Author: organic fertilizer production line

The workflow of a rotary drum granulator is a continuous process, mainly involving several key steps such as raw material preparation, granulation, particle screening, and post-treatment. The following is a typical workflow of a rotary drum granulator:

Raw material preparation:

The raw materials (such as the components of NPK fertilizers) are first crushed to an appropriate particle size to ensure uniform dispersion during the granulation process. Subsequently, the raw materials are mixed to achieve the desired chemical composition ratio. The mixed raw materials are fed into the cylindrical granulation chamber of the rotary drum granulator through the feeding port.

Granulation process:

Entering the granulation chamber: The raw materials enter the granulation chamber, which is usually a tilted cylinder with specific structural designs inside, such as blades or elevators, to promote the rolling and mixing of the raw materials.

Water spray/binder addition: spray an appropriate amount of water or binder evenly to raw materials through the spray system in the granulation room. The amount of water or binder added needs to be precisely controlled to ensure the granulation effect and particle quality.

Rolling and Agglomeration: As the cylinder rotates, the raw materials roll inside, and small particles aggregate into larger particles through bonding. The inclination and rotation speed of the cylinder can be adjusted to control the size and shape of the particles.

Particle screening:

Discharge and screening: After granulation is completed, the particles are discharged from the discharge port of the granulation chamber. These particles will pass through a screening device, usually a rotating screen or vibrating screen, to remove particles that are too small or too large, ensuring uniform particle size in the final product.

Post processing:

Drying: The screened particles may need to enter a dryer to remove excess moisture added during the granulation process, ensuring the stability and storage performance of the particles.

Cooling: Dried particles may need to be cooled to reduce temperature and prevent possible clumping or deterioration during subsequent processing.

Packaging: The cooled particles can undergo final packaging for sale or storage.

The workflow of the rotary drum granulator is a highly integrated and automated continuous production process, and the design of each link and the adjustment of operating parameters have a significant impact on the quality and production efficiency of the final product. By precisely controlling the mixing of raw materials, the amount of moisture/binder added, the rotation speed and tilt angle of the cylinder, etc., granular products that meet specific needs can be produced.

The rotary drum granulator has demonstrated significant advantages in multiple industries due to its unique design and efficient granulation performance, including:

High granulation efficiency:

The rotary drum granulator can quickly convert powder or fine granular materials into uniform and dense particles. Its continuous production mode and efficient material processing capacity make the granulation process fast and high-yield.

Strong adaptability:

This device is capable of processing various types of raw materials, including but not limited to dry powder, wet powder, organic and inorganic materials. It has good adaptability to the humidity and viscosity of raw materials, and can adjust granulation parameters according to different raw material characteristics to achieve the best granulation effect.

Controllable granulation effect:

By adjusting parameters such as the rotation speed, tilt angle, water spray system, and raw material feeding rate of the drum, the size, shape, and density of particles can be flexibly controlled to meet the specific needs of different products.

Relatively low energy consumption:

The rotary drum granulator utilizes the natural process of physical rolling and chemical bonding for granulation. Compared to other granulation technologies such as high-pressure extrusion granulation, it has lower energy consumption and is more economical and environmentally friendly.

Easy operation and maintenance:

The equipment structure design is reasonable, the operating interface is friendly, and it is easy for operators to control and monitor the granulation process. Meanwhile, the maintenance of the rotary drum granulator is relatively simple, easy to clean and maintain, which helps to extend the service life of the equipment.

Stable particle quality:

By precisely controlling the granulation process, particles with uniform particle size, moderate hardness, and good flowability can be produced. These particles have good physical and chemical stability, which is conducive to storage and transportation.

Wide applicability:

The rotary drum granulator is not only widely used in industries such as fertilizers, chemicals, and food, but also has important applications in pharmaceuticals, environmental protection, minerals, and other fields. Its wide applicability makes it the preferred equipment for granulation processes in many industries.

High cost-effectiveness:

Although the initial investment may be high, the high production efficiency, low operating costs, and long-term stability of the rotary drum granulator make it cost-effective in long-term operation, which can bring high returns to manufacturers.

In summary, the rotary drum granulator plays an important role in many industrial fields due to its high efficiency, strong adaptability, controllable granulation effect, and low energy consumption. It is one of the key equipment for achieving large-scale production of granular products.

