fertilizer production line

Rotary drum dryers are professionally used in the manufacturing of NPK fertilizer and organic fertilizer processing. The dried and cooled fertilizers are suitable for storage and transportation, and will not deteriorate due to excessive humidity.

Working process of Rotary drum dryers

The fertilizer to be dried enters into the receiving tank of the drum dryer from the high-level tank. The material is attached to the surface of the drum by the film distributing device. There is a heating medium in the drum, and the material is heat transferred by the simple wall during the rotation of the drum to make it vaporized. In one rotation cycle, the rolling cylinder completes the process of film distribution, vaporization and dehydration. The dried materials are scraped off by a scraper and sent to the finished product storage tank by a conveyor, and finally crushed or directly packed. The water evaporated in heat transfer can be introduced into the corresponding treatment device for dust capture or emission according to its nature.

When the dryer can meet the output of organic fertilizer production line, the drying effect is not good, most of the internal structure is unreasonable, or the cylinder length is not enough. Although these are not big problems, they affect the interests of users to a great extent. The solution is to reasonably adjust the internal lifting plate and length according to the material demand. The lifting plate can increase the contact area between the diffusion material and hot gas, and the increase of cylinder length can prolong the drying time.

During the granulation process using a disc granulator, the following common issues may be encountered:

Uneven particle size:

Reason: Inconsistent humidity of raw materials, unsuitable disc speed, clogged or damaged screen mesh.

Solution: Adjust the humidity of the raw materials to a suitable level, optimize the disc speed of the disc granulator, clean or replace the screen mesh.

Poor particle shape:

Reason: Uneven particle size of raw materials, too fast or too slow disc rotation speed, improper amount of adhesive used.

Solution: Optimize the particle size distribution of raw materials, adjust the disc speed to a suitable level, and adjust the amount of adhesive used.

Low production:

Reason: Insufficient feeding of raw materials, low disc speed, and small mesh size.

Solution: Increase the feeding amount of raw materials, increase the disc speed, and replace the appropriate screen mesh.

Equipment blockage:

Reason: The humidity of the raw materials is too high, the viscosity of the raw materials is too high, and the mesh size is not suitable.

Solution: Reduce the humidity of raw materials, adjust the amount of adhesive used, and replace the appropriate screen mesh.

Equipment wear and tear:

Reason: Long term high load operation, high hardness of raw materials, and improper maintenance.

Solution: Regularly shut down for rest, choose components made of wear-resistant materials, and strengthen daily maintenance.

High temperature:

Reason: Long term continuous operation, cooling system failure, high ambient temperature.

Solution: Regularly shut down for rest, inspect and repair the cooling system, and improve the working environment.

Excessive energy consumption:

Reason: Low equipment efficiency, improper operation, and untimely maintenance.

Solution: Optimize the operation process, regularly maintain the disc granulator, and choose high-efficiency and energy-saving equipment.

Excessive noise:

Reason: Equipment aging, loose components, improper maintenance, etc.

Solution: Regularly inspect fasteners, replace worn parts, and strengthen equipment maintenance.

Excessive dust:

Reasons: Raw material drying, screening process, poor equipment sealing, etc.

Solution: Increase raw material humidity, optimize screening system, and improve equipment sealing performance.

Complex operation:

Reason: Insufficient proficiency in equipment operation, lack of effective training, etc.

Solution: Provide sufficient training and guidance to ensure that operators are familiar with equipment operation and maintenance.

By analyzing and solving these common problems, the efficiency and product quality of the disc granulator can be effectively improved, while extending the service life of the equipment.

The fertilizer produced by the disc granulator has the following characteristics:

Particle shape rules:

The disc granulator can usually produce round or nearly round particles with a relatively regular shape, which is conducive to mechanized sowing and fertilization.

Adjustable particle size:

By adjusting the rotation speed of the disc and the aperture of the sieve, particles of different sizes can be produced to meet the needs of different crops and soil conditions.

High strength and moderate hardness:

The fertilizer granules produced by the disc granulator have a certain mechanical strength, which can resist crushing during transportation and use, and have moderate hardness, making it easy for crop roots to absorb.

