Organic Fertilizer Processing Plant In Korea

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Construction content and scale

The main construction content of this 4t/h organic fertilizer processing plant in Korea project is shown in the table below:

Engineering category	Single engineering name	Main engineering content and scale
Main engineering	Organic fertilizer production workshop	A fermentation area is set up, using tank fermentation. The fermentation tank is treated for leakage prevention. A simple insulation shed is set up above the fermentation area for winter fermentation. The fermentation temperature is monitored during the fermentation process. When the temperature is too high, it needs to be turned over and the temperature is controlled at 60-70°. Turning machines, semi-wet material crushers, screening machines, etc. are set up. It is mainly used for the production of organic fertilizers, with an annual output of 10,000 tons of organic fertilizers
Storage and transportation engineering	Raw material area	Located in the production workshop, with an area of ​​about 500m2, it is located on the south side of the organic fertilizer production workshop. It is mainly used to store straw raw materials, agricultural waste and finished products. After livestock and poultry manure is transported to the factory area, it is directly transported to the fermentation workshop without storage.
	Finished product stacking area	Located in the organic fertilizer production workshop, with an area of ​​about 500m2, located on the northwest side of the organic fertilizer production workshop, it is used to store finished organic fertilizer products
	Raw material transportation	The raw materials of this project have strong odor from livestock and poultry manure. During transportation, the transportation boxes must be fully sealed, and the transportation route avoids residential areas. After the raw materials are transported to the organic fertilizer production workshop, they are unloaded.
Public engineering	Power supply	Supplied by the municipal power grid, with an annual power consumption of 100,000 kWh
	Water supply	Supplied by the municipal pipeline network, with an annual water consumption of 4100t/a
	Drainage	Domestic sewage is discharged into the local river after deep treatment at the sewage treatment plant to meet the discharge standards

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Product plan

After completion, the 4t/h organic fertilizer processing plant in Korea project will be able to produce 10,000 tons of organic fertilizer annually. The specific annual product plan is shown in the table below:

No.	Industry category	Product name	Production capacity	Remarks
1	Organic fertilizer and microbial fertilizer manufacturing	Organic fertilizer	10,000 tons	Moisture content 25%, powder, 50kg/bag

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Technical index requirements for organic fertilizer

The organic fertilizer products processed by this 4t/h organic fertilizer processing plant in Korea project can meet the following standards:

Item	Indicator
Organic matter mass fraction (on a dry basis), %	≥30
Total nutrients (N+P2O5+K2O) mass fraction (on a dry basis), %	≥4.0
Water (H2O) mass fraction, %	≤30
Acidity, (pH)	5.5~8.5
Mechanical impurities mass fraction, %	≤0.5
Total arsenic (As) (on a dry basis), mg/kg	≤15
Total mercury (Hg) (on a dry basis), mg/kg	≤2
Total lead (Pb) (on a dry basis), mg/kg	≤50
Total cadmium (Cd) (on a dry basis), mg/kg	≤3
Total chromium (Cr) (on a dry basis), mg/kg	≤150
Fecal coliform count, %	≤100
Ascaris egg mortality, individual/g	≥95
A. Total nutrients can be the sum of nitrogen, phosphorus and potassium, or any one of them. b. In addition to the indicators in the table, other indicators should comply with the provisions of the corresponding product standards, such as compound fertilizers (complex fertilizers), chloride ion content in blended fertilizers, biuret content in urea, etc.

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Material balance table

The material balance of this 4t/h organic fertilizer processing plant in Korea project is shown in the following table:

No.	Raw material input				No.	Output
	Input		Usage/t			Destination		Output/t
1	Livestock and poultry manure (water content 20%)		3000		1	Water evaporation		2984.92
2	Agricultural waste (water content 15%)		235		2	Dust generation		3.35
3	Straw (water content 15%)		5000		3	Odor generation		1.98
4	Pre-wetting water		3500		4	Product organic fertilizer (water content 25%)		10000
5	Biological strains		500
6	Nitrogen fertilizer, phosphorus fertilizer, potassium fertilizer		755.25
Total		12990.25		Total			12990.25

Nitrogen balance sheet

The nitrogen balance sheet for this 4t/h organic fertilizer processing plant in Korea project is as follows:

