New Type Organic Fertilizer Granulator

Equipment Introduction

The New Type Organic Fertilizer Granulator, also known as an internal rotary stirring tooth granulator or wet granulator, is designed and manufactured using a new wet continuous pusher granulation process. It is specifically designed for difficult-to-process coarse fibrous 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.

This equipment is mainly used for granulating various fermented organic materials. Its technological breakthrough lies in the fact that the raw materials do not need to be dried and crushed before granulation. The wet material after fermentation can be directly fed into the granulator from the fermentation tank, eliminating the energy-intensive drying pretreatment step in traditional processes. This process differs from conventional organic granulation methods; direct batching produces spherical granules, effectively saving significant energy and time costs.

The granules produced by this equipment are spherical with an organic content of up to 100%, achieving pure organic granulation. Utilizing the characteristic that organic microparticles can interlock and grow under certain forces, no binder needs to be added during granulation. The granules are firm and can be screened immediately after granulation, greatly reducing drying energy consumption. This machine is suitable for granulating lightweight, fine powder materials.

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.

Equipment Structure

The new type of organic fertilizer granulator mainly consists of the following core components:

Structural Features:

1. The transmission and main body are mostly fixed on the same frame, resulting in a robust structure, smooth operation, and easy installation.

2. Cylinder installation angle: 2°-2.5° (slight tilt), with the feed end 3-5cm higher than the discharge end.

3. Rubber or wooden boards are used for shock absorption between the frame and the foundation.

Raw Materials for the Equipment

This equipment is suitable for the following raw materials, and performs particularly well with coarse fibers or special materials that are difficult to process using traditional granulators:

Plant-based materials such as crop straw, rice husks, and corn cobs;

Livestock manure (chicken manure, pig manure, cow manure, etc.);

Drinking lees, brewing lees, and medicinal residues;

Humic acid, biogas slurry, and humic acid;

Urban sludge and industrial organic waste.

Raw materials with a moisture content of 40%-45% can be granulated before fermentation. Its unique design allows for the processing of wet materials, overcoming the limitations of ordinary equipment on wet raw materials.

Applications of the Equipment:

Agricultural Waste Treatment: Straw, rice husks, distiller's grains, mushroom residue, etc., are processed into granular fertilizer.

Livestock and Poultry Waste Treatment: Animal manure, chicken manure, pig manure, cow manure, etc., are treated.

Urban Waste and Environmental Applications: Sludge, humic acid, etc., can be recycled into granular fertilizer.

Pharmaceutical Waste Recycling: Pharmaceutical residues are processed into fertilizer granules.

Mineral Additive Fertilizer Granule Production: Optimizes the granule form of mineral and organic fertilizers.

Other Special Fields: For example, it can also be applied to the recycling of some industrial wastes.

Fermentation and Granulation Process of the Equipment

Fermentation Process: Raw materials need to undergo preliminary composting fermentation (trough-type or turning machine recommended) to reduce the moisture content to below 50%.

Pulverization Process: The fermented material needs to pass through a high-moisture material pulverizer to ensure a fineness of 40 mesh or higher.

Granulation Stage: Adjust the material moisture content to 35%-45% before feeding it into the new type of granulator.

Post-processing Stage: The granulated particles need to undergo drying, cooling, sieving, and coating before final packaging as the finished product.

Fermentation Process of the Equipment

The new type of organic fertilizer granulator itself does not directly participate in the fermentation process, but in the organic fertilizer production line, fermentation is a pre-process for granulation—fermentation provides qualified raw materials for granulation.

1. Key Points of Fermentation Process

Livestock and poultry manure, straw, and other organic waste must first undergo composting and fermentation.

During fermentation, a turning machine (trough-type turning machine, tracked turning machine, etc.) is used to turn the compost regularly to provide sufficient oxygen.

The fermentation cycle is generally 10-25 days, depending on the type of material and process conditions.

The moisture content of the material after fermentation should be around 30%-40%.

2. Impact of Fermentation on Granulation

The degree of fermentation directly affects the granulation effect—incompletely fermented material has insufficient viscosity and a low granulation rate.

