6 T/H Fertilizer Manufacturing Plant In Kyrgyzstan

This project uses the supporting facilities in the breeding base for production, covering an area of 13,209m2 and a construction area of 9,060m2. The building content includes 2 one-story workshops, with an estimated annual output of 30,000 tons of bio-organic fertilizer. The production process includes mixing, nano-film covering fermentation, aging, crushing, and batching.

It is worth mentioning that in this project, all the equipment in the organic fertilizer production workshop is provided by us, RICHI MACHINERY, while all the equipment used in the nano-film fermentation workshop is provided by other manufacturers.

The buildings involved in this fertilizer manufacturing plant in Kyrgyzstan project are mainly nano-film fermentation workshops and organic fertilizer production workshops, both of which are 1-story buildings. The project has 10 employees, none of whom are boarded and lodged in the project, working in two shifts a day, 8 hours a day, and 300 days a year.

Project construction content

The composition of each project of this fertilizer manufacturing plant in Kyrgyzstan project is shown in the following table:

Main products and production capacity

The main products of this fertilizer manufacturing plant in Kyrgyzstan project are bio-organic fertilizers, with an annual output of 30,000 tons, including 15,000 tons of bio-organic fertilizers, 10,000 tons of organic fertilizers and 5,000 tons of organic-inorganic compound fertilizers.

The specifications are all 40kg/bag, with a moisture content of about 30%. The products meet the corresponding standards in "Bio-organic Fertilizer", "Organic Fertilizer" and "Organic-inorganic Compound Fertilizer". The specific product plan is shown in the table below:

Note: The output of powdered or granular organic fertilizer will be allocated according to actual order requirements.

Product Index List

The product technical index requirements of this fertilizer manufacturing plant in Kyrgyzstan project are shown in the table below.

Note: The moisture content of organic-inorganic compound fertilizers shall prevail after factory inspection.

Main production processes and production equipment

The production processes of this fertilizer manufacturing plant in Kyrgyzstan project include mixing, nanofilm-covered fermentation, aging, crushing, batching, granulation, etc., which are carried out in the nanofilm fermentation workshop and the organic fertilizer production workshop respectively. The specific production equipment used in the project is shown in the table below.

Types and quantities of main raw and auxiliary materials and fuels

This fertilizer manufacturing plant in Kyrgyzstan project does not require additional heating or fuel; the raw materials used in the production process are mainly chicken manure produced in the breeding base and purchased rice bran, bacterial agents, organic waste, etc., and auxiliary materials are mainly humic acid and potassium fulvic acid added to different products.

In addition, to ensure the reproduction of microorganisms, the initial moisture content of the fermentation material is maintained at 60%~65%. The specific use of raw and auxiliary materials is shown in the table below.

