Bio-organic fertilizer production system

Abstract

The utility model discloses a bio-organic fertilizer production system. The bio-organic fertilizer production system comprises a two-stage crusher, a continuous stirrer, an extrusion granulator, a feeding dryer and the like along the material flowing direction. And the two-stage crusher integrates an impact crusher and an extrusion crusher and is hermetically communicated with the continuous stirrer through a bucket elevator. A spiral feeder is arranged at a feeding hole of the bucket elevator and is used for adding solid fertilizer. The continuous stirrer comprises an upper stirring device and a lower stirring device, and a rotating shaft drives a stirring rod and a rotating drum to rotate oppositely so as to continuously stir materials. And an atomizer communicated with the liquid stirring tank is arranged below the blanking port, so that the powdery fertilizer is wetted while the liquid fertilizer is supplemented. The wet powdery fertilizer enters an extrusion granulator to be granulated, the extrusion granulator is communicated with the feeding dryer in a closed mode, and after the dried granular fertilizer is sieved, fine granules return to the continuous stirring machine. The device is small in occupied area, high in production efficiency and flexible in workshop and equipment arrangement, and can be used for producing products with different proportions.

Description

Technical Field

[0001] This invention is applied to the field of bio-organic fertilizer manufacturing, specifically a bio-organic fertilizer production system. Background Technology

[0002] With advancements in organic fertilizer production technology, bio-organic fertilizers have evolved from large blocks to granular forms, facilitating uniform soil absorption. Furthermore, the addition of nitrogen, phosphorus, potassium, and trace elements creates organic fertilizers that both improve soil quality and provide nutrients. The production process includes fermentation and drying of the bio-raw material, crushing, batching, mixing, granulation, drying, sieving, and packaging. Crushing involves breaking down the dried bio-raw material into fine particles to prepare for subsequent granulation. Batching involves adding nitrogen, phosphorus, potassium, and trace elements to the bio-raw material, mixing thoroughly, moistening, and then extruding and granulating. After granulation, drying and sieving result in a finished organic fertilizer product with uniform particle size. While equipment for each process is commercially available, the numerous specialized pieces require significant space and substantial investment. Therefore, the applicant, drawing on years of production experience, has improved or developed key core equipment to create a highly efficient, low-energy-consumption production system suitable for continuous bio-organic fertilizer production. CN201694966U Organic fertilizer continuous production equipment still uses heating furnace and drum dryer; CN206721064U A compound fertilizer granulation production system still uses hot air furnace, drum dryer and drum cooler; CN219567829U A system for producing organic fertilizer solid granules using biogas residue still uses equipment such as spheroidizer, dryer, hot air furnace and cooler. Utility Model Content

[0003] The technical problem solved by this utility model is to provide a biological organic fertilizer production system that enables uninterrupted material conveying, continuous and efficient production, small footprint, and can meet the production needs of products with different proportions.

[0004] The technical solution adopted in this utility model is as follows: A bio-organic fertilizer production system, along the material flow direction, includes core equipment such as a two-stage crusher, a continuous mixer, a powder conveyor belt, an extrusion granulator, and a feeding dryer. The upper part of the two-stage crusher is an impact crusher, and the lower part is an extrusion crusher, connected by a discharge hopper. This two-stage crusher integrates impact crushing and extrusion crushing, reducing the floor space and improving crushing efficiency. The two-stage crusher is connected in a closed loop via a bucket elevator and a continuous mixer. At least two screw feeders are installed at the feed inlet of the bucket elevator for adding solid fertilizer to the material. The continuous mixer includes two concentric rotating mixing devices, whose shafts are connected by a coupling. An atomizer is installed below the discharge inlet of the continuous mixer, connected to a liquid mixing tank containing liquid fertilizer. The atomizer can directly wet the powdered fertilizer discharged from the continuous mixer. The discharge port of the continuous mixer is connected to the feed port of the extrusion granulator by a powder conveyor belt, providing time for the powdered fertilizer to wet and penetrate. The extrusion granulator and the feeding dryer are connected in a closed loop.

