Fertilizer Machine Manufacturer Introduces How to Produce Compound Fertilizer Granules

The common granulation processes of compound fertilizer include tower granulation, rotary drum granulation (NPK fertilizer production line), spray granulation and so on. As fertilizer machine manufacturer, let’s introduce these production processes from the perspective of fertilizer production.

 

  1. High tower granulation process is mainly used for the production of high concentration nitro compound fertilizer. It can directly use concentrated ammonium nitrate solution, eliminating the links of spraying granulation, and granular compound fertilizer eliminates the process of crushing operation. At the same time, the compound fertilizer granules produced by the high tower granulation process are very uniform, the qualified rate is very high, the quality is good, easy to dissolve, and the caking phenomenon will not occur.

 

  1. Rotary drum granulator has little restriction on compound fertilizer formulation, high production yield, low investment and construction speed. It is favored by investors of small and medium-sized compound fertilizer plants and widely used in compound fertilizer production. The complete drum granulation process is a NPK compound fertilizer production line, which includes fertilizer granulator, automatic batching system, mixer, crusher, drum dryer, drum cooler, coating machine, packaging machine and other equipment.

NPK compound fertilizer production line

 

  1. The spray granulation process adopts the slurry method. The slurry is sprayed into the equipment by heating and pumping, so that the moisture in the slurry is vaporized and separated, and the retained solid forms a granular compound fertilizer. This kind of process is widely used in large-scale compound fertilizer production. Its advantages are that it can be used to produce NPK compound fertilizer, and can also be used to produce ammonium phosphate compound fertilizer. At the same time, it has less energy consumption, large production scale and low production cost. The quality and strength of the products are very good.

 

Tianci fertilizer machine manufacturer with many years of experience. The drum granulation NPK compound fertilizer production line is our main equipment product. Among the equipment sold, it is highly praised by many fertilizer factories internationally.

Fermentation Mode of Chicken Manure Organic Fertilizer Manufacturing Process

Organic fertilizer, commonly known as farm manure, consists of various animal, plant residues or metabolites, such as human and animal manure, straw, animal residues, slaughterhouse waste, etc. Carbon-containing materials, mainly from plants and animals, are applied to the soil to provide plant nutrition as its main function. It not only provides comprehensive nutrition for crops, but also has long fertilizer efficiency. It can increase and renew soil organic matter, promote microbial reproduction, improve soil physical and chemical properties and biological activity. It is the main nutrient in green food production.

The production of organic fertilizer must go through composting fermentation process. Composting is a process in which organic matter is continuously degraded and stabilized by microorganisms under certain conditions, and a product suitable for land use is produced.

Site selection

The site should be flat, near the water source and sunny from the leeward. It does not pollute the environment and is easy to provide water.

windrow turner

Chicken Manure Organic Fertilizer Fermentation Mode

  1. Store the materials and add the bacteria proportionally. Water content should be controlled at 60%-70%. Fermentation of less water is slow and aeration of more water is poor. Oxygen deficiency will corrupt and produce odor.
  2. The start-up temperature is better than 15℃ (can be operated in four seasons, not affected by season, fermentation in indoor or greenhouse in winter as far as possible), and the fermentation temperature should be controlled between 60 ~65℃.
  3. Fermentation of organic fertilizer needs oxygen consumption fermentation. In the process of operation, oxygen supply measures should be increased so as to mix well, turn over frequently and ventilate properly. The windrow turnercan work accurately to meet the requirements, it’s an important equipment of fertilizer fermention. Windrow compost turning machine has the advantage of high efficiency, smooth operation, strong and durable, even turning throw.
  4. Fermentation

Warming-up stage: generally only one day is needed from room temperature to 50℃.

High temperature stage: generally only 2 days from 50-70℃.

Cooling stage: from high temperature to below 50℃, generally about two weeks. The temperature began to drop to normal temperature, indicating that the fermentation was completed.

FAQ of Organic Fertilizer Fermentation:

  1. Slow warming: no or slow warming of the reactor

Material is too wet, too dry, there is not enough nitrogen source, and the pH is too low.

  1. Heap temperature is too high: during fermentation, the heap temperature is more than 65℃.

Poor permeability.

  1. Odor: The odor of rotten eggs or rotten eggs is emitted from the stack.

Ammonia content is too high, material stacking is too dense.

After being processed by the chicken manure organic fertilizer production equipment, these organic fertilizers can be sold. Huaqiang fertilizer machine manufacturer supply professional organic fertilizer production line, and a series comprehensive service.