Good uniformity:

Due to the uniform mixing and rolling of raw materials on the disc, the nutrient distribution of the produced fertilizer particles is uniform, which is conducive to the balanced absorption of nutrients by crops.

Wide applicability:

Suitable for producing various types of fertilizers such as organic fertilizers, compound fertilizers, and slow-release/controlled-release fertilizers, it has a wide range of applicability.

High production efficiency:

The production efficiency of the disc granulator is relatively high, and it can produce a large amount of fertilizer particles in a short period of time.

Low energy consumption:

Compared to other granulation technologies, the disc granulator has lower energy consumption during the production process, which is beneficial for energy conservation.

environment protection

It can effectively utilize agricultural waste and industrial by-products, reduce environmental pollution, and reduce excessive use of fertilizers, which is conducive to sustainable agricultural development.

Easy to store and transport:

The formed fertilizer particles have a relatively small volume, light weight, and are easy to store and transport, reducing logistics costs.

Strong market competitiveness:

Due to the aforementioned advantages of its fertilizers, it has strong competitiveness in the market and can meet the needs of different customers.

At present, the manufacturing of NPK fertilizer is almost all automatic configuration, and the organic fertilizer production process is basically realized by mechanical equipment. The fertilizer production process is relatively strict. Before operation, it must be controlled according to the strict control process, so as to give full play to the energy efficiency of the equipment and achieve twice the result with half the effort.

The development of organic fertilizer equipment is getting faster and faster, especially in recent years, in view of the prominent problems in China’s agricultural production such as excessive use of fertilizer, low efficiency, and declining quality of cultivated land, the main goal of bio-organic fertilizer production equipment is to reduce the use of fertilizer, improve the quality of cultivated land, and realize the industrialization of new and efficient bio-fertilizer.

In the operation of fertilizer equipment, before the initial start-up of the machine, the machine should be debugged, especially rotary drum granulator, dryer, cooler and other equipment. During debugging, proper tools should be used. And when removing components, do not use too much force to avoid damage to parts. After debugging, the loose parts should be tightened

In order to make fertilizer production equipment perform better functions, it is not only normal control process, but also need to carry out regular inspection and maintenance to prevent unnecessary problems during operation.

The maintenance of the disc granulator after granulation mainly includes the following aspects:

1. Cleaning work:

After the disc granulator stops, first turn off the power, then open the machine door and take out the remaining raw materials and particles.

Use appropriate tools (such as soft brushes, compressed air, etc.) to remove residues inside the granulator, especially the sieve and feeding port, to prevent blockage and corrosion.

Cleaning the surface of the machine, removing dust and dirt, and keeping the equipment clean can help ensure normal start-up and operation for the next use.

2. Inspection and fastening:

Check all fasteners of the machine to ensure there is no looseness. If necessary, use a torque wrench to tighten again.

Check the transmission parts, including gears, chains, and belts, to ensure they are not worn or broken, and lubricate them if necessary.

3. Lubrication and maintenance:

Lubricate all parts that require lubrication, such as bearings, gears, etc., using recommended lubricating oil or grease.

Check if the lubrication system is working properly and ensure that the lubricating oil flow and pressure meet the requirements.

4. Electrical system inspection:

Inspect the electrical control cabinet to ensure that all wires are securely connected and free from erosion or corrosion.

Check electrical components such as contactors, relays, sensors, etc. to ensure they are working properly and not damaged.

5. Inspection of worn parts:

Regularly inspect vulnerable parts such as screens, blades, hammers, etc., and determine whether replacement is necessary based on the degree of wear.

For severely worn components, they should be replaced in a timely manner to avoid affecting the normal operation and production efficiency of the equipment.

6. Storage and Protection:

After maintenance is completed, store the equipment in a dry and ventilated environment to avoid moisture and corrosion.

For equipment stored outdoors, it should be covered with rainproof cloth to prevent rainwater from entering.

7. Record and track:

Record the date, content, and replaced parts of each maintenance, and establish a maintenance file.

Based on maintenance records, develop subsequent maintenance plans and preventive maintenance measures.

