12T/H Organic Fertilizer Pellet Plant in Iran

Product plan and production scale

The product plan and scale of this organic fertilizer pellet plant in Iran project are detailed in the table below.

Construction content and scale

The organic fertilizer pellet plant in Iran project covers a total area of about 5,000 square meters and a construction area of about 4,000 square meters. The current land use status of the project site is mainly the existing old factory buildings, and the original use of the land is industrial land. The total equipment investment of the project is $630,000.

The project has a total of 1 production line and 8 factory buildings. The factory area is divided into two parts, east and west. The east plot is the fermentation plant, raw material warehouse, and machine repair plant, and the west plot is used as a production workshop, raw material warehouse, finished product warehouse, etc.; in addition, corresponding offices and canteens are provided. See the table below for specific construction content.

Raw and auxiliary materials and energy consumption

The main sources of straw in the raw and auxiliary materials of this organic fertilizer pellet plant in Iran project are rice straw, corn straw, and other economic crop straw grown in surrounding farmland, and livestock and poultry manure mainly comes from manure produced by surrounding farms. This project is strictly prohibited from mixing with dead animals and viscera and other wastes produced by slaughtered animals.

The ratio of straw to manure used in this project is 6:4, of which 1 ton of biological organic fertilizer requires 20 grams of bacteria. The raw and auxiliary materials and energy consumption are detailed in the table below.

Physical and chemical properties of main raw and auxiliary materials and products:

• Plant residues such as straw:
  Such plant residues are rich in cellulose and can provide a large amount of essential elements such as C, H, O, and N for the growth of microorganisms. The main sources of straw are rice straw, corn straw, and other economic crop straws planted in surrounding farmland.
• Fermentation strains:
  The fermentation strains used in this project are fermentation strains specially used for the production of high-quality organic fertilizers. They are composite microbial preparations fermented by special processes. The main ingredients are Bacillus, lactic acid bacteria, yeast, actinomycetes, nitrogen-fixing bacteria, phosphate-solubilizing bacteria, potassium-solubilizing bacteria and other beneficial microorganisms. The content of live bacteria is ≥ 5 billion per gram.
• Livestock and poultry manure:
  Mainly livestock and poultry manure from surrounding farms, mainly chicken, duck, pig, cattle, sheep and other livestock and poultry manure. According to the information provided by the customer, the animal manure purchased is manure that has undergone preliminary fermentation.

Organic fertilizer manufacturing Equipment list

The equipment list of this organic fertilizer pellet plant in Iran project is detailed in the table below.

Raw material transportation and storage

Raw materials are mainly transported into the factory by car. In the process of transporting the main raw materials straw and animal manure, closed car transportation is required to reduce the impact of the stench of animal manure on the surrounding environment.

After the straw enters the factory, it is stacked and stored in the raw material workshop. The amount of animal manure stacked in the factory area is not large. It is transported into the factory by surrounding farms as needed. The animal manure is stacked in the raw material workshop.

Construction process

The construction process of this organic fertilizer pellet plant in Iran project is relatively simple, and the specific procedures are as follows:

1. Construction of buildings:
   Relying on the existing factory building to renovate the construction of buildings → Indoor and outdoor decoration of buildings.
2. Construction of water supply and drainage facilities:
   Excavation and filling of water supply, drainage pipelines and ditches → Installation of water supply and drainage facilities.
3. Construction of power supply and telecommunications facilities:
   Excavation and filling of special channels for cable lines → Installation of power supply, telecommunications, telecommunications, and monitoring facilities.
4. Transportation:
   Transportation of various building materials in the project area, transportation of foundation excavation materials, and filling materials, etc.

Design of organic fertilizer processing process

According to customer needs, the four types of products produced in this organic fertilizer production line in Iran project will adopt four processes. These four process flows are similar and different. The process flow is introduced as follows:

