Process and equipment configuration of high cost-effective NPK fertilizer production line

fertilizer granulator Aug 5, 2024

fertilizer equipment manufacturer specializes in producing fertilizer machines. We have designed various types of fertilizer production lines. For example, NPK fertilizer manufacturing process is designed for the production of special compound fertilizer. The design of fertilizer production line has important advantages for the development of agriculture. As the NPK fertilizer manufacturing process is adopted, different types and series of compound fertilizer machinery are equipped to complete the production process, which improves the work efficiency and simplifies the fertilizer production process. It also saves more labor costs for investors.

In addition to providing professional fertilizer manufacturing technology and equipment, we also provide a number of services.

Pre sales service: fertilizer manufacturing process equipment manufacturers provide you with project design, process design, recommend the appropriate NPK fertilizer granulator for you according to your raw materials, and formulate a suitable selection scheme of machinery and equipment. According to the special needs of users, design and manufacture products, train technical operators for users.

In sale service: accompany you to complete the acceptance of the equipment, and assist in drawing up the construction scheme and detailed process.

After sales service: the company sends technical personnel to the site to guide the installation and commissioning of organic fertilizer equipment (except for vulnerable parts), and guarantee the quality within one year.

The process of processing pig manure fertilizer on the organic fertilizer production line of pig farms

fertilizer granulator Aug 5, 2024

Pig manure is a very good organic fertilizer, which contains a lot of nitrogen, phosphorus and potassium required by plant growth. It is suitable for plant growth and can increase the yield of food crops. The production of organic fertilizer from pig manure is a way to turn pig manure into treasure.

The pig manure organic fertilizer production line has achieved breakthrough results in the harmlessness and resource reuse of pig manure. The whole set of equipment for making organic fertilizer from pig manure makes pig manure into organic fertilizer, which solves the chronic problem that pig manure is difficult to recycle and seriously pollute the environment.

The process flow of pig manure organic fertilizer equipment production line is a little more complex than NPK fertilizer manufacturing process, and the raw materials need fermentation first, then granulation processing.

1. Raw material fermentation.

2. Computer belt scale automatic batching.

3. Crushing and mixing.

4. Granulation.

5. Drying organic fertilizer granules by dryer.

6. Organic fertilizer particles are cooled by cooler. 

7. The qualified organic fertilizer particles are screened out by the screening machine.

8. Coating machine film particles, more smooth.

9. Automatic filling and sealing of organic fertilizer granules by packing scale.

What is the workflow of a rotary drum granulator

fertilizer granulator Aug 5, 2024

The workflow of the rotary drum granulator mainly includes the following steps:

Raw material preparation:

Raw materials (such as organic materials, inorganic materials, compound fertilizers, etc.) usually require pre-treatment before entering the rotary drum granulator. This may include crushing to ensure that the raw materials reach the appropriate particle size; Mixing to ensure uniform distribution of various components; And humidity adjustment to control the moisture content of the raw materials, making them suitable for granulation.

Raw material feeding:

The preprocessed raw materials are evenly fed into the rotary drum granulator through a feeding device. The control of feeding rate is crucial for maintaining the stability and particle quality of the granulation process.

Granulation process:

When the raw materials enter the rotary drum granulator, centrifugal force begins to act, causing the raw materials to move towards the edge of the rotary drum granulator. During this process, the raw material particles begin to roll and collide with each other, gradually forming larger particles through the viscous interaction between the raw materials.

To promote particle formation, it may be necessary to spray an appropriate amount of water during the granulation process to increase the viscosity of the raw materials. The water spray system is usually located above the disc and can precisely control the amount of water sprayed.

Particle screening:

As the particles gradually increase, they will gradually slide from the edge of the rotary drum granulator to the screening device below. The screening device usually includes sieves with different pore sizes to separate particles that meet the requirements.

Smaller particles that have not been screened or fully formed particles will be sent back to the disc for further granulation, while oversized particles may need to be crushed and reintroduced into the granulation process.

Drying and cooling:

The initially screened particles may contain high moisture and need to be dried using drying equipment to reduce moisture content and improve particle stability. After drying, the particles may need to undergo a cooling process to reduce temperature and avoid chemical reactions or deterioration during storage or transportation.

Packaging and Storage:

The final dried and cooled granular fertilizer can be weighed, packaged, and then stored or directly transported to the market for sale.

The workflow of the rotary drum granulator is a continuous process, which can effectively produce high-quality granular fertilizers by precisely controlling the feeding rate of raw materials, the rotation speed of the disc, the working status of the water spray system, and the parameters of the screening equipment. Throughout the entire process, the pretreatment of raw materials and the drying and cooling of the final product are key steps in ensuring the quality and performance of granular fertilizers.

