Fertilizer production process, production line and production equipment

Abstract

The invention discloses a fertilizer production process, a production line and production equipment, and belongs to the technical field of fertilizer production. The fertilizer production process comprises the following steps: putting raw materials and water into a collecting tank, mixing the raw materials and water through a stirring mechanism to form a first intermediate product, inputting the first intermediate product into plasma treatment equipment through a sewage pump, adjusting the pH value of slurry to obtain a second intermediate product, and outputting the second intermediate product into a sealing tank to obtain the fertilizer. After the natural reaction of the second intermediate product, ammonia gas generated by the second intermediate product is removed through negative pressure suction to obtain a third intermediate product, and the third intermediate product is subjected to dehydration treatment by adopting a dehydration device; and collecting the fourth intermediate product to a fermentation area to complete aerobic fermentation. According to the method, the organic fertilizer is rapidly prepared through plasma pretreatment, efficient deamination and rapid fermentation processes, worm eggs and germs are killed, the energy consumption is lower, and the product is environmentally friendly.

Description

Technical Field

[0001] The present invention belongs to the technical field of fertilizer production, and in particular relates to a fertilizer production process, a production line and production equipment. Background Art

[0002] Traditional chicken manure fertilizer processing mostly uses natural composting or high-temperature drying methods, which have the following technical drawbacks: Long composting cycle: Natural composting takes 2-3 months and is prone to ammonia volatilization and greenhouse gas emissions. Secondary pollution risk: Incompletely decomposed manure may carry pathogens, causing soil and groundwater pollution. Nutrient loss: The high-temperature drying process destroys the activity of organic matter, resulting in a loss rate of up to 30% in nutrients such as nitrogen and phosphorus. High energy consumption: Traditional equipment (such as drum dryers) requires a lot of heat energy, which is costly.

[0003] Patent CN108862354A discloses a granular fertilizer screening and return system, but fails to address the energy consumption associated with repeated granulation of powdered fertilizer. Patent CN104341177A proposes using sugarcane filter mud to produce fertilizer, but fails to optimize its physical stability, resulting in pulverization during storage. Conventional drum granulation processes have a granulation rate of only 30%-50% and require the addition of clay-based auxiliary materials, increasing costs.

[0004] Existing technologies have not yet achieved the coordinated optimization of efficient and harmless organic waste treatment and nutrient retention. There is an urgent need to develop an integrated process with low energy consumption, short cycle times, and high fertilizer efficiency. To this end, we have proposed a fertilizer production process, production line, and production equipment to address these issues. Summary of the Invention

[0005] The purpose of the present invention is to solve the problem of long production cycle and low efficiency of chicken manure fertilizer in the prior art, and to propose a fertilizer production process, production line and production equipment.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A fertilizer production process comprises the following steps:

[0008] S1: putting raw materials and water into a collection tank, and mixing the raw materials and water through a stirring mechanism to form a first intermediate product;

[0009] S2: The first intermediate product is fed into a plasma treatment device through a sewage pump, a high-frequency pulse electric field is applied, ozone is injected simultaneously to break the molecular chains of the feces, and the pH value of the slurry is adjusted to obtain a second intermediate product;

[0010] S3: Output the second intermediate product to a sealed pool, and after the second intermediate product has reacted naturally, remove the ammonia generated by the second intermediate product by negative pressure suction to obtain a third intermediate product;

[0011] S4: Dehydrating the third intermediate product with a dehydrating device to obtain a fourth intermediate product, collecting the fourth intermediate product to a fermentation area, adding a composite bacterial agent, and adjusting the temperature and humidity of the fermentation area to complete aerobic fermentation in the fermentation area.

[0012] Preferably, the plasma treatment equipment adjusts the pH value by spraying a citric acid solution, and the direction of the high-frequency electric field is perpendicular to the direction of the magnetic field.

[0013] Preferably, the dehydration treatment in step S4 includes the following steps:

[0014] (4a) centrifugal dehydration: the third intermediate product is fed into a centrifuge and processed by the centrifuge to obtain a preliminarily dehydrated material;

[0015] (4b) Waste heat air drying: The preliminarily dehydrated material is transported to the waste heat air dryer and gradient dried using the exhaust gas discharged from the high-temperature dryer. The preliminarily dehydrated material is dried in stages using exhaust gases of different temperatures.

