Tag: disc granulator

organic fertilizer equipment

Outstanding features of fertilizer production of biological organic fertilizer production line

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Amid the wave of green agricultural development, bio-organic fertilizers are becoming a new trend in the fertilizer market due to their eco-friendliness and high nutrient efficiency. Fertilizers produced by specialized bio-organic fertilizer production lines exhibit distinct characteristics through their unique production processes, providing strong support for sustainable agricultural development.

A broad range of raw material sources and environmental friendliness are key features of these production lines. These production lines utilize organic waste, such as livestock and poultry manure, crop straw, garden waste, and food waste, as their primary raw materials. These wastes, which could otherwise pose an environmental burden, are transformed into nutrient-rich organic fertilizers through the production line’s pulverization, composting, and fermentation processes, effectively turning waste into treasure. Compared to traditional chemical fertilizers that rely on non-renewable resources, this production line not only reduces waste disposal costs but also mitigates the pollution caused by indiscriminate storage of organic waste, aligning with the concept of circular agriculture.

A comprehensive nutrient profile and biological activity are key features of these production lines. During the production process, the bio-organic fertilizer production line precisely controls fermentation temperature, humidity, and microbial strain ratio to preserve nutrients such as organic matter, amino acids, and vitamins in the raw materials, while also promoting the proliferation of beneficial microorganisms (such as Bacillus subtilis and lactic acid bacteria). When applied to the soil, this type of fertilizer not only provides crops with slow-release, long-lasting nutrients, preventing the rapid nutrient loss associated with chemical fertilizers, but also improves the soil’s microbial community structure through beneficial microorganisms, enhancing soil aeration and water and nutrient retention. Long-term use can effectively alleviate soil compaction and improve soil fertility.

The green production process and high product safety are also prominent features. The bio-organic fertilizer production line utilizes high-temperature aerobic fermentation technology, which effectively kills pathogens, insect eggs, and weed seeds in the raw materials, reducing the risks of fertilizer use. Furthermore, the production line uses no chemical synthetic additives. Exhaust gas generated during production is treated in biological filters before meeting discharge standards, and wastewater is recycled through a recycling system to reduce waste, ensuring a green and environmentally friendly process from production to use. In addition, the biological organic fertilizers produced have undergone strict testing, and the heavy metal content is far lower than the national standard. After application, it will not cause secondary pollution of the soil, ensuring the quality and safety of agricultural products and meeting consumers’ demand for green and healthy agricultural products.

organic fertilizer equipment

Benefits of Using a Disc Granulator in Organic Fertilizer Production Lines

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Among the core equipment in organic fertilizer production lines, disc granulators are the preferred choice for many companies, especially small and medium-sized production lines, due to their strong adaptability, high-quality granulation, and convenient operation. They significantly improve production efficiency and product quality.

The disc granulator‘s most prominent advantage is its excellent granulation performance. Its unique disc structure uses the synergistic effect of centrifugal force and gravity to create a stable “rolling granulation zone” within the disc, achieving a granulation rate exceeding 90%, far exceeding that of some extrusion granulation equipment. The resulting granules are not only highly rounded and smooth, but also uniform in size (typically controlled within 2-5mm). This not only prevents nutrient loss due to granule breakage during transportation, but also meets the granule shape requirements of mechanized fertilization, significantly enhancing product market acceptance.

Secondly, it offers excellent raw material compatibility. Organic fertilizer raw materials come from a wide range of sources, from decomposed chicken manure and cow dung to straw powder and mushroom residue, with widely varying composition. The disc granulator can easily adapt to different raw material characteristics by adjusting the disc inclination angle (45°-55°), rotation speed (15-20 rpm), and feed rate.

