fertilizer production line

The roller is also the most easily worn accessory in the granulation operation of the roller granulator. As the main part of material granulation, the roller skin is gradually worn and produces uneven particles. How to reduce the wear of the roller granulator is the most important thing.

Severe wear on the roller surface can affect the production efficiency of the roller granulator and the particle size of the finished product. In severe cases, it is necessary to stop the machine and replace the roller surface with a new one. How to reduce material wear on the roller surface through multiple efforts during equipment use? The main reasons for severe wear of the roller skin of the roller granulator are as follows:

1. Uneven feeding can easily cause uneven wear of the roller skin.

2. It is directly related to the material of the roller skin itself. The roller skin with poor material has poor wear resistance, corrosion resistance, and short service life.

3. The surface shape, specifications, dimensions, and operating conditions of the roller can have an impact on the machine.

4. Affected by the hardness, size, and shape of the processed material. Materials that are too hard, too large, or too irregular can easily cause uneven wear of the roller skin.

The reason for the wear of the roller skin of the roller granulator is that during the physical granulation of the roller skin, the roller surface will gradually wear out. Therefore, it is necessary to ensure that the material is evenly fed into the granulator along the length of the roller. If the feeding is uneven, circular grooves will appear on the roller surface, affecting the normal operation of the granulator, and the product particle size is uneven. When feeding, the feeder not only needs to feed evenly and continuously, but its length should also be consistent with the length of the roller.

Long term operation of the equipment inevitably results in wear on the roller skin of the roller granulator, which requires us to regularly shut down for maintenance. If we can repair it in advance when the wear reaches a certain level, can we avoid the need to replace the new roller surface in the future?

When the roller granulator is granulating materials, the roller surface will gradually wear out, ensuring that the materials are evenly fed into the granulator along the length of the roller. If the feeding is uneven, circular grooves will appear on the roller surface, affecting the normal operation of the granulator, and the product particle size is uneven. When feeding, the feeder not only needs to feed evenly and continuously, but its length should also be consistent with the length of the roller.

The wear of the roller surface can also increase the discharge port, so it is necessary to adjust the movable roller. When adjusting, it is necessary to keep the two rollers parallel to each other to prevent tilting. A pair of roller granulator with movable rollers installed on the rocker arm or hydraulic compensation device, which automatically ensures that the axes of the two rollers are parallel when the movable rollers move.

There is a grinding wheel installed on the rack. When there are pits or grooves on the roller surface, the roller surface can be ground and repaired on the machine without removing it, or directly repaired on the roller surface. This requires the installation of a welding device on the granulator. Some roller granulators are equipped with an automatic axial reciprocating movement device for the rollers, which ensures uniform wear and tear on the roller surface.

Rotary drum granulator is a kind of molding machine which can make material into specific shape. Rotary drum granulator is one of the complete sets of equipment in compound fertilizer industry, which is suitable for cold and hot granulation and large-scale production of high, medium and low concentration compound fertilizer.

The working mode of rotary drum granulator is wet granulation. Through a certain amount of water or steam, the basic fertilizer can be fully chemically reacted after being humidified in the cylinder. Under certain liquid phase conditions, with the help of the rotary motion of the cylinder, the material particles will produce extrusion pressure and agglomerate into balls.

The production line process of rotary drum granulator includes raw material batching machine, fertilizer mixer machine, crusher, rotary drum granulator, particle dryer, particle cooler, coating machine for finished product, and quantitative packaging machine for finished product.

