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AGRICULTURAL MACHINERY FUNCTIONAL AND SAFETY TESTING SERVICE

TEST REPORT No. 05d - 001

MACHINE FOR SOIL DISINFECTION AND DISINFESTATION

USING STEAM AND EXOTHERMIC REACTION SUBSTANCES (BIOFLASH SYSTEM):

ECOSTAR SC 600

MANUFACTURER: CELLI S.P.A. Via Masetti, 32 – 47100 Forlì (FC)

Rome, March 2005

Celli ECOSTAR SC 600

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TESTS CARRIED OUT IN COMPLIANCE WITH ENAMA PROTOCOL NO. 05D REV. 1.0 – 15 OCTOBER 2004 BY C.R.A. - EXPERIMENTAL INSTITUTE FOR AGRICULTURAL MECHANISATION, MONTEROTONDO – ROME.

Supervisor: Dr Giuliano Colorio Test engineers: Dr Roberto Tomasone Ing. Paolo Pagliari

Dr Mauro Bozzoli Dr Carla Cedrola Dr Danila Scermino

Collaborators: Mr Fabrizio Pallotta

TABLE OF CONTENTS

DESCRIPTION OF MACHINE p. 3 TESTING OF PERFORMANCE p. 6

LIST OF LABORATORY TESTS p. 6 TYPE OF FIELD TESTS p. 6 TEST CONDITIONS p. 7

RESULTS OF TESTS p. 7 STATIC TESTS IN LABORATORY p. 8 FIELD TESTING p. 8

Technical characteristics of machine p. 8 Working capacity of machine p. 10

CONTROLS AND ADJUSTMENTS p. 10 TESTING OF SAFETY REQUIREMENTS p. 10

To facilitate interpretation of the results, it should be remembered that:

1 Mpa = 1000 kPa ≈ 10 bar ≈ 10 kg force /cm2

1 m/s = 3.6 km/h 1 daN = 1.02 kg force

MANUFACTURER: CELLI S.P.A FORLÌ Tel 0039.0543794711- Fax 0039.0543794747

email: : [email protected] – internet: www.celli.it


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DESCRIPTION OF MACHINE

The machine is self-propelled, treating the soil via continuous, direct steaming. The machine is endowed with a special system called “BIOFLASH” patented by Celli S.p.a., using steam in association with an inorganic non-toxic substance (calcium oxide, potassium hydroxide, etc.), causing an exothermic reaction when mixed with soil. Steam is applied to the soil via implements that move and horizontally enter the soil to a given depth. An external pipe distributes the steam over the soil surface. The machine has been identified and classified as a “integrated system” performing soil treatment in (continu-

ous) movement. Being a multipurpose system, the tractor unit was examined separately from working parts. The

latter consist of: equipment for steam generation; systems for distributing the exothermic reaction substance; parts for mixing this substance in the soil; systems for distributing steam to the soil; instruments to avoid the dispersion of steam; accessories. This classifica-tion was drawn up on the basis of ma-terials supplied by the manufacturer, first and foremost the instruction and maintenance handbook (Fig. 1). The machine consists of two parts, the most important being the self-propelled unit containing the steam generator and all devices for the functioning of work-ing parts (Tab. 1) The operating system is situated at the rear of the self-propelled unit. It performs soil disinfes-

tation and disinfection work by injecting steam after having dispensed the exo-

Fig. 1 – general scheme for “integrated system” self-propelled unit A – Characteristics of self-propelled unit: 1 driving joystick; 2 driver’s seat; 3 oil and diesel tanks; 4

boiler; 5 burner; 6 track traction; 7 diesel engine; 8 radiator; 9 water tank; 10 hydraulic pump and power generator; 11 operating unit; 12 rubber tracks.

B – Characteristics of operating system: 1 steam supply tube; 2 coupling of self-propelled unit; 3 hopper for exothermic reaction substance; 4 rotary hoe; 5 upper boom for injections; 6 lower boom; 7 plastic film roll for mulching; 8 rubber wheel; 9 tamper.

