NPK fertilizer production line utilizes roller extrusion granulator to process fertilizers

fertilizer granulator May 6, 2025

The roller extrusion granulator in the fertilizer production line creates high-strength fertilizer particles in its unique way.

The pre treated mixed fertilizer material is orderly fed into the extrusion granulator. The powerful pressure device inside the granulator begins to operate, exerting enormous pressure on the material. Under this powerful force, the material is forced to pass through specific shaped mold holes. At the moment when the material is extruded from the mold, a columnar shape is formed, and then the cutting device precisely cuts it into particles of appropriate length.

The fertilizer granules produced by the roller extrusion granulator have remarkable high strength. This is due to the high-pressure extrusion process, which greatly compresses the distance between material molecules and makes the internal structure of particles more compact. This high-strength particle performs well during storage and transportation, and is less prone to breakage and pulverization, effectively ensuring the quality and nutrient content of fertilizers.

In addition, a major advantage of the roller extrusion granulator is its ability to accurately control the shape and size of particles. By simply changing different molds, various shapes and specifications of fertilizer granules can be produced, fully meeting the diverse needs of different users and markets. Whether it is special agricultural planting needs or specific requirements for fertilizer granules in industrial applications, extrusion granulators can handle them with ease.

Moreover, the roller extrusion granulator has high production efficiency and can work continuously and stably, producing a large amount of fertilizer particles per hour. At the same time, it has strong adaptability to raw materials, and can smoothly carry out granulation processing for both organic and inorganic materials. In the fertilizer production line, the roller extrusion granulator provides a solid guarantee for producing high-quality and diversified fertilizers with its high efficiency, precision, and durability, driving the fertilizer production industry to constantly reach new heights.

Efficient Production Process of NPK Fertilizer Production Line

fertilizer granulator May 6, 2025

As an important input for modern agricultural production, the production process of NPK fertilizer is crucial to ensuring the quality of fertilizer and production efficiency. This NPK fertilizer production line covers multiple closely connected links, each of which has a significant impact on the quality of the final product.

The process begins with the preparation of raw materials. The main raw materials required for producing NPK fertilizers include nitrogen-containing compounds (such as urea and liquid ammonia), phosphorus containing ores (such as apatite), and potassium salts (such as potassium chloride and potassium sulfate). These raw materials are first transported to the storage area and await further processing. At this stage, precise raw material quality testing and inventory management are crucial to ensure the stability of subsequent production.

Raw material pretreatment is the second step. Raw materials with high hardness such as phosphate ore need to be crushed by a fertilizer crusher to reduce their particle size to a suitable range, so that subsequent reactions can proceed more fully. At the same time, in order to remove impurities from the raw materials, screening and magnetic separation methods will be used to ensure that the purity of the raw materials entering the next stage meets the standard.

The mixing process is one of the core components of NPK fertilizer production. Various pre processed raw materials are transported to high-efficiency mixing equipment according to specific formula ratios. Here, different raw materials are fully blended to ensure even distribution of nitrogen, phosphorus, potassium, and other trace elements. Accurate formula control and efficient mixing operations are key to ensuring nutrient balance in fertilizers.

The mixed material enters the granulation stage. Common granulation methods include disc granulation and extrusion granulation. The disc granulator rotates the disc to gradually aggregate the material into granules under the action of centrifugal force and friction force; Squeezing granulation is the process of using pressure to extrude materials through a mold into a shape. The granulation process determines the shape, size, and strength of fertilizer particles, directly affecting the effectiveness and storage performance of fertilizers.

After the particles are formed, they need to be dried. By using a dryer and hot air to remove excess moisture from particles, the stability and storage period of fertilizers are enhanced. The drying temperature and time need to be strictly controlled to avoid affecting the nutrient content of the fertilizer.

The cooling process follows closely behind, rapidly reducing the particle temperature through air or water cooling, further improving the physical properties of the particles.

The next step is the screening process, which uses equipment such as vibrating screens to screen out qualified particles that meet the particle size requirements. Particles that do not meet the standards will be separated, or re crushed and mixed, or processed separately.

Finally, there is the packaging process. The fertilizer particles that have passed the inspection are transported to the automatic packaging machine, packaged according to the specified weight, labeled, and can enter the market for circulation.

