Steel structure enables efficient granulation

A dedicated extrusion granulation production line has been successfully put into operation in Colombia, enabling high-efficiency granulation through steel structures!

In May 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the installation and commissioning of a steel-structured extrusion granulation production line tailored for a Colombian client, officially entering the stage of large-scale production. This production line, with its steel structure plant layout as its core adaptation, integrates the entire chain of processes including mixing, lifting, feeding, granulation, screening, and packaging. With its robust configuration of two 3.0-type extrusion granulators, compact and efficient space utilization, and stable and reliable operation, it has become another benchmark project for Chinese granulation equipment in the South American market, providing local fertilizer producers with a highly adaptable and cost-effective mass production solution.

Production Line Configuration and Core Equipment Analysis

The entire steel-structured extrusion granulation production line is built around a closed-loop logic of “precise pretreatment – efficient granulation – quality control – finished product output.” Equipment selection is closely matched to the load-bearing capacity and spatial layout of the steel-structured plant, with each unit seamlessly integrated. This ensures production efficiency while maximizing plant space utilization, fully meeting the large-scale production needs of Columbia’s clients.

Raw Material Pretreatment and Conveying Unit: Laying a Solid Foundation for Uniform Granulation

Efficient Mixing Process: The production line uses a 2000-type disc mixer as the core of raw material pretreatment. This equipment features a large-diameter disc design with a mixing diameter of 2.0 meters, providing ample volume for batch mixing of multi-component raw materials. The mixing blades adopt a spiral layout, coupled with a variable frequency speed control system (speed range 10-25 r/min), which can flexibly adjust the mixing intensity according to the raw material moisture and ratio, ensuring sufficient convection and shearing of nitrogen, phosphorus, and potassium main raw materials and trace elements. The mixing uniformity error is ≤2%, providing a uniform raw material foundation for subsequent granulation. The equipment features wear-resistant lining plates to extend its service life and is equipped with an automatic unloading device to ensure continuous production.

Stable Lifting and Feeding: The mixed raw materials are vertically conveyed to subsequent stages via a 315-type bucket elevator (10 meters). This elevator is optimized for the vertical space of steel structure plants, with a small footprint and high load-bearing capacity. It uses a plate chain drive structure, ensuring smooth and noiseless operation, with a conveying efficiency of 6 tons/hour. Its excellent sealing effectively prevents the raw materials from becoming damp, contaminated, or generating dust during lifting. The lifted raw materials then enter a 2000-type disc feeder. The feeder uses frequency conversion control and automatic material level monitoring technology to precisely regulate the feed rate, ensuring uniform feeding to the two extrusion granulators. This avoids fluctuations in granulation quality or equipment overload caused by uneven feeding, achieving precise matching between raw material supply and granulation rhythm.

Core Granulation Unit: Dual-Machine Parallel Operation Enhances Efficiency

The core equipment of the production line consists of two 3.0-type extrusion granulators. This model is a mature product developed by Huaqiang Heavy Industry for medium to large-scale production capacity needs. It is specifically optimized for the load-bearing standards of steel-structured plants, featuring a compact structure and reasonable weight distribution, perfectly adapting to the load-bearing limitations of the plant. The granulator adopts a high-strength double-roller extrusion design with a roll diameter of 300mm and a roll width of 250mm. The extrusion pressure (6-18MPa) is precisely controlled through a hydraulic pressurization system, adapting to the granulation needs of organic fertilizer and compound fertilizer raw materials with different moisture content (28%-35%) and different compositions.

The granulator rollers are made of high-chromium alloy, with a hardness exceeding HRC62 after quenching. This results in three times the wear resistance compared to ordinary materials, extending the service life to over 10,000 hours. The roller surface features a customized anti-slip texture design, enhancing material gripping force and effectively preventing slippage. The granulation rate remains consistently above 93%, with uniform particle size controlled at 3-5mm and a compressive strength of 2.7MPa. The granules are not prone to pulverization, fully meeting the needs of Colombian agriculture for fertilization and long-distance transportation. Two granulators can operate in parallel, each with a capacity of 2.5 tons per hour. Combined operation achieves a total capacity of 5 tons per hour and a daily capacity of 120 tons, significantly improving customer production efficiency.