• Chicken manure:
  The chicken manure of the fertilizer manufacturing plant in Kyrgyzstan project comes from the chicken farm, and the maximum chicken manure production of the chicken farm is about 30,000 t/a.
• Other organic waste:
  Including crop straw, wood chips, peanut shells, pine shells, oil cakes, rapeseed cakes, peanut bran, cassava residue, citric acid residue, beet residue, green manure, leaves and weeds, shell powder, kelp residue and by-products of fruit and vegetable processing plants, which are rich in organic matter and are good raw materials for composting fermentation.
  They are easily absorbed by plants, loosen the soil and relieve soil compaction; they do not contain sludge, other industrial solid wastes and hazardous wastes. The above-mentioned organic wastes mainly come from surrounding agricultural users or food processing enterprises in the region.
  Before entering the factory, they are pre-treated by the supplier to meet the corresponding fermentation requirements. At the same time, the construction unit will inspect the organic waste entering the factory to ensure that the moisture content, heavy metal content, etc. meet the corresponding fermentation requirements. Sludge, other industrial solid wastes and hazardous wastes will not be used for fermentation.
• Microbial agents:
  live bacterial preparations made from beneficial microorganisms, which have the functions of directly or indirectly improving soil, restoring soil fertility, preventing soil-borne diseases, maintaining the balance of rhizosphere microbial flora and degrading toxic substances.
  Proper use of agricultural microbial agents can increase agricultural product yields, improve agricultural product quality, reduce fertilizer use, reduce costs, improve soil, and protect the ecological environment.
• Deodorant:
  The main ingredients are amylase, protease, lipase, etc. It is a natural composite organic enzyme product, combined with other biological growth factors, with the functions of cleaning, deodorizing, and reducing sludge. It is non-toxic and biodegradable.
• Humic acid:
  It has more active genes, a large surface area, and strong adsorption, exchange, complexation, and chelation capabilities. Humic acid is the most effective product for improving, removing, and degrading heavy metals in soil polluted by chemical agriculture today.
  At the same time, humic acid has a strong detoxification effect and is extremely effective in removing agricultural residues and urea toxicity in the soil. Humic acid is effective in activating soil, improving soil compaction, and treating acidified soil in organic farming.
• Potassium humate:
  A pure natural mineral active potassium fertilizer. Potassium humate contains trace elements, rare earth elements, plant growth regulators, virus inhibitors and other nutrients, making nutrients more sufficient and replenishment more reasonable.
  It can replenish nutrients lost in the soil in a timely manner, activate the soil, make it vital, and reduce the continuous cropping disease caused by excessive absorption of nutrients in the soil. The product can completely replace potassium sulfate or potassium chloride and potassium sulfate magnesium with the same content, and it is natural and environmentally friendly.
• Pre-oxidant:
  Odor pre-spraying requires the addition of a pre-oxidant, which is mainly composed of ferrous sulfate, hydrogen peroxide, and hydroxyl compounds in a certain proportion.

Fertilizer Processing Technology Design in Kyrgyzstan

The production process of bio-organic fertilizer in the fertilizer manufacturing plant in Kyrgyzstan project is mainly divided into two parts: nano-film covering fermentation and processing of finished products according to different properties. They are carried out in two workshops respectively. The specific production process is as follows:

Nano-film covering fermentation workshop production process

The nano-film covering fermentation workshop production process of this fertilizer manufacturing plant in Kyrgyzstan project was designed by RICHI Machinery, and relevant manufacturers were recommended to customers.

Material premixing and coating:

The premixing process is carried out in the fermentation tank. After the chicken manure is mixed with auxiliary materials such as mushroom residue and bacterial agents, they are stacked in layers.

Materials such as rice bran with low moisture content are placed at the bottom layer to reduce the amount of fermentation leachate produced; and the porosity between materials is controlled, and the moisture is kept between 60-65%; then the nano-film is covered. During the laying process of the nano-film, the edge is sealed using bandages and hooks.

Nanofilm covered fermentation:

After the pile is pre-treated and stacked in the tank, it enters the aerobic fermentation process. Due to the addition of bacterial agents, aerobic microorganisms will accelerate the decomposition of organic matter in the material. Aerobic decomposition proceeds rapidly, while releasing heat, causing the temperature of the pile to rise rapidly.

Usually, the pile temperature rises from room temperature to about 60°C after 2-3 days of stacking; the temperature is maintained at about 60°C for 7 days (if the pile temperature exceeds 75°C, increase the aeration volume and cool it down in time to about 70°C) to kill pathogens, parasite eggs and weed seeds in the material, and basically achieve harmless treatment. After 15-20 days, after the high-temperature fermentation is completed, the mixed material is completely decomposed and odorless.

During the aerobic fermentation process, part of the material moisture evaporates due to the increase in temperature, and part is lost by microorganisms. Therefore, under the condition of controlling the initial moisture of the fermented material, the amount of leachate produced during the fermentation process is relatively small.

The fermentation pollutants are mainly odors that cannot be intercepted by some nanofilms (mainly NH3 and H2S), a small amount of leachate and waste nanofilms. The leachate is collected from the bottom of the fermentation tank. After the fermentation is completed, it is absorbed by auxiliary materials such as rice bran and mushroom residue and reused as fermentation water for the next batch of material fermentation.

The core fermentation process uses nano-covering membrane + aeration system. The main functional film is expanded polytetrafluoroethylene membrane. The membrane has a special physical structure and a pore size larger than the steam molecule.