Disc granulators also offer significant advantages in terms of operation and cost. The device boasts a simple structure, with the disc and drive system as its core components. Routine maintenance requires only regular inspections of bearing wear and disc flatness, resulting in maintenance costs approximately 30% lower than those of a drum granulator. Furthermore, its energy consumption is low, with a single unit consuming approximately 5-10 kWh per hour. This makes it suitable for the production needs of small and medium-sized production lines (with a single unit capable of flexibly adjusting daily output to 5-20 tons). The investment threshold is significantly lower than that of large-scale drum granulation equipment, enabling companies to quickly achieve operational and profitability.

Disc granulators also align with green production trends. Their enclosed design reduces dust emission from raw materials, and combined with a spray moisturizing system, they effectively control dust pollution during the production process. Some units can also be integrated into the production line’s waste heat recovery system, further reducing energy consumption. For organic fertilizer production companies that pursue high efficiency, economy and environmental protection, disc granulator is undoubtedly the ideal choice to balance quality and cost.

organic fertilizer equipment

Core Features of the Bio-Organic Fertilizer Production Line

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Amidst the wave of green agricultural transformation, bio-organic fertilizer production lines are a key link between agricultural waste resource utilization and soil fertility improvement. Their strengths lie in four key dimensions: efficiency, environmental protection, quality, and intelligence.

Efficient production is the primary highlight of the bio-organic fertilizer production line. The production line utilizes continuous operation, integrating all processes from raw material pretreatment to finished product packaging. An automated loading system, combined with high-temperature aerobic fermentation technology, shortens the composting process from over 30 days to 7-10 days. A single line boasts an average daily production capacity of 50-200 tons, significantly improving supply efficiency and meeting the needs of large-scale agriculture.

Environmental protection is a core competitive advantage. The enclosed design prevents exhaust gas leakage, and the biofilter deodorization system removes over 95% of harmful gases such as ammonia and hydrogen sulfide. Solid-liquid separation enables waste recycling, with treated liquids used for irrigation and solid residues used as raw materials. This truly “zero waste” approach helps control agricultural non-point source pollution.

Product quality and stability are outstanding. The production line is equipped with online testing equipment to monitor fermentation temperature, humidity, and pathogen levels in real time. Intelligent control ensures that the finished product maintains an organic matter content consistently exceeding 40%, an effective viable bacterial count of at least 200 million CFU per gram, and heavy metal levels far below national standards. This addresses the uneven quality of traditional compost and provides a guarantee for soil improvement.

Intelligent management and control injects technological vitality. The central control system remotely monitors and adjusts parameters, automatically adjusting agitation speed and ventilation volume based on sensor data, reducing manual intervention. It also records data from the entire process, creating a traceable quality profile for management optimization and quality traceability.

Furthermore, the bio-organic fertilizer production line offers flexible adaptability, allowing process parameters to be adjusted based on raw material type (such as straw, mushroom residue, and livestock and poultry manure). This allows for the production of specialized organic fertilizers tailored to different crops (such as fruits and vegetables, grains, and flowers) to meet diverse agricultural needs. This highly efficient, environmentally friendly, high-quality, and intelligent production model not only transforms agricultural waste into valuable resources but also contributes to the green and sustainable development of agricultural production.

organic fertilizer equipment

Why Choose a Disc Granulator for Granulation?

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In industries requiring granular materials, such as fertilizers, building materials, and metallurgy, the choice of granulation equipment directly impacts production efficiency and product quality. Disc granulators, with their numerous advantages, have become the preferred equipment for many companies.

In terms of granulation efficiency, disc granulators excel. Their unique disc design allows the material to quickly form a stable trajectory during rotation, shortening the time it takes for the material to aggregate and granulate. For example, in fertilizer production, under similar operating conditions, a disc granulator can process dozens of tons of raw materials per hour, increasing efficiency by over 30% compared to traditional granulation equipment. This significantly reduces production cycle time and meets the needs of large-scale production.

Granulation quality is a key consideration when choosing a granulator, and disc granulators offer significant advantages in this regard. By precisely controlling the disc’s rotational speed, inclination, and material moisture content, they achieve uniform granule size, typically maintaining a stable diameter of 2-5 mm. The granules are also strong and resistant to breakage. This characteristic is particularly important in fertilizer production. High-quality granulated fertilizers are not only easy to store and transport, but also ensure uniform nutrient release, improving fertilizer utilization and enhancing product market competitiveness.

