Creating a production line capable of generating 20 tons per hour of charcoal-based fertilizer involves setting up a series of processes and using specific machinery to ensure efficiency and quality. Here’s a detailed guide on how to set up this production process, including the use of a rotary drum granulate equipment and two horizontal mixer equipment:
1. Overview of the Production Process
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Composting the carbon and organic matters: Decomposing organic matter to form a nutrient-rich base.
Adding Carbon Powder into organic matters: Integrating charcoal powder to enhance the carbon content.
Mixing the carbon and organic matters: Thoroughly blending the compost and carbon powder to ensure uniformity.
Crushing the carbon and organic matters: Breaking down any large particles to create a consistent size.
Granulating the carbon and organic matters: Forming the material into granules using a granulator.
Drying the carbon and organic matters: Removing moisture to stabilize the granules.
Cooling the carbon and organic matters: Reducing the temperature of the dried fertilizer to enhance stability.
Packaging the carbon and organic matters: For easier storage and transportation.
2. Equipment Specification
Rotary Drum Granulator:
This is central to the granulation process. You’ll need a rotary drum granulator that can handle the desired throughput of 20 tons per hour. Ensure it has adequate capacity and power to operate continuously under full load.
Horizontal Mixers:
Two mixers are recommended to efficiently mix large volumes of material. These mixers will be used in both the initial mixing of compost and carbon powder, and the post-crushing mixing to ensure a homogenous mixture before granulation.
3. Advantages of Using a Rotary Drum Granulator
Scalability: Suitable for large-scale production due to its high capacity.
Efficiency: Provides continuous processing, which is vital for achieving a 20 tons per hour production rate.
Uniformity: Ensures that the granules are uniform in size and shape, which is crucial for consistent product quality.
Versatility: Capable of handling different types of materials and moisture contents, making it adaptable to various formulations of charcoal-based fertilizer.
4. Benefits of Granulating Carbon-Based Fertilizer
Improved Nutrient Delivery: Granules break down slowly, providing a gradual release of nutrients, which is beneficial for plant growth.
Reduced Dust Pollution: Granulating the fertilizer minimizes dust, making the product safer and cleaner to handle and transport.
Enhanced Product Handling: Granules are easier to apply using standard farming equipment, improving usability for end-users.
Marketability: Granular fertilizers are often preferred by farmers due to their ease of use and storage, leading to better market acceptance.
5.Production Line Setup
Feed Preparation:
Use shredders and crushers to prepare the raw materials for composting. Ensure the compost reaches the necessary maturity before adding charcoal powder.
Initial Mixing:
Load the mature compost and charcoal powder into the twin shaft mixers. Mix thoroughly to ensure an even distribution of charcoal.
Secondary Processing:
Crush the mixed material to ensure it is fine enough for granulation. Pass the crushed mixture through the second mixer to achieve a uniform, fine blend.
Granulation:
Feed the uniformly mixed material into the rotary drum granulator. Adjust the moisture content and drum speed to optimize granule formation.
Drying and Cooling:
Convey the granules through a drying system to reduce moisture content. After drying, cool the granules to enhance their stability and reduce caking.
Packaging and Storage:
Package the cooled granules for distribution. Store in a dry, cool place to maintain product quality.Implementing this detailed process will help you achieve a high-efficiency production line for charcoal-based fertilizer, aiming for an output of 20 tons per hour. If you have any question, you can click here to cantack us.