No.	Raw material input		No.	Output
	Input	Nitrogen content (t)		Destination	Nitrogen content (t)
1	Livestock manure (nitrogen content 0.854%)	25.62	1	Product organic fertilizer (nitrogen content 2.2%)	220
2	Agricultural waste (nitrogen content 0.4%)	0.94
3	Straw (nitrogen content 0.4%)	20
4	Nitrogen fertilizer (nitrogen content 45%)	173.44
Total		220	Total		220

Phosphorus balance table

The phosphorus balance of this 4t/h organic fertilizer production plant in Korea project is as follows:

No.	Raw material input		No.	Output
	Input	Phosphorus content (t)		Destination	Phosphorus content (t)
1	Livestock and poultry manure (phosphorus content 0.72%)	21.6	1	Product organic fertilizer (phosphorus content 1.5%)	150
2	Agricultural waste (phosphorus content 0.02%)	0.05
3	Straw (containing 0.02% phosphorus)	1
4	Phosphorus fertilizer (containing 55% phosphorus)	127.35
Total		150	Total		150

Potassium balance table

The potassium balance of this 4t/h organic fertilizer processing plant in Korea project is as follows:

No.	Raw material input		No.	Output
	Input	Potassium content (t)		Destination	Potassium content (t)
1	Livestock and poultry manure (containing 0.49% potassium)	14.7	1	Product organic fertilizer (containing 2.2 potassium)	150
2	Agricultural waste (containing 1% potassium)	2.35
3	Straw (containing 1% potassium)	50
4	Nitrogen fertilizer (containing 45% potassium)	82.95
Total		150	Total		150

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Main raw and auxiliary materials

The main raw and auxiliary materials and energy consumption of this 4t/h organic fertilizer processing plant in Korea project are detailed in the table below:

No.	Name	Annual Usage	Maximum Storage Volume	Remarks	Storage Cycle	Properties
1	Livestock and Poultry Manure	3000t	/	Recovered from surrounding breeding farms, livestock and poultry manure that has been harmlessly treated, moisture content ≤20%	Straw and agricultural waste are stored in the raw material area. This project purchases livestock and poultry manure that has been harmlessly treated and is used for fermentation upon arrival at the factory without storage. A fermentation cycle is about 15 days	Solid
2	Agricultural waste (bacteria sticks, fruit shells, etc.)	235t	50t	Moisture content 10%~ 15%		Solid
3	Straw	5000t	50t	Moisture content 10%~ 15%		Solid
4	Fermentation bacteria	500t	1t	/		Solid
5	Urea (nitrogen fertilizer)	385.5t	0.5t	Nitrogen content 45%		Solid
6	Superphosphate (Phosphate Fertilizer)	231.5t	0.5t	Phosphorus Content 55%		Solid
7	Potassium Chloride (Potassium Fertilizer)	138.25t	0 .5t	Potassium content 60%		Solid
8	Organic fertilizer bags	200,000	10,000	/		Solid
9	Deodorant	5t	1t	/		Solid state
10	Engine oil	1t	0.3t	/		Solid state
11	Water	4400t	/	/	/	/
12	Electricity	100,000kwh	/	/		/

Note: Physical and chemical properties of raw and auxiliary materials:

Fermentation strains: biological organic fertilizer strains, which are used to ferment, deodorize and fully decompose organic solid waste (including organic garbage, straw, livestock and poultry manure, cakes and dregs, agricultural and sideline products and solid waste generated by food processing) into organic fertilizer strains, including various fermentation strains such as actinomycetes.

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Main organic fertilizer manufacturing machines

The main fertilizer making machines list of this 4t/h organic fertilizer processing plant in Korea project is shown in the table below:

No.	Equipment Name	Equipment Parameters	QTY	Production Unit
1	Crawler Type Turning Machine	φ2400	1 Unit	Organic fertilizer manufacturing
2	Forklift silo	φ 1500*2500	1 unit
3	Straw crusher	φ500	1 unit
4	Semi-wet fertilizer crusher machine	φ500	1 unit
5	Screening machine	φ1000*3000	1 unit
6	Horizontal mixer	φ700*1500	1 unit
7	Packaging machine	B500	1 unit
8	High-precision fertilizer detector	φ2400	1 unit	Organic fertilizer detection
9	Electronic balance	NT-GF	1 unit

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Public works

(1) Water supply

① Domestic water

The project has a labor quota of 30 people. The factory does not provide accommodation. The water use standard is calculated based on the local industrial enterprise employee office and domestic water quota.

