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semi-permeable ePTFE membrane complete system for compost fermentation to organic waste
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Company Introduction
Qingdao Jiguang Environmental & Energy Technology Co., Ltd. (hereinafter referred to as Jiguang Technology) was established on January 30, 2019 and is located in Laoshan District, Qingdao. Since its establishment, the company has been committed to the R & D, technical optimization and promotion of China's "membrane-covered fermentation technology". It has successively reached cooperation with nearly 100 enterprises and institutions such as New Hope Liuhe, Yili, Changchun Agricultural Machinery Research Institute, Agricultural Expo Park and Nanjing Tech University, and is responsible for the implementation of projects. During this period, a total of more than 1,200 sets of equipment have been promoted, installed and debugged, and the projects in Malaysia and the Philippines have also been completed. Through nearly six years of technical promotion and application, the "membrane-covered fermentation technology" has become a widely accepted aerobic fermentation technology in China. With its technical characteristics of low investment, simple operation, low energy consumption and "0" maintenance, it has been widely used in China, and is also promoted and applied as a key agricultural technology in various places.
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System composition: e-PTFE composting membrane ·· Intelligent control system ·· Micro-pressure air supply system ·· Monitoring system
2. Technology Introduction
The e-PTFE membrane-covered aerobic composting technology adopted by Jiguang Technology is a process technology that uses a special functional membrane as a covering for the aerobic fermentation treatment of pig manure. The core of this process technology is a functional membrane with special micropores. Its semi-permeable function can achieve a relatively constant climate environment. Under the action of air blowing, a micro-high pressure inner cavity can be formed in the fermenter, making the oxygen supply of the composting body uniform and sufficient, and the temperature distribution uniform, thus creating a suitable environment for aerobic fermentation. Water vapor and carbon dioxide can diffuse out through the microporous structure of the functional membrane, maintaining the air flow balance inside and outside the membrane of the fermentation composting body, ensuring that the aerobic fermentation is more complete, and effectively killing pathogenic microorganisms to ensure the hygienic level of the fermented products.
3. Process Features
1. Environmentally friendly, no odor emission.
2. Simple operation, intelligent and unattended.
3. Low energy consumption. It uses low-voltage and low-energy consumption fans to run intermittently. It only costs 7 yuan in electricity to ferment one ton of organic fertilizer.
4. "Zero" failure, no need for maintenance, and a simple system.
5. High product quality. Through long-term high-temperature fermentation, the organic fertilizer has a high degree of maturity and good sterilization.
Semi-permeable e-PTFE Membrane Complete System for Compost Fermentation
1. System Overview
The semi-permeable expanded polytetrafluoroethylene (e-PTFE) membrane complete system is an advanced closed aerobic compost fermentation solution tailored for organic waste resource utilization. It integrates membrane separation technology, micro-pressure aeration and intelligent temperature & humidity control, breaking through the limitations of traditional open and simple covering composting processes. As a core environmentally friendly composting technology widely applied in global organic waste treatment, the system realizes efficient, stable and pollution-free aerobic fermentation of livestock manure, food waste, municipal sludge, garden waste and other organic raw materials, achieving standardized production of high-quality organic fertilizer.
Different from conventional composting systems, this system takes the functional semi-permeable e-PTFE membrane as the core barrier medium, constructing a relatively closed and dynamically balanced fermentation microenvironment. It perfectly solves the pain points of traditional composting such as serious odor escape, rainwater infiltration, low fermentation efficiency, unstable temperature and vulnerable to seasonal climate interference.
2. Core Working Principle
The core technical support of the system lies in the unique microporous structure and selective permeability of the e-PTFE membrane material. The e-PTFE membrane is formed by special stretching and expanding process, with uniform and dense micropores on the surface, and the pore size is precisely controlled between 0.2–0.5 μm. This structural feature endows the membrane with exclusive hydrophobic and air-permeable molecular screening performance.
During compost fermentation, the membrane acts as an efficient molecular filter: it allows small molecular substances such as oxygen, carbon dioxide and water vapor to pass freely, ensuring the aerobic respiration and metabolic cycle of fermentation microorganisms. Meanwhile, it effectively intercepts large molecular pollutants including ammonia gas, volatile organic compounds (VOCs), odor molecules, dust and pathogenic bacteria inside the fermentation pile. In addition, the membrane’s excellent hydrophobic performance completely blocks external rainwater, dew and liquid water from penetrating into the pile, avoiding material dilution and secondary pollution.
Cooperated with the micro-pressure positive pressure aeration system, a stable gas buffer layer is formed between the membrane cover and the compost pile surface. This structure realizes self-regulation of the internal fermentation environment, maintains constant temperature and humidity conditions required for microbial proliferation, and accelerates the decomposition and humification process of organic matter.
3. Complete System Composition
The whole set of e-PTFE membrane compost fermentation system consists of four core modules, which cooperate with each other to form a fully functional and automated fermentation system:
3.1 Three-layer Composite e-PTFE Membrane Cover System
It is the core functional component of the system, adopting a three-layer laminated composite structure. The outer layer is high-strength UV-resistant polyester protective fabric, which resists outdoor ultraviolet radiation, wind and rain erosion, and prolongs the service life of the membrane body. The middle layer is the key semi-permeable e-PTFE functional membrane, undertaking the core gas-liquid separation and pollutant interception functions. The inner layer is a breathable and wear-resistant protective layer, which prevents the membrane from being scratched by compost materials and ensures long-term stable permeability. The overall membrane body has the characteristics of high tensile strength, aging resistance, low temperature resistance and flame retardancy, adapting to all-weather outdoor operation.
