Small Scale Fertilizer Plant In Australia

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Project content and scale

The main construction content of the small scale fertilizer plant in Australia project includes the production and processing workshop of the main project, the raw material storage workshop and auxiliary material warehouse of the storage and transportation project, and related environmental protection projects are also set up.

There is no canteen, dormitory and office building in the project site. By utilizing the existing office building and canteen of the company’s large-scale chicken farm, the office staff do not stay in the site and are local residents. The project composition is shown in the table below.

Engineering name		Construction content
Main engineering	Production and processing workshop	Size: 70.5×13.5×8m, covers an area of ​​about 951.8m2, 1F, three-sided closed steel frame structure, with secondary turning area, crushing, screening, packaging, and finished product storage area.
Storage and transportation engineering	Raw material storage workshop	Size: 48×17.8×8m, covers an area of ​​about 854.4m2, 1F, three-sided closed steel frame structure
	Finished product storage area	Located in the eastern part of the production and processing workshop, covering an area of ​​200m2.
Auxiliary engineering	Office Area	Use the office area of ​​the large-scale chicken farm for office work

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Product plan

The finished product of this small scale fertilizer plant in Australia project is mainly organic fertilizer, with an annual output of 3,000 tons of organic fertilizer. The specific product output is shown in the table below.

No.	Product Name	Output (t/a)	Main Technical Indicators	Remarks
1	Organic Fertilizer	3000	Nitrogen (N) + Phosphorus (P) + Potassium (K) ≧6.0%; Organic Matter ≧45%; Beneficial Active Bacteria ≧200 million/g	Applicable to fruits and vegetables, bagged, 40kg/bag, finished product moisture content less than 30%

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Product index requirements

① Appearance

Uniform appearance, powdery or granular, no foul odor. Visual and olfactory determination.

② Technical indicators

The technical indicators of organic fertilizers should meet the requirements of the following table.

Item	Indicator
Mass fraction of organic matter (on a drying basis), %	≥30
Mass fraction of total nutrients (N+P2O5+K2O) (on a drying basis), %	≥4.0
Mass fraction of water (fresh sample), %	≤30
pH	5.5~8.5
Seed germination index (GI), %	≥70
Mass fraction of mechanical impurities, %	≤0.5

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Main raw and auxiliary materials and fuel types and materials

The main raw and auxiliary materials used in this small scale fertilizer plant in Australia project are shown in the following table:

No.	Item	Name	Annual Consumption(t/a)	Remarks
1	Raw Materials	Chicken Manure	3200	Chicken manure cleaned by fully automatic dry manure cleaning machine in large-scale chicken farms is directly transported to the raw material storage workshop by small loading vehicles for standby use. The moisture content of chicken manure is 50%.
2		Bisquite	100	Bisquite produced by biogas digesters in large-scale chicken farms, which is directly piped into the storage tank of the raw material storage workshop
3		Rice bran	400	Local purchase
4		Egg shell	10	Relying on the broken egg shells of large-scale chicken farms
5		Sawdust	500	Local purchase
6		Mushroom residue	100	Local purchase, rich in crude protein and cellulose
7	Auxiliary materials	Fermentation bacteria	6	Functional bacteria have the function of promoting fermentation and regulating organic fertilizer nutrients
8		Lime	10	Used for raw material sterilization

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Energy consumption

The main energy consumption of this small scale fertilizer plant in Australia project is shown in the table below.

No.	Name	Annual consumption	Remarks
1	Water	10t/a	Local water well
2	Electricity	60,000 kwh/a	Local power supply
3	Diesel	4t/a	Non-road mobile machinery uses oil barrels for refueling in the field, chicken manure loading trucks refuel at gas stations

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Main fertilizer production processes design

The main production units of this small scale fertilizer plant in Australia project are fermentation tanks and production and processing workshops. The main production process is to collect chicken manure or biogas residue and store it in the raw material storage workshop, and then form organic fertilizer products through fermentation-turning-second composting fermentation-crushing-screening-packaging and sales.

1. Prepare raw materials

The pipeline of the biogas tank pressure water tank is connected to the storage tank of the raw material storage workshop. The biogas residue overflows directly from the pressure water tank into the storage tank through the pipeline. The chicken manure is loaded from the large-scale chicken farm into the site of this project by a loader, and directly dumped into the raw material storage workshop for storage. Then, the chicken manure raw material storage workshop is shoveled into the fermentation tank feed port by a forklift.

