Category: organic fertilizer equipment

The entire production process of biofertilizer project is divided into ten steps, each of which will directly affect the quality of bio-organic fertilizer production line, which cannot be reduced in production.

The following is the process of producing biological organic fertilizer:
1. The raw materials such as animal manure must be fermented and rotted. During the entire fermentation process, harmful bacteria inside can be killed, which is also the most important in the entire organic fertilizer manufacturing process.

2. Secondly, the semi-wet material crusher of organic fertilizer crushing equipment is used to preliminarily decompose the raw materials.

3. Ingredients are a key step in fertilizer production. Its main function is to add appropriate ingredients in proportion to make the organic fertilizer rich in organic matter and improve its quality.

4. Granulation is required after the materials are evenly mixed, which is also the most important part of the whole process.

5. The material gets high temperature during the drying process, and then it needs to be cooled. Because water cannot be used for cooling, a cooling device is needed here.

6. Screening is the need to screen out the unqualified fertilizer, and the unqualified materials will return to the production line for qualified processing and processing again. The screening equipment here has the advantage of being efficient and easy to operate.

7. the stirred material into the required particles, especially suitable for high viscosity materials.

8. The material of the stirring container must meet the requirements of the production process, such as pressure resistance, temperature resistance, medium corrosion resistance, and product cleanness. Due to different materials, the manufacturing process and structure of the stirring container are also different.

9. Conveying is to transport the finished fertilizer to a higher place, and it is prepared for convenient storage.

10. Packaging is the last link in fertilizer equipment. In order to protect the product during circulation, facilitate storage and transportation, and promote sales, the overall name of the container, material, and auxiliary materials used in accordance with certain technical methods; also refers to the above to achieve the above. Objective To apply certain technical methods and other operating activities in the process of using containers, materials and auxiliary materials.

The equipment required for the production of bio-organic fertilizers are fermentation stackers, shredders, mixers, fertilizer granulator machine, dryers, sieving machines, and packaging machines.

Bio-organic fertilizer equipment has always been the star product of our factory. There are many production processes for producing bio-organic fertilizer, and each production process has its own characteristics. The key to the production process of biofertilizer project is the choice of granulation method. According to the production process requirements, the current granulation methods commonly used in bio-organic fertilizer are mainly disc granulation and stirring granulation. Due to different requirements of raw materials for different granulation methods, there are differences in the production process of biological organic fertilizer. At present, our organic fertilizer equipment has the following production processes.

Using the disk granulation production process, the raw materials need to be dried to remove a certain amount of water (when drying, the raw materials are sterilized), and then crushed, and then a certain amount of acid and alkali is added to adjust the PH of the carrier and mixed with the inorganic fertilizer part, and sent into The disc granulator sprays a certain amount of bacteria during the granulation process, and the granulated product is dried and sieved at low temperature to obtain the finished product.

The tooth-granulation granulation process is to use the high-speed rotating mechanical stirring force and the aerodynamic force generated thereby to continuously realize the process of mixing, granulating, spheroidizing and densifying the fine powder in the machine, thereby achieving the purpose of granulation. The shape of the particles is spherical, the sphericity is ≥0.7, the particle size is generally between 0.3-3 mm, and the granulation rate is ≥90%. The size of the particle diameter can be appropriately adjusted by the material mixing amount and the spindle speed. Generally, the lower the mixing amount, the rotation speed the higher, the smaller the particles, and vice versa.

From the process flow, the two processes have the same equipment before granulation and the area is about the same, so the difference in investment mainly depends on the fertilizer granulator machine. The same is the case of a 10,000 t / a scale production capacity. 4000 ～ 5000 yuan / set, while the stirring granulator is generally 50,000 yuan / set (the specific price is determined by the specific specifications and the manufacturer’s price is for reference only), and the low temperature dryer is 12-15 thousand yuan / set. Therefore, from the perspective of investment, the disc granulation production process is relatively higher than the extrusion granulation process, and the specific production process needs to be tailored by a professional technical team.

