10-15T/H Ruminant Alfalfa Grass Pellet Production Line in Tunisia For Sheep Cattle

Construction scale and construction content

This 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project covers an area of 10,000m2, a construction area of 7,000m2, a total investment of US$590,000, and a production line of 30,000 tons of high-quality compound pellet feed per year will be built. The client owns a seed company, and the project is built in the existing seed workshop. Therefore, the civil engineering investment cost is relatively low.

The main construction content of this project includes crushing, batching, mixing system, granulation, cooling, storage, packaging system, steam system, compressed air system, etc. See the table below for a list of project engineering components.

Product plan

The product of this 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project is mainly high-quality compound pellet feed, which is a low-sugar, low-starch, high-fiber, high-protein, low-temperature and high-humidity feed suitable for ruminants and horses. The product plan and parameters are shown in the table below.

Product plan and parameter table of this project:

Product quality standards for this project:

Consumption of raw and auxiliary materials

The consumption of main raw and auxiliary materials for this 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project is shown in the table below.

The main raw and auxiliary materials of this project are as follows:

Main energy consumption

The power consumption of this 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project is shown in the table below.

Main production equipment

The main ruminant cattle grass pellet production equipment of this large ruminant feed production line in Tunisia project is shown in the table below.

Material balance

The material balance table for this 10-15t/h ruminant sheep cattle grass alfalfa pellet production line in Tunisia project is as follows:

Public works

Water supply

The production water and domestic water of this 10-15t/h ruminant sheep cattle feed production line in Tunisia project are both supplied by the local water supply network, with a pipe diameter of DN300 and a pressure of 0.30MPa. The water units of this project are water for soft water equipment, domestic water and greening water, with a total water consumption of 19.05m3/d and 4572m3/a.

Water for resistive steam generation system

This project has 3 sets of 0.5t/h resistive steam generation systems to supply steam to the production line at the same time, with a steam consumption of 1.5m3/h and an annual steam consumption of 2880t.

When producing steam for this project, the resistive steam generation system needs to consume 1.5m³/h (12m³/d, 2880.00m³/a) of pure water, all of which are produced by the soft water equipment equipped with the system. The pure water preparation rate is 80%, and 15m³/d and 3600m3/a of fresh water are used.

Laboratory water

The laboratory of this project is mainly used for physical experiments such as determining ash content and moisture, and does not involve chemical reagents. Therefore, the main pollutant in the water used to wash laboratory utensils is SS, and the flushing water consumption is 0.5m3/d (120m3/a).

Domestic water

The labor quota of this 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project is 50 people, and the project works 240 days a year. The living water consumption of employees is calculated at 60L/person·d, so the water consumption is 3.0m3/d and 720m3/a.

Greening water

The greening area of the plant area of this project is 500m2, and the greening water quota of this project is determined to be 1. 1L/(m2•d). The number of days for greening water consumption is calculated as 180 days. After verification, the annual greening water consumption is 99m3/a and the daily water consumption is 0.55m3/d.

Drainage Project

The steam used in the production line of this project adopts direct injection technology, which cannot be recycled and all enters the product and is lost. Therefore, the resistive steam generation system has no wastewater generation and discharge.

Therefore, the drainage of this project mainly includes soft water equipment concentrated water, laboratory wastewater and domestic sewage.

Soft water equipment concentrated water

The concentrated water generated by the soft water equipment of this project is calculated as 80% of the water consumption, so the concentrated water generated by the soft water equipment is 3.0m3/d and 720m3/a, which is discharged into the original septic tank and finally discharged into the local sewage treatment plant.

Laboratory wastewater

The laboratory wastewater generated by this project is mainly wastewater from washing utensils. The laboratory wastewater is calculated as 80% of the water consumption, so the laboratory wastewater generation is 0.4m3/d and 96m3/a.

After all of them are discharged into the septic tank for treatment, they are discharged into the park sewage network and finally discharged into the local sewage treatment plant.

