Fertilizer Production Line Configurations

The new fertilizer production line project should comprehensively consider local resources, market capacity and market coverage radius. In general, the annual output of small new plants is 10000 tons (1.5 tons / hour), 20000 tons (3 tons / hour) and 30000 tons (4.5 tons / hour). The annual output of medium-sized factories is 50000-100000 tons, and that of large-scale factories is 100000-300000 tons.

The investment scale and scheme design should be made according to the following conditions: raw material resource characteristics, local soil conditions, local planting structure and main crop varieties, plant site selection, NPK fertilizer granulator selection, production automation degree, etc.

Fertilizer production line

Several equipments of chemical fertilizer production line

1. Mixer. In addition to chemical fertilizer raw materials, some cohesive materials, such as clay, can be properly added in the mixing process. During operation, the material is evenly mixed by stirring back and forth with multi-channel rotating blades.

2. Fertilizer granulator. Organic fertilizer granulator is generally used in small-scale production to meet the requirements.

3. The rotary dryer is mainly composed of drying cylinder, transmission device, support device and cylinder tail sealing parts. The diameter ranges from 80 cm to 3 m and the length depends on the drying requirements. The dryer is a cylinder inclined to a certain angle in the horizontal direction. The material is added from the high end, and the high temperature flue gas and the material enter the cylinder in parallel. As the cylinder rotates, the material moves to the lower end due to gravity. The lifting plate is welded on the inner wall of the cylinder to absorb and drop materials, and fully contact with hot air in the falling process to achieve the purpose of drying.

4. The rotary cooler can reduce the moisture content when cooling a certain temperature. It is the same as the dryer equipment, but uses space-time gas to pump from the head to the outside, so there is no need to seal the tail.

5. Combined screen is adopted for drum screen, which is convenient for maintenance and replacement. This machine has the advantages of simple structure, convenient operation and stable operation.

Pan Granulation Technology

As a fertilizer granulator which has been used for a long time in chemical fertilizer plant, pan granulator has its unique advantages. In the production of fertilizer granulation, the following factors exist in the particle uniformity.

Structure of pan pan granulator

The disc granulator adopts the whole arc structure, which effectively improves the granulation rate. Combined with non power scraper equipment, it can reduce the accumulation of materials in the granulation process and maximize the use of raw materials. In order to facilitate the flexibility and flexibility of field use, the base is firmly thickened and weighted, without the need for additional anchor screws to fix, which also helps to prevent chassis deformation. The disc granulator is very suitable for field operation, reduces the tedious installation and layout procedures, saves time and improves the work efficiency.

In the granulation stage of NPK fertilizer production line, with the continuous addition of raw materials, under the action of centrifugal force, the manufactured particles fall into the lower belt conveyor through the edge of the plate.

Pan fertilizer granulator

Elements of Pan fertilizer granulator

When the plate granulator processes raw materials, many parameters affect each other. For example, the smaller the diameter of the pelletizing disk is, the lower the disk height is, the larger the inclination angle of the disk is, and the higher the rotation speed is; if the disk height is increased, the inclination angle and rotation speed are higher. The smaller the tilt, the lower the speed.

As a NPK compound fertilizer production equipment, another factor affecting the disc granulator is the tilt angle of the disc. The angle of inclination should not be less than 35 ° during granulation, otherwise the material will stick to the disc and rotate with the disc body. With the increase of inclination angle and rotation speed, the material can avoid accumulating in the lower part without falling and rolling up and down.  More info on pan granulation process, go here with the link.

However, the larger the inclination angle is, the faster the downward rolling speed is, and the smaller the overflow particles are. The most suitable slant point of the disk is related to the diameter of the disk, that is, the slope of the disk decreases with the increase of the disk diameter. 

This is because the end velocity of particles moving along the disk surface increases as the disk diameter increases. In order to avoid the impact and fracture of other particles when the particles are down, the tilt of the disk must be reduced.

Chicken Manure Composting Methods

 Composting method of chicken manure in garden

Animal manure such as chicken manure, duck manure and cow manure can be recycled by composting, and then made into organic fertilizer for use in the garden. Chicken manure composting is not only environmentally friendly, but also conducive to the growth of garden plants. Different from the fertilizer products produced by professional organic fertilizer production equipment, this method is simple and easy to use, and can be made and used by ourselves.

Simple composting method of garden chicken manure

1. Chicken manure, grass, flowers, leaves and other wastes are mixed with water, picked up the mixture, piled up, covered with plastic fermentation, when the fermentation temperature reaches 45 ° C, diffusion cooling, when the temperature is constant, the fermentation process is solved, and fermentation can be used.