The process flow of NPK fertilizer production line, from raw material preparation to finished product packaging, is closely connected and indispensable at every step. Only through scientific and rational process design and strict quality control can high-quality fertilizers that meet agricultural needs be produced.

Common granulation equipment used in fertilizer production lines during granulation

fertilizer granulator May 6, 2025

Granulation equipment is the core part of fertilizer production lines, which endows fertilizers with appropriate particle shapes and has a significant impact on the performance, storage, and transportation of fertilizers.

Disc granulator is one of the common granulation equipment. During work, the disc continuously rotates, and the material gradually aggregates and grows into particles at the edge of the disc under the combined action of centrifugal force, friction force, and gravity. The particles produced by the disc granulator are round and relatively uniform in size, which can be more evenly distributed in the soil during fertilization, which is beneficial for crops to absorb nutrients. Moreover, the device has a simple structure, easy operation and maintenance, relatively low investment cost, and is suitable for use by small and medium-sized enterprises.

The extrusion granulator uses strong pressure to extrude the material from the mold into shape. This granulation method produces fertilizer particles with high density and strength, which are not easily broken or powdered during storage and transportation. Squeezing granulator can accurately control the shape and size of particles, meeting the special requirements of different users for fertilizer particle specifications. It is commonly used in the production of fertilizer products with high particle strength requirements.

The rotary drum granulator uses the rotation of the drum to make the material roll and collide inside to achieve granulation. It has high production efficiency and can continuously and stably carry out large-scale production. The rotary drum granulator has strong adaptability to raw materials and can handle various materials with different properties. By adjusting parameters such as drum speed and material humidity, the size and strength of particles can be flexibly controlled.

The fluidized bed granulator adopts fluidization technology. The material is in a fluidized state under the action of hot air, and the nozzle sprays a binder solution onto the material, causing the material particles to quickly bond into particles. The fluidized bed granulator has a fast granulation speed, produces fertilizer particles with good breathability and solubility, and has high energy utilization efficiency. By controlling relevant parameters, the particle characteristics can be accurately controlled.

The spray granulator first atomizes the fertilizer solution into tiny droplets. The droplets evaporate rapidly in the hot air environment, and the solute crystals agglomerate to form particles. It can produce fertilizer particles with highly uniform particle size, good particle flowability, and can handle special fertilizer formulas. The production process is relatively clean and suitable for producing high-end and fine fertilizers.

These granulation equipment have their own advantages. Fertilizer production enterprises can choose suitable granulation equipment based on their own production scale, product positioning, raw material characteristics, and other factors to produce high-quality fertilizer products that meet market demand.

How to use a disc granulator to process fertilizers in a fertilizer production line

fertilizer granulator May 6, 2025

In the fertilizer production line, the disc granulator is like a skilled “shaper”, endowing fertilizers with ideal shapes.

After various fertilizer ingredients are mixed according to precise formulas, they enter the disc granulator. The machine starts and the disc begins to slowly rotate. Under the clever action of centrifugal force, frictional force, and gravity, materials gradually gather at the edge of the disc. At first, these materials were just a loose collection, but as the disk continued to rotate, the materials kept rolling, and newly added materials continued to adhere to existing small particles, like rolling snowballs, gradually growing and forming.

The fertilizer particles produced by the disc granulator have regular shapes, mostly round spherical shapes. This perfect spherical particle has obvious advantages in the fertilization process, as it can be more evenly dispersed in the soil, ensuring a more balanced absorption of nutrients by crops. Moreover, the structure of the disc granulator is relatively simple, and the operation and maintenance are not complicated. For many fertilizer production enterprises, lower equipment costs and convenient maintenance methods greatly reduce the production threshold.

In actual production, operators can precisely control the size and strength of fertilizer particles by adjusting parameters such as the rotation speed of the disc, the rate of material addition, and humidity. For example, increasing the rotational speed of the disc appropriately can make the material move more vigorously on the disc, which helps to form smaller particles; Increasing the humidity of the material enhances the viscosity between particles, resulting in higher particle strength of the produced fertilizer.

The disc granulator occupies an important position in fertilizer production lines due to its unique granulation method and numerous advantages. It provides strong support for the production of high-quality and uniform fertilizers, meets the strict requirements of agricultural production for the physical form and quality of fertilizers, and is an indispensable key equipment in the fertilizer production process.