How to achieve rapid fermentation of raw materials in organic fertilizer production lines

fertilizer granulator Aug 5, 2024

The other 75% nutrients in chicken, sheep and pig feed were excreted with feces, including nitrogen, phosphorus, potassium, organic matter, amino acid, protein and so on. A series of treatments in the organic fertilizer manufacturing process turn manure into organic fertilizer. How can organic fertilizer equipment achieve rapid fermentation and deodorization to produce finished products? What are the advantages of this process over ordinary fermentation?

Fermentation technology of organic fertilizer

1. The energy consumption of compost turning machine is low.

Fecal composting fermentation process can use biological heat to evaporate a large amount of water, low energy consumption, save coal, electricity, labor intensity, can better control the fermentation humidity, reduce the loss of effective substances.

2. Organic fertilizer equipment fermentation environment pollution is small.

Closed equipment is used in compost tipper to strengthen the controllability of factory production and reduce the exposure of mosquito and fly parasitism source. This can effectively control environmental pollution and produce high-quality organic fertilizer under the premise of ensuring the environment.

3. The processing time of organic fertilizer fermentation equipment is short.

First, the factory fermentation process is used to inoculate high-efficiency active bacteria, so that the microorganisms can quickly form dominant bacteria, shorten the fermentation time, and accelerate the deodorization. Generally, deodorization can be completed within 2 to 3 days. At the same time, the turning of the turning machine increases the oxygen required for microbial activities and speeds up composting. Under normal natural conditions, open-air composting often takes several months.

Only by understanding the advantages and functions of the equipment can it play its role better. We provide organic fertilizer manufacturing process and NPK fertilizer manufacturing process to ensure the steady improvement of agricultural production efficiency.

The necessary production process and equipment configuration for manufacturing organic fertilizers

fertilizer granulator Aug 5, 2024

Fertilizer Equipment Manufacturer will introduce you to the production process and process of fertilized fertilizer in large fertilizer plants. Friends who want to build a fertilizer plant can refer to it.
Production process of organic fertilizer

1.After mixed fermentation of bacteria and raw materials, the composting machine is used in the fermentation process. Fermented compost can provide nutrients and improve soil properties, especially for sandy soil, clay and salinized soil.

2.The rotten raw materials are crushed and screened, and then arrive at the deep processing workshop through the elevator.

3.The fertilizer is mixed by the raw material mixer and then enters the fertilizer granulator for pelleting.

4.Next, the pelletized fertilizer is sent to the pelletizing equipment for rounding.

5.The particles after rounding reach the drying cylinder through the conveyor belt. The dried particles are then transported to the cooling drum through the conveyor belt for cooling.

6.The dust generated in the drying and cooling process enters the dedusting equipment through the induced air for dedusting. The cooled particles are then transported by the conveyor belt to the screening machine.

7.Then the sieved particles enter the quantitative packaging equipment through the conveyor belt for packaging, and become finished fertilizer.

Equipment selection of NPK fertilizer granulator

There are many types of fertilizer processing equipment in the above process, such as granulation link. Different types of NPK fertilizer granulators are suitable for different processing processes, including disc granulator, rotary drum granulator, roller extrusion granulator, etc. When selecting production equipment, fertilizer plants should consider their own plant planning, estimated annual output, type of raw materials, etc., which are related to how to select the most suitable equipment and ensure the maximum benefit.
Matters needing attention

Finally, fertilizer granulator equipment manufacturers remind everyone to consider the sales path of raw materials and fertilizers. Organic fertilizer raw materials that can be considered include crop straw, green manure, weeds and other plant materials, as well as manure and sludge. Attention should be paid to whether the raw material of livestock and poultry manure contains hormone residues, heavy metal overruns and other issues. The selection of bacteria should pay attention to the activity of bacteria and the number of useful live bacteria. Regarding marketing, we must examine the local fertilizer demand and transportation convenience.

What kind of fertilizer granulator is commonly used in NPK fertilizer production lines

fertilizer granulator Aug 5, 2024

On the production line of NPK fertilizers (nitrogen phosphorus potassium compound fertilizers), the commonly used types of fertilizer granulators mainly include drum granulators, disc granulators, and extrusion granulators. Among them, rotary drum granulators and extrusion granulators are common choices in NPK fertilizer production because they can handle the high mixing ratios and complex components required for NPK fertilizers, while ensuring the uniformity and stability of the particles. Below are the characteristics of these two types of granulators:

Drum granulator:

The rotary drum granulator achieves the granulation process through a rotating drum shaped container. The raw materials roll in the drum, and appropriate amount of water or binder is added through the spray system to gradually agglomerate the raw materials into particles. The rotary drum granulator is capable of processing highly viscous materials and is suitable for the production of NPK fertilizers, as it can effectively control the size and shape of particles while ensuring uniform distribution of fertilizer components.