Common problems of NPK compound fertilizer production

NPK compound fertilizer is synthesized from chemical raw materials needed by various plants. NPK fertilizer has played a significant role in increasing production and income of agricultural production. So what are the common problems in the NPK fertilizer production process and what needs to be known about the equipment for the production of NPK fertilizer?

 

  1. Specialized NPK fertilizer production equipment is naturally used for fertilizer production, but due to the nature of compound fertilizer itself, fertilizer equipment is easy to be corroded, and some frequently used equipment has been seriously corroded in less than a year. Normal loss is inevitable, but necessary equipment maintenance can prolong the service life of fertilizer processing equipment.

 

  1. When crushing raw materials, we should try our best to ensure that there are no large hard blocks in the raw materials. In the compound fertilizer raw materials, if there are stones or even iron blocks, it will cause serious damage to the high-speed rotating mill rotor. Only by ensuring that the raw materials are clean and free of impurities can the equipment of fertilizer production process not be affected.

 

  1. Mechanical equipment relies on motor and reducer to obtain power source. Periodically adding lubricating oil to fertilizer granulator machinecan better ensure their operation. There are many types of lubricating oil, so we should choose suitable grease according to the principle of climate and mechanical transmission. For example, in cold areas and hot and humid environment, it is necessary to select the appropriate lubricant to ensure better operation of the equipment. In addition, when filling oil, control the amount of oil, so as not to affect the effect too little, or too much waste.

 

  1. Different equipments have different productivity. We should use the equipments reasonably according to their productivity. For example, in the compounding stage of fertilizer manufacturing process, forklift trucks should be allowed to drop materials slowly when feeding into silos, so as not to damage the equipment. When mixing, the raw materials should not be too full, and materials should be added after the start of the mixer, in order to avoid equipment damage due to excessive stirring resistance.

NPK fertilizer production process

In short, there are many details about the production of NPK fertilizer. Only by maintaining the fertilizer production equipment can they work better and bring us more benefits.

 

Fermentation Mode of Chicken Manure Organic Fertilizer Manufacturing Process

Organic fertilizer, commonly known as farm manure, consists of various animal, plant residues or metabolites, such as human and animal manure, straw, animal residues, slaughterhouse waste, etc. Carbon-containing materials, mainly from plants and animals, are applied to the soil to provide plant nutrition as its main function. It not only provides comprehensive nutrition for crops, but also has long fertilizer efficiency. It can increase and renew soil organic matter, promote microbial reproduction, improve soil physical and chemical properties and biological activity. It is the main nutrient in green food production.

The production of organic fertilizer must go through composting fermentation process. Composting is a process in which organic matter is continuously degraded and stabilized by microorganisms under certain conditions, and a product suitable for land use is produced.

 

Site selection

The site should be flat, near the water source and sunny from the leeward. It does not pollute the environment and is easy to provide water.

windrow turner

Chicken Manure Organic Fertilizer Fermentation Mode

  1. Store the materials and add the bacteria proportionally. Water content should be controlled at 60%-70%. Fermentation of less water is slow and aeration of more water is poor. Oxygen deficiency will corrupt and produce odor.

 

  1. The start-up temperature is better than 15℃ (can be operated in four seasons, not affected by season, fermentation in indoor or greenhouse in winter as far as possible), and the fermentation temperature should be controlled between 60 ~65℃.

 

  1. Fermentation of organic fertilizer needs oxygen consumption fermentation. In the process of operation, oxygen supply measures should be increased so as to mix well, turn over frequently and ventilate properly. The windrow turnercan work accurately to meet the requirements, it’s an important equipment of fertilizer fermention. Windrow compost turning machine has the advantage of high efficiency, smooth operation, strong and durable, even turning throw.
  2. Fermentation

Warming-up stage: generally only one day is needed from room temperature to 50℃.

High temperature stage: generally only 2 days from 50-70℃.

Cooling stage: from high temperature to below 50℃, generally about two weeks. The temperature began to drop to normal temperature, indicating that the fermentation was completed.

 

FAQ of Organic Fertilizer Fermentation:

  1. Slow warming: no or slow warming of the reactor

Material is too wet, too dry, there is not enough nitrogen source, and the pH is too low.

 

  1. Heap temperature is too high: during fermentation, the heap temperature is more than 65℃.

Poor permeability.

 

  1. Odor: The odor of rotten eggs or rotten eggs is emitted from the stack.

Ammonia content is too high, material stacking is too dense.

 

After being processed by the chicken manure organic fertilizer production equipment, these organic fertilizers can be sold. Huaqiang fertilizer machine manufacturer supply professional organic fertilizer production line, and a series comprehensive service.