Compost turner machine, NPK fertilizer manufacturing process, organic fertilizer manufacturing process, crusher, mixer, screening machine are our main products. The chain plate compost turning machine has unique advantages in the production of organic fertilizer. The following is its instructions.

1. Chain plate compost turning machine is suitable for large-scale fermentation tanks with high and wide tanks, which can save composting workshop area and reduce civil engineering investment. The traditional trough type overturning and throwing machine is generally suitable for the height of 0. 8~1。 5 m fermentation tank, and the machine is suitable for height 1. 5~2。 It can meet the requirements of large-scale and wide tank operation. Compared with small-scale fermentation tank, the area of composting workshop can be reduced by 40 ~ 60%, and the construction cost of fermentation tank can be reduced by at least 1 / 3.

2. The chain compost turning machine adopts the supporting plate structure of chain drive and rolling support, which has small turning resistance, energy saving and is suitable for deep groove operation. The tipping support plate is equipped with flexible tension and elastic damping system to protect the transmission system and working parts for efficient operation. Through the horizontal and longitudinal shifting mechanism, the overturning parts can be operated in any position in the same fermentation tank, which improves the operation flexibility and reduces the installation capacity and power distribution requirements of the matching motor.

3. Compost turner machine is equipped with a strong and stable hydraulic lifting system to lift the overturning parts. At the beginning and end of turning, the hydraulic lifting system can be used to realize the lifting and lowering of tipping components easily through remote control or field operation, which is stable, reliable and fast.

4. The control cabinet is used to control the operation of the whole machine, and the manual control and automatic control are combined. The machine can be remotely controlled to move forward, move horizontally, flip and retreat quickly. Field operators don’t have to work at random, they can complete all operations by remote control at one end or far away of fermentation tank, which greatly improves the field environment of organic fertilizer manufacturing process.

Drum granulator is a granulation equipment widely used in the fertilizer, chemical, food and other industries. Its working principle is based on the combination of physical and chemical processes, mainly completed through the following steps:

Raw material mixing and pretreatment:

Firstly, various raw materials (such as nitrogen, phosphorus, and potassium compounds in NPK fertilizers) are mixed in a certain proportion. The raw materials may need to be crushed, sieved, or pre dried to ensure their uniform dispersion during the granulation process.

Granulation process:

The raw materials enter the cylindrical granulation chamber of the rotary drum granulator, which is composed of a tilted and slowly rotating cylinder. The raw material forms a spiral motion under the action of the rotational force and centrifugal force of the cylinder.

In the granulation room, the raw materials are evenly sprayed with appropriate amount of water or binder through the spray system. The function of water or binder is to enhance the cohesion between particles and promote the aggregation of small particles into larger ones. This process is called “drum granulation” or “rotary granulation”.

Particle growth and solidification:

As the cylinder rotates, small particles gradually grow through rolling and collision. Moisture or binders allow the components in the raw materials to adhere at the contact points, forming a more stable structure.

During the granulation process, the size and shape of the particles can be controlled by adjusting the rotation speed of the cylinder, the water spray system, and the feeding rate of the raw materials. The longer the particles roll inside the cylinder, the larger the particle size will generally be.

Particle screening and post-processing:

After granulation is completed, the particles are passed through a sieve or screening device at the end of the cylinder to remove oversized or undersized particles, ensuring uniform particle size in the final product.

The particles may also need to be dried to remove excess moisture and prevent clumping during storage and transportation. In some cases, cooling, polishing, or coating treatment may also be necessary to improve the hardness and stability of the particles.

The working principle of a rotary drum granulator is to use the combination of physical motion (such as rotation and rolling) and chemical action (such as the addition of moisture or binders) to form uniform and stable particles of raw materials. This process can not only improve the efficiency of raw material utilization, but also customize the size, shape, and hardness of particles according to specific needs to meet the needs of different industries and applications.

Drum granulator is a device that utilizes physical and chemical principles to process powder or fine granular materials into larger and more uniform particles. Its working principle mainly includes the following steps:

Raw material preparation:

The raw materials are first sent to the granulator, which can be dry powder, wet powder, or pre treated materials. The initial state and composition of the raw materials will affect the parameter settings of the subsequent granulation process.

Entering the drum:

The raw materials enter the cylindrical granulation chamber of the rotary drum granulator through the feeding port. The granulation chamber is usually a tilted cylinder, which may be equipped with lifting plates, blades, or other structures inside to promote the rolling and mixing of materials.