The moisture content of the fermented material must be controlled within the range required by the equipment (20%-50%).

If the moisture content after fermentation is too high (>45%-50%), simple dehydration or the addition of auxiliary materials such as rice husk powder or straw powder is required for adjustment.

3. Seamless Integration of Fermentation and Granulation

One of the core advantages of the new organic fertilizer granulator is that the wet material after fermentation can be directly fed into the machine for granulation after exiting the fermentation tank. This characteristic eliminates the need for drying equipment between the fermentation and granulation sections, greatly simplifying the process and reducing material loss and time waste during intermediate transfers.

Granulation Process of the Equipment

The new organic fertilizer granulator adopts a wet continuous pusher granulation process. The core process parameters and control points are as follows:

1. Process Principle

Utilizing the high-speed rotating mechanical stirring force and the resulting aerodynamics, fine powder materials are continuously mixed, granulated, pelletized, and densified within the machine. This process leverages the characteristic that organic particles can interlock and grow under certain forces to achieve granulation.

2. Key Process Parameters

Material Moisture Content: 20%-50%, optimal 30%-40%

Spindle Speed: Organic fertilizer (containing coarse fiber) 220-260 r/min

Gap between stirring teeth and chamber wall: 5-10 mm

Finished Particle Diameter: 0.3-5 mm

Pelletizing Rate: ≥85%-90%, some models can reach over 95%

Organic Content: Up to 100%

3. Process Features

No Drying Required: High moisture content materials can be directly granulated without pre-drying.

No Crushing Required: Fermented materials can be fed into the machine without crushing.

No Binder Required: Utilizing the self-embedding characteristics of organic microparticles, no binder needs to be added.

One-Step Forming: The entire process of mixing, granulation, and pelletizing is completed in one step within the machine.

High Particle Roundness: The finished product is spherical granules with good appearance quality.

Adjustable Particle Size: Particle size can be controlled by adjusting the material mixing amount and spindle speed.

Application of the Equipment in the Production Line

The new type of organic fertilizer granulator is the core forming equipment in the organic fertilizer production line. It undertakes the front-end pre-treatment process and connects to the back-end finished product processing process. It is the key hub of the entire production line. The complete production line process is as follows: Raw material crusher → Mixing and blending machine → Fermentation and turning equipment → Screening machine → New type of organic fertilizer granulator → Dryer → Cooler → Screening and polishing machine → Coating machine → Automatic packaging machine. The equipment can operate as a single small unit, suitable for simple production by individual households and small workshops; it can also be linked with a complete production line to achieve fully automated assembly line operation from raw material processing to finished product packaging, suitable for large-scale, standardized, and intelligent organic fertilizer production projects. It can also be integrated with municipal solid waste treatment and livestock manure treatment projects.

Common problems with the equipment

Target Customers and Suitable Clients:

Small and medium-sized organic fertilizer manufacturers and fertilizer processing enterprises need to upgrade their outdated granulation equipment and improve their ability to process difficult-to-form materials;

Large-scale livestock and poultry farms and breeding cooperatives need to solve the problem of manure accumulation and pollution, and achieve profitable manure resource granulation;

Family farms and planting bases produce and use their own organic fertilizer to reduce planting costs and achieve waste recycling;

Wineries, pharmaceutical factories, and edible fungi factories need to treat industrial organic waste residue and achieve solid waste recycling;

Municipal environmental protection companies and solid waste treatment companies undertake projects for the harmless treatment of urban sludge and garden straw;

Organic fertilizer entrepreneurs and new project investors are building new organic fertilizer production lines and seeking highly adaptable and cost-effective core granulation equipment.

The new type of organic fertilizer granulator (stirring tooth granulator) has become the preferred granulation equipment for organic fertilizer, bio-organic fertilizer, and organic-inorganic compound fertilizer production lines due to its core advantages such as superior adaptability to coarse fibrous materials, high pelletizing rate, no binder required, and direct wet granulation. It specifically solves the industry pain point of traditional disc granulators and rotary drum granulators in handling high-fiber materials such as straw, mushroom residue, and medicinal residue.

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 fibrous materials and need technical support—we are always ready to provide you with professional and sincere service.