 

 

Production Advantage of NPK Compound Fertilizer with Double Roller Granulator

NPK compound fertilizer production mainly deals with raw materials in the state of powder, bulk, solution and molten liquid to produce particles with certain shape and size. Fertilizer granulator machine is an important equipment for compound fertilizer processing. Generally speaking, many parameters of fertilizer granulator can be adjusted, so it can adapt to a large range of raw materials.

 

Although many conventional compound fertilizer equipments still use wet granulation process to produce spherical pellet fertilizer, extrusion granulation process has many advantages, among which the most important is: low energy consumption of roller granulator NPK fertilizer production process, no need for liquid binder in granulation, many kinds of raw materials can be used, and the composition of raw materials is flexible. The function of roller fertilizer granulator is applicable to a wide range of large or small devices. Therefore, extrusion granulation NPK fertilizer production process has attracted more and more interest. Many fertilizer factories are considering dry extrusion NPK fertilizer production granulation process in construction.

In dry roller granulator equipment, the powder is applied force and compacted between two pairs of rollers. As with powder material, the quality requirement of roller granulator is reasonable formula, all kinds of components are complete and mixed evenly.In addition, the quality of particles produced by the double roller fertilizer granulator has the following two indicators:

 

  1. Hardness

Generally speaking, manufacturers usually want the particles to be harder. But whether from the point of view of use effect or manufacturing cost, it can not be said that the harder the better. The particle hardness produced by the double roller fertilizer granulator can be measured by the particle hardness meter and expressed by the pressure. According to the variety of materials, it is generally 0.06-0-12 MPa.

 

  1. Powdered rate

The method of determining the pulverization rate is to put a certain number of finished granules in a special pulverization rate measuring instrument, and turn them over at a prescribed speed in a prescribed time, and then determine the proportion of the powder transformed from granules in all materials. Generally, the powdered rate should not exceed 10% and the quality product should not exceed 5%.

Economic Benefit of Producing Slow-acting NPK Complex Fertilizer

Because of the low utilization rate of chemical fertilizer, people try to make a slow-release and high-utilization fertilizer to meet the demand of nitrogen in different growth stages of crops, reduce the loss of nitrogen leaching and volatilization, reduce the fixation of phosphorus and potassium fertilizers in the soil, so that the fertilizer can supply nutrients according to the requirement of crop fertilizer. The available CaO, MgO, SiO 2 and various trace elements in fertilizers are also good soil amendments. The coated NPK fertilizer manufacturing process can produce suitable fertilizer products.

 

Slow release coated fertilizer manufacturing process

NPK Fertilizer Production Process

According to the sustainable development of agriculture and the demand of improving fertilizer utilization rate, Zhengzhou Tianci Fertilizer Machine Manufacturer has developed a slow-acting, high-utility coated complex fertilizer manufacturing process. The fertilizer manufacturing process is based on the instant granular fertilizer as the core, one or more slow-release plant nutrients as the coating, inorganic acid complex, slow solvent and other binders to wrap water-soluble fertilizer, forming a complex fertilizer with both quick-acting and slow-acting components. We provide fertilizer manufacturing process including fertilizer granulator machine, pulverizer, rotary dryers, coolers, drum screening machines, coating machines, packing machines and other equipment. The whole set of fertilizer production equipment can complete the processing and coating of the particles of the complex fertilizer, so that the fertilizer has high utilization rate in the soil.

 

Benefits of NPK Fertilizer Production Process

In the process of fertilizer production, the structure and composition of cladding layer can be adjusted to control the release rate of nutrients so as to reduce leaching loss and improve the utilization rate of fertilizers. This fertilizer product not only has the characteristics of slowly releasing nutrients, but also can meet the needs of nutrients for the whole growth period of crops and the ratio of nutrient utilization rate by one basal application. Conventional quick-acting fertilizer increased by 10-30 percentage points, the utilization rate of nitrogen fertilizer could reach 50%-70%, and the amount of fertilizer used could be reduced by 10%-40%. Due to the remarkable economic and social benefits of slow-acting and high-utilization wrapped complex fertilizer, and in line with the direction of fertilizer development, it is worth vigorously promoting.

Main Granulating Methods of NPK Compound Fertilizer Production

NPK fertilizer can supply many kinds of nutrients needed by crops at the same time. The economic benefit is obvious. The production cost can be reduced by using compound fertilizer.

Compound fertilizer is not easy to agglomerate, easy to store and use, and is widely welcomed. How to select granulator for NPK fertilizer production line? Several main granulation methods are introduced here.