Domestic sewage

The amount of domestic sewage is calculated as 80% of the water consumption, so the amount of domestic sewage generated by employees is 2.4m3/d and 576m3/a. After being treated in a septic tank, it is discharged into the sewage pipe network and finally discharged into the sewage treatment plant.

Power supply project

This 10-15t/h ruminant sheep cattle feed alfalfa grass pellet plant in Tunisia project is equipped with 2 1600kVA/10/0.4kV transformers. The power supply is drawn from different bus sections on the 10kV side of the local substation. It adopts dual-circuit power supply and is equipped with a diesel generator set as an emergency power supply.

Heating project

The winter heating of this project is heated by centralized heating pipe network and electric radiator. Among them, the heat source of the heating pipe network is the municipal centralized heating pipe network. The pipe diameter of the municipal network is DN300, and the supply and return water temperature is 75/50℃.

Tunisia Grass Pellet Processing Project Process Design

The process flow of this 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project includes: raw material receiving section, raw material crushing section, batching and mixing section, granulation, cooling, storage and packaging section. The main production process of this project is described in detail as follows:

1. Raw material receiving section

In order to prevent the raw materials from mildew and deterioration during storage, the purchased alfalfa hay, sheep grass hay and oat hay and other raw materials transported to the factory area are first placed in the drying yard for drying, so that the moisture in the raw materials can be evaporated to a certain extent, and then sent to the raw material warehouse for storage.

The storage time is generally about 10 days, and the raw material warehouse is kept cool, ventilated and dry.

2. Raw material crushing section

Alfalfa hay, sheep grass hay and oat hay are transported to the hay coarse powder machine for coarse crushing by the long grass conveyor. The coarsely crushed hay is then finely crushed by the hay secondary fine powder machine. The finely crushed materials are transported to the anti-arch hay powder silo by the closed air screw conveyor and bucket elevator for standby.

The coarse crushing of the two hay coarse powder machines and the fine crushing of the two secondary crushers are collected by the pulse dust collectors (4 sets in total) provided by the equipment, and the dust generated is returned to the coarse crushing and fine crushing systems respectively. The small amount of dust after dust removal is discharged through the 15m high exhaust pipe.

The silage corn in the silage silo is crushed by the silage crusher, and the crushed materials are sprayed to the silage anti-arch weight reduction silo; corn flour, soybean meal, sunflower seed meal and other materials are crushed by the water drop crusher machine, and the iron impurities in the materials are removed by the permanent magnetic cylinder to improve the palatability and safety of the feed. Then it is transported to the corresponding powder batching bin by bucket elevator for standby.

During the crushing process of a water drop crusher, a set of pulse dust collector is configured to collect the generated dust. The collected dust is returned to the powder crushing system, and the small amount of dust after dust removal is discharged through a 15m high exhaust pipe.

(The water drop crusher uses a high-speed rotating hammer to hit, shear, grind and other multiple processing methods to make the material smaller and achieve the purpose of crushing. Inside the water drop crusher, the material is piled up and hit by the high-speed rotating hammer.

Under the action of friction and shear, it is crushed into the material of the required particle size. At the same time, by adjusting the mesh aperture of the water drop crusher, the material can be graded and screened.)

3. Batching and mixing section

The powder in each batching bin is equipped with a powder bin discharge machine, which is measured according to the batching ratio by the batching scale. The measured powder is sent to the horizontal spiral mixer by the conveyor, and the measured minerals and vitamins are sent to the horizontal spiral mixer by the small material spiral machine.

The fully mixed powder is transported to the anti-arch buffer bin, and then sent to the anti-arch granulation bin by the bin discharge belt conveyor, bucket elevator and pneumatic tee.

4. Granulation, cooling, storage, and packaging process

The powder in the anti-arching granulation bin enters the ruminant feed pellet machine through a uniform speed feeder, a stainless steel modulator, and a grass powder forced feeder. The powder is first removed by a safety magnet to remove iron and impurities and then evenly conditioned.

