10T/H Compost Manufacturing Plant In South Africa

Main construction content

The compost manufacturing plant in South Africa project covers an area of 5742m2 and a total construction area of 5570m2. The construction content includes production workshops, warehouses, offices, accessories rooms, temporary rest rooms for employees and their supporting facilities. The project engineering content is detailed in the table below.

Product plan

The main products and annual output of this compost manufacturing plant in South Africa project are shown in the table below.

The technical indicators of the products produced by this compost manufacturing plant in South Africa project are shown in the table below.

Main raw and auxiliary materials and energy consumption

The raw materials of this compost manufacturing plant in South Africa project are mainly cattle and sheep manure, and pig manure and chicken manure are not used. The raw materials come from farms and individual farmers around the project. The consumption of main raw and auxiliary materials is shown in the table below.

Main equipment

The main equipment of this compost manufacturing plant in South Africa project is detailed in the table below.

Design of organic fertilizer production process flow

Aerobic fermentation

Buy cattle and sheep manure (water content 50% to 55%, and has undergone preliminary fermentation) is transported to the factory by sealed vehicles. After entering the factory, it does not need to be aired and directly enters the fermentation workshop to be sprayed with fermentation agents. Generally, 0.025L of fermentation agent is sprayed on 1t of manure.

In order to spray the agent evenly, the agent must first be poured into a bucket and diluted with water by about 1000 times (1L of fermentation bacteria is diluted to 1000L with water, that is, 1t of manure is sprayed with 25L of diluted agent), and the diluted agent is sprayed on the surface of cattle and sheep manure with a spray gun.

Use a forklift to turn the sprayed sheep manure evenly and pile it into strips for aerobic composting fermentation (the fermentation form of this project is strip-type aerobic turning fermentation, that is, the fertilizer is piled into a long row to increase the contact area between the fertilizer and the air). As the aerobic fermentation time increases, the temperature of the fertilizer pile gradually increases.

When the temperature of the fertilizer pile reaches 60℃～65℃, a turning machine is needed to turn the fertilizer so that the fertilizer in the pile core is fully in contact with the air and the efficiency of aerobic fermentation is improved. The pile is turned 1～2 times a day and fermented continuously for 20～25 days.

Aging and fermentation

After the aerobic fermentation is completed, aging and fermentation are required. Both aging and aerobic fermentation are carried out in the tank fermentation workshop, that is, the fertilizer is pushed into a large pile by a forklift for further fermentation and maturation.

The aging and fermentation time is 10 days. A large amount of water is evaporated during the fermentation process, and the moisture content of cattle and sheep manure is reduced to 30%～35% after fermentation and maturation.

Loading

The fermented cattle and sheep manure is sent into the collecting hopper by a forklift.

Branching

The compost manufacturing plant in South Africa project products have two specifications, one is granular fertilizer and the other is powder fertilizer.

Therefore, after the raw materials are mixed, they need to be branched to the corresponding production lines to produce products of corresponding specifications. Two discharge ports are provided below the upper hopper, which are connected to two crushers respectively.

Production of powdered organic fertilizer

The raw materials enter the horizontal crusher for crushing, then are screened by the screening machine, and then are sent to the packaging scale through a closed conveyor belt.

After quantitative measurement and packaging by the packaging scale, they are bagged and stored (the bag mouth is directly put on the discharge port of the packaging scale, and the product is directly put into the bag without falling to the ground).

Production of granular organic fertilizer

1. Crushing
   In order to make the granulated fertilizer more uniform and smooth, the cattle and sheep manure to be granulated needs to be crushed.
   The cattle and sheep manure to be granulated arrives above the horizontal return material crusher with the belt, falls from the feed port of the horizontal return material crusher into the horizontal return material crusher, closes the feed port of the horizontal return material crusher, and crushes.
2. Screening
   The crushed raw materials enter the screening machine for screening, and the raw materials that meet the specifications are screened out.
3. Granulation
   The screened raw materials are transported to the organic fertilizer pellet machine by a closed conveyor belt for granulation. During the granulation process, the fully automatic water supply system sprays water into the granulator to make the raw materials moist and facilitate granulation.
   The amount of water sprayed per ton of raw materials is 40L. The cattle and sheep manure is degassed and spirally pre-compressed in the granulator and transported to the arc-shaped notch of the two rollers. The two rollers rotate at the same speed and in opposite directions, bite the material into the groove and compress it by force.
   The pressure on the material after passing through the compression zone gradually decreases, and its surface tension and gravity make it naturally escape to form particles. By changing the groove form of the roller surface, materials in the shape of flakes, strips, olives, and oblate balls can be obtained.
4. First drying and one-time cooling
   The granulated cattle and sheep manure is transported to the primary dryer by a closed conveyor belt for drying. The primary drying temperature is 160-180℃ and the drying time is 10-30min. After the primary drying, the moisture content of the material is reduced from 35% to 25%.
   The primary drying is heated by a natural gas hot air drying furnace. The dried material enters the cooler for cooling. The cooling method is air cooling, and no wastewater is generated. After the material cools to room temperature, it enters the next process.
5. Secondary drying and secondary cooling
   In order to further reduce the moisture content in the material, the cow and sheep manure after primary drying is transported to the secondary dryer by a closed conveyor belt for drying. The secondary drying temperature is 200℃ and the drying time is about 10 minutes.
   After secondary drying, the moisture content in the material is reduced from 25% to 10%. The secondary drying is heated by natural gas. The material after secondary drying enters the cooler for cooling. The cooling method is air cooling. After the material cools to room temperature, it enters the next process.
6. Screening
   The dried raw materials are screened again, and the pellets that meet the specifications are screened out and enter the next process.
7. Adding biological agents and trace elements
   According to customer needs, some granular materials are transported by conveyor belts to the bacteria tank to add biological agents and trace elements.
8. Weighing and packaging
   After screening, the granular materials are sent to the packaging scale by a closed conveyor belt according to the particle size. After quantitative measurement and packaging by the packaging scale, they become finished products.