The feed port is lifted to the top of the fermentation tank and enters the fermentation tank body from the top. At the same time, auxiliary materials such as rice bran, egg shells, sawdust or mushroom residue are added at a certain proportion on the top to prepare for composting fermentation in the tank body. The moisture content is controlled below 70%.

2. Composting Fermentation

① Principles and Conditions of Composting Fermentation

Composting is a microbiological process that uses bacteria, actinomycetes, fungi and microorganisms widely distributed in nature or artificially adds highly efficient composite microbial agents to artificially promote the biochemical transformation of biodegradable organic matter into stable small molecules and humus under appropriate conditions such as ventilation, humidity, pH, porosity, etc.

The fermentation method of this project is aerobic composting fermentation process. The complete composting process consists of four stages: low temperature, medium temperature, high temperature and cooling. The composting temperature is generally 50~60℃. Regardless of the classification of the composting process, there are two fermentation processes: main fermentation and post-fermentation.

② Fermentation

The main fermentation of this small scale fertilizer plant in Australia project is carried out in the fermentation tank. After the chicken manure and other auxiliary materials enter the tank, the mixer in the tank continuously stirs. In the initial stage of composting, the fermentation takes 1-3 days. Since the oxygen-containing materials themselves can meet the needs of microorganisms, the microorganisms first decompose the perishable substances, and then absorb the carbon/nitrogen nutrients of the decomposed organic matter.

Some nutrients 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 more active; as the pile temperature continues to rise, when the temperature is between 45 and 65°C, the thermophilic microorganisms such as thermophilic bacteria and actinomycetes gradually dominate, are decomposed, and humus begins to form.

According to RICHI’s rich project practice, when the composting temperature is above 60°C for 3 days, the parasite eggs and pathogens in the materials can be killed, and the purpose of composting harmlessness can be achieved. The process of gradually increasing the temperature from low temperature to high temperature is the process of composting harmlessness. Compost is maintained at high temperature (45~65℃) for 7 days, and pathogens, insect eggs, etc. are killed.

The main fermentation process of this project is about 7 days. After the main fermentation, the moisture content of the material drops to about 32%. The matured mixed material enters the production and processing workshop through the conveyor belt at the bottom of the fermentation tank for secondary composting fermentation. The main fermentation process will produce odorous gases, water vapor, carbon dioxide and other gases.

③ Turning the compost

When the compost temperature rises to above 60℃, turn the compost after 48 hours (but when the temperature exceeds 70℃, turn the compost immediately, and the compost temperature should not exceed 70℃, otherwise it will cause the beneficial microorganisms to dormant or even die). When turning the compost, be sure to turn the compost evenly and thoroughly, and turn the bottom material into the upper part of the pile as much as possible to fully decompose it. The number of turnings depends on the composting process.

Generally, the compost can be turned once every 2~5 days to provide oxygen, dissipate heat and make the material ferment evenly. This project uses a compost turning machine. If the material is found to be too dry during fermentation, water should be sprayed in time when turning the compost to ensure smooth fermentation. The oxygen content of the pile weight is maintained between 5 and 15%. The oxygen content is expressed as ventilation.

④ Post-maturity fermentation

Based on fermentation, as the compost temperature drops, the mesophilic microorganisms begin to become active again, and the compost enters the second fermentation. This period can be called post-maturity fermentation or aging stage.

This is conducive to the decomposition of organic matter that is difficult to decompose into relatively stable organic matter such as humus and amino acids, which greatly improves the fertilizer efficiency. With the help of turning the compost, it can generally be decomposed in 15 to 20 days.

The characteristics of mature organic compost are: the temperature of compost naturally drops in the later stage, no longer attracts flies, no odor, soft texture, reduced volume, dark brown or black brown, and dead insect eggs; with fecal coliform group as the evaluation index, the possibility of pathogenic bacteria is also very small when the fecal coliform value is 0.1~0.01; the moisture content of mature organic fertilizer is less than 30%, and the post-ripening fermentation process is carried out in the workshop.

3. Crushing and screening

The mature fertilizer enters the crushing and screening process, and the large particles of fertilizer are crushed into fine particles by the fertilizer crusher. After crushing, the fertilizer enters the fertilizer screening equipment to screen out the large particles and return to the crusher for crushing again. The qualified particle size fertilizer enters the metering packaging machine for packaging and storage for sale.

