NPK Compound Fertilizer Production Line Equipment Compound Fertilizer Granulation Line

NPK  Compound fertilizer production line introduction

            A complete set of NPK composite fertilizer production line usually includes raw material handling equipment, batching and mixing equipment, granulation equipment, drying and cooling equipment, screening equipment, coating equipment, packaging equipment and so on, the following is the specific introduction:

1. Raw Material Handling & Preparation System

1.1 Storage & Feeding Equipment

• Batching System :

◦ The batching system is a set of equipment and control systems used for weighing two or more raw materials in a specific proportion. It is mainly used for proportionally dispensing three, four, or even more types of raw materials through weighing and control systems..

•Raw Material Silos :

◦ Constructed from Q345 steel or reinforced concrete, equipped with anti-caking agitators and level sensors, suitable for storing urea (N), diammonium phosphate (DAP, P), potassium chloride (KCl, K), and additives (micronutrients, attapulgite). Silo capacity typically ranges from 50–500 m³ based on 8–12 hours of production demand.

• Precision Feeding Devices :

◦ Frequency-controlled Screw Feeders : Stainless steel screws with 10–30 rpm rotation for granular materials (eg, urea), accuracy ±0.5%.

◦ Vibrating Feeders with Weighing Bins : For powdery materials (eg, superphosphate), integrated with PLC-controlled weighing systems (error ≤ 0.3%) and dust suction ports.

1.2 Crushing & Screening Equipment

• Crushers :

◦ Jaw Crushers (PE Series) : Primary crushing for raw phosphate rock, reducing particle size from ≤150 mm to <25 mm.

◦ Vertical Shaft Impact Crushers (VSI) : Secondary crushing for fine particles (<5 mm), suitable for hard materials like potassium sulfate.

• Linear Vibrating Screens :

◦ 3-layer mesh screens (aperture 0.5–5 mm) to separate oversize particles, with recycling conveyors for re-crushing.

2. Mixing & Batching System

2.1 Intensive Mixing Equipment

• Twin-Shaft Paddle Mixer (JS Series) :

◦ Double-shaft counter-rotating paddles with wear-resistant alloy linings, mixing time 3–8 minutes, uniformity coefficient ≥95%. Suitable for batches of 1–5 tons.

• Rotary Drum Mixer (DZM Series) :

◦ Diameter 2–4 m, length-to-diameter ratio 4:1, with internal lifting blades and steam spraying for humidification. Ideal for continuous production (50–200 tons/hour), equipped with anti-corrosion rubber linings.

3. Granulation System (Key Process)

3.1 Mechanical Granulation Equipment

• Drum Granulator (ZG Series) :

◦ Rotating drum (length 10–20 m, diameter 2–3 m) with spray nozzles and steam jacket, forming granules via rolling agglomeration. Output: 8–30 tons/hour, particle size 2–8 mm, sphericity ≥80%.

• Disc Granulator (PG Series) :

◦ Inclined disc (diameter 2–5 m, angle 45–55°), rotating at 10–20 rpm. Suitable for high-phosphate formulas, with granulation efficiency 75–85%, adjustable particle size via disc speed and inclination.

• Extrusion Granulator (DZJ Series) :

◦ Screw extrusion type, working pressure 5–10 MPa, for dry granulation (moisture <8%). Ideal for high-NPK formulas (eg, 25-15-15), producing dense granules with hardness 2–5 N.

3.2 Special Process Equipment

• Prilling Tower (for melt granulation) :

◦ Height 30–50 m, with melt spray nozzles and countercurrent cooling air. Applicable for high-concentration NPK (eg, 30-5-5), requiring urea melting tanks (temperature 130–150°C) and vacuum systems.

4. Drying & Cooling System

4.1 Rotary Dryer

• Three-Cylinder Dryer :

◦ Inner cylinder diameter 1.2–2 m, outer cylinder 2.5–4 m, hot air temperature 350–500°C. Reduces moisture from 12–18% to <1.5%, thermal efficiency ≥75%, fuel options: coal, natural gas, or biomass pellets.

• Fluidized Bed Dryer :

◦ Suitable for fine granules (<3 mm), with air velocity 1.5–3 m/s, drying time 5–10 minutes, and low dust emission (≤30 mg/m³).

4.2 Cooling Equipment

• Rotary Cooler :

◦ Similar structure to the dryer, using ambient air or forced ventilation to cool granules from 60–80°C to ≤35°C, preventing caking during storage.

5. Screening & Coating System

5.1 Multi-Layer Screening Machine

• Circular Vibrating Screen (YK Series) :

◦ 4-layer screens (aperture 1–6 mm) to separate undersize (<2 mm), qualified (2–4 mm), and oversize (>4 mm) particles. Oversize materials are sent to a crusher for recycling, with screening efficiency ≥90%.

5.2 Anti-Caking Coating Machine

• Drum Coater :

◦ Rotating drum with mist sprayers for coating agents (eg, talc, mineral oil), reducing surface moisture to <0.5% and preventing agglomeration.

6. Packaging & Control System

6.1 Quantitative Packaging Equipment

• Automatic Bagging Machine :

◦ Weighing range 25–50 kg/bag, accuracy ±0.2%, with sewing machines and metal detectors. Production speed: 40–80 bags/hour.

• Bulk Loading System :

◦ For large-scale shipments, equipped with belt conveyors and truck loaders, capacity 50–100 tons/hour.

6.2 Central Control System

• PLC + HMI Control Panel :

◦ Siemens S7 or Mitsubishi Q series PLC, monitoring real-time data (material flow, temperature, humidity), with fault alarms and production report generation.

7. Auxiliary Systems

• Dust Collection System :

◦ Bag filter (filtration efficiency ≥99.5%) and induced draft fans, maintaining workshop dust concentration <10 mg/m³.

• Steam Generation System :

◦ 2–10 t/h industrial boilers (gas/coal-fired), providing saturated steam (pressure 0.5–0.8 MPa) for granulation and drying.

• Water Treatment System :

◦ Circulating cooling water towers for equipment cooling, water reuse rate ≥90%.

Technical Parameters & Configurations

        This description integrates engineering practice, technical specifications, and industry standards, suitable for production line design, equipment procurement, or technical documentation.

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FAQ

Q: What are the typical raw materials used in this production line?
A: The raw materials used in the Organic Fertilizer Granules Production Line include compost manure, farm waste, city garbage, and other organic materials.
Q: What is the capacity range of this production line?
A: The capacity of the Organic Fertilizer Granules Production Line ranges from 1 to 300 tons per hour.
Q: What is the maximum allowable humidity level for raw materials in this production line?
A: The maximum allowable humidity level for raw materials in the Organic Fertilizer Granules Production Line is ≤30%.
Q: Is this production line automated?
A: Yes, the Organic Fertilizer Granules Production Line is fully automatic, minimizing manual intervention and maximizing efficiency.
Q: What are the key steps involved in the production process?
A: The production process of the Organic Fertilizer Granules Production Line includes crushing, mixing, granulating, screening, and packaging.
Q: What is the shape of the granules produced by this production line?
A: The granules produced by the Organic Fertilizer Granules Production Line have a ball-type shape.