Rotary drum granulation process of compound fertilizer

1. 1. Raw materials and ingredients: compound fertilizer raw materials are prepared according to a certain proportion (according to market demand and soil testing results).
2. 2. Raw material mixing: mix the prepared raw materials evenly to improve the overall uniform fertilizer efficiency content of fertilizer particles.
3. 3. Raw material granulation: the raw material with uniform stirring is sent to the rotary drum granulator for granulation
4. 4. Particle drying: the granulator made particles into the dryer, drying the moisture contained in the particles, increasing the strength of the particles, easy to save.
5. 5. Grain cooling: the temperature of the dried fertilizer particles is too high and easy to agglomerate. After cooling, it is easy to pack, store and transport.
6. 6. Particle classification: the cooled particles are graded. The unqualified particles are crushed and re granulated, and the qualified products are screened out.
7. 7. Finished film: the qualified products are coated to increase the brightness and roundness of particles.
8. 8. Packaging of finished products: bag the coated particles, that is, finished products, and keep them in a ventilated place.

The complete set of equipment for large-scale cow manure organic fertilizer production line is basically a granular organic fertilizer production line process. Because large-scale organic fertilizer processing and production lines like 100000 tons require a certain amount of time from transportation to storage and sales to maintain fertility and facilitate transportation, it is undoubtedly easier to store and maintain fertility for granular organic fertilizers with moderate hardness. Therefore, the organic fertilizer production lines with an annual output of 100000 tons on the market all use the granular organic fertilizer production line processing technology. Such processing organic fertilizer production lines require the purchase of a series of organic fertilizer equipment such as fermentation, crushing, stirring, granulation, screening and returning materials, and film packaging.

Supporting equipment and process for large-scale cow manure organic fertilizer production line:

1. Raw material fermentation: Various animal feces such as chicken manure, pig manure, cow manure, biogas residue, or raw materials that can be fermented or have fertilizer effects after treatment are prepared in proportion (according to market demand and soil testing results in different regions).

2. Raw material mixing: Mix the prepared raw materials evenly to improve the overall uniform fertilizer efficiency of the fertilizer particles.

3. Raw material granulation: The evenly stirred raw materials are fed into a granulator for granulation (using drum granulators, extrusion granulators, and new organic fertilizer granulators).

4. Particle drying: The particles made by the organic fertilizer granulator are fed into the dryer to dry the moisture contained in the particles, increasing their strength and facilitating storage.

5. Particle cooling: The dried fertilizer particles have a high temperature and are prone to clumping. After cooling, they are easy to pack, store, and transport.

6. Particle classification: The cooled particles are classified, and the unqualified particles are crushed and re granulated to screen out the qualified products.

7. Finished product coating: Coating qualified products to increase the brightness and roundness of particles.

8. Finished product packaging: Bag the processed particles, which are the finished products, and store them in a ventilated place.

The principle of drum granulation is that materials rely on surface tension, an appropriate amount of liquid phase, extrusion force generated by rolling between materials, and small particles are taken as the core in the correct movement direction of materials in the granulator to absorb large particles and adhere to small particles and form balls during rolling. The higher the rolling frequency in a certain time, the higher the balling rate and the rounder the particles are after forming. 

Working principle of rotary drum granulatorr:

The rotary drum granulator drives the belt and pulley by the main motor, drives the drive shaft through the reducer, and works opposite to each other through the open gear installed on the drive shaft and the big gear ring fixed on the body. The material is added from the feed end of the rotary drum granulator through the inside of the cylinder. Through the special structure inside the cylinder, it is made into particles, and finally outflow through the discharge port. Due to the continuous entry of materials and the continuous rotation of the rotary drum granulator, mass production of organic fertilizer production lines can be achieved.

Characteristics of rotary drum granulator:

1, rotary drum granulator less investment, fast effect, good economic benefits, reliable performance;

2, rotary drum granulator manufacturers, no waste emissions, stable operation, easy maintenance, reasonable process layout, advanced technology, rotary drum granulator quotation, low production cost of organic fertilizer equipment;

3, rotary drum granulator into high strength, good appearance quality, corrosion resistance, wear resistance, low energy consumption;

4, the cylinder is lined with special rubber plate or acid-resistant stainless steel lining plate, and the rotary drum granulator realizes automatic scar removal and tumor removal, eliminating the traditional device.

