Tag: Flat die granulator

organic fertilizer equipment

Key points for retrofitting organic fertilizer production lines under environmental compliance requirements

by organic fertilizer production line

With increasingly stringent environmental protection policies, environmental retrofitting of organic fertilizer production lines has become an industry imperative, focusing on the treatment of “three wastes” and compliance upgrades.

For waste gas treatment, organic fertilizer production lines must be equipped with sealed fermentation chambers and ammonia collection systems. Biofilter technology is used to control ammonia concentrations generated during the fermentation process to within standards. Some areas also require VOC monitoring equipment to ensure real-time upload of emission data.

For wastewater treatment, production lines must establish a recycling system to sediment and filter wash water and condensate before reusing them for raw material moisture conditioning, achieving zero wastewater discharge.

For solid waste treatment, optimized screening processes are employed to re-crush fermentation residues before mixing them back into fermentation, achieving full solid waste utilization.

Furthermore, the environmental impact assessment process imposes stricter requirements on production line site selection and capacity planning, such as requiring them to be at least 500 meters away from residential areas and designing production capacity to match the regional environmental carrying capacity. Although these transformations increase initial investment (usually the transformation cost of a single production line accounts for about 15%-20% of the total investment), the energy consumption of the organic fertilizer production line can be reduced by 12%-18% after the transformation.

organic fertilizer equipment

How can you use new type organic fertilizer granulators more efficiently and save energy and materials?

by organic fertilizer production line

Many organic fertilizer plants are concerned about costs. However, when using new type organic fertilizer granulators, paying attention to two small details can significantly save energy and materials.

To save energy, most new type organic fertilizer granulators are equipped with variable-frequency motors. Avoid running them at maximum speed all the time. For example, when initially feeding, use a low speed of 15 rpm. Once the raw materials have stabilized in the granulation chamber, gradually increase the speed to 20-25 rpm. This prevents the motor from exerting sudden force, saving 10%-15% of energy per hour. Additionally, avoid idling the machine. Do not start the machine until the raw materials are ready. The energy wasted in idling for one hour is enough to generate granules for 20 minutes.

To save materials, the key is to reduce waste. New type organic fertilizer granulators have a return device. Instead of discarding the crushed granules, they are directly returned to the granulation chamber through the return port, where they are mixed with new raw materials and granulated again. This can reduce the waste rate from 10% to less than 3%. Also, do not mix impurities such as stones and iron wire into the raw materials. Impurities will wear out machine parts and crush good particles. Use a sieve before feeding each time to avoid a lot of material waste.

organic fertilizer equipment

When using windrow compost turning machines in different seasons, pay attention to key details

by organic fertilizer production line

A windrow compost turning machine isn’t a one-size-fits-all model. Adjusting details according to the season will ensure smooth fermentation of your organic fertilizer.

Spring’s high humidity and fluctuating temperatures can easily lead to a musty odor in the compost. When using a compost turner, increase the frequency of turning the compost. Instead of turning every two days, turn every 1.5 days in spring. Loosen the compost to allow moisture to escape, and monitor the temperature. If the temperature is below 50°C, slow the compost turner’s speed to allow for a more thorough turning, allowing microbial activity to raise the temperature.

Summer temperatures are high, and the compost easily overheats (over 70°C kills beneficial bacteria). Reduce the depth of each turning to avoid bringing all the hot material below to the surface. Turn the compost once a day. Sprinkle a thin layer of soil on the surface after each turning to provide shade and reduce temperatures while preventing rapid evaporation.

Autumn is dry, and the pile is prone to dehydration and cracking. Use a windrow compost turning machine with an atomizer, spraying small amounts of water as you turn to maintain a humidity level of 50%-60%. Slow the turning speed to allow the water and raw materials to mix thoroughly and avoid patches of dryness or wetness.

Winter is cold, and the pile struggles to heat up. Reduce turning frequency to once every three days, avoiding frequent turning to disperse heat. When turning, pile the pile higher (1.2-1.5 meters). Try turning the cold material in the center with the windrow compost turning machine, covering the hot material on the outside to help retain heat and ferment.

organic fertilizer equipment

How to adapt a BB fertilizer blender to different raw material characteristics?

by organic fertilizer production line

BB fertilizer raw materials come in a variety of forms (granular, powdered, and fiber-containing). BB fertilizer blenders require targeted adjustments to accommodate these different raw material characteristics and avoid mixing problems.

For pure granular raw materials (such as urea and diammonium phosphate granules), which have relatively small density differences but are prone to rolling and stratification, the BB fertilizer blender should be equipped with guide plates within the mixer drum to guide the raw materials into upward and downward circulation and control the feed order. Adding the denser diammonium phosphate first, followed by the lighter urea, can reduce initial stratification. The speed can be appropriately reduced in the later stages of mixing to prevent excessive collisions between particles that could lead to breakage.

