Category: organic fertilizer equipment

The manufacturing of NPK fertilizer is mainly the mixing of different chemical fertilizer raw materials, and the most important step in the process of producing organic fertilizer from livestock manure is composting and fermentation. Nowadays, with the development of Industrial Science and technology, fertilizer plants often choose compost turner to replace labor.

The organic fertilizer production line adopts compost turner equipment, which has larger production capacity, lower production cost and guaranteed fertilizer quality. So how do these turner machines carry out composting and fermentation?

Ground fermentation turning machine
Corn flour can be added into the fermentation products to increase sugar content for the fermentation of bacteria, so that the multi-dimensional complex enzyme bacteria quickly take the advantage. The stirred ingredients are piled into long piles with a width of 1.5m-2m and a bottom of 0.8m-1m, covered with sacks for aerobic fermentation. Then feed the mixed material into the mixer for mixing. The mixing must be even and thorough, and there is no dead block left. Then add the corn flour war fungus. As usual, 45% dew is required for fermentation, that is, the feet are pinched into a ball, and there is water between the fingers, but there is no dripping water. It can be collected as soon as you let go. The windrow turner machine regularly stirs the fermented product. This fermentation method is more suitable for individuals or small businesses. In the processing of organic fertilizer, the trough compost turning machine is more widely used.Trough compost turning machine

In terms of the fermentation process, the temperature on the first day of composting can reach 60 degrees Celsius to 80 degrees Celsius, which can kill E. coli, insect eggs and other pests; the second day eliminates the smell of chicken manure; the third day compost becomes loose, dry and less Modest red mycelium; on the fourth day, a kind of koji fragrance is recovered; on the fifth day, the bacterial fertilizer will be fermented and mature, and the bag can be unpacked and shipped out of the factory after a little reduction and drying. It is heated in one day, odorless in two days, loose in three days, fragrant in four days, and fertilizer in five days. The organic matter content of the green ecological organic fertilizer is above 45%, which is a kind of organic fertilizer with comprehensive nutrients.

The following measures can be taken to prevent material agglomeration when the disc granulator is stopped:

Control the humidity of raw materials:

Before shutting down, try to remove excess moisture from the raw materials as much as possible, but do not let them become too dry, so as not to affect the granulation effect during the next start-up.

If the humidity of the raw materials is high, it is possible to consider using desiccants or heating equipment for pretreatment.

Adjust the sieve appropriately:

Before stopping the disc granulator, the aperture of the sieve can be appropriately increased to reduce the residence time of materials on the sieve, thereby reducing the chance of agglomeration.

Ensure that the sieve is clean and unobstructed to facilitate the smooth passage of materials.

Use anti caking agent:

Adding an appropriate amount of anti caking agents such as diatomaceous earth, starch, etc. to the raw materials can effectively prevent material clumping.

Regularly clean equipment:

During shutdown, regularly clean the interior of the equipment, especially the parts that are prone to clumping, such as feeding ports, screens, and granulation chambers.

Use appropriate tools such as scrapers or soft brushes to gently clean away clumped materials.

Control downtime:

Try to shorten the downtime as much as possible, reduce the residence time of materials in the equipment, and thus reduce the risk of agglomeration.

Reasonably design shutdown procedures:

Before shutting down, gradually reduce the speed and feeding amount of the disc granulator to allow the equipment to transition slowly to a stop state, avoiding material clumping caused by sudden stops.

Storage conditions:

If possible, store unused raw materials in a dry and well ventilated place to avoid clumping caused by moisture.

By implementing the above measures, it is possible to effectively prevent material agglomeration during the shutdown of the granulator, and maintain the normal operation and production efficiency of the equipment.

The use of conversion granulators or roller extrusion granulators to produce granular fertilizers will have different effects on the physical properties and production process of the final product:

1. Physical properties of the product:

Conversion granulator:

The produced particles usually have good fluidity and uniformity because they are formed on a rotating disk, which helps to produce particles with regular shapes and consistent sizes.

The surface of the particles may not be as smooth as that of a roller extrusion granulator, and sometimes there may be some cracks or incomplete molding.

Due to the effect of centrifugal force, the density of particles may be lower, but the density and hardness of particles can be optimized by adjusting process parameters.

Roll squeezing granulator:

The produced particles usually have high density and hardness because they are squeezed between two rotating rollers, which helps to produce dense and uniform particles.

The particle shape is regular, usually cylindrical or square, with a smooth surface and no cracks.

Due to the possibility of high temperatures during the extrusion process, it is necessary to pay attention to controlling the thermal stability of the raw materials to avoid thermal decomposition or loss of nutrients.

