28-30 t/h industrial scale biofertilizer production unit project

The client of this 28-30 t/h biofertilizer production unit project is a bioenergy limited company, which was established in March 2019. The client invested 3 million US dollars to use the existing plant to build a "large-scale organic fertilizer manufacturing project". The project uses sludge and manure to produce organic fertilizer through aerobic fermentation.

After the completion of the fertilizer unit project, it can produce 50,000 tons of green organic fertilizer and 10,000 tons of farmland organic fertilizer annually. The project started construction in April 2021 and was completed in July 2021.

• Capacity: 28-30t/h, with an annual output of 60,000 tons of organic fertilizer
• Nature of construction: newly built
• Occupied area (square meter): 38666 m²
• Biofertilizer production unit cost: 3 million USD
• Number of employees: 10 people, no canteen or dormitory.
• Working hours: 8 hours a day, 260 working days a year.
• Power consumption: The total annual power consumption of the project is about 1 million kWh.
• Heat supply: The bio fertilizer unit project does not use heat for production, and the office uses split air conditioners for cooling in summer and heating in winter.

The factory area of the 28-30 t/h biofertilizer production unit project covers an area of 38666.86m², with a construction area of 12799.37m², of which:

• No.1 workshop is 5840.87m², from west to east is the temporary storage and fermentation area for auxiliary materials;
• No. 2 workshop, 6713.5m², from west to east is drying, crushing, granulating and packaging;
• Office 230m2, power distribution room 15m².

The overall plan layout is clearly divided, each functional area is divided by passages, arranged according to the process flow and material conveying direction, the process route is short and fast, energy consumption is reduced, and the requirements of process flow, safe production, fire protection, maintenance, and transportation are met, and the flow of people and vehicles are separated. arrangement to ensure the safety of personnel. Therefore, the overall layout is more reasonable. (Find RICHI on Facebook)

The construction content of the 28-30 t/h biofertilizer production unit project includes main works, auxiliary works, public works and environmental protection works:

• 1# Workshop: Block 1, 1F, construction area 5840.87m², mainly for aerobic fermentation. The workshop is divided into 10 fermentation areas, including 8 green organic fertilizer fermentation areas and 2 farmland organic fertilizer fermentation areas.
• 2# Workshop: Block 1, 1F, construction area 6713.5m², drying area on the west side. To the east is the crushing, granulating, packaging area, and the finished product temporary storage area. A general solid waste temporary storage site is set up in the northeast corner of 2# workshop.
• Office 1, 1F, with a construction area of 230m², is adjacent to the west side of 1# workshop.
• Power distribution room 1, 1F, covers an area of 15m², and is located on the south side of the gate of the factory.

The followings are raw materials used in the 28-30 t/h biofertilizer production unit:

1. Sludge: The consumption is 50,000t/a, the moisture content is about 60%, and the sludge from the domestic sewage treatment plant in the surrounding area and the pretreatment sludge from the water company are used.
2. Animal manure: the consumption is 10,000t/a, the moisture content is 60%, and all animal manure is purchased from local farms.
3. Peanut shells and straw chips: the consumption is 10000t/a.
4. Fermentation bacteria (liquid): Consumption of 20t/a, the introduction of advanced Japanese strain stock solution, using pure natural high-efficiency strains and biologically active enzymes, after natural selection of strains, combined with advanced production and distribution methods, it can be directly As a starter, it is used for compost fermentation to promote the reproduction of other microorganisms in the raw materials, and it also has the function of biological deodorization.
5. Deodorant (liquid): Consumption 20, using the principle of biological deodorization to spray deodorizing bacteria to remove odors.
6. Quicklime: Consumption 2000, used for sterilization, deodorization, and raising the fermentation temperature.
7. Packing bags: the annual consumption is 1.5 million.

The sludge used in this 28-30 t/h biofertilizer production unit project mainly comes from domestic sewage treatment plants and surrounding areas, and the sludge from local domestic sewage treatment plants is given priority.

The animal manure used in this organic manure production plant project is mainly from the animal manure of local farmi. The sludge and animal manure are all transported in closed container vehicles to reduce the odor and leakage during transportation.

Before the raw material sludge used in this project enters the site, a batch of samples will be sampled by the sludge supplier every month and a company with testing qualifications will be entrusted to conduct testing. If the sludge is qualified, it will be transported to the plant of this project.

If heavy metals exceed the standard, the raw sludge of this batch will be rejected to ensure that all heavy metals in the sludge must meet the requirements of the "Mud Quality for Landscaping of Sludge Disposal in Urban Sewage Treatment Plants" (GBT 23486-2009).

The 28-30 t/h biofertilizer production unit project produces green organic fertilizer with sludge as raw material and farmland organic fertilizer with animal manure as raw material.

Each fertilzier series is divided into two types: powder and pellet.

Note: All green organic fertilizer products produced by this organic fertilizer production line project are sold to companies with forestry certificates.

The 28-30 t/h biofertilizer production unit project's farmland organic fertilizer implements the industry standard "Technical Specifications for Livestock and Poultry Manure Composting" of the Ministry of Agriculture:

The sludge used in the 28-30 t/h biofertilizer production unit project mainly comes from the surrounding areas. The sludge from the local domestic sewage treatment plant and the animal manure from the local farm are given priority. All of them are transported in closed container vehicles to reduce the odor and leakage during transportation.

Before the raw material sludge used in this project enters the site, a batch of raw material sludge is sampled every month and entrusted to a company with testing qualifications to conduct testing.

If heavy metals exceed the standard, the raw material sludge of this batch will be rejected to ensure that the heavy metal indicators of the sludge must meet the "urban Sewage treatment plant sludge disposal landscaping mud" (GBT 23486-2009) standard requirements.

Quicklime is packed in 25kg bags, and peanut shells/straw chips are packed in 20kg bags, which can reduce the generation of dust during transportation and unloading.

After the quicklime is transported in closed vehicles, it is manually unloaded to the raw material temporary storage area. Handle with care to reduce the amount of dust in the fermentation area.

The 28-30 t/h biofertilizer production unit project adopts the method of "aerobic strip-stack fermentation", without setting up a separate sludge temporary storage field, and directly batches and transports the incoming materials to the fermentation tanks specially set up in the partition, and uses bricks and then cement to smooth them out.

The height of each fermentation tank is 50cm , an area of 400 square meters, a total of 10 fermentation tanks, 2 for the production of farmland organic fertilizer, 8 for the production of green organic fertilizer.

Fermentation and composting is carried out once a day, and 300 tons of sludge is added at a time. According to the process requirements, the proportion of peanut shells and straw debris is further reduced to 50%.

At the same time, the fermentation bacteria (self-heating fermentation bacteria) and quicklime required by the process are added (Bactericidal effect), deodorant, put into the No. 1 fermentation tank, and the next day, the incoming material is repeatedly put into the No. 2 fermentation tank, and so on.

On the eighth day, the incoming material is put into the No. 8 fermentation tank. The fermentation tank completes the fermentation operation (the general fermentation period is 7 days).

Each fermentation tank is turned over once a day, and deodorant is supplemented when turning over. The fermentation area and the ground are laid parallel to the aerator blowing pipeline, and there is a blowing hole above the pipeline, and the blowing pipeline is connected to the aerator outside the workshop, which is used for blowing oxygen during the fermentation process.

During the fermentation process, an aerator is used to introduce air from the outside of the workshop to supplement oxygen from the bottom of the material through the aeration line to provide aerobic fermentation conditions.

The fermented material is transported to the drying area by a closed conveyor belt for drying. The material (with a moisture content of about 40%) that has reached the humidity required by the process is returned to the fertilizer crusher machine for pulverization.
 

Part of the crushed material is packaged as powdered organic fertilizer, and the other part is transferred to the organic fertilizer pellet machine for spray granulation. Our precision-crafted pellet dies apply just the right amount of pressure at low temperature to preserve the nutrients and microorganisms that Contribute to healthy soils and healthy plants.

The finished product after granulation is packaged as spherical organic fertilizer. The packaging is weighed and packaged in a woven bag lined with a plastic bag, 40kg per bag.

The water used in this 28-30 t/h biofertilizer production unit project is mainly vehicle washing water, granulation water and domestic water.

• Water for vehicle washing: The transport vehicles need to be washed every time they are transported. The chassis, wheels and the surroundings of the vehicle body must be washed clean, and they must not be carried on the road with dust. A car washing station is set up near the entrance of the factory area.
  
  The total length of the car washing station is not less than 7 meters, the total width is not less than 5 meters, and baffles are set on both sides. The water spraying height shall not be lower than 1.2 meters, the water spraying pressure shall not be lower than 0.4 MPa, and the vehicle cleaning time shall not be less than 5 minutes.
  
  The maximum transportation volume of a single vehicle in the project is 20t, and about 36,000 vehicles/a need to be transported. Both entry and exit need to be washed (72,000 times/a). The actual flushing water volume is about 0.4m3/vehicle.
  
  The water volume is 28,800t/a, the vehicle washing wastewater is recycled after sedimentation in the sedimentation tank, and is not discharged outside, and the loss is regularly replenished (about 25% of the loss). ).
• Water for granulation: The granulation process needs to use atomized water to humidify and help granulation. The output of granulation products is about 35,000 tons, and the water consumption is 2%. The water for granulation is about 700t/a (all from the precipitation of the spray tower pool backwater).
• Domestic water: The labor quota of this 28-30 t/h biofertilizer production unit project is 10 people, and the annual working time is 260 days. According to the "Code for Design of Water Supply and Drainage in Buildings" (GB 50015-2003, 2009 Edition), the water consumption for non-residential personnel is 80L/person·d, and the domestic water consumption for employees is 208t/a.

The amount of domestic sewage produced by the bio fertilizer unit project is calculated as 85% of the domestic water consumption, and the domestic sewage production is about 177t/a. After being treated in the septic tank, the agricultural fertilizer is used outside.

Sludge and animal feces with a moisture content of 60% bring in 36,000t/a of water, and fermentation bacteria/deodorants bring in 40t/a of water; the product has a moisture content of 40%, and the product takes away 24,000t/a of water, which is formed by fermentation and drying.

The water vapor is 12040t/a, after being absorbed by the spray tower, the waste water enters the sedimentation tank to clarify the supernatant, part of which is reused for vehicle washing 7200t/a, part of which is used for granulation water 700t/a, and part of which is reused for plant greening 2340t /a, and part of it will be used for supplementary water of biofilter 1800t/a.
 

Looking at agricultural countries around the world, it is a common phenomenon to substantially increase the proportion of organic fertilizer use, and most of them have exceeded the watershed of half.

The data shows that in the fertilizer structure of European and American countries, organic fertilizer plays a decisive role. In the United States, organic fertilizer accounts for 46%; Britain accounts for 57%; Germany accounts for 60%; France accounts for 37%; Australia accounts for 55%; Canada accounts for 60%, etc.

However, the proportion of organic fertilizers in my country's chemical fertilizer use is only 5%-10%. If the proportion can reach 10%, its market capacity will reach 14 million tons. In the future, with the gradual expansion of the proportion of organic fertilizer use, to It is expected to reach 23 million tons in 2023.

Therefore, for Chinese enterprises, it is promising to enter the organic fertilizer processing industry.