2. Raw materials (taking the production of 1 ton of organic fertilizer as an example): 1.8 tons of livestock manure, 0.3 tons of rice straw powder or leaf powder, 2.5 kg of corn flour and 1 kg of rapid bacterial starter are required. Animal excreta + leaf or grass powder + corn flour + strain + mixture + compost + air drying.

2.1. First of all, the water content of the mixed raw materials should be controlled between 40% - 50%. Then, bacteria are mixed on the surface of the mixed fertilizer, and the raw materials are evenly put into the mixer for crushing and mixing. When mixing and crushing fertilizer, the water content should be controlled within 40% - 45%. Too much or too little water will affect the quality of fermentation. Stir evenly, thoroughly and fluffy without lumps.

2.2. The mixing raw materials are stacked into straw curtains with width of 1.5-2 meters and height of 0.3-0.4 meters, covered with aerobic fermentation. Generally speaking, the temperature rises to 50 ° C in 24 hours and 60-70 ° C in 48 hours. In the fermentation process, high temperature can kill all pathogenic bacteria, eggs, grass seeds, etc. According to composting experiments, composting usually takes 6-15 days in spring, summer and autumn, and longer in winter. When the fertilizer is covered with white hypnosis, that is, all the fertilizer is rotten and can be slightly dried and screened.

3. Chicken manure contains a lot of harmful microorganisms, which can not be used directly. Deep high temperature fermentation is necessary. One is sterilization, the other is organic dyspepsia substances, increase the actual organic content.

Composting Techniques of chicken manure

1. Fermentation is mainly carried out in fermentation pair or in-vessel fermentation tank. The best way is to add appropriate amount of fermentation bacteria at the same time. The film is then covered with agriculture and the fermentation time is usually 10-20 days.

2. Chicken manure was dried and crushed after deep fermentation. Chicken manure can be used directly. But this fertilizer cannot be called commercial organic fertilizer. Compost is a high-quality organic fertilizer on the market after being processed, dried and screened by organic fertilizer pelletizer. The compound fertilizer is produced by NPK fertilizer production line and different proportions of fertilizer.

Small Capacity Fertilizer Production Costs

Plant construction plan of small organic fertilizer production line

The 20000 ton small-scale organic fertilizer production equipment is a granulated organic fertilizer processing production line based on 5-8 tons organic fertilizer granulator. The production line mainly uses local animal manure and vegetable manure to ferment organic fertilizer and bio organic fertilizer. The main production process of the equipment is: fermentation + crushing + mixing + granulation + drying + cooling + screening + packaging, etc.

Organic fertilizer production line equipment

raw material

20000 tons of small organic fertilizer production line equipment can process raw materials, mainly fresh chicken, pig manure and other raw materials. It does not contain any chemical components, but the digestion capacity of chickens and pigs is poor, so only 25% of the nutrients can be consumed, while the other 75% of the nutrients in the feed are discharged together with the feces, making the dried products contain nitrogen, phosphorus, potassium, organic matter, amino acids, protein and other components.

Organic fertilizer production equipment has the following advantages

Low energy consumption, small floor area, no odor, no pollution, good ventilation, deodorization only takes 1-2 days. The organic fertilizer production line has compact structure and advanced technology. It uses harmless living bacteria preparation to treat livestock and poultry excreta, ferments under the action of various beneficial microorganisms, decomposes organic matter and releases nutrients. The bio heat and high temperature fermentation process can kill bacteria and insect eggs, remove toxins and odors, purify the environment, realize harmless, resource-based and industrialization, and stabilize product quality with low source consumption.

The 20000 ton organic fertilizer production line equipment is based on the customer's site conditions, local raw material sources, land nutrition and planting conditions to give a comprehensive plant construction plan and equipment. The equipment includes granulator (disc fertilizer granulator, organic fertilizer granulator, flat mold granulator, roller granulator), pulverizer, composter, screening machine, drying and cooling system, and packaging machine.

As the mainstream organic fertilizer production line in the market, the small organic fertilizer production line with a capacity of 20000 tons is easy to set up, and the storage and transportation distance of raw materials is relatively close. At the same time, it also avoids the disadvantages of organic fertilizer processing enterprises in small family workshops. It is the main choice of initial investment for planting enterprises and fertilizer processing enterprises.

Organic fertilizer production business plan

Under the concept of sustainable development, green sustainable development technology refers to the use of advanced science and technology to promote the transformation of enterprises and the development of new energy, and minimize the impact of organic fertilizer production on the environment. Through organic fertilizer production equipment, reduce environmental pollution, and ultimately achieve the balance between economic development and ecological environment protection, and form the production technology of economic and social development form.

