Author: organic fertilizer production line

 Organic fertilizer granulation equipment is the primary and necessary granulation equipment in feed processing and production and processing of organic fertilizer and compound fertilizer. And in the processing of raw materials, granulator can normal task production, which directly affects the economic benefits of production enterprises is directly related, so the accurate operation of granulator is very important.

NPK fertilizer granulator with high degree of automation has extrusion granulation equipment, and then the organic fertilizer wet granulation machine, rotary drum granulator and other equipment also meet the processing needs of different people in different aspects, and the granulation equipment in organic fertilizer processing equipment is becoming more and more abundant.

Flat die extrusion granulator, the representative product of extrusion granulation process, has a large market. It can be formed at room temperature without drying, and can realize automatic production without manual operation, which is highly praised by most users. Flat die pellet mill has also rapidly become a star product in the organic fertilizer production and processing industry.

The important principle of compound fertilizer production by rotary drum granulator is to reduce the addition of water during granulation as much as possible, and moderately increase the temperature and solubility of materials, so as to reduce the heat consumption, improve the qualified rate of pelletizing, increase the output and reduce the production cost.

As an important molding process in the production and processing of organic fertilizer, fertilizer granulator has a great impact on the production of complete sets of organic fertilizer equipment. The strength, uniformity and size of finished organic fertilizer particles are affected by the granulation equipment. Therefore, we will pay special attention to the selection of granulator when applying organic fertilizer granulation equipment to produce organic fertilizer. We need to pay attention to the market In order to make the right choice, we must have a thorough understanding of the basic equipment.

Ensuring the stability and reliability of the crusher in the NPK fertilizer production line is crucial for maintaining production efficiency and product quality. Here are some key measures to ensure the stable operation and long-term reliability of fertilizer crushers:

Select appropriate model and specifications: Choose the appropriate crusher type and specifications based on the material properties (such as hardness, humidity), yield requirements, and particle size requirements of the fertilizer production line. Ensure that the processing capacity of the crusher matches the production line, avoiding overload or insufficient capacity.

Quality control: Choose crushers from reputable and experienced manufacturers to ensure the manufacturing quality and material durability of the equipment. Check whether the structural design, manufacturing process, and materials of the equipment meet the requirements for long-term stable operation.

Regular maintenance: Establish a regular maintenance plan, including cleaning up dust and residual materials inside and outside the equipment, inspecting and fastening all connecting parts, lubricating rotating parts, inspecting and replacing worn hammer heads, screens, and other vulnerable parts. Regular maintenance can extend equipment lifespan and reduce failure rates.

Monitoring and adjustment: Install a monitoring system to monitor the operating status of the crusher in real time, such as temperature, vibration, current and other parameters, and promptly detect abnormalities and make adjustments or maintenance. Adjust the feed rate, speed, and other parameters of the crusher in a timely manner according to production needs to ensure that the equipment operates at its optimal state.

Operation training: Provide professional training to operators to ensure they understand the operating procedures, safety precautions, and basic fault diagnosis and handling methods of the equipment. Proper operation can reduce abnormal wear and failure of equipment.

Spare parts management: Establish a spare parts inventory to ensure timely replacement of critical vulnerable parts such as hammers, screens, bearings, etc. Establish good cooperative relationships with suppliers to ensure rapid supply of spare parts in emergency situations.

Environmental control: Keep the working environment clean and avoid the impact of dust, moisture, etc. on equipment. For crushers that handle materials with high humidity, appropriate moisture-proof measures should be taken to avoid material clumping or corrosion inside the equipment.

Through the above measures, the stability and reliability of fertilizer crushers in NPK fertilizer production lines can be effectively improved, ensuring the continuity of the production process and the stability of product quality.