 

  1. Solid aggregate method

The basic monomer fertilizers such as urea, ammonium nitrate, ammonium chloride, ammonium sulfate, monoammonium phosphate, diammonium phosphate and potassium chloride are used as raw materials. After crushing to a certain fineness, the materials are agglomerated and granulated in a disc fertilizer granulator (or rotary drum granulator) by adding water and heating. NPK compound fertilizer products can be obtained by drying, cooling and sieving granules, which is also one of the widely used methods in the world.

This method has a wide range of raw materials, simple processing process, less investment, low production cost, flexibility, and raw materials are solid. Because it is a secondary process of basic fertilizer, there is almost no environmental pollution problem.

 

  1. Bulk blending method

According to the requirement of nutrient distribution ratio, mixed fertilizers with uniform nutrient distribution were prepared from various solid basic fertilizers of nitrogen, phosphorus and potassium without obvious chemical reaction, with basically identical granularity and roundness. The process of this method is simple and the investment cost is low, mainly use bulk blending mixer. It is a very practical and easy to promote method.

Bulk blending fertilizer has comprehensive nutrients, high concentration and flexible formula. It can be flexibly changed according to the different conditions of crop nutrition, soil fertility and yield level. The method is simple in processing, low in production cost and pollution-free.

 

  1. Extrusion method

Extrusion granulation is a dry granulation process in which solid materials are agglomerated by external pressure. Double roller press granulator is mainly used for granulation. The machine have two shaft with one fixed and the other can move, which can adjust the distance between the two shafts. And the granules will be extrude between the shafts.

Double Roller Press Granulator

Extrusion method of NPK fertilizer production has the following advantages:

(1) Drying and cooling processes are generally not needed in the production process, which can save investment and energy consumption.

(2) The operation is simple and there is no three wastes discharged during production.

(3) High-concentration compound fertilizer with lower concentration than general compound fertilizer can be produced. Organic fertilizer and other nutrients can also be added in production according to need. The production capacity of a single extruder is small. If large-scale production is needed, it can be combined with multiple units for factory production.

Potassium chloride production process by disc granulator machine

In the production of potassium chloride granular fertilizer, fertilizer granulator can be used to granulate powder. The particles produced by disc granulator are spherical and have good strength, which can be widely used in agricultural production.

 

Disc Pan Granulator

In the granulation process of disc pan granulator, it is necessary to add a binder to make the granules shape. Binder can be compounded by common inorganic minerals in a certain proportion. Binder has synergistic effect when potassium chloride is pelleted. The effect of pelletizing rate and particle strength is good when the binder is used for pelletizing. Potassium chloride was granulated by disc pan granulator machine, and the granules were spherical.

Pan Granulator NPK Fertilizer Production Line

NPK Fertilizer Production Line

NPK fertilizer production line deals with potassium chloride fertilizer. First, all raw materials are mixed by the batching system, and the material is crushed by chain mill to the appropriate size. The disc granulator makes the powder into granules. After drying and cooling, the granules of potassium chloride are coated with protective film by the fertilizer coating machine to complete the granular processing of potassium chloride.

 

When applying potassium chloride, attention should be paid to the appropriate period of potassium application. Generally, the application period of potassium fertilizer should be early or not late, and should be used as base fertilizer and early recovery period. When the application amount of potassium fertilizer is less, it can be used as base fertilizer once, and when the application amount of potassium fertilizer is more or the soil texture is lighter, the application effect is better divided into base fertilizer and topdressing fertilizer. Soil nutrients and fertilization status should also be taken into account in determining the suitable application period of potassium fertilizer. In severe potassium deficiency soils, all potassium fertilizers should be used as base fertilizers in medium soil potassium supply, and suitable organic fertilizers should be applied as base fertilizers, combined with topdressing.

 

Note the method of application of potassium chloride. The concentrated application of potassium fertilizer is beneficial to improve its utilization rate and obtain better results. However, it is not advisable to have direct contact with seeds or seedlings. For general crops, a combination of soil fertilization and foliar fertilization can be used.

How to Make Organic Fertilizer by Feces Composting

Fecal composting organic fertilizer manufacturing process is to adjust the carbon-nitrogen ratio in the manure of the livestock and poultry by turning machine, manually controlling the conditions of water, temperature, pH and the like, and treating the manure of the livestock and poultry by the fermentation of the microorganisms to produce organic fertilizer.

 

I. Major organic fertilizer production equipmentfor composting

The composting process requires a large number of organic fertilizer processing equipment.

(1). Pre-treatment equipment: mainly include stockyard, unloading platform, feeding door, loading machinery, transport machinery and so on.