Grading and Finished Product Output Unit: Strict Quality Control and Efficient Delivery

Precise Screening and Recycled Material Utilization: Granulated particles are transported via a conveyor system to a 1.2×4.0 meter drum screen. This equipment is optimized for the lateral space of steel structure plants, maximizing floor space and screening efficiency. The screen uses a single-layer high-precision screen design, with screen apertures customizable to customer needs. Grading and screening are achieved through uniform drum rotation (18 r/min). Qualified particles (3-5 mm diameter) achieve a 98% pass rate, while substandard particles (too coarse or too fine) are returned to the raw material mixing front end via a 5-meter return conveyor belt, re-entering the granulation process. Material utilization reaches 99%, effectively reducing production costs. The screen is equipped with an automatic screen cleaning device, which cleans material adhering to the screen surface in real time, preventing screen blockage and ensuring stable screening efficiency. The equipment features a sealed enclosure design, reducing dust pollution and meeting local environmental protection requirements.

Finished Product Storage and Automated Packaging: Qualified granules are conveyed to the finished product warehouse via a 7-meter belt conveyor for temporary storage. The warehouse is a custom-designed steel-structure plant with a sealed structure and a dehumidification and ventilation system to effectively prevent fertilizer from absorbing moisture and clumping, ensuring product storage stability. The warehouse capacity can meet the storage needs of 5 consecutive hours of full-load production. Material level sensors are installed inside the warehouse to provide real-time inventory feedback, facilitating customers to rationally plan their shipments. The packaging process utilizes an automatic packaging scale that supports rapid switching between various packaging sizes such as 25kg and 50kg. Employing gravity-based metering principles and high-precision sensors, the metering error is ≤±0.2kg, with a packaging speed of up to 80 bags/hour. This enables rapid, quantitative packaging of finished products, and, in conjunction with the subsequent transfer system, efficiently completes finished product warehousing and shipping.

Core Advantages of the Production Line and its Compatibility with Steel Structures

Exclusive Optimized Design for Steel Structures: All equipment in the production line is customized and optimized for the spatial dimensions, load-bearing standards, and ventilation conditions of steel structure workshops. The equipment layout is compact and rational, requiring only 450 square meters of space, saving 25% compared to traditional production lines. Simultaneously, optimized equipment maintenance access adapts to the maintenance needs of steel structure workshops, ensuring convenient and efficient operation and maintenance.

Stable, Reliable, and Highly Adaptable: Core equipment uses high-temperature, wear-resistant, and corrosion-resistant materials, adapting to the tropical climate of Colombia and effectively resisting the impact of high temperature and humidity. The 3.0-type extrusion granulator can flexibly adapt to various materials such as organic fertilizer, compound fertilizer, and bio-organic fertilizer, supporting rapid switching between different formulations to meet the diverse agricultural fertilization needs of the region.

High Efficiency, Energy Saving, and Cost-Effectiveness: The entire production line uses energy-saving motors and optimized process design, reducing energy consumption by 13% compared to conventional production lines with the same capacity. The equipment has a high degree of modularity, short installation cycle, and standardized design for key components. Wear parts are highly interchangeable. The company provides comprehensive spare parts supply and overseas technical guidance services, significantly reducing customers’ subsequent operation and maintenance costs. The successful commissioning of the Colombian steel extrusion pelletizing production line not only demonstrates Huaqiang Heavy Industry’s comprehensive strength in high-end pelletizing equipment R&D, customized steel structure design, and overseas project implementation, but also provides efficient and stable equipment support for the modernization of agriculture in South America. In the future, Huaqiang Heavy Industry will continue to focus on the production conditions and needs of different regions, optimize product performance and service solutions, and provide global customers with more competitive customized solutions, allowing “Made in China” to shine even brighter in the international market.

Expert Application of Dry Granulation Technology

This successful Colombian project showcases the practical application of a specialized extrusion granulation line, expertly engineered for a steel structure environment. It is a prime example of a specific fertilizer granulation technology being deployed to meet localized production needs efficiently.

The core of this line is the fertilizer compactor performing fertilizer granules compaction, which falls under the category of dry granulation processes. This method is one of several fertilizer granulation processes available to manufacturers. In the broader context of the npk manufacturing process, producers can choose between different types of fertilizer processing machine technologies. For dry compaction, a roller press granulator production line is typically used. For wet granulation, a rotary drum granulator would be the appropriate choice. Each technology represents a different pathway within the overall suite of fertilizer granulation technology, allowing producers to select the optimal method based on raw material properties and final product requirements. this project underscores the importance of matching the right granulation technology to the specific physical, chemical, and economic constraints of the production site, ensuring both operational efficiency and product quality.

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Why does wet granulation dominate the production of high-quality organic fertilizers?