Through the above maintenance steps, it can be ensured that the disc granulator receives appropriate maintenance after granulation is completed, extending the service life of the equipment and ensuring production efficiency and product quality.

Fertilizer produced using a disc granulator has the following benefits:

Good uniformity:

Due to the working principle of the disc granulator, the fertilizer particles produced have good uniformity, which helps crops absorb nutrients more evenly.

High strength and wear resistance:

The fertilizer particles produced by the disc granulator have high mechanical strength and can resist crushing during transportation and use, reducing the generation of dust.

Strong adaptability:

The disc granulator can process various types of raw materials, including wet and dry materials, as well as raw materials of different particle sizes, with strong adaptability.

High production efficiency:

The production efficiency of the disc granulator is relatively high, and it can produce a large amount of fertilizer particles in a short period of time.

Energy conservation and environmental protection:

The disc granulator has low energy consumption during the production process and can further reduce energy consumption through methods such as recovering heat energy.

At the same time, the dust and exhaust emissions during the production process are relatively low, and the impact on the environment is minimal.

Easy to automate control:

The disc granulator can be equipped with advanced control systems to achieve automated production, reduce manual operations, and improve production efficiency and product quality.

High flexibility:

By adjusting the parameters of the disc granulator, such as speed and feeding speed, it is easy to adjust the particle size and density of the product to meet the needs of different users.

Low maintenance cost:

The structure of the disc granulator is relatively simple, easy to maintain and clean, and reduces long-term operating costs.

Improving fertilizer quality:

By precisely controlling the production process, high-quality fertilizers that meet specific standards can be produced to meet market demand.

Promote resource recycling:

The disc granulator can convert agricultural waste, industrial by-products, etc. into valuable fertilizer resources, which helps to achieve resource recycling.

In summary, fertilizers produced using disc granulators have multiple advantages, meeting the modern agricultural demand for efficient, environmentally friendly, and sustainable fertilizers while improving production efficiency and product quality.

After the production and processing of organic fertilizer, the storage of fertilizer should be considered. How to make the fertilizer effect non-volatile, the most important process to consider is actually one part of the organic fertilizer manufacturing process, which is the drying of organic fertilizer. After the organic fertilizer dryer machine drying, the moisture in the organic fertilizer granules is evaporated, and the dried particles can be stored in the warehouse for a long time.

The function of organic fertilizer dryer is not only here, but also the granulation results of inspection equipment. The fertilizer particles processed by the rotary drum granulator enter the drying procedure, and the particles are full and round after drying, but they will not be cracked and broken. If the dried fertilizer granules have too many cracks, the proportion of fertilizer should be adjusted in the previous fermentation and granulation.

Rotary drum dryer plays an important role in fertilizer production process. It consists of cylinder, gear, pinion, stop roller, drag roller, front roller ring, rear roller ring, discharge part, lifting plate, reducer, motor, and hot air. It is composed of parts such as channel, feed chute and furnace body. The NPK fertilizer manufacturing process can be equipped with multiple hot air stoves when the production volume is large, which is simple and easy to operate, and the production effect is also very good.Adding cooling system can greatly improve the production effect of fertilizer. Tianci fertilizer equipment company, we produce and sell products: chicken manure dryer, rotary dryer, cow manure dryer, pig manure dryer, organic fertilizer dryer, NPK compound fertilizer dryer. According to the needs of the fertilizer production line, the production process can be adjusted and the dryer size can be customized.

Pig farms are large in scale and produce more pig manure every day. The handling of pig manure is also a headache. The odor of pig manure pollutes the air, and the breeding of mosquitoes and flies causes problems to the environment, humans and animals. Through aerobic fermentation, the organic fertilizer production line can solve this problem by turning pig manure into organic fertilizer. The fermentation compost turning machine is the core equipment of aerobic fermentation. So what is the fermentation process of pig manure?