The future development potential of organic fertilizer production lines is enormous. Due to the current agricultural situation in China, organic fertilizer raw materials are abundant and of high quality, and the market demand for organic fertilizer is also large. The scale of use of organic fertilizer is also very wide, whether it is farmland or vegetable cultivation greenhouses, or the beautification of fruit trees, flower gardens, and soil improvement, organic fertilizer is widely used. It also conforms to the national agricultural development policy, indicating that the prospect of organic fertilizer production lines is very broad.

The organic fertilizer production line is composed of many small machinery and equipment, each of which affects, restricts, and complements each other. After a certain process flow, high-quality organic fertilizer can be processed. The production process of the organic fertilizer production line is as follows:

1. The raw materials, auxiliary materials, and fermentation agents are pre mixed evenly through the equipment in proportion, with a moisture content of about 60. They are transported by conveyor belts and distributed to the fermentation tank through shuttle belt distribution machines.

2. In order to fully ferment the materials in the fermentation tank, a chain plate tipping machine is used to flip and shift the materials. At the same time, the aeration system is used to aerate the bottom of the tank, allowing the materials to undergo aerobic fermentation.

3. The fermentation of the material is basically completed in the fermentation tank for about 7 to 10 days. Under the flipping displacement of the flipping machine, the material is flipped to the discharge end, and then transported to the aging tank through the pool changing discharge machine, discharge belt machine, and shuttle type distribution machine for secondary fermentation of aging, so that the material is thoroughly decomposed.

4. The decomposed materials are transported to the granulation workshop through conveyor belts, and are screened and processed by drum screening machines and vertical crushers to remove large pieces of material;

5. The screened materials and other inorganic nutrients are proportionally transported to a dual shaft paddle mixer using a batching belt scale for mixing. Uniformly mixed materials can be packaged as powder products, and can also be granulated by adjusting the moisture content to around 40.

6. Materials with a moisture content of about 40% are produced into columnar semi-finished products through a granulator, which are then shaped into spherical granular semi-finished products through a shaping machine. They are transported by a conveyor belt to a tubular dryer for low-temperature drying, and then screened and cooled by a cooling screening machine to reduce the moisture content to between 15 and 30. They can also be coated and packaged as needed;

7. The finished particles are transported to the packaging workshop through bucket elevators and finished product conveyor belts, and are packaged using automatic measuring packaging scales and manually stacked.

The construction of an organic fertilizer production line has a market opportunity. Nowadays, people are pursuing a high-quality life, and their pursuit of food quality is also increasing. Under the strong call of national policies, more and more farmers are applying organic fertilizer, which has a long-lasting effect and contains various nutrients that crops need. Maintaining fertilizer and water can also prevent and control diseases and pests. The small organic fertilizer production line has a very broad profit margin and is an ideal project.

Livestock and poultry manure is a relatively good quality organic fertilizer. Livestock and poultry manure must be decomposed by a decomposing agent, and the parasites and eggs in livestock and poultry manure, as well as some infectious bacteria, are inactivated and deodorized through the process after decomposing. The production process of livestock manure organic fertilizer is closely related to the equipment configuration of organic fertilizer production line. Generally, the complete set of equipment of organic fertilizer production line mainly consists of fermentation system, drying machine, deodorization and dust removal system, crushing machine, batching system, mixing machine, fertilizer granulator machine, and screening system and finished product packaging system. The production process of livestock manure organic fertilizer roughly includes: raw material selection (livestock manure, etc.) → drying and sterilization → mixing of ingredients → granulation → cooling and screening → metering sealing → finished product storage.

Performance characteristics:
Production process design of livestock manure organic fertilizer production line includes: 1. Efficient compound strain and its propagation technology; 2. Advanced raw material allocation technology and biological fermentation system; 3. The best special fertilizer formula technology (can be flexibly according to the local Soil and crop characteristics, design the best combination of product formula); 4. Reasonable secondary pollution (exhaust gas and worry) control technology; 5. Design and manufacturing technology for complete sets of process equipment for fertilizer production.

The construction scale of animal manure organic fertilizer production line equipment configuration is generally 30,000 to 100,000 tons per year. Comprehensive consideration must be given to local resources, market capacity, and market coverage. The investment scale and product plan design need to be formulated according to the following conditions: characteristics of raw material resources, local soil conditions, local planting structures and main crop varieties, factory site conditions, and the degree of automation of production.