In the field of high-quality organic fertilizer production, wet granulation has become the dominant choice due to its precise adaptation to raw material characteristics and stable assurance of finished product quality. Compared to dry granulation, it effectively addresses the core needs of organic fertilizer raw materials, which are complex and require a balance between nutrient retention and molding effect. This is the key to its dominant position.

Organic fertilizer raw materials are mostly animal manure and fermented crop residues, with significant fluctuations in moisture content and composition. In organic fertilizer production lines, wet granulation can precisely control moisture to create suitable viscosity in the raw materials, allowing for efficient molding without excessive binders. Both rotary drum granulators and disc granulators operate based on this principle. This reduces costs and avoids the impact of external additives on the purity of organic fertilizers, ensuring the natural safety of the product.

High-quality organic fertilizers require uniform particle size, moderate strength, and good water solubility. Wet granulation, through a continuous process of mixing, crushing, and granulation, ensures thorough mixing of raw materials and even distribution of nutrients; the formed granules have a dense structure, making them easy to store and transport without breaking; and the appropriate moisture content also improves the water solubility of the granules, accelerating nutrient release and better meeting the absorption needs of crops.

From a production feasibility perspective, wet granulation technology is mature and suitable for large-scale organic fertilizer production lines. Wet granulation lines composed of rotary drum granulators and disc granulators can adapt to different raw materials by adjusting moisture and rotation speed, offering strong flexibility; and the granulation process produces less dust, and when combined with subsequent drying and screening steps, it can achieve clean production, meeting environmental protection requirements.

Large wheel compost turning machine: The high-efficiency engine of organic fertilizer production lines

In modern organic fertilizer production, a complete production line is transforming traditional composting with its systematic operation. Each link in this line has its specific function, and the large wheel compost turning machine, with its unique working method, is a crucial guarantee for the efficient operation of the entire system.

In open windrow fermentation fields, the large wheel compost turning machine demonstrates excellent adaptability. Its unique large-diameter turning discs can penetrate deep into the material, achieving thorough turning and mixing. Compared to traditional equipment, it has a larger processing capacity and more uniform turning, creating ideal conditions for aerobic fermentation.

Once the initially composted material enters the processing area, the new type organic fertilizer granulator begins to play a key role. Through unique molding technology, it transforms powdery organic raw materials into uniform and plump granules. This transformation not only improves the marketability of the product but also solves the dust problem during organic fertilizer application, facilitating subsequent mechanized fertilization.

From the raw material processing by the large wheel compost turning machine to the finished product forming by the new type organic fertilizer granulator, the entire organic fertilizer production line demonstrates the systematic advantages of modern agricultural equipment. Each link is closely connected, jointly constructing an efficient conversion channel from organic waste to high-quality fertilizer.

This complete organic fertilizer production line not only improves production efficiency but also represents a modern direction for resource recycling. It transforms various organic wastes into valuable resources that nourish the land through systematic treatment, playing an increasingly important role in sustainable agricultural development.

Fertilizer granules compaction technology: The core optimization engine of bio-organic fertilizer production lines

In bio-organic fertilizer production lines, fertilizer granules compaction technology is not merely a single granulation step, but a core optimization process that runs through the entire process from raw material processing to finished product. Its precise integration with various bio-organic fertilizer equipment directly determines the efficiency, quality, and environmental performance of the production line, making it a critical technological support for bio-organic fertilizer production.

Adaptation in the pretreatment stage is fundamental to the successful implementation of the process. Fermented organic fertilizer raw materials need to be processed by crushing and screening equipment. The requirements of the fertilizer granules compaction technology regarding raw material particle size and moisture content drive the precise control of the pretreatment equipment—ensuring that the raw materials are refined to a particle size suitable for extrusion, and the moisture content is controlled within the optimal range of 30%-40%, avoiding problems such as roller sticking and uneven molding.

In the core granulation stage, this technology works efficiently with the fertilizer compaction machine. The fertilizer compaction machine receives the pre-treated raw materials and completes the molding process by setting parameters such as extrusion pressure and roller speed. Compared with other processes, it does not require the addition of extra binders, ensuring particle hardness and molding rate while maximizing the retention of nutrients in the raw materials. The resulting granules are also better suited for subsequent cooling and screening equipment.

In subsequent stages, the advantages of the process become even more apparent. The extruded granules have high uniformity, which improves the heat exchange efficiency of the cooling equipment, reduces the sorting load of the screening equipment, and ensures the smooth operation of the production line.