A B


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thermic reaction substance and mixed it in the soil (Tab. 2). The self-propelled unit consists of a mobile motorised frame on rubber tracks, allowing for easy deployment and reduced tamping under all working conditions typical of protected crops. The driving seat is located to the front of the frame, enclosed in a fibreglass body. The machine is equipped with a Lombardini LDW 2004/T water-cooled turbodiesel engine, displacement 2,068 cm3, having a power of 44 kW. The steam generator is installed inside the body frame, and consists of a horizon-tal cylindrical steam boiler. In the same compartment there is the water tank for

the boiler, the parts required to produce electrical and hydraulic power as well as mechanisms to regulate the ma-chine’s functions. The machine has an unladen mass of 2,550 kg. Drive to the driving pinions of the tracks is hydraulic, managed by an ad hoc electronic control unit connected to operating and control systems. The movement of the self-propelled unit is controlled using a biaxial joystick en-dowed with a multipurpose keypad. The machine can be driven in two ways: manually, for rapid movement when transporting the machine; automatically, during the soil treatment phase. Inside the central unit of the machine, next to the engine is the steam genera-tor, having a capacity of 33.98 litres; it is cylindrical and horizontal, arranged lengthways between the two tracks to keep the height of the machine to a minimum. The 0.6 m3 stainless steel water tank is located to the side of the boiler, opposite the engine (Fig. 1) The steam generator consists of an instan-taneous steam boiler with a maximum operating pressure and temperature of 1,176 kPa (11.8 bar) and 190.7°C re-spectively. The manufacturer proposes as an accessory a cationic exchange resin decalcifier, useful for very “hard” waters. The decalcifier cannot be in-stalled on the machine. Inside the body frame are parts for the transmission of power required by the machine. The hydraulic pump, having a nominal flow of 11 l/sec at 180 bar, and an 8 kW current generator are con-nected to the machine’s diesel engine. The main properties of the self-propelled unit and relative parts are given in table 1.

Tab. 1 - GENERAL PROPERTIES OF “ECOSTAR SC 600”

MEASUREMENTS Max. length mm 2,650 Max. width mm 1,660 Max. height mm 1,750 Mass, full load kg 3,330 Diesel tank capacity l 120

DIESEL ENGINE Power kW - CV 44 – 60 Cooling - Water Speed of rotation Rpm 2,600

FORWARD MOVEMENT PARTS Length of rubber track mm 1,960 Width of rubber track mm 320 Height of rubber track mm 520 Drive - Hydraulic

POWER GENERATORS Max. hydraulic press. bar 180 Pump flow at 2,600 rpm l/min 28 Alternat. voltage triphase 380 V – 50 Hz

kW 8

BOILER FOR STEAM GENERATION Heat potential installed kcal/h 360,000 Steam geneation potential kg/h 600 Average temperature of steam °C 190.7 Average pressure of steam kPa - bar 1176 11.8 Max. consumption of diesel kg/h 42.3


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Properties of operating unit (Tab. 2). The operating unit is coupled to the machine frame via a special “three-point hitch” consisting of a pair of free lower arms and two joined centrally upper arms (third point), each endowed with a hydraulic jack for lifting and ad-justing the working depth. The operat-ing unit consists of a metal frame on which all treatment devices are fitted (Fig. 1B). A support connecting the three-point hitch to the frame of the operating unit has a runner to move the operating system in a sideways direc-tion. This device makes it possible to move closer to the edge of green-houses or tunnels in order to treat the entire surface area. The frame of the operating unit sup-ports: the hopper that dispenses the exothermic reaction substance; the rotary hoe that mixes the exothermic reagent in the soil and the steam supply system. The attachments of the mulch-ing machine, with plastic film, are situ-ated to the rear of the body frame. The trapezoidal hopper for dispensing the exothermic reaction substance (CaO, KOH) is made from stainless steel sheet, and has a capacity of 230 litres. Distribution is by dripping through a slit in the lower section of the recipi-ent, situated immediately in front of the rotary hoe. The opening for the reagent to pass through is controlled by a lever that moves along a calibrated guide to manually adjust the established dose. A rotating axle with blades located at the hopper exit facilitates the introduction of the reagent into the dispenser below. The axle is operated by an electric motor, endowed with an adequate gear reducer. The rotary hoe is located below the main frame, close to the hopper exit. The rotary hoe makes it possible to work on a strip of land 1,750 mm in width and up to 210 mm in depth. The speed of rotation of the hoe is about