Bio-organic fertilizer is based on organic waste from livestock and poultry manure, crop stalks, agricultural by-products, and food processing. It is equipped with a multi-functional fermentation strain agent to quickly deodorize, rot, and dehydrate, and then add functional biological strain An organic fertilizer containing a certain amount of functional microorganisms processed by an agent.

Bio fertilizer project production line contains the main equipment:
1. Automatic batching system: The automatic batching system is mainly composed of a feeding system, a weighing device, a silo, and a conveyor belt. And the static batching system has both the speed of dynamic batching and the accuracy of ordinary static batching (0.2%).

2. New type organic fertilizer granulator machine: It is designed and manufactured by wet continuous pusher granulation. This machine can not only granulate a variety of organic materials, especially for coarse fiber materials that are difficult to granulate using conventional equipment.

3. Horizontal mixer: This series of horizontal mixer is a new generation of mixing equipment developed by our company. The machine has high mixing degree and low residual amount, which is suitable for mixing organic fertilizer and inorganic fertilizer.

4. Drum sieve: The machine uses a combined sieve for easy maintenance and replacement. Its simple structure, convenient operation and stable operation are ideal equipment for compound fertilizer production.

5. Conveyor: suitable for coal, metallurgy, mining, chemical industry, building materials, docks, warehouses, construction sites, etc. for conveying bulk materials or bag-like articles, especially suitable for use in environments such as fertilizer plants and cement plants where manual loading is required Save a lot of staff.

6. Dryer: This machine has the characteristics of beautiful appearance, simple operation, low energy consumption, long life, uniform drying and convenient maintenance. It is a relatively advanced compound fertilizer drying equipment in China.

7. Hot blast stove: The hot blast stove boiler adopts backwater ejection and other technologies to solve the problems of tube plate cracks in boiler shell boilers, drum bulging under the drum, water wall burst, low thermal efficiency, insufficient output, and poor coal adaptability.

8. Packaging scale: The packaging scale is mainly composed of automatic quantitative packaging scale (consisting of storage hopper, feeder, weighing bag hopper, kneading mechanism, computer control, pneumatic execution part, etc.) and optional parts (conveyor, sewing Mouth machine / heat sealing machine).

 NPK fertilizer production line with steam drum granulation production is a process to achieve thermal granulation, by raising the temperature of the material, increase the solubility of the salt of the granulation water system, so as to achieve low moisture content to meet the needs of the material grain ingenuity of the liquid phase, reduce the thermal energy consumption of the drying process, improve the production capacity of equipment. Therefore, the quality of granulation performance of compound fertilizer equipment is one of the keys to determine the yield and quality of compound fertilizer produced by rotary drum granulator.

Next, Zhengzhou Huaqiang Heavy Industries will analyze the advantages and disadvantages of rotary drum type fertilizer granulator machine in the NPK fertilizer production line for you.

The advantages of rotary drum granulator in the NPK fertilizer production line
1, save the urea concentrate granulation, packaging, transportation and other costs, but also eliminate the solid urea compound fertilizer when broken, solid material meter, transportation and other troublesome operations.
2, urea solution directly involved in granulation, can make compound fertilizer production line granulation material granulation temperature from about 40 degrees C to about 60 degrees C, granulation moisture from 5% to 2.5%, greatly reducing the drying load.
3, the use of urea solution stickiness, in the granulation machine to help the material granulation, improve the granulation rate of the material, so that its production capacity increased by about 30%, the corresponding reduction of power consumption 30%.
4, compound fertilizer equipment products from the original 12N to 30N, the finished moisture from 2.0% to 1.00%, the appearance of the particles improved, the block situation can be slowed down.

The disadvantage of rotary drum granulation in the NPK fertilizer production line
1, anti-material more;
2, dust large;
3, power consumption is large;
4, the particles are not smooth and round enough;
5, compound fertilizer production line operating environment is not good.