[0016] A production line for implementing the above process includes the following equipment modules:

[0017] Raw material pretreatment unit: including a collecting tank, an output port is provided at the bottom of the collecting tank, a stirring device is provided in the collecting tank, and the output port of the collecting tank is connected to the plasma processing equipment;

[0018] Deamination reaction unit: including a sealed tank and an ammonia recovery device, wherein the ammonia recovery device is arranged on the top of the sealed tank;

[0019] Dehydration and air drying unit: includes a centrifuge and a waste heat air dryer. The centrifuge is provided with a spiral shaft, and the centrifuge output port is higher than the input port. The centrifuge is connected to the output port of the sealing tank. After dehydration, the preliminarily dehydrated material is transported to the feed port of the waste heat air dryer.

[0020] Fermentation and post-processing unit: fermentation area, high-speed crusher, mixer, secondary dryer;

[0021] Each unit is connected by a sealed conveying pipe, and the central controller of the production line adjusts the temperature, speed and pH parameters in real time according to the sensor feedback.

[0022] Preferably, the plasma processing equipment includes a synchronous controller that couples the high-frequency power supply and the strong magnetic field generator to dynamically match the electric field frequency and the magnetic field intensity. The matching formula is:

[0023] f=K·B 0.5

[0024] Where f is the frequency of the high-frequency electric field, B is the magnetic induction intensity, and K is the correction coefficient.

[0025] Preferably, a multi-layer baffle with an inclination angle of 15°-30° is provided in the sealed pool, the spacing between adjacent baffles is 1 / 5-1 / 3 of the pool width, and the top is connected to an ammonia collection hood and an activated carbon-sulfuric acid composite adsorption tower.

[0026] Preferably, a temperature and humidity sensor and an aeration device are provided in the fermentation chamber, and the aeration volume is dynamically controlled by the following calculation:

[0027]

[0028] Among them, Q is the real-time aeration volume, Q0 is the reference aeration volume, and E a is the activation energy of the bacterial agent, R is the gas constant, T0 is the reference temperature, and T is the real-time fermentation temperature.

[0029] Preferably, the ammonia recovery device includes a negative pressure suction device and a composite adsorption tower, and the composite adsorption tower is filled with a composite adsorption layer of activated carbon and sulfuric acid.

[0030] In summary, the technical effects and advantages of the present invention are as follows: This scheme significantly extends the movement path of charged particles in the reaction chamber through the orthogonal synergistic effect of plasma and magnetic field, enhances the collision probability of ozone and fecal molecules, and realizes efficient breaking of organic molecular chains. The multi-layer baffle structure design is combined with the ultrasonic cavitation effect to form a multi-stage gas-liquid mass transfer interface in the sealed tank, greatly extending the slurry flow path. The dynamic aeration system constructed based on the bacterial metabolic kinetics model monitors the maturity and temperature changes of the material in real time and adaptively adjusts the oxygen supply. The thermal energy coupling design of the waste heat air dryer and the high-temperature dryer realizes energy reuse in the drying process by recovering waste heat from exhaust gas. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic diagram of the process steps in the present invention;

[0032] Figure 2 It is a schematic diagram of the production line structure in the present invention. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0034] like Figure 1 As shown, a fertilizer production process includes the following steps:

[0035] S1: putting raw materials and water into a collection tank, and mixing the raw materials and water through a stirring mechanism to form a first intermediate product;

[0036] S2: The first intermediate product is fed into a plasma treatment device through a sewage pump, a high-frequency pulse electric field is applied, ozone is injected simultaneously to break the molecular chains of the feces, and the pH value of the slurry is adjusted to obtain a second intermediate product;

[0037] S3: Output the second intermediate product to a sealed pool, and after the second intermediate product has reacted naturally, remove the ammonia generated by the second intermediate product by negative pressure suction to obtain a third intermediate product;

[0038] S4: Dehydrating the third intermediate product with a dehydrating device to obtain a fourth intermediate product, collecting the fourth intermediate product to a fermentation area, adding a composite bacterial agent, and adjusting the temperature and humidity of the fermentation area to complete aerobic fermentation in the fermentation area.

[0039] 1. Raw material pretreatment subsystem

[0040] Collection tank: volume 5-10m 3 , equipped with a double-shaft spiral stirrer, stirring speed 20-30rpm, mixing uniformity ≥ 95%;

[0041] Water distribution system: integrated ultrasonic atomizer, water and chicken manure are accurately mixed in a mass ratio of 1:2, with an error of ≤±2%;

[0042] Sewage pump: adopts corrosion-resistant ceramic rotor pump, flow adjustment range 0.5-2.0m 3 / h.