Equipment for raw material processing in NPK fertilizer production line

fertilizer granulator May 6, 2025

In the NPK fertilizer production line, raw material processing is a crucial initial step that directly affects the quality and performance of the final fertilizer. The efficient operation of this process relies on a series of sophisticated equipment, each performing its own duties and jointly laying the foundation for creating high-quality fertilizers.

Firstly, the crushing equipment for raw materials. Raw materials such as phosphate ore and potassium ore usually exist in block form, with large sizes, making it difficult to directly participate in the subsequent processing flow. Jaw crusher is a powerful assistant for processing such raw materials. It has strong crushing ability and can quickly crush large ores into smaller particles through the mutual compression between the moving jaw and the fixed jaw. Its structure is simple, sturdy and durable, and can adapt to long-term, high-intensity work, providing materials with suitable particle size ranges for subsequent processing.

After the raw materials are crushed, they need to be mixed and stirred to ensure the uniform distribution of various nutrients such as nitrogen, phosphorus, and potassium. The horizontal mixer plays an important role in this process. It has a unique helical structure, driven by the mixing shaft, the inner and outer helical belts respectively push the material to make axial and radial movements, forming complex convection and shear in the mixing drum, thus achieving rapid and sufficient mixing. Whether it is raw materials with different viscosities or various trace elements added, they can be uniformly blended in a horizontal mixer.

For some raw materials with high humidity, such as organic materials containing a certain amount of moisture, drying equipment is essential. Rotary dryer is one of the commonly used drying equipment, which uses high-temperature hot air to fully contact the material in the rotating cylinder, causing the moisture in the material to quickly evaporate. The temperature of hot air and the residence time of materials in the cylinder can be precisely controlled, which can ensure the drying effect and avoid the deterioration of raw materials or nutrient loss caused by excessive drying.

Magnetic separators and screening equipment play an important role in removing impurities from raw materials. Magnetic separators use magnetic force to adsorb magnetic impurities such as iron filings in raw materials, preventing them from entering subsequent processing stages, damaging equipment, or affecting fertilizer quality. The vibrating screen screens and grades the raw materials through different aperture screens, separating materials that do not meet the particle size requirements, or returning them to the crusher for further processing or other disposal to ensure that the particle size of the raw materials entering the next process is uniform and consistent.

In the NPK fertilizer production line, the raw material processing equipment works closely together to precisely control every step from crushing, mixing, drying to impurity removal and screening grading, providing a solid guarantee for the production of high-quality NPK fertilizers. It is an indispensable and important component of the entire production line.

Fertilizer mixing equipment commonly used in fertilizer production lines

fertilizer granulator May 6, 2025

In fertilizer production lines, mixing equipment plays a crucial role in ensuring the uniform fusion of various fertilizer raw materials, laying the foundation for the production of stable quality fertilizers.

The dual axis blade mixer is a classic mixing device. It has two shafts with special blades that rotate towards each other. During the rotation process, the blades push the material to make complex three-dimensional movements, causing strong convection and shear within the mixer. This unique exercise method can fully mix different fertilizer ingredients in a short period of time, even for materials with large density differences and different particle sizes, achieving efficient mixing.

Horizontal mixer is also one of the commonly used mixing equipment. The internal spiral belt structure is ingeniously designed, with the outer spiral belt pushing the material to move axially and the inner spiral belt promoting the material’s radial movement. Through this composite motion, the material continuously rolls and mixes inside the mixing drum, achieving uniform mixing. The horizontal screw belt mixer has a large mixing capacity and is suitable for large-scale fertilizer production, meeting the needs of different yields.

The plow blade mixer also performs well in fertilizer mixing. It is equipped with a high-speed rotating plow blade, which produces strong shearing and dispersing effects on the material during high-speed operation, allowing the material to mix quickly. At the same time, a flying knife device can be installed inside the mixer to further refine the materials and enhance the mixing effect. Plowing blade mixer is commonly used in fertilizer production scenarios that require high mixing uniformity, ensuring accurate distribution of various nutrients in the fertilizer.