Brief description of organic fertilizer production process

1. Premixing:
   The crushed straw and the livestock manure from the farm that has undergone primary fermentation (fermentation period 15-20 days) are premixed and mixed evenly in a ratio of 6:4 after being measured on a measuring scale. Since livestock manure contains a certain amount of water, no water is required in the premixing process. The premixing process is physical mixing.
2. Main fermentation:
   The mixed straw and manure in this organic fertilizer pellet plant in Iran project are fermented for 15-20 days. When white mycelium is produced in the pile, the material is loose, and there is no original odor of the material, it is an organic fertilizer semi-finished product.
3. Mixing:
   Use a mixer to mix the organic fertilizer semi-finished product.
4. Crushing:
   Use a crusher to crush the mixed organic fertilizer semi-finished products, and send part of them to the organic fertilizer pellet machine through a belt conveyor; the other part is passed through a screening machine to obtain powdered organic fertilizer less than or equal to 40 mesh, and the powdered organic fertilizer finished product is obtained after metering and packaging. The powder larger than 40 mesh is transported back to the crusher for further crushing.
5. Granulation:
   Add 5% water to the crushed semi-finished products (adding water is to increase the strength of the semi-finished products), and load them into the organic fertilizer granulator through the transmission system for granulation. According to market demand, organic fertilizer semi-finished particles with a particle size of 1-4.75mm are produced. This process contains moisture, so basically no dust is generated during the granulation process.
6. Drying:
   The granulated semi-finished products are conveyed to the dryer for drying. The drying temperature at the fire mouth is about 200-300℃, and the temperature at the outlet is about 50-60℃; the heat energy of this organic fertilizer pellet plant in Iran project is provided by the electric dryer.
7. Natural cooling:
   The semi-finished products after drying are naturally cooled.
8. Screening:
   The unqualified semi-finished products with a diameter greater than 4.75mm and less than 1mm are transported to the crusher for re-crushing, and dust is generated during this process.
9. Measuring and packaging:
   The organic fertilizer pellets are weighed and put into woven bags (25kg/bag, which are finished products and stored for sale.

Brief description of the production process of biological organic fertilizer

1. Premixing:
   The crushed straw and the livestock and poultry manure that have undergone primary fermentation (fermentation period 15-20 days) from the farm are premixed and mixed evenly in a ratio of 6:4 after being measured on a measuring scale. Since livestock and poultry manure contains a certain amount of water, no water is required in the premixing process. The premixing process is physical mixing.
2. Main fermentation:
   Add the mixed straw and manure to the fermentation strain (20 grams of strain is required for 1 ton of biological organic fertilizer) and ferment them together for 15-20 days. When white mycelium is produced in the pile, the material is loose, and there is no original odor of the material, it is a semi-finished biological organic fertilizer.
3. Mixing:
   Use a mixer to mix the semi-finished biological organic fertilizer.
4. Crushing:
   Use a crusher to crush the mixed bio-organic fertilizer semi-finished products, and send all the semi-finished products to the organic fertilizer pelletizer through a belt conveyor.
5. Granulation:
   Add 5% water to the crushed semi-finished products (adding water is to increase the strength of the semi-finished products), and put them into the extrusion granulator through the transmission system for granulation. According to market demand, bio-organic fertilizer semi-finished particles with a particle size of 1-4.75mm are produced. This process contains moisture, so basically no dust is generated during the granulation process.
6. Drying:
   The granulated semi-finished products are conveyed to the dryer for drying. The drying temperature at the fire mouth is about 200-300℃, and the temperature at the outlet is about 50-60℃; the heat energy of this organic fertilizer pellet plant in Iran project is provided by the electric dryer.
7. Natural cooling:
   The semi-finished products after drying are naturally cooled.
8. Screening:
   The unqualified semi-finished products with a diameter greater than 4.75mm and less than 1mm are transported to the crusher for re-crushing.
9. Measuring and packaging:
   Weigh the bio-organic fertilizer granules and put them into woven bags (25kg/bag), which are finished products and stored for sale.

Brief description of the production process of organic-inorganic compound fertilizer

1. Mixing and stirring:
   Mix organic fertilizer, nitrogen fertilizer, phosphate fertilizer and potassium fertilizer in proportion.
2. Crushing:
   Use a crusher to crush the semi-finished organic-inorganic compound fertilizer, and send all the semi-finished products to the granulator through a belt conveyor.
3. Granulation:
   Add 5% water to the semi-finished product after crushing (adding water is to increase the strength of the semi-finished product), and put it into the extrusion granulator through the transmission system for granulation. According to market demand, organic-inorganic compound fertilizer semi-finished granules with a particle size of 1-4.75mm are produced. This process contains water, so basically no dust is generated during the granulation process.
4. Drying:
   The granulated semi-finished products are sent to the dryer for drying. The drying temperature at the fire mouth is about 200-300℃, and the temperature at the outlet is about 50-60℃. The heat energy of this organic fertilizer pellet plant in Iran project is provided by the electric dryer.
5. Natural cooling:
   The semi-finished products after drying are naturally cooled.
6. Screening:
   The unqualified semi-finished products with a diameter greater than 4.75mm and less than 1mm are sent to the crusher for re-crushing.
7. Measuring and packaging:
   The organic-inorganic compound fertilizer particles are weighed and packed into woven bags (25kg/bag), which are the finished products and stored for sale.