[0043] The core of raw material pretreatment lies in achieving efficient homogenization of chicken manure and water. As a complex organic material, chicken manure has a dense fiber structure, making direct processing inefficient. The mechanical shearing action of a twin-shaft spiral agitator, combined with ultrasonic atomization technology, allows for microscopic water molecule penetration.

[0044] The twin-shaft agitator's spiral blades are arranged at a specific angle, creating a staggered shear force field. When the blades rotate at 25 rpm, the combined centrifugal and centripetal forces exert force on the manure clumps, simultaneously applying forces in both the radial and axial directions. This multi-directional force field disrupts the hydrogen bond network between cellulose and lignin, allowing water molecules to more easily penetrate the internal pores.

[0045] Mixing uniformity directly impacts the availability of microorganisms for subsequent processing. When moisture distribution is uneven, localized high concentrations inhibit aerobic bacterial activity, while low concentrations lead to incomplete enzymatic hydrolysis. Real-time viscosity monitoring and feedback control ensure that the moisture gradient is within the optimal range for microbial metabolism.

[0046] 2. Plasma-ozone synergistic treatment subsystem

[0047] Plasma treatment equipment:

[0048] High-frequency power supply: output frequency 10-50kHz, voltage 1-5kV, pulse width 50-200μs;

[0049] Strong magnetic field generator: generates 0.5-1.5T alternating magnetic field, the direction of the magnetic field is perpendicular to the direction of the electric field, forming the Lorentz force action area;

[0050] Ozone injection unit: ozone dosage is calculated based on COD equivalent

[0051] (Formula: [O3]=1.2×[COD] 初始 ×e -0.05t ;

[0052] Among them, [COD] 初始 is the initial chemical oxygen demand (COD) concentration in sewage, e -0.05t is the natural decay function of ozone over time.

[0053] pH adjustment module: spray 5%-10% citric acid solution, pH control accuracy ±0.3.

[0054] The high-frequency electric field causes polar molecules in manure (such as water and organic acids) to undergo dipole oscillations, generating Joule heating through intermolecular friction. Simultaneously, the vertical alternating magnetic field induces eddy currents in the fluid, creating a rotating force field. This electromagnetic torque acts like the angular momentum transfer of a galaxy's spiral arms, causing macromolecular chains to spiral and eventually break.

[0055] The introduction of ozone doesn't simply oxidize, but rather acts as a "molecular scissors." Under the impact of high-energy electrons generated by the plasma, ozone decomposes into atomic oxygen and excited oxygen molecules. These active particles preferentially attack the benzene ring structure of lignin, with selectivity comparable to that of biological enzymes, but at a reaction rate three orders of magnitude higher.

[0056] Citric acid is used for pH adjustment rather than strong acids because its complexing action stabilizes heavy metal ions, preventing microbial poisoning during subsequent fermentation. A dynamic spray system adjusts flow based on real-time pH monitoring to maintain the reaction system in the optimal degradation range.

[0057] 3. Deamination reaction subsystem

[0058] The sealed reaction pool is equipped with baffles and negative pressure suction system.

[0059] Baffle array: tilt angle 15°-30°, spacing 1 / 5-1 / 3 of the pool width, flow path optimized based on CFD;

[0060] Negative pressure suction system: vacuum degree -5~-15kPa, ammonia collection efficiency ≥90%;

[0061] Composite adsorption tower: filled with a composite adsorption layer of activated carbon and 20% sulfuric acid, with an ammonia recovery rate ≥95%.

[0062] The inclination angle and spacing of the baffles have been calculated and optimized, so that the manure produces a periodic acceleration-deceleration motion when flowing through the baffles, promoting the mass transfer of ammonia molecules from the liquid phase to the gas phase.

[0063] The negative pressure environment maintained by the vacuum system has a dual role: on the one hand, it reduces the partial pressure of ammonia to promote escape, and on the other hand, it drives fluid movement through pressure difference.

[0064] 4. Dehydration and fermentation subsystem

[0065] Horizontal spiral centrifuge: speed 2000-3000rpm, free water removal rate ≥60%;

[0066] Waste heat air dryer: The heat source comes from the high temperature dryer exhaust gas (120-150℃), and the heat exchange efficiency is ≥65%;

[0067] Fermentation warehouse:

[0068] Composite microbial agent: Bacillus subtilis, lactic acid bacteria, white rot fungi (mass ratio 3:2:1);

[0069] Temperature and humidity control: temperature 50-60℃, humidity 60-70%, PID closed-loop adjustment;

[0070] Aeration device: Dynamically control the aeration volume based on the Arrhenius equation. The calculation formula is as follows:

[0071]

[0072] Among them, Q is the actual aeration volume, Q0 is the standard aeration volume, E a is the activation energy, R is the ideal gas constant, T0 is the standard temperature, and T is the real-time temperature.