It is then evenly distributed between the compression mixing and compression dies. In this way, the material enters the extrusion area from the feeding area and the compression area, and is clamped into the die hole by the compression roller for continuous extrusion and separation to form a columnar feed. As the die rotates, it is cut into pelletized feed by a cutter fixed outside the die.

Due to the high-temperature and high-humidity steam introduced during the pelleting process, and the large amount of heat generated by the material being squeezed, the moisture content of the pellet feed is as high as 15% and the temperature is as high as 98℃ when it just comes out of the ruminant cattle feed pellet machine. Under such conditions, the pellet feed is easy to deform and break, and it will also produce adhesion and mildew during storage.

The moisture content must be reduced to below 12.5%, which requires cooling. Therefore, the pellet feed is cooled by the bucket elevator, pneumatic tee, and buffer bucket into the countercurrent cooler. The cooled pellet material is transported to 2 finished product silos for storage by the bucket elevator, or the material is packaged by a baler, and the packaged pellet feed is transported to the finished product warehouse for storage.

The body of the resistance steam generator boiler is welded by a φ916×8 boiler shell, a φ900×8 front and rear head, and 8 electric heating pipe seats. The heater uses 304 stainless steel heating pipes.

Since the boiler uses electric heating, only the heat loss on the boiler body surface is lost, and the thermal efficiency is as high as 98%, achieving pollution-free. Heating is uniform and stable, with a large evaporation area. The feed machine is equipped with a 0.5-ton steam boiler and an electric heating 240KW steam boiler steam generator.

In addition to conventional pressure control, it is also equipped with an automatic sewage discharge system, advanced program control, automatic interlocking, automatic alarm, and full automatic control. The heater starts and stops in stages to reduce the impact on the power grid. It has automatic protection functions such as overheating, overpressure, water shortage, short circuit, phase loss, and leakage, and is easy to operate.

The three countercurrent coolers use fans to make the cooler air flow back to cool the granular materials, and are equipped with 3 sets of bag dust collectors to remove trace dust in the induced draft system. The dust collected by the bag dust collector is recycled and granulated. The small amount of dust after dust removal is discharged through a 15m high exhaust pipe.

Principles of process design and equipment configuration

• Equipped with a complete set of 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia (including raw material cleaning, crushing, lifting, batching, mixing, automatic packaging and other equipment), and equipped with a complete dust removal system and electronic control system; for the production of pellet feed products, it is also equipped with post-processing equipment such as granulation or puffing, cooling, crushing, grading, drying, etc.;
• The batching and mixing sections adopt computer automation control systems, and the dynamic accuracy of batching is not more than 3‰, and the static accuracy is not more than 1‰; 4. The production line of ruminant feed should be set up separately, and the production equipment shall not be shared with other non-ruminant feed production lines;
• The coefficient of variation of the mixing uniformity of the mixer shall not exceed 7%;
• The pulverizer, air compressor, and high-pressure fan shall use sound insulation or silencer devices, and the noise control of the production workshop and workplace shall comply with the relevant Tunisian regulations;
• The dust removal system of the Tunisia grass pellet processing line uses a pulse dust collector or dust removal equipment with better performance, and adopts a combination of centralized dust removal and single-point dust removal. The feeding port adopts a single-point dust removal method; the dust concentration and emission concentration in the working area comply with the relevant Tunisian regulations;
• Electronic scales are provided for small material preparation and verification respectively;
• If there is an additive premixing process, at least one mixer shall be separately equipped. The part of the mixer machine (including the mixer buffer bin) in contact with the material shall be made of stainless steel, and the coefficient of variation of the mixing uniformity of the mixer shall not exceed 5%.

General layout

This 10-15t/h ruminant sheep cattle alfalfa grass pellet production line in Tunisia project uses the existing factory area to build the production workshop, office, laboratory and finished product warehouse of this project on the east side of the production workshop of the seed processing center.

