Organic Fertilizer Processing Plant In Saudi Arabia

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overview

The main product processed in this organic fertilizer processing plant in Saudi Arabia project is biological organic fertilizer.

Biological organic fertilizer refers to organic fertilizer containing a certain amount of functional microorganisms, which is made from organic waste such as animal manure, humic acid, and crop straw, and is processed with multifunctional fermentation agents. It has the advantages of comprehensive nutrients, fertilizer and water conservation, soil improvement, crop growth promotion, and agricultural product quality improvement, and is called environmentally friendly fertilizer.

According to relevant data, my country’s fertilizer use is nearly 200 million tons, accounting for 28% of the world’s use. The fertilizer use per unit farmland area is twice that of developed countries, while the utilization rate of organic fertilizer is only 50% of that of developed countries.

Due to unreasonable and unscientific fertilizer application, not only resources are wasted and agricultural costs are increased, but also soil is destroyed, the environment is polluted, and the survival of animals and plants and human health are threatened.

It is imperative to apply fertilizers scientifically, reasonably, and reduce pollution, and replace traditional single-element inorganic fertilizers with high-quality biological organic fertilizers.

In view of this, the client of the project, a Saudi Arabian biotechnology company, invested 630,000 US dollars to build an annual production of 50,000 tons of organic fertilizer production project. The organic fertilizer processing plant in Saudi Arabia project has a labor quota of 8 people, three shifts, 8 hours a day, and an annual production time of 300 days.

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Main construction content

The organic fertilizer processing plant in Saudi Arabia 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.

Engineering classification	Engineering name	Construction content	Number of floors	Remarks
Main engineering	Production workshop	1, with a construction area of ​​3870m2, including granulation production, granule packaging area, weighing area, and finished product storage area.	1 floor	Colored steel structure
	Trough fermentation workshop	1, with a construction area of ​​1440m2, mainly for aerobic fermentation and aging fermentation.	1st floor	Colored steel structure
Storage and transportation engineering	Raw material storage	Cow and sheep manure is directly transported to the tank fermentation workshop in the factory for fermentation, and is not stored in other locations in the factory; other bagged raw materials are stored in the production workshop.	—	—
	Finished product storage	Bagged finished products are stored in the finished product storage area in the production workshop.	—	—
	Transportation	Raw materials mainly rely on social transportation forces and are transported by closed vehicles; transportation within the factory is mainly transported by forklifts and closed conveyor belts.	—	—
Auxiliary Engineering	Office	150m2, for daily office	1st floor	brick-concrete structure
	Staff Lounge	80m2, for temporary rest	1st floor	brick-concrete structure
	Accessories Room	30m2, for storing equipment accessories	1st floor	brick-concrete structure

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Product plan

The main products and annual output of this organic fertilizer processing plant in Saudi Arabia project are shown in the table below.

No.	Name	Specifications	Production Scale	Remarks
1	Biological Organic Fertilizer	40kg/bag	20000t/a	Powdered Organic Fertilizer
2			30000t/a	Pelletized Organic Fertilizer

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Technical indicators of organic fertilizer products

The technical indicators of the biological organic fertilizer products produced by this organic fertilizer processing plant in Saudi Arabia project are shown in the table below.

Item	Indicator
Mass fraction of organic matter (on a dry basis), %	≥45
Mass fraction of total nutrients (ammonia + phosphorus pentoxide + potassium chloride) (on a dry basis), %	≥5.0
Mass fraction of water (fresh sample), %	≤30
Acidity, p H	5.5~8.5
Number of fecal coliform bacteria, pieces/g	≤100
Ascaris egg mortality, %	≥95
Total arsenic (As) (on a dry basis)	≤15
Total mercury (Hg) (on a dry basis)	≤2
Water content, %	≤30.0
pH	5.5~8.5
Fecal coliform count, pieces/g	≤100
Ascaris egg mortality, %	≥95
Validity period, months	≥6

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Main raw and auxiliary materials and energy consumption

The raw materials of this organic fertilizer processing plant in Saudi Arabia 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. The consumption of main raw and auxiliary materials is shown in the table below.

No.	Raw material name	Consumption	Packaging method	Remarks
Raw and auxiliary materials
1	Cow and sheep manure	54000t/a	Bulk	The purchased cow and sheep manure is dehydrated or dried and preliminarily fermented, with a moisture content of 50%~55%.
2	Fermentation agent	0.8t/a	Bagged, 50kg/bag	Fermentation functional bacteria
3	Biological bacteria Agent	10t/a	Bag, 20kg/bag	Bacillus subtilis, Bacillus licheniformis and other functional bacteria
4	Trace elements	1.5t/a	Bag, 20kg/bag	Zinc, manganese, copper, calcium, magnesium
5	Product packaging bags	1.25 million/a	—	—
Energy consumption
1	Fresh water	2376m3/a		Supplied by the water supply network
2	Electricity	1 million KWh/a		Supplied by power supply lines
3	Natural gas	1.08 million m3/a		Transported by natural gas supplier tank trucks

Physical and chemical properties of raw materials

The physical and chemical properties of the main raw materials for this organic fertilizer processing plant in Saudi Arabia project are shown in the table below.

No.	Name	Main physical and chemical properties
1	Fermentation agent	Probiotics, lactic acid bacteria, yeast, photosynthetic bacteria, Gram-positive actinomycetes and other beneficial microorganisms 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.
2	Biological agent	The new biological strain with the trait of powder has the characteristics of rapid reproduction, strong vitality, safety and non-toxicity. Characteristics: pure strain, high number of viable bacteria, no foreign bacteria; promote the growth of crops, improve the quality of agricultural products, and prevent diseases; improve soil and dissolve ineffective phosphorus; high temperature resistance, no inactivation during granulation and drying, and can be stored for a long time.
3	Trace elements	Trace elements refer to chemical elements 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”. Applying trace element fertilizers is conducive to increasing yields.