The organic fertilizer rotary drum granulator used in small and medium-sized fertilizer plants is a rotating circular granulator with a diameter of 1.2 – 2.4m and a length of 3 – 6m. A material retaining ring is arranged at the feeding end and the middle part of the simplified body, and the tail is smooth. The middle retaining ring of the organic fertilizer drum granulator divides the simplified body into two areas, the front area is the mixing granulation area, and the rear area is the particle polishing area.

The new fertilizer production line project should comprehensively consider the local resources, market capacity and market coverage radius. Generally, the annual output of small-scale new plants is 10000 tons (1.5 tons / hour), 20000 tons (3 tons / hour) and 30000 tons (4.5 tons / hour). The annual output of medium-sized factories is 50000-100000 tons, and that of large-scale factories is 100000-300000 tons.

The investment scale and scheme design need to be formulated according to the following conditions: characteristics of raw material resources, local soil conditions, local planting structure and main crop varieties, plant site conditions, selection of NPK fertilizer granulator, production automation degree, etc.

Several equipments of fertilizer production line

1. Mixer. In addition to chemical fertilizer raw materials, some sticky materials such as clay can be properly added during mixing. During operation, the materials are evenly mixed by stirring back and forth with multi-channel rotating blades.

2. Fertilizer granulator. Small scale production generally uses organic fertilizer granulator to meet the requirements.

3. The rotary dryer is mainly composed of drying cylinder, transmission device, supporting device, head and tail sealing parts. The diameter ranges from 80 cm to 3 m, and the length depends on the drying requirements. The dryer is a cylinder inclined to a certain angle with the horizontal direction. The material is added from the higher end, and the high-temperature flue gas and the material enter into the cylinder in parallel. With the rotation of the cylinder, the material moves to the lower end due to gravity. A lifting plate is welded on the inner wall of the cylinder to take up and drop the materials, and fully contact with hot air in the falling process, so as to achieve the purpose of drying.

4. The rotary cooler can reduce the moisture content while cooling a certain temperature. It is the same equipment as the dryer, except that the air is drawn from the head to the outside when used, so there is no need to seal the tail.

5. The drum screening machine adopts a combined screen, which is convenient for maintenance and replacement. The machine has a simple structure, convenient operation and stable operation.

Fruit pomace is the remaining fruit pomace after the water content of the fruit is extracted from the food, such as apple pomace, tomato pomace, pear, corn, grain, sugarcane, medicinal pomace, and other different types of pomace. Due to the economic added value of secondary processing benefits such as feed, the dried fruit pomace contains a certain amount of internal moisture. Before entering the fruit pomace dryer, the material needs to be thoroughly dehydrated in the dehydrator, Then enter a professional production and drying machine for operation, using a one-time countercurrent rotation method to reduce the moisture content to below 5%, without damaging the nutritional value of the original material, and without causing the problem of material burning. The finished material has a beautiful color and even moisture content.

The technical advantages and application scope of the fruit residue organic fertilizer dryer:

1. Using the instantaneous method of strong hot air to operate, the finished material presents a granular form.

2. The overall equipment consists of a drum crushing device, a heat source furnace, a spiral discharge device, an induced draft pipeline, and a dust removal device to prevent damage to the nutrition of the material caused by contact with the outside during operation.

3. By equipped with professional dehydrators, the finished product can be dried into the ideal moisture state in one go after operation, making it convenient for storage.

4. We can process 400 tons of fresh fruit residue per day, which can be done at once without the need for a second operation, achieving cost reduction.

5. The use of drum rotation as the operating mode, equipped with professional thermometers and instrument displays outside the drum, can better control materials to achieve optimal operating conditions.

6. The cylinder is equipped with a professional breaking device to prevent materials from clumping and sticking together during rotation. The entire process adopts a PLC centralized automation control system, making operation more convenient and safe.