[0073] The extracellular enzymes secreted by Bacillus subtilis create a living environment for subsequent bacterial communities; lactic acid bacteria quickly lower the pH value to form selective inhibition; white rot fungi finally intervene, and their degradation products become the carbon source for the first two.

[0074] Temperature control utilizes a feedforward-feedback strategy: heat generation trends are predicted based on the specific heat capacity of the material, while infrared thermal imaging provides real-time corrections. A porous evaporation surface is installed on the top of the silo, utilizing residual heat from fermentation to drive water circulation.

[0075] 5. System integration relationship

[0076] Central controller: realizes the linkage control of each unit through the Industrial Internet of Things (IIoT);

[0077] Sensor network: including pH sensor, ammonia concentration sensor, temperature and humidity sensor, etc., with data sampling frequency ≥10Hz;

[0078] Sealed conveying pipeline: lined with polytetrafluoroethylene coating to prevent material adhesion and corrosion.

[0079] The technical solutions in the above-mentioned embodiments of the present application have at least the following technical effects or advantages: plasma pretreatment reduces the crystallinity of cellulose from 65% to 38% (XRD verification), and the fermentation efficiency of the composite bacterial agent is increased by 3 times; low-temperature dehydration (60-80°C) retains volatile fatty acids, and negative pressure deamination reduces nitrogen loss by 12-15 percentage points.

[0080] The present invention also provides a fertilizer production line, including the following equipment modules:

[0081] Raw material pretreatment unit: collection tank, stirring device, plasma treatment equipment;

[0082] Deamination reaction unit: sealed tank, ammonia recovery device;

[0083] Dehydration and air drying unit: horizontal spiral centrifuge, waste heat air dryer;

[0084] Fermentation and post-processing unit: fermentation area, high-speed crusher, mixer, secondary dryer;

[0085] Each unit is connected by a sealed conveying pipe, and the central controller of the production line adjusts the temperature, speed and pH parameters in real time according to the sensor feedback.

[0086] Physicochemical mechanism of plasma-ozone synergistic treatment

[0087] (1) High-frequency electric field and magnetic field coupling design

[0088] Plasma generation principle:

[0089] According to Maxwell's equations, the interaction of a high-frequency electric field (E) and an alternating magnetic field (B) generates plasma:

[0090]

[0091] Where E is the electric field intensity and its curl Represents the vortex characteristics of the electric field; B is the magnetic induction intensity, is its rate of change over time. μ0 is the vacuum magnetic permeability, ∈0 is the vacuum dielectric constant, is the time derivative of the electric field, which represents the rate of change of the electric field with time, and J is the current density.

[0092] When the electric field frequency f = 40kHz and the magnetic field strength B = 1.0T, the ionization requirements of organic matter in manure and sewage are met.

[0093] The orthogonal electromagnetic field topology is used, with electric field lines extending axially and magnetic field lines distributed radially. This configuration forms an electromagnetic "mesh," in which charged particles, driven by the Lorentz force, move in a spiral motion, extending the effective action path.

[0094] Ozone synergistic effect:

[0095] Ozone (O3) decomposes into hydroxyl radicals (·OH) in a plasma environment, and its generation rate follows:

[0096]

[0097] in, is the change in ozone concentration per unit time, [O3] is the instantaneous ozone concentration, [OH] is the hydroxyl radical concentration, and k is the reaction rate constant.

[0098] (2) Mechanical model of molecular chain breakage

[0099] Lorentz force:

[0100] The force on a charged particle in a vertical electromagnetic field is:

[0101] F=q(E+v×B)

[0102] Among them, q is the charge of the charged particle, E is the electric field strength, v is the instantaneous speed of the charged particle, and B is the magnetic induction intensity.

[0103] When q = 1.6 × 10 -19 C, which is sufficient to destroy the cellulose-lignin complex.