Organic fertilizer equipment inevitably experiences wear and tear during operation. Within the safe service life of the equipment, these controllable damages and wear may not have a significant impact on the equipment, so there is no need to worry too much. However, severe wear and tear is different. Some only affect the normal operation of the equipment, while others can also cause safety hazards. Therefore, manufacturers should carry out inspection and management of the wear and tear of organic fertilizer equipment.

Eight unexpected wear and tear situations of organic fertilizer equipment:

1. Break-in wear: This is the most common normal wear and tear of organic fertilizer equipment. When friction begins between new friction surfaces, the wear rate is faster. After reaching a certain level, the actual contact area between the friction surfaces increases, and the unit pressure decreases accordingly, resulting in a decrease in wear rate.

2. Grinding wear: Wear caused by hard particles cutting off the worn surface.

3. Adhesive welding wear: caused by factors such as too light a certain material on the friction surface, excessive contact pressure, poor lubrication conditions, or high temperature.

4. Fatigue wear: This occurs more frequently on friction surfaces with rolling friction, manifested in the formation of crack surfaces on the friction surfaces of parts, leading to metal surface detachment. The main reason is that the contact pressure of the surface material exceeds the compressive limit strength due to compression, elastic extension, and cold and hot effects.

5. Corrosion and wear: The friction surface undergoes oxidation and deterioration due to the continuous infiltration of media such as water vapor, chemical gases, or oxides between the friction surfaces. Generally, it is oxidation wear and chemical corrosion wear.

6. A relatively easy factor to cause wear and tear on organic fertilizer equipment is dust. Organic fertilizer equipment actually generates a certain amount of dust during operation and after discharge. If not cleaned and maintained in a timely manner, the dust will enter various connections within the equipment, accumulating over time. As the amount increases, the friction at the equipment connections will increase, and even bacteria will accumulate, causing corrosion to the equipment and affecting its performance. So we require the staff to conduct a comprehensive inspection and maintenance of the organic fertilizer equipment in addition to using it.

7. During the operation of organic fertilizers, our staff also need to pay attention to the lubrication of the equipment connections. Long term use of the equipment poses a severe challenge to equipment lubrication. Once there is a lag, the friction force of the equipment will increase. Only high lubrication will provide good power support for the operation of organic fertilizer equipment, and staff should develop a good habit of regularly cleaning and maintaining the equipment.

8. In addition, we need to pay special attention to motor friction, otherwise it will affect the effectiveness of organic fertilizer equipment. The staff should pay attention to constantly checking the operation of the motor. Especially before running under load, the circuit of the motor should be checked and updated immediately if there is any damage to ensure safe operation.

The above 8 accidental damages and their causes can actually be avoided through normal maintenance in daily life. There are 5 daily maintenance elements to be done.

1. Machines and parts that have a significant impact on the system and have no maintenance time.

2. Patrol and inspect the oil supply, abnormal noise, vibration, temperature, etc. of the machine and parts; If these machines and parts are not inspected and processed daily, they may cause major accidents.

3. Although the impact on the system is relatively small, machines and parts that are prone to abnormal conditions.

4. Conduct corresponding inspections at the start and end of the day.

5. Regular inspection, adjustment, and cleaning of organic fertilizer equipment should be carried out.

Note on equipment selection of organic fertilizer production line, divided into the following six points:
1. Determine the size of the organic fertilizer equipment, such as how many tons are produced annually, or how many tons are produced in one hour. The size is determined before the price can be determined.

2. Determine the shape of the granules, which is the type of fertilizer granulator machine to choose. Is it powdery, columnar, oblate, or standard? The commonly used granulating organic fertilizer equipment includes: disc granulator, drum granulator, wet granulator, roll extrusion granulator, flat die granulator, ring membrane granulator. The selection of granulator should be determined according to the local fertilizer sales market. The shape of the particles is different, and the processes of the organic fertilizer equipment are also different.

3. Understand the configuration of organic fertilizer equipment, the configuration level is different, the price of organic fertilizer equipment is different, the amount of labor is different, the stable and high yield of organic fertilizer equipment is different: the general configuration is increased, automatic batching device, automatic Packaging device, automatic quantitative feeding device, cyclone dust removal and ink dust removal.

