Improving the granulation efficiency in NPK fertilizer production lines can not only increase production speed, but also improve pellet quality and reduce energy consumption. Here are some effective methods to improve granulation efficiency:

Raw material pretreatment:

Control the humidity of raw materials: The humidity of raw materials has a direct impact on granulation efficiency. Excessive humidity can cause materials to stick in the granulator, affecting the granulation effect; Low humidity makes it difficult to form stable particles. Therefore, by pre drying or humidifying, controlling the humidity of the raw materials within the optimal range can improve granulation efficiency.

Raw material crushing: Ensure that the particle size of the raw material is uniform and meets the requirements of the granulator. Raw materials with excessively large or uneven grains will increase the difficulty of granulation and reduce granulation efficiency.

Optimize granulation equipment:

Choose the appropriate fertilizer granulator: Based on production needs and raw material characteristics, choose the most suitable type of granulator, such as disc granulator, drum granulator, or extrusion granulator. Different granulators may have different efficiencies and effects when processing specific materials.

Adjust the parameters of the granulator, including speed, feed rate, water addition, etc. Reasonable parameter settings can improve granulation efficiency and particle quality. For example, increasing the rotational speed appropriately can accelerate the granulation process, but excessively high rotational speed may cause particle wear.

Using granulation agents: Adding an appropriate amount of binders or granulation agents, such as organic binders, inorganic binders, or surfactants, can improve the granulation performance of materials, increase granulation efficiency and particle strength.

Optimize the mixing process: Ensure that the raw materials are thoroughly and evenly mixed before entering the granulator. The use of efficient mixing equipment, such as high-speed mixers or planetary mixers, can improve the mixing effect and thus enhance the granulation efficiency.

Drying and cooling: After granulation, excess moisture in the particles is quickly removed through drying and cooling equipment to prevent particle adhesion and improve particle stability. Proper drying and cooling can improve the overall efficiency of granulation.

Maintenance and upkeep: Regularly maintain and upkeep the fertilizer granulator to ensure that the equipment is in optimal condition. Cleaning the interior of the granulator, inspecting and replacing worn parts can prevent malfunctions and improve production continuity and efficiency.

Process control and monitoring: An automated control system is used to monitor and adjust key parameters during the granulation process in real-time, such as temperature, humidity, pressure, etc., to maintain the stability and efficiency of the granulation process.

Through the above measures, the granulation efficiency in the NPK fertilizer production line can be significantly improved, while ensuring the quality and consistency of the granules, thereby improving overall production efficiency and economic benefits.

 Working principle of organic fertilizer granulator: 

The organic fertilizer granulation equipment manufactured by Tianci factory uses the high-speed rotating mechanical stirring force and the resulting aerodynamic force to continuously realize the mixing, spheroidizing, granulating, extrusion, collision, densification and polishing of fine powder materials in the machine, so as to achieve the purpose of granulation. The particle shape of organic fertilizer granulation equipment is spherical, and the granulation rate is 90%. The particle diameter can be adjusted by material mixing amount and spindle speed. Generally, the lower the mixing amount, the smaller the particles and the higher the speed.

The granulation machine produced by NPK fertilizer granulator manufacturer is based on the manufacturing experience of rotary drum granulator and agitating gear granulator, which is carefully developed, repeated experiments and improved granulation equipment. Disc granulator and organic fertilizer granulator are produced at normal temperature with reasonable structure design. They can produce spherical granular products with low moisture content, high molding rate, easy drying, beautiful appearance and good particle strength. They are the ideal granulating equipment for organic inorganic fertilizer, biological organic fertilizer and organic fertilizer inorganic compound fertilizer.

Application scope of organic fertilizer granulating equipment: 

This machine is especially suitable for granulation of light and fine powder materials, and has more powerful granulation function for organic-inorganic compound fertilizer production line. Organic wastes such as chicken manure, peat, straw, sludge, livestock manure, lignite, wine, filter mud of sugar factory, paper sludge, bean dregs, peat and other organic wastes can be directly pelletized after fermentation treatment, which completely solves the key technical problems of traditional granulation process, such as fermentation, etc.