The planetary mixer has attracted attention for its unique mixing method. The mixing shaft revolves around the central axis while also rotating on its own. This complex motion trajectory creates a comprehensive mixing effect for the material inside the mixing drum. The planetary mixer also has good mixing ability for fertilizers with high viscosity, which can effectively avoid material agglomeration and ensure mixing quality.

These mixing devices each have their own characteristics and are widely used in fertilizer production lines according to different production needs and raw material characteristics. They use efficient mixing to evenly distribute various nutrients such as nitrogen, phosphorus, and potassium in fertilizers, providing balanced nutrition for crops and being a key equipment to ensure fertilizer quality.

Roller extrusion granulator assists in efficient operation of fertilizer production line

fertilizer granulator May 6, 2025

The roller extrusion granulator is one of the key equipment for achieving efficient production of high-quality fertilizers in fertilizer production lines. Its working process reflects the strong mechanical pressure effect.

During fertilizer production, the pre treated mixed material is fed into the squeeze fertilizer granulator. The powerful pressure device inside the granulator exerts enormous pressure on the material, forcing it to pass through specific shaped mold holes. At the moment of passing through the mold, the material is squeezed into a cylindrical shape and then cut into particles of appropriate length by a cutting device.

The outstanding characteristics of the roller extrusion granulator make it highly favored in the field of fertilizer production. On the one hand, the fertilizer particles it produces have high strength. This is because during the high-pressure extrusion process, the distance between material molecules is greatly compressed, resulting in a tight internal structure of the particles. High strength particles are less prone to breakage and pulverization during storage and transportation, ensuring the quality and nutrient content of fertilizers. On the other hand, extrusion granulation can precisely control the shape and size of particles. By replacing different molds, various shapes and specifications of fertilizer granules can be produced to meet the diverse needs of different users and markets.

In addition, the production efficiency of the roller extrusion granulator is relatively high. It can work continuously and stably, producing a large amount of fertilizer particles per hour. Moreover, the granulator has strong adaptability to raw materials, and can effectively process both organic and inorganic materials.

In the fertilizer production line, the squeeze fertilizer granulator provides reliable guarantee for the production of high-quality and diversified fertilizers with its high efficiency, precision, and durability, promoting the continuous development and progress of the fertilizer production industry.

Raw materials and equipment required for NPK fertilizer production line to process fertilizers

fertilizer granulator May 6, 2025

NPK fertilizer, as an essential element in agricultural production, provides three key nutrients: nitrogen (N), phosphorus (P), and potassium (K) for the healthy growth of crops. An efficient NPK fertilizer production line relies on high-quality raw materials and advanced equipment, which work together to ensure the quality and yield of fertilizers.

The raw materials for NPK fertilizer production line are abundant and diverse. Common nitrogen fertilizer raw materials include liquid ammonia, urea, etc. Liquid ammonia has a high nitrogen content and is an efficient nitrogen source that can quickly provide nitrogen elements for fertilizers in production; Urea has good chemical stability and solubility, and is easily absorbed by crops. It is widely used in the manufacture of various NPK fertilizers. The main raw material for phosphate fertilizer is phosphate rock, which undergoes a series of processing and transformation into intermediate products such as phosphoric acid, ultimately becoming the effective phosphorus component in fertilizers. Potassium salt is the main source of potassium fertilizer, such as potassium chloride, potassium sulfate, etc. They provide necessary potassium elements for physiological processes such as crop growth and development, enzyme activity regulation, etc. In addition, in order to improve the comprehensive performance of fertilizers, some auxiliary materials such as fillers and binders will be added. Fillers can improve the physical properties of fertilizers, making them easier to store and apply; Adhesive helps to shape fertilizer particles, ensuring their strength and stability.

In terms of equipment, the NPK fertilizer production line covers professional equipment for multiple key links. In the raw material pretreatment stage, the fertilizer crusher is used to crush block shaped phosphate ore and other raw materials to meet the particle size requirements for subsequent processing; Mixing equipment such as horizontal mixers can thoroughly and evenly mix various raw materials to ensure consistent nutrient distribution. The granulation process is the core of the production line, and common granulators include disc granulators, extrusion granulators, etc. The disc granulator rotates the disc to agglomerate the material into granules under the action of centrifugal force and friction, producing particles that are relatively round; The extrusion granulator relies on strong pressure to extrude the material from the mold into particles with high particle strength. After the fertilizer is formed, the dryer is used to remove moisture from the particles, enhance the stability and storage period of the fertilizer; The cooling machine rapidly reduces the particle temperature and improves the physical properties of the particles. The screening equipment can screen out finished particles that meet the particle size requirements, and unqualified particles can be returned for reprocessing. Finally, the packaging equipment achieves automated packaging of fertilizers, improving production efficiency.