[0005] Furthermore, the stirring device includes a rotating shaft and a rotating drum. A stirring rod and a main gear are mounted on the rotating shaft. A gear ring is fixedly mounted on the lower surface of the bottom plate of the rotating drum. A transition gear is fitted between the gear ring and the main gear, so that when the rotating shaft rotates, the stirring rod and the rotating drum rotate in opposite directions. The rotating drum is supported by a ball bearing assembly, which is fixed to a support plate. A semi-circular arc-shaped discharge port is provided on the support plate between the ball bearing assembly and the gear ring. A discharge hole is provided on the bottom plate of the rotating drum between the ball bearing assembly and the gear ring. A valve assembly is installed below the discharge hole. The valve assembly includes a blocking plate and a rotating wheel. When the rotating wheel moves on the support plate, the blocking plate blocks the discharge hole. When the valve assembly rotates above the arc-shaped discharge hole, the valve assembly opens the discharge hole by its own weight. There are two evenly distributed discharge holes, which, together with the semi-circular arc-shaped discharge hole, form a continuous discharge.

[0006] Furthermore, in the two-stage crusher, the impact crusher includes blades and wear-resistant impact plates, with an impact chamber between them; the extrusion crusher includes extrusion rollers and extrusion plates, with the gap between them being the particle size of the powdered fertilizer.

[0007] Furthermore, the feeding dryer includes a rotating seal, a hollow shaft, spiral blades, and stirring rods. The spiral blades are fixedly mounted on the hollow shaft, and the stirring rods are evenly distributed and fixed on the spiral blades. One end of the hollow shaft is sealed, and the other end is tubular and connected to the rotating seal, which is connected to an air heating box via an air supply pipe. Air supply holes are machined on the hollow shaft, and the hot air blown out of the air supply holes directly dries the granular fertilizer. A gear is installed at one end of the hollow shaft, which is driven to rotate by a reducer. A resistance wire is installed inside the air heating box, which can heat the air to 40-80℃ when energized. During the feeding process, the feeding dryer dries and polishes the granules, integrating feeding, drying, and polishing functions into one unit.

[0008] Furthermore, to match production capacity, there is no less than one feeding dryer, and each feeding dryer is equipped with an air heating box; a valve is installed between the discharge port of the extrusion granulator and the feed port of each feeding dryer, and each feeding dryer is controlled independently.

[0009] Furthermore, the discharge port of the feeding dryer is located above the vibrating filter screen; the fine particles filtered by the vibrating filter screen are returned to the continuous mixer, and the granular fertilizer is transported to the finished fertilizer silo by the finished product belt conveyor.

[0010] Furthermore, to reduce dust pollution, dust removal ports are installed at the feed inlet of the two-stage crusher, the discharge port of the continuous mixer, and the discharge port of the feeding dryer.

[0011] The beneficial effects of this utility model are: the production system occupies a small area, and the layout of the workshop and equipment is flexible. It has high crushing and mixing efficiency, meeting the needs of continuous large-scale production, and is equipped with both solid and liquid fertilizer addition methods, enabling the formulation of products with different ratios. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the main structure of this utility model;

[0013] Figure 2 This is a schematic diagram of the internal structure of a two-stage crusher;

[0014] Figure 3 This is a schematic diagram of the internal structure of a continuous mixer;

[0015] Figure 4 This is a schematic diagram of the feeding dryer structure;

[0016] Among them: 1-Bio-fertilizer bin, 2-Raw material belt conveyor, 3-Two-stage crusher, 4-Bucket elevator, 5-Continuous mixer, 6-Liquid mixing tank, 7-Powder belt conveyor, 8-Extrusion granulator, 9-Feeding dryer, 10-Vibrating filter screen, 11-Finished product belt conveyor, 12-Air heating box, 13-Atomizer, 14-Screw feeder;