Improving the granulation efficiency in NPK fertilizer production lines can not only increase production speed, but also improve pellet quality and reduce energy consumption. Here are some effective methods to improve granulation efficiency:

Raw material pretreatment:

Control the humidity of raw materials: The humidity of raw materials has a direct impact on granulation efficiency. Excessive humidity can cause materials to stick in the granulator, affecting the granulation effect; Low humidity makes it difficult to form stable particles. Therefore, by pre drying or humidifying, controlling the humidity of the raw materials within the optimal range can improve granulation efficiency.

Raw material crushing: Ensure that the particle size of the raw material is uniform and meets the requirements of the granulator. Raw materials with excessively large or uneven grains will increase the difficulty of granulation and reduce granulation efficiency.

Optimize granulation equipment:

Choose the appropriate fertilizer granulator: Based on production needs and raw material characteristics, choose the most suitable type of granulator, such as disc granulator, drum granulator, or extrusion granulator. Different granulators may have different efficiencies and effects when processing specific materials.

Adjust the parameters of the granulator, including speed, feed rate, water addition, etc. Reasonable parameter settings can improve granulation efficiency and particle quality. For example, increasing the rotational speed appropriately can accelerate the granulation process, but excessively high rotational speed may cause particle wear.

Using granulation agents: Adding an appropriate amount of binders or granulation agents, such as organic binders, inorganic binders, or surfactants, can improve the granulation performance of materials, increase granulation efficiency and particle strength.

Optimize the mixing process: Ensure that the raw materials are thoroughly and evenly mixed before entering the granulator. The use of efficient mixing equipment, such as high-speed mixers or planetary mixers, can improve the mixing effect and thus enhance the granulation efficiency.

Drying and cooling: After granulation, excess moisture in the particles is quickly removed through drying and cooling equipment to prevent particle adhesion and improve particle stability. Proper drying and cooling can improve the overall efficiency of granulation.

Maintenance and upkeep: Regularly maintain and upkeep the fertilizer granulator to ensure that the equipment is in optimal condition. Cleaning the interior of the granulator, inspecting and replacing worn parts can prevent malfunctions and improve production continuity and efficiency.

Process control and monitoring: An automated control system is used to monitor and adjust key parameters during the granulation process in real-time, such as temperature, humidity, pressure, etc., to maintain the stability and efficiency of the granulation process.

Through the above measures, the granulation efficiency in the NPK fertilizer production line can be significantly improved, while ensuring the quality and consistency of the granules, thereby improving overall production efficiency and economic benefits.

 Working principle of organic fertilizer granulator: 

The organic fertilizer granulation equipment manufactured by Tianci factory uses the high-speed rotating mechanical stirring force and the resulting aerodynamic force to continuously realize the mixing, spheroidizing, granulating, extrusion, collision, densification and polishing of fine powder materials in the machine, so as to achieve the purpose of granulation. The particle shape of organic fertilizer granulation equipment is spherical, and the granulation rate is 90%. The particle diameter can be adjusted by material mixing amount and spindle speed. Generally, the lower the mixing amount, the smaller the particles and the higher the speed.

The granulation machine produced by NPK fertilizer granulator manufacturer is based on the manufacturing experience of rotary drum granulator and agitating gear granulator, which is carefully developed, repeated experiments and improved granulation equipment. Disc granulator and organic fertilizer granulator are produced at normal temperature with reasonable structure design. They can produce spherical granular products with low moisture content, high molding rate, easy drying, beautiful appearance and good particle strength. They are the ideal granulating equipment for organic inorganic fertilizer, biological organic fertilizer and organic fertilizer inorganic compound fertilizer.

Application scope of organic fertilizer granulating equipment: 

This machine is especially suitable for granulation of light and fine powder materials, and has more powerful granulation function for organic-inorganic compound fertilizer production line. Organic wastes such as chicken manure, peat, straw, sludge, livestock manure, lignite, wine, filter mud of sugar factory, paper sludge, bean dregs, peat and other organic wastes can be directly pelletized after fermentation treatment, which completely solves the key technical problems of traditional granulation process, such as fermentation, etc.