Efficient operation of bio-organic fertilizer equipment: The crucial role of the fertilizer mixer machine

The efficient operation of a complete set of bio-organic fertilizer equipment is key to producing high-quality organic fertilizer. The fertilizer mixer machine, as the core equipment connecting raw material pretreatment and subsequent processing, directly determines the efficiency of the entire system and the quality of the product. It is an indispensable basic guarantee in all stages of production.

In the raw material pretreatment stage, the fertilizer mixer machine undertakes the core mixing task. Bio-organic fertilizer raw materials have complex components, requiring the precise mixing of fermented materials, beneficial microbial agents, and conditioning additives. The mixer machine ensures thorough contact between various raw materials through stable mixing, guaranteeing the even dispersion of microbial agents and laying the foundation for subsequent complete fermentation.

Improving the adaptability of the fertilizer mixer machine can further optimize the overall system efficiency. A high-quality mixer can flexibly adjust the rotation speed and duration according to the moisture content and particle size of the raw materials, preventing material clumping or excessive pulverization, and producing uniformly conditioned materials. This directly improves the operating efficiency of subsequent granulation and drying equipment.

Therefore, the fertilizer mixer machine is not an isolated link in the bio-organic fertilizer equipment system, but a fundamental core component that ensures continuous production and improves product quality. Paying attention to its selection and operational control is essential for the complete set of equipment to fully utilize its potential and consistently produce high-quality bio-organic fertilizer.

Drying and cooling: The core of quality assurance in fertilizer granule post-processing

Fertilizer granules after granulation often suffer from problems such as high moisture content, high temperature, and low strength, making them unsuitable for direct storage and transportation. In the post-processing stage of organic fertilizer production lines, the coordinated operation of dryers and coolers is crucial to solving these problems. They form a complete chain of “dehydration and shaping – cooling and strengthening,” directly determining the final quality of the fertilizer granules.

The drum fertilizer dryer undertakes the core task of “dehydration and shaping.” Granules fresh from the fertilizer granulator usually have a moisture content of 20%-30%, and need to be sent to the dryer to complete the drying process through a hot air circulation system: high-temperature hot air (60-80℃, adapted to the characteristics of organic fertilizer) fully contacts the granules, and with the help of internal baffles, ensures that each granule is evenly dehydrated, ultimately controlling the moisture content within the safe range of 12%-14%.

The drum fertilizer cooler connects the critical “cooling and strengthening” stage. The temperature of the dried granules can reach 60-80℃. If directly piled up, they are prone to re-moisturizing and clumping, and may even break due to thermal expansion and contraction. The cooler uses the principle of cold air heat exchange to quickly cool the high-temperature granules to near ambient temperature (temperature difference ≤5℃), and at the same time further tightens the granule structure during the cooling process, significantly improving the strength and hardness of the granules.

The core advantage of their combined operation lies in “process+quality complementarity.” During operation, it is necessary to match the capacities of the two machines, adjust the drying temperature and cooling air speed according to the granule size and raw material characteristics, and regularly clean the accumulated material inside the equipment to ensure smooth ventilation. As the “golden partners” in the post-processing of organic fertilizer production lines, their coordinated operation can increase the qualified rate of fertilizer granules to over 95%.

Core Cooling Equipment for Multiple Industries: Rotary Drum Cooler

In numerous industrial sectors such as cement calcination, chemical synthesis, metallurgical smelting, and building materials processing, cooling high-temperature materials is a crucial step in ensuring smooth subsequent production processes. The rotary drum cooler (also known as a gyratory cooler), as a core piece of equipment specifically designed for cooling high-temperature materials, has become an indispensable cooling tool in industrial production due to its efficient heat exchange capacity, stable operating performance, and wide adaptability. Through scientific heat exchange principles, it precisely cools high-temperature materials to a suitable temperature for storage, transportation, or further processing, providing solid support for enterprises to improve production efficiency and ensure product quality.

The stable and efficient operation of the rotary drum cooler stems from its scientifically designed structure, with each core component working in tandem to form a complete cooling system. The drum itself, the core of the equipment, houses a cooling device and lifting plates. This design is key to improving cooling efficiency—the lifting plates repeatedly lift and drop the material as the drum rotates, significantly increasing the contact area between the material and the cooling medium. The transmission device, composed of a motor, reducer, gears, and rollers, provides stable rotational power to the drum, ensuring uniform drum operation. The inlet and outlet respectively handle the entry of high-temperature materials and the discharge of cooled materials, ensuring smooth material flow. The cooling medium supply system provides air, water, or refrigerant, providing the necessary conditions for heat exchange. The support device uses a combination of rollers and support wheels to firmly support the drum, reducing frictional losses during rotation and ensuring stable operation. The sealing device effectively prevents leakage of cooling medium and materials, avoiding resource waste and improving cooling efficiency. Furthermore, the control system ensures a stable and efficient cooling process through precise control of parameters such as temperature and speed.

The working principle of the drum cooler is based on efficient heat exchange, with a clear process and rigorous logic. When high-temperature materials enter the drum through the inlet, the transmission device drives the drum to rotate slowly. During rotation, the lifting plates inside the drum continuously lift the material to a certain height before scattering it, creating a uniform curtain of material in a tumbling state. Simultaneously, the cooling medium supply system continuously inputs cooling medium into the drum, allowing the material and cooling medium to come into full contact and undergo direct heat exchange—the heat of the material is rapidly carried away by the cooling medium, thus lowering the temperature. The cooled material is discharged from the outlet under the driving force of the rotating drum; the cooling medium (such as hot air) that has absorbed heat is discharged through the exhaust port. The entire process is continuous and efficient, meeting the cooling needs of large-scale high-temperature materials.

The unique structure and working principle of the drum cooler give it many significant advantages, making it adaptable to the complex needs of multiple industries. High cooling efficiency is its core competitiveness. Through direct heat exchange and the assistance of the lifting plates, the material is cooled evenly and quickly, while also having a large throughput, easily handling the cooling of large batches of high-temperature materials. It is highly adaptable, capable of handling various materials of different sizes and shapes, whether it be cement clinker, metallurgical slag, or chemical synthetic materials, achieving stable cooling. The equipment has a relatively simple structure, a reasonable layout of core components, is easy to operate, and has low maintenance costs, significantly reducing the operational and maintenance burden on enterprises. Compared with other cooling methods, the drum cooler consumes less energy, especially when processing large batches of materials, where the energy-saving effect is more significant. Furthermore, the equipment is highly flexible in operation; by adjusting parameters such as drum speed and cooling medium flow rate, the degree of cooling can be precisely controlled to adapt to the cooling needs of different materials. More importantly, the discharged heat medium has the potential for recycling and can be used to preheat other materials or for drying operations, further improving energy efficiency and aligning with the concept of green production.

From clinker cooling in the cement industry to slag cooling in the metallurgical industry, from synthetic material cooling in the chemical industry to finished product cooling in the building materials industry, the drum cooler, with its core advantages of high efficiency, stability, and energy saving, provides strong support for the smooth operation of production processes in various industries. Against the backdrop of industrial production transforming towards higher efficiency and greener practices, this multi-industry-compatible cooling core equipment not only improves enterprise production efficiency but also helps enterprises achieve energy conservation and emission reduction goals, becoming one of the important pieces of equipment driving high-quality industrial development.

Integrating Cooling into Modern Fertilizer Manufacturing

The rotary drum cooler exemplifies the importance of specialized thermal management in continuous industrial processes. Its role is equally critical within the fertilizer industry, where precise temperature control is essential for producing high-quality, stable products.

Specifically, in a complete npk fertilizer production line, the cooler is a vital piece of professional fertilizer manufacturing equipment. It is typically positioned after the granulation and drying stages within the npk fertilizer production process. For example, following disc granulation production line shaping by a disc granulator for shaping or compaction in a roller press granulator production line, the hot granules must be rapidly cooled to set their structure and prevent caking. This cooling stage works in synergy with upstream equipment like the npk blending machine and the fertilizer granulator. Similarly, in an organic fertilizer production line that begins with a windrow composting machine, a cooler ensures the stability of the final granulated product from a bio organic fertilizer production line. Thus, the drum cooler is an indispensable link that bridges high-temperature processing with final product packaging and storage.

Ultimately, by ensuring granules are cooled efficiently and uniformly, this equipment protects product quality and enables the reliable, large-scale output that defines modern fertilizer manufacturing.

Malaysian Oil Palm Biomass: Oil Palm Empty Fruit Bunch (OPEFB)

A highly promising sustainable biofuel feedstock and fertilizer resource in the context of global energy challenges

Over the past few decades, global energy demand has increased dramatically, while traditional fossil fuels such as coal, oil, and natural gas have become increasingly scarce. Furthermore, the burning of these fossil fuels is a major driver of climate change, making it imperative to conserve existing energy resources and explore sustainable alternatives. Converting renewable energy materials into biofuels has emerged as a viable solution, offering a pathway to address pressing issues such as solid waste management, environmental pollution, the greenhouse effect, and energy shortages. Notably, oil palm biomass, a byproduct of the oil palm industry, is not only a highly promising biofuel feedstock but also has widespread and important applications in the fertilizer industry. Among these, oil palm empty fruit bunches (OPEFB), with their unique physicochemical properties, have become a high-quality resource in the fertilizer sector.

