New Type Organic Fertilizer Granulator

new type organic fertilizer granulator

Equipment Introduction

The new type of organic fertilizer granulator, also known as a stirring tooth granulator, wet internal rotating stirring tooth granulator, or pusher granulator, is designed and manufactured using a new wet continuous pusher granulation process. It is a key granulation equipment in organic fertilizer, bio-organic fertilizer, and organic-inorganic compound fertilizer production lines, balancing "wet material pelleting" and "round pellets." This patented product addresses the core pain point of "difficulty in pelleting coarse fibers" in organic fertilizer production. It changes the traditional disc or drum granulation process, employing wet continuous pusher granulation technology. Through the high-speed rotating mechanical stirring teeth and aerodynamics, the material achieves continuous mixing, granulation, pelletizing, and densification within the machine. It is specifically designed for difficult-to-process coarse fiber materials such as straw, distiller's grains, mushroom residue, medicinal residue, and animal manure, achieving efficient and stable granulation after fermentation. This equipment also demonstrates excellent granulation efficiency for urban sludge, humic acid, coal ash, and other special organic materials, making it an important piece of equipment for modern environmentally friendly organic fertilizer processing.

Core Advantages:

1. High Pelletizing Rate: Up to 90%-97% or higher, low pulverization rate, and minimal material loss.

2. Strong Adaptability to Coarse Fibers: Excellent granulation effect for coarse fiber materials (straw, distiller's grains, mushroom residue, medicinal residue, etc.) that are difficult to granulate with conventional equipment.

3. No Binder Required: Utilizes the interlocking growth characteristics of organic microparticles, typically eliminating the need for chemical binders.

4. High Pellet Quality: Finished pellets have a sphericity ≥0.7, smooth surface, and high uniformity.

5. Energy Efficient: Gentle granulation process, lower energy consumption than traditional granulation methods.

6. Compact Structure: Small footprint, easy installation, and stable operation.

Equipment Structure

The new organic fertilizer granulator mainly consists of three parts:

1. Body: The main load-bearing structure, welded from high-quality steel, is robust and durable. The material completes the entire process from feeding to granulation and discharge within the machine. The internal design includes a well-designed granulation chamber, providing space for high-speed mixing and forming of the material.

2. Granulation Rotor (Core Working Component): The rotor is equipped with stirring teeth (also known as agitating teeth or granulating teeth), which are the core components for achieving the granulation function. When the rotor rotates at high speed, the stirring teeth generate strong mechanical stirring and shearing forces on the material, enabling continuous mixing, granulation, balling, and densification processes within the machine. The stirring teeth are typically made of high-strength wear-resistant alloy, with replaceable alloy cutter heads at the ends to extend their service life.

3. Transmission System: This includes the electric motor, reducer, drive shaft, and pulleys. The electric motor provides power, which is reduced and increased in torque by the reducer to drive the granulation rotor to rotate at high speed. The transmission system and the main body are mostly fixed on the same frame, resulting in a reasonable structure, stable operation, and very convenient installation.

4. Frame and auxiliary accessories: Motor mount, V-belt, shock absorbers, etc., to ensure stable equipment operation.

Some models are also equipped with a spraying device for evenly spraying clean water or binder solution onto the material during granulation to regulate material moisture.

Raw Material Requirements for the Equipment

Physical Property Requirements

Chemical Property Requirements

pH Value: 6.0-8.5; adjustment required for excessively acidic or alkaline conditions

Salinity: Excessive salinity affects particle strength and solubility

Heavy Metals: Must comply with national standards for organic fertilizers (NY 525-2021)

Common Raw Material List

Organic Materials: Chicken manure, pig manure, cow manure, sheep manure, straw powder, biogas residue, mushroom compost, soybean meal, bone meal, humic acid

Auxiliary Materials: Bentonite (optional, for adjusting binding properties), zeolite powder, perlite

Inorganic Materials: Urea, ammonium phosphate, potash fertilizer, trace elements (added during compound fertilizer production)

Working Principle of the Equipment

The new type of organic fertilizer granulator operates on a wet granulation mechanism based on the synergistic effect of high-speed mechanical stirring and aerodynamics. It relies on the material's own moisture viscosity and mechanical extrusion and kneading force to achieve natural granulation without binders. The process consists of four continuous granulation stages, ensuring stable processing and uniform granulation results.

