Organic Fertilizer Factory In Belarus

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Engineering Content

The main construction content of the organic fertilizer factory in Belarus project is as follows:

Engineering Category	Engineering Name	Engineering Content and Scale
Main engineering	Composting	Building area of ​​1,200 square meters, mainly used for manure and straw composting.
	Fermentation Area	Building area of ​​1,400 square meters, 4 meters high, equipped with turning machines and other equipment, mainly used for the first and second fermentation of organic fertilizer.
Auxiliary engineering	Crushing Workshop	Located on the east side of the fermentation area, with a building area of ​​about 500m2 and a height of 5m, it is equipped with a crushing production line, crushers, screening machines, etc., mainly used for crushing and screening of straw and large pieces of compost.
	Granulation workshop	Located on the east side of the crushing workshop, with a construction area of ​​about 500m2 and a height of 5m, it is equipped with drying machines, fertilizer granulators, etc., and is mainly used for granulation of organic fertilizers.
	Packaging workshop	Located in the southeast corner of the plant, with a construction area of ​​500m2 and a height of 5m, it is equipped with packaging machines, sealing machines, etc.
	Office room	Located in the northeast corner of the plant, it is used for office work, with a construction area of ​​about 200 square meters.
Storage and transportation engineering	Finished product warehouse	Located in the north part of the plant, with a construction area of ​​about 700m2, it is mainly used for temporary storage of finished products.
Public engineering	Water Supply Engineering	Water supply network, mainly for domestic use, with a water consumption of 2997m3/a.
	Drainage Engineering	Rainwater and sewage are separated, and the domestic sewage of the project is regularly cleaned after being treated in the septic tank and reused for mixed compost production, and is not discharged externally.
	Power Supply Engineering	Power Supply Network

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Main product solutions

The product solutions for this organic fertilizer factory in Belarus project are shown in the table below:

No.	Product plan	Annual output
1	Bio-organic fertilizer (solid)	20,000 t/a

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Organic fertilizer quality technical indicators

The product quality of this organic fertilizer factory in Belarus project should meet the following standards:

No.	Item	Indicator
1	Quality Standard	“Agricultural Industry Standard – Organic Fertilizer Raw Materials”
2	Appearance	Brown or gray-brown, powdery, granular or granular
3	Smell	No odor
4	Organic matter mass fraction (on a drying basis), %	≥ 45
5	Total nutrients (on an oven-dried basis), %	≥5.0
6	Water (fresh sample) mass fraction, %	≤30
7	pH	5.5~8.5

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Consumption of main raw and auxiliary materials

The consumption of raw and auxiliary materials and energy for this organic fertilizer factory in Belarus project is shown in the following table:

No.	Material name	Maximum storage capacity in the factory t/a	Annual consumption t/a	Remarks
1	Livestock manure	5000	15000	Automobile, tanker transport
2	Straw	1000	5000	Purchased from outside,
3	EM bacteria agent	20	20	25kg/barrel
4	Packaging bags	/	800,000	Used for packaging organic fertilizer, 25kg/bag
5	Lubricating oil	0.3	0.3	10kg/barrel
6	Electricity	20,000 Kwh/a		Local power supply network
7	Water	2997m3/a		Local water supply network

Raw materials and auxiliary materials:

EM bacteria: EM bacteria are composite bacteria, including beneficial microorganisms from five categories of microorganisms: photosynthetic bacteria, lactic acid bacteria, yeast, Gram-positive actinomycetes, and fermentation-based filamentous bacteria. They are medium- and high-temperature aerobic bacteria that are good at decomposing crude protein, fat, cellulose, and lignin.

They can accelerate fermentation and ripen, convert macromolecular nutrients such as nitrogen, phosphorus, and potassium in fermented materials into small molecular fast-acting nutrients that are beneficial to crop absorption, and form a large amount of humus and trace elements. At the same time, they have the ability to remove odors and improve the environment.

The removal efficiency of EM bacteria for hydrogen sulfide is about 80%, and the removal efficiency for ammonia is 70-90%. Fermented fertilizers have the effects of reducing soil capacity, increasing soil activity, strengthening roots, curbing soil-borne diseases, and increasing crop yield and quality.