The disc granulator’s wide range of applications is a key factor in its popularity. It can efficiently adapt to applications ranging from organic fertilizer and compound fertilizer production lines to the processing of building materials such as cement and expanded clay, and even to the granulation of metal ore powders. Different materials require only adjustments to relevant parameters, eliminating the need for large-scale replacement of equipment components. This reduces equipment costs associated with producing different products and enhances production flexibility.

Disc granulators also offer advantages in terms of energy consumption and cost. Their relatively simple structure and low power consumption during operation can reduce energy costs per ton of material produced by 15%-20% compared to other types of granulators. Furthermore, the equipment’s low manufacturing and maintenance costs, along with the limited number of wearing parts and easy replacement, reduce ongoing operating expenses and offer significant financial savings.

Overall, the disc granulator‘s advantages in efficiency, quality, applicability, and cost make it an ideal choice for granulation production.

organic fertilizer equipment

How to choose the right organic fertilizer granulator based on your needs?

by organic fertilizer production line

In the organic fertilizer production process, the granulator is one of the key pieces of equipment, directly affecting the quality of fertilizer pellets and production efficiency. However, there are many types of organic fertilizer granulators on the market, each with different functions. So how do you choose the most suitable equipment based on your specific needs?

1.Characteristics of Raw Materials

Different organic fertilizer raw materials (such as livestock manure, straw, sludge, etc.) have varying moisture levels, viscosity, and compositions, which require different types of granulators. For example, high-moisture materials are better suited for stirring tooth granulators or flat die granulators, while dry powdery materials are more suitable for disc granulators or drum granulators.

2.Production Scale and Capacity Requirements

Small farms or startups may only need a small granulator with an hourly output of 0.5-1 ton, while large processing plants require high-efficiency equipment with an hourly output of 5 tons or more.

3.Pellet Quality and Shape

Different crops or markets have different requirements for fertilizer pellet strength, density, and shape. For instance, disc granulators produce spherical pellets, which are ideal for commercial sales, while flat die granulators produce cylindrical pellets, making them more suitable for mechanical application.

4.Energy Consumption and Maintenance Costs

Although energy-efficient granulators may have a higher initial investment, they can significantly reduce electricity consumption and maintenance costs over time. It is recommended to choose equipment with a simple structure, fewer wearable parts, and easy operation to minimize downtime and long-term maintenance expenses.

In summary, selecting the right organic fertilizer granulator requires a comprehensive consideration of raw material characteristics, production capacity needs, pellet quality, and cost factors.

organic fertilizer equipment

Common Problems with Disc Granulators in Fertilizer Production

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Fertilizer granulators are widely used in the fertilizer industry, and disc granulators are particularly common. What are some common problems with disc granulators in fertilizer production? If problems such as material sedimentation and clumping occur during granulator operation, how can you resolve them? Below, we will guide you through resolving these issues.

Precipitation can occur during fertilizer production. Some materials cannot be mixed; when they are mixed and dissolved in water, precipitation occurs. Some fertilizers are soluble in certain proportions, but above a certain concentration, salting out occurs, causing another material to precipitate. Some materials, such as metal salts, are easily soluble in acidic media, but will precipitate. Other materials, such as humic acid, are easily soluble in alkaline media, but will precipitate when dissolved in acidic solutions.

The main methods to prevent precipitation are to properly adjust the pH of the solution, add cosolvents, and increase the solubility of insoluble substances. The raw materials used in NPK fertilizer production lines should be properly proportioned to prevent salting out and oversaturation. Appropriate additives should be added to protect the reaction materials and prevent precipitation. Appropriate raw materials should be selected to prevent precipitation caused by reactions between them.