The raw material of our granulation equipment is bio organic fertilizer. The finer the basic particles of fine powder materials are, the higher the sphericity of particles is, and the better the quality of pellets is. The granulation equipment of organic fertilizer generally requires that the particle size of materials before granulation should be less than 50 mesh. Typical application materials: pig manure, chicken manure, cow manure, clay, carbon black, kaolin, phosphorus, nitrogen, potassium and other organic-inorganic compound fertilizers are suitable.

On the NPK (nitrogen phosphorus potassium) fertilizer production line, the fertilizer crusher is one of the key equipment used to crush large raw materials or semi-finished products into small particles for subsequent mixing, granulation and other processes. The commonly used types of fertilizer crushers include:

Hammer crusher: It crushes materials by striking them with a high-speed rotating hammer head. Suitable for crushing materials with moderate hardness and brittleness, with high crushing efficiency, but the processing effect is not good for materials with high hardness or high viscosity.

Cage crusher (or cage crusher): It uses the relative motion between a rotating cage and a fixed cage bar to crush, shear, and impact materials. Suitable for processing materials containing certain moisture and viscosity, such as materials after wet granulation.

Roller crusher: using two relatively rotating rollers to squeeze and shear materials, suitable for processing materials with high hardness and large block size, such as phosphate rock, limestone, etc.

Vibration screen crusher: Combining the functions of vibration screen and crushing, the material passes through the sieve under the action of vibration, achieving a dual effect of crushing and screening. Suitable for handling materials with high granularity requirements.

Chain crusher: It uses a high-speed rotating chain to impact and shear materials, suitable for crushing materials containing certain fibers or toughness, such as organic fertilizer raw materials.

Gear disc crusher: uses the relative motion between the rotating gear disc and the fixed gear disc to cut, squeeze and crush materials. Suitable for processing materials with uniform and fine particle size requirements.

When choosing a fertilizer crusher, it is necessary to determine based on the specific properties of the material (such as hardness, moisture, particle size requirements, etc.) and the production line’s capacity requirements to ensure the crushing effect and production efficiency. Reasonable selection and configuration of crushers are prerequisites for achieving efficient and stable production in NPK fertilizer production lines.

The equipment configuration of an NPK fertilizer production line may vary depending on the production process, but generally speaking, a complete NPK fertilizer production line will include the following main equipment:

Raw material storage and transportation equipment: used for storing and transporting various raw materials (such as urea, monoammonium phosphate, potassium chloride, etc.). Including raw material warehouses, conveyor belts, screw conveyors, bucket elevators, etc.

Raw material crusher: used to crush raw materials to a particle size suitable for subsequent processes. Common types include hammer mills, cage mills, roller mills, etc.

Ingredient system: Accurately weigh various raw materials according to formula ratios, usually including electronic scales, ingredient hoppers, etc.

Mixing equipment: Mix various raw materials thoroughly and evenly. Commonly used types include disc mixers, horizontal mixers, vertical mixers, etc.

Granulation equipment: Mix the evenly mixed raw materials into granules. Common types include disc granulators, drum granulators, extrusion granulators, etc.

Drying equipment: used to remove the water added during the granulation process, so that the fertilizer particles reach the required moisture content. Commonly used ones include rotary drum dryer, fluidized bed dryer, etc.

Cooling equipment: Cool and dry fertilizer particles to prevent clumping and improve storage stability. Commonly used ones include drum coolers, fluidized bed coolers, etc.

Screening equipment: used to screen out particles that do not meet the particle size requirements, commonly including vibrating screens, drum screens, etc.

Packaging equipment: Quantitatively package qualified fertilizer granules, commonly used include automatic packaging machines, sealing machines, etc.

Dust removal equipment: used to collect and process dust generated during the production process to meet environmental protection requirements. Commonly used ones include bag filters, cyclone dust collectors, etc.

Control system: including PLC control cabinet, touch screen, sensors, etc., used to automate the operation of the entire production line, improve production efficiency and product quality.