[0104] Fluid Dynamics Optimization of Deamination Reaction

[0105] (1) CFD simulation of baffle design

[0106] Flow state analysis:

[0107] The flow of manure between baffles is simulated based on the Navier-Stokes equation:

[0108]

[0109] Where ρ is the fluid density, is the rate of change of velocity field with time, which characterizes the unsteady flow characteristics. is the convective acceleration term; is the pressure gradient term, which represents the driving force for the fluid to move from the high-pressure area to the low-pressure area, and its direction is opposite to the pressure gradient; is the viscous force term; ρg is the volume force term, which represents the acceleration effect of gravity on the fluid particles.

[0110] When the baffle inclination angle θ = 25° and the spacing d = 0.2m (pool width 1.0m), the Reynolds number (Re = 5200) forms turbulent flow to enhance mass transfer.

[0111] Ammonia gas evolution calculation:

[0112] Ammonia partial pressure and liquid concentration The relationship is modified by Henry's law:

[0113]

[0114] Where H is the solubility coefficient of ammonia under specific conditions, and ΔT is the temperature change.

[0115] Under negative pressure conditions (P = 0.05 atm), the ammonia evolution rate increases.

[0116] Biological metabolic regulation of fermentation process

[0117] (1) Bacterial agent growth kinetics model

[0118] Monod equation optimization:

[0119] The relationship between the specific growth rate μ of the composite bacterial agent and the substrate concentration [s] is:

[0120]

[0121] Among them, k s is the substrate affinity constant, μ max is the maximum specific growth rate.

[0122] Heat balance control:

[0123] Fermentation heat production rate Q gen Relationship with bacterial growth rate rX:

[0124] Q gen =ΔH r ·r x

[0125] Where ΔH r Q is the metabolic heat released during the growth of a unit of bacterial mass, gen is the fermentation heat production rate, which is defined as the total heat released by microbial metabolism in unit volume of fermentation liquid per unit time, r x The bacterial growth rate is defined as the increase in bacterial mass per unit time in a unit volume of culture medium.

[0126] Biosensors implanted in the fermentation chamber monitor the NADH / NAD+ ratio in real time, reflecting the metabolic intensity of the bacterial flora. This signal is converted into aeration volume commands using a fuzzy logic algorithm, simulating the adaptive regulation of cardiopulmonary function during human exercise. When hypermetabolism is detected, the system proactively increases oxygen supply, avoiding the time lag of traditional control.

[0127] The waste heat recovery system utilizes a bionic fractal flow channel design, allowing high-temperature exhaust gas to extract heat in a stepped manner within multiple layers of nested pipes. Phase-change heat storage materials are also introduced to mitigate energy fluctuations on the production line.

[0128] The pipeline is designed as a reconfigurable intelligent network, with the pipe diameter dynamically adjusted according to the material's rheological characteristics. When handling high-viscosity media, standing wave vibrations are generated on the pipe wall to reduce flow resistance.

[0129] Example data verification

[0130] Raw materials: Chicken manure with a moisture content of 72%, total nitrogen of 3.8%, and COD of 85g / L

[0131] Processing parameters:

[0132] Plasma: 40kHz / 3.5kV, magnetic field 1.0T, ozone 8g / L

[0133] Deamination: -10kPa, 35min

[0134] Fermentation: 50℃ / 60% humidity, bacterial agent dosage 2%

[0135] result:

[0136] Fermentation period: 6 days (60 days for traditional process)

[0137] Total nutrients: 9.2% (N 4.1% + P2O5 3.0% + K2O 2.1%)

[0138] Pathogen inactivation rate: 99.99% (E. coli was not detected).

[0139] This example relies on the theory of microbial metabolic kinetics and thermodynamic phase transition to construct a composite bacterial agent directional fermentation system. The synergistic metabolic pathway of Bacillus licheniformis and Aspergillus niger (ratio 4:1) is based on the Monod equation, and the activity of the bacterial community is verified by monitoring the ATP concentration (≥5.6nmol / g). The temperature gradient in the fermentation chamber (60±2℃) is dynamically adjusted by the Arrhenius equation to ensure an oxygen concentration of 12%-15%.

[0140] Equipment structure

[0141] Multispectral sensing system

[0142] A multispectral probe with a wavelength of 400-1000 nm was integrated to establish a maturity prediction model (with an error of <2 hours) using the partial least squares (PLS) method. The maturity index showed a strong correlation with cellulase activity (≥220 U / g).

[0143] Hot air-microwave coupled drying module

[0144] The microwave generator (2450MHz) is positioned orthogonally to the hot air duct, utilizing the principle of selective heating by dipole molecules (penetration depth 10-15cm) to prevent crusting on the material surface. Thermodynamic simulations show a 30% reduction in specific energy consumption.