The raw materials and equipment of NPK fertilizer production line complement each other. High quality raw materials are the foundation, providing necessary nutrients for fertilizers; Advanced equipment is the guarantee, which transforms raw materials into high-performance and reliable NPK fertilizers through scientific processing, meeting the diverse needs of agricultural production.

Raw material processing equipment in the fertilizer production line for processing fertilizers

fertilizer granulator May 6, 2025

In fertilizer production lines, raw material processing equipment is the foundation and key presence, laying a good foundation for subsequent production processes.

Firstly, the fertilizer grinder. The raw materials for fertilizer production, such as phosphate ore, potassium ore, etc., often exist in large chunks and require fertilizer crushers to reduce their particle size. Jaw crusher is widely used, which compresses and crushes materials through the relative motion of moving and fixed jaws. The powerful crushing force can easily handle ores with high hardness, crushing them into suitable sizes for subsequent processing.

Next is screening equipment, with vibrating screening machines being a common type. The crushed material is screened through a vibrating screen, and particles of different sizes can be separated by screens with different apertures. Particles that meet the requirements enter the next process, while oversized particles are returned to the fertilizer crusher for further processing to ensure uniform particle size of the raw materials entering the mixing stage, which helps to improve the uniformity of fertilizer mixing.

Magnetic separator is also an indispensable equipment in raw material processing. In the raw materials, there may be some magnetic impurities mixed in, such as iron filings. Magnetic separators use magnetic force to adsorb these magnetic impurities, preventing them from entering subsequent equipment and avoiding equipment wear or affecting fertilizer quality.

For raw materials with high humidity, drying equipment can play an important role. The rotary dryer quickly evaporates the moisture in the material by fully contacting it with high-temperature hot air. The temperature of the hot air and the residence time of the material inside the cylinder can be adjusted, which can effectively control the degree of drying, ensure the drying effect of the raw materials, and avoid nutrient loss.

There is also a raw material conveyor, which is responsible for transporting various raw materials from the storage area to various processing stages. Belt conveyor is a commonly used type, which has the advantages of large conveying capacity, stable operation, and easy operation. It can efficiently and reliably complete the conveying task of raw materials, ensuring the continuous operation of the production line.

These raw material processing equipment cooperate with each other, from crushing, screening, impurity removal, drying to transportation, every step is closely connected, ensuring that the quality and condition of the raw materials entering the core link of fertilizer production are qualified and suitable, providing a solid guarantee for the production of high-quality fertilizers and an important support for the normal operation of fertilizer production lines.

Application of disc granulator in fertilizer production line granulation

fertilizer granulator May 6, 2025

In the fertilizer production line, the disc fertilizer granulator plays an important role. Its working principle is based on the motion characteristics of materials on a rotating disk.

After the various raw materials required for fertilizer production are mixed evenly in proportion, they are transported to the disc granulator. The disc begins to rotate, and the material gradually gathers at the edge of the disc under the combined action of centrifugal force, frictional force, and gravity. As the disk continues to rotate, the material keeps rolling, and the newly added material adheres to the already formed small particles, gradually growing in size.

The disc fertilizer granulator has many advantages. Firstly, the fertilizer particles it produces have regular shapes, mostly round spherical shapes. These shaped particles are more easily dispersed evenly in the soil during fertilization, which is beneficial for the balanced absorption of nutrients by crops. Secondly, the structure of the granulator is relatively simple, and it is easy to operate and maintain. For some small-scale fertilizer production enterprises, lower equipment costs and maintenance difficulties lower the production threshold.

In actual production, operators can control the size and strength of fertilizer particles by adjusting parameters such as the rotation speed of the disc, the rate of material addition, and humidity. For example, increasing the rotational speed of the disc appropriately can make the material move more vigorously on the disc, which helps to form smaller particles; Increasing the humