The advantages of roller extrusion granulator in the production line of cow manure organic fertilizer

fertilizer granulator Sep 4, 2024

In the production line of powdered organic fertilizer from cow manure, the roller extrusion granulator has significant advantages compared to other granulation methods, which are reflected in the following aspects:

1. Efficient granulation

The roller extrusion granulator can quickly process organic materials such as cow manure into granules through high-pressure extrusion, with high granulation efficiency and fast production speed, suitable for large-scale production.

2. High particle strength

During the extrusion granulation process, the raw materials form particles under high pressure, resulting in a tight internal structure, high strength, and resistance to breakage, which is beneficial for the storage, transportation, and application of fertilizers.

3. Uniform particle size

The roller extrusion granulator can produce uniformly sized particles, thanks to the precise control of the roller gap and raw material feed rate by the equipment, ensuring the consistency and quality stability of the final product.

4. Low energy consumption

Compared to other granulation methods, the energy consumption of the roller extrusion granulator during the granulation process is relatively low because it mainly relies on mechanical extrusion rather than thermal action, reducing energy consumption and lowering production costs.

5. Environmentally friendly

The roller extrusion granulator generates relatively less dust and noise during operation, which helps improve the working environment and reduce environmental pollution.

6. Wide applicability

The roller extrusion granulator is not only suitable for cow manure, but also for processing various organic materials, including chicken manure, pig manure, straw, grass powder, etc., with a wide range of raw material adaptability.

7. Self cleaning function

Some roller extrusion granulators are designed with self-cleaning systems that can automatically clean residual materials on the pressure rollers, reduce downtime for maintenance, and improve production continuity and efficiency.

8. Easy to maintain

The structure of the roller extrusion granulator is relatively simple, and the operation and maintenance are relatively easy. The main maintenance work focuses on regular inspection and replacement of worn rollers, resulting in lower maintenance costs.

9. Customizable

According to the specific needs of the production line, the roller extrusion granulator can be customized, such as adjusting the size, shape, and gap of the pressure roller to meet the requirements of different particle sizes and yields.

In summary, the roller extrusion granulator has become one of the key equipment for achieving industrial production of organic fertilizers in cattle manure powder organic fertilizer production lines due to its efficient granulation capacity, high-quality particles, low energy consumption, and environmental friendliness.

What are the special requirements for the granulator of earthworm manure organic fertilizer

fertilizer granulator Sep 4, 2024

Compared with other organic fertilizers, the granulation process of earthworm castings organic fertilizer has its own characteristics. Therefore, when selecting and using a granulator, the following special requirements need to be considered:

1. Moderate viscosity

Adhesive selection: Earthworm castings themselves have a certain degree of viscosity, but may not be sufficient to form stable and uniform particles. Therefore, the granulator needs to be able to process raw materials with appropriate amounts of binders (such as humic acid, starch, cellulose, etc.) added to enhance the stability of the particles.

Adhesive addition system: The organic fertilizer granulator should be equipped with a precise adhesive addition system to control the amount of adhesive added and avoid excessive hardness or insufficient looseness of particles.

2. Humidity control

Humidity sensitivity: The moisture content of earthworm castings has a significant impact on granulation efficiency, and high or low humidity can affect particle formation and stability. Therefore, the granulator should have humidity regulation capability, or humidity regulation equipment should be equipped in the production line to ensure that the raw materials are pelletized at a suitable humidity.

Humidity monitoring: The organic fertilizer granulator should be equipped with a humidity sensor to monitor the humidity of the raw materials in real time, ensuring humidity control during the granulation process.

3. Temperature management

Temperature sensitivity: Microorganisms and enzymes in earthworm castings are sensitive to temperature, and excessive temperature can damage their activity, affecting the biological activity of organic fertilizers. Therefore, the granulator should be designed with a good heat dissipation system to avoid excessive temperature during the granulation process.

4. Particle strength and uniformity

Particle strength: The particles of earthworm manure organic fertilizer need to have a certain mechanical strength to avoid breakage during transportation and storage. The granulator should be designed with a mechanism for adjusting particle strength, such as pressure regulation.