The production process of this compost manufacturing plant in South Africa project involves three screening processes, and the unqualified products screened out are returned to the feeding process for production.

Physical and chemical properties of raw materials

The physical and chemical properties of the main raw materials used in this compost manufacturing plant in South Africa project are shown in the following table:

Fermentation agents:

Beneficial microorganisms such as probiotics, lactic acid bacteria, yeast, photosynthetic bacteria, and Gram-positive actinomycetes are fermented through special processes and are rich in active ingredients such as various microorganisms and metabolites, organic acids, amino acids, small molecule biological peptides, and beneficial growth factors.

Fermentation agents can promote the proliferation of beneficial bacteria on fermentation raw materials, and organic matter is continuously decomposed and transformed and releases energy in the form of high temperature, thereby inhibiting and killing harmful pathogens, parasite eggs, and weed seeds.

During the fermentation process, nutrients are transformed from ineffective to effective and fast-acting; a large amount of biologically active substances such as glucose, amino acids, auxins, vitamin groups, and nitrogen, phosphorus, potassium, and trace elements necessary for plants are decomposed and synthesized; humification is promoted and odors are quickly eliminated, the activity of beneficial microorganisms in the soil is increased, the nutrients in the base soil are enhanced, crop yields are increased, quality is improved, costs are reduced, and ecological cycle planting is realized.

Biological agents:

The new biological strains with the characteristics of powders have the characteristics of rapid reproduction, strong vitality, safety, and non-toxicity.

Characteristics: pure strains, high number of live bacteria, no foreign bacteria; promote crop growth, improve the quality of agricultural products, prevent diseases; improve soil, dissolve inactive phosphorus; high temperature resistance, no inactivation during granulation and drying, and can be preserved for a long time.

Trace elements:

Trace elements refer to a chemical element with very low content in nature. Some trace elements have biological significance and are necessary for the normal growth and life of plants and animals. They are called "essential trace elements" or "trace nutrients", usually referred to as "trace elements".

The role of essential trace elements in plants and animals is highly specific and is indispensable and irreplaceable.

When the supply is insufficient, plants often show specific deficiency symptoms, crop yields decrease, quality declines, and in severe cases, they may be completely eliminated. The application of trace element fertilizers is conducive to increasing yields.

Public works

Water supply

The workshop cleaning of this compost manufacturing plant in South Africa project is carried out by a sweeper, and there is no need to wash the workshop floor with water. The production water is water for granulation and washing water for raw material transport vehicles.

The wheels and bodies of vehicles transporting cattle and sheep manure need to be washed when entering and leaving the tank fermentation workshop. The amount of washing water generated is 2m3/d and 600m3/a. During the production process, the granulation process sprays water into the organic fertilizer granulator. 40L of water is required for each ton of raw materials.

The water consumption is 7.2m3/d and 2160m3/a, which is composed of vehicle washing wastewater and fresh water. The amount of fresh water added is 5.6m3/d and 1680m3/a.

This project does not have a canteen. The domestic water is the water for employees to wash. The labor quota of this project is 8 people. The water consumption is calculated based on 40L/person·d, so the domestic water consumption is 0.32m3/d and 96m3/a. In summary, the total water consumption of this project is 7.92m3/d and 2376m3/a.

Power supply

The power supply for this compost manufacturing plant in South Africa project is provided by the local power supply line, with an annual power consumption of about 1 million kW·h, which can meet the power demand of this project.

Environmental protection engineering

What is the prospect of building a compost manufacturing plant in South Africa?

The prospect of building an organic fertilizer production line in South Africa is relatively optimistic, mainly based on the following considerations:

• Market demand growth:
  With the development of South African agriculture, the demand for organic fertilizers is also growing. The adoption of precision agricultural technology, the growing demand for organic fertilizers, and the increasing popularity of special fertilizers such as micronutrients have provided a broad space for the development of the organic fertilizer market.
• Policy support:
  The South African government's emphasis on agriculture and environmental protection has promoted the development of organic agriculture and precision fertilization technology. These policy supports will help further expand and develop the organic fertilizer market.
• Import substitution effect:
  Although South Africa has a certain fertilizer production capacity, it still needs to rely on imports to meet the demand for some fertilizer products.
  By building an organic fertilizer production project, it can reduce dependence on imported fertilizers, meet domestic market demand, and may also export to neighboring countries to further expand the market.
• Environmental protection and sustainable development:
  In view of the increasing prominence of environmental problems, the South African fertilizer industry is committed to exploring more environmentally friendly and sustainable solutions.
  Promoting the development of organic agriculture and the application of precision fertilization technology to reduce dependence on traditional chemical fertilizers also provides an opportunity for the development of organic fertilizers.

If you want to build a compost manufacturing plant in South Africa, feel free to contact RICHI MACHINERY to get free customized solution design, equipment quotation, project video and other information!