be conducted in 3-level of plant, workshop, and work group.

4.3.5 The main measures for labor safety and health

(1) This project will be designed in accordance with the requirements of hygienic regulation for food processing plant. Ceramic tile is adopted on the interior wall for cleaning and disinfection.

(2) Corrosion protection measures are considered in the room with corrosive medium. And operating workers should be equipped with protective equipment.

(3) To reduce the heavy manual labor, Mechanization and automation operating are adopted; lifting equipment, forklifts and conveyor belt are used for transporting raw materials and finished products.

(4) Automated alarm and emergency shutdown and other safety measures are adopted.

(5) Anti-noise ear muff and masks should be equipped in the high-noise and dust section.

(6) All the workers should be trained and start to work with qualification.

 Chapter 5  Investment Estimation

Table 1 Investment Estimation                             Million USD

NO.

Name of the cost

Amount of Investment

percentage of total cost

Total

Foreign exchange

1

Construction investment

22.2671

0

74.32%

1.1

Construction investment static part

20.8524

0

69.60%

1.1.1

Construction engineering cost

8.260

0

27.57%

1.1.2

Purchase of equipment and tools

11.14

0

37.18%

1.1.3

Installation fee

0.47

0

1.57%

1.1.4

Other construction costs

0.6667

0

2.23%

1.1.5

The basic reserve funds

0.3157

0

1.05%

1.2

Construction investment dynamic part

1.4148

0

4.72%

1.2.1

Increase reserve funds

0.3968

0

1.32%

1.2.2

Interest during construction

1.0180

0

3.40%

2

Working capital

7.6922

0

25.68%

3

The total project investment funds (1+2)

29.9593

0

100.00%

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