220 rpm, adequate for burying the exothermic substance and spreading it evenly in the soil before the steam is applied. Rotary hoe power transmission is hydraulic-mechanical, using a hy-draulic motor connected to the shaft via a chain-based rotation speed reducer. Steam is released into the soil on two levels: on the surface and at a given depth. The tubular pipe for delivering the steam to the surface is made of stainless steel and has a square sec-tion of 25 x 25 mm, 1,650 mm in length. The diffusor is housed inside the casing of the rotary hoe, which acts as a chamber to prevent the dispersion of steam; it is connected to the steam supply tube in a central position, and has 43 alternating holes of φ 1.5 and 2 mm, facing downwards towards the ground. The lower pipe consists of a diffusor blade that cuts into the soil horizontally at the desired depth in order to inject the steam. It is made up of two parts, one to cut and the other to dispense the steam. The front part is a triangular-shaped steel blade, that cuts into the soil and then protects the steam diffu-sor. It is endowed with 2 vertical side supports connected to the main frame. The second part is a stainless steel tube having an internal φ of 25 mm and a length of 1,700 mm. Its supplies ar-rive via tubes connected to the two ends. The tube has 60 holes of φ 1.5 mm, arranged in 1 dispensing row in the opposite direction to that in which the machine is travelling (Fig. 1B). With the use of two regulator valves it is possible to direct the flow of the generator be-tween the surface tube and the depth tube, depending on the heating levels to be reached in the various soil layers.


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Accessories. The only accessory pro-posed for the machine by the firm is a system for covering treated soil with black plastic film, very effective for avoiding the surface dispersion of steam and heat. The implement is a normal “mulcher” used in market and flower gardening for the laying and tucking of the sheet along the rows. The main properties of the working parts of the machine and accessories proposed by the manufacturer are summarised in Tab. 2. TESTING OF PERFORMANCE The performance of the “Ecostar SC 600” was tested using the methodology set forth in ENAMA protocol no. 05d. Machine performance was tested in a static manner in the laboratory and under actual field conditions.

LIST OF LABORATORY TESTS Performance was tested under static conditions on specially prepared “test benchs” in the workshop areas and yards of the ISMA. Tests were con-cerned with: - the flow, pressure and temperature of

steam under the conditions given in the instruction handbook;

- the positioning and adjustment of the machine’s working parts;

- the quantity and evenness of dispens-ing of the chemical additive;

- the stability of the machine. TYPE OF FIELD TESTS Technical tests in the operating phase were carried out on a “field test bench” specially prepared in a green-house – tunnel. The test ground had chemical-physical properties suitable for growing quality market gardening crops. Prior to testing, measurements were taken to analyse soil characterisa-tion, in accordance with the reference protocol. Operating tests were as follows: Technical-mechanical efficiency test - Power of machine; - Transmission of power from the trac-tor unit to the operating unit; - Forward speed while working; - Theoretical working width, effective and real. Consumption of fuel, water and additives - Consumption of fuel to move machine and generate steam; - Consumption of water to supply steam; - Consumption of exothermic reagents. Thermal efficiency of treatment - Amount of steam supplied at different operating speeds; - Depth of steam emission; - Differential rise in surface tempera-ture at different speeds;

Tab. 2 - PROPERTIES OF OPERATING UNIT

HOPPER Capacity litres 230 Adjustment - Manual Rotary mixing boom Electrical ROTARY HOE

Rotation system - Hydraulic Flow of hydraulic pump l/min 28 Displacement of hydraulic motor cm3 125.7 Speed of rotation of rotovator Rpm 222 Width of rotary hoe mm 1,750 Tools – curved hoe blades No. 28 Max. working depth mm 210 UPPER STEAM BUS BAR Length mm 1.650 Holes No. 43 Diameter of holes mm 1.5 - 2 LOWER STEAM BUS BAR Length mm 1,700 Holes N° 60 Diameter of holes mm 1.5 ACCESSORIES Water softener H2O ex-change resins