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Main fertilizer processing machines and parameters

The main fertilizer making machines used in this small scale fertilizer plant in Australia project are shown in the table below.

No.	Name	QTY	Model
1	Fermentation tank	1	SDFJG-120A Aerobic fermentation tank, 28KW
2	Ground compost turner	2	RY-LFD2500/FY-LFD2000< /td>
3	Feeding hopper	1	3.0×1.8×2.2m
4	Feeding belt conveyor	1	4kw, B650, length 3.4m
5	Crushing belt conveyor	1	2.2kw, B650, Length 5.6m
6	Vertical fertilizer crusher machine	1	22kw, JLF700
7	Screening belt conveyor	1	3kw, B650, length 10m
8	Fully enclosed grading screen	1	4kw, JGS1.4×3M
9	Packaging belt conveyor	1	3kw, B650, length 8.4m
10	Silo	1	2.2kw
11	Forklift	2	/

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Plant layout

This small scale fertilizer plant in Australia project has three plant buildings. The raw material storage workshop is located in the west of the site, the production and processing workshop is located in the north of the site, and the auxiliary material warehouse is located in the east of the site.

The fermentation tank and its supporting biological deodorization facilities are set up between the production and processing workshop and the raw material storage workshop. The production and processing workshop is arranged from west to east as a turning area, crushing, screening, and packaging process, and the finished product storage area is arranged near the packaging process. The access road is located in the northeast of the project site and connects to the local village road.

The functional zoning of the production workshop of this project is detailed. It is laid out according to the production process assembly line. The production line is neatly concentrated, easy to manage, and can ensure the smooth flow of logistics and people. The distribution of pollution sources is relatively concentrated, occupying a small space. High-noise equipment is located in the production and processing plant.

Under the premise of strictly implementing pollution prevention and control measures, all pollutants can be discharged in compliance with the standards. In summary, from the perspective of process flow, material transportation, environmental protection, etc., the plane layout of this project is very reasonable.

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Technical support

During the installation of this small scale fertilizer plant in Australia project, RICHI Machinery dispatched technical engineers to the project site to provide full installation support. Based on Australia’s strict environmental protection requirements, the customer encountered many environmental problems during the installation process. Finally, with the technical support of RICHI engineers, the following problems were all solved:

1. There is no wall around the raw material storage workshop of the project. Only a collection pool is set up in the lowest northern part. During the storage of chicken manure, there is a small amount of leachate, and there is a possibility that the leachate will flow out into the surrounding soil.

2. The floors of the raw material storage workshop, auxiliary material warehouse and production and processing workshop are cast with concrete, and the ground is not treated for anti-seepage.

3. During the period when the fermentation tank failed and stopped operation, there was a phenomenon of directly transporting chicken manure to the production and processing workshop for turning and composting.

4. The management measures for rainwater and sewage diversion in the factory area are improper, and the interception measures for initial rainwater and later rainwater, as well as the diversion ditch in the factory and the interception ditch outside the site are not set.

Therefore, in response to the above existing major environmental problems, our engineers proposed the following rectification measures:

1. Set up walls on the east, west and south sides of the raw material storage workshop, and set up diversion ditches at the same time. The leachate generated during the raw material storage process should flow into the collection pool and be shoveled into the fermentation tank feeding port together with chicken manure to participate in fermentation and composting. It is strictly forbidden to discharge it.

2. Strict anti-seepage treatment should be carried out inside the raw material storage workshop, production and processing workshop and auxiliary material warehouse, especially in the area where biogas residue and chicken manure are stored.

3. During the period when the fermentation tank fails, the construction unit should stop operation and strictly follow the functional zoning requirements to avoid mosquitoes, flies, bacteria, etc. generated by unfermented raw materials from polluting the secondary composting fermentation area.

Interception ditches are set up around the plant area to prevent rainwater from entering the plant area. Rainwater diversion ditches are set up inside the plant, and interception devices are set up at the rainwater outlet of the plant area.

The rainwater 10 minutes before the rainy season should be intercepted and flowed into the sedimentation tank, and used for fermentation after sedimentation. After 10 minutes, the rainwater will be blocked by the interception facilities to block the diversion ditch entering the collection tank, so that the clean rainwater in the later period can be discharged from the plant area.