Under the action of blasting and the temperature difference between the inside and outside, a micro-high pressure cavity is formed inside the fermentation body, so that the pile body is evenly supplied with oxygen and the temperature is evenly distributed, which builds a suitable closed small environment for aerobic fermentation.

At the same time, water vapor and carbon dioxide can diffuse out with the help of the microporous structure of the membrane, maintaining the air flow balance inside and outside the fermentation pile, ensuring that aerobic fermentation is more thorough and pathogenic microorganisms are effectively killed to ensure the sanitation level of the fermented product.

At the same time, the molecular filtration microporous structure of the membrane can isolate dust, bacteria, etc. from the outside world. Ammonia, an important source of odor generated during aerobic fermentation, can be isolated and absorbed by the water film on the inner wall of the membrane and controlled by the degradation of microorganisms.

Process design of organic fertilizer production workshop

Based on the customer's raw materials, product types and process requirements, the organic fertilizer production process we designed for the customer is as follows:

1. Aging:
   After the nano-membrane high-temperature aerobic fermentation is completed, the moisture content of the material can generally drop to about 40%. Use a forklift to transport the fermented material to the aging workshop through a closed conveyor belt for aging.
   The purpose of aging is to further decompose and stabilize the undegraded macromolecular organic matter in the material to meet the needs of subsequent products. The aging cycle is about 10 days on average, and can also be flexibly adjusted according to product requirements.
   Since the material has been decomposed at high temperature, there is basically no odor volatilization, and the deodorant is sprayed on the material during the aging process to further inhibit the generation of odor.
2. Crushing:
   During the fermentation and aging process, there are many large particles in the decomposed material, which need to be crushed by a fertilizer grinder and then enter screening.
3. Screening:
   There are impurities such as plastic bags and bricks in the crushed decomposed material. These impurities need to be screened by a drum fertilizer screening machine to leave qualified powdered decomposed material ready for the next process.
4. Dynamic batching:
   After screening, qualified decomposed materials are added with corresponding substances through a dynamic batching machine according to different product requirements. Organic fertilizer products need to be supplemented with humic acid, and organic-inorganic compound fertilizers need to be supplemented with potassium humate, and then enter the next process.
5. Mixing:
   After dynamic batching, the materials and nutrients are fully mixed by a double-shaft fertilizer blending equipment.
6. Packaging of finished powder products:
   After complete mixing, the finished powder products can be packaged.
7. Granulation:
   The large-size materials in the screening process are transported to the fertilizer granulator machine for granulation. The fertilizer granulator machine uses the high-speed rotating mechanical stirring force and the resulting air power to continuously mix the materials in the machine, granulate, spheroidize, and densify, thereby achieving the purpose of granulation.
8. Packaging of finished granular products:
   After complete mixing, the finished granular products can be packaged. The packaging process mainly produces dust and packaging waste.

Public works

Water supply

The water used in this fertilizer manufacturing plant in Kyrgyzstan project is based on the existing water supply network in the farm, mainly for employees' living water, fermentation supplementary water and waste gas treatment facilities.

Drainage

The drainage of this project is designed and implemented according to the rain and sewage diversion drainage system. There is no wastewater discharge in the production process of this project. The water used in the waste gas treatment facility of fermentation leachate is recycled.

The domestic sewage of employees is treated by the existing sewage treatment facilities in the chicken farm and is reused for fruit forest irrigation after meeting the standards. It is not discharged.

Power supply

The electricity used in this fertilizer manufacturing plant in Kyrgyzstan project is based on the existing municipal power grid in the breeding farm, and no generator is required.

Fire protection system

The fire resistance level of the building of this project is level 2, and it is designed strictly in accordance with the "Building Design Fire Protection Code" and "Automatic Sprinkler Fire Extinguishing System Design Code".

The layout of indoor and outdoor fire hydrants should meet the requirements of the design specifications. A fire alarm system should be installed in the production workshop, and sufficient portable fire extinguishers should be equipped.

Ventilation system

The building adopts a mechanical ventilation system, and no boiler or central air conditioning is installed.

What is the prospect of building a chicken manure organic fertilizer production line in Kyrgyzstan?