1. Detailed Explanation of the Granulation Process

Stage 1: Material Feeding and Initial Mixing

Fermented powdery material (moisture content 35%-45%) enters the cylinder at a uniform speed through the feed inlet. The granulation rotor rotates at high speed, and the alloy stirring teeth apply strong shearing and stirring action to the material, breaking up clumps and ensuring uniform moisture content and density, laying the foundation for subsequent granulation.

Stage 2: Nucleation and Agglomeration

Under the high-speed mechanical force of the stirring teeth, the finely crushed material undergoes tight adhesion between molecules; simultaneously, the moisture in the material forms liquid-phase capillary adsorption, promoting the combination of fine powder particles and initially agglomerating them into uniformly sized granules with a diameter stable in the range of 1.5-3mm.

Stage Three: Stratification and Spheroidization The initially formed small spherical nuclei, under the continuous pushing, tumbling, and friction of the rotor's agitator teeth, continuously adsorb surrounding loose fine powder, achieving layer-by-layer growth. Continuous mechanical friction between the material and the inner wall of the machine casing gradually densifies and rounds the loose particles, increasing their strength.

Stage Four: Polishing and Discharge Under the secondary polishing action of the sealed cavity of the cylinder and the agitator teeth, the formed particles continue to grow to the finished product size (2-5mm). Finally, the qualified finished particles are smoothly discharged from the discharge end of the machine under the axial thrust of the rotor, completing the continuous granulation operation.

2. Key Process Parameters (Core Control Indicators)

Rotor Speed: High-speed rotation generates high-intensity mechanical stirring force and aerodynamic force, which is the core power source for material granulation.

Material Moisture Content: 35%-45%, the optimal granulation range for the equipment, ensuring pelleting rate and preventing powder discharge or adhesion.

Feed Particle Size: Fine powder of 50 mesh (approximately 0.3mm) or larger. The finer the powder, the more uniform the granules and the better the quality.

Granulation Temperature: The temperature inside the equipment's working chamber can reach 60-100℃, which can slightly evaporate the surface moisture of the material, effectively reducing energy consumption and cost in subsequent drying processes.

Particle Diameter Adjustment: Can be adjusted bidirectionally through material feed rate and spindle speed; the lower the feed rate and the higher the speed, the smaller the finished particle size, adapting to various production requirements.

Granulation Process of the Equipment

I. Complete Process Flow

Main Production Flow: Raw Material Fermentation → Crushing and Screening → Batching and Mixing → New Organic Fertilizer Granulation → Drying → Cooling → Screening → Coating → Packaging

Circular Process Description: The equipment adopts a closed-loop return material production mode. Unqualified fine powder and granular materials screened out in the screening process can be returned to the front-end batching and mixing process to re-participate in granulation production. The return material ratio is controlled at 2:1 to 4:1 throughout the process.

Process Advantages: Utilizing returned granules as a nucleation substrate effectively improves the pelleting rate of materials, reduces raw material waste, and ensures continuous and stable production of the production line.

II. Key Points of Process Control

III. Trial Run and Debugging Process Specifications

1. For the initial trial run of the equipment, materials with lower moisture content should be used for trial granulation. A lower initial pelleting rate is normal and no parameter adjustment is required.

2. After trial production of 200-300 kg of material, precisely adjust the raw material moisture content according to the finished particle state:

• Finished particles are too large and sticky → Reduce the raw material moisture appropriately

• Finished particles are too small, with high powder output and poor forming → Increase the raw material moisture appropriately

3. After the equipment enters normal mass production, it is essential to ensure uniform feeding speed and consistent raw material moisture content to guarantee a continuous and stable output of high-quality granular organic fertilizer from the production line.

Equipment Operation Method

1. Pre-start Preparation

Inspect Equipment: Confirm all bolts are tight, agitator teeth are not loose, and the casing is well sealed.

Check Lubrication: Add gear oil to the reducer to the oil level line; ensure sufficient grease in the bearing housing.

Check Electrical: Confirm the motor rotation direction is correct (reverse rotation is strictly prohibited).

Adjustment and Installation: Ensure the feed end is 3-5cm higher than the discharge end.