2. Production process:

Conversion granulator:

The production process is relatively mild, and the raw materials experience less shear force on the rotating disk, making it suitable for handling heat sensitive or fragile raw materials.

It can handle wet and dry materials, but for highly viscous raw materials, desiccants may need to be added to reduce adhesion.

The energy consumption during the production process is relatively low.

Roll squeezing granulator:

During the production process, a large amount of pressure is required to squeeze the raw materials, which may cause local overheating of the raw materials. It is necessary to control the temperature of the raw materials to prevent thermal damage.

The gap between the rollers can be adjusted to meet the production needs of different particle sizes.

The energy consumption during the production process is relatively high, especially when dealing with hard or high viscosity raw materials.

3. Applicability:

Conversion granulator:

Suitable for producing various types of granular fertilizers, including organic fertilizers, inorganic fertilizers, compound fertilizers, etc., as well as special fertilizers that require maintaining a certain shape and particle size uniformity.

For materials with strong viscosity or fragility, pre-treatment or the addition of additives may be necessary to improve the molding effect.

Roll squeezing granulator:

Specially suitable for producing granular fertilizers with high hardness and density, such as organic-inorganic compound fertilizers, slow-release/controlled-release fertilizers, etc.

For highly viscous raw materials, it may be necessary to add desiccants or pretreatment to improve the molding effect.

4. Economy and sustainability:

Conversion granulator:

Due to the low energy consumption in the production process and wide adaptability to raw materials, the conversion granulator performs well in terms of economy and sustainability.

Energy consumption can be further reduced by recycling and reusing waste heat from the production process.

Roll squeezing granulator:

Although the production efficiency is relatively high, due to high energy consumption, the roller extrusion granulator may be slightly inferior to the conversion granulator in terms of economy and sustainability.

However, for certain special types of fertilizer production that require high-density and high hardness particles, a roller extrusion granulator may be a more economical choice.

When choosing which granulator to use, the characteristics of raw materials, expected product quality, production costs, and environmental impact should be comprehensively considered. For most conventional pellet fertilizer production, the conversion granulator is widely used due to its low energy consumption and good applicability. The roller extrusion granulator plays an important role in producing high-density and high hardness granular fertilizers.

Rotary drum dryers are professionally used in the manufacturing of NPK fertilizer and organic fertilizer processing. The dried and cooled fertilizers are suitable for storage and transportation, and will not deteriorate due to excessive humidity.

Working process of Rotary drum dryers

The fertilizer to be dried enters into the receiving tank of the drum dryer from the high-level tank. The material is attached to the surface of the drum by the film distributing device. There is a heating medium in the drum, and the material is heat transferred by the simple wall during the rotation of the drum to make it vaporized. In one rotation cycle, the rolling cylinder completes the process of film distribution, vaporization and dehydration. The dried materials are scraped off by a scraper and sent to the finished product storage tank by a conveyor, and finally crushed or directly packed. The water evaporated in heat transfer can be introduced into the corresponding treatment device for dust capture or emission according to its nature.

When the dryer can meet the output of organic fertilizer production line, the drying effect is not good, most of the internal structure is unreasonable, or the cylinder length is not enough. Although these are not big problems, they affect the interests of users to a great extent. The solution is to reasonably adjust the internal lifting plate and length according to the material demand. The lifting plate can increase the contact area between the diffusion material and hot gas, and the increase of cylinder length can prolong the drying time.

During the granulation process using a disc granulator, the following common issues may be encountered:

Uneven particle size:

Reason: Inconsistent humidity of raw materials, unsuitable disc speed, clogged or damaged screen mesh.

Solution: Adjust the humidity of the raw materials to a suitable level, optimize the disc speed of the disc granulator, clean or replace the screen mesh.

Poor particle shape:

Reason: Uneven particle size of raw materials, too fast or too slow disc rotation speed, improper amount of adhesive used.

Solution: Optimize the particle size distribution of raw materials, adjust the disc speed to a suitable level, and adjust the amount of adhesive used.

Low production:

Reason: Insufficient feeding of raw materials, low disc speed, and small mesh size.

Solution: Increase the feeding amount of raw materials, increase the disc speed, and replace the appropriate screen mesh.

Equipment blockage:

Reason: The humidity of the raw materials is too high, the viscosity of the raw materials is too high, and the mesh size is not suitable.

Solution: Reduce the humidity of raw materials, adjust the amount of adhesive used, and replace the appropriate screen mesh.

Equipment wear and tear:

Reason: Long term high load operation, high hardness of raw materials, and improper maintenance.

