The Engineered Compost Systems Toolkit:
Our Dedication to Excellence
The ECS Toolkit offers an unparalleled range of proven process technologies engineered to enable client success. Our designs are based on deep scientific understanding of the composting process, our rigorous engineering approach, and our nearly 20-year quest for continuous improvement.
We model, prototype, and pilot our products extensively before they go to full-scale installation. Once at a working facility, the real-world learning starts. We record and analyze the strengths and weaknesses of our products over the long term, and use this feedback to improve and expand of our offerings.
So, whether you are planning a whole new facility or are looking for a single component to improve an existing facility, the ECS Toolkit will provide a custom solution to best fit your business plan, operational needs, risk tolerance, and regulatory requirements.
You can rely on ECS ASP technology to be an efficient tool to control odors and make great compost. Our systems feature dynamically controlled aeration with the wide range of air deliver rates required to keep oxygen and temperature at Best Measurement Practice levels throughout the pile. At the same time, they are the most energy efficient ASPs (measured by air-volume delivered/unit of fan energy used) in the industry. Our dedication to continuous improvement has led to ASP designs that simplify construction, provide uniform distribution of air, are uniquely effective at controlling leachate, facilitate maintenance and operations, and will run reliably for decades. ECS ASPs come in positive, negative, and reversing configurations, and are sized and equipped to best fit your site, feed stocks, and economics.
The ECS ATP system combines the excellent aeration and control of the ECS ASP. The added benefit of the ATP comes from turning the pile, which provides optimal bio-stabilization rates and fines yield at the product screen.
ECS ATPs can be configured for either straddle or block turning machines, and for either positive or reversing aeration, per client preferences. Block turners move batches through a series of aeration and control zones. This is no problem for the ECS CompTroller™ control technology, which seamlessly tracks and controls the batches as they move through the facility.
ECS offers the only In-Vessel Tunnel-type composting system developed and built in North America. This technology offers the ultimate in Best Management Practice compliance, odor and leachate control, and below freezing cold weather performance.
Their sealed, well-drained, and highly controlled aeration allows them to reliably manage less-than-ideal feedstock mixes without creating nuisance odors. Their unique level of thermal control provides rapid heating of cold loads and very uniform temperatures throughout the pile to insure the Process to Further Reduce Pathogens (PFRP) is quickly and reliably achieved. Additionally, the robust design and construction of ECS' In-Vessel Tunnels means that they will last for decades.
The ECS In-Vessel Container system provides the same environmental and process controls as the In-Vessel Tunnel systems, but with several unique advantages: these vessels are mobile; they are picked up, moved, and emptied with a roll-off truck. This makes them a good choice for smaller facilities with limited area, sites that may need to be moved in the future, or for facilities that need to minimize construction costs and complexities. This technology is generally best for facilities composting less than 50 tons per day.
We are happy to help our clients succeed any way we can. Many of the components that make our full systems so effective have been integrated into owner-designed facilities to support and improve operations.
Aeration floors are arguably the most critical component in an aerated composting system. ECS has invested heavily in the development of four distinct aeration floor technologies, each with its own set of pros and cons.
The primary goal is always to provide the right amount of airflow to sustain Best Management Practice levels of oxygen and temperature as uniformly throughout the pile as possible. Secondary goals include: simplifying operations and maintenance, efficiently collecting leachate, minimizing energy use, and making the floors robust. To help you choose the right floor we need to understand your tolerance for operational expenditure vs. capital expenditure, what aeration direction is required, and site tolerance for dirty water.
Biofilters are a well-established method for controlling odorous and volatile organic compound air emissions from composting operations. When designed and operated per Best Management Practices they routinely reduce air and odor emissions by more than 95%. ECS has designed and provided the air distribution, control, and monitoring systems for dozens of biofilters at large composting facilities and processing buildings. In addition, we've measured the scrubbing efficiency of many biofilters; we know what makes them tick.
The photograph to the right is from a reversing aeration floor system in Washington State that uses a face turner to move material through the facility. Prior to this photograph, half the system was set to negative (steam venting off the biofilter - furthest from the camera) and the other half was set to positive aeration venting off the surface of the piles themselves (nothing venting to the biofilter - closest to the camera).
CONTROL & MONITORING SYSTEMS
Compost operators are busy; they need a system to automatically display and record all vital process data, optimize their aeration system, and give warnings when problems arise. ECS has been perfecting our CompTroller™ for 20 years to serve exactly these purposes. We have optimized the hardware to be resilient, simple, and easily expanded. The software provides an intuitive web-hosted user interface that is OS independent and can be accessed from all manner of devices. Best of all, the system architecture allows ECS engineers to give timely and detailed support to our clients all over the world.
The first step to great composting is to start with a weight-controlled mix. Helm Welding and ECS have worked together providing compost feedstock mixing systems for 20 years to serve this purpose. No one in the industry builds a tougher mixer than Helm. ECS integrates the Helm mixers with smart controls, conveyors, hoppers, and motors to provide a complete solution.
We offer mixers in both horizontal and vertical format, the two images on the right show the horizontal mixer.
ECS/Helm Mixer in Action:
WIRELESS TEMPERATURE PROBES
Some compost is not kind to electrical cables. For those facilities, ECS developed a wireless temperature probe, the RF TeleProbe™. The RF TeleProbe™ delivers accurate wireless compost temperature data for process control and regulatory compliance. Twenty years of continuous improvement have endowed the RF TeleProbe™ with the industry’s best battery life and data rates in a super robust package. No wonder it has been the repeated choice at the industries largest and most demanding composting facilities.