l/min about 20

Mulcher width of sheet mm 1,650


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- Differential rise in temperature in depth at different speeds; - Evenness of boom dispensing; - Efficiency of heat distribution from upper boom; - Efficiency of heat distribution from lower boom; - Heat efficiency. TEST CONDITIONS Laboratory tests were performed at the ISMA site. Prior to tests at the field test bench, the soil was suitably prepared in the three specially prepared small greenhouses. The soil was carefully tilled via digging to a depth of 0.3 m. Soil humidity was rendered uniform via overhead micro-irrigation. Tests were carried out under the machine’s operating conditions, in an environment suitable for growing quality crops, for which the system being tested is intended. Tests on the quantity and evenness of dispensing of the exothermic substance were carried out chiefly in the static laboratory tests. Tests were established by calculating doses using the calibra-tion chart of the hopper. Three doses were used: recommended by the manu-facturer; reduced by 50%; twice the recommended amount. The hopper was filled up completely, and also to 1/8 of its capacity. In the field tests, a known mass of reagent was put into the hopper, weigh-ing the residual product after treatment of a preselected area. As it was not possible to find the reagent dispersed into the soil, only the amount of reagent distributed was measured. Measurements of the evenness of steam emission from the surface and depth booms performed on the labora-tory test bench provided approximate values. Field tests on the other hand made it possible to measure the in-crease in soil humidity due to steam condensation. In order to obtain signifi-

cant results, it was necessary to carry out a large number of tests in view of the variability of operating conditions. Heat distribution efficiency was studied by measuring the temperatures of the soil treated with steam only. To be able to compare these values, the “differential temperature” between the maximum reached by the soil and the initial value (heat increase) was calculated. The theoretical capacity was calculated via the maximum working width of the machine at a speed of 100 m/h. The operative working capacity was tested by treating 5 neighbouring strips having a length of 50 m at minimum speed, believed to be most suitable for obtaining the best heating of the soil under test conditions. The operative working width was taken as the theo-retical value minus the overlapping strips. The real working capacity of the ma-chine was established by subtracting from operations the time needed to turn the machine round and fill up with wa-ter, fuel and chemical reagent. RESULTS OF TESTS The results of all tests carried out are given in the summarising table no. 6. Below is an illustration of the most significant results from single tests. STATIC TESTS IN LABORATORY The summary of functional characteris-tics of the “ECOSTAR SC 600”, as per static tests, is given in Tab. 3.

Tab. 3 – MAIN RESULTS OF LABORATORY TESTS

Steam flow 659 kg/h Temp. and press. at boom 160°C - 600 kPa Quantity of thermal addi-tives 0 to 8,000 kg

Longitudinal evenness of thermal additive dispensing Var. max. 11.6%

Crosswise evenness of thermal additive dispensing Var. max. 23.8%

Stability of machine Stable beyond 8.5°


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The production of steam from the boiler was slightly above the nominal value (+10%). Results on the function-ing of the system for dispensing the exothermic substance given in the table refer to the test performed with the dosage recommended by the manufac-turer, with the hopper full.

FIELD TESTING Prior to the start of technical testing on the field test bench, the chemical-physical properties of the soil were analysed. These characteristics are given in Table 4. Technical characteristics of machine The main results obtained by the ma-chine on the field test bench are given in Table 5 and in the figures below. The working speed of the machine depends on the increase in temperature required to obtain good disinfection and disinfestation of the soil. The amount of calories distributed with the steam is constant, thus the temperature reached by the soil depends on the speed of treatment and on the volume of soil to be treated (area of front section x speed). The treatment front is normally 1.52 m in width (1,660 - 8% of overlap-ping of rows) and 200 mm in depth (steam bus bar 150 mm from the sur-face). Under test conditions the ideal speed of the machine to obtain an optimal heating of the substratum, given the initial temperature conditions of the farming soil, approximately 25-

30°C, was 60 m/h. The quantity and evenness of steam dispensing in the soil, measured by the % of condensa-tion water, are given in Table 5 and Fig. 2.

