fertilizer production line

Organic fertilizer fermentation process

1. Pile livestock and poultry manure and other materials, domestic garbage, sludge and other fertilizer base materials on a flat ground in a chopped shape. (The trough compost windrow turner directly puts the material into the trough), the pile width is equal to the turning pile width of the equipment, the height is as high as possible, and the length is as long as possible, such as 50 meters, 100 meters, etc., the ground should be flat, cement, Land can be used.

2. Sprinkle the piled up livestock manure and other materials, household garbage, sludge and other fertilizer base materials on the biological fermentation bacteria agent.

3. Use a compost windrow turner to mix straw, livestock and poultry manure and other materials, domestic garbage, sludge, (water content should be 50%-70%), fermentation bacteria, etc., and deodorize in 3-5 hours. Raise the temperature to 50°C in 16 hours, and when the temperature reaches 55°C, turn the stack again to increase oxygen. Afterwards, start stirring whenever the material temperature reaches 55°C, which has the effect of uniform fermentation, aeration and cooling. Repeat the last process until it is complete decomposed.
4. If the moisture content of livestock manure and other materials, domestic garbage, sludge, etc. is too high, you can add organic, relatively dry auxiliary materials that can absorb moisture and place the last dried fertilizer underneath to form a chop shape to reduce the moisture content. Larger livestock and poultry manure and other materials, household garbage, sludge, etc. are placed in the middle, so that the water from the top can seep to the bottom.

5. The general fertilizer process takes 7-10 days. Due to the different climates in different regions, it may take 10-15 days before the materials will be completely decomposed. It is truly odorless, free of bacteria, eggs, weed seeds, and humus High, increased potassium content, etc. Powdered organic fertilizer is made.

6. If you want to make powdered fertilizer into granular fertilizer, you need to add organic fertilizer granulator, crusher, grading screen, dryer, cooler, automatic packaging machine, belt conveyor and other equipment.

The spatial layout of organic fertilizer fermentation equipment is closely related to the size and investment of infrastructure. A reasonable layout of organic fertilizer fermentation equipment can reduce investment, effectively utilize production space, and maximize the effect with the least amount of money.

How to Make a Good Space Layout for Organic Fertilizer Fermentation Equipment

1、 The impact of raw materials on the process equipment and plant design of organic fertilizer production lines.

Due to the different raw materials, which affect the production process, most organic fertilizer raw materials have pollution effects. One situation is that for the pre-treatment process of raw materials, the manufacturer can directly pre-treat the raw materials in the breeding farm or planter, and then store and transport them to the manufacturer in a closed manner; Another scenario is to directly collect untreated waste from growers and farms for pre-treatment in the factory area. These two methods have a direct impact on the construction of processing zone area.

2、 The influencing factors of fermentation process.

The fermentation process needs to be based on the amount of materials. Currently, the fermentation process that meets national production standards is aerobic fermentation, and the fermentation cycle consists of two parts: fermentation maturity and secondary aging. In order to meet the standards, it is recommended to use tank fermentation or stack fermentation as much as possible. Compared to the two, with the same production capacity requirements, stack fermentation occupies a larger area of the factory area.

Another factor affecting the fermentation process is the fermentation equipment used. Tank type fermentation often uses a mobile crane with multiple tanks for fermentation, and the overturning and throwing process directly realizes the movement of materials towards the discharge port. The secondary aging stage can be transferred from the fermentation tank, thus achieving continuous fermentation,; However, the stack type uses a walking composting machine or a tipping machine, which is inherently inconvenient for material transfer and often results in the secondary aging process stage being aged in place, affecting the fermentation cycle.

3、 Process impact in the later stage of deep processing.

The post processing process of organic fertilizer production line equipment can be divided into powder organic fertilizer production line process and particle organic fertilizer production line process, with significant differences in occupied area and equipment infrastructure investment between the two.

Starting from the production line process of powdered organic fertilizer, the processing process of powdered organic fertilizer is that after the raw materials are fermented and matured, the main equipment can be sold as long as the processes such as crushing, stirring, and packaging are used. To put it bluntly, the production line process of powdered organic fertilizer is part of the particle processing process.

In terms of particle organic fertilizer production line technology, in addition to crushing, stirring, packaging and other processes, drying, granulation, particle grading, and particle coating are also required. Therefore, only processing production lines with an annual production capacity of over 10000 tons choose particle processing technology, while small capacity enterprises often choose powder fertilizer processing technology.