The average daily water use per person is 100L, and the annual working days are 300 days. Therefore, the domestic water consumption is 3m3/d (900m3/a). The sewage generation is calculated as 80% of the water consumption, so the domestic sewage generation is 2.4m3/d (720m3/a).

② Pre-wetting water

The livestock and poultry manure, straw, and agricultural waste used in the project need to be pre-wetted before fermentation. The water content of the purchased livestock and poultry manure is about 20%. According to the “Technical Specifications for Livestock and Poultry Manure Composting”, “Mix the livestock and poultry manure and auxiliary materials evenly, and the moisture content of the mixed materials should be 45%~65%”.

This 4t/h organic fertilizer processing plant in Korea project needs to be pre-wetted to 55% moisture content before fermentation. The annual pre-wetting water consumption of the project is about 3500t. The pre-wetting water is finally included in the product and will not be discharged.

(2) Drainage

The wastewater of the fertilizer plant project is mainly domestic sewage. After being treated in a septic tank, the domestic sewage enters the sewage treatment plant for deep treatment and meets the pollutant emission standards before being discharged into the local river.

(3) Power supply

The annual power consumption of the project is about 100,000 KW·h, which is supplied by the municipal power supply and can meet the production and living needs of the project.

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fertilizers manufacturing process design

Fertilizer process description of this 4t/h organic fertilizer processing plant in Korea:

1. Straw crushing:

The purchased straw is crushed by a straw crusher. After the straw is crushed, it can be fermented more fully.

2. Pre-wetting of livestock and poultry manure:

Sprinkle water on various livestock and poultry manure to increase its moisture content. The higher the moisture content, the faster the fermentation in the later stage.

3. Mixing:

Add the crushed straw to the pre-wetted livestock and poultry manure and stir and mix.

4. Spraying fermentation bacteria:

Spray the fermentation bacteria on the mixed material to promote the fermentation of the material.

5. Mixing:

The material sprayed with the fermentation bacteria is stirred and mixed using a crawler-type flipping machine.

6. Fermentation, aging, and turning:

The aerobic composting fermentation of this project adopts natural fermentation, without artificial heating means, and the natural fermentation time is 30-35 days.

The organic fertilizer production workshop of this project is fully enclosed, and the fermentation area is separately enclosed. It is planned to use micro-negative pressure to collect odor, and then discharge it in an organized manner after treatment by a biological deodorization tower.

The organic fertilizer production area is completely sealed to collect waste gas. The organic fertilizer fermentation area is 1000m2, and the height after sealing is about 3m, so the volume is 3000m3. It is planned to use 8 times/h for air change, and the fan air volume is 24000m3/h.

Aerobic composting fermentation is divided into warming stage, high temperature stage, cooling stage and mature fertilizer preservation stage.

The warming stage generally refers to the initial stage of the composting process. In this stage, the compost temperature rises from room temperature to about 45℃. The main microorganisms are mesophilic microorganisms, including bacteria, fungi and actinomycetes, which decompose macromolecules such as sugars and starch. The high temperature stage refers to the stage when the temperature of the compost rises to above 50℃.

In this stage, if the temperature is too high, the thermophilic microorganisms will be inhibited or even die. The residual and newly generated soluble organic matter in the compost continues to be oxidized and decomposed, and complex organic matter such as hemicellulose-cellulose and protein also begins to be strongly decomposed. The activities of microorganisms appear alternately.

Usually, the most active ones are thermophilic fungi and actinomycetes at around 50℃. When the temperature rises to 60℃, the fungi almost stop their activities completely, and only thermophilic bacteria and actinomycetes are active. When the temperature rises to 70℃, most thermophilic microorganisms are no longer adapted and enter the dormant and death stage in large numbers.

This 4t/h organic fertilizer processing plant in Korea project adopts RICHI modern technology to produce organic fertilizers. The optimal temperature is 55℃ and the maximum temperature does not exceed 70℃. This is because most microorganisms are most active in this temperature range and are easy to decompose organic matter, while most pathogens and parasites can be killed. The high temperature stage will inevitably cause the death and reduced activity of microorganisms, and gradually enter the low temperature stage.

In this stage, mesophilic microorganisms begin to dominate again, further decomposing the residual organic matter that is difficult to decompose, but the activity of microorganisms generally decreases, the heat generation of the pile decreases, the temperature begins to drop, the organic matter tends to stabilize, the oxygen demand is greatly reduced, and the compost enters the mature or post-mature stage.