Humidification and bonding:

In the granulation room, evenly spray appropriate amount of water or binder to the raw materials through the spray system. The addition of water or binder is crucial in the granulation process, as their function is to bond the particles in the raw material together and form larger particles. The amount of humidification and the type of binder need to be precisely controlled based on the characteristics of the raw materials and the properties of the target particles.

Rolling granulation:

As the granulation chamber rotates, the material rolls inside, and small particles aggregate into larger particles under the action of moisture or binder. The inclination angle and rotation speed of the cylinder can be adjusted to control the size and shape of the particles. By combining physical rolling and chemical bonding, the material gradually forms the required particles.

Particle screening:

After granulation is completed, the particles are discharged through the discharge port of the granulation chamber. These particles are usually subjected to a screening device, such as a vibrating screen or a rotary screen, to remove particles that are too small or too large, ensuring uniform particle size in the final product.

Post processing:

The screened particles may require further processing, such as drying, to remove excess moisture added during the granulation process and avoid clumping during storage or transportation. In some cases, cooling, polishing, or surface treatment may also be necessary to improve the physical properties of the particles.

The workflow of a rotary drum granulator is a continuous process, which can produce granular products with specific physical and chemical properties by precisely controlling parameters such as raw material mixing, humidification amount, cylinder rotation speed, and tilt angle. This process is not only applicable to industries such as fertilizers, chemicals, and food, but also has a wide range of applications in agriculture, pharmaceuticals, and environmental protection.

The npk fertilizer production line will generally crush the fermentation materials that have completed the secondary aging and stacking process and enter the mixing and mixing system. Before mixing and mixing, according to the formula, N, P, K and other trace elements will be added into the mixing and mixing system to start mixing.

Types of potash fertilizer
1. Potassium chloride is more suitable for cotton, wheat and other crops, but not suitable for melons and fruits.

2. Potassium sulfate, potassium content as high as 52-53, is a high purity, no chloride ion potassium fertilizer, more suitable for melon and fruit application.

3. Potassium nitrate, nitrogen and potassium binary compound fertilizer, containing nitrate nitrogen, has fast absorption and quick effect, but it is not suitable for paddy field.

4. Potassium dihydrogen phosphate, phosphorus potassium binary compound fertilizer, on fruit expansion and coloring are effective, but excessive use will also lead to negative effects.

5. Professional phosphorus and potassium fertilizer, the use of phosphorus and potassium complementary special process, so as to achieve the expansion of fruit coloring, sweet and improve the quality of the first selected products. The manufacturing of NPK fertilizer can improve the efficiency of potassium fertilizer.The main function of potassium fertilizer

1. The application of potassium fertilizer can promote the photosynthesis of crops, promote crop fruiting, improve the cold resistance and disease resistance of crops, so as to improve agricultural yield.

2. The organic fertilizer manufacturing process deals with potassium fertilizer. Potassium exists in plants in the form of free potassium ions, which can promote the metabolism of carbohydrate and nitrogen.

3. Control and regulate the activities of various mineral nutrients, activate the activities of various enzymes, and control the transportation of nutrients and water. The internal pressure of cells is maintained to prevent the plant from withering.

4. Improve the quality of crop products, increase the protein content of grain crops, crude fat and palmitic acid content of oil crops, starch and sugar content of potato and sugar crops.

5. Increase fiber length, strength and fineness of fiber crops and cotton. Adjust the sugar acid ratio of fruit and increase the content of vitamin C.

6. Improve the shape, size, color and flavor of fruits and vegetables, and enhance their storability.

The rotary drum granulator is widely used in the production line of NPK fertilizers (nitrogen phosphorus potassium compound fertilizers) and plays a key role in the production process of NPK fertilizers. The following are several important aspects of the application of rotary drum granulators in NPK fertilizer production lines:

Raw material mixing and granulation:

The rotary drum granulator can effectively mix raw materials through its rotating cylindrical structure. The raw materials for NPK fertilizers usually include different proportions of nitrogen, phosphorus, potassium, and possibly trace elements. After these raw materials are mixed evenly in a drum, stable particles are formed by adding an appropriate amount of water or binder. The mixing and granulation process of the rotary drum granulator can ensure the uniform distribution of various components in NPK fertilizer, which is crucial for improving the efficiency of fertilizer use and crop absorption.