(2). Composting equipment: mainly trough compost turning machine, windrow turner machine, fermentation tank.

(3). Fertilizer granulator machine : mainly drum granulator, disc granulator, flat-die extrusion pelleting machine, organic fertilizer granulator, ring-die pelleting machine.

(4). Screening and packaging equipment: mainly drum screener, fertilizer packing machine.

organic fertilizer production equipment

 

II. Main Technical Parameters of composting

(1). C/N ratio: C/N balance of compost mixture is the key factor for microorganisms to achieve better biological activity. The C/N ratio of compost mixture should be kept at 25-35:1.

 

(2). Humidity: Aerobic composting should generally be maintained at 40-70%.

 

(3). Acidity and alkalinity: Acidity and alkalinity vary with the types of compost mixtures and different stages of composting process. Normally, they need not be regulated. If they need to be regulated, they can be regulated by adding alkaline or acidic substances to the mixture before the beginning of composting degradation.

 

(4). Other design parameters: Rectangular fermentation stacking composting mode, the windrow turner should be used regularly to turn the pile, so that the temperature is kept below 75℃, and the turning frequency is 2-10 days/time. The width and depth of rectangular stacks are limited only by the overturning equipment. The stacks are generally 1.2-1.8 meters deep and 1.8-3 meters wide. The height of the compost is usually 2.5-4.5 meters, and the width is usually twice the depth. Fermentation tank composting, need to build fermentation tank, fermentation tank length is unlimited.

 

III. Matters needing attention in composting

(1). Composting time: Composting time varies with C/N ratio, humidity, weather conditions, type of composting operation and management, waste and additives. The composting time of well-managed strip-cutting fermentation compost in summer is generally 14-30 days.

(2). Temperature: We should pay attention to the monitoring of composting temperature. The composting temperature should exceed 55℃, so as to be conducive to microbial fermentation and kill pathogens.

(3). Humidity: Pay attention to monitoring the humidity of compost mixture periodically. Excessive or low humidity will reduce or stop the composting speed.

(4). Odor: Odor is a good indicator of composting operation stage. Decay odor may mean that compost is changed from aerobic to anaerobic.

How to Choose Suitable Fertilizer Granulator Machine

Granulating fertilizer with granulator makes it easy to store and sow. It is beneficial to the even distribution of nutrients and slow release the fertilizer efficiency. Different types of fertilizers, different sizes and shapes of fertilizer particles, and different granulators are used.

We can choose the right fertilizer granulator machine according to the specific function of the machine.

 

Rotary Drum Granulator

Drum Granulator is a larger production version of the disc granulator, make the fertilizer powder into round particles. It is suitable for hot and cold granulation and high, medium and low concentrations of mass production of fertilizer. The shell of the machine uses special rubber slab lining or acid-resistant stainless lining board which realizes auto scar removal and de-tumor instead of traditional drawknife equipment.

Rotary Drum Granulator

Disc Fertilizer Granulator

Disc Granulator, also called pan granulator, not only produce organic fertilizer, but also compound fertilizer. The disc bottom adopts multiple steel plates which are firm, durable, not deforming. The granulator’s main gears adopt high temperature quenching technology, doubling the service life. Granulation rate reaches above 93%.

Flat Die Extrusion Pelleting Machine

Flat die extrusion pelleting machine is used for granulation to all kinds of organic matter after fermentation, break through the conventional organic prilling before granulation needs not to dry and crush the raw materials. Pelleting machine can direct burdening to work out cylindrical grain, has better granulation effect on fertilizers containing more straw, can save a lot of energy.

 

New Type Organic Fertilizer Granulator

This Organic Fertilizer Granulator is used for making granulation of organic matter after fermentation, dedicated to the production of organic fertilizer granules. After fermentation organics don’t need to dry, it process fertilizer powder into granules, the organic content can be high to 100%. The granulator have the feature of simple machine structure, easy operation and maintenance, low power consumption.

 

Double Roller Press Granulator

Double roller press granulator is often used to manufacture NPK compound fertilizer, such as ammonium choride, ammonium sulphate, ammonium nitrate, diamonium phosphate, potassium Sulphate, magnesium sulfate, magnesium silicate, zinc sulphate, phosphorus pentoxide, etc. This machine diameter of the ball can be made according to the requirement of the customers. The roller press granulator machine have two shaft with one fixed and the other can move, which can adjust the distance between the two shafts, the materials will be extrude between the shafts.

Double Roller Press Granulator

 

For more information on how to choose granulator machine, please contact us. We are a well-known fertilizer machine manufacturer in China. We have many years of rich experience and we will try our best to give you a detailed answer.