Bloating in fertilizer production is caused by the release of gas from the reaction of two or more materials. Materials that may cause bloating during fertilizer production include borax, ammonium salts, and fillers. To effectively prevent bloating, the following points should be noted when using a disc granulator to produce pellets: When sourcing qualified raw materials, avoid blindly pursuing low costs; and ensure that raw materials are properly combined to prevent chemical reactions between them.

Clumping in fertilizer production: This problem is primarily related to the raw materials, humidity, temperature, external pressure, and storage time. Organic fertilizer production equipment requires the proper selection of raw materials, meaning those that are less prone to caking.

organic fertilizer equipment

Disc granulators are a powerful granulation tool for diverse applications

by organic fertilizer production line

As a highly efficient granulation machine, disc granulators have broad and important applications across multiple industries thanks to their simple structure, convenient operation, and excellent granulation results.
In fertilizer production, disc granulators are essential key equipment. They play a vital role in the production of compound fertilizers, organic fertilizers, and slow-release fertilizers. In compound fertilizer production lines, disc granulators mix various basic fertilizer ingredients in appropriate proportions. The rotating motion of the discs gradually forms uniform granules under the influence of centrifugal force and gravity. The resulting granulated fertilizer is not only easy to store and transport, but also improves fertilizer utilization and reduces nutrient loss. In organic fertilizer production lines, disc granulators ferment organic materials such as livestock and poultry manure and straw before granulating them. This converts loose organic materials into granulated organic fertilizer, improving its physical properties and making it easier for farmers to use. This also promotes the resource utilization of agricultural waste.
The metallurgical industry is also a key application for disc granulators. In the processing of metal ore powder, granulation is often necessary to improve smelting efficiency and utilization. Disc granulators can granulate metal ore powders such as iron ore and manganese ore. The resulting granules are characterized by high strength and good air permeability. Once introduced into smelting equipment such as blast furnaces, they facilitate a more complete smelting reaction, laying the foundation for efficient production in metallurgical enterprises.
In the environmental protection field, disc granulators have demonstrated significant application value in solid waste treatment. Granulating solid wastes such as sludge generated by municipal sewage treatment plants and slag discharged from industrial production using disc granulators not only reduces the volume of solid waste, facilitating subsequent landfill, incineration, or resource recovery, but also reduces the risk of environmental pollution.
Due to its flexible applicability, disc granulators continue to play an important role in various application scenarios. As production requirements continue to increase across various industries, their application prospects will continue to expand.

organic fertilizer equipment

Bio-Organic Fertilizer Production Line Equipment Maintenance Guide

by organic fertilizer production line

Bio-Organic Fertilizer production line equipment must cope with the corrosive and sticky nature of mature materials. Scientific maintenance is key to avoiding malfunctions and ensuring product quality. The following summarizes key maintenance points from three perspectives: core equipment maintenance, general maintenance principles, and special precautions.

Core equipment maintenance requires precise implementation. Check the wear of the turning teeth of the fermentation turning machine weekly. Replace any wear exceeding 5mm to prevent uneven turning. Clean the reducer oil and replace the lithium-based grease monthly to prevent damage from high temperatures. Clean residual material from the crushing machine after each shutdown to prevent caking and blockage. Check the hammer gap quarterly to maintain a 1-2mm gap to ensure a consistent particle size. Disc granulators require daily cleaning with soft tools. Bearing grease should be replaced monthly. Liner wear should be inspected annually and replaced if the thickness decreases by 1/3. Clean dust from the heat exchange tubes of the drying and cooling equipment weekly. Check the conveyor belt tension every six months to prevent deviation and slippage.

General maintenance principles must be adhered to throughout the entire process. Before starting up each day, check the motor voltage and current of each device to ensure normal operation. After shutting down, clean the equipment surface and remove any residual material. Tighten the bolts of transmission components monthly to prevent loosening and vibration. Quarterly, inspect equipment seals, such as the crusher feed inlet seal and the dryer door seal, and replace any damaged seals promptly to prevent dust leakage or heat loss.