[0017] 31-Blade, 32-Wear-resistant impact plate, 33-Impact cavity, 34-Extrusion roller, 35-Extrusion plate, 36-Feeding bin;

[0018] 51-Shaft, 52-Stirring rod, 53-Rotating drum, 54-Ball assembly, 55-Valve assembly, 56-Coupling, 57-Gear ring, 58-Transition gear, 59-Main gear;

[0019] 101-Rotating sealer, 102-Hollow shaft, 103-Helical blade, 104-Stirring rod. Detailed Implementation

[0020] For ease of understanding, the terms "dropping material" and "feeding material" are modifiers, such as "dropping port," "dropping hopper," and "feeding inlet." The term "discharging material" is a verb, and "unloading material" refers only to "unloading hole." All measurement and weighing information pertains to existing technology and is not mentioned below.

[0021] The raw materials for the bio-organic fertilizer produced by this invention include bio-based fertilizer, nutrient element fertilizers (urea, potassium dihydrogen phosphate, etc.), micronutrient fertilizers (such as calcium, magnesium, boron, zinc, iron, manganese, copper, etc.), and a small amount of other soil-improving fertilizers (such as lignin, humic acid, penetrants, soil loosening agents, etc.). The bio-based fertilizer consists of large lumps of fermented animal manure (such as pig manure, chicken manure, cow manure, sheep manure, etc.) that have been dried. The remaining nutrient element fertilizers, micronutrient fertilizers, and other fertilizers are purchased externally, either as fine-grained solid fertilizers or liquid fertilizers. The bio-organic fertilizer is based on the bio-based fertilizer, and nutrient element fertilizers and micronutrients are added according to the soil properties and crop needs to form an organic fertilizer that both improves the soil and provides nutrients to crops. The finished product is a uniformly sized granular fertilizer. The production process is as follows: drying bio-based fertilizer—crushing—adding solid fertilizer—stirring evenly into powder fertilizer—adding liquid fertilizer or water—extruding and granulating into granular fertilizer—drying—screening—packaging.

[0022] The schematic diagram of the layout structure of the organic fertilizer production system of this utility model is attached. Figure 1 As shown, the material flows from left to right. The core equipment includes a two-stage crusher 3, a bucket elevator 4, a continuous mixer 5, an extrusion granulator 8, a feeding dryer 9, and a vibrating filter screen 10.

[0023] After being air-dried or oven-dried, the bio-fertilizer raw materials are loaded into the bio-fertilizer bin 1 by a loader, and then conveyed into the two-stage crusher 3 by the raw material belt conveyor 2.

[0024] The structure of the two-stage crusher 3 is shown in the attached figure. Figure 2As shown, the detailed structure can be found in the applicant's recently filed utility model patent "A Bio-based Fertilizer Crushing Device" (application number 2024229370631). The top is the feed inlet, the bottom is the discharge outlet, the upper part is an impact crusher, and the lower part is an extrusion crusher, connected by a discharge bin 36. The impact crusher includes blades 31 and wear-resistant impact plates 32, with an impact chamber 33 between them. When large pieces of bio-based fertilizer fall from the feed inlet, they are impacted by the high-speed rotating blades and propelled onto the wear-resistant impact plates 32 for further impact. Within the impact chamber 33, there are also impacts between the bio-based fertilizer pieces. Thus, the impact crusher crushes the large pieces of bio-based fertilizer into smaller pieces, which then enter the extrusion crusher from the discharge bin 36. The extrusion crusher includes extrusion rollers 34 and extrusion plates 35, with the gap between them determining the particle size of the crushed fertilizer powder. Small pieces of bio-based fertilizer are crushed into fine particles by the extrusion rollers and extrusion plates, and then fall into the feed inlet of the bucket elevator 4 through the bottom discharge port.

[0025] Multiple screw feeders 14, usually no fewer than two, are installed at the feed inlet of the bucket elevator to feed different solid fertilizers into the bucket elevator. The bucket elevator then feeds these solid fertilizers and crushed bio-based fertilizers into the continuous mixer 5. Alternatively, the screw feeders 14 can be installed at the discharge port of the bucket elevator or the feed inlet of the continuous mixer 5, but this would be too high and inconvenient for feeding operations.