[0145] High temperature resistant bacterial agent carrier

[0146] The inner wall of the fermentation chamber is made of porous alumina ceramics (porosity>35%), which enhances the colonization stability of the bacterial agent through surface adsorption theory.

[0147] Bio-mechanical synergy

[0148] Plasma pretreatment enhancement: UV radiation (185-254nm) inactivates 99.9% of E. coli (D10 value = 12mJ / cm 2 ), creating a competitive advantage for functional microbiota.

[0149] Metabolic pathway optimization: Cellulase secreted by Aspergillus niger increases the lignin degradation rate to 82% through the β-glucosidic bond cleavage mechanism.

[0150] This example integrates a fluid dynamics model (Reynolds-averaged NS equations) with a logic tree analysis (FTA fault tree) to construct a production line parameter optimization system. Computational fluid dynamics (CFD) simulations of the flow field distribution within the plasma reaction chamber verify the effects of turbulence intensity (TI = 12%) and vortex size (λ = 0.15 m) on mass transfer efficiency.

[0151] Control strategy design

[0152] Viscosity-speed feedback loop

[0153] The Coriolis mass flowmeter monitors the slurry viscosity in real time (range 0-1000 mPa·s), and the centrifuge differential speed (15-25 rpm) is adjusted through the transfer function model (G(s) = K / (Ts+1)).

[0154] Energy cycle optimization module

[0155] The waste heat air dryer is connected to the high temperature dryer exhaust pipe through a bellows. The second law of thermodynamics analysis shows that the heat recovery efficiency is ≥65%.

[0156] The fault diagnosis system builds an early warning model based on the LSTM neural network (with an accuracy rate of 92%) and locates fault nodes through the logic tree decomposition technology.

[0157] System integration verification results

[0158] The operating data of the pilot production line (capacity 5t / d) shows that:

[0159] Plasma treatment energy consumption ≤ 0.8kWh / kg H2O;

[0160] The fermentation cycle is shortened to 7 days (traditional process ≥15 days);

[0161] Ammonia emission concentration ≤8mg / m 3

[0162] The technical solutions in the above-mentioned embodiments of the present application have at least the following technical effects or advantages: through the orthogonal synergistic effect of plasma and magnetic field, the movement path of charged particles in the reaction chamber is significantly extended, the collision probability of ozone and fecal molecules is enhanced, and the efficient breaking of organic molecular chains is achieved. The multi-layer baffle structure design is combined with the ultrasonic cavitation effect to form a multi-stage gas-liquid mass transfer interface in the sealed tank, which greatly extends the slurry flow path. The dynamic aeration system constructed based on the bacterial metabolic kinetics model monitors the maturity and temperature changes of the material in real time and adaptively adjusts the oxygen supply. The thermal energy coupling design of the waste heat air dryer and the high-temperature dryer realizes energy reuse in the drying process by recovering waste heat from exhaust gas.

[0163] Example 2

[0164] like Figure 2 As shown, a fertilizer production line comprises:

[0165] 1. Collection pool (raw material pretreatment):

[0166] Double-shaft spiral agitator: speed 20-30rpm, equipped with variable frequency motor, mixing uniformity ≥95%.

[0167] Ultrasonic atomization water distribution system: water and chicken manure are accurately distributed in a mass ratio of 1:2, with an error of ≤±2%.

[0168] pH online monitor: Real-time detection of the pH value of the mixed slurry (initial range 6.5-8.0), and the linkage spray system is adjusted to the target pH 7.0±0.3.

[0169] Impurity removal grid: aperture 10mm×10mm, separates impurities such as stones and feathers.

[0170] In this module, chicken manure enters the collection tank via a conveyor belt, is mixed with atomized water, and is homogenized by a twin-shaft spiral agitator. The pH adjustment system dynamically adjusts the pH through a citric acid / sodium bicarbonate spray module. The mixed slurry is filtered through a screen and then transported to a high-temperature dryer by an elevator.

[0171] 2. High temperature dryer (sterilization and dehydration)

[0172] Multi-stage drum dryer: divided into three temperature zones (120℃→150℃→100℃), residence time 30 minutes.

[0173] High-pressure steam sterilization system: steam pressure 0.3MPa, temperature 135℃, sterilization rate ≥99.99%.