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Main equipment for organic fertilizer processing plant in Saudi Arabia

The main equipment of this organic fertilizer processing plant in Saudi Arabia project is detailed in the table below.

No.	Equipment Name	Specification Model	QTY
1	Collective Hopper	4m×1.5m	6
2	Horizontal Crusher	—	2
3	Organic Fertilizer Pellet Making Machine	YZ-3500 Type	4
4	First fertilizer dryer	2.2m×20m	1
5	First fertilizer granule cooler	2.0m×20m	1
6	Second fertilizer dryer	2. 0m×20m	1
7	Second fertilizer granule cooler	1.8m×18m	1
8	Bacteria tank	JJG-100	1
9	Screening machine	FS-2200 Type	1
10	Packaging scale	KL-400	2
11	Hot air drying furnace (matching burner)	RSJ-240	2
12	Screening machine	FS-2000 Type	2
13	Wheel hydraulic tipping machine	KD-1800 type	1
14	Forklift	ZL-50-ZN	1
15	Material conveying belt	KD-60 type	10
16	Sweeper	Mini-100	1
Total			36

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Process design of Saudi Arabia organic fertilizer production line project

Process flow of this organic fertilizer processing plant in Saudi Arabia project:

(1) 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 spray the fermentation agent. Generally, 0.025L of fermentation agent is sprayed on 1t of manure.

In order to spray the agent evenly, the agent must 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.

(2) 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.

(3) Loading

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

(4) Branching

The products of this organic fertilizer processing plant in Saudi Arabia project 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 line to produce products of corresponding specifications. Two discharge ports are set below the upper hopper, which are connected to two crushers respectively.

① Powder production

The raw materials enter the horizontal crusher for crushing, then screened by the screening machine, and then 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).

② Granular material production

A. Crushing

In this organic fertilizer processing plant in Saudi Arabia project, 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.

B. Screening

The crushed raw materials enter the screening machine for screening, and the raw materials that meet the specifications are screened out.

C. Granulation

The screened raw materials are transported to the organic fertilizer granulator machine by a closed conveyor belt for granulation.

During the granulation process, the fully automatic water supply system sprays water into the organic fertilizer pellet mill to make the raw materials moist and facilitate granulation.

The water spraying amount 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.

D. First drying and first cooling

In this organic fertilizer processing plant in Saudi Arabia project, the granulated cattle and sheep manure is transported to the first dryer by a closed conveyor belt for drying. The first drying temperature is 160-180℃ and the drying time is 10-30min. After the first drying, the moisture content of the material is reduced from 35% to 25%.

The first 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.

E. Second drying and second cooling

In order to further reduce the moisture content in the material, the cow and sheep manure after the first drying is transported to the second dryer for drying by a closed conveyor belt. The second drying temperature is 200℃ and the drying time is about 10 minutes.

After the second drying, the moisture content in the material is reduced from 25% to 10%. The second drying is heated by natural gas. After the second drying, the material enters the cooler for cooling. The cooling method is air cooling. After the material cools to room temperature, it enters the next process.

F. Screening

The dried raw materials are screened again, and the pellets that meet the specifications are screened out and enter the next process.

G. Adding biological agents and trace elements

In this organic fertilizer processing plant in Saudi Arabia project, according to customer needs, some granular materials are transported by conveyor belts to the bacteria tank to add biological agents and trace elements.

H. Weighing and packaging

After screening, the pelletized 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.

This organic fertilizer production line project involves three screening processes in the production process. The unqualified products screened out are returned to the feeding process for production.

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Public works

Water supply:

The workshop cleaning of this organic fertilizer processing plant in Saudi Arabia project is carried out by a sweeper. There is no need to wash the workshop floor with water. The production water is granulation water and raw material transportation vehicle washing water.

Vehicles transporting cattle and sheep manure need to wash their wheels and bodies when entering and leaving the tank fermentation workshop. According to the information provided by the construction unit, the amount of washing water generated is 2m3/d and 600m3/a.

During the production process, the granulation process sprays water into the disc granulator. This project requires 40L of water per ton of raw materials, and 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, and domestic water is used for washing of employees. T

he labor quota of this project is 8 people, and the water consumption is calculated at 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.

Drainage:

The amount of vehicle washing wastewater generated is 80% of the water consumption, 1.6m3/d, 480m3/a, and flows into the sedimentation tank on the west side of the trough workshop through the drainage ditch for sedimentation treatment.

The washing wastewater mainly contains cattle and sheep manure, and the main pollutant is SS. After precipitation, it contains a small amount of SS, which is all reused for granulation in the granulator; the raw materials in the granulator are cattle and sheep manure, and the water quality requirements for the granulator are not high, so the wastewater reuse is feasible.

The water added in the granulator is all evaporated, and there is no wastewater discharge during the production process.

Domestic sewage is the staff’s washing wastewater, and the amount is calculated as 80%, which is 0.256m3/d and 76.8m3/a, all of which are used for dust suppression in the factory area.

The factory area is equipped with anti-seepage dry toilets, and the feces and sewage in the dry toilets are cleaned by local farmers and used as agricultural fertilizer.

(3) Power supply

The electricity used in this organic fertilizer processing plant in Saudi Arabia 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.

If you are interested in our organic fertilizer processing plant in Saudi Arabia project, feel free to contact RICHI MACHINERY to customize the production line process plan and equipment configuration plan for free, and design civil engineering, equipment layout and other plans according to your factory building.