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Design of belarus organic fertilizer factory process design

Based on the customer’s raw materials, product types and process requirements, we finally customized the organic fertilizer process for the organic fertilizer factory in Belarus project as follows:

(1) Straw crushing:

The purchased straw is sent to the fertilizer grinder for crushing.

(2) Mixing:

Add livestock and poultry manure, EM bacteria agent, crushed straw, etc. in proportion and stir and mix in fertilizer blending machine. The livestock and poultry manure has a large water content, so no water is added during the mixing process. During the mixing process, due to the high humidity of livestock and poultry manure, no dust is generated.

(3) Stacking:

This process is carried out in the composting field. After continuous stacking for 7-10 days, the moisture is controlled. No wastewater is generated during the normal fermentation process. September and October are rainy seasons, and the moisture content of the raw materials increases.

A small amount of leachate is generated in the early stage of natural composting. The leachate flows into the filtrate collection tank through the set groove for temporary storage and is reused for mixed material production.

(4) Composting fermentation:

After water control, the raw materials are stored and fermented in a pile in the fermentation area. The length is unlimited, and air holes are made in the pile with a stick. When the pile temperature rises to 50℃, the pile is turned over once a day. If the pile temperature exceeds 65℃, it is turned over again, and the temperature is controlled below 70℃. A small amount of odor is generated during the turning process.

At the same time, turning the pile can promote the evaporation of water in the solid fermentation material. After the water evaporates, the moisture content is about 25%. The first fermentation time is about 12 to 15 days, and the second fermentation time is 12-15 days. When white mycelium is produced in the pile, the material is loose, and there is no original odor of the material, the fermentation is complete.

The fermentation adopts the turning fermentation technology, which uses EM microbial agents to decompose fecal odor under aerobic conditions, and at the same time decomposes the macromolecular organic matter in livestock and poultry feces into low-molecular compounds that are easy for plants to absorb.

The large amount of heat generated during the fermentation process evaporates the water in the feces and dries it, while achieving the purpose of killing harmful bacteria. After adding microbial strains, about 98% of the NH3 and H2S produced can be removed at the beginning of fermentation. As the fermentation time increases, the concentration of malodorous gases gradually decreases. After the fermentation reaches the 72nd hour, the malodorous gases are basically non-volatile.

(5) Crushing and screening:

Crushing and screening the fermented organic fertilizer.

(6) Drying:

The crushed and screened organic fertilizer is heated and dried by a fertilizer drying machine. The dryer in this organic fertilizer factory in Belarus project uses electric heating to provide heat source.

(7) Granulation:

The dried organic fertilizer is processed into granules by a compost granulating machine.

(8) Packaging:

The granulated organic fertilizer is packaged with fertilizer bagging equipment and waits for sale.

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Main bio fertilizer machines list

The main bio fertilizer making machines used in this organic fertilizer factory in Belarus project are shown in the table below:

No.	Main production unit	Main process	Production equipment name	QTY	Production facility parameters		Operation time (h)
					Parameter name	Design value
1	Composting fermentation unit	Fermentation	Fermentation tank	1	/	/	7200
			Turning machine	1	/	/	7200
2	Granulation unit	Screening	Screening machine	1 unit	/	/	2400
3		Drying	Drying machine	1 unit	/	/	2400
4		Crushing	fertilizer crusher machine	1 unit	/	/	2400
5		Granulation	organic fertilizer granulator machine	1unit	/	/< /td>	2400
6		Packing	Packing machine	1 unit	/	/	2400
8	Shared unit	Waste gas treatment	Bag filter	1 unit	/	/	2400
9			Bio-deodorization tower	1 unit	/	/	7200
10			Blower	2 units	/	/	/

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Water balance analysis

1. Water use

① Domestic water:

The organic fertilizer factory in Belarus project has a labor quota of 20 people. In the absence of a canteen, the water consumption is 60L/(d · person), so the water consumption is 1.2m3/d; the drainage coefficient is 0.8, so the project staff’s domestic drainage is 0.96m3/d. Domestic sewage is treated in a septic tank and regularly cleaned and reused for mixed composting production without being discharged.