Tab. 5 - OPERATING TESTS IN THE FIELD

Technical-mechanical efficiency test Recommended operating speed 60 – 75 m/h

Working operating width 1.52 m

Consumption of fuel kg/h Engine 7.3 Boiler 38.9 Tot. 46.2

Thermal efficiency of treatment test Steam dispensed at 59.3 m/h 7.3 kg/m2

Depth of steam dispensing I and II steam bus bar

I surface II 150 mm

Increase in surface temp. at 59.3 m/h 37.2 °C Increase in depth temp. at 59.3 m/h 52.7 °C Heat efficiency 87 % Specific consumption at 59.3 m/h kg/m2 0.526 Working capacity Theor. nom. working capacity - 100 m/h 166 m2/h

Real working capacity at 59.3 m/h 90.1 m2/h

Tab. 4 – SOIL PROPERTIES OF TEST FIELDS

Granulometry Franco – limy - clayey Atterberg limits Plasticity index 24.9

Prof. 0 - 200 mm 16.2 Humidity % 200, 400 = 18.4 App- volum. mass Density 1.49 g/ cm2 Penetr. Resist. Lav. 0 – 0.3 m 0.56 MPa

Prepar. soil Clod level index = excel-lent


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Fig. 3 – increases in treated soil temperature measured on horizontal plane at depth of 25 mm

1 2 3 4 5 6 7 8S1

S3

S5 0 5

10 15 20 25 30 35 40 45 50 55 60

Diff

eren

tial t

empe

ratu

re °C

Distribution of soil surface temperatures

55-60 50-55 45-50 40-45 35-40 30-35 25-30 20-25

Crosswise distributionStan.Dev. % = 10,6

Longitudinal distribution Stan.Dev. % = 1,8

Fig. 2 – amount of steam dispensed by nozzles along the booms, meas u red by increase in soil humidity

% in

crea

se in

wat

er in

soil

dispensing along steam bus bars

Evenness of steam dispensing from the 2 bars

Surface bar Depth bar S t a n . Dev. % surface boom

=

8,7 St an . Dev.

% depth boom = 15,0

1 2 3 4 5 6 7 8

0 0,5

1 1,5

2 2,5

3 3,5


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The measured increase in soil tempera-ture is given in Tab. 5 and in Figures 3 and 4. Working capacity of machine The theoretical working capacity and the real working capacity of the ma-chine are given in Tab. 5. CONTROLS AND ADJUSTMENTS Controls pertaining to the flow and dis-pensing of steam between the 2 levels of emission, the depth of treatment and transport speed of the machine are manual. Controls adjusting the produc-tion and pressure of steam are auto-matic. The operating speed of the ma-chine is adjusted electronically. The filling of water tanks and introduction of chemical additives and fuels are manual.

TESTING OF SAFETY REQUIREMENTS The machine is endowed with CE mark-ing, an identification plate, safety picto-grams, a user and maintenance hand-book and an EC manufacturer’s declara-tion of conformity. The EC manufacturer’s declaration of conformity certifies that the machine conforms to the following harmonised standards and technical specifications: UNI EN 708:2002, UNI EN 1553:2001, ISO 11684:1995 e prEN 14018:2003. Checks carried out with reference to documentation sent by the Manufacturer did not show up inconsistencies with the contents of the aforementioned stan-dards. The relative documentation has been filed.

Fig. 4 - increases in treated soil temperature measured on horizontal plane at depth of 150 mm

1 2 3 4 5 6 7 8S1

S3

S5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Diff

eren

tial t

empe

ratu

re °C

Crosswise distributionLongitudinal distribution

Distribution of temperatures generated by depth boom

75-80 70-75 65-70 60-65 55-60 50-55 45-50 40-45 35-40 30-35

Stan.Dev. % = 11,9 Stan.Dev. % = 2,5


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Tab- 6 – SUMMARY OF ALL TEST RESULTS MACHINE FOR THE DISINFESTATION OF SOIL FOR GROWING QUALITY CROPS

TYPE OF TEST RESULT OF TEST STATIC TESTS

Working flow, pressure and temperature of steam Q. 659 kg/h –T. 186°C – P. 980 kP Working depth of rotary hoe and boom Max. 270 mm Quantity and evenness of dispensed exothermic additives 0 to 8,000 kg – ind. Max. var. % 11.6 Crosswise evenness of dispensed additives Irreg. Coeffic. Max. +23.8 – 19.1 Stability of the machine Stable on bench inclined over 8.5°