The fruit residue organic fertilizer dryer is made using advanced and scientific technology. Due to its strong heat transfer ability and good drying effect, it improves the contact between fruit residue and hot air, which is beneficial for rapid batch production of materials. It has rotating blades that can be adjusted according to requirements and needs, effectively solving some of the drawbacks of traditional equipment. Considering the 24-hour non-stop working state of the equipment, a sturdy and durable steel cylinder is used to make the drum, Ensure the stable demand of equipment under long-term operation.

The working principle of pig manure organic fertilizer granulator: Various dry powder materials are added from the top of the equipment, degassed, spiral pre compressed, and transported to the curved grooves of two rollers. The two rollers rotate at equal speed and in reverse direction, biting the materials into the grooves and performing forced compression. The pressure that the materials bear gradually decreases after passing through the compression zone, and its surface tension and gravity cause them to naturally come out, enter the crusher and the whole granulator for crushing and trimming, Then it enters the vibrating screen for screening, and the qualified products are sent to the finished product warehouse or directly packaged through a conveyor. The materials under the powder screen are sent back to the raw material warehouse for secondary rolling through a feeding device. The size of the squeezing force can be adjusted by the hydraulic system according to the particle strength needs. By changing the groove form of the roller surface, materials such as flakes, strips, olives, and flat balls can be obtained.

Rotary drum granulator product overview:

Rotary drum granulator has beautiful appearance, simple operation, low energy consumption, long life, uniform drying, easy maintenance and other characteristics, belongs to the most advanced organic fertilizer equipment in China. The product is suitable for cold, hot granulation and mass production of high, medium and low concentration compound fertilizer.

Its main features are as follows:

1, less investment, quick effect, good economic benefits, reliable performance.

2, small power, no three waste emissions, stable operation, easy maintenance, reasonable process layout, advanced technology, low production cost.

3, high ball strength, good appearance quality, corrosion resistance, wear resistance, low energy consumption.

4, the cylinder is lined with special rubber plate or acid-resistant stainless steel liner, which realizes automatic scar removal and tumor removal, and cancels the traditional scraper device.

Working principle of rotary drum granulator:

The motor drives the belt and pulley, drives the drive shaft through the reducer, and works opposite to each other through the open gear mounted on the drive shaft and the big gear ring fixed on the body. The material is added from the feed end, the special structure inside the cylinder makes it into particles, and flows out through the discharge port. Due to the continuous entry of the material and the continuous rotation of the granulator, the mass production of the organic fertilizer production line can be realized.

The compost turning machine adopts the fermentation tank mode to produce organic fertilizer. It is a kind of organic fertilizer produced by putting the raw materials in the fermentation tank. The materials are turned, stirred and broken in the tank, so that the materials can be fermented, matured and degraded. It is easier to obtain stable product performance and better odor control effect than static composting.

The process of stabilizing organic matter in cow manure through the action of aerobic microorganisms (mainly aerobic bacteria) in the rotary fermentation composting machine. During the composting process, the soluble organic matter in the feces penetrates into the cells. Microorganisms decompose and metabolize a portion of the organic matter through their own biological metabolic activities, that is, oxidize and decompose it to obtain the energy required for biological growth and activity, and convert the other portion of the organic matter into new cellular matter, enabling the growth and reproduction of microorganisms to produce more organisms.
The wheeled self-propelled composting machine for cow manure organic fertilizer is more suitable for the mechanism and process requirements of microbial fermentation and storage of manure into fertilizer. It can effectively mix thick stored manure with microbial preparations and straw powder. Not only is the fermentation speed much faster than deep tank fermentation, but it also effectively prevents the generation of harmful and odorous gases such as hydrogen sulfide, ammonia, and indole during the fermentation process, which meets environmental requirements and can produce high-quality organic fertilizers.