The raw material of our granulation equipment is bio organic fertilizer. The finer the basic particles of fine powder materials are, the higher the sphericity of particles is, and the better the quality of pellets is. The granulation equipment of organic fertilizer generally requires that the particle size of materials before granulation should be less than 50 mesh. Typical application materials: pig manure, chicken manure, cow manure, clay, carbon black, kaolin, phosphorus, nitrogen, potassium and other organic-inorganic compound fertilizers are suitable.

On the NPK (nitrogen phosphorus potassium) fertilizer production line, the fertilizer crusher is one of the key equipment used to crush large raw materials or semi-finished products into small particles for subsequent mixing, granulation and other processes. The commonly used types of fertilizer crushers include:

Hammer crusher: It crushes materials by striking them with a high-speed rotating hammer head. Suitable for crushing materials with moderate hardness and brittleness, with high crushing efficiency, but the processing effect is not good for materials with high hardness or high viscosity.

Cage crusher (or cage crusher): It uses the relative motion between a rotating cage and a fixed cage bar to crush, shear, and impact materials. Suitable for processing materials containing certain moisture and viscosity, such as materials after wet granulation.

Roller crusher: using two relatively rotating rollers to squeeze and shear materials, suitable for processing materials with high hardness and large block size, such as phosphate rock, limestone, etc.

Vibration screen crusher: Combining the functions of vibration screen and crushing, the material passes through the sieve under the action of vibration, achieving a dual effect of crushing and screening. Suitable for handling materials with high granularity requirements.

Chain crusher: It uses a high-speed rotating chain to impact and shear materials, suitable for crushing materials containing certain fibers or toughness, such as organic fertilizer raw materials.

Gear disc crusher: uses the relative motion between the rotating gear disc and the fixed gear disc to cut, squeeze and crush materials. Suitable for processing materials with uniform and fine particle size requirements.

When choosing a fertilizer crusher, it is necessary to determine based on the specific properties of the material (such as hardness, moisture, particle size requirements, etc.) and the production line’s capacity requirements to ensure the crushing effect and production efficiency. Reasonable selection and configuration of crushers are prerequisites for achieving efficient and stable production in NPK fertilizer production lines.

The equipment configuration of an NPK fertilizer production line may vary depending on the production process, but generally speaking, a complete NPK fertilizer production line will include the following main equipment:

Raw material storage and transportation equipment: used for storing and transporting various raw materials (such as urea, monoammonium phosphate, potassium chloride, etc.). Including raw material warehouses, conveyor belts, screw conveyors, bucket elevators, etc.

Raw material crusher: used to crush raw materials to a particle size suitable for subsequent processes. Common types include hammer mills, cage mills, roller mills, etc.

Ingredient system: Accurately weigh various raw materials according to formula ratios, usually including electronic scales, ingredient hoppers, etc.

Mixing equipment: Mix various raw materials thoroughly and evenly. Commonly used types include disc mixers, horizontal mixers, vertical mixers, etc.

Granulation equipment: Mix the evenly mixed raw materials into granules. Common types include disc granulators, drum granulators, extrusion granulators, etc.

Drying equipment: used to remove the water added during the granulation process, so that the fertilizer particles reach the required moisture content. Commonly used ones include rotary drum dryer, fluidized bed dryer, etc.

Cooling equipment: Cool and dry fertilizer particles to prevent clumping and improve storage stability. Commonly used ones include drum coolers, fluidized bed coolers, etc.

Screening equipment: used to screen out particles that do not meet the particle size requirements, commonly including vibrating screens, drum screens, etc.

Packaging equipment: Quantitatively package qualified fertilizer granules, commonly used include automatic packaging machines, sealing machines, etc.

Dust removal equipment: used to collect and process dust generated during the production process to meet environmental protection requirements. Commonly used ones include bag filters, cyclone dust collectors, etc.

Control system: including PLC control cabinet, touch screen, sensors, etc., used to automate the operation of the entire production line, improve production efficiency and product quality.