Malaysia is the world’s second-largest producer and exporter of palm oil, playing a crucial role in the global palm oil industry. In 2016, its production accounted for over 30% of the global total, and its exports accounted for 37% of global exports. This thriving industry generates a large amount of oil palm biomass annually—over 80 million tons of dry weight—a figure projected to increase by at least 40% by 2020. With the expansion of oil palm plantations, annual production is expected to increase by as much as 50 million tons by 2030. The main byproducts include palm kernel shells (PKS), oil palm empty fruit bunches (OPEFB), oil palm fronds (OPF), oil palm mesocarp fiber (OPMF), and palm oil mill effluent (POME). In 2017 alone, Malaysia generated 51.19 million tons of oil palm biomass residue from replanting, pruning, and processing activities, while the total amount of fresh fruit bunches processed during the same period was 101.02 million tons.

Unfortunately, due to the lack of effective utilization technologies, most of this biomass is discarded or burned, exacerbating waste problems, wasting cellulose-rich resources, and causing serious environmental problems such as air pollution. In fact, the value of oil palm biomass in the fertilizer industry is severely underestimated. Oil palm biomass is inherently rich in various essential plant nutrients such as nitrogen, phosphorus, potassium, calcium, and magnesium, and contains abundant organic matter, making it an ideal raw material for producing organic fertilizers. Oil palm empty fruit bunches (EFBs) are particularly noteworthy, as they have the lowest lignin content among all types of oil palm biomass (only about 14%), making them easier to decompose and mature, and allowing for faster release of nutrients into the soil.

In practical applications, oil palm biomass and EFBs can be converted into fertilizer through various methods. The most common is composting, where EFBs are mixed with manure, palm oil mill effluent, etc., and fermented to produce high-quality organic fertilizer. This process activates the nutrients and kills harmful bacteria and insect eggs. When applied to farmland, this organic fertilizer significantly increases soil organic matter content, improves soil structure, enhances soil water and nutrient retention capacity, and promotes the activity of soil microbial communities, reducing soil compaction and erosion. Furthermore, EFBs can be converted into biochar fertilizer through pyrolysis technology. Biochar has a porous structure that not only improves soil fertility but also adsorbs heavy metals and harmful substances from the soil, proving particularly effective in improving acidic and peat soils. Additionally, components such as potassium carbonate can be extracted from oil palm biomass ash for the preparation of liquid fertilizers, enabling the precise recovery and utilization of nutrients.

Beyond its value in the fertilizer sector, oil palm residue and other lignocellulosic biomass are among the most abundant renewable green carbon sources on Earth, with the potential to become substitutes for petroleum-based products. Their carbohydrate composition makes them suitable raw materials for renewable energy production, capable of producing biofuels such as bioethanol, biobutanol, and biomethane, as well as various value-added products. Currently, second-generation bioethanol extracted from lignocellulosic biomass is the most advanced of these products. Lignocellulosic biomass is mainly composed of lignin, cellulose, and hemicellulose. While cellulose and hemicellulose can be converted into ethanol, the high lignin content in oil palm biomass poses a significant challenge due to its complex and difficult-to-decompose structure. Therefore, pretreatment (delignification) is crucial before enzymatic hydrolysis, fermentation, and distillation to reduce the recalcitrance of the biomass. Effective pretreatment can alter the chemical composition, macrostructure, and microstructure of biomass, reducing cellulose crystallinity and increasing porosity. Ideal pretreatment techniques should be inexpensive, easy to operate, and yield high product recovery.

Notably, the lignin content of different types of oil palm biomass varies significantly (14% to 36%), with oil palm fruit residue having the highest lignin content and oil palm empty fruit bunches having the lowest. This characteristic not only facilitates its efficient utilization in the fertilizer industry but also guides the selection of appropriate pretreatment methods for biofuel conversion. With the growing global demand for alternatives to fossil fuels, food security concerns prioritizing non-edible biofuel sources, and the increasing demand for green organic fertilizers in agriculture, oil palm biomass has attracted widespread research attention. Its dual value in both the biofuel and fertilizer sectors makes it an important resource for promoting sustainable energy development and ecological agriculture, with broad application prospects.

