Introduction to a 10,000-ton-per-year Rotary Drum Granulation Production Line for Granulated Organic Fertilizer
The 10,000-ton/Year organic fertilizer granule production line is a standardized and automated production line designed for large and medium-sized organic fertilizer production enterprises. It uses a rotary drum granulator as the core forming equipment, and is equipped with equipment for the entire process, including raw material pretreatment, fermentation, drying, cooling, screening, and packaging. It can efficiently convert organic raw materials such as livestock and poultry manure, humic acid, and straw into standard granular organic fertilizer that meets the requirements . It is suitable for the needs of large-scale agricultural fertilization, soil improvement, and green agricultural development, and achieves a stable annual production capacity of 10,000 tons (calculated based on 300 days of operation per year and an average daily production capacity of approximately 333 tons).
Process Stages and Equipment Configuration
- Pre-processing section: laying the foundation for raw materials
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Raw material crushing equipment : 2 Φ800 hammer mills (processing capacity 20-25 tons/hour) to crush coarse fiber raw materials such as straw and mushroom residue to more than 80 mesh, and at the same time to perform secondary crushing of livestock and poultry manure fermentation material to ensure uniform particle size of raw materials and improve subsequent granulation efficiency;
Raw material mixing equipment : 1 twin-shaft paddle mixer (volume 5m³, mixing time ≤3 minutes/batch), which accurately mixes the crushed organic raw materials, conditioning agents (zeolite powder/gypsum, addition amount 3%-5%) and microbial agents (added during the production of bio-organic fertilizer), with a mixing uniformity ≥95%, ensuring the balanced nutrients of the finished product.
Core granulation section: Rotary drum granulator is the main molding unit.
One Φ2.0×6.0m rotary drum granulator (core parameters: processing capacity 15-18 tons/hour, motor power 37kW) is used as the core forming equipment of the production line, and its advantages make it suitable for an annual production capacity of 100,000 tons.
The inner lining of the roller is made of 30mm thick wear-resistant rubber sheet, which is resistant to acid corrosion and friction of organic raw materials and has a service life of ≥3 years;
Equipped with 4 sets of precision spray binder devices (starch paste or sodium humate solution can be used, with an addition amount of 2%-4%), the spray volume is adjusted by a PLC control system to ensure that the granule forming rate is stable at 85%-90%;
Equipped with a variable frequency speed control system (speed adjustable from 5-10 r/min), the granulation speed can be flexibly adjusted according to the moisture and viscosity of the raw materials, avoiding the granules from collapsing due to excessive dryness or clumping due to excessive moisture, ensuring a stable daily output of 333 tons of semi-finished granules.
Post-processing section: Improving the quality and stability of finished products
Drying equipment : 1 Φ3.2×12m rotary dryer (heat source: biomass pellet burner, environmentally friendly and pollution-free), which dries the pellets with a moisture content of 30%-35% after granulation to ≤15%, with a drying efficiency of 18-20 tons/hour, ensuring that the pellets do not mold during storage;
Cooling equipment : 1 Φ2.5×8m counter-flow cooler to cool the dried 60-80℃ granules to room temperature (temperature difference ≤5℃), to prevent the granules from absorbing moisture during the cooling process and to improve the compressive strength (particle strength ≥2.8N after cooling);
Screening equipment : 1 Φ1.8×4.0m drum screen (equipped with 2-5mm and 5-8mm double-layer screens) to classify the cooled particles. The undersized fine powder (≤2mm) is returned to the crusher for secondary use, and the qualified particles (2-8mm) on the screen enter the packaging section. The screening efficiency is ≥18 tons/hour and the finished product qualification rate is ≥98%.
Auxiliary and Packaging Section: Ensuring Continuous Production and Convenient Storage and Transportation
Dust removal equipment : The entire production line is equipped with a pulse bag dust collector (handling air volume of 20,000 m³/h) to collect dust generated during crushing, drying and screening. The dust emission concentration is ≤10mg/m³, which complies with GB13271-2014 Boiler Air Pollutant Emission Standard.
Packaging equipment : 2 automatic quantitative packaging machines (packaging specifications 25kg/bag or 50kg/bag, packaging speed 400-500 bags/hour), equipped with belt conveyors and palletizing robots to realize automated packaging and palletizing of finished products, reduce labor costs and improve storage and transportation efficiency.
Support and Services:
At Tianci Heavy Industry Machinery, we are committed to providing complete support and services to ensure every customer achieves the best results from our equipment. From project planning to after-sales maintenance, our team offers professional assistance at every stage.
1. Pre-sales Consultation
We help customers choose the most suitable machines according to their materials, capacity, and production needs. Customized design and technical solutions are available to meet specific project requirements.
2. Installation and Training
Our experienced engineers can guide installation on-site or online. We also provide detailed operation manuals and training to ensure smooth and efficient production startup.
3. After-sales Service
We offer long-term technical support, quick spare parts supply, and regular maintenance guidance. Any issues are addressed promptly to minimize downtime and keep your production running steadily.
4. Global Support
With successful projects in over 200 countries, we understand the needs of different markets and provide reliable service wherever you are.
At Tianci, our mission is not only to deliver high-quality machines but also to build lasting partnerships through trust, professionalism, and continuous support.
Rotary Drum Granulator Frequently Asked Questions (FAQs)
Q: Could you please specify the hourly output range of your drum granulator?