Solution: Regularly shut down for rest, choose components made of wear-resistant materials, and strengthen daily maintenance.

High temperature:

Reason: Long term continuous operation, cooling system failure, high ambient temperature.

Solution: Regularly shut down for rest, inspect and repair the cooling system, and improve the working environment.

Excessive energy consumption:

Reason: Low equipment efficiency, improper operation, and untimely maintenance.

Solution: Optimize the operation process, regularly maintain the disc granulator, and choose high-efficiency and energy-saving equipment.

Excessive noise:

Reason: Equipment aging, loose components, improper maintenance, etc.

Solution: Regularly inspect fasteners, replace worn parts, and strengthen equipment maintenance.

Excessive dust:

Reasons: Raw material drying, screening process, poor equipment sealing, etc.

Solution: Increase raw material humidity, optimize screening system, and improve equipment sealing performance.

Complex operation:

Reason: Insufficient proficiency in equipment operation, lack of effective training, etc.

Solution: Provide sufficient training and guidance to ensure that operators are familiar with equipment operation and maintenance.

By analyzing and solving these common problems, the efficiency and product quality of the disc granulator can be effectively improved, while extending the service life of the equipment.

The fertilizer produced by the disc granulator has the following characteristics:

Particle shape rules:

The disc granulator can usually produce round or nearly round particles with a relatively regular shape, which is conducive to mechanized sowing and fertilization.

Adjustable particle size:

By adjusting the rotation speed of the disc and the aperture of the sieve, particles of different sizes can be produced to meet the needs of different crops and soil conditions.

High strength and moderate hardness:

The fertilizer granules produced by the disc granulator have a certain mechanical strength, which can resist crushing during transportation and use, and have moderate hardness, making it easy for crop roots to absorb.

Good uniformity:

Due to the uniform mixing and rolling of raw materials on the disc, the nutrient distribution of the produced fertilizer particles is uniform, which is conducive to the balanced absorption of nutrients by crops.

Wide applicability:

Suitable for producing various types of fertilizers such as organic fertilizers, compound fertilizers, and slow-release/controlled-release fertilizers, it has a wide range of applicability.

High production efficiency:

The production efficiency of the disc granulator is relatively high, and it can produce a large amount of fertilizer particles in a short period of time.

Low energy consumption:

Compared to other granulation technologies, the disc granulator has lower energy consumption during the production process, which is beneficial for energy conservation.

environment protection

It can effectively utilize agricultural waste and industrial by-products, reduce environmental pollution, and reduce excessive use of fertilizers, which is conducive to sustainable agricultural development.

Easy to store and transport:

The formed fertilizer particles have a relatively small volume, light weight, and are easy to store and transport, reducing logistics costs.

Strong market competitiveness:

Due to the aforementioned advantages of its fertilizers, it has strong competitiveness in the market and can meet the needs of different customers.

At present, the manufacturing of NPK fertilizer is almost all automatic configuration, and the organic fertilizer production process is basically realized by mechanical equipment. The fertilizer production process is relatively strict. Before operation, it must be controlled according to the strict control process, so as to give full play to the energy efficiency of the equipment and achieve twice the result with half the effort.

The development of organic fertilizer equipment is getting faster and faster, especially in recent years, in view of the prominent problems in China’s agricultural production such as excessive use of fertilizer, low efficiency, and declining quality of cultivated land, the main goal of bio-organic fertilizer production equipment is to reduce the use of fertilizer, improve the quality of cultivated land, and realize the industrialization of new and efficient bio-fertilizer.

In the operation of fertilizer equipment, before the initial start-up of the machine, the machine should be debugged, especially rotary drum granulator, dryer, cooler and other equipment. During debugging, proper tools should be used. And when removing components, do not use too much force to avoid damage to parts. After debugging, the loose parts should be tightened

In order to make fertilizer production equipment perform better functions, it is not only normal control process, but also need to carry out regular inspection and maintenance to prevent unnecessary problems during operation.

The maintenance of the disc granulator after granulation mainly includes the following aspects:

1. Cleaning work:

After the disc granulator stops, first turn off the power, then open the machine door and take out the remaining raw materials and particles.

Use appropriate tools (such as soft brushes, compressed air, etc.) to remove residues inside the granulator, especially the sieve and feeding port, to prevent blockage and corrosion.

Cleaning the surface of the machine, removing dust and dirt, and keeping the equipment clean can help ensure normal start-up and operation for the next use.

2. Inspection and fastening:

Check all fasteners of the machine to ensure there is no looseness. If necessary, use a torque wrench to tighten again.

Check the transmission parts, including gears, chains, and belts, to ensure they are not worn or broken, and lubricate them if necessary.