Conclusion: A Sustainable Cycle from Waste to Resource

The Oil palm empty fruit bunch (OPEFB) exemplifies a perfect model of circular economy, transitioning from a major agricultural waste to a valuable resource. The primary uses of oil palm empty fruit bunch are realized through its integration into sustainable agricultural systems, most notably as a primary feedstock for organic fertilizer production.

To leverage OPEFB effectively, it is processed through a complete organic fertilizer manufacturing system. The journey begins with controlled organic fertilizer fermentation, optimized by advanced fermentation composting turning technology to accelerate decomposition and enhance quality. The resulting mature compost can then be processed through a bio organic fertilizer production line. For final product formation, the material undergoes organic fertilizer production granulation. Producers can choose specialized equipment like an organic fertilizer disc granulation production line or opt for a more versatile organic fertilizer combined granulation production line to shape the compost into uniform, market-ready fertilizer granules. This systematic approach transforms OPEFB waste into a high-value soil amendment, closing the nutrient loop sustainably.

Thus, by combining innovative biological treatment with modern mechanical processing, OPEFB is successfully converted from an environmental burden into a cornerstone of sustainable agriculture and green industry.

Customized Powder Fertilizer Production Line for Malaysia: Grinding Enables Powder Fertilizer Production!

 In October 2024, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. successfully completed the installation and commissioning of a powder fertilizer production line tailored for a Malaysian client, officially entering the large-scale production stage. This production line focuses on the refined processing needs of powder fertilizers, integrating core processes such as raw material feeding, crushing, screening, and conveying. With efficient equipment configuration, compact layout design, and stable product quality, it provides local fertilizer production enterprises with a one-stop powder processing solution, helping to improve agricultural production efficiency and fertilizer utilization.

Production Line Configuration and Core Equipment Analysis

The entire powder fertilizer production line follows a closed-loop design of “raw material pretreatment – refined processing – finished product conveying.” Equipment selection is tailored to the characteristics of powder fertilizer production, the process is smoothly connected, and each unit works synergistically to fully ensure uniform product fineness and purity standards.

Raw Material Feeding and Conveying Unit: Stable Supply as the Foundation The production line starts with a forklift feeding hopper. The hopper features a large-capacity design to accommodate the rapid feeding of bulk raw materials. The feed inlet is equipped with spill-proof baffles and buffer devices to reduce material loss due to airflow and prevent large impurities from entering. Raw materials are smoothly transferred to subsequent processing stages via a 9-meter belt conveyor. The conveyor uses food-grade wear-resistant rubber belts with an anti-slip surface. The operating speed is adjustable via a frequency converter (0.8-1.5 m/s), achieving a conveying efficiency of 6 tons/hour, ensuring a continuous and stable supply of raw materials to meet the full-load operation requirements of the production line.

Core Grinding Unit: Fine Grinding Ensures Perfect Powder

The grinding process utilizes a 1500-type vertical crusher, the core equipment for powder production. It employs a combined “high-speed impact + grading crushing” process, with a rotor speed reaching 3000 r/min. The hammers are made of high-chromium alloy, achieving a hardness of HRC58 or higher after heat treatment, providing exceptional wear resistance. It can crush lumpy raw materials (particle size ≤80mm) into uniform fine powder of 100-200 mesh (0.075-0.15mm), achieving a grinding efficiency of 5 tons/hour. The equipment features a built-in grading screen, which can be flexibly replaced according to customer requirements for powder fineness. It is also equipped with an overload protection device that automatically shuts down the machine when hard impurities are mixed in with the raw materials, preventing equipment damage and ensuring production safety.

The crusher adopts a sealed design, coupled with a negative pressure dust collection interface, effectively reducing dust leakage during grinding, improving the production environment, and meeting local Malaysian environmental standards. The equipment’s operating noise is controlled below 78dB, achieving low-noise and high-efficiency production.

Grading and Screening & Finished Product Conveying Unit: Strict Quality Control and High-Efficiency Output

The crushed material is transferred via a 12-meter belt conveyor to a 2.0×6.0-meter drum screen. This equipment uses a single-layer high-precision screen design, and the screen aperture can be customized according to the fineness requirements of the finished product. Through the uniform rotation of the drum (18 r/min), substandard coarse particles are screened and separated, while qualified fine powder passes through the screen and enters the subsequent conveying stage. The screening efficiency reaches 5.5 tons/hour, and the finished product qualification rate is consistently above 99%. The separated coarse particles can be returned to the crusher for reprocessing via a return device (optional for customers), improving raw material utilization.