These devices constitute the main part of the NPK fertilizer production line, and the selection and configuration of each device need to be determined based on specific production needs, raw material characteristics, production capacity requirements, and other comprehensive factors. When designing a production line, it is also necessary to consider the connection between equipment, material transportation paths, energy consumption, and environmental requirements to achieve efficient and stable operation of the production line.

Organic fertilizer production line is a kind of equipment to process organic materials into organic fertilizer after a series of treatment. In this process, it is very important to decompose organic materials. Many users don’t know how organic materials are decomposed in organic fertilizer production equipment. Here is a brief explanation.

In the process of decomposition of organic materials, organic materials become small molecular humic acid under the decomposition of microorganisms, decompose unusable nutrients into available nitrogen, phosphorus and potassium, and transform macromolecular proteins into small molecular amino acids to realize the degradation of organic materials, which is a process of organic matter transformation.

At the same time, the compost material also gathers a lot of heat to make the temperature of the pile body reach above 60 ℃, and for a period of time, it has a killing effect on pathogenic bacteria and weed seeds, etc., to achieve the process of harmless composting. The low-temperature aging process of organic fertilizer can enable microorganisms to reproduce gently and continue to decompose organic materials. In addition, in the process of propagation and decomposition of organic materials, it can secrete a large amount of biostimulants to improve the quality and efficiency of organic fertilizer.

However, a large amount of oxygen is required during the active period of microorganisms. The height of trough compost is high, and it is difficult for oxygen to enter. Therefore, external force is required to force aeration into the pile body. Use organic fertilizer turning equipment to process materials, with high ventilation rate and full automatic control. The fermented materials are then processed into organic compound fertilizer using a rotary drum granulator or other granulation equipment.

The rotary drum granulator may encounter various malfunctions in the NPK fertilizer production line, which may affect production efficiency and product quality. Here are some common faults and their causes:

Uneven particles:

This may be caused by uneven mixing of raw materials, malfunction of the water spray system (such as nozzle blockage or unstable water pressure), or improper setting of the drum speed. Inconsistent particle size and shape can reduce the effectiveness and market value of fertilizer use.

Wall sticking phenomenon:

The material may adhere to the inner wall of the drum during the granulation process, leading to a decrease in granulation efficiency and even blockage. This is usually due to the high moisture content of the material or improper setting of the tilt angle of the drum.

Equipment wear and tear:

The inner wall of the drum, mixing device and other components will wear and tear due to material friction and corrosion during long-term operation, affecting the performance and service life of the granulator. Regular inspection and maintenance are necessary.

Transmission system malfunction:

Transmission components such as motors, reducers, chains, or belts may be damaged due to overload, poor lubrication, or aging, resulting in the inability of the drum to rotate normally and seriously affecting production.

Poor sealing:

If the sealing components of the rotary drum granulator age or are damaged, it can cause dust and moisture to enter, affecting equipment performance and even causing motor short circuits. Maintaining a good sealing condition is crucial for the normal operation of the equipment.

Control system malfunction:

Electronic devices and sensors used to control drum speed, water spray system, temperature, and humidity may malfunction, resulting in inaccurate parameter control during the production process, affecting particle quality and production efficiency.

Material blockage:

The inlet or outlet may be blocked by material clumping or oversized particles, resulting in poor material flow and affecting continuous production.

Vibration and noise:

Equipment imbalance, loose fasteners, or worn bearings can all cause abnormal vibrations and noise, which can accelerate equipment wear and affect the health of operators over long-term operation.

In order to reduce the occurrence of these faults, maintenance personnel need to conduct regular equipment inspections, including cleaning, lubrication, fastening, and replacement of worn parts, as well as calibration and maintenance of the control system. In addition, operators should receive appropriate training to understand the correct operation and troubleshooting methods of the equipment, in order to ensure the stable operation of the rotary drum granulator and the efficient production of the NPK fertilizer production line.