These devices constitute the main part of the NPK fertilizer production line, and the selection and configuration of each device need to be determined based on specific production needs, raw material characteristics, production capacity requirements, and other comprehensive factors. When designing a production line, it is also necessary to consider the connection between equipment, material transportation paths, energy consumption, and environmental requirements to achieve efficient and stable operation of the production line.

Organic fertilizer production line is a kind of equipment to process organic materials into organic fertilizer after a series of treatment. In this process, it is very important to decompose organic materials. Many users don’t know how organic materials are decomposed in organic fertilizer production equipment. Here is a brief explanation.

In the process of decomposition of organic materials, organic materials become small molecular humic acid under the decomposition of microorganisms, decompose unusable nutrients into available nitrogen, phosphorus and potassium, and transform macromolecular proteins into small molecular amino acids to realize the degradation of organic materials, which is a process of organic matter transformation.

At the same time, the compost material also gathers a lot of heat to make the temperature of the pile body reach above 60 ℃, and for a period of time, it has a killing effect on pathogenic bacteria and weed seeds, etc., to achieve the process of harmless composting. The low-temperature aging process of organic fertilizer can enable microorganisms to reproduce gently and continue to decompose organic materials. In addition, in the process of propagation and decomposition of organic materials, it can secrete a large amount of biostimulants to improve the quality and efficiency of organic fertilizer.

However, a large amount of oxygen is required during the active period of microorganisms. The height of trough compost is high, and it is difficult for oxygen to enter. Therefore, external force is required to force aeration into the pile body. Use organic fertilizer turning equipment to process materials, with high ventilation rate and full automatic control. The fermented materials are then processed into organic compound fertilizer using a rotary drum granulator or other granulation equipment.

The rotary drum granulator may encounter various malfunctions in the NPK fertilizer production line, which may affect production efficiency and product quality. Here are some common faults and their causes:

Uneven particles:

This may be caused by uneven mixing of raw materials, malfunction of the water spray system (such as nozzle blockage or unstable water pressure), or improper setting of the drum speed. Inconsistent particle size and shape can reduce the effectiveness and market value of fertilizer use.

Wall sticking phenomenon:

The material may adhere to the inner wall of the drum during the granulation process, leading to a decrease in granulation efficiency and even blockage. This is usually due to the high moisture content of the material or improper setting of the tilt angle of the drum.

Equipment wear and tear:

The inner wall of the drum, mixing device and other components will wear and tear due to material friction and corrosion during long-term operation, affecting the performance and service life of the granulator. Regular inspection and maintenance are necessary.

Transmission system malfunction:

Transmission components such as motors, reducers, chains, or belts may be damaged due to overload, poor lubrication, or aging, resulting in the inability of the drum to rotate normally and seriously affecting production.

Poor sealing:

If the sealing components of the rotary drum granulator age or are damaged, it can cause dust and moisture to enter, affecting equipment performance and even causing motor short circuits. Maintaining a good sealing condition is crucial for the normal operation of the equipment.

Control system malfunction:

Electronic devices and sensors used to control drum speed, water spray system, temperature, and humidity may malfunction, resulting in inaccurate parameter control during the production process, affecting particle quality and production efficiency.

Material blockage:

The inlet or outlet may be blocked by material clumping or oversized particles, resulting in poor material flow and affecting continuous production.

Vibration and noise:

Equipment imbalance, loose fasteners, or worn bearings can all cause abnormal vibrations and noise, which can accelerate equipment wear and affect the health of operators over long-term operation.

In order to reduce the occurrence of these faults, maintenance personnel need to conduct regular equipment inspections, including cleaning, lubrication, fastening, and replacement of worn parts, as well as calibration and maintenance of the control system. In addition, operators should receive appropriate training to understand the correct operation and troubleshooting methods of the equipment, in order to ensure the stable operation of the rotary drum granulator and the efficient production of the NPK fertilizer production line.