Start-up Operation Steps

Step 1: Start the motor under no-load and run for 2-3 minutes, checking for any abnormal noise or vibration.

Step 2: Confirm the rotation direction is correct (if reverse rotation is detected, stop the machine immediately and adjust).

Step 3: Start the water spray/spraying system (adjust moisture content if necessary).

Step 4: Feed slowly and evenly, starting with materials with a lower moisture content for trial operation.

Step 5: Observe the pelleting situation and gradually adjust the feed speed and moisture content.

Step 6: After stable pelleting, proceed with continuous production.

2. Key Adjustments During Operation:

Particles too large: Reduce raw material moisture or increase spindle speed.

Particles too small/containing powder: Increase raw material moisture or decrease speed.

Low pelleting rate: Check raw material fineness and moisture content to ensure they are within the optimal range.

Severe wall adhesion: Appropriately reduce moisture or stop the machine for cleaning.

Shutdown Procedure:

Stop feeding first, and stop the machine only after most of the material has been discharged.

If necessary, restart the machine after stopping for 2-3 minutes to expel all remaining material.

Never start the machine with material on it to avoid equipment damage.

3. Emergency Handling:

Material jamming or excessive power load: Immediately reduce feeding and stop the machine for inspection.

Cleaning adhered material: Open the machine casing for cleaning, or add water to the casing for rinsing.

Common Problems and Solutions

Application of the Equipment in the Production Line

The new type of organic fertilizer granulator is typically used as the core granulation equipment in the production line, located after the fermentation, crushing, and mixing processes, and before the drying, cooling, and screening processes.

1. Typical Flowchart of Organic Fertilizer Production Line

Raw Material Fermentation (Compost Turner) → Semi-Wet Material Crusher → Horizontal Mixer → New Organic Fertilizer Granulator → Dryer → Cooler → Drum Screen → Automatic Packaging Machine

2. List of Supporting Equipment

Fermentation Equipment: Trench Compost Turner, Tracked Compost Turner, etc.

Crushing Equipment: Semi-Wet Material Crusher, Vertical/Horizontal Crusher

Mixing Equipment: Horizontal Mixer, Twin-Shaft Mixer

Granulation Equipment: New Organic Fertilizer Granulator (Core)

Drying Equipment: Rotary Dryer

Cooling Equipment: Rotary Cooler

Screening Equipment: Drum Screen, Vibrating Screen

Packaging Equipment: Automatic Quantitative Packaging Machine

3. Process Features

Adopts a new wet continuous pusher granulation process.

Fermented materials can be directly granulated without drying or crushing.

Continuous production from fermentation to packaging is possible.

Equipment can be used as a single machine or combined in multiple units to form a mechanized continuous production line with an annual output of 10,000-100,000 tons.

4. Advantages compared to traditional processes: Traditional organic fertilizer granulation requires drying and crushing of materials before granulation, which is energy-intensive and time-consuming. The new organic fertilizer granulator allows materials with a moisture content of up to 20%-50%, and fermented wet materials can be directly fed into the machine for granulation, eliminating the energy-intensive drying pretreatment step in traditional processes, thus saving a significant amount of energy and time costs.

Comparison of the new organic fertilizer granulator with other granulation equipment

The new type of organic fertilizer granulator, with its unique technological advantages such as wet continuous pusher granulation process, direct granulation of high-moisture materials, no need for drying and crushing, and no need for binders, has become the preferred granulation equipment in the organic fertilizer industry for processing high-moisture, high-viscosity, and coarse-fiber organic materials. Its core technology lies in utilizing high-speed rotating stirring teeth to generate mechanical stirring force and aerodynamics, enabling the material to continuously complete the entire process of mixing, granulation, pelletizing, and densification within the machine. This equipment solves the industry problem of traditional granulation equipment's inability to handle coarse-fiber materials, achieving pure organic granulation (organic matter content up to 100%).

The equipment has a scientifically sound structure, is easy to operate and maintain, and has a wide production capacity range from 1 ton/hour to 10 tons/hour. Whether you are building a new organic fertilizer production line and need a complete equipment solution, upgrading an existing production line and need equipment selection advice, or encountering difficulties in granulating coarse-fiber materials and need technical support—we are always ready to provide you with professional and sincere service.