[0026] The structure of the continuous mixer 5 is shown in the attached figure. Figure 3As shown, the detailed structure can be found in the applicant's recently filed utility model patent "A Bio-organic Fertilizer Raw Material Mixing Device" (application number 2024229437148). The top is the feed inlet, and the bottom is the discharge outlet. It includes two mixing devices with essentially identical structures, one above the other, with their rotation centers concentric. The only difference is the position of the arc-shaped discharge outlet. The rotating shafts 51 of the two mixing devices are connected by a coupling 56, and the shafts 51 are driven by a motor. A mixing rod 52 is mounted on this shaft. A gear ring 57 is fixedly mounted on the lower surface of the bottom plate of the rotating drum 53, and a main gear 59 is mounted on the rotating shaft. A transition gear 58 is fitted between the main gear 59 and the gear ring 57. Thus, the rotating shaft drives the gear ring and the rotating drum to rotate through the main gear and the transition gear. The rotation direction of the rotating drum is opposite to the rotation direction of the mixing rod, i.e., one rotates clockwise and the other counterclockwise. This opposing rotation effectively increases the rotational speed of the mixing rod, enhancing the mixing effect. The rotating drum is supported by a ball bearing assembly 54, which is fixed to a support plate. A nearly semi-circular arc-shaped discharge port is provided on the support plate between the ball bearing assembly 54 and the toothed ring 57. A discharge hole is provided on the bottom plate of the rotating drum between the ball bearing assembly and the toothed ring, and a valve assembly 55 is installed below this discharge hole. The valve assembly 55 includes a blocking plate and a rotating wheel. When the rotating wheel moves on the support plate, the blocking plate blocks the discharge hole. When the valve assembly 55 rotates above the arc-shaped discharge port, its own weight opens the discharge hole, and the mixed fine granular fertilizer in the mixing device is discharged under the impetus of the agitation. If the arc-shaped discharge port is semi-circular and there are two symmetrical discharge holes, the discharge from the mixing device becomes continuous, thus achieving uniform mixing during continuous feeding and discharging.

[0027] Below the discharge port of the continuous mixer 5, an atomizer 13 and a powder conveyor 7 are installed. The powder conveyor 7 feeds the uniformly mixed powdered fertilizer into the extrusion granulator 8. The atomizer 13 can be a ring tube with fine atomizing nozzles installed on it. The atomizer pipe is connected to a liquid mixing tank 6, which is used to hold the liquid fertilizer. A small flow pump is installed on the connecting pipe of the atomizer to pressurize the liquid fertilizer. The fine atomizing nozzles of the atomizer atomize the liquid fertilizer and spray it onto the discharged powdered fertilizer. The atomized liquid fertilizer wets the powdered fertilizer and also eliminates dust. During the transport of the powdered fertilizer on the powder conveyor, the liquid fertilizer gradually permeates and diffuses into the powdered fertilizer. If no liquid fertilizer is added, an aqueous solution of binder is used instead.

[0028] The moistened powdered fertilizer falls into the extrusion granulator 8, and under the extrusion of the paired extrusion rollers, it becomes granules. The moist granulated fertilizer enters the feeding dryer 9 from the discharge port at the bottom of the extrusion granulator.

