Scale: Small, Medium, Large
Daily Production Capacity: 5-10t/d, 10-50t/d, 50-100t/d
Floor Area: 500-800m2, 1000-2000m2, 2500m2
Processed Raw Materials: Nitrogen, phosphorus, and potassium sources, supplemented with binders such as bentonite and additives such as trace elements.
1. Raw Material Pretreatment System: Includes a crusher and screener.
2. Batching and Mixing System: Consists of an automatic batching system and a mixer.
3. Granulation System: The core equipment is the granulator, with common types including drum granulators, disc granulators, and extruder granulators.
4. Drying and Cooling System: Includes a dryer and cooler.
5. Cooler: Rapidly cools hot granules to near room temperature, with a temperature difference of ≤5°C, facilitating subsequent processing.
6. Screening and Packaging System: Consists of a grading screen and an automatic packaging line.
7. Environmental Protection System: Typically uses a cyclone dust collector and a pulse bag filter to remove coarse and fine dust.
The NPK compound fertilizer production line has a clear and well-organized process flow, primarily encompassing the following steps:
1. Raw Material Pretreatment: Nitrogen, phosphorus, and potassium sources are individually pulverized to the specified fineness, then screened to remove impurities, ensuring pure, uniform particle size.
Ingredient Mixing: According to the pre-set fertilizer formula, an automated batching system accurately weighs each ingredient. The ingredients are then fed into a mixer for thorough mixing to ensure uniform nutrient distribution.
2. Granulation: The mixed powdered material is fed into a granulator, where it is formed into granules with a diameter of 2-5mm using methods such as drum tumbling, disc rotation, or extrusion, with the addition of an appropriate amount of steam or water as a binder.
3. Drying and Cooling: After granulation, the wet granules enter a dryer, where hot air reduces the moisture content to ≤2%. They then enter a cooler, where heat exchange with cold air cools them down to near-room temperature while further removing trace moisture.
4. Screening and Packaging: The cooled granules are screened and separated. Large particles are returned to the crusher for further processing, while fine powder is returned to the granulation stage for reuse. Qualified granules are then packaged in fixed quantities on an automated packaging line, completing the finished product.
Advantages of the NPK compound fertilizer production line:
1. Comprehensive and balanced nutrients:
The product contains nitrogen, phosphorus, potassium, and trace elements, meeting the diverse nutritional needs of crops during growth, reducing fertilization frequency and improving planting efficiency.
2. Flexible and diverse formulas:
The ratios of nitrogen, phosphorus, potassium, and other elements can be flexibly adjusted to meet the needs of different crops, soil types, and planting stages, creating customized formulas with high specificity.
3. Excellent physical properties:
The granular product has good flowability, facilitating mechanized fertilization and reducing labor costs. The granules are strong and resistant to breakage and clumping, making them easy to store and transport.
4. High degree of automation:
From raw material batching to finished product packaging, the entire process is PLC-controlled, reducing manual intervention, improving production efficiency, and ensuring consistent product quality.
5. Efficient resource utilization:
Rejected granules and fines generated during the production process can be recycled, reducing raw material waste and lowering production costs.
Comparison Dimension | Small production line | Medium-sized production line | Large production line |
Hourly output | 1-5 tons | 5-20 tons | 20+ tons |
Degree of automation | The degree of automation is low and relies on manual operation. | Some key links are automated and labor costs are moderate. | The entire process is automated, with the PLC control system controlling each link, and manual work is only responsible for equipment inspection and maintenance. |
Product quality | The stability is slightly poor, and there are fluctuations in particle uniformity and nutrient consistency. | The product is relatively stable, with good indicators such as particle uniformity and strength, and can meet most market demands. | The product quality is high and stable, with round particles, high strength, and precise and uniform nutrients, and can be used to produce high-end and special compound fertilizer products. |
Applicable Scenarios | Suitable for small fertilizer plants and regional agricultural input enterprises, meeting the needs of surrounding small-scale markets | It is suitable for medium-sized fertilizer companies and can provide common compound fertilizer products for field crops and cash crops. | It is used by large fertilizer groups to meet the needs of large-scale agricultural planting and diversified markets. |
Floor space | 500㎡ | 500-2000㎡ | 2000㎡+ |
What are the processes and characteristics of the granulation process?
Drum granulation: Suitable for large-scale production, with high granule roundness and strength, but requiring a high equipment investment.
Disc granulation: Simple structure, low energy consumption, suitable for small production lines or frequent formulation adjustments, with limited production capacity.
Extrusion granulation: No water addition is required, making it suitable for sensitive formulations such as those containing high urea. However, the granule appearance is slightly inferior, and maintenance costs are higher.
How can we ensure uniform nutrient content in compound fertilizers?
Raw materials are crushed and screened to 80-100 mesh to ensure uniform particle size. A PLC-controlled automatic batching system accurately controls the amount of material. A high-efficiency mixer ensures a uniformity of over 95%. Regular sampling and calibration parameters are conducted.
What are the raw material requirements for the production line? What are the consequences of unstable raw material quality?
The production line requires raw materials of high purity and low impurities. Raw materials should be of moderate particle size, generally crushed to 80-100 mesh, to facilitate mixing and granulation. Unstable raw material quality can make it difficult to precisely control the formulation, leading to fluctuations in the nutrient content of the product and affecting fertilizer efficiency.
How are the waste gas, wastewater, and waste residue generated during the production process handled?
①Waste gas: Dust is recovered using a pulse dust collector, and hot air furnace exhaust undergoes desulfurization and denitrification treatment.
②Wastewater: Sedimentation, filtration, and biochemical treatment are followed before reuse or discharge.
③Waste residue: Unqualified particles and waste dust can be landfilled, while nutrient-rich residue can be used for soil improvement.
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