Due to the complex composition of NPK fertilizers, the rotary drum granulator has become the preferred choice for NPK fertilizer production lines. It can process high concentration raw materials while controlling particle size and density by adjusting the drum speed and water spray system.

Squeezing granulator:

The extrusion granulator squeezes the raw material into strips through a pair of rollers (opposite rollers) that rotate in opposite directions, and then forms particles through cutting. This granulation method is suitable for dry or semi dry materials and can produce particles with high hardness and regular shape.

For NPK fertilizer production, the extrusion granulator can provide high-density, high-strength particles, which helps stabilize the fertilizer during transportation and storage. At the same time, the high production efficiency and particle uniformity of the extrusion granulator are also one of the reasons why it is popular in NPK fertilizer production lines.

The choice of granulator mainly depends on the production requirements, raw material characteristics, production scale, and cost considerations of NPK fertilizer

If high-density and high-strength particles need to be produced, and the raw materials are relatively dry, an extrusion granulator may be a better choice.

If the raw material contains high moisture or requires the addition of liquid binders during the granulation process to promote particle formation, a rotary drum granulator is more suitable.

Considering the complex composition of NPK fertilizers and the need to ensure uniform distribution of ingredients, the mixing capacity of the rotary drum granulator gives it an advantage in this regard.

In actual NPK fertilizer production lines, a combination of drum granulators and extrusion granulators may be used based on specific needs and raw material characteristics to achieve optimal production efficiency and product performance. In addition, other aspects of the production line, such as raw material pretreatment, drying, cooling, and packaging, also have a significant impact on the quality of the final product. Therefore, the comprehensive design and optimization of the entire production line are crucial.

Three fermentation methods for commonly used bio organic fertilizers in aquaculture farms

fertilizer granulator Aug 5, 2024

The processing method of bio organic fertilizer is more complex than that of general compound fertilizer. The manufacturing of NPK fertilizer is mainly the mixing granulation of different fertilizers. The production of bio organic fertilizer involves composting and fermentation of feces.

Direct composting

The main technological process is to mix chicken manure with straw or peat, pile up about 1 meter high, compost at high temperature, periodically turn and ventilate fermentation, and use it as product after fermentation. The advantages of this mode are: the organic fertilizer manufacturing process is simple, less investment, low cost.

The main problem is that：

1. The accumulation time of products is too long, which is greatly affected by various external conditions, so the quality of products is difficult to guarantee.

2. The degree of continuous factory production is not high and the production cycle is long.

3. The product has low nutrient content and high moisture content, which can not meet the requirements of commercialization.
Tower fermentation

The main process is to mix chicken manure with sawdust and other auxiliary materials, and then connect to the biological bacteria agent. At the same time, the tower body is automatically ventilated, and the biological growth is used to accelerate the fermentation and deodorization of chicken manure. After a fermentation cycle, the product comes out of the tower body It’s basically a product. This model has the advantages of small footprint, low energy consumption, low pollution and high degree of factoryization.

But its current problems are:

1. Relying only on the biological heat generated by fermentation to remove moisture, the moisture content of the product cannot meet the requirements of commercialization.

2. The current process flow is not running smoothly, resulting in a large increase in labor costs, and the output fails to meet the design requirements.

3. The corrosion problem of equipment is serious, which restricts its further development.
Fermentation tank fermentation
This organic fertilizer manufacturing process is to mix chicken manure, grass charcoal, and sawdust into a cement tank, and use a compost turning machine to process the fermented material to fully ferment the material. After the fermentation is completed, the compost is crushed, sieved and packaged into products. The advantages of this model are: the production process is simple and convenient, the investment is small, and the production cost is low. It is very suitable for the bio-organic fertilizer manufacturing process, and is widely used in industrial production and processing.

Troubleshooting rules for daily organic fertilizer composting equipment fermentation

fertilizer granulator Aug 5, 2024

Organic fertilizer composting equipment is simple and practical, and the fertilizer produced can be absorbed by crops quickly. In order to make better use of the compost turning machine in the organic fertilizer manufacturing process, it is very important to maintain the fertilizer equipment.

1. The bearing in organic fertilizer equipment bears all the load of the machine, so good lubrication has a great relationship with the bearing life

2. Lubricating oil directly affects the service life and operation rate of organic fertilizer equipment. Therefore, it is required that the lubricating oil injected must be clean and well sealed. The main oil injection place of the machine is the rotating shaft roller bearing, all gear movable bearings and sliding surfaces.