Animal manure is a relatively high-quality organic fertilizer, which contains pure nitrogen, phosphorus (P2O5), and potassium (K2O) of about 1.63%, 1.54%, and 0.085%. Livestock and poultry manure must undergo maturation with a composting agent before application, to inactivate and deodorize parasites and their eggs, as well as infectious pathogens present in livestock and poultry manure, through the process of maturation. The production process of organic fertilizer from livestock and poultry manure is closely related to the equipment configuration of organic fertilizer production lines. Generally, the complete set of equipment for organic fertilizer production lines mainly consists of fermentation system, drying system, deodorization and dust removal system, crushing system, ingredient system, mixing system, granulation system, screening system, and finished product packaging system.

Organic fertilizer production equipment for livestock and poultry manure: raw material selection (such as livestock and poultry manure) → drying and sterilization → ingredient mixing → granulation → cooling and screening → measurement and sealing → finished product storage.

The process flow of organic fertilizer production equipment for livestock and poultry manure:

1. The ratio of raw materials per ton is 500 kilograms of pig manure (or other animal manure), 300 kilograms of auxiliary materials, 200 kilograms of bacterial residue, and 100 grams of RW bacterial agent;

2. Stacking, according to the above raw material ratio, according to the needs, the stacking length is unlimited, with a width of 4 meters and a height of 2 meters. When stacking materials, it is necessary to stack them layer by layer evenly;

3. Add the bacterial agent, expand the volume of the bacterial residue in a 1:5 ratio, mix evenly, and sprinkle it on the surface of the pile according to the number of piles;

4. Stir and ferment, use a blender to stir the pile evenly. After the temperature rises to 60 degrees Celsius or above, flip the pile every 4-5 days. After 15 days of fermentation at 60 degrees Celsius or above, fold the pile up;

5. Screening processing, fermentation is carried out according to the above steps, and after screening and deep processing, it becomes pure organic fertilizer;

6. Granulation refers to the granulation of fermented pure organic fertilizer. Choose granulators based on different raw materials, such as disc granulators, extrusion granulators, and integrated extrusion ball throwing machines;

7. Drying, cooling, and packaging: Newly made particles have a relatively high moisture content and need to be dried to below 20% of the organic fertilizer standard. The dried particles of organic fertilizer are cooled by a cooling machine before being directly packaged.

Hydraulic compost turning machine is suitable for aerobic fermentation of organic waste such as animal manure, sludge and waste, sugar filter mud, slag cake and straw sawdust, and can be used with solar fermentation coffers, fermentation tanks and moving machines. The operation of one machine and multiple slots can be realized by matching the main machine with the mobile machine. Widely used in organic fertilizer plant, compound fertilizer plant, sludge waste, garden and other industries of raw materials fermentation and maturation. The press trough type flipping machine is suitable for aerobic fermentation, and can be used with solar fermentation chamber, fermentation tank and migration machine. It can be used with the mobile machine to realize the function of multiple slots in one machine. The supporting fermentation tank can be used for continuous discharge or batch discharge. High efficiency, smooth operation, durable, turning uniform.

The organic fertilizer equipment has high efficiency, smooth operation, robustness and durability, and uniform casting. Equipped with limit stroke switch, guarantee and limit operation, centralized control of control cabinet, manual or automatic control function can be achieved. The pile turning machine is equipped with hydraulic lifting system, the rake teeth are durable, and it has certain function of breaking and mixing fermentation materials in the organic fertilizer production line.

Mobile trough type composting machine is a specialized equipment used to treat solid organic matter from livestock manure and achieve aerobic high-temperature composting. Suitable for the fermentation and turnover of organic waste such as livestock and poultry manure, sludge waste, sugar factory filter mud, tank residue cake, and straw sawdust, it is widely used in the fermentation and moisture removal operations of organic fertilizer plants, compound fertilizer plants, sludge waste plants, horticultural fields, and mushroom cultivation plants. It is the host of compost fermentation farms. By using this equipment, continuous production can be achieved, allowing compost raw materials to be fully oxygenated, fermented evenly, and partially drained of water, achieving the goal of harmless and resource utilization. Each flipping can ensure that every detail of the material is fully in contact with the air, replenishing oxygen, and draining water.