Systems, methods, and apparatus for converting a biosolid to an enhanced cylindrical class A fertilizer

A system, comprising;

• at least one greenhouse for receiving and pre-drying biosolids, wherein the greenhouse comprises a hydronic floor heating system integrated into a reinforced concrete slab operatively configured with a vapor barrier and an odor control system,
• at least one pasteurization building operably connected to the at least one greenhouse to receive the biosolids through an inlet, the at least one pasteurization building comprising at least one pasteurization system,
• the at least one pasteurization system comprising at least one heat up belt, a burner fan to heat a gas that passes through the heat up belt and the biosolids, wherein the burner fan heats the biosolids to at least 70° C.,
• at least one pasteurization belt operably connected to the at least one heat up belt, wherein the at least one pasteurization belt conveys the biosolids through at least one pasteurization chamber wherein the at least one pasteurization chamber maintains the temperature of the biosolids at least at 70° C. for at least 30 minutes;
• a pit/conveyor and bucket elevator for receiving and elevating class A biosolids into one or more holding tanks from a first source;
• the one or more holding tanks operably connected to a scale and blender unit by way of one or more second conveyors;
• one or more storage tanks for holding one or more enhancements operably connected to the scale/blender unit;
• wherein the scale/blender unit weighs and proportions the biosolids and enhancements and homogenizes a resulting blended mixture;
• one or more pellet mills, each of which comprising at least one flat die, at least one roller, at least one hopper, and at least one dust control system, operably connected to the scale/blender, wherein the one or more pellet mills mill and compress the blended mixture through at least one flat die, heating the blended mixture to approximately 65-93° C. to activate the lignin and form a pellet, the pellet mill then cuts the hardened blended mixture to one or more desired lengths using one or more knives as the blended mixture leaves the bottom of the die;
• a hydronic, oil, refrigerant or compressed air heating/cooling system piped through the die to regulate the temperature of the die;
• a shaker table to separate dust and off spec pellets and return them to the system for reprocessing;
• the at least one dust control system operably connected to the shaker table and the pellet mill for capture of dust and return to the system;
• a cooler, operably connected to the pellet mill and the shaker table to remove heat from the pellets and solidify the lignin thereby hardening the pellet and forming a shell;
• an automated bagging system, operably connected to the cooler via the bucket elevator, to weigh and batch fertilizer pellets into plastic bags and convey them to a robotic stacker, also operably connected to the dust control system to return dust to the system;
• a robotic bag stacker that stacks bags on pallets on pallet wrappers;
• a plurality of pallet wrappers for wrapping;
• and
• a variable logic control system that automates starting and stopping of conveyance and equipment and controls flow rates and batch timing.