Tag: rotary drum granulator

To maximize the performance of a windrow compost turner, a scientific and standardized operating process must be followed. The entire process of the windrow compost turner revolves around four key steps: raw material pretreatment, windrow accumulation, turning and fermentation, and determination of maturity.

Raw material pretreatment is fundamental. Collected organic materials must first be sorted to remove impurities such as metal and plastic. Livestock and poultry manure should be air-dried to a moisture content below 65%, and straw should be pulverized to 5-10 cm in length. The raw materials should then be mixed at a carbon-to-nitrogen ratio of 25-30:1. The carbon and nitrogen content can be adjusted by adding straw or manure, ultimately achieving a moisture content of 55%-60%. At this point, the material will clump when held and fall apart upon contact, achieving optimal fermentation conditions.
Next, the pre-treated raw materials are stacked into trapezoidal stacks at the fermentation site. These stacks are typically 3-5 meters wide at the base, 1.5-2.5 meters wide at the top, and 1-1.8 meters high. The stack length can be adjusted flexibly based on the site and production volume. A 1.5-2 meter passageway is left between the stacks to facilitate equipment access and ventilation.

Turning and tossing is a key step in fermentation. After starting the windrow compost turner, the depth of the tossing mechanism is adjusted according to the height of the stack, ensuring that the tossing teeth penetrate 10-20 cm into the bottom of the material. The initial fermentation lasts 1-3 days, with the first tossing occurring when the material temperature reaches 50-60°C. The high-temperature period lasts 4-10 days. When the temperature rises to 60-70°C, the stacks are tossed every 1-2 days to kill harmful bacteria. The cooling period lasts 11-20 days. When the temperature drops to 40-50°C, the stacks are tossed every 2-3 days to promote humus formation. The entire fermentation cycle lasts 15-25 days.

Finally, the material is judged by maturity. When the temperature is close to room temperature, the color is dark brown, the texture is loose, and there is no odor or earthy smell, it is considered mature and can be sent to the next stage for processing.

In the fertilizer production industry, different types of fertilizer production lines correspond to varying production requirements and process characteristics. Understanding common fertilizer production line types and key equipment configurations is crucial for companies to plan production and improve efficiency.

Currently, mainstream fertilizer production lines include organic fertilizer production lines, NPK fertilizer production lines, and bio-organic fertilizer production lines. Organic fertilizer production lines primarily use agricultural waste and livestock manure as raw materials, producing organic fertilizer through fermentation, crushing, and granulation. NPK fertilizer production lines focus on optimizing the ratio of nitrogen, phosphorus, and potassium to produce compound fertilizers. Bio-organic fertilizer production lines build on traditional organic fertilizer production by incorporating biological strains to enhance the bioactivity of the fertilizer.

While different production lines have different focuses on equipment configuration, they share common core equipment. The crushing stage typically requires a fertilizer crusher to ensure the raw material particle size meets subsequent processing requirements. The granulation stage utilizes fertilizer granulators, such as disc granulators and rotary drum granulators. The mixing stage relies on a fertilizer mixer to ensure uniform mixing of the raw materials. Furthermore, fertilizer conveyors, screening machines, dryers, and coolers are essential equipment, collectively forming the complete fertilizer production process.

When configuring equipment, companies should carefully select equipment specifications and models based on the production line’s capacity, raw material characteristics, and product requirements to ensure optimal compatibility across all stages and improve overall production efficiency.

As a long-term operating equipment in fertilizer production, BB fertilizer mixers require scientific daily maintenance to effectively reduce downtime, extend their service life, and ensure stable production. Maintenance should focus on the core components of the BB fertilizer mixer, with the mixing mechanism being the key. Regularly inspect the agitator shaft and blades for wear. Deformed or damaged blades should be replaced promptly to prevent poor mixing performance. Regular lubrication of the agitator shaft bearings is also crucial to reduce friction and minimize the risk of damage.

Maintenance of the drive system, including the motor and reducer, is also crucial. Regularly monitor the motor’s temperature and noise during operation. Any abnormal heating or noise should be promptly investigated to prevent motor burnout. Reducer lubrication should be regularly replaced to ensure transmission efficiency and avoid excessive wear due to insufficient lubrication.

Maintenance of the feed and discharge systems is equally critical. After each run, check the feed and discharge ports for residual material blockages and clean them promptly to ensure smooth material flow. Also, check the seal of the discharge valve to prevent material leakage that could cause waste or pollute the production environment.

In addition, after each production, the inside of the mixing drum needs to be thoroughly cleaned to avoid residual raw materials from clumping and to prevent contamination of new raw materials during the next production. With the help of the easy-to-clean design features of the BB fertilizer mixer, the cleaning work can be completed efficiently.

With the large-scale development of the organic fertilizer industry, production lines are placing increasingly stringent demands on equipment adaptability. With its exceptional integration capabilities, large wheel compost turners have become core equipment for large-scale organic fertilizer production lines.

Within the production line process, they seamlessly connect pre-treatment and processing. During pre-treatment, raw materials such as livestock and poultry manure processed by a solid-liquid separator and pulverized straw from a pulverizer are piled into windrows 5-8 meters wide and 1.5-2 meters high. The large wheel compost turner slowly moves along the windrows, turning and fermenting the material. The fermented material is then conveyed by conveyor to equipment such as granulators, screens, and dryers, forming a complete production chain from pre-treatment to fermentation, enabling continuous production.

For large-scale production lines with an annual output of over 100,000 tons, the equipment rotates through multiple windrows: one receiving fresh raw material, one performing high-temperature fermentation, and one completing cool-down composting. This fixed cycle allows for a daily processing capacity of 800-1,500 tons, meeting the needs of large-scale production.

In addition, its electronic control system flexibly adjusts the turning and travel speeds, adjusting the fermentation progress based on the raw material supply and pelletizing capacity, ensuring a stable production line. Furthermore, compared to tank fermentation, it improves site utilization by over 30%, saving valuable land resources for large-scale production lines.

When selecting a rotary drum granulator, companies should pay close attention to its core structure to ensure it precisely matches their production line requirements. A rotary drum granulator primarily consists of a rotating drum, transmission, support system, and spray system. The performance of each component directly impacts the overall performance of the equipment.

The rotating drum, as the core working component, is constructed from rolled steel plate. Lifting plates or spiral blades on the inner wall enhance the tumbling and collision effect of the material. When selecting a granulator, consider whether the steel plate thickness and blade design are compatible with the characteristics of the production material. The transmission provides power, and the power and quality of the motor and reducer affect the equipment’s operational stability and should be selected based on production capacity.

The support system bears the weight and rotation of the drum. The selection of rolling or sliding bearings should be considered based on the equipment load and operating environment. Furthermore, the atomization effect of the spray system determines the accuracy of humidity control, ensuring uniform spraying of water or adhesive. Only by comprehensively considering these structural details can you select a rotary drum granulator that is compatible with your production line and operates efficiently.