Green and sustainable organic fertilizer production technology can promote the technical transformation of organic fertilizer industry, conform to the trend and concept of international ecological environment protection development, realize low emission and low energy consumption of organic fertilizer, realize the purpose of protecting ecological environment, and realize the coordinated development of economic development and ecological environment protection.

Organic fertilizer production technology aerobic composting technology

Aerobic composting technology is an important technology to treat organic waste, especially suitable for agricultural solid waste fertilization and substrate. Aerobic composting technology is the most effective industrial method to treat agricultural waste, ferment into organic fertilizer and realize resource utilization. Countries all over the world attach great importance to the application of advanced engineering technology, improve the industrialization level of aerobic composting technology, and make composting technology develop towards mechanization, environmental protection, high efficiency and comprehensive development.

Granulation process of organic fertilizer

According to the soil formula and production process, other nutrients are added into the organic matter, and the organic fertilizer is further processed by the organic fertilizer granulator to convert the organic fertilizer into granules. Fermentation compost can be used as organic fertilizer. But for commercial products, further testing is needed. In terms of industry standards, organic fertilizer products have relevant regulations from nutrient content to harmful substance content and water content. Therefore, it is necessary to add necessary nutrients according to the detection situation to become a real organic fertilizer product. The commonly used organic fertilizer granulation equipment includes disc fertilizer granulator, flat mold granulator, rotary drum granulator, etc.

Wet Granulation Line

The supporting equipment of fertilizer granulation production line includes: composter, crusher, mixer, fertilizer granulator, belt conveyor, dryer, cooler, drum screen machine, automatic packaging machine for finished products. Fertilizer production line can not be without granulator, but in the granulation equipment, plate wet granulator has become a classic, why?

Disc wet granulator equipment

There are five reasons why the pan granulator is widely used

1. The new structure of disc granulator reduces the weight and height. The layout of chemical fertilizer production process is flexible and convenient, which is suitable for the transformation of old plants.

2. The tilt angle of the large plate can be adjusted. The angle gasket is flexible and easy to adjust.

3. The granulator adopts unique non power combination scraper integration to reduce auxiliary power consumption.

4. The large board is composed of the board body and the board part to reduce the power of the main motor. In addition, the disc connector can be adjusted up and down along the disc body.

5. New design of disc granulator, edge cleaning and bottom cleaning by combination scraper without power, angle cleaning scraper winding angle, with unique disc body processing technology, good dredging effect, no large mud, material ball diameter of 90% in 3-5mm.

The advantages of selecting disc granulation production line are that the whole set of equipment is easy to operate, the adjustable range is large, and the finished product particles are round. This wet granulation line has been considered as the preferred configuration for fertilizer granulation!

Sugar Dregs Fertilizer Production

Filter mud, chicken manure, pig manure, fur residue and sugar residue left by sugar processing can be used as raw materials for organic fertilizer production. Under appropriate conditions, organic matter is formed by fermentation, and then processed by organic fertilizer production equipment to provide nutrients for crops.

Fermentation method of sugar residue organic fertilizer.

1. Raw materials and requirements:

Main materials: animal manure, sugar residue, Chinese medicine residue, fruit residue, mushroom residue, distiller grain, fur residue and other bulk materials, biological bacteria fertilizer fermentation agent. The moisture content should be controlled between 50% - 65%. Due to the high acidity of fermentation materials, quick lime should be used in advance to adjust the pH value to 8.0%.

Accessories: rice bran, sawdust, cake powder, rice straw powder and other auxiliary materials are dried in the form of powder with rich carbon content.

Raw material ratio: main material: auxiliary material = 5:1-3:1

Sugar residue as organic fertilizer

2. Operation method:

The law requires a mixture of all. The material strips are stacked into piles with a height of about 1.2 meters, with unlimited length and ambient temperature. When the pile temperature rises to 45 ° C, the pile should be turned over every three days. If the pile temperature exceeds 65 ° C, it shall be turned over every two days.

Signs of ripening: the temperature of the material is reduced, the material is loose, the material has no original flavor, there is a slight ammonia smell, and the pile is covered with white hyphae.

Compost stacking: it can be used directly after stacking and fermentation, and can also be used as the main material. Fertilizer granulator will be processed into commercial organic fertilizer, bio organic fertilizer, organic-inorganic compound fertilizer, bio organic inorganic compound fertilizer, etc.

Advantages of sugar residue organic fertilizer

The fertilizer efficiency is high and the application is convenient. Because the fermentation period is only 7-15 days, the nutrients in the sugar residue are retained as much as possible; due to the decomposition of microorganisms, some substances that are difficult to be absorbed and utilized by crops are rapidly transformed into effective nutrients. After fertilization, it can give full play to the role of fertilizer in a short period of time, quickly supplement the nutrients needed for crop growth, and maintain the fertilizer effect for a long time. The rotten filter mud is tasteless, dry, loose and easy to diffuse.