Brief description of compound fertilizer production process

1. Mixing and stirring:
   Mix nitrogen fertilizer, phosphate fertilizer and potassium fertilizer in proportion. Dust and noise are generated in this process.
2. Crushing:
   Use a crusher to crush the mixed compound fertilizer semi-finished products, and send all the semi-finished products to the granulator through a belt conveyor.
3. Granulation:
   Add 5% water to the crushed semi-finished product (adding water is to increase the strength of the semi-finished product), and load it into the extrusion granulator through the transmission system for granulation. According to market demand, compound fertilizer semi-finished granules with a particle size of 1-4.75mm are produced. This process contains moisture, so basically no dust is generated during the granulation process.
4. Drying:
   The granulated semi-finished product is conveyed to the dryer for drying. The drying temperature at the fire mouth is about 200-300℃, and the temperature at the outlet is about 50-60℃; the heat energy of this organic fertilizer pellet plant in Iran project is provided by the electric dryer.
5. Natural cooling:
   The semi-finished product after drying is naturally cooled.
6. Screening:
   The unqualified semi-finished products with a diameter greater than 4.75mm and less than 1mm are transported to the crusher for re-crushing. Dust is generated during this process.
7. Measuring and packaging:
   After weighing the compound fertilizer granules, they are packed into woven bags (25kg/bag), which are finished products and stored for sale.

Although this organic fertilizer pellet plant in Iran project produces four different products, namely organic fertilizer, bio-organic fertilizer, organic-inorganic compound fertilizer and compound fertilizer, the processes after the "crushing" process are basically the same, so the four products can share one production line.

Plane layout

The organic fertilizer pellet plant in Iran project has no new factory buildings, and all rely on the original old factory buildings. The project is divided into two plots, east and west. The east plot is divided into reserved workshops, fermentation workshops, raw material workshops and employee dormitory buildings from north to south.

The fermentation plant is located in the east plot of the factory area, far away from the residential population; the east side of the west plot is divided into finished product warehouses, office buildings, employee canteens and reserved workshops from north to south; the west side of the west plot is the production workshop and finished product warehouse; the main entrance and exit of the factory area is located on the northwest side of the factory building.

What is the prospect of organic fertilizer granule processing in Iran?

‌The prospect of setting up organic fertilizer pellet plant in Iran is relatively optimistic, but many factors need to be considered.

• First of all, Iran's agricultural production has a large demand for fertilizers, especially organic fertilizers. Although Iran's fertilizer use accounts for a relatively low proportion of the global total, only 0.7%, it is unable to meet its own fertilizer needs, especially phosphate fertilizer and potash fertilizer, which are basically dependent on imports. This shows that organic fertilizer has a large market demand in Iranian agriculture.
• Secondly, Iran's soil structure is poor and the organic matter content is low, so the demand for organic fertilizer is high. In addition, Iran also needs some salt-resistant fertilizers, which also provides market opportunities for organic fertilizer processing.

However, Iran's agricultural production faces some challenges. Due to years of sanctions and internal problems, agricultural production development has been restricted, and fertilizer production cannot meet demand. In addition, Iran's labor costs continue to rise and the level of mechanization is low, which limits agricultural production efficiency. These factors may affect the cost and market competition of organic fertilizer processing.

‌Market Opportunities and Challenges‌:

• ‌Market Opportunities‌:
  Iran has a large demand for organic fertilizers, especially soil improvement and salt-resistant fertilizers, which provides a broad market space for organic fertilizer processing.
• Challenges:
  Years of sanctions and internal problems, rising labor costs, low mechanization levels and other factors may increase production costs and affect market competition.

‌Suggestions‌:

• ‌Understand local agricultural policies:
  Before investing, you need to understand Iran's agricultural policies in detail to ensure that the project meets local policy requirements.
• ‌Market research‌:
  Conduct in-depth market research to understand the demand and payment ability of local farmers for organic fertilizers.
• ‌Cost control‌:
  Pay attention to controlling production costs and improving production efficiency to cope with the problem of rising labor costs.
• ‌Technological innovation‌:
  Actively adopt new technologies to increase the added value of products and enhance market competitiveness.

If you want to build an organic fertilizer pellet plant in Iran, feel free to contact RICHI MACHINERY to get organic fertilizer production project construction plans and equipment quotes!