The application of rotary drum granulator in agriculture is mainly concentrated in the field of fertilizer production, and its specific applications include:

NPK fertilizer production:

NPK fertilizer is a widely used compound fertilizer in agriculture, which contains the three main nutrients required for plant growth: nitrogen (N), phosphorus (P), and potassium (K). The rotary drum granulator can evenly mix and granulate NPK raw materials, producing granular fertilizers with uniform particle size, moderate hardness, and good flowability, which are easy to store, transport, and use, and also improve the efficiency of fertilizer use.

Organic fertilizer production:

Organic fertilizers are usually made from organic materials such as animal and plant residues, livestock and poultry manure, and urban organic waste. The rotary drum granulator can process and granulate these organic raw materials appropriately to produce granular fertilizers rich in organic matter, which helps improve soil structure and enhance soil fertility.

Microbial fertilizer production:

Microbial fertilizers refer to fertilizers containing specific beneficial microorganisms that can improve soil environment and promote plant growth. The rotary drum granulator can mix microorganisms with carrier materials and granulate them in the production of microbial fertilizers, ensuring the activity and stability of microorganisms during storage and use.

Production of slow-release fertilizers:

Slow release fertilizers can continuously release nutrients over a long period of time, avoiding waste and environmental pollution caused by excessive release of nutrients at once. The rotary drum granulator can add slow-release materials during the production process to form granular fertilizers with slow-release properties through granulation.

Production of specialized fertilizers:

The rotary drum granulator can also be used to produce specialized fertilizers for specific crops or soil conditions, such as rice specific fertilizers, fruit tree specific fertilizers, etc. By adjusting the raw material ratio and granulation parameters, granular fertilizers that meet specific needs can be produced.

Production of soil amendments:

In addition to fertilizers, rotary drum granulators can also be used to produce soil amendments, such as particles containing humic acid, to improve soil structure, enhance soil water retention and permeability.

The application of rotary drum granulator in agriculture not only improves the production efficiency and quality of fertilizers, but also promotes sustainable development of agriculture. By improving the efficiency of fertilizer use, it reduces the negative impact on the environment and meets the needs of modern agriculture for efficient and precise fertilization.

 The composition of organic fertilizer is complex, so it is very important to be reasonable in application. The manufacturer of fertilizer granulator equipment suggests that we pay attention to the following two points.

1. Organic fertilizer should be fully decomposed before application. If some animal manure, such as pig manure, cattle manure and sheep manure are directly applied to the soil without fermentation and decomposition, the decomposed organic fertilizer in the soil will be decomposed and fermented by microorganisms, and the ammonia gas produced will easily cause crop root burning, and some will breed weeds and spread diseases and insect pests.

We advocate the use of compost turning machine to fully ferment the manure before application. The compost is moistened with water and put into the fermentation tank to make the temperature reach 35-40 ℃. When the manure is fully fermented at high temperature, it can kill the eggs and weed seeds in the compost, which is safer and more effective.

2. Organic fertilizer should not be concentrated or applied too much. Especially in the dry land crop fertilization, if the organic fertilizer is directly applied between the rows or near the root of the crop, because of the small water holding capacity of the dry soil, the concentration around the root system is too high. After the root system contacts the fertilizer pile, it will cause the physiological water loss of the crop and form the reverse osmosis phenomenon. The crop will not only not absorb the nutrient, but also make the water and nutrient in the root system seep out, making the crop grow badly or wilt However, water loss and dead seedlings caused soil nutrient imbalance.

The fertilizer made by the NPK fertilizer manufacturing process cannot alleviate soil problems, and organic fertilizer has a great effect on fertilizing the soil. Therefore, organic fertilizer should be used as a base fertilizer and mixed evenly in the soil to integrate with the soil. When applying organic fertilizer during the growth period, it should be applied in trenches or in a hole. After application, cover the soil and must not spread it on the ground. Leafy vegetables generally should not be sprayed with high-concentration liquid organic fertilizer as foliar fertilizer.