[0174] Exhaust gas heat recovery device: preheat fresh air through plate heat exchanger, thermal efficiency ≥65%.

[0175] Humidity closed-loop control: Microwave moisture sensor (accuracy ±0.5%) is linked to the air intake, reducing the moisture content from 70% to 30%.

[0176] In this module, an elevator delivers the slurry to the dryer's feed port. Inside the drum, the slurry, stirred by the blades, passes through the high-temperature sterilization section and the gradient drying section. High-pressure steam is injected through the interlayer, directly contacting the material. The exhaust gas, after dust removal, enters the waste heat recovery system. After drying, the material is conveyed by the elevator to the cooler.

[0177] 3. Cooler (heat exchange and anti-caking)

[0178] Fluidized bed cooler: cold air temperature 20-25℃, wind speed 2-4m / s, cooling time 15 minutes.

[0179] Anti-caking crushing roller: stainless steel toothed roller (speed 50rpm), crushes agglomerated materials to particle size ≤10mm.

[0180] Dust recovery system: cyclone separation + bag dust removal, dust recovery rate ≥ 98%.

[0181] In this module, high-temperature materials enter the fluidized bed and come into contact with cold air in the opposite direction, reducing their temperature from 100°C to below 40°C. Crushing rollers simultaneously crush agglomerated materials, and the cooled particles are transported to a high-speed crusher via an elevator.

[0182] 4. High-speed grinder (fine grinding and secondary sterilization)

[0183] Hammer mill unit: main rotor speed 3000rpm, equipped with 60 mesh screen, crushing particle size ≤0.5mm.

[0184] Ozone dynamic sterilization: Ozone concentration is 20ppm, injected into the crushing chamber through the Venturi tube, and the sterilization rate is ≥99.9%.

[0185] Nitrogen protection system: The oxygen content in the crushing chamber is ≤5% to prevent oxidation of organic matter.

[0186] In this module, cooled material enters the pulverizing chamber, where it is pulverized by high-speed hammers and sterilized by ozone injection. The pulverized powder is then conveyed to the mixer via a nitrogen stream, where dust is recovered by a bag filter.

[0187] 5. Mixer (nutritional enhancement and bacterial agent addition)

[0188] Double planetary mixer: orbital speed 20rpm, rotation speed 50rpm, mixing uniformity CV ≤ 5%.

[0189] Bacteria spray gun: add Bacillus subtilis + lactic acid bacteria (viable bacteria ≥ 1×10 9 CFU / g), spraying amount 0.5-1.0%.

[0190] Trace element metering scale: Accurately add N / P / K (ratio 15:5:10), with an error of ≤±1%.

[0191] In this module, the crushed material, inoculant, and nutrients are simultaneously fed into the mixer, where a dual planetary agitator achieves three-dimensional mixing. The mixed material is then conveyed to the fermentation chamber via an elevator.

[0192] 6. Fermentation area (aerobic fermentation and composting control)

[0193] Intelligent compost turning system: crawler compost turning machine (travel speed 0.5m / min), compost turning frequency 8 hours / time.

[0194] Temperature and humidity control: temperature 50-60℃ (thermocouple control ±1℃), humidity 60-70% (infrared hygrometer feedback adjustment).

[0195] Aeration pipe network: perforation rate 30%, aeration volume according to the formula Q = 0.2 e 0.05(T-50) Dynamic adjustment (unit: m 3 / h·m 2 ).

[0196] In this module, the mixed materials are piled 1.5 meters high in the fermentation bin. A compost turner regularly turns the materials to promote oxygen diffusion, and an aeration system dynamically supplies oxygen based on data from temperature and humidity sensors. The fermentation cycle is 7 days, and the humic acid content is ≥25%.

[0197] 7. Packaging (finished product processing and moisture-proofing)

[0198] Automatic quantitative packaging machine: weighing accuracy ±50g, packaging speed 10 bags / minute.

[0199] Vacuum nitrogen replacement: oxygen content in the packaging bag is ≤3%, extending the shelf life to 18 months.

[0200] Metal detector: sensitivity Fe ≥ 1.5mm, SUS ≥ 2.0mm, linkage rejection device.

[0201] In this module, fermented fertilizer is vibrated and screened (2mm mesh) to remove undecomposed impurities. Qualified materials enter the packaging line. The bags are nitrogen-purged and heat-sealed before the finished products are stored.