Control particle size and shape:

The rotary drum granulator can precisely control the size and shape of particles by adjusting its rotation speed and the parameters of the water spray system. This is very important for NPK fertilizers, as different crops and planting environments may require different specifications of granular fertilizers. For example, larger particles may be suitable for field crops, while smaller particles may be more suitable for fine planting or greenhouse environments.

Improve the stability of particles:

The components in NPK fertilizers, especially nitrogen and potassium, are prone to volatilization or decomposition. The rotary drum granulator can improve the stability of particles, reduce the loss of fertilizer components, extend storage time, and improve transportation safety through physical and chemical reactions during the granulation process.

Improve production efficiency:

The continuous operation mode and high processing capacity of the rotary drum granulator greatly improve the production efficiency of NPK fertilizers. For large fertilizer production enterprises, this can significantly increase production capacity and meet market demand.

Reduce energy consumption:

Although the operation of the rotary drum granulator requires a certain amount of power, compared to other granulation methods such as high-pressure extrusion granulation, its overall energy consumption is relatively low. This is because the rotary drum granulator utilizes the physical properties and chemical forces of the material itself, reducing the dependence on additional energy.

Strong adaptability:

The rotary drum granulator can process raw materials with different humidity and viscosity levels, which is a huge advantage for NPK fertilizer production, as the properties of fertilizer raw materials may vary depending on the season, source, and processing method. The flexibility and adaptability of the rotary drum granulator ensure the stable operation of the production line and the consistency of product quality.

In summary, the application of rotary drum granulators in NPK fertilizer production lines can not only improve the uniformity of fertilizer components and the stability of particles, but also bring significant economic benefits to fertilizer manufacturers by optimizing production efficiency and reducing energy consumption. At the same time, its adaptability to raw material characteristics and controllability of particle size and shape enable NPK fertilizers to better meet different agricultural needs and improve crop yield and quality.

Due to its unique granulation principle and efficient production performance, rotary drum granulators are widely used in multiple industries, including but not limited to:

Fertilizer industry:

Drum granulator is a key equipment in the production process of NPK fertilizers, phosphate fertilizers, potassium fertilizers, organic fertilizers, etc. It can process various raw materials such as urea, phosphate, potassium salt, etc., producing uniform and stable granular fertilizers, improving the efficiency and storage performance of fertilizers.

Chemical industry:

In the field of chemical engineering, rotary drum granulators can be used to produce particles of various chemical products, such as catalysts, dyes, plastic additives, detergents, desiccants, etc. By adjusting the granulation parameters, granular products with specific physical and chemical properties can be produced.

Pharmaceutical industry:

In the pharmaceutical industry, rotary drum granulators are used to granulate drug powders to improve their flowability and compressibility, facilitating the production of subsequent tablets, capsules, and other formulations. The granulation process can also improve the stability of drugs and reduce dust pollution.

Food processing industry:

In the field of food processing, rotary drum granulators can be used to produce granular food, such as seasonings, instant drinks, food additives, etc. The granulation process can improve the solubility, taste, and shelf life of food.

Environmental Protection Industry:

The rotary drum granulator can be used for waste recycling and treatment, such as granulating biomass waste (such as rice husks, sawdust) into biomass fuel, or treating sludge, industrial waste, etc., to improve the utilization value and treatment efficiency of waste through granulation.

Mineral and metallurgical industries:

In the fields of mining and metallurgy, rotary drum granulators are used to granulate mineral powder and metal powder to improve the transportation and processing performance of materials, such as in pellet production and metal powder pretreatment.

Ceramic and Building Materials Industry:

The rotary drum granulator also plays an important role in the production of ceramics and building materials, such as for producing ceramic raw material particles, refractory material particles, building additive particles, etc., to improve product performance and processability.

The reason why the rotary drum granulator has a wide range of applications is that it can process various forms of raw materials and produce granular products with specific physical properties. At the same time, its operation is flexible, production efficiency is high, and energy consumption is low, which can meet the special needs of different industries for granulation processes.

 Straw is one of the raw materials in the production of organic fertilizer, which is different from the manufacturing of NPK fertilizer and the treatment of livestock manure. There are special requirements and characteristics when straw is treated by organic fertilizer manufacturing process, which needs composting processing.