Preparation of fermentation materials

Pig manure, auxiliary materials (rice bran, broken straw, mushroom residue, etc.) and fermentation agent were mixed in a certain proportion. This step can adjust C / N ratio (C / N is about 25%) and water content (water content is 50% – 60%).
Fermentation process control

Put the mixed raw materials into the fermentation tank. In the process of fermentation, it is necessary to regularly turn over the raw materials through the pig manure fermentation organic manure tipper. The oxygen content of the materials can be increased through the compost turner, so as to speed up the fermentation process.

Fermentation compost turning machine can achieve the following effects:

1. Through the organic fertilizer turning machine, the air permeability of the material can be improved and the oxygen content of the material can be increased.

2. The compost turning machine is equipped with turning and throwing teeth, which can further crush the material during the turning and throwing process.

3. Each time the pig manure is thrown, the material can be moved back 4-5 meters, and new material can be put into the empty space to make the fermentation continue.Finished fermentation

The entire fermentation process takes 8-15 days, and the temperature of the fully fermented and decomposed materials begins to drop to room temperature without any peculiar smell. It has a dark brown appearance and can be safely applied to farmland. We provide a complete set of organic fertilizer equipment, NPK fertilizer manufacturing process, fertilizer production machinery. The organic fertilizer production line can further process the decomposed compost.

Poultry manure organic fertilizer production line uses straw and pig manure as raw materials to produce organic fertilizer through harmless treatment of pollutants by equipment. The products of the project mainly use chicken, duck, goose, pig and other excrement and crop straw as the main raw materials, use the natural fermentation of microbial flora and organic matter, add a variety of pollution-free additives such as nitrogen releasing agent, organic activator, etc., and make high-efficiency organic ecological fertilizer after scientific treatment of organic fertilizer manufacturing process.

According to the rich wastes of farm breeding and crop straw, straw and pig manure are used as raw materials to convert into organic fertilizer. The compost turning machine is used in the fermentation stage to ensure the smooth progress of oxygen consumption fermentation of raw materials. On site production and digestion not only solve the problem of straw outlet and fecal pollution, but also produce benefits, which can be regarded as an efficient and environmentally friendly ecological development mode.

Regardless of the country, similar regions can also learn from the organic fertilizer production line straw fertilization model to find a way for the comprehensive utilization of straw and farm manure. I believe everyone will understand the development trend of organic fertilizer manufacturing process after reading the above content.

To improve the production efficiency of the disc granulator, it can be achieved by adjusting the speed, but at the same time, the particle quality and stable operation of the machine need to be considered. Here are some specific steps and suggestions:

Raw material analysis:

Firstly, analyze the physical properties of the raw materials, such as moisture content, particle size distribution, and adhesion. These factors will directly affect the appropriate speed range.

Starting point:

Starting from the recommended standard speed of the equipment, this is usually a balance point that can ensure basic granulation effect while avoiding excessive pressure on the equipment.

Incremental adjustment:

Gradually increase the speed, and the adjustment range should not be too large each time to avoid sudden changes causing damage to the equipment. Observe changes in particle size and shape, as well as improvements in production efficiency.

Efficiency monitoring:

Record the production efficiency after each adjustment, including the output and particle quality per unit time. Find the optimal balance between yield and quality.

Quality Control:

If a decrease in particle quality is observed (such as particles being too large or broken), the rotational speed should be appropriately reduced. Maintaining particle quality is a prerequisite for improving production efficiency.

Equipment capability:

Ensure that the adjustment of speed does not exceed the design limit of the equipment to avoid overloading or malfunction.

Overall consideration:

The adjustment of the rotational speed of the disc granulator should not only consider production efficiency, but also take into account energy consumption, equipment wear and maintenance costs.

Experimental optimization:

In the actual production process, small-scale experiments can be conducted to continuously adjust and test to find the most suitable speed for the current raw materials and production conditions.

Record and feedback:

Record in detail the results of each adjustment, including speed, yield, particle quality, and other data. Through these data feedbacks, continuously optimize the production process.

technical support:

If necessary, you can consult the technical support of the equipment manufacturer for more professional advice.

Through the above steps, the optimal speed setting for improving the production efficiency of the disc granulator can be found while ensuring the quality of the particles. Remember, the raw materials for each production batch may vary, so adjustments may need to be made based on the actual situation.