The application of rotary drum granulator in agriculture is mainly concentrated in the field of fertilizer production, and its specific applications include:

NPK fertilizer production:

NPK fertilizer is a widely used compound fertilizer in agriculture, which contains the three main nutrients required for plant growth: nitrogen (N), phosphorus (P), and potassium (K). The rotary drum granulator can evenly mix and granulate NPK raw materials, producing granular fertilizers with uniform particle size, moderate hardness, and good flowability, which are easy to store, transport, and use, and also improve the efficiency of fertilizer use.

Organic fertilizer production:

Organic fertilizers are usually made from organic materials such as animal and plant residues, livestock and poultry manure, and urban organic waste. The rotary drum granulator can process and granulate these organic raw materials appropriately to produce granular fertilizers rich in organic matter, which helps improve soil structure and enhance soil fertility.

Microbial fertilizer production:

Microbial fertilizers refer to fertilizers containing specific beneficial microorganisms that can improve soil environment and promote plant growth. The rotary drum granulator can mix microorganisms with carrier materials and granulate them in the production of microbial fertilizers, ensuring the activity and stability of microorganisms during storage and use.

Production of slow-release fertilizers:

Slow release fertilizers can continuously release nutrients over a long period of time, avoiding waste and environmental pollution caused by excessive release of nutrients at once. The rotary drum granulator can add slow-release materials during the production process to form granular fertilizers with slow-release properties through granulation.

Production of specialized fertilizers:

The rotary drum granulator can also be used to produce specialized fertilizers for specific crops or soil conditions, such as rice specific fertilizers, fruit tree specific fertilizers, etc. By adjusting the raw material ratio and granulation parameters, granular fertilizers that meet specific needs can be produced.

Production of soil amendments:

In addition to fertilizers, rotary drum granulators can also be used to produce soil amendments, such as particles containing humic acid, to improve soil structure, enhance soil water retention and permeability.

The application of rotary drum granulator in agriculture not only improves the production efficiency and quality of fertilizers, but also promotes sustainable development of agriculture. By improving the efficiency of fertilizer use, it reduces the negative impact on the environment and meets the needs of modern agriculture for efficient and precise fertilization.

 The composition of organic fertilizer is complex, so it is very important to be reasonable in application. The manufacturer of fertilizer granulator equipment suggests that we pay attention to the following two points.

1. Organic fertilizer should be fully decomposed before application. If some animal manure, such as pig manure, cattle manure and sheep manure are directly applied to the soil without fermentation and decomposition, the decomposed organic fertilizer in the soil will be decomposed and fermented by microorganisms, and the ammonia gas produced will easily cause crop root burning, and some will breed weeds and spread diseases and insect pests.

We advocate the use of compost turning machine to fully ferment the manure before application. The compost is moistened with water and put into the fermentation tank to make the temperature reach 35-40 ℃. When the manure is fully fermented at high temperature, it can kill the eggs and weed seeds in the compost, which is safer and more effective.

2. Organic fertilizer should not be concentrated or applied too much. Especially in the dry land crop fertilization, if the organic fertilizer is directly applied between the rows or near the root of the crop, because of the small water holding capacity of the dry soil, the concentration around the root system is too high. After the root system contacts the fertilizer pile, it will cause the physiological water loss of the crop and form the reverse osmosis phenomenon. The crop will not only not absorb the nutrient, but also make the water and nutrient in the root system seep out, making the crop grow badly or wilt However, water loss and dead seedlings caused soil nutrient imbalance.

The fertilizer made by the NPK fertilizer manufacturing process cannot alleviate soil problems, and organic fertilizer has a great effect on fertilizing the soil. Therefore, organic fertilizer should be used as a base fertilizer and mixed evenly in the soil to integrate with the soil. When applying organic fertilizer during the growth period, it should be applied in trenches or in a hole. After application, cover the soil and must not spread it on the ground. Leafy vegetables generally should not be sprayed with high-concentration liquid organic fertilizer as foliar fertilizer.