Most of the organic matter has been decomposed. In order to maintain the stability of the formed humus and trace elements such as nitrogen, phosphorus, and potassium fertilizers, the mature fertilizer can maintain physical balance. After the compost is mature, the volume shrinks.

When the compost temperature is slightly higher than the air temperature, the pile should be compacted to keep the organic components under anaerobic conditions to prevent mineralization and facilitate the preservation of organic fertilizer fertility.

Aerobic fermentation process control:

① Oxygen supply control

This project adopts a trough aerobic fermentation process. In order to maintain the efficient fermentation, it is necessary to ensure sufficient oxygen supply to the pile. This project adopts mechanical turning and forced ventilation to increase oxygen. Trough composting can meet its oxygen supply needs through ventilation and aeration and regular turning. The frequency of compost turning is determined by combining the properties of the material and the change in compost temperature.

② Temperature control

The temperature change of compost is the most direct and sensitive indicator to reflect whether the fermentation is normal. The requirements for the temperature change of compost are: the temperature rises steadily in the early stage, the high temperature is maintained moderately in the middle stage, and the temperature drops slowly in the late stage.

At present, this 4t/h organic fertilizer processing plant in Korea project mainly controls the fermentation temperature by mechanical compost turning, following the principle of “not isothermal at the time, not isothermal at the temperature”, that is, in the early stage of composting, the temperature change of the pile is controlled by temperature detection, and the compost is turned after 48 hours to avoid the formation of an anaerobic environment in the pile.

In the middle and late stages of composting, once the temperature is too high, the compost must be turned in time, and it cannot be turned after the set time.

7. Product monitoring:

Semi-finished compost must undergo maturity testing, quality testing, and safety testing.

8. Adjusting NPK content:

According to the monitoring results, the semi-finished products after monitoring need to add nitrogen, phosphorus and potassium fertilizers to ensure that the nitrogen, phosphorus and potassium content of the organic fertilizer reaches the organic fertilizer nitrogen, phosphorus and potassium content index in the “Technical Index Requirements for Organic Fertilizer Products of Biological Livestock and Poultry Manure”.

9. Semi-wet crushing:

The fermented materials need to be crushed by a crusher, and the large pieces of materials are returned to the mixing process for re-fermentation. Since the materials are in a wet state during the crushing process, no dust is generated, and odor is generated in this process.

10. Screening:

The crushed fertilizer will be screened by a screening machine, and the fertilizer with larger particle size will be re-entered by the crusher for crushing. Since the materials are in a wet state during the screening process, no dust is generated, and odor is generated in this process.

11. Packaging and warehousing:

The crushed and screened materials are sent to the packaging machine by a belt conveyor for product packaging, and the finished organic fertilizer is packaged.

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What is the prospect of building an organic fertilizer processing plant in South Korea?

The prospects for building an organic fertilizer processing plant in South Korea are generally optimistic. Here are several key factors:

Favorable factors:

• Policy support: The South Korean government actively promotes the development of organic agriculture, encourages the use and production of organic fertilizers through subsidies, tax incentives and other policies, and provides a good policy environment for the organic fertilizer industry.
• Market demand growth: As consumers pay more attention to food safety and environmental protection, the demand for organic agricultural products continues to increase, which in turn drives the demand for organic fertilizers.
• Increased environmental awareness: Korean society pays more and more attention to environmental protection. Organic fertilizers, as environmentally friendly products that reduce the use of chemical fertilizers and improve soil health, have received more attention.
• Technological progress: South Korea has continuously innovated in organic fertilizer production technology, improved production efficiency and product quality, and enhanced market competitiveness.

Challenges to start organic fertilizer production business:

• Raw material supply: Organic fertilizer production relies on a stable supply of raw materials, such as livestock and poultry manure, crop straw, etc. The cost of obtaining and transporting raw materials may affect production.
• Market competition: The organic fertilizer market is highly competitive, and new entrants need to face the competitive pressure of existing companies.
• Consumer awareness: Some consumers lack awareness of organic fertilizers, which may affect their acceptance and market promotion.

Overall, the Korean organic fertilizer market has a good prospect, but companies need to pay attention to challenges such as raw material supply, market competition and consumer education.

If you are interested in building an organic fertilizer production 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.!