3.2 Micro-pressure Aeration Air Supply System
Composed of low-noise Roots fans, air supply pipelines, uniform air distribution holes and pressure regulating valves, this module provides continuous and stable micro-positive pressure aeration for the compost pile. Different from the violent aeration of traditional processes, the micro-pressure air supply mode ensures uniform oxygen distribution inside the pile, avoids local anaerobic fermentation and odor accumulation, and maintains the optimal aerobic metabolic state of microorganisms. The adjustable air volume and pressure can adapt to different raw material moisture, pile volume and fermentation stages.
3.3 Intelligent Environmental Control System
Equipped with high-precision temperature, humidity and oxygen sensors, as well as an intelligent PLC control cabinet. It can monitor the real-time changes of internal fermentation temperature (55–70 °C optimal fermentation range), material humidity and oxygen concentration in real time. The system automatically links with the aeration system to adjust air supply volume and frequency, realizing intelligent constant-temperature fermentation. It effectively shortens the fermentation cycle, ensures thorough harmless treatment of materials, and kills pathogenic bacteria, eggs and weed seeds in organic waste.
3.4 Fixed Support and Sealing System
Including galvanized steel or aluminum alloy support frame, tensioning devices and surrounding sealing accessories. The support frame fixes the membrane cover to form a stable closed fermentation space; the tensioning structure ensures the membrane surface is flat and stress-balanced without sagging or deformation. The fully enclosed sealing design prevents odor leakage and external wind interference, ensuring the stability of the internal micro-pressure environment.
4. Core Technical Advantages
4.1 Efficient Odor and Pollution Control
The semi-permeable membrane can intercept more than 95% of odor pollutants such as ammonia and VOCs, realizing almost odor-free operation of the composting site. It avoids the atmospheric pollution problem of traditional open composting, enables the composting project to be built near residential areas, and fully meets environmental protection emission standards.
4.2 Shortened Fermentation Cycle and High Efficiency
The system maintains a stable high-temperature aerobic fermentation environment, activates microbial activity to the maximum extent, and accelerates organic matter decomposition and humification. The primary fermentation cycle is shortened to 3–4 weeks, which is nearly half of the traditional composting cycle. The fermentation is thorough, the material maturity is high, and the production efficiency of organic fertilizer is greatly improved.
4.3 All-weather Stable Operation
The closed membrane cover completely isolates external rainwater, snow, frost and extreme temperature changes. It avoids material deterioration caused by rainy season water inflow and low fermentation efficiency in high-temperature or cold seasons, realizing standardized and stable production throughout the year without seasonal shutdown.
4.4 Low Operating Cost and Simple Maintenance
The system adopts passive gas exchange + micro-pressure low-energy aeration mode, with low fan power consumption and no need for additional deodorization equipment, saving a lot of equipment investment and operating electricity costs compared with fully enclosed workshop composting. The e-PTFE membrane has a service life of more than 8–10 years, with low daily maintenance cost and simple operation process, no frequent turning required.
4.5 High-quality Compost Output
Stable high-temperature fermentation ensures thorough harmless treatment of materials. The loss of nitrogen and organic matter in raw materials is effectively reduced, and the nutrient content of nitrogen, phosphorus and potassium in finished compost is retained to the greatest extent. The produced organic fertilizer has uniform maturity, loose texture and no peculiar smell, meeting agricultural planting and ecological greening application standards.
5. Main Application Scenarios
This complete system is widely applicable to the aerobic fermentation and resource treatment of various organic solid wastes, covering multiple fields:
Livestock and poultry breeding waste: chicken manure, cow manure, pig manure and other breeding manure composting
Kitchen and food waste: catering waste, food processing residue, kitchen waste fermentation treatment
Urban organic waste: municipal sludge, garden green waste, dead leaves and branch waste
Agricultural waste: crop straw, rice husk, peanut shell and other agricultural by-products composting
Industrial organic residue: pharmaceutical residue, sugar residue, wine residue and other organic industrial waste treatment
6. Key Technical Parameters
Membrane pore size: 0.2–0.5 μm
Membrane water permeability: 0 (completely waterproof)
Gas permeability: ≥8000 g/(m²·24h)
Odor interception rate: ≥95%
Fermentation temperature range: 55–70 °C (automatic constant temperature)
Primary fermentation cycle: 21–28 days
Membrane service life: 8–10 years (outdoor all-weather use)
Material harmless rate: 100%
7. System Value and Industry Significance
The semi-permeable e-PTFE membrane compost fermentation complete system solves the core pain points of traditional organic waste composting technology, realizing the integration of environmental protection, high efficiency and economy. It not only reduces the environmental pollution risk of organic waste stacking and fermentation, but also improves the resource utilization rate of organic waste. The standardized and modular system design is convenient for centralized and large-scale promotion, providing a reliable, low-cost and environmentally friendly technical solution for the resource disposal of urban and rural organic waste, and promoting the green and sustainable development of organic fertilizer industry and ecological environmental protection cause.
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