[0202] The system works as follows: Based on the synergistic effects of high-temperature sterilization and bio-fermentation, it achieves resource utilization of chicken manure through gradient processing and energy recycling. This includes pretreatment in a collection pool, high-temperature drying and sterilization, cooling and pulverization, mixed fermentation, and packaging. High-temperature drying and dual sterilization with ozone / UV light effectively inactivate harmful organisms and shorten processing time. The combination of mechanical and thermal dehydration addresses the low efficiency of traditional dehydration. A composite bacterial agent is used in the mixed fermentation stage to accelerate the decomposition of organic matter and improve fertilizer efficiency. Meanwhile, waste heat recovery and automated control reduce energy consumption.

[0203] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A fertilizer production process, characterized in that: The steps include: S1: putting raw materials and water into a collection tank, and mixing the raw materials and water through a stirring mechanism to form a first intermediate product; S2: The first intermediate product is fed into a plasma treatment device through a sewage pump, a high-frequency pulse electric field is applied, ozone is injected simultaneously to break the molecular chains of the feces, and the pH value of the slurry is adjusted to obtain a second intermediate product; S3: Output the second intermediate product to a sealed pool, and after the second intermediate product has reacted naturally, remove the ammonia generated by the second intermediate product by negative pressure suction to obtain a third intermediate product; S4: Dehydrating the third intermediate product with a dehydrating device to obtain a fourth intermediate product, collecting the fourth intermediate product to a fermentation area, adding a composite bacterial agent, and adjusting the temperature and humidity of the fermentation area to complete aerobic fermentation in the fermentation area.

2. The fertilizer production process according to claim 1, characterized in that: In step S2, the plasma treatment equipment adjusts the pH value by spraying a citric acid solution, and the direction of the high-frequency electric field is perpendicular to the direction of the magnetic field.

3. The fertilizer production process according to claim 1, characterized in that: The dehydration process in step S4 comprises the following steps: (4a) centrifugal dehydration: the third intermediate product is fed into a centrifuge and processed by the centrifuge to obtain a preliminarily dehydrated material; (4b) Waste heat air drying: The preliminarily dehydrated material is transported to the waste heat air dryer and gradient dried using the exhaust gas discharged from the high-temperature dryer. The preliminarily dehydrated material is dried in stages using exhaust gases of different temperatures.

4. A fertilizer production line, characterized in that: Includes the following equipment modules: Raw material pretreatment unit: including a collecting tank, an output port is provided at the bottom of the collecting tank, a stirring device is provided in the collecting tank, and the output port of the collecting tank is connected to the plasma processing equipment; Deamination reaction unit: including a sealed tank and an ammonia recovery device, wherein the ammonia recovery device is arranged on the top of the sealed tank; Dehydration and air drying unit: includes a centrifuge and a waste heat air dryer. The centrifuge is provided with a spiral shaft, and the centrifuge output port is higher than the input port. The centrifuge is connected to the output port of the sealing tank. After dehydration, the preliminarily dehydrated material is transported to the feed port of the waste heat air dryer. Fermentation and post-processing unit: including fermentation area, crusher, mixer, and secondary dryer; Each unit is connected by a sealed conveying pipe, and the central controller of the production line adjusts the temperature, speed and pH parameters in real time according to the sensor feedback.

5. The fertilizer production line according to claim 4, characterized in that: The plasma processing equipment includes a synchronous controller that couples a high-frequency power supply and a strong magnetic field generator to dynamically match the electric field frequency and the magnetic field intensity. The matching formula is: f=K·B 0.5 Where f is the frequency of the high-frequency electric field, B is the magnetic induction intensity, and K is the correction coefficient.

6. The fertilizer production line according to claim 4, characterized in that: The sealed pool is provided with multi-layer baffles with an inclination angle of 15°-30°, the spacing between adjacent baffles is 1 / 5-1 / 3 of the pool width, and the top is connected to an ammonia collection hood and an adsorption tower.

7. The fertilizer production line according to claim 4, characterized in that: The fermentation chamber is equipped with a temperature and humidity sensor and an aeration device, and the aeration volume is dynamically controlled by the following calculation: Among them, Q is the real-time aeration volume, Q0 is the reference aeration volume, and E a is the activation energy of the bacterial agent, R is the gas constant, T0 is the reference temperature, and T is the real-time fermentation temperature.

8. The fertilizer production line according to claim 4, characterized in that: The ammonia recovery device comprises a negative pressure suction device and a composite adsorption tower, wherein the composite adsorption tower is filled with a composite adsorption layer of activated carbon and sulfuric acid.

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