Organic Fertilizer Manufacturing Plant In Kazakhstan

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Project composition

The organic fertilizer manufacturing plant in Kazakhstan project mainly includes main engineering, storage and transportation engineering, public engineering, environmental protection engineering, etc. The project composition is shown in the table below.

Engineering composition		Engineering situation
Main engineering	Production workshop	Covering an area of ​​2400m2, 1F, it mainly installs discharge tanks and crushers, dryers, granulators, packaging machines and other equipment, and is equipped with environmental protection dust removal and deodorization and other production auxiliary equipment. A closed fermentation tank is arranged on the north side of the workshop.
Storage and transportation engineering	Raw materials and finished product areas	The raw material area is located in the north of the production workshop, and the product area is located in the south of the production workshop.
	Sulfuric acid tank area	The tank area is equipped with 3 sulfuric acid storage tanks (horizontal tanks), with a cofferdam at the bottom and anti-seepage treatment
Public engineering	Water supply system	Equipped with water supply pipelines, supplied by the municipal water supply network
	Heating system	No heat is required for project production
	Power supply system	Provided by the power supply network

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Main economic and technical indicators

The main economic and technical indicators of the organic fertilizer manufacturing plant in Kazakhstan project are shown in the table below.

No.	Name	QTY
A	Product Solution
1	Microbial Organic Fertilizer	80,000 t/a
B	Raw and auxiliary materials
1	Beer mud	8000t/a
2	Soybean meal	16000t/a
3	Rapeseed cake	16000t/a
4	Edible fungus residue	16000t/a
5	Pig manure (dry pig manure without leachate)	24000t/a
6	Deodorizing strain	4t/a
7	Caustic soda flakes	0.45t/a
8	98% concentrated sulfuric acid	1460t/a
C	Energy indicators
1	Electricity	1.769 million kW·h/a
2	Fresh water	250m3/a
D	Labor quota and work system
1	Labor quota	30 people
2	Working hours	24h/d
3	Working days	300d/a
E	Building indicators
1	Land area	6660m2
2	Building area	2400m2

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Material storage and transportation situation

The amount of raw and auxiliary materials and product conditions required for this organic fertilizer manufacturing plant in Kazakhstan project are shown in the table below.

No.	Raw material name	Annual usage (t/a)	Storage method
1	Beer mud	8000	Stacking
2	Soybean meal	16000	Stacking
3	Rapeseed cake	16000	Stacking
4	Edible fungus residue	16000	Stacking
5	Pig manure (dry pig manure without leachate)	24000	Stacking
6	Deodorizing strain	4	Bagged
7	Caustic soda flakes	0.45	Bagged
8	98% concentrated sulfuric acid	1460	Storage tank

Introduction to the physical and chemical properties of the main raw and auxiliary materials:

Pig manure:

Manure contains rich organic matter and various nutrients required by crops, which has a good effect on increasing crop yields and improving soil fertility.

Soybean meal, rapeseed cake, edible fungus residue:

Contains a large amount of organic matter, nitrogen, phosphorus, potassium and trace elements.

Beer mud:

The residue produced by making beer, which is rich in protein and trace elements, can also be used for fermentation materials.

Deodorizing fermentation bacteria:

Eliminate environmental odors and inhibit the proliferation of harmful pathogens.

Sulfuric acid:

Molecular formula H2SO4, molecular weight 98, strong acidity, pure product is colorless, transparent oily liquid, odorless. Concentrated sulfuric acid has a strong water absorption capacity, is easily soluble in water, and can be mixed with water in any ratio. Sulfuric acid is used to produce chemical fertilizers, and is also widely used in industries such as chemicals, medicines, plastics, dyes, and petroleum refining.

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Design of process flow for production of biological organic fertilizers

The organic fertilizer manufacturing plant in Kazakhstan project uses existing plant buildings for construction. There is no civil engineering during the construction period, and only equipment installation and commissioning are involved. According to the customer’s raw materials and product types, the RICHI engineering team designed the following biological organic fertilizer processing flow for the customer:

(1) Mixing

Pig manure, beer mud, soybean meal, rapeseed cake, and edible fungus residue are mixed in a ratio of 3:1:2:2:1 into the mixing tank for mixing. The mixing tank is a closed type. During the closed mixing process, concentrated sulfuric acid is measured and pumped into the mixture in the tank through the closed pipeline through the sulfuric acid inlet valve of the mixing tank, and quickly mixed with the mixture.

Since concentrated sulfuric acid is a strong acid with a high boiling point and is difficult to volatilize, it has strong oxidizing properties. After being mixed into the material, it can react and consume quickly with the organic matter in the mixture to achieve the effect of sterilization and bleaching. After sufficient mixing, the pH of the mixture is neutral, which is convenient for fermentation. A small amount of sulfuric acid mist is generated during the mixing process.