Production technology of organic fertilizer for processing straw
1. Traditional straw composting

The traditional straw composting technology has the advantages of long fermentation time, poor fermentation effect and simple equipment, which is suitable for small-scale application. The method of straw fermentation is as follows: firstly, the straw is crushed with a pulverizer, but not excessively crushed, and the factors such as moisture, carbon nitrogen ratio and pH value are adjusted. The optimum ratio of carbon to nitrogen is 25:1. Therefore, adjusting the ratio of carbon and nitrogen in composting materials is an effective measure to accelerate the maturity and improve the humus coefficient.

Generally, the preparation methods of fermentation compost include adding phosphate fertilizer, adding lime, adding manure and urine, etc. Straw should be soaked with enough water to make the moisture content of straw reach 60% – 70%, which is the key to success or failure of composting. The compost piles without decomposition agent are usually stored for about 40 days in summer, and the temperature in the compost can rise to 50 ~ 60. After the high temperature stage, the compost can be dumped inside and outside. The standard of rotten is: black, rotten and smelly, that is, straw turns brown or black brown. When wet, it is soft and elastic, and when dry, it is brittle and easy to be broken.

2. New-type straw organic fertilizer manufacturing process

Use large-scale, high-efficiency organic fertilizer fermentation equipment and biochemical technology to accelerate crop straw rot. That is, the method of mixing with fast decomposing agent and using compost turning machine to increase the temperature and speed of compost and shorten the period of compost. Generally, the straw is mixed with livestock manure (or urea) to meet the nitrogen required for microbial fermentation. Use a complete set of organic fertilizer turning machine for trough turning and throwing fermentation to improve fermentation efficiency, shorten fermentation cycle, and increase production capacity.

In the NPK fertilizer production line, both rotary drum granulators and extrusion granulators have their unique advantages and limitations. The choice of which one to use mainly depends on production needs, raw material characteristics, and the quality requirements of the final product. The following are the main advantages and disadvantages of these two types of granulators:

Rotary Drum Granulator

advantage:

Wide applicability: The rotary drum granulator can process materials with high viscosity and high moisture content, and is suitable for granulating various complex components in NPK fertilizers.

Particle uniformity: By adjusting the rotation speed of the drum and the water spray system, the size and shape of the particles can be controlled to ensure the uniformity of the particles and the uniform distribution of fertilizer components.

Good mixing effect: During the granulation process, the materials roll and mix in the drum, which helps to improve the uniformity of various components in NPK fertilizer.

High flexibility: By adjusting process parameters, granular fertilizers of different specifications and characteristics can be produced.

Disadvantages:

Relatively high energy consumption: The rotary drum granulator requires a large amount of power during the granulation process, and its energy consumption may be higher compared to the extrusion granulator.

Large footprint: The equipment size of rotary drum granulators is usually large, requiring a large production space.

High drying requirements: Due to the possibility of water spraying during the granulation process, the subsequent drying process requires high standards to ensure the stability and storage performance of the particles.

Extrusion granulator

advantage:

Low energy consumption: The extrusion granulator forms particles through physical extrusion, which has lower energy consumption compared to the rotary drum granulator.

High production efficiency: The extrusion granulator has a fast production speed and is suitable for large-scale fertilizer production lines.

High particle strength: The particles produced by the extrusion granulation mechanism have high hardness and are not easily broken, making them suitable for long-distance transportation and long-term storage.

Simple operation and maintenance: The structure of the extrusion granulator is relatively simple, and the operation and maintenance costs are low.

Disadvantages:

Limited applicable materials: Extrusion granulators are more suitable for processing dry or semi dry materials, and their granulation effect may be poor for high moisture or high viscosity materials.

Particle shape limitation: Squeezing granulators usually produce particles with more regular shapes, but may not have as diverse particle shapes as drum granulators.

High requirements for raw material pretreatment: In order to ensure the effectiveness of extrusion granulation, the raw materials may need to undergo additional pretreatment, such as crushing and mixing, to ensure the uniformity and suitable physical properties of the materials.

summary

The selection of rotary drum granulator and extrusion granulator in NPK fertilizer production line needs to comprehensively consider factors such as raw material characteristics, production scale, product requirements, and cost-effectiveness. In practical applications, it may be necessary to combine these two types of granulators to achieve optimal production efficiency and product quality. For example, first use a rotary drum granulator for initial granulation and mixing, and then use an extrusion granulator for secondary granulation to improve the hardness and stability of the particles.