Organic fertilizer should not be mixed with strong acid, alkali, volatile chemicals and fungicides. Shunxin factory provides a complete set of organic fertilizer equipment and designs fertilizer production line for customers free of charge.

Pan Pelletizer Working Principle

The main structure of disc granulator is disc. The disc designed by ShunXin fertilizer granulation plant is thicker, heavier and stronger, and the base design does not need to be fixed with anchor bolts, so the operation is stable. The granulation plate of pan granulator has three sockets, which is convenient for intermittent production and operation, greatly reduces the labor intensity and improves the labor efficiency. The reducer and motor are driven by flexible belt, which can start stably, reduce the impact force and improve the service life of the equipment.

The main motor drives the pulley and belt and drives the pinion through the reducer. The big gears fixed at the bottom of the disc mesh with each other and work in the opposite direction. The large gear is specially designed for mounting on the spindle of the housing adjusting disc to support the work of the whole granulator (in conjunction with the sprayer).

We have designed an automatic cleaning device on the top of the pan to prevent the material from sticking to the wall, thus greatly improving the service life of the pan granulator. With the continuous rotation of the motor and the continuous entry of materials, mass production can be realized.

The disc surface of the disc granulator should be flat and the disc roundness should be high. On the one hand, the CD theme affects the overall beauty of the device, on the other hand, it is also the most important. Only when the roundness and flatness meet the requirements, the equipment can run well, the bottom scraper and side scraper can play a role, fully contact the disc surface and bottom, scrape off the materials attached to the disk surface and bottom, and further form a spherical shape.

Organic fertilizer granulator types

In order to process commercial organic fertilizer with animal manure, equipment and early fermentation are the key to the production. In the early stage of fermentation, the C / N ratio, moisture and oxygen status of fermentation materials should be adjusted to improve the working conditions of microorganisms and shorten the fermentation time of organic materials. In the later stage, the processing of organic fertilizer mainly focused on granulation.

Organic fertilizer granulator is a kind of molding machine which can make the material form a specific shape. There are many kinds of granulators, such as rotary drum granulator, new organic fertilizer granulator, disc granulator, two position No.1 NPK fertilizer granulator, flat mold granulator, etc. According to the characteristics of production materials and granulation requirements, choose different granulation equipment.

The pan angle of the pan granulator adopts full arc structure, and the pelletizing plate is equipped with three discharge ports, which is convenient for intermittent production. The reducer and motor are driven by flexible belt, which can start smoothly and reduce the impact force of disc granulator. The base plate at the bottom of the plate is heavy, strong and thickened. It is reinforced by a variety of radiation steel plates, durable. It does not need to be fixed with anchor bolts, and runs smoothly.

The two in one NPK fertilizer granulator adopts granule wet granulation method. Through a certain amount of water or steam, the basic fertilizer can completely react after adjusting the cylinder humidity, In a certain liquid phase condition, with the help of the rotary motion of the cylinder, in order to squeeze the material particles into balls, we add the high-speed rotating mechanical stirring force and the aerodynamic force generated by the hobbing cutter on this basis, so that the fine powder materials can be continuously mixed in the machine.

Before granulation, the flat die extrusion granulator must first use a semi wet raw material grinder to crush the organic fertilizer raw material, and use a cutter to granulate the raw material into a cylinder. For the whole organic fertilizer granulation equipment, we can provide you with a complete production line work plan. Help users choose the right granulation equipment to meet the requirements of the production line.

Fertilizer Dryer Role in Fertilizer Production

Our rotary drum dryer is made for chemical fertilizer production line, continuous improvement, has broad prospects for development. Innovation has always been the need of the market, in the face of such a situation, all manufacturers have won a new era.

To jointly promote the continuous progress of machinery and equipment, we should implement more long-term planning policies, so as to achieve better product effect, constantly improve our products and improve product quality. As a fertilizer producer, this has always been our driving force.

Fertilizer drum dryer from ShunXin Fertilizer Machinery

Shunxin chemical fertilizer plant has been committed to the drying equipment of agricultural machinery. This technology is different from other production technologies because of the different raw materials and properties of chemical fertilizer, and the process flow and technical conditions of different fertilizer production lines are also different.

Therefore, in view of the chemical fertilizer production technology, we can not simply copy others, we must test our own equipment, and must meet the fertilizer standards after drying, so as to maximize the use. Organic fertilizer drum dryer is an important role in this situation.

The fertilizer granules made by ShunXin fertilizer granulator can be stored and transported normally after being processed by dryer for long-term storage and use. The dryer speeds up the chemical fertilizer production process and is an indispensable equipment in the fertilizer production line.