There is a certain prospect for building a chicken manure organic fertilizer production line in

Kyrgyzstan, but it is necessary to comprehensively consider the country's agricultural structure, market demand, policy support and economic environment. The following is a detailed analysis of this prospect:

Kyrgyzstan's agricultural background

Kyrgyzstan is an agricultural country, and agriculture accounts for a large proportion of GDP. The main crops include wheat, corn, potatoes, vegetables and fruits.

Animal husbandry occupies an important position in Kyrgyzstan's agriculture, the poultry industry is large in scale, and chicken manure resources are abundant.

Agriculture is an important pillar of Kyrgyzstan's economy, but agricultural production efficiency is relatively low, and soil degradation and improper use of fertilizers are the main problems.

Chicken manure organic fertilizer can improve soil quality and increase crop yields, which meets the needs of sustainable agricultural development in Kyrgyzstan.

Market demand

• Demand for soil improvement: There are soil degradation problems in some areas of Kyrgyzstan. Chicken manure organic fertilizer can improve soil structure and increase soil fertility.
• Demand for agricultural inputs: Farmers' demand for high-efficiency fertilizers is gradually increasing, and organic fertilizers are popular for their environmental protection and sustainable characteristics.
• Potential for organic agriculture: Although organic agriculture in Kyrgyzstan is relatively small, with the growth of the global organic food market, organic agriculture has great development potential, which in turn drives the demand for organic fertilizers.

Policy support

• National agricultural policy: The Kyrgyz government encourages agricultural modernization and sustainable development, and may provide certain policy support for organic fertilizer production.
• Environmental protection policy: The Kyrgyz government has gradually increased its attention to environmental protection, and the production of chicken manure organic fertilizer is in line with the direction of environmental protection policy.
• International cooperation: Kyrgyzstan has cooperation with many international organizations and countries, and may receive technical support and financial assistance.

Technical and production feasibility

• Raw material supply: Kyrgyzstan has a large scale of poultry farming and abundant chicken manure resources, which can be used as raw materials for organic fertilizers, and the supply is relatively sufficient.
• Technology introduction: Kyrgyzstan's local fertilizer production technology is relatively backward, but it can build production lines by introducing advanced foreign technology.
• Byproduct utilization: Byproducts (such as biogas) produced during the production of chicken manure organic fertilizer can be further utilized to improve economic benefits.

Competition and challenges

• Market competition: Kyrgyzstan's fertilizer market is relatively small, but some local and international companies have entered, and competition may gradually intensify.
• Initial investment cost: The construction of a chicken manure organic fertilizer production line requires a certain amount of capital investment, including equipment procurement, technology introduction and factory construction.
• Farmer acceptance: Kyrgyz farmers' traditional fertilization habits may have a low acceptance of organic fertilizers, which needs to be promoted through publicity and demonstration.
• Economic environment: Kyrgyzstan's economy is relatively backward, and there may be certain uncertainties in the investment environment.

Economic benefits

• Cost and benefit: Chicken manure has a low cost as a raw material, while the selling price of organic fertilizer is high, especially in areas with strong demand for soil improvement, with a large profit margin.
• Market demand potential: With the development of agricultural modernization and organic agriculture, the market demand for organic fertilizers is expected to grow.
• Export potential: Organic fertilizers in Kyrgyzstan can not only meet local demand, but also be exported to neighboring countries (such as Kazakhstan, Uzbekistan, etc.).

There is a certain prospect for building a fertilizer manufacturing plant in Kyrgyzstan, especially driven by soil improvement, agricultural modernization and organic farming development, market demand is expected to grow.

However, investors need to fully consider challenges such as market competition, initial investment and farmer acceptance, and formulate a reasonable business plan to ensure the successful operation of the fertilizer manufacturing plant in Kyrgyzstan project.

By utilizing Kyrgyzstan's agricultural resources and policy support, the chicken manure organic fertilizer production line is expected to become an investment project with both economic and environmental benefits.

If you are also interested in building a fertilizer manufacturing plant in Kyrgyzstan, feel free to contact RICHI MACHINERY for information such as plant construction plans, equipment quotations, full plant layout, project operation videos, etc.!