(2) Composting fermentation

The organic fertilizer manufacturing plant in Kazakhstan project uses semi-dry aerobic composting fermentation technology. No leachate will be generated during the fermentation process. The bottom of the fermentation tank is poured with impermeable cement.

In the initial stage of composting for 1-3 days, since the material itself contains oxygen to meet the needs of biological bacteria, aerobic biological bacteria first decompose perishable materials, and then absorb the carbon/nitrogen nutrients of the decomposed organic matter, all of which are used for bacterial reproduction, and the remaining nutrients are decomposed into carbon dioxide and water, while releasing heat to increase the temperature of the pile.

When the temperature is between 25 and 45°C, the mesophilic microorganisms are relatively active; as the temperature of the pile continues to rise, when the temperature is between 45 and 65°C, high-temperature microorganisms such as thermophiles and actinomycetes gradually dominate, are decomposed, and humus begins to form.

Practice has proved that when the composting temperature is above 60°C for three days, parasite eggs and pathogens in the material can be killed, and the composting can be harmless. The process of gradually increasing the temperature from low temperature to high temperature is the process of harmless composting.

The composting temperature is maintained at 45-65°C for about 10 days, and pathogens and insects are killed. When the compost temperature reaches 60℃, the compost is turned by a compost turning machine. The frequency of turning is generally once every 48 hours to provide oxygen, dissipate heat and make the material uniform.

The fermentation process (including compost turning) of this organic fertilizer manufacturing plant in Kazakhstan project takes 15 days.

(3) Drying

The fermented fertilizer contains a certain amount of water and needs to be dried. Electric furnace is used for drying and a gas collector is installed to collect dust.

(4) Granulation and screening

Granular products need to undergo a granulation process. The crushed material is transported to the organic fertilizer pellet making machine. Granulation is carried out by using the characteristics that organic particles can be embedded in each other under a certain force. No binder is added during granulation, and the granulated particles do not need to be dried.

Granular fertilizers are screened by a screening machine. Granules that meet the requirements are packaged and sold. Granular fertilizers that do not meet the requirements are re-entered into the organic fertilizer crushing machine for crushing.

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Main production equipment facilities and parameters

The fertilizer making machines of this organic fertilizer manufacturing plant in Kazakhstan project are shown in the table below.

No.	Equipment Name	QTY	Remarks
1	Mixing Tank	20	/
2	manure dryer equipment	4	/
3	organic fertilizer granulator machine	4	/
4	Dispensing machine	10	/
5	Fermentation tank	4	φ6m×5m
6	Feeding pool	2	22m×6.1m
7	fertilizer crusher machine	4	/
8	Screening machine	4	/
9	Filter press	1	/
10	fertilizer conveyor	2	/
11	Environmental protection equipment	2	One set of bag dust collector, one set of water spray + alkali spray
12	Sulfuric acid storage tank	6	φ3m×9.5m, volume 60m3, horizontal tank, used to store 98% concentration sulfuric acid

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Plane layout and rationality analysis

1. Plane layout

• The northern part of the plant area of this organic fertilizer manufacturing plant in Kazakhstan project is the production workshop.
• The northern part of the workshop is the raw material area and the discharge pool.
• The middle part is arranged with production equipment.
• The southern part is the product area and hazardous waste warehouse.
• The back of the production workshop is a sulfuric acid storage tank, an emergency pool and a fermentation pool.
• The southern part of the plant is an idle warehouse. An entrance and exit are set up in the western part of the plant.

2. Rationality analysis

① The layout of each unit in the organic fertilizer plant is compact. The raw material area and the production area are both located inside the plant, which is convenient for the storage, transportation and use of raw materials.

② The production processes in the workshop are arranged in a centralized manner. Under the premise of meeting the requirements of the production process, the layout distance of each production equipment is short, which is conducive to production, management, investment saving and land occupation reduction.

③ One entrance and exit is set up in the south of the production workshop and one entrance and exit is set up in the west of the plant, which are connected to the external road to facilitate the transportation of project products in and out.

The functional area layout of the proposed project is reasonable, which can make full use of the site, facilitate the connection between various production facilities, and facilitate the access to external electricity and gas. Therefore, the plane layout of the proposed project is basically reasonable.

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Public and auxiliary engineering

Water supply and drainage

(1) Water supply

The water used in this organic fertilizer manufacturing plant in Kazakhstan project is supplied by the municipal water supply network, and all fresh water is used. The water used in the proposed project is mainly for spray tower supplementary water and employee living water.

The water used for water spraying and alkali spraying in this project includes absorption water and evaporation water. According to the information provided by the enterprise, the annual water consumption of the spray tower is 100m3.