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What is the prospect of building a chicken manure fertilizer plant in Australia?

Building a large and small scale fertilizer plant in Australia has good prospects. The main reasons include the sustainable development needs of Australian agriculture, the growth potential of the organic fertilizer market, and the government’s support for environmental protection and organic agriculture. The following is a detailed analysis of this prospect:

Australian agricultural background

Australia is a large agricultural country with developed animal husbandry and planting industries, especially a large-scale poultry industry and abundant chicken manure resources.

Sustainable agricultural development is an important goal of Australia. Reducing the use of chemical fertilizers and improving soil health are the current trends in agricultural development.

Chicken manure organic fertilizer can replace some chemical fertilizers, help improve soil structure and increase soil fertility, and meet the needs of sustainable agriculture.

Market demand

• Growth of organic agriculture: The organic agriculture market in Australia has grown rapidly in recent years, and consumers’ demand for organic food has increased, driving the demand for organic fertilizers.
• Promoted by environmental protection policies: The Australian government encourages the reduction of chemical fertilizer use and the promotion of organic fertilizers and environmentally friendly agricultural technologies.
• Utilization of chicken manure resources: If the chicken manure produced by chicken farms is not treated, it may cause pollution to the environment (such as ammonia emissions and groundwater pollution). Converting it into organic fertilizer can not only solve environmental problems, but also create economic value.

Policy support

The Australian government has clear policy support for agricultural environmental protection and sustainable development, such as:

• Emission reduction targets: Australia is committed to reducing greenhouse gas emissions, and organic fertilizer production can reduce methane and ammonia emissions generated during the decomposition of chicken manure.
• Agricultural subsidies: Some state governments provide financial support or tax incentives for organic agriculture and environmental protection projects.
• Waste management regulations: Strict environmental regulations require farms to properly handle livestock and poultry manure, which provides a policy driving force for the production of chicken manure organic fertilizer.

Technology and production feasibility

• Mature organic fertilizer production technology: Chicken manure organic fertilizer production technology is already very mature, including fermentation, composting, granulation and other processes, which can efficiently convert chicken manure into high-quality organic fertilizer.
• Localized production advantages: Building large and small scale organic fertilizer production plant in Australia can reduce transportation costs and better meet local agricultural needs.
• By-product utilization: By-products (such as biogas) generated during the production process can be further utilized to improve economic benefits.

Competition and Challenges

• Market Competition: Although the Australian organic fertilizer market is growing rapidly, some local and international companies have entered the market, and competition may intensify.
• Initial investment cost: Building large and small scale fertilizer plant in Australia requires a certain amount of capital investment, including equipment procurement, technology introduction and factory construction.
• Stability of chicken manure supply: The stable operation of the production line depends on the continuous supply of chicken manure, and it is necessary to establish a long-term cooperative relationship with the chicken farm.
• Strict environmental protection requirements: Australia has high environmental protection requirements, and the production line needs to comply with relevant emission standards and waste treatment regulations.

Economic Benefits

• Cost and Benefit: Chicken manure is a low-cost raw material, while the selling price of organic fertilizer is high, especially in areas where organic agriculture is developed, with a large profit margin.
• Stable market demand: With the promotion of organic agriculture, the market demand for organic fertilizer will continue to grow.
• Export potential: Australia’s organic fertilizer can not only meet local demand, but also be exported to other countries in the Asia-Pacific region.

Development Suggestions

• Market research: Before investing, it is necessary to conduct a detailed research on the organic fertilizer market in each state of Australia to understand demand, competition and policy support.
• Cooperation model: Cooperate with local chicken farms, farms or agricultural cooperatives to ensure raw material supply and sales channels.
• Environmental protection technology: Use advanced environmental protection technology to ensure that the production line complies with Australia’s environmental protection regulations.
• Brand building: Improve the market competitiveness of products through certification (such as organic certification) and brand promotion.

There is a good prospect for building a large and small scale fertilizer plant in Australia, especially driven by organic agriculture and environmental protection policies, market demand will continue to grow. However, investors need to fully consider challenges such as market competition, initial investment and environmental protection requirements, and formulate a reasonable business plan to ensure the successful operation of the project.

If you are interested in building large and small scale fertilizer plant in Australia 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.!