4. Choose the type of fertilizer produced, is it compound fertilizer or organic fertilizer? For the same output, the equipment for producing organic fertilizer generally takes into account the high water content, the strains are not resistant to high temperature, and the model is generally larger than the compound fertilizer model. Organic fertilizer types can be divided into four types, pure organic fertilizer, organic-inorganic compound fertilizer, biological organic fertilizer, compound microbial fertilizer, different types of organic fertilizer equipment is also different.

5. Selection of compost turning machine, the general fermentation forms are: stack fermentation, shallow fermentation, deep tank fermentation, tower fermentation, rotary drum fermentation, different fermentation methods, and different organic fertilizer equipment . Generally, shallow tank stacker is suitable for the principle of aerobic fermentation.

6. the level of environmental protection requirements, low environmental protection requirements generally choose heavy dust reduction, organic fertilizer equipment investment is low; places with high environmental protection requirements generally choose heavy dust reduction plus ink and dust, which can meet the national air emission quality standards.

The disc granulator has the characteristics of stable operation, sturdiness and durability. It is a common granulation equipment in organic fertilizer production line. The principle is that after the powdery material is added to the rotating disc, a water spray device is added to continuously spray water, and the material is made into granules under the effect of rolling friction of the material. Different materials have different granulation effects, such as ball formation rate, particle size, granulation amount, etc.

The discs granulated by the fertilizer granulator machine adopt the overall arc structure, and the granulation rate can reach more than 93%. The granulating disc is provided with three discharge openings, which is convenient for intermittent production operations, greatly reducing labor intensity and improving labor efficiency.

The reducer and electric motor are driven by flexible belts, which ensures smooth starting, reduces impact and cushions, and improves equipment life. The bottom of the granulating disk is strengthened with multiple radiant steel plates, which is durable and never deformed. Thicker, heavier, and sturdy base design, no anchor bolts required, smooth operation.

The disc granulator is widely used for conveying various non-stick materials such as pulverized coal, cement, clinker, fertilizer, etc. in powder, material or small blocks.

The inclination of the large plate can be adjusted. The angle gasket is adopted for flexible and convenient adjustment, and the unique unpowered combination scraper blade is integrated to reduce the auxiliary power consumption. The large disk is composed of a disk body and a disk section, which reduces the power of the main motor. The disk section can be adjusted up and down along the disk body. The end of the disk section is a side flange. When the ball is out of the disk, it can ensure that the ball is not pulled or torn.

The failure of the organic fertilizer production line will affect the normal working progress of the equipment, delay the production plan, and cause production losses. Organic fertilizer enterprises should implement strategies to reduce failures in organic fertilizer production lines, in order to save capital for enterprise production.

1. Maintaining the initial and basic state of the organic fertilizer production line, and maintaining the original design parameters: this is the most basic work, which means that the first step in reducing faults in the organic fertilizer production line is to restore the basic state of the organic fertilizer equipment;

2. Strictly abide by operating procedures, prevent and avoid destructive operations, and prevent and avoid overload operation: Most problems in organic fertilizer production lines are caused by improper operation or inadequate maintenance. The significance of standardizing employee behavior is to prevent and reduce problems in organic fertilizer production lines caused by such simple reasons;

3. Continuously discovering, preventing, and repairing natural degradation, allowing organic fertilizer production lines to be repaired in potential failure states: The significance of independent maintenance lies in the involvement of frontline employees in identifying problems in the first time, comprehensively standardizing production maintenance, advocating for the discovery and removal of six sources of activity, and a very important link is to solve the problem of the fault source;

4. Correct defective designs and carry out proactive maintenance with incidental improvements to the design and manufacturing defects of organic fertilizer equipment;

5. Prevent human degradation, avoid human damage, and prevent destructive maintenance;

6. Control any abnormal external conditions and accelerate the deterioration of organic fertilizer production lines.

No matter what equipment is used, it is inevitable that some malfunctions will occur. Perhaps due to equipment quality, improper use, or long-term wear and tear of parts, organic fertilizer production lines may also experience some malfunctions after prolonged use. Effective control measures for faults in organic fertilizer production lines, making judgments based on the situation, and timely maintenance.