② Leachate:

After livestock and poultry manure enters the plant area, it is unloaded and mixed in the composting area. After the mixing is completed, it is left to stand for about a week and then enters the fermentation area for fermentation treatment. Due to the effect of gravity, a small amount of leachate will be produced during the stacking process. The leachate contains rich organic matter. The generated leachate is collected and reused for production without being discharged. The amount of leachate produced is about 0.5% of the amount of fresh manure.

The annual consumption of livestock and poultry manure in this project is about 15,000 tons, so the amount of leachate produced is about 75m3/a, 0.25m3/d). The project plans to set up a filtrate collection pool with a volume of 4m3 to collect the leachate generated during the production process. The leachate flows into the filtrate collection pool through the set groove for temporary storage, and is reused for mixed composting production without external discharge.

③ Water for fermentation and composting:

During composting fermentation, water is sprayed for mixing according to the situation, and the water consumption is 10m3/d. Based on this, the annual water consumption is calculated to be 2997m3/a. A small part of the water used for fermentation and composting in this project comes from the leachate of livestock and poultry manure and treated domestic sewage, and most of it comes from the local tap water network.

2. Drainage

Sewage discharge adopts the principle of “rainwater and sewage diversion”. The leachate from livestock and poultry manure in the project is collected and reused for fermentation and composting. Domestic sewage is treated in septic tanks and regularly cleaned and reused for mixed composting production without external discharge.

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 Plant layout

According to the topography, wind direction, roads and other natural conditions of the plant site, in accordance with the principles of reasonable layout, functional zoning, orderly processes and reduced land acquisition, and in accordance with the requirements of production process functions, we designed the customer’s plant into three functional areas: composting and fermentation area, production and processing area and storage and office area.

According to the plan design, the main entrance and exit of the plant is set on the west side, the composting and fermentation area is located on the west side of the workshop, the production and processing area is located on the east side of the workshop, and the office area is located in the northeast corner of the workshop.

The overall layout of production and life in the workshop is conducive to saving energy and pipelines, reducing losses, saving land, and facilitating management. The exhaust gas is treated by environmental protection treatment facilities and meets the emission standards, which has little impact on the surrounding environment.

In summary, after taking sufficient environmental protection measures, the organic fertilizer factory in Belarus project has a very reasonable plan layout from an environmental protection perspective.

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Environmental protection measures

The environmental protection measures taken by this organic fertilizer factory in Belarus project are as follows:

Wastewater treatment	Rainwater and sewage are separated. Domestic sewage from the project is treated in a septic tank and then regularly cleaned and reused for mixed compost production without being discharged.
Waste gas treatment	The odor generated by mixing, stockpiling, fermentation, etc. is treated by setting up a closed workshop to collect the waste gas in the workshop under negative pressure. After the waste gas is collected, it enters the biological deodorization tower for treatment and is discharged through a 15m high exhaust pipe.
	A gas collection hood is set above the crusher, sifter, and granulator to collect and treat the dust generated in the area and then discharge it through a 15m high exhaust pipe.
Noise control	Sound insulation of the plant, vibration reduction of equipment, and sound insulation.
Solid waste disposal	Domestic waste is regularly cleared and transported by the local sanitation department; the dust collected by the general solid waste dust collector is collected and reused in the production line, and the waste packaging materials are sold to the material recycling department. Hazardous waste, waste lubricating oil and oil drums are collected and temporarily stored in the hazardous waste temporary storage room, and then handed over to qualified units for disposal. The hazardous waste temporary storage room is located in the northwest corner of the warehouse and is treated for anti-seepage, sun protection, wind protection and rain protection.

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What are the prospects for building an organic fertilizer factory in belarus?