A: The standard hourly output of our drum granulator ranges from 1 to 300 tons. If you have higher output demands (e.g., over 25 tons per hour), we can tailor a customized solution based on your specific production needs.
Q: HOW DOES A ROTARY DRUM GRANULATOR WORK?
A: A drum granulator works by tumbling material in the presence of a liquid binder to encourage granule formation and growth. Feed material and binder are constantly fed through the rotating drum. The rolling action, combined with the stickiness from the binder, causes fines to collect together into particles. These particles continue to pick up additional fines and binder as they tumble in the bed, causing them to densify and pick up additional layers in a phenomenon known as coalescence. Tumbling flights can be incorporated into the unit to increase agitation of the material bed.
This way of forming agglomerates is a type of agitation agglomeration also known as wet granulation, balling, or pelletizing.
Q: WHAT TYPES OF MATERIALS CAN A ROTARY DRUM GRANULATOR PROCESS?
A: Generally speaking, drum granulators can process any bulk solid in the form of a dry, fine powder. This flexibility lends well to a host of industries, processing materials ranging from specialty chemicals and fertilizers, to minerals and ores, and everything in between.
In some cases, the feedstock may require pretreatment in the form of crushing, grinding, or drying to be a suitable feed for the granulator and produce the characteristics desired in the end product.
Q: WHAT’S THE ADVANTAGE OF A ROTARY DRUM GRANULATOR OVER A DISC PELLETIZER?
A: In choosing between a drum granulator and a disc pelletizer, the drum is often chosen because it offers a higher throughput than the disc pelletizer. The rotary drum also has the advantage of being a “closed” system, meaning that granulation occurs inside a contained environment, so fugitive material is limited.
WHAT CAPACITIES CAN A GRANULATION DRUM ACCOMMODATE?
A: Granulation drums can be customized to nearly any size, accommodating capacities ranging from 500 lb/hr – 3500 TPH+.
ARE DRUM GRANULATORS BATCH OR CONTINUOUS?
A: Rotary drum granulators are typically employed in a continuous setting, though they may function as a batch device in some R&D environments, such as the TIANCI Innovation Center.
Q: WHAT IS THE RETENTION TIME OF A ROTARY DRUM GRANULATOR?
A: Retention time is one process parameter used to control the characteristics and quality of the material exiting the drum, so it can vary significantly depending on the process and product goals. In general, retention time in a granulator may fall anywhere between 30 seconds and 60 minutes.
Q: WHAT ARE THE TYPICAL WEAR ITEMS?
A: Rotary drum granulators are generally low maintenance, but some items can become worn, depending on the operating conditions, and particularly if the drum falls out of alignment. The most common wear items for a drum granulator typically include the liner (where applicable), tumbling flights (where applicable), and potentially trunnion wheels, tires, and thrust rollers.
Rotary drum alignment is an important aspect of drum maintenance to prevent wear of the tires and trunnion wheels. When a drum falls out of alignment, it puts added stress on all components, encouraging undue wear.
Q: DOES THE PRODUCT EXITING THE GRANULATOR REQUIRE DRYING?
A: Since the granulation process relies on a liquid binder to form and layer granules, the product exiting the granulator is wet and must be dried unless it is moving immediately to a downstream process that does not require drying (such as in the case of iron ore balling, where pellets go to a grate kiln).
Drying is typically carried out in a rotary dryer, which further rounds and “polishes” the granules as a result of the tumbling action that occurs as the drum rotates.
Q: HOW DO I KNOW IF A ROTARY DRUM GRANULATOR IS RIGHT FOR MY APPLICATION?
A: Whether or not a rotary drum granulator is the right fit for a given project depends on specific process and product goals, such as capacity, level of control over particle characteristics, product parameters, and more.
When it is not clear if a drum granulator will be able to meet the project objectives, testing can be carried out in the TIANCI Innovation Center to evaluate the process and identify the most suitable equipment configuration.
Q: IS ANY OTHER EQUIPMENT REQUIRED TO SUPPORT A ROTARY DRUM GRANULATOR?
A: Drum granulators require a feeding and offtake system to convey material into and away from the drum. They also typically require screens and a recycle circuit to recover overs and unders and recycle them back into the process
Drum granulators are also typically followed by a rotary dryer and in some cases, may be preceded by a mixer for providing a homogeneous feedstock to the unit.
Q: WHAT DOES THE DESIGN PROCESS LOOK LIKE?
A: Rotary drum granulator design typically begins with testing to assess the feasibility of granulating the intended material and to gather key process data such as percent fill, retention time, drum speed and slope, spray system design, and more.
Once the data has been gathered, engineers work off of this to size the drum and incorporate any necessary features or modifications needed to produce the desired product at the intended capacity.
Q: WHAT DATA IS NEEDED TO DESIGN A ROTARY DRUM GRANULATOR?
A: A variety of data points are necessary to design the granulator. Along with a process description, the follow data is typically required:
Why Choose Us?
Support and Services:
We are committed to providing our customers with comprehensive support and reliable services. Our company offers free process design drawings tailored to your needs, as well as free trial testing services to ensure optimal machine performance. Every machine comes with a one-year warranty for worry-free operation. In addition, we provide free installation and professional training services, helping your team quickly master the equipment and achieve efficient production.
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