The organic fertilizer production plant project employees do not eat and stay in the factory, and the living water quota is calculated based on 50L/(person/day). The project has a labor quota of 10 people and an annual working time of 300 days, so the living water consumption is 0.5m3/d and 150m3/a.

In summary, the fresh water consumption of the project is 250m3/a.

(2) Drainage

The drainage of this organic fertilizer manufacturing plant in Kazakhstan project adopts the rainwater and sewage diversion system. After the rainwater is collected by the rainwater system in the factory area, it is discharged into the ditch outside the factory. The wastewater from the spray tower and the alkali solution of the alkali spray tower are replaced regularly. They are hazardous wastes and are entrusted to qualified units for disposal.

The amount of domestic sewage generated by this project is calculated as 80% of the water consumption. The domestic water consumption is 150m3/a, and the amount of domestic sewage generated is 120m3/a. Domestic sewage is discharged into the septic tank and is regularly extracted by the sanitation department and not discharged.

Power supply

After the fertilizer plant project is put into operation, the power consumption is 1.769 million kWh/a, which is provided by the municipal power supply network. Dual power supply is adopted, connected by the substation, and both are directly buried, and the power supply is guaranteed.

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Environmental protection measures

The environmental protection management measures taken by this organic fertilizer manufacturing plant in Kazakhstan project are as follows:

Item	Pollution generating links	Pollutant composition	Control measures
Waste gas	Drying, granulation, screening, packaging dust	Dust	is collected by the hood and enters the bag filter for treatment before being discharged through a 15m high exhaust chimney.
	Mixing waste gas	Sulfuric acid mist	After being collected, it is discharged through a 15m high exhaust pipe after being treated by water spraying + alkali spraying
	Fermentation odor	Odor, hydrogen sulfide, ammonia	After being collected, it is discharged through a 15m high exhaust pipe after being treated by water spraying + alkali spraying
	Sulfuric acid storage tank size breathing waste gas	Sulfuric acid mist	Strengthen management, unorganized emission
	Unorganized waste gas at the factory boundary	Dust, sulfuric acid mist, odor	Strengthen management, unorganized emission
Solid waste	General solid waste	Waste packaging materials, dust collected by bag dust collector	Waste packaging materials and dust collected by bag dust collector are general wastes. Waste packaging materials are collected and sold for comprehensive treatment; dust collected by bag dust collector is reused in production
	Hazardous waste	Spraying waste liquid, waste packaging bags of caustic soda	Temporarily stored in the hazardous waste temporary storage room, entrusted to qualified units for disposal
	Employees’ domestic waste	Domestic waste	Collected and treated by the sanitation department
Wastewater	Employees’ domestic waste	Domestic sewage	After being treated in septic tanks, it is regularly removed by the sanitation department
Noise	Noise generated by the operation of fans, pumps, agitators, etc.		Take measures such as noise reduction, vibration reduction, and reasonable layout

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Prospects for building organic fertilizer manufacturing plant in Kazakhstan

The prospects for processing organic fertilizers in Kazakhstan are relatively optimistic, mainly based on the following aspects:

(1) First, market demand and policy support are key factors in promoting the development of the organic fertilizer processing industry. The Kazakh government attaches great importance to agricultural development, especially in increasing the added value of agricultural products.

The government has formulated an industrial upgrading plan, aiming to increase the proportion of deep processing of agricultural products to 70% by 2028, in order to further increase the added value of agricultural products and enhance international competitiveness. This policy orientation provides a broad market space for organic fertilizer processing.

(2) Secondly, agricultural resources and production capacity also provide a good foundation for organic fertilizer processing. Kazakhstan has fertile land, a suitable climate, and great potential for agricultural development.

The government’s investment in agricultural infrastructure continues to increase, and the improvement of cold chain logistics, storage facilities and transportation systems will further promote agricultural development. These infrastructure improvements will help improve agricultural production efficiency, thereby increasing the demand for high-quality organic fertilizers.

(3) In addition, technical cooperation and financial support are also important factors in promoting the development of the organic fertilizer processing industry. The Kazakh government plans to modernize agriculture by introducing high-tech means. Technologies such as smart irrigation systems, drone seeding and precision agriculture will become the key to agricultural development.

Fertilizer equipment companies can provide advanced agricultural technology and processing technology, cooperate with local farms to carry out intelligent management, and help improve agricultural production efficiency and product quality. This technical cooperation will not only help improve the quality and production efficiency of organic fertilizers, but also drive the overall development of local agriculture.

(4) Finally, the international trade environment also provides a good external environment for organic fertilizer processing. Kazakhstan is one of the world’s major wheat exporters, and its agricultural products are distributed in Central Asia, the Middle East and some European markets.

If you are interested in building an organic fertilizer manufacturing plant in Kazakhstan 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.!