OPERATING TESTS IN THE FIELD Technical-mechanical efficiency test

Power of machine Max. 44 kW Transmission of power from the tractor unit to the operating unit Electr. 8 kW – hydraulic 28 l/1’ x 180 bar

Forward speed while working (recommended) 60 – 75 m/h Theoretical and real working width Nominal 1.66 m – operating 1.52 m

Consumption of fuel, water and additives Consumption of fuel to move machine and generate steam Engine 7.3 Boiler 38.9 Tot. 46.2 kg/h Consumption of water to generate steam 659 kg/h Consumption of exothermic reagents CaO 4-8,000 kg/ha– KOH 2–4,000 kg/ha

Thermal efficiency of treatment Quantity of steam distributed at speed of 59.3 m/h 7.3 kg/m2

Average depth of steam distribution

I boom on surface II boom 150 mm

Differential increase in surface temp. at 59.3 – 68.9 – 88.5 m/h 37.2 – 28.6 and 19.8 °C Differential increase in temp. at depth at 59.3 – 68.9 – 88.5 m/h 52.7 – 35.9 and 27.4°C Evenness of steam dispensed by booms Stan. Dev. %: upper 8.7, lower 15.0 Efficiency of heat distribution from upper steam bus bar Stan. Dev. %: crosswise 10.6, longit. 1.8 Efficiency of heat distribution from lower steam bus bar Stan. Dev. %: crosswise 11.9, longit. 2.5 Heat efficiency 87 %

Energy use and energy efficiency Unit fuel consumption at speed of 59.3 m/h Kg/m2 0.526 – g/°C m2 11.7 Unit fuel consumption at speed of 68.9 m/h Kg/m2 0.455 – g/°C m2 12.9 Consumption of fuel at speed of 88.5 m/h Kg/m2 0.358 – g/°C m2 15.2

Working capacity Theoretical working capacity – speed 100 m/h 166 m2/h Effective working capacity – speed 59.3 m/h 94.9 m2/h Real working capacity – non-working time included 90.1 m2/h

CONTROLS, ADJUSTMENT AND MAINTENANCE Steam production and pressure Automatic Flow and distribution of supply Manual Forward speed of machine: Transport / In operation Manual / Electronic Adjustment of working depth Manual Filling of tanks: H2O / CaO / Diesel Manual


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The present test report is valid for a period of five years or until reference standards for the machine for the disinfection and dis-infestation of soil, Mod. “ecostar sc 600” are altered, and is offi-cially recognised by ENAMA MEMBERS:

ASSOCAP (Associazione Nazionale dei Consorzi Agrari) (National Association of Agricultural Consortia) CIA (Confederazione Italiana Agricoltori) (Italian Farmers Confederation) COLDIRETTI (Confederazione Nazionale Coltivatori Diretti) (National Confederation of Independent Farmers) CONFAGRICOLTURA (Confederazione Generale Agricoltura) (General Agricultural Confederation) UNACMA (Unione Nazionale Commercianti Macchine Agricole) (National Union of Agricultural Machine Dealers) UNACOMA (Unione Nazionale Costruttori Macchine Agricole) (National Union of Agricultural Machine Manufacturers) UNIMA (Unione Nazionale Imprese Meccanizzazione Agricola) (National Union of Agricultural Mechanisation Enterprises)

AND BY MEMBERS OF THE EXECUTIVE COUNCIL OF THE ENAMA, IN WHICH THE FOLLOWING ARE ALSO REPRESENTED:

MIPAF (Ministry for Agricultural and Forestry Policies) Regions and Autonomous Provinces ISMA (Istituto Sperimentale per la Meccanizzazione Agricola) (Experimental Institute for Agricultural Mechanisation)

E.NA.M.A. - ENAMA - ENTE NAZIONALE PER LA MECCANIZZAZIONE AGRICOLA (NATIONAL AGRICULTURAL MECHANISATION BODY) VIA LAZZARO SPALLANZANI, 22/A - 00161 ROME

TEL. 06/4403137-4403872 FAX 06/4403712 email: [email protected] http://www.enama.it

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