Tag: organic fertilizer granulation process

Drying and Cooling Processes in Organic Fertilizer Production Lines

In the drying and cooling stages of the organic fertilizer production line, drum fertilizer dryers and drum fertilizer coolers have become key equipment for achieving large-scale production due to their stable and efficient performance. The two are seamlessly connected to jointly ensure the quality of organic fertilizer products and production efficiency.

The drum fertilizer dryer is essential for dehydrating and shaping organic fertilizer. The moisture content of fermented organic fertilizer can reach as high as 50%-60%, requiring treatment in the drum dryer to reduce it to a safe storage range of 15%-20%. This equipment utilizes an inclined drum structure. External heating or hot air penetration ensures continuous tumbling of the material within the drum, ensuring full contact with the heat source. During operation, the hot air temperature must be precisely controlled at 60-80°C, ensuring rapid water evaporation while preventing high temperatures from damaging beneficial microorganisms such as Bacillus subtilis and lactic acid bacteria, as well as organic matter in the organic fertilizer. Furthermore, the drum dryer’s sealed design and exhaust gas recovery system effectively reduce dust and volatile gas emissions, meeting environmental standards and adapting to the needs of production lines of varying sizes. The drum cooler is a key piece of equipment for cooling and improving the quality of dried materials. The temperature of dried organic fertilizer can reach 40-50°C. Direct packaging can easily generate condensation, leading to clumping.

The drum fertilizer cooler utilizes a countercurrent heat exchange principle. Cool air enters from one end of the drum and contacts the hot material at the other end. As the material rotates, it efficiently cools the material, keeping it within +5°C of the ambient temperature. Its unique internal lifting plate structure ensures uniform material agitation and cooling, while further removing any residual free moisture. This loosens the organic fertilizer particles, improving product flowability and appearance. Furthermore, the drum cooler’s enclosed design reduces dust spillage, minimizing dust pollution in the production environment and ensuring smooth subsequent screening and packaging processes.

The synergistic application of the drum fertilizer dryer and drum fertilizer cooler creates an efficient and stable drying and cooling system for the organic fertilizer production line. By rationally matching equipment parameters and process conditions, we can maximize the retention of organic fertilizer nutrients and biological activity, improve production efficiency, reduce energy consumption and losses, provide high-quality and stable organic fertilizer products for the agricultural field, and promote the development of green agriculture.

Analysis of Common Problems in the Organic Fertilizer Production Line

Organic fertilizer production lines improve efficiency through continuous operation, but improper integration of various stages can easily lead to problems, impacting production stability and product quality.

The raw material pretreatment stage is prone to conveyor blockage. If raw materials such as straw and manure are not crushed to a particle size of 5-10mm or have a moisture content exceeding 65%, they can easily form lumps in belt conveyors and screw feeders, causing production line downtime. Screener machines should be added to the pretreatment stage to control the particle size. At the same time, the moisture content should be adjusted to 55%-60% through drying or the addition of dry materials to ensure smooth material conveyance.

Uneven compost turning and insufficient oxygen supply are common problems in fermentation systems. If the chain compost turning machine rotates too fast or has an inappropriate stroke setting, the compost will not be turned thoroughly, resulting in local temperatures below 55°C and failure to achieve the desired compost maturity. Insufficient fan pressure can cause oxygen deprivation in the compost, producing harmful gases such as hydrogen sulfide. To address this, adjust the compost turner speed according to the pile height (2-3 rpm is recommended). Regularly check the fan filter to ensure a ventilation rate of 0.3-0.5 m³/min per cubic meter of pile.

The drying process is prone to moisture control imbalances. If the feed rate to the drum fertilizer dryer fluctuates, or if the hot air temperature fluctuates by more than ±5°C, the finished product moisture content will fluctuate (the acceptable standard is 15%-20%), impacting subsequent granulation. Install an automatic feed regulating valve to stabilize the feed rate, employ a temperature control system to precisely control the hot air temperature at 80-100°C, and install a moisture detector at the discharge end for real-time monitoring.

Inaccurate metering and loose sealing are common problems in the packaging process. Aging load cells in quantitative packaging machines can lead to bag weight errors exceeding ±2%. Low temperatures or insufficient pressure in heat sealers can cause cracking in the bag seals and moisture absorption and caking of the finished product. The load cell must be calibrated monthly, the heat sealing temperature must be adjusted to 150-180°C, and the pressure must be controlled at 0.3-0.5 MPa to ensure packaging quality.

Addressing issues in all aspects of the organic fertilizer production line requires strengthening equipment maintenance and process control to achieve continuous and stable production and guarantee the quality of organic fertilizer.

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