3. Lubrication and maintenance:

Lubricate all parts that require lubrication, such as bearings, gears, etc., using recommended lubricating oil or grease.

Check if the lubrication system is working properly and ensure that the lubricating oil flow and pressure meet the requirements.

4. Electrical system inspection:

Inspect the electrical control cabinet to ensure that all wires are securely connected and free from erosion or corrosion.

Check electrical components such as contactors, relays, sensors, etc. to ensure they are working properly and not damaged.

5. Inspection of worn parts:

Regularly inspect vulnerable parts such as screens, blades, hammers, etc., and determine whether replacement is necessary based on the degree of wear.

For severely worn components, they should be replaced in a timely manner to avoid affecting the normal operation and production efficiency of the equipment.

6. Storage and Protection:

After maintenance is completed, store the equipment in a dry and ventilated environment to avoid moisture and corrosion.

For equipment stored outdoors, it should be covered with rainproof cloth to prevent rainwater from entering.

7. Record and track:

Record the date, content, and replaced parts of each maintenance, and establish a maintenance file.

Based on maintenance records, develop subsequent maintenance plans and preventive maintenance measures.

Through the above maintenance steps, it can be ensured that the disc granulator receives appropriate maintenance after granulation is completed, extending the service life of the equipment and ensuring production efficiency and product quality.

Fertilizer produced using a disc granulator has the following benefits:

Good uniformity:

Due to the working principle of the disc granulator, the fertilizer particles produced have good uniformity, which helps crops absorb nutrients more evenly.

High strength and wear resistance:

The fertilizer particles produced by the disc granulator have high mechanical strength and can resist crushing during transportation and use, reducing the generation of dust.

Strong adaptability:

The disc granulator can process various types of raw materials, including wet and dry materials, as well as raw materials of different particle sizes, with strong adaptability.

High production efficiency:

The production efficiency of the disc granulator is relatively high, and it can produce a large amount of fertilizer particles in a short period of time.

Energy conservation and environmental protection:

The disc granulator has low energy consumption during the production process and can further reduce energy consumption through methods such as recovering heat energy.

At the same time, the dust and exhaust emissions during the production process are relatively low, and the impact on the environment is minimal.

Easy to automate control:

The disc granulator can be equipped with advanced control systems to achieve automated production, reduce manual operations, and improve production efficiency and product quality.

High flexibility:

By adjusting the parameters of the disc granulator, such as speed and feeding speed, it is easy to adjust the particle size and density of the product to meet the needs of different users.

Low maintenance cost:

The structure of the disc granulator is relatively simple, easy to maintain and clean, and reduces long-term operating costs.

Improving fertilizer quality:

By precisely controlling the production process, high-quality fertilizers that meet specific standards can be produced to meet market demand.

Promote resource recycling:

The disc granulator can convert agricultural waste, industrial by-products, etc. into valuable fertilizer resources, which helps to achieve resource recycling.

In summary, fertilizers produced using disc granulators have multiple advantages, meeting the modern agricultural demand for efficient, environmentally friendly, and sustainable fertilizers while improving production efficiency and product quality.

After the production and processing of organic fertilizer, the storage of fertilizer should be considered. How to make the fertilizer effect non-volatile, the most important process to consider is actually one part of the organic fertilizer manufacturing process, which is the drying of organic fertilizer. After the organic fertilizer dryer machine drying, the moisture in the organic fertilizer granules is evaporated, and the dried particles can be stored in the warehouse for a long time.

The function of organic fertilizer dryer is not only here, but also the granulation results of inspection equipment. The fertilizer particles processed by the rotary drum granulator enter the drying procedure, and the particles are full and round after drying, but they will not be cracked and broken. If the dried fertilizer granules have too many cracks, the proportion of fertilizer should be adjusted in the previous fermentation and granulation.

Rotary drum dryer plays an important role in fertilizer production process. It consists of cylinder, gear, pinion, stop roller, drag roller, front roller ring, rear roller ring, discharge part, lifting plate, reducer, motor, and hot air. It is composed of parts such as channel, feed chute and furnace body. The NPK fertilizer manufacturing process can be equipped with multiple hot air stoves when the production volume is large, which is simple and easy to operate, and the production effect is also very good.Adding cooling system can greatly improve the production effect of fertilizer. Tianci fertilizer equipment company, we produce and sell products: chicken manure dryer, rotary dryer, cow manure dryer, pig manure dryer, organic fertilizer dryer, NPK compound fertilizer dryer. According to the needs of the fertilizer production line, the production process can be adjusted and the dryer size can be customized.