Qualified powder is conveyed to the finished product storage or packaging area via an 8-meter belt conveyor. The belt conveyor uses a fully sealed cover design to prevent the powder from absorbing moisture, clumping, or generating dust during transportation, ensuring product purity and a clean production environment. The production line can be flexibly integrated with finished product silos, automatic packaging machines, and other downstream equipment according to customer needs, achieving fully automated operation from raw material processing to finished product delivery.

Core Advantages and Adaptability of the Production Line:

Outstanding Refined Processing Capabilities: The precise combination of a 1500-type vertical crusher and a high-precision drum screen ensures uniform powder fineness and no impurities, meeting the application requirements of different crops for powdered fertilizers, resulting in faster fertilizer dissolution and higher absorption efficiency.

Compact Layout and Strong Adaptability: The production line adopts a modular and compact design, requiring only 400 square meters of space, saving 25% compared to traditional powder production lines, and is suitable for the limited space conditions in Malaysian factories; the equipment can flexibly adapt to the processing of various materials such as organic fertilizers, compound fertilizers, and micronutrient fertilizers, offering extremely high versatility.

High Efficiency, Energy Saving, and Environmental Protection: Core equipment uses energy-saving motors, reducing energy consumption by 12% compared to conventional equipment with the same capacity; the fully sealed design and dust removal system effectively control dust pollution, achieving green production.

Looking ahead, the company will continue to focus on the production needs of different regions, optimize equipment performance and process solutions, and provide global customers with more targeted powder fertilizer production line solutions to contribute to the high-quality development of the agricultural industry.

Complementary Technologies for a Complete Product Portfolio

This powder fertilizer production line represents a specialized segment of the modern fertilizer processing machine industry. It expertly addresses the market need for fine, highly soluble fertilizer powders. This successful project illustrates how specialized solutions fit into a broader ecosystem of fertilizer production machine technologies.

While this line is designed for powder, many producers also require granulated products for different applications. This is where other specialized equipment comes into play. The npk fertilizer manufacturing process, for instance, often requires fertilizer granules compaction via a roller press granulator production line using a fertilizer compactor. Alternatively, for a wet granulation approach, a rotary drum granulator (or drum granulator) is used. Similarly, an organic fertilizer disc granulation production line or a flat die pelleting machine might be chosen to shape organic compost into granules. Each of these systems—powder processing, dry compaction, or wet granulation—serves a distinct market niche and product specification, demonstrating the diversity of equipment available within the npk manufacturing process and organic fertilizer production.

Thus, a manufacturer’s complete offering is built by integrating multiple, targeted production lines, enabling them to supply both the powder and granular fertilizers that modern agriculture demands.

Finally, we warmly welcome people from all walks of life to visit us, provide guidance, and discuss business with us, joining hands with Huaqiang Heavy Industry to create a new blueprint for green agricultural development!

Double roller press granulator and roller press granulation production line: The synergy of core equipment and system

In the field of particle preparation, the double roller press granulator and the roller press granulation production line form a core combination. The former is the key granulation equipment, while the latter provides the system support for efficient mass production. Their synergistic operation ensures stable particle quality and improves production efficiency, making them a core configuration in the granulation process for industries such as fertilizers and chemicals.

The double roller press granulator is the “heart” of the roller press granulation production line, with its core function being high-pressure extrusion and molding of raw materials. Its advantages lie in high granulation strength and wide adaptability to raw materials; it can handle both organic fertilizer fermentation materials and chemical dry powder raw materials without the need for excessive binders, ensuring the purity of the finished product.

The roller press granulation production line is a complete system built around the double roller press granulator, encompassing the entire process from raw material pretreatment, core granulation, post-treatment, and intelligent control. Pretreatment ensures that the raw materials meet the required particle size and moisture content; post-treatment (crushing, screening, and drying) optimizes particle quality. Compared to a single piece of equipment, the fertilizer production line significantly reduces manual intervention, improves mass production capacity, and its fully enclosed design controls dust pollution, meeting environmental protection requirements.

The two complement each other: the performance of the double roller press granulator determines the baseline of particle quality, while the configuration of the roller press granulation production line determines the upper limit of production efficiency. In practical applications, it is necessary to match the appropriate equipment and production line based on raw material characteristics and production capacity requirements to achieve both quality and efficiency improvements.