Particle uniformity: The uniformity of particles has a direct impact on the effectiveness of fertilization. The granulator should be able to stably produce particles with consistent particle size and shape.

5. Cleaning and maintenance

Easy to clean: Earthworm castings may contain incompletely decomposed organic matter, which can accumulate in equipment and affect granulation efficiency. The granulator should be designed with a structure that is easy to clean, facilitating regular maintenance and cleaning.

Anti corrosion design: The acidity and alkalinity of earthworm castings may cause corrosion to equipment. Organic fertilizer granulators should use corrosion-resistant materials or coatings to extend the service life of the equipment.

6. Environmental requirements

Low dust operation: Dust may be generated during the granulation process, and the organic fertilizer granulator should be equipped with an efficient dust removal system to reduce pollution to the working environment.

In summary, the earthworm manure organic fertilizer granulator needs to have good viscosity, humidity, and temperature control capabilities, while ensuring particle strength and uniformity, easy cleaning and maintenance, and meeting environmental requirements. When choosing a granulator, these factors should be comprehensively considered to ensure high-quality production of earthworm manure organic fertilizer.

Equipment processing flow of the entire organic fertilizer production line

fertilizer granulator Sep 4, 2024

The equipment processing flow of the entire organic fertilizer production line is a systematic project, covering the entire process from raw material processing to finished product packaging. The following is a typical equipment processing flow for an organic fertilizer production line:

1. Raw material pretreatment

Solid liquid separator: For raw materials with high moisture content, such as livestock manure, a solid-liquid separator is used for preliminary dehydration.

Crusher: Grind raw materials into particles suitable for fermentation and granulation.

Blender: Mix the crushed raw materials with auxiliary materials (such as straw, rice husk, etc.), microbial agents, and other additives to prepare for fermentation.

2. Fermentation

Fermentation equipment: using fermentation tanks, fermentation chambers or fermentation tanks, through aerobic fermentation process, the organic matter in the raw materials is decomposed, while sterilization and odor removal are carried out.

Composting machine: Regularly turning compost to ensure uniform fermentation and improve fermentation efficiency.

3. Drying

Drying machine: The fermented material needs to be dried to remove excess moisture for granulation and storage. Common drying equipment includes drum dryers, belt dryers, etc.

4. Screening and crushing

Screening machine: Screen the dried material to remove large blocks or impurities, ensuring uniform particle size.

Crusher: Crushing the selected large materials to meet the granulation requirements in terms of particle size.

5. Granulation

Granulator: The screened material is sent to the organic fertilizer granulator for processing into granules. Common granulators include disc granulators, roller granulators, drum granulators, etc.

6. Particle screening

Screening machine: Screen the particles after granulation to ensure uniform particle size and remove unqualified particles.

7. Particle drying and cooling

Drying machine: Drying the screened particles to remove surface moisture and improve particle strength.

Cooling machine: The dried particles need to be cooled to prevent excessive dust generation during the packaging process and to avoid the impact of high temperatures on the particles.

8. Packaging

Packaging machine: Quantitatively package cooled granular fertilizers, usually using automatic packaging machines for bagging or boxing, for easy transportation and sales.

9. Finished product storage

Storage facilities: Finished fertilizers need to be stored in a dry and ventilated warehouse to avoid moisture and pollution.

10. Auxiliary equipment and control system

Conveying equipment: such as belt conveyors and screw conveyors, used for conveying materials between various processes.

Dust removal equipment: used to collect and process dust during the production process, improving the working environment.

Control system: including PLC control system, used to monitor and adjust the operating parameters of the production line, achieving automated production.

The equipment configuration and processing flow of the entire organic fertilizer production line need to be reasonably planned and designed based on factors such as raw material characteristics, production scale, product quality requirements, and budget.

What is the working principle of the organic fertilizer roller extrusion granulator

fertilizer granulator Sep 4, 2024

Organic fertilizer roller extrusion granulator is a device that uses mechanical pressure to extrude powdered or small particle materials into particles with certain strength and shape. Its working principle mainly includes the following steps:

1. Raw material preparation

Firstly, the raw materials (such as cow manure, chicken manure, crop straw, and other organic materials) need to be pre treated, including crushing, mixing, and adjusting the moisture content appropriately to ensure that the materials have appropriate viscosity and flowability for subsequent extrusion granulation.

2. Raw material feeding

The preprocessed raw materials are uniformly fed into the two relatively rotating pressure rollers of the counter roller extrusion granulator through a feeding device. These two pressure rollers usually have high hardness and wear resistance to withstand the high pressure during the extrusion process.

3. Extrusion granulation

When the raw material enters the gap between the pressure rollers, it is compressed under high pressure due to the squeezing effect of the rollers. The intermolecular forces are enhanced, and physical and chemical bonds are formed between the material particles, thereby forming particles with a certain shape and strength. The gap size of the pressure roller can be adjusted according to the required particle size to control the final particle size.

4. Particle Forming and Separation

The extruded material forms a continuous strip or block structure, which is then cut into independent particles by a crushing or cutting device. These particles usually have high strength and stability due to the pressure and viscosity during the extrusion process.

5. Granularity screening

Finally, the particles are screened by equipment to remove particles that do not meet the requirements (such as oversized or undersized particles), ensuring that the final product has uniform particle size.

6. Post processing

The screened particles may also need to undergo post-processing steps such as drying, cooling, and packaging to achieve optimal storage and usage conditions.

The working principle of the roller extrusion granulator is based on the physical properties of the material, which is formed into particles through high-pressure extrusion. This process does not require the addition of additional binders and is suitable for various types of organic fertilizer raw materials. It is one of the key technologies for achieving efficient granulation in organic fertilizer production lines.

The granulation process of the entire earthworm manure organic fertilizer production line

fertilizer granulator Sep 4, 2024

Earthworm castings organic fertilizer has become a high-quality soil amendment and plant growth promoter due to its rich organic matter and microbial activity. The granulation process of the entire earthworm manure organic fertilizer production line mainly includes key steps such as raw material preparation, granulation, drying, screening, and packaging. Below is a detailed introduction to this process:

1. Raw material preparation

Earthworm castings pretreatment: The collected earthworm castings need to be screened to remove impurities such as undigested organic matter, stones, etc. Sometimes it is necessary to adjust according to the humidity of the raw materials to ensure a smooth granulation process.

Raw material mixing: If other organic or inorganic nutrients such as chicken manure, cow manure, phosphorus and potassium fertilizers need to be added, they should be mixed evenly with earthworm castings at this stage.

2. Granulation

Choose a granulator: Choose the appropriate granulator based on production scale and demand, commonly including disc granulator, extrusion granulator, drum granulator, etc. For raw materials such as earthworm castings, disc granulators and extrusion granulators are commonly used.

Granulation process: The prepared raw materials are fed into a granulator and formed into particles through mechanical force or chemical reactions (such as adding binders). During the granulation process, it is necessary to control the humidity and temperature of the material to ensure the molding rate and strength of the particles.

3. Drying

Particle drying: After granulation, the particles need to be dried to remove excess moisture and prevent clumping during storage or transportation. Common drying equipment includes drum dryers, belt dryers, etc.

4. Screening

Particle screening: After drying, the particles are screened by a screening machine to remove unqualified particles (such as oversized or undersized particles), ensuring that the product particle size is uniform and meets market standards.

5. Packaging

Finished product packaging: Qualified particles after screening are quantitatively packaged by an automatic packaging machine. The common packaging form is bagged, and sealing and labeling are also required during the packaging process.

6. Finished product storage and sales

Storage and sales: Packaged earthworm manure organic fertilizer needs to be stored in a dry and ventilated warehouse to avoid moisture and pollution, and is ready for sale to agricultural growers or fertilizer distributors.

7. Auxiliary equipment

Conveying equipment: such as belt conveyors and screw conveyors, used for conveying materials between various processes.

Dust removal equipment: used to collect and process dust during the production process, improving the working environment.

The granulation process of the entire earthworm manure organic fertilizer production line needs to be reasonably planned and designed based on factors such as raw material characteristics, production scale, product quality requirements, and budget to ensure production efficiency and product quality.

Equipment configuration for processing fertilizers in poultry manure organic fertilizer production line

fertilizer granulator Sep 4, 2024

The equipment configuration of the poultry manure organic fertilizer production line is designed based on the characteristics of poultry manure, production scale, fertilizer quality requirements, and cost-effectiveness. A complete poultry manure organic fertilizer production line usually includes the following key equipment and process flow:

1. Raw material pretreatment equipment

Solid liquid separator: used for preliminary dehydration of poultry manure, removing excess water and improving the efficiency of subsequent processing.

Crusher: Grind the separated solid and liquid poultry manure to achieve uniform particle size, facilitating mixing and fermentation.

Blender: Mix crushed poultry manure with auxiliary materials (such as straw, sawdust, grass powder, etc.) and microbial agents evenly to promote fermentation and improve fertilizer quality.

2. Fermentation equipment

Fermentation tank or fermentation chamber: used for composting fermentation, which decomposes organic matter in poultry manure through microbial activity, generating high temperatures to kill bacteria and eliminate pathogens.

Stacker: Regularly flips materials during the fermentation process to ensure oxygen supply and uniform fermentation.

3. Drying equipment

Drying machine: The fermented material needs to be dried to remove excess moisture for granulation and storage. Common drying machines include drum drying machines, belt drying machines, etc.

4. Granulation equipment

Granulator: Choose the appropriate organic fertilizer granulator according to the needs, such as disc granulator, roller extrusion granulator, drum granulator, etc., to process the dried material into granules.

Screening machine: used to screen particles after granulation, remove unqualified particles, and ensure uniform particle size of the product.

5. Post processing equipment

Cooling machine: cools the granules after granulation to avoid the impact of high temperature on packaging and storage.

Packaging machine: Quantitatively package cooled granular fertilizers for easy sales and transportation.

6. Auxiliary equipment

Conveyor: Used for transporting materials between different equipment to improve production efficiency.

Dust removal system: reduces dust emissions during the production process and improves the working environment.

Control system: including PLC control system, used to monitor and adjust the operating parameters of the production line, achieving automated production.

7. Exhaust gas treatment equipment

Deodorization device: used to treat the foul odors generated during the fermentation process, ensuring the environmental friendliness of the production line.

The selection and configuration of equipment need to comprehensively consider factors such as production scale, raw material characteristics, target product quality, and budget. Reasonable equipment configuration and process design are key to ensuring the efficient operation of the poultry manure organic fertilizer production line and the production of high-quality fertilizers.

Performance characteristics of organic fertilizer roller extrusion granulator

fertilizer granulator Sep 4, 2024

Organic fertilizer roller extrusion granulator is an efficient granulation equipment widely used in the granulation production process of organic fertilizers, compound fertilizers and other fertilizers. Its main performance characteristics are as follows:

1. High pressure granulation

The roller extrusion granulator squeezes the raw materials through two sets of high hardness rollers that rotate relative to each other, generating high pressure and forming particles under high pressure. This high-pressure granulation method can effectively improve granulation efficiency and is suitable for granulation of high viscosity or low viscosity materials.

2. Low energy consumption

Compared to other granulation methods, the roller extrusion granulator has lower energy consumption during the granulation process. Due to its granulation process mainly achieved through mechanical extrusion, without the need for additional heating or cooling, it has significant advantages in energy consumption.

3. High particle strength

Through high-pressure extrusion, the granulator can produce particles with high strength and resistance to breakage. This not only facilitates the packaging, transportation, and storage of fertilizers, but also improves the efficiency of fertilizer use during application.

4. Uniform particle size

The roller extrusion granulator can produce uniformly sized particles by precisely controlling the gap between the pressure rollers and the feed rate of the raw materials, ensuring the consistency of fertilizer quality and facilitating uniform fertilization.

5. Wide adaptability

The roller extrusion granulator can process various types of raw materials, including organic fertilizers, compound fertilizers, biological fertilizers, etc. It is suitable for granulation needs with different raw material characteristics and has high adaptability.

6. Self cleaning function

Some of the roller extrusion granulators are designed with self-cleaning systems, which can effectively remove residual materials on the rollers by rotating them in reverse or using cleaning devices, reduce downtime for cleaning, and improve production efficiency.