[0029] The structure of the feeding dryer 9 is shown in the attached figure. Figure 4As shown, the detailed structure can be found in the applicant's recently filed utility model patent, "A Biological Organic Fertilizer Feeding and Drying Device" (application number 2024230151828). This feeding and drying machine is an improvement on a screw feeder. The screw blades 103 are fixedly mounted on a rotating shaft 102, which is a hollow shaft with one tubular end and a sealed end. Air supply holes are machined on the hollow shaft. The tubular end of the hollow shaft is connected to a rotating seal 101, and the other end of the rotating seal 101 is connected to an air heating box 12 via an air supply pipe. A resistance wire is installed inside the air heating box 12, which heats the air to 40-80℃ when energized. The rotating seal is fixedly connected at one end and rotatably connected at the other. A gear is installed at one end of the hollow shaft, which is connected to a reducer to drive the hollow shaft and screw blades to rotate. A circumferentially distributed stirring rod 104 is fixedly installed on the spiral blade 103. During the process of extruding and conveying the granular fertilizer from the inlet to the outlet by the rotating spiral blade, the stirring rod 104 rotates and stirs the granular fertilizer. A blower sends air into an air heating chamber; after heating, the air is blown out through the air outlet on the hollow shaft, directly drying the granular fertilizer. This drying method, where hot air is directly blown onto the surface of the granular fertilizer, results in fast drying speed and high efficiency. The extrusion friction between the granular fertilizer and the spiral blade and stirring rod, as well as the self-friction of the granules, causes the fine particles at the edges of the extruded granules to peel off, resulting in round granules. The feeding dryer integrates feeding, drying, and polishing.

[0030] It should be noted that the production capacity of the feeding dryer is limited. However, the upstream components such as the two-stage crusher, bucket elevator, continuous mixer, powder conveyor, and extrusion granulator have a wider range of adjustable production capacities. To match production capacity, multiple feeding dryers can be installed, each equipped with a corresponding air heating box, forming a complete feeding dryer system. A valve is installed between the feed inlet of the extrusion granulator and the feeding dryer, and each feeding dryer system is individually controlled.

[0031] The dried granular fertilizer enters the vibrating filter screen 10 from the feed dryer's discharge port. After being cooled by the vibrating filter screen 10, and having its edge and fine particles filtered out, the uniformly sized granular fertilizer falls onto the finished product conveyor belt 11, which transports it to the finished product silo, and then to the packaging machine for drum or bagging. The filtered edge and fine particles are recovered and returned to the continuous mixer.

[0032] This production system is divided into three workshops by two belt conveyors. The workshop before the raw material conveyor is a storage workshop for bio-fertilizer raw materials, which has a strong odor. The production workshop is located between the raw material and finished product conveyors, and the packaging workshop is located after the finished product conveyor. Within the production workshop, the powder conveyor provides time for wetting the powdered fertilizer and is also divided into two working areas: crushing and mixing, and granulation and drying. Both solid and liquid fertilizers are added in the crushing and mixing area, making it a crucial area for different proportions of bio-organic fertilizer and a key production area for product quality control. Furthermore, the two-stage crusher, bucket elevator, and continuous mixer in the crushing and mixing area are sealed and connected to prevent dust from scattering and causing pollution. Dust collectors are installed at the feed inlets of the two-stage crusher and the discharge inlet of the continuous mixer. In the granulation and drying area, the extrusion granulator and the feeding dryer are sealed and connected. A dust collector is installed at the discharge inlet of the feeding dryer, from which the hot air from the feeding dryer is mainly blown out, while the airflow simultaneously cools the granulated fertilizer on the filter screen.

[0033] This utility model production system: 1) Eliminates the need for dedicated heating furnaces, drying drums, polishing machines, and cooling drums. The feeding dryer integrates feeding, drying, and polishing. The drying of granular fertilizer enhances the diffusion gradient of moisture, with hot air directly blowing over the surface of each granular fertilizer, rather than the temperature of the hot air itself. Since the temperature of the granular fertilizer is not high, the vibrating filter screen also has filtering and cooling functions. This system reduces the equipment footprint and investment. 2) The two-stage crusher integrates impact crushing and extrusion crushing, resulting in high crushing efficiency and a smaller equipment footprint. 3) The continuous mixer ensures uniform mixing during continuous material transport, improving production efficiency. 4) The division into three workshops and two work areas allows for flexible and adaptable layout of workshops and equipment. 5) It includes both solid and liquid fertilizer addition methods to meet the production needs of different ratios of bio-organic fertilizer.