The prospect of building an organic fertilizer production line in Belarus is relatively optimistic. The following is a detailed analysis of several key factors:

Policy support

• Government promotion of organic agriculture: In recent years, the Belarusian government has actively promoted the development of organic agriculture and regarded it as an important part of the national agricultural policy. The government has adopted a series of policies to encourage farmers to switch to organic farming and reduce their dependence on chemical fertilizers and pesticides.
• Subsidies and tax incentives: In order to promote the use and production of organic fertilizers, the government provides various forms of subsidies and tax incentives. For example, companies that produce organic fertilizers may enjoy tax exemptions, while farmers who use organic fertilizers may receive direct economic subsidies. These policies have created a good policy environment for the organic fertilizer industry, reduced the operating costs of enterprises, and improved market competitiveness.

Market demand growth

• Consumers’ increased attention to food safety and environmental protection: With the improvement of global awareness of food safety and environmental protection, Belarusian consumers are also paying more and more attention to the health and sustainability of food. Organic agricultural products are favored by more and more consumers because of their characteristics such as no chemical residues and environmental protection.
• Rising demand for organic agricultural products: With the expansion of the organic agricultural product market, farmers’ demand for organic fertilizers has also increased. As the core input of organic agriculture, the market demand for organic fertilizer is closely related to the demand for organic agricultural products. Therefore, the market prospects of organic fertilizer are closely linked to the development of organic agriculture.

Increased environmental awareness

• The society attaches great importance to environmental protection: Belarusian society attaches increasing importance to environmental protection, and the government and all sectors of society are actively promoting sustainable development. As an environmentally friendly fertilizer, organic fertilizer can reduce the use of chemical fertilizers, improve soil structure, and reduce environmental pollution, so it has received more attention and recognition.
• Reduce the use of chemical fertilizers and improve soil health: Long-term use of chemical fertilizers will lead to soil degradation, environmental pollution and other problems. Organic fertilizer can not only provide the nutrients needed by plants, but also improve the physical, chemical and biological properties of the soil, enhance the soil’s ability to retain water and fertilizer, and promote the sustainable development of agriculture.

Agricultural foundation

• Developed agriculture and large demand for chemical fertilizers: Belarus is a country with developed agriculture, and agriculture occupies an important position in the national economy. As an important input for agricultural production, chemical fertilizers have always been in great demand. However, with the rise of organic agriculture, traditional chemical fertilizers have gradually been replaced by organic fertilizers, which provides a broad market space for organic fertilizers.
• Potential of organic fertilizer as a substitute: As farmers’ understanding of organic fertilizer gradually deepens, more and more farmers are trying to use organic fertilizer instead of chemical fertilizer. This not only helps to improve the quality of agricultural products, but also reduces the negative impact on the environment.

Abundant raw materials

• Livestock and agriculture are well developed, and raw materials are in sufficient supply: Belarus’s animal husbandry and agriculture are very developed, which provides a rich source of raw materials for the production of organic fertilizer. Agricultural waste such as livestock and poultry manure and crop straw are the main raw materials for the production of organic fertilizer. These raw materials are in sufficient supply in Belarus and are low in cost.
• Sustainability of raw materials: The use of agricultural waste to produce organic fertilizer can not only solve the problem of waste disposal, but also realize the recycling of resources, which is in line with the concept of sustainable development. Therefore, the sufficient supply of raw materials provides a solid foundation for the construction of fertilizer plant projects.

Overall, the prospects for the construction of organic fertilizer production plants in Belarus are relatively optimistic. The government’s policy support, the growth of market demand, the enhancement of environmental awareness, the developed agricultural foundation and the abundant supply of raw materials have all provided favorable conditions for the development of the organic fertilizer industry.

However, enterprises still need to pay attention to challenges such as market competition, technological improvement and consumer education to ensure that they occupy a favorable position in the market. By improving product quality, increasing market promotion efforts, and introducing advanced technologies, enterprises can better seize opportunities in the Belarusian organic fertilizer market and achieve sustainable development.

If you are interested in building an organic fertilizer factory in Belarus project, feel free to contact RICHI Machinery for technical support on organic fertilizer processing plant design, equipment configuration, production line layout, civil engineering solutions, etc.!