The organic fertilizer machine mixes livestock manure and other breeding wastes, straw, sawdust and other biomass and reflux materials in a certain proportion, so that the moisture content reaches the design requirements of 60-65%, and then enters the three-dimensional aerobic system. By adjusting the moisture content, oxygen content and temperature changes of raw materials, the materials are fully aerobic fermentation and decomposition.

The compost windrow turner can control the temperature between 55 ℃ and 60 ℃ through ventilation, aeration, stirring and other functions, so as to achieve the optimal temperature of livestock and poultry manure fermentation treatment. At this temperature, a large number of pathogenic sheath and parasites in livestock and poultry manure can be killed. At the same time, the deodorization system is used to carry out biological odor to the discharged gas, so as to achieve the purpose of harmless treatment of livestock and poultry manure. The organic fertilizer machine has the following advantages:

1. The high temperature biological sheath technology has the advantages of low energy consumption and low operation cost;

2. High degree of automation, simple operation, one person can complete the fermentation process;

3. The deodorization system is used to carry out biological odor to the discharged gas, so as to achieve the gas emission standard and avoid secondary pollution. 

In the 1990s, the Chinese government made plans and action deployments for the comprehensive utilization of crop straw resources. Mainly including the following aspects: 1. As of the end of 2000, the country had invested 367 million yuan in building 13 straw livestock demonstration zones and 380 demonstration counties nationwide, directly promoting the development of herbivorous livestock in China. With the deepening of the government’s understanding of the ban on straw burning, in May 1998, China decided to implement a national demonstration project for straw gasification. The country allocates a portion of funds annually to support the promotion of straw gasification technology in rural areas, solve rural energy consumption problems, and alleviate rural environmental pollution. The technological innovation of straw comprehensive utilization in the 3 straw innovation industries has been listed as one of the focuses of the Ministry of Science and Technology in recent years, including straw fertilizer technology, straw feed technology, straw fuel technology, straw industrial raw material technology, and straw as a substrate for edible fungi technology. Overall, the comprehensive utilization of straw in China started relatively late compared to developed countries abroad, but the results of comprehensive utilization are relatively significant.

It is not only an energy project, but also conducive to promoting the industrialization of bioenergy. It is also a good agricultural development project. Using straw to produce organic fertilizer can effectively improve the growth environment of crops, increase their yield and agricultural benefits, and is conducive to increasing farmers’ income and efficiency. It is very in line with the needs of China’s comprehensive promotion of new rural construction and has broad application prospects in rural areas.

The straw organic fertilizer production equipment can quickly and harmlessly solve the problem of agricultural waste such as straw, wheat straw, corn straw, and vegetable residues, edible mushroom residues, plant manure, tobacco residues, etc. that are casually discarded in the field and rotting or burning in the open air. It can completely eliminate diseases, pests, and weeds in agricultural waste and quickly convert them into excellent organic fertilizer. The birth of straw organic fertilizer equipment can harmless solve the problem of straw burning. This production equipment has the advantages of low investment, small land occupation, high profits, and good efficiency. The straw organic fertilizer production equipment is used to process and ferment the remaining stem and leaf parts of corn, rice, wheat, and other cereal crops after ripening and threshing. After preliminary fermentation treatment and later deep processing and granulation, qualified commercial organic fertilizers are produced.

The machinery commonly used in straw organic fertilizer production equipment includes: organic fertilizer stacker, organic fertilizer crusher, organic fertilizer mixer, organic fertilizer granulator, rotary dryer, rotary cooling machine, organic fertilizer screening machine, organic fertilizer coating machine, organic fertilizer packaging equipment, organic fertilizer belt conveyor, etc.

Due to factors such as wear and tear of parts or improper human use caused by long-term use, some faults are inevitable during the use of organic fertilizer fermentation equipment. Therefore, how to minimize equipment failure rate, reduce maintenance frequency, and extend equipment service life has been a problem that organic fertilizer equipment manufacturers have been studying.

Correct maintenance methods for organic fertilizer fermentation equipment

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

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

3. Correct defective designs and proactively repair design and manufacturing defects in organic fertilizer fermentation equipment with accompanying improvements;

4. Control any abnormal external conditions and accelerate the deterioration of organic fertilizer equipment.

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

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

The microbial strains in the finished organic fertilizer processed by the organic fertilizer equipment can improve the soil structure, increase the content of organic matter in the soil, and use chemical fertilizers and compound fertilizers to greatly increase crop yield. The organic fertilizer fermentation equipment can not only solve the environmental pollution caused by the storage of agricultural breeding wastes, but also improve the soil structure and increase the crop yield. Recycling resources plays a crucial role in promoting sustainable development in agriculture.

Organic fertilizer production process: A package of ‘high temperature bacteria starter for poultry feces’ is mixed with a small amount of corn flour and directly sprinkled into duck and goose feces for fermentation, each package can ferment 1 cubic meter; or a package of ‘special high temperature bacteria starter for poultry manure’ and corn flour can be directly used; or one package of this product can be mixed with brown sugar (white sugar and molasses can be used) and warm Water, made into a mixture of bacteria, fermentation 24 hours standby, we call the activated strain, can ferment 2-3 cubic meters.

The activated bacteria were layered or simply mixed into 2-3 cubic meters of duck and goose feces, and a small amount of bacteria mixture was left on the upper layer of the whole pile. Duck and goose manure with water content more than 80% will slow down the fermentation. Some auxiliary materials (hay, mushroom bran, straw, etc.) can be added. The moisture content of duck and goose manure after fermentation should be kept at about 65%, and the fermentation speed is the fastest.
The fermentation material pile is simply covered with thin film, which does not need to be sealed, and it should be protected from rain. Generally, the internal temperature can reach above 75, after 24 hours of fermentation, and the fermentation compost windrow turner turns the pile for 1-2 times or does not turn the pile (turning the pile will speed up the fermentation speed, and the quality is better). After the temperature is relatively constant, the fermentation is completed. The symbol of successful fermentation is: the material has completely no odor of feces, on the contrary, it has a light aroma after biological fermentation, and the pile is full of a large number of white hyphae.

There are two steps to process commercial organic fertilizer in the organic fertilizer production line: early fermentation and treatment part and deep processing granulation part. Organic fertilizer equipment needs fermentation compost windrow turner, crusher, mixer, organic fertilizer granulator, dryer, cooler, screening machine, coating machine, packaging machine, conveyor and other equipment. 

Small organic fertilizer processing plants generally refer to small organic fertilizer processing equipment with an annual output of thousands of tons. The commonly used organic fertilizer processing equipment includes: organic fertilizer tipping machines, semi wet material crushers, organic fertilizer packaging machines, and fermentation tanks can be selected according to the situation. In general, organic fertilizer processing equipment without a fermentation tank can produce organic fertilizer for less than 100000 yuan. If a fermentation tank needs to be purchased, the price is about 200000 yuan to achieve organic fertilizer production.

The production equipment used in small organic fertilizer processing plants is not just a few simple fixed equipment, but needs to be determined based on the customer’s on-site site and materials. For example, chicken manure has a high amount of moisture, and when fermenting, the moisture must be reduced. Corn cobs and other materials such as straw can be added to crush them, otherwise they cannot be granulated. Sheep manure is relatively dry, and when fermenting, controlling the moisture does not require adding straw or other materials to directly granulate. The equipment used varies depending on the process. The conventional organic fertilizer production process is divided into: organic fertilizer powder production equipment and organic fertilizer granular production equipment.

Advantages of small organic fertilizer processing plants:

1. The investment equipment price for small-scale organic fertilizer processing is low, the production project cost is low, and the equipment investment returns quickly. Generally, the output of small-scale organic fertilizer processing plants is below 30000 tons, and the corresponding investment amount is much smaller. A small organic fertilizer processing plant can achieve mass production for hundreds of thousands of yuan. In contrast, if it is a large organic fertilizer processing plant, the equipment cost may be over a million yuan. For those who are new to the organic fertilizer processing industry, there are significant risk concerns. Compared to investment, small organic fertilizer processing plants have a strong annual cost recovery ability and can basically achieve profitability within one year.

2. The Xiaofei Organic Fertilizer Processing Plant covers a small area and has low infrastructure costs. Due to the fact that the fermentation equipment and deep processing equipment for organic fertilizer processing are relatively large machines, which can be several meters or even tens of meters long, it is also a significant cost for the land used in the factory area.

3. The source of raw materials for small organic fertilizer processing plants is convenient for storage, transportation, and collection. We all know that the main raw material for organic fertilizer is the storage, transportation, and collection of animal manure, which is also a headache. Small organic fertilizer processing plants can reduce the transportation radius of raw materials, making storage and transportation more convenient and reducing storage and transportation costs.

4. Small organic fertilizer processing plants have good scalability. In the initial stage, many organic fertilizer processing factories put into production with a trial mentality, and then with the development of business, we need to increase production and increase production lines. Our company’s existing equipment and processes all have the ability to expand production in order to increase production capacity.

5. The equipment invested in small organic fertilizer processing plants has the advantages of simple operation, less labor, and convenient and simple maintenance.