The workflow of a rotary drum granulator is a continuous process, mainly involving several key steps such as raw material preparation, granulation, particle screening, and post-treatment. The following is a typical workflow of a rotary drum granulator:

Raw material preparation:

The raw materials (such as the components of NPK fertilizers) are first crushed to an appropriate particle size to ensure uniform dispersion during the granulation process. Subsequently, the raw materials are mixed to achieve the desired chemical composition ratio. The mixed raw materials are fed into the cylindrical granulation chamber of the rotary drum granulator through the feeding port.

Granulation process:

Entering the granulation chamber: The raw materials enter the granulation chamber, which is usually a tilted cylinder with specific structural designs inside, such as blades or elevators, to promote the rolling and mixing of the raw materials.

Water spray/binder addition: spray an appropriate amount of water or binder evenly to raw materials through the spray system in the granulation room. The amount of water or binder added needs to be precisely controlled to ensure the granulation effect and particle quality.

Rolling and Agglomeration: As the cylinder rotates, the raw materials roll inside, and small particles aggregate into larger particles through bonding. The inclination and rotation speed of the cylinder can be adjusted to control the size and shape of the particles.

Particle screening:

Discharge and screening: After granulation is completed, the particles are discharged from the discharge port of the granulation chamber. These particles will pass through a screening device, usually a rotating screen or vibrating screen, to remove particles that are too small or too large, ensuring uniform particle size in the final product.

Post processing:

Drying: The screened particles may need to enter a dryer to remove excess moisture added during the granulation process, ensuring the stability and storage performance of the particles.

Cooling: Dried particles may need to be cooled to reduce temperature and prevent possible clumping or deterioration during subsequent processing.

Packaging: The cooled particles can undergo final packaging for sale or storage.

The workflow of the rotary drum granulator is a highly integrated and automated continuous production process, and the design of each link and the adjustment of operating parameters have a significant impact on the quality and production efficiency of the final product. By precisely controlling the mixing of raw materials, the amount of moisture/binder added, the rotation speed and tilt angle of the cylinder, etc., granular products that meet specific needs can be produced.

The rotary drum granulator has demonstrated significant advantages in multiple industries due to its unique design and efficient granulation performance, including:

High granulation efficiency:

The rotary drum granulator can quickly convert powder or fine granular materials into uniform and dense particles. Its continuous production mode and efficient material processing capacity make the granulation process fast and high-yield.

Strong adaptability:

This device is capable of processing various types of raw materials, including but not limited to dry powder, wet powder, organic and inorganic materials. It has good adaptability to the humidity and viscosity of raw materials, and can adjust granulation parameters according to different raw material characteristics to achieve the best granulation effect.

Controllable granulation effect:

By adjusting parameters such as the rotation speed, tilt angle, water spray system, and raw material feeding rate of the drum, the size, shape, and density of particles can be flexibly controlled to meet the specific needs of different products.

Relatively low energy consumption:

The rotary drum granulator utilizes the natural process of physical rolling and chemical bonding for granulation. Compared to other granulation technologies such as high-pressure extrusion granulation, it has lower energy consumption and is more economical and environmentally friendly.

Easy operation and maintenance:

The equipment structure design is reasonable, the operating interface is friendly, and it is easy for operators to control and monitor the granulation process. Meanwhile, the maintenance of the rotary drum granulator is relatively simple, easy to clean and maintain, which helps to extend the service life of the equipment.

Stable particle quality:

By precisely controlling the granulation process, particles with uniform particle size, moderate hardness, and good flowability can be produced. These particles have good physical and chemical stability, which is conducive to storage and transportation.

Wide applicability:

The rotary drum granulator is not only widely used in industries such as fertilizers, chemicals, and food, but also has important applications in pharmaceuticals, environmental protection, minerals, and other fields. Its wide applicability makes it the preferred equipment for granulation processes in many industries.

High cost-effectiveness:

Although the initial investment may be high, the high production efficiency, low operating costs, and long-term stability of the rotary drum granulator make it cost-effective in long-term operation, which can bring high returns to manufacturers.

In summary, the rotary drum granulator plays an important role in many industrial fields due to its high efficiency, strong adaptability, controllable granulation effect, and low energy consumption. It is one of the key equipment for achieving large-scale production of granular products.