3. The newly installed wheel tyre is easy to loose, so it should be checked frequently.

4. Attention should be paid to the normal operation of each part of the compost turning machine.

5. Pay attention to check the wear degree of the easily worn parts of the turner machine and replace the worn parts at any time.

6. Dust and other sundries should be removed from the underframe plane of the movable device of the compost turning machine, so as to avoid serious accidents due to the failure of the movable bearing to move on the underframe when the machine encounters materials that cannot be broken.

7. When the rotating gear of turner machine is running, if there is impact sound, stop the machine immediately for inspection and eliminate it.

In the manufacturing of npk fertilizer and organic fertilizer, it is necessary to make a detailed description and solution to the wear and tear of machine parts and common faults in the instructions. On the other hand, routine maintenance is more important. Compliance routine maintenance can effectively reduce failures and prolong service life.

What are the advantages of rotary drum granulator in NPK production line

fertilizer granulator Aug 5, 2024

The rotary drum granulator is widely used in fertilizer manufacturing and other industrial fields, and its advantages are mainly reflected in the following aspects:

Easy to operate and maintain:

The structure of the rotary drum granulator is relatively simple, easy to operate, and user-friendly. Meanwhile, due to its simplified design, daily maintenance and troubleshooting are also relatively convenient, reducing maintenance costs and downtime.

Uniform granulation effect:

The rotary drum granulator can uniformly process materials and form particles of consistent size and shape. This uniformity is crucial for ensuring consistency in fertilizer quality and improving crop absorption efficiency.

Wide applicability:

This granulator is capable of processing various types of raw materials, including organic matter, inorganic matter, and their mixtures. Both dry materials and materials with certain humidity can be effectively granulated under appropriate conditions.

High production flexibility:

The rotary drum granulator can flexibly control the size and density of particles by adjusting the speed, water spray system, and feeding rate of raw materials. This flexibility enables the machine to adapt to the needs of different product specifications.

Low energy consumption:

Compared to other types of granulators, such as roller extrusion granulators, rotary drum granulators have lower energy consumption. This is mainly because its granulation process relies mainly on centrifugal force and the viscosity of the material itself, without the need for additional high pressure or high temperature.

High production efficiency:

The rotary drum granulator can operate continuously, process large amounts of materials, and achieve efficient batch production. This is particularly important for large-scale fertilizer production, as it can meet the demand for high yields.

Good cost-effectiveness:

Due to its simple operation, low maintenance costs, and low energy consumption, the rotary drum granulator has demonstrated high cost-effectiveness in long-term operation. For fertilizer manufacturers, this helps to reduce production costs and improve market competitiveness.

Environmentally friendly:

Low energy consumption and simple structure result in minimal environmental impact during the production process of the rotary drum granulator. This is a significant advantage for modern industries that pursue sustainable production and reduce their carbon footprint.

In summary, the rotary drum granulator occupies an important position in the fertilizer manufacturing industry and other industrial fields that require granular materials due to its advantages of easy operation, high production flexibility, low energy consumption, and good cost-effectiveness. By rational design and optimization of process parameters, the rotary drum granulator can efficiently produce high-quality granular products.

Drying treatment of sheep manure organic fertilizer production line by organic fertilizer dryer

fertilizer granulator Aug 5, 2024

Sheep manure organic fertilizer dryer is also known as drum dryer. This dryer can dry fresh sheep manure with moisture content of 60% into granular dry products with moisture content less than 13%. It is a necessary equipment for organic fertilizer manufacturing process. In the process of organic fertilizer processing, the use of high temperature dryer to kill the bacteria in animal manure, and the use of water circulation and civil deodorization facilities in tail gas treatment can greatly reduce the air pollution and make the dry products easy to use, store and transport.

Sheep manure organic fertilizer dryer components:

It is mainly composed of rotary body, lifting plate, transmission device, support device and sealing ring. The length depends on the drying requirements. It is also commonly used in the manufacturing of NPK fertilizer and is one of the traditional drying equipment.Advantages of sheep manure organic fertilizer dryer

Sheep dung drum dryer has the function of improving the soil environment, improving the quality of crops, improving the quality of fruits and vegetables, and is beneficial to human health. It occupies an important position in agriculture.
The dried materials are sent to the cooler through the belt conveyor for cooling. In the cooling process, the natural air is sent to the cooler through the pipeline by the fan to cool the materials. The wind direction in the cooler is countercurrent. The tail gas pumped into the sedimentation chamber through the fan and pipeline is treated as the drying tail gas and discharged into the atmosphere.
The cooled materials enter the screening. After crushing, the large particle materials and the screened powder enter the return belt and are transported to the granulator for re granulation. The finished products enter the automatic packaging system for packaging.