If the raw materials contain powdered ingredients (such as potassium chloride powder or trace element powder), a dustproof seal should be installed at the BB fertilizer blender feed port to prevent dust from escaping. Additionally, an atomizing humidifier (control the humidity to ≤15%) should be installed within the mixer drum. A small amount of humidification can enhance adhesion between the powdered raw materials and the granules, preventing dust from becoming suspended.

When the raw materials contain fiber organic fertilizer (such as fermented straw powder), it is necessary to use a paddle with a shearing function to prevent the fibers from entangled and clumping. At the same time, the fiber raw materials should be crushed to less than 3mm in advance to reduce mixing resistance. During the mixing process, the machine can be stopped and observed every 3 minutes. If fiber clumps are found, the paddle angle needs to be adjusted to enhance the shearing and dispersion effect to ensure that the fibers and granular fertilizer are fully integrated.

organic fertilizer equipment

Controlling pellet strength in ring die granulators: Key to fertilizer transportation and storage

by organic fertilizer production line

Pellet strength is a core performance indicator for fertilizer products. Ring die granulators require multi-step control to ensure pellets can withstand the pressure of transportation and stacking, minimizing breakage and loss.

First, consider the raw material ratio. If the organic matter content in production is too high (over 60%), binders such as clay and bentonite should be added (control the amount to 3%-5%) to increase the viscosity of the raw materials and lay the foundation for pellet strength.

If the proportion of inorganic fertilizer is high, the moisture content of the raw materials should be controlled between 14% and 16% to avoid pellet brittleness caused by too low a moisture content and easy sticking to the ring die granulator due to too high a moisture content.

Selecting the ring die granulator compression ratio is also crucial. The compression ratio (the ratio of the ring die aperture to the effective thickness) should be adjusted according to the fertilizer type. For organic fertilizers with high fiber content, a low compression ratio of 1:8-1:10 is recommended to prevent pellets from being too hard and easily broken. For compound fertilizers, a high compression ratio of 1:12-1:15 is recommended to enhance pellet density. During production, regular spot checks can be performed using a pellet strength tester. If the strength is insufficient, the steam supply to the conditioner can be temporarily increased (by 10%-15%).

In addition, the gap between the roller and the ring die should be controlled within a range of 0.1-0.3mm. A gap too large will cause the raw material to slip, resulting in insufficient pellet density; a gap too small will increase wear and affect pellet consistency. By synergistically controlling these three factors, the compressive strength of fertilizer pellets can be stabilized at above 20N, meeting transportation and storage requirements.

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

Where are flat die granulators used?

by organic fertilizer production line

With its unique extrusion molding principle, flat die granulators have demonstrated strong application potential in a variety of fields, making them an ideal choice for small- and medium-scale production. Their core structure consists of a flat die and a pressure wheel. The rotation of the pressure wheel squeezes the material through the die holes, forming cylindrical pellets. This simple and direct operation gives them wide applicability.

Flat die granulators perform exceptionally well in fertilizer production lines. When processing bio-organic fertilizers, they can directly pelletize wet fermented materials without the need for additional drying pretreatment, preserving the activity of beneficial bacteria while streamlining the production process. For nitrogen, phosphorus, and potassium compound fertilizers, their powerful extrusion capabilities can compress mixed powders into high-strength pellets, effectively eliminating the clumping problem associated with traditional pelleting. They are particularly suitable for producing high-concentration specialty fertilizers.

Flat die granulators are also essential for the feed processing industry. For poultry and livestock feed, they can compress raw materials such as straw powder and soybean meal into pellets, reducing feed losses during transportation. High-temperature extrusion kills parasite eggs in the raw materials, enhancing feed safety. In aquatic feed production, pellet density can be controlled by adjusting die hole size to meet the feeding needs of fish in different water layers.

In the environmental protection field, flat die granulators are a valuable aid in solid waste treatment. They can compress municipal sludge, agricultural and forestry waste, and other materials into fuel pellets, realizing waste resource utilization. These pellets have high combustion efficiency and low pollutant emissions, providing new ideas for the development of new energy sources.

The flat die granulator‘s advantages also lie in its flexible operation. By simply replacing dies with different apertures, a wide range of pellet specifications can be produced to meet the needs of diverse industries. The equipment also occupies a small footprint and is easy to install and maintain, making it suitable for small and medium-sized enterprises. As the concept of green production becomes increasingly popular, the flat die pelletizer, with its high efficiency, energy conservation, and versatility, continues to provide a reliable solution for material forming in various fields.

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