Claims

1. A bio-organic fertilizer production system, characterized in that: Along the flow direction of the material, the core equipment includes a two-stage crusher (3), a continuous mixer (5), a powder belt conveyor (7), an extrusion granulator (8), and a feeding dryer (9). The upper part of the two-stage crusher (3) is an impact crusher, and the lower part is an extrusion crusher. The two are connected by a discharge bin (36). The two-stage crusher (3) is connected in a closed manner through a bucket elevator (4) and a continuous mixer (5). At least two screw feeders (14) are provided at the feed inlet of the bucket elevator (4). The continuous mixer (5) includes two concentric rotating mixing devices, and the shafts of the two mixing devices are connected by a coupling (56); an atomizer (13) is provided below the discharge port of the continuous mixer (5), and the atomizer (13) is connected to the liquid mixing tank (6); the discharge port of the continuous mixer (5) and the feed port of the extrusion granulator (8) are connected by a powder conveyor belt (7); The extrusion granulator (8) and the feeding dryer (9) are connected in a closed loop.

2. The bio-organic fertilizer production system according to claim 1, characterized in that: The stirring device includes a rotating shaft and a rotating drum. A stirring rod (52) and a main gear (59) are installed on the rotating shaft. A gear ring (57) is fixedly installed on the lower surface of the bottom plate of the rotating drum. A transition gear (58) is installed between the gear ring (57) and the main gear (59). The rotating drum is supported and rotated by a ball assembly (54), which is fixed on a support plate. A semi-circular arc-shaped discharge port is provided on the support plate between the ball assembly (54) and the gear ring (57). A discharge hole is provided on the bottom plate of the rotating drum between the ball assembly (54) and the gear ring (57). A valve assembly (55) is installed below the discharge hole. The valve assembly (55) includes a blocking plate and a rotating wheel. When the rotating wheel moves on the support plate, the blocking plate blocks the discharge hole. When the valve assembly (55) rotates above the arc-shaped discharge port, the valve assembly opens the discharge hole by its own weight.

3. The bio-organic fertilizer production system according to claim 2, characterized in that: The feeding holes are two evenly distributed holes.

4. The bio-organic fertilizer production system according to claim 1, characterized in that: The impact crusher includes blades (31) and wear-resistant impact plates (32), with an impact chamber (33) between them; the extrusion crusher includes extrusion rollers (34) and extrusion plates (35), with the gap between them being the particle size.

5. The bio-organic fertilizer production system according to claim 1, characterized in that: The feeding dryer (9) includes a rotary seal (101), a hollow shaft (102), a spiral blade (103), and a stirring rod (104); the spiral blade (103) is fixedly installed on the hollow shaft (102), and the stirring rod (104) is evenly distributed and fixed on the spiral blade (103) around its circumference; one end of the hollow shaft (102) is sealed, and the other end is tubular and connected to the rotary seal (101), which is connected to an air heating box through an air supply pipe; an air supply hole is machined on the hollow shaft (102), and a gear is installed at one end of the hollow shaft (102).

6. The bio-organic fertilizer production system according to claim 5, characterized in that: The air heating box (12) is equipped with a resistance wire, which can heat the air to 40-80℃ after being powered on.

7. The bio-organic fertilizer production system according to claim 5, characterized in that: There shall be at least one feeding dryer (9), and each feeding dryer (9) shall be equipped with an air heating box (12); a valve shall be provided between the discharge port of the extrusion granulator (8) and the feed port of each feeding dryer (9).

8. The bio-organic fertilizer production system according to claim 1, characterized in that: The discharge port of the feeding dryer (9) is located above the vibrating filter screen (10); the fine particles after being filtered by the vibrating filter screen (10) are returned to the continuous mixer (5).

9. A bio-organic fertilizer production system according to claim 1, characterized in that: Dust removal ports are provided at the feed inlet of the two-stage crusher (3), the discharge port of the continuous mixer (5), and the discharge port of the feeding dryer (9).

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