fertilizer production line

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.

Compost turner machine, NPK fertilizer manufacturing process, organic fertilizer manufacturing process, crusher, mixer, screening machine are our main products. The chain plate compost turning machine has unique advantages in the production of organic fertilizer. The following is its instructions.

1. Chain plate compost turning machine is suitable for large-scale fermentation tanks with high and wide tanks, which can save composting workshop area and reduce civil engineering investment. The traditional trough type overturning and throwing machine is generally suitable for the height of 0. 8~1。 5 m fermentation tank, and the machine is suitable for height 1. 5~2。 It can meet the requirements of large-scale and wide tank operation. Compared with small-scale fermentation tank, the area of composting workshop can be reduced by 40 ~ 60%, and the construction cost of fermentation tank can be reduced by at least 1 / 3.

2. The chain compost turning machine adopts the supporting plate structure of chain drive and rolling support, which has small turning resistance, energy saving and is suitable for deep groove operation. The tipping support plate is equipped with flexible tension and elastic damping system to protect the transmission system and working parts for efficient operation. Through the horizontal and longitudinal shifting mechanism, the overturning parts can be operated in any position in the same fermentation tank, which improves the operation flexibility and reduces the installation capacity and power distribution requirements of the matching motor.

3. Compost turner machine is equipped with a strong and stable hydraulic lifting system to lift the overturning parts. At the beginning and end of turning, the hydraulic lifting system can be used to realize the lifting and lowering of tipping components easily through remote control or field operation, which is stable, reliable and fast.

4. The control cabinet is used to control the operation of the whole machine, and the manual control and automatic control are combined. The machine can be remotely controlled to move forward, move horizontally, flip and retreat quickly. Field operators don’t have to work at random, they can complete all operations by remote control at one end or far away of fermentation tank, which greatly improves the field environment of organic fertilizer manufacturing process.

Drum granulator is a granulation equipment widely used in the fertilizer, chemical, food and other industries. Its working principle is based on the combination of physical and chemical processes, mainly completed through the following steps:

Raw material mixing and pretreatment:

Firstly, various raw materials (such as nitrogen, phosphorus, and potassium compounds in NPK fertilizers) are mixed in a certain proportion. The raw materials may need to be crushed, sieved, or pre dried to ensure their uniform dispersion during the granulation process.

Granulation process:

The raw materials enter the cylindrical granulation chamber of the rotary drum granulator, which is composed of a tilted and slowly rotating cylinder. The raw material forms a spiral motion under the action of the rotational force and centrifugal force of the cylinder.

In the granulation room, the raw materials are evenly sprayed with appropriate amount of water or binder through the spray system. The function of water or binder is to enhance the cohesion between particles and promote the aggregation of small particles into larger ones. This process is called “drum granulation” or “rotary granulation”.

Particle growth and solidification:

As the cylinder rotates, small particles gradually grow through rolling and collision. Moisture or binders allow the components in the raw materials to adhere at the contact points, forming a more stable structure.

During the granulation process, the size and shape of the particles can be controlled by adjusting the rotation speed of the cylinder, the water spray system, and the feeding rate of the raw materials. The longer the particles roll inside the cylinder, the larger the particle size will generally be.

Particle screening and post-processing:

After granulation is completed, the particles are passed through a sieve or screening device at the end of the cylinder to remove oversized or undersized particles, ensuring uniform particle size in the final product.

The particles may also need to be dried to remove excess moisture and prevent clumping during storage and transportation. In some cases, cooling, polishing, or coating treatment may also be necessary to improve the hardness and stability of the particles.

The working principle of a rotary drum granulator is to use the combination of physical motion (such as rotation and rolling) and chemical action (such as the addition of moisture or binders) to form uniform and stable particles of raw materials. This process can not only improve the efficiency of raw material utilization, but also customize the size, shape, and hardness of particles according to specific needs to meet the needs of different industries and applications.

Drum granulator is a device that utilizes physical and chemical principles to process powder or fine granular materials into larger and more uniform particles. Its working principle mainly includes the following steps:

Raw material preparation:

The raw materials are first sent to the granulator, which can be dry powder, wet powder, or pre treated materials. The initial state and composition of the raw materials will affect the parameter settings of the subsequent granulation process.

Entering the drum:

The raw materials enter the cylindrical granulation chamber of the rotary drum granulator through the feeding port. The granulation chamber is usually a tilted cylinder, which may be equipped with lifting plates, blades, or other structures inside to promote the rolling and mixing of materials.

Humidification and bonding:

In the granulation room, evenly spray appropriate amount of water or binder to the raw materials through the spray system. The addition of water or binder is crucial in the granulation process, as their function is to bond the particles in the raw material together and form larger particles. The amount of humidification and the type of binder need to be precisely controlled based on the characteristics of the raw materials and the properties of the target particles.

Rolling granulation:

As the granulation chamber rotates, the material rolls inside, and small particles aggregate into larger particles under the action of moisture or binder. The inclination angle and rotation speed of the cylinder can be adjusted to control the size and shape of the particles. By combining physical rolling and chemical bonding, the material gradually forms the required particles.

Particle screening:

After granulation is completed, the particles are discharged through the discharge port of the granulation chamber. These particles are usually subjected to a screening device, such as a vibrating screen or a rotary screen, to remove particles that are too small or too large, ensuring uniform particle size in the final product.

Post processing:

The screened particles may require further processing, such as drying, to remove excess moisture added during the granulation process and avoid clumping during storage or transportation. In some cases, cooling, polishing, or surface treatment may also be necessary to improve the physical properties of the particles.

The workflow of a rotary drum granulator is a continuous process, which can produce granular products with specific physical and chemical properties by precisely controlling parameters such as raw material mixing, humidification amount, cylinder rotation speed, and tilt angle. This process is not only applicable to industries such as fertilizers, chemicals, and food, but also has a wide range of applications in agriculture, pharmaceuticals, and environmental protection.