7. Easy to operate and maintain

The structure of the roller extrusion granulator is relatively simple, and the operation and maintenance are relatively easy, making it suitable for large-scale continuous production. Key components such as pressure rollers are usually made of wear-resistant materials, which have a long service life.

8. Dust control

The roller extrusion granulator generates less dust during the granulation process, which is beneficial for cleaning the working environment and reducing potential hazards to the health of operators.

9. Customizable

According to production needs, the roller extrusion granulator can be customized with different sizes of pressure rollers and different granulation parameters to meet specific particle size and production requirements.

The organic fertilizer roller extrusion granulator, with its advantages of high efficiency, energy saving, and excellent particle quality, has been widely used in the fertilizer production industry and is one of the indispensable key equipment in modern organic fertilizer production lines.

What are the commonly used organic fertilizer fermentation and composting machines in pig farms

fertilizer granulator Sep 4, 2024

In the process of processing pig manure and converting it into organic fertilizer in pig farms, commonly used organic fertilizer fermentation and composting machines mainly include the following types, which provide efficient and convenient solutions for pig manure fermentation according to different working principles and applicable scenarios:

1. Trough type flipping machine

Working principle: The slot type flipping machine performs flipping operations in a fixed slot, flipping the materials inside the stack through a mechanical arm or flipping mechanism to promote air circulation and temperature uniformity.

Advantages: High degree of automation, uniform flipping, suitable for large-scale production, good fermentation effect, and controllable temperature and oxygen supply during the fermentation process.

2. Mobile flipping machine

Working principle: The mobile composting machine can move freely on the ground, flipping materials through devices such as screws, chain rakes, or buckets, and is suitable for open composting sites.

Advantages: High flexibility, easy operation, suitable for medium and small-scale pig farms, and relatively low requirements for the site.

3. Drum type flipping machine

Working principle: Organic materials such as pig manure are flipped inside a rotating drum, and air can be introduced into the drum to promote aerobic fermentation.

Advantages: High fermentation efficiency, enclosed design helps control odors, suitable for use in areas with high environmental requirements.

4. Horizontal spiral conveyor flipping machine

Working principle: Organic materials such as pig manure are flipped horizontally by a screw conveyor and transported simultaneously, suitable for continuous fermentation production lines.

Advantages: High degree of automation, suitable for continuous production, and occupying a small area, suitable for pig farms with limited space.

5. Chain type stacker

Working principle: Using the principle of a chain conveyor, the rake or shovel is driven by the chain to flip the materials inside the pile.

Advantages: Simple structure, low maintenance cost, suitable for pig farms with strict cost control.

6. Self propelled stacker

Working principle: Similar to agricultural tractors, it comes with a tipping device that allows it to walk on the pile and flip materials on its own.

Advantages: Strong maneuverability, flexible operation, suitable for pig farms of various sizes, especially for small or medium-sized composting sites that require frequent flipping.

Choosing a suitable organic fertilizer fermentation and composting machine requires consideration of the specific conditions of the pig farm, such as site size, production scale, fermentation cycle requirements, cost budget, and environmental standards. Reasonable selection and use of turntables can significantly improve the efficiency and quality of pig manure fermentation, bringing economic benefits to pig farms while also promoting resource recycling and environmental protection.

What are the common problems in the granulation process of organic fertilizers

fertilizer granulator Sep 4, 2024

There may be various problems encountered during the granulation process of organic fertilizers, which may affect granulation efficiency, particle quality, and the operational stability of the entire production line. The following are several common problems and their solutions in the granulation process of organic fertilizers:

1. Insufficient particle strength

Reason: The moisture content of the raw materials is too high or too low, the fiber content in the raw materials is insufficient, and the pressure setting of the organic fertilizer granulator is improper.

Solution strategy: Adjust the moisture content of the raw materials to a suitable range (usually 25% -35%), increase the binder or fiber content appropriately, and optimize the pressure and speed settings of the granulator.

2. Irregular particle shape

Reason: Uneven particle size of raw materials and improper setting of granulator parameters.

Solution: Use a crusher to ensure consistent particle size of the raw materials, adjust the speed of the organic fertilizer granulator and the gap between the pressure rollers to obtain a uniform particle shape.

3. Excessive dust

Reason: The raw materials are too dry or crushed, and the sealing of the granulator is poor.

Solution strategy: Control the moisture content of raw materials, avoid excessive crushing, check and improve the sealing of the granulator, and install a dust collection system.

4. Low granulation efficiency

Reason: Improper pre-treatment of raw materials, insufficient maintenance of organic fertilizer granulator, and unreasonable production parameter settings.

Solution strategy: Optimize the raw material pretreatment process, regularly maintain and clean the granulator, adjust production parameters to improve efficiency.

5. Different particle sizes

Reason: The parameters of the granulator are unstable, and the raw materials are mixed unevenly.

Solution: Use a vibrating screen to screen the particles, ensuring uniform mixing of raw materials and stable working parameters of the granulator.

6. Surface cracks or breakage of particles

Reason: Low moisture content in raw materials, excessive granulation pressure, and improper cooling process.

Solution strategy: Increase the moisture content of the raw materials appropriately, adjust the granulation pressure, ensure uniform cooling of the particles, and avoid sudden temperature changes.

7. Production line malfunction

Reason: Equipment aging, improper operation, and insufficient maintenance.

Solution strategy: Regularly maintain and inspect production line equipment, train operators, and replace worn parts in a timely manner.

8. Cost control

Reason: High energy consumption, waste of raw materials, and low equipment efficiency.

Solution strategy: Adopt energy-saving equipment, optimize production processes, reduce raw material loss, and improve equipment utilization.

Solving these problems requires a comprehensive understanding of the organic fertilizer production line, including raw material characteristics, equipment performance, and operating standards. By continuously optimizing production processes and equipment maintenance, the efficiency and product quality of organic fertilizer granulation can be effectively improved.

Granulation characteristics of disc granulator in organic fertilizer production line

fertilizer granulator Sep 4, 2024

The disc granulator is one of the key equipment in organic fertilizer production lines, mainly used to process uniformly mixed organic fertilizer raw materials into spherical particles. The granulation process and characteristics are as follows:

Granulation process

Raw material pretreatment: Before entering the disc granulator, the raw materials need to undergo pre wetting, preheating and other treatments to reach the appropriate moisture content and temperature, in order to improve granulation efficiency and particle quality.

Entering the disc: The pre processed raw materials enter the disc from the top center of the disc granulator, and the disc tilts at a certain angle and rotates at a certain speed.

Granulation process: Under the rotation of the disc, the raw materials begin to roll into clusters and gradually form particles through their own gravity and centrifugal force. At the edge of the disc, particles are ejected due to centrifugal force and enter the subsequent processing stage.

Particle forming: During the rolling process, due to the viscosity of the raw material, the particles gradually increase until they reach the desired size and shape.

Granulation characteristics

High granulation efficiency: The continuous granulation method of the disc granulator can quickly and efficiently process raw materials into granules, improving production efficiency.

Particle uniformity: By precisely controlling the rotation speed, tilt angle, and humidity of the raw materials, particles of uniform size and shape can be produced, which is beneficial for the uniform application and storage of fertilizers.

Easy to operate: The disc granulator has a simple structure and is relatively easy to operate and maintain, making it suitable for large-scale production.

Strong adaptability: capable of handling various types of organic fertilizer raw materials, including powdered, granular, and partially fibrous raw materials, suitable for granulation needs with different raw material characteristics.

Low energy consumption: Compared with other granulation methods such as extrusion granulation, the disc granulator has lower energy consumption during the granulation process, which helps to reduce production costs.

Good particle strength: By adjusting the parameters during the granulation process, the hardness and compressive strength of the particles can be controlled, ensuring that they are not easily broken during transportation and use.

Easy to adjust particle size: By changing the tilt angle, rotation speed, and feed rate of the disc, the particle size can be flexibly adjusted to meet the needs of different fertilizer products.

The disc granulator plays an important role in organic fertilizer production lines. Its efficient granulation ability and adaptability to various raw materials can significantly improve production efficiency and product quality, making it one of the indispensable key equipment in organic fertilizer production lines.