Special precautions must not be overlooked. Bio-organic fertilizer materials contain microorganisms. After maintenance, equipment must be flushed with a high-pressure water jet to prevent residual material from mold and affecting subsequent production. During the rainy season, electrical cabinets must be protected from moisture, and wiring insulation must be regularly inspected to prevent short circuits. Maintenance records should also be established to record maintenance times and component replacements for each device. This data can be used to predict failures and minimize downtime losses.

In short, maintenance of bio-organic fertilizer production line equipment requires consideration of material characteristics, targeted maintenance of core equipment, adherence to general principles, and attention to specific details to ensure continuous and stable operation of the production line.

organic fertilizer equipment

Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines

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In organic fertilizer production lines, the disc granulator is the core equipment for raw material processing. Its operating condition directly affects product quality and production efficiency. Scientific maintenance can extend equipment life, reduce downtime, and lower costs. The following details maintenance methods from three perspectives: daily, periodic, and long-term.

Daily maintenance requires “cleaning and inspection in tandem.” After each shutdown, promptly clean the discs of residual material to prevent hardening and scratching of the disc surface or increased operating load. Use soft tools to prevent damage to the liner. Also, check the disc’s tilt angle (normally 45°-55°). If offset, correct it using the bracket bolts. Observe the transmission system daily for abnormal noise and check the motor and reducer temperatures. If the temperature exceeds 60°C, shut down the machine for inspection.

Regular maintenance focuses on “component maintenance and lubrication.” Perform a comprehensive weekly inspection, focusing on the meshing of the transmission gears. Adjust and replace any wear or excessive clearance. Inspect the bearing seals to prevent dust intrusion. Replace the bearing grease monthly. Choose a high-temperature, dust-resistant lithium-based grease, filling it to fill 2/3 of the bearing’s internal space. Disassemble and inspect the scraper blade quarterly. If the blade wear exceeds 3mm, polish or replace it. Ensure a 1-2mm gap between the blade and the liner to prevent material adhesion.

For long-term maintenance, maintain “equipment inspection and record keeping.” Perform a comprehensive annual disassembly and inspection. If the liner thickness decreases by 1/3, replace it entirely. Perform a flaw inspection on the frame to identify any weld cracks and repair them. Maintain a maintenance log, recording maintenance times, details, and replaced parts. Use data analysis to predict failures and plan maintenance in advance.

In short, disc granulator maintenance should adhere to the principle of “prevention first, prevention combined.” This involves combining daily cleaning, regular maintenance, and ongoing inspections to ensure optimal equipment operation and a stable and efficient organic fertilizer production line.

organic fertilizer equipment

Analysis of the unique advantages of disc granulator fertilizer production technology

by organic fertilizer production line

As a classic fertilizer granulation device, the disc granulator plays an essential role in producing compound fertilizers, organic fertilizers, and bio-fertilizers. Compared to traditional granulation methods, its unique process characteristics make it widely popular among small and medium-sized fertilizer manufacturers.

Core Features of the Disc Granulation Process:

1.Unique Tilted Rotating Design

The disc granulator features an adjustable tilt angle (15-55°) and a rotational speed of 2.2 to 6 rpm. This allows materials to roll and form granules naturally under gravity. This design ensures uniform granule size while preventing breakage caused by excessive pressure.

2.Open and Visible Operation

Unlike enclosed granulation equipment, the disc granulator operates completely openly. Operators can visually observe the entire granulation process in real-time, allowing them to adjust parameters like water spray volume and feed rate accurately, significantly improving process control precision.

3.Low Energy Consumption and High Efficiency

The disc granulator requires no complex drive system. Its power consumption is only 60%-70% of that of a drum granulator with equivalent output. This makes it especially suitable for areas with unstable power supply, significantly reducing production costs.

As demand grows for organic and specialty fertilizers, the disc granulator is gaining wider use in small-scale, high-end fertilizer production due to its process flexibility and cost-effectiveness.

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