Horizontal organic fertilizer mixer is a widely used equipment in the production process of organic fertilizers, used to evenly mix raw materials and ensure the quality and uniformity of the final product. Its working principle and characteristics are as follows:

working principle

A horizontal organic fertilizer mixer usually consists of a horizontally placed mixing tank and an internal mixing device. The mixing device can be in various forms such as propeller type, blade type, double axis spiral type, etc., and the specific design depends on the characteristics and requirements of the mixing material. During operation, materials enter the mixing tank from the feeding port, and the mixing device rotates under the drive of the motor. Through forces such as shearing, mixing, and flipping, various raw materials are fully mixed to achieve a uniform and consistent effect. After mixing is completed, the material is discharged from the discharge port and enters the next processing step.

characteristic

Efficient mixing: The horizontal organic fertilizer mixer can quickly and evenly mix various raw materials, ensuring that each part of the material can be fully contacted and mixed, improving mixing efficiency and product quality.

Strong adaptability: Suitable for mixing various organic fertilizer raw materials, including dry powder, granules, liquids, etc., capable of handling viscous or fibrous materials, with a wide range of applications.

Compact structure: The horizontal design makes the mixer compact in structure, occupies a small area, and is easy to arrange and use in the production line.

Easy to clean and maintain: The mixing tank is usually designed to be easy to disassemble, facilitating cleaning and maintenance, reducing downtime and maintenance costs.

Low energy consumption: Horizontal mixers have relatively low energy consumption during the mixing process, which helps to reduce production costs and improve economic efficiency.

Good sealing: A well-designed seal can prevent material leakage and dust flying, maintain a clean production environment, and reduce raw material loss.

Automated control: It can be equipped with an automated control system to achieve precise material ratio and mixing time control, improving the stability and controllability of the production process.

Durability: Blenders are typically made of high-strength materials that can withstand prolonged continuous operation and have a long service life.

The horizontal organic fertilizer mixer plays an important role in organic fertilizer production. Through its efficient and uniform mixing ability, it can significantly improve product quality and is one of the indispensable key equipment in organic fertilizer production lines.

The granulation process of a small-scale chicken manure organic fertilizer production line is a key step in converting pre treated and fermented chicken manure into granular organic fertilizer. This process not only improves the physical properties of chicken manure organic fertilizers, such as ease of storage, transportation, and application, but also ensures the uniform distribution of fertilizer components. The following are the main steps of the granulation process in a small-scale chicken manure organic fertilizer production line:

1. Raw material pretreatment

Before granulation, chicken manure raw materials need to be pre treated, including crushing and mixing. Crushing is the process of crushing fermented chicken manure into small particles to increase its surface area, which is beneficial for the subsequent granulation process. Mixing refers to thoroughly mixing chicken manure with other organic or inorganic materials that may be added, such as straw powder, peat, phosphate powder, etc., to adjust the nutritional composition and physical properties of the fertilizer.

2. Adjust the moisture content

Before granulation, it is necessary to adjust the moisture content of chicken manure to a suitable range for granulation, usually 25% -35%. Excessive or insufficient moisture can affect the granulation effect. Moisture adjustment can be achieved by adding water or drying.

3. Granulation

Granulation is the process of processing pre treated chicken manure raw materials into granules. The granulation equipment commonly used in small-scale chicken manure organic fertilizer production lines includes the following:

Disc granulator: suitable for producing small to medium-sized particles. The raw materials are fed into a rotating disk and form particles under the action of centrifugal and frictional forces.

Drum granulator: suitable for large-scale production. The raw materials form particles inside the rotating drum through physical compression or chemical bonding.

Extrusion granulator: suitable for specific raw materials and particle shapes. The raw materials are extruded into specific shaped particles through the mold of the extruder.

4. Particle size adjustment

After granulation, it is necessary to use a screening machine to screen out particles that do not meet the requirements, such as particles that are too large or too small, to ensure uniform particle size in the final product.

5. Drying and cooling

The pelletized chicken manure organic fertilizer particles may contain a high amount of moisture and need to be dried using a dryer to reduce the moisture content to a suitable level for storage and application. After drying, the fertilizer particles need to be cooled to room temperature to avoid clumping due to high temperatures during storage and transportation.

6. Packaging

Finally, the cooled chicken manure organic fertilizer particles are quantitatively packaged using an automatic weighing and packaging machine, ready for sale or storage.

The granulation process of a small-scale chicken manure organic fertilizer production line converts chicken manure into high-value organic fertilizer through scientific processes and appropriate equipment. This not only solves the problem of chicken manure treatment, but also provides high-quality organic fertilizer sources for agricultural production, promoting sustainable development of agriculture.

The construction of NPK fertilizer production line involves multiple key links, each of which requires specific equipment to ensure the smooth progress of the production process and product quality. Here are some key equipment in the NPK fertilizer production line:

Raw material storage equipment: used to store various raw materials such as urea, monoammonium phosphate, potassium sulfate, etc. Common equipment includes raw material warehouses, hoppers, etc.

Raw material crushing equipment: If the raw material particles are too large, a crusher needs to be used to crush them to a particle size suitable for subsequent processes. Common equipment includes hammer crushers, jaw crushers, roller crushers, etc.

Raw material conveying equipment: used to transport raw materials from storage equipment to subsequent processing equipment, including screw conveyors, belt conveyors, bucket elevators, etc.

Ingredient equipment: Accurately weigh various raw materials according to the formula to ensure the accuracy of NPK ratio. Commonly used ones include electronic scales, batching machines, etc.

Mixing equipment: Mix various raw materials thoroughly and evenly to ensure the uniform distribution of fertilizer components. Commonly used types include horizontal mixer, vertical mixer, and double shaft propeller mixer.

Granulation equipment: Mix the evenly mixed raw materials into granules. Common granulators include disc granulators, drum granulators, extrusion granulators, etc.

Drying equipment: used to remove the water added during the granulation process, ensuring the stability and quality of fertilizer particles. Common ones include rotary drum dryer, fluidized bed dryer, etc.

Cooling equipment: Cool and dry fertilizer particles to prevent clumping and improve storage stability. Common ones include drum coolers, fluidized bed coolers, etc.

Screening equipment: used to screen unqualified particles, such as particles that are too large or too small, to ensure the consistency of particle size in the final product. Common types include vibrating screens, drum screens, etc.

Packaging equipment: Quantitatively package qualified fertilizer granules, including automatic packaging machines, sealing machines, palletizing machines, etc.

Environmental protection equipment: used to treat dust, waste gas, etc. generated during the production process, including bag filters, wet dust collectors, waste gas treatment devices, etc.

Automation control system: including PLC control system, touch screen, sensors, etc., used to monitor and control the operation of the production line, improve production efficiency and product quality.

These devices form the core of the NPK fertilizer production line, and selecting the appropriate equipment type and specifications is crucial for the efficient operation and product quality of the production line. When planning a production line, it is necessary to select and configure equipment reasonably based on actual production needs, raw material characteristics, production capacity requirements, environmental standards, and other factors to achieve the best production effect.

The organic fertilizer rotary drum granulator plays a crucial role in processing NPK fertilizers (nitrogen, phosphorus, and potassium fertilizers). NPK fertilizer is a widely used compound fertilizer in modern agriculture, which contains three essential nutrients for crop growth: nitrogen (N), phosphorus (P), and potassium (K). By using a rotary drum granulator, NPK fertilizer raw materials can be processed into uniform and stable granular fertilizers, improving the efficiency of fertilizer storage, transportation, and application. The following are the application details of the rotary drum granulator in processing NPK fertilizers:

working principle:

The rotary drum granulator mainly processes NPK fertilizer raw materials into granules through the following process:

Raw material mixing: First, mix nitrogen fertilizer, phosphorus fertilizer, potassium fertilizer, as well as possible organic materials and additives in a certain proportion to ensure that each fertilizer particle contains balanced nutrients.

Pre wetting of raw materials: In order to promote the formation of particles, it is usually necessary to pre wet the mixed raw materials and adjust their humidity to a suitable level for granulation. Pre wetting can be done using water or liquids containing certain nutrients.

Granulation: The pre wetted raw materials are fed into the drum of the drum granulator. The drum is tilted and equipped with specially designed blades or lifting plates inside. When the drum rotates, the raw materials continuously roll under the action of gravity and centrifugal force, gradually forming particles through mutual collision and adhesion. At the same time, rotary drum granulators are usually equipped with a water spray system, which can adjust the water spray amount as needed to control the formation and size of particles.

Drying: After granulation is completed, the particles need to undergo drying treatment to reduce moisture content and improve particle stability. Usually, a dryer is used for this process.

Cooling and screening: The dried particles need to be cooled to a suitable temperature, and then screened by a screening machine to remove unqualified particles and ensure the quality of the final product.

Packaging: Qualified NPK fertilizer granules are packaged and ready for sale or storage.

advantage:

Improving fertilizer utilization efficiency: Compared to powdered fertilizers, granular NPK fertilizers are less likely to be blown away by wind or washed away by rainwater, which can effectively maintain nutrients in the soil and improve fertilizer utilization efficiency.

Convenient storage and transportation: Granular fertilizers have a small volume and heavy weight, making them easy to package, store, and transport, reducing logistics costs.

Improving application effect: Granular fertilizers are evenly distributed during application, avoiding excessive or insufficient local fertilizer concentration, which is beneficial for balanced crop growth.

Extended storage time: After granulation and drying, the fertilizer has a low moisture content and is not easily moldy or spoiled, which extends the storage time of the fertilizer.

By using a rotary drum granulator, the production of NPK fertilizers not only improves efficiency, but also ensures the quality and application effect of fertilizers, which is of great significance for the sustainable development of modern agriculture.

The total cost of establishing an organic fertilizer production line with an annual output of 5000 tons will vary depending on multiple factors, including the degree of automation of the production line, the quality of equipment, the configuration of the production line, civil engineering costs, installation and commissioning costs, raw material procurement costs before operation, and possible investment in environmental protection facilities. The following is an overview of some major costs, but please note that this is only an estimated range and actual costs may vary due to market conditions, supplier quotes, and specific needs:

Equipment cost: The cost of organic fertilizer equipment includes raw material pretreatment equipment (such as crushers and mixers), fermentation equipment (such as fermentation tanks and stackers), granulation equipment (such as roller extrusion granulators), drying and cooling equipment, screening equipment, packaging equipment, and conveying equipment. These costs may range from several hundred thousand yuan to several million yuan.

Civil engineering costs: including factory construction, equipment infrastructure construction, warehouse construction, etc. This part of the cost may range from several hundred thousand yuan to several million yuan depending on the size of the factory and the construction location.

Installation and commissioning: The installation and commissioning costs of equipment, including labor costs and possible additional material costs, typically account for 10% to 20% of the equipment cost.

Pre operational costs: including raw material procurement, pre operational market research, personnel training, and preparation of operating funds. These costs may vary from several hundred thousand yuan to several million yuan depending on the specific situation.

Environmental protection facilities: In order to comply with environmental standards, it may be necessary to invest in environmental protection facilities such as exhaust gas treatment systems, wastewater treatment systems, etc. The cost of this part may range from several hundred thousand yuan to several million yuan depending on the type and scale of the equipment.

Working capital: The initial requirement for working capital during operation, used to pay for daily operating costs such as wages, utilities, maintenance expenses, etc., which may range from tens of thousands to millions of RMB.

Based on the above costs, the total investment for an organic fertilizer production line with an annual output of 5000 tons may range from several million yuan to over 10 million yuan. However, in order to obtain a more accurate investment estimate, it is recommended to consult a professional organic fertilizer production line design company or equipment supplier to provide a detailed quotation and plan based on your specific needs. When considering investment, the long-term operating costs, maintenance costs, production efficiency, and possible market returns of the equipment should also be taken into account to make more reasonable decisions.

The investment cost of NPK fertilizer production line is influenced by various factors, including the scale of the production line, degree of automation, equipment quality, production line design, geographical location, construction cost, environmental requirements, and whether it includes upstream and downstream facilities such as raw material procurement and finished product sales. Here are some rough investment cost ranges, but please note that actual costs may vary significantly depending on specific projects:

Small NPK fertilizer production line: A production line with an annual capacity of less than 5000 tons, with investment costs ranging from several hundred thousand to several million RMB. This type of production line usually has a low degree of automation and a small equipment scale.

Medium sized NPK fertilizer production line: A production line with an annual capacity of 5000 to 50000 tons, with an investment cost of several million to tens of millions of RMB. This type of production line may include more advanced equipment and a certain degree of automation.

Large scale NPK fertilizer production line: A production line with an annual capacity of over 50000 tons, with investment costs that may reach tens of millions or even billions of RMB. This type of production line is usually highly automated, equipped with advanced technology, and may include more comprehensive environmental protection facilities and quality control equipment.

The composition of investment costs may include but is not limited to:

Equipment cost: including various key equipment mentioned above.

Civil engineering cost: including infrastructure construction such as factory building, raw material warehouse, and finished product warehouse.

Installation and commissioning costs: The installation, commissioning, and trial operation costs of the equipment.

Operating preparation costs: including employee training, raw material procurement before operation, etc.

Working capital: used for raw material procurement, salary payment, daily operations, etc. in the early stage of operation.

Environmental and safety costs: The cost of ensuring that NPK fertilizer production line comply with local environmental and safety standards.

To obtain a more accurate estimate of investment costs, it is recommended to consult professional equipment suppliers, engineering design companies, or industry consultants who can provide detailed cost analysis based on your specific needs and conditions. In addition, it is important to consider long-term operating costs, market potential, policy environment, and other factors to ensure the feasibility, profitability, and sustainability of the project.

The rotary drum granulator has demonstrated its unique functions and advantages in processing NPK fertilizers (nitrogen phosphorus potassium compound fertilizers). These functions not only improve production efficiency, but also optimize the physical and chemical properties of fertilizers, thereby enhancing the quality and application effect of fertilizers. The following are the special functions of the rotary drum granulator in processing NPK fertilizers:

Continuous granulation capability: The rotary drum granulator can continuously process a large amount of raw materials, making it suitable for large-scale fertilizer production. Its design allows the raw materials to roll continuously in the drum, forming uniform particles. This process can be carried out continuously, improving production efficiency and capacity.

Controllable particle size and shape: By adjusting the parameters of the drum, such as drum speed, raw material humidity, and feed rate, the particle size and shape can be precisely controlled. This ensures the uniformity and consistency of the final product, which is crucial for the effectiveness of fertilizer application.

Efficient mixing and granulation: During the granulation process, the raw materials are thoroughly mixed and squeezed through the rotation of the drum and internal structures such as lifting plates and stirring blades, which helps to achieve uniform distribution of raw materials and particle formation, improving granulation efficiency and particle quality.

Integrated drying and cooling functions: Some drum granulators are designed with integrated drying and cooling functions, which can directly dry and cool the particles after granulation, reducing the number of production processes, saving energy and time, and improving the stability and storage performance of the particles.

Strong adaptability: The rotary drum granulator can process different types of raw materials, including various components of NPK fertilizers. It can adapt to the characteristics and requirements of different raw materials, and produce granular fertilizers that meet specific needs by adjusting process parameters.

Environmentally friendly: The rotary drum granulator is designed with a focus on environmental protection. By optimizing the process and equipment, it reduces energy consumption and exhaust emissions during the production process, which helps to achieve green production and meets the requirements of sustainable development.

Easy to maintain and operate: Drum granulators typically have a user-friendly interface and automated control, making operation simple and maintenance convenient. Its design considers long-term stability, reducing downtime and maintenance costs.

Through the above functions, the rotary drum granulator can provide high-quality granular products when processing NPK fertilizers, meeting the high standard requirements of modern agriculture for fertilizers, and is an indispensable key equipment on the fertilizer production line.

On the organic fertilizer production line, in order to reduce the impact on the environment, a series of environmental protection measures are usually taken to ensure that the production process meets environmental standards. Here are some common environmental measures:

Waste gas treatment: A certain amount of dust and odorous gases will be generated during the production process. Common waste gas treatment facilities include:

Dust collector: such as bag filter and cyclone dust collector, used to capture and treat dust generated during the production process.

Biological filter: using microorganisms to decompose organic matter in exhaust gas, suitable for treating exhaust gas containing organic odors.

Activated carbon adsorption: used to adsorb harmful gases in exhaust gas, such as ammonia, hydrogen sulfide, etc.

Wet scrubber: Wash exhaust gas with water mist or chemical solution to remove dust and harmful gases.

Wastewater treatment: The wastewater generated during the production process of organic fertilizer production line needs to be treated to meet discharge standards. Common wastewater treatment methods include:

Physical treatment: such as precipitation and filtration, used to remove suspended solids from wastewater.

Biological treatment, such as activated sludge process and biofilter, is used to degrade organic matter in wastewater.

Chemical treatment: such as coagulation and flocculation, used to remove colloids and dissolved substances from wastewater.

Deep processing: such as membrane filtration and advanced oxidation, used to treat difficult to degrade pollutants.

Noise control: The mechanical equipment of the organic fertilizer production line generates noise during operation. Common noise control measures include:

Soundproofing materials: Use soundproof materials around the equipment, such as soundproof walls and soundproof covers.

Silencer: Install silencers at noise sources such as fans and compressors.

Layout optimization: Reasonably layout the production line and keep noise sources away from sensitive areas.

Resource recycling and reuse:

Water cycle system: Establish a wastewater recovery system to recycle the treated wastewater and reduce water resource consumption.

Thermal energy recovery: Utilizing waste heat from the production process, such as hot air generated during the drying process, to recover thermal energy and reduce energy consumption.

Waste recycling: Classify and treat waste generated during the production process, and reuse recyclable materials.

Environmental monitoring: Regularly monitor the production environment, including air quality, water quality, noise levels, etc., to ensure that the production process does not have adverse effects on the surrounding environment.

By adopting the above environmental protection measures, the organic fertilizer production line can not only reduce the negative impact on the environment, but also improve resource utilization efficiency and achieve sustainable production. When planning and operating production lines, local environmental regulations and standards should be strictly followed to ensure that production activities are coordinated with environmental protection.

Chain type organic fertilizer crusher is a key equipment used in organic fertilizer production, mainly used to crush large organic materials such as straw, livestock manure, etc. to a particle size suitable for granulation. In order to ensure the long-term stable operation and extend the service life of the equipment, maintenance after use is crucial. Here are some maintenance points for chain organic fertilizer crushers after use:

Cleaning: After each use, the residual materials inside and outside of the Chain type organic fertilizer crusher should be thoroughly cleaned. Use a soft brush or compressed air to remove residue from blades, chains, and sieves to avoid affecting their next use after the material has hardened.

Check the blades and chains: Check the wear of the blades and chains. Blades and chains are vulnerable parts in crushers and may need to be sharpened or replaced after prolonged use. Regularly inspect and adjust or replace blades and chains based on wear to ensure effective crushing.

Lubrication: Regularly lubricate the bearings, chains, and other moving parts of the crusher, using appropriate lubricating oil or grease to reduce wear and extend service life.

Check fasteners: Check all fasteners of the chain organic fertilizer crusher, including screws, bolts, etc., to ensure that they are not loose. Loose fasteners may cause unstable equipment operation and even damage the equipment.

Checking the sieve: The cleanliness and integrity of the sieve are crucial for maintaining the crushing effect. Check if the screen mesh is damaged or blocked, and if necessary, clean or replace it.

Electrical inspection: Check the electrical components of the crusher, such as the motor, cables, and control panel, to ensure that they are in good condition and there are no exposed wires or damaged parts.

Storage: When not in use, the crusher should be stored in a dry, ventilated environment to avoid moisture and corrosion.

Regular maintenance: According to the recommendations of the equipment manufacturer, perform deep maintenance regularly, including replacement of worn parts, comprehensive cleaning and inspection, to ensure optimal performance of the equipment.

Operation record: Record the time of each use, the type and quantity of crushed materials, maintenance and inspection status, in order to track the operation status and maintenance history of the equipment.

Train operators: Ensure that all operators have received appropriate training, understand the operation, maintenance, and safety procedures of the equipment, and reduce the risk of operational errors and accidents.

By following the above maintenance points, the reliability and efficiency of the Chain type organic fertilizer crusher can be significantly improved, the failure rate can be reduced, the service life of the equipment can be extended, thereby reducing production costs and improving production efficiency.

There are many significant benefits to using a rotary drum granulator for granulation of NPK fertilizers. These advantages not only improve the production efficiency and product quality of fertilizers, but also optimize the storage, transportation, and application effects of fertilizers. The following are the main benefits of using a rotary drum granulator to granulate NPK fertilizer:

Improving the physical properties of fertilizers:

Uniform particle size: The rotary drum granulator can produce particles of uniform size, which helps to evenly distribute fertilizers in the soil, avoid local fertilizer concentrations that are too high or too low, and promote balanced crop growth.

Enhanced particle strength: Through the granulation process, the physical strength of the particles is enhanced, reducing crushing and dust generation during storage and transportation, and improving the storage stability and logistics efficiency of fertilizers.

Improve fertilizer utilization efficiency:

Reduce loss: Granular NPK fertilizers are less likely to be blown away by wind or washed away by rainwater than powdered fertilizers, reducing fertilizer loss and improving the retention rate of fertilizers in the soil, thereby increasing fertilizer utilization efficiency.

Controlled release effect: The release rate of granular fertilizers is relatively more controllable, which helps to gradually release fertilizer nutrients, meet the nutritional needs of crops at different growth stages, and avoid excessive or insufficient nutrition.

Convenient storage and transportation:

Small size and heavy weight: Granular fertilizers have a small volume and heavy weight, making them easy to package, store, and transport, reducing the need for storage and transportation space, and lowering logistics costs.

Optimize application effect:

Uniform application: Granular fertilizers are distributed more evenly during application, avoiding the problem of high or low local concentration of fertilizers, helping crops absorb nutrients in a balanced manner, and promoting healthy growth.

Reducing environmental pollution: The application of granular fertilizers reduces the volatilization and loss of fertilizers, reduces environmental pollution, and contributes to the sustainable development of agriculture.

Extended storage time:

Reduce moisture content: Through granulation and drying processes, the moisture content of granular fertilizers is reduced, reducing their moisture absorption and the possibility of mold and deterioration, and extending their storage time.

By using a rotary drum granulator to granulate NPK fertilizer, not only does it improve the physical and chemical stability of the fertilizer, but it also optimizes the application effect and reduces the impact on the environment. It is an indispensable technical means in modern agricultural fertilizer production.