Other public auxiliary workshop facilities are arranged on the southeast and south sides of the factory area according to the actual situation and process needs of the factory area. The south side is the raw material warehouse and drying yard from east to west.

According to the specific conditions of the peripheral roads of the factory area, the entire factory area is equipped with an external entrance and exit on the north side. The green area is set around the factory area and the office and living area to reduce the impact on the surrounding environment.

Principles of factory layout

1. The grass pellet production line in Tunisia project shall set up an independent factory area, and there shall be no pollution sources around the factory area that affect the quality and safety of feed products.
2. The production area should be reasonably laid out according to the production process. Solid additive premix feed, concentrated feed, compound feed, and concentrate supplements should have relatively independent production workshops, raw material warehouses, batching rooms, and finished product warehouses that match the production scale.
3. The buildings in the production area should be well ventilated and lit. Natural lighting facilities should have rainproof functions, and artificial lighting lamps should have explosion-proof functions.
4. Necessary fire-fighting facilities or equipment should be equipped in the cattle feed factory area.
5. The factory area should have a complete drainage system, with anti-blocking devices at the entrance of the drainage system and devices to prevent animal intrusion at the exit.

Environmental protection measures

The environmental protection measures adopted by this grass pellet production line in Tunisia project are as follows:

What is the prospect of building a ruminant sheep cow grass feed production line in Tunisia?

The prospects of grass feed processing in Tunisia can be analyzed from many aspects:

• ‌Livestock Industry Foundation‌:
  Tunisia has a long history of animal husbandry and is an important part of the country's agricultural sector.
  Animal husbandry is mainly focused on the breeding of animals such as cattle, sheep, poultry and camels, with a large flock of sheep and a continuously growing beef and poultry production‌1. This provides a stable market demand for grass feed processing.
• ‌Market Demand‌:
  With the continuous increase in domestic meat consumption in Tunisia, especially lamb and chicken, the demand for grass feed is also increasing.
  In addition, Tunisia also exports a certain amount of livestock products to Europe and the Middle East, which requires livestock products to meet international standards and quality certification, further promoting the development of the grass feed processing industry‌.
• ‌Policy Support‌:
  The Tunisian government has realized the importance of enhancing the competitiveness of animal husbandry and has begun to implement a series of measures to promote the development of the industry.
  These measures include introducing modern breeding technology and equipment, improving production efficiency, and promoting animal husbandry to develop in a more environmentally friendly and sustainable direction. These policies are also conducive to the upgrading and development of the grass feed processing industry‌.
• ‌Technological innovation‌:
  With the advancement of technological innovation, the grass feed processing industry can introduce more advanced processing technologies and equipment to improve the nutritional value and digestibility of feed, thereby meeting the needs of animal growth, production and health. This will help enhance the market competitiveness of grass feed products‌.
• ‌Environmental protection and sustainable development‌:
  As consumers pay more attention to environmental protection and sustainable development, the grass feed processing industry also needs to develop in a more environmentally friendly and sustainable direction.
  For example, adopting localized feed production methods, reducing dependence on imported feed, and exploring models of organic animal husbandry and ecological agriculture, etc.‌.
• ‌International cooperation‌:
  Tunisia has a superior geographical location, is close to the European market, and has established a long-term cooperation framework with the European Union, which facilitates its grass feed products to enter the international market.
  With the advancement of the "Belt and Road" initiative, Tunisia's economic and trade ties with Asian countries such as China are becoming increasingly close, providing a broader market space for the grass feed processing industry‌.

In summary, building grass pellet production line in Tunisia has broad prospects. However, it is also necessary to pay attention to challenges such as rising feed costs, water shortages, animal diseases, and competitive pressures in the international market.

Therefore, the grass feed processing industry needs to continue to innovate, improve product quality and safety to meet market demand and achieve sustainable development.

Please note that the above analysis is based on current information and trends, and the situation may change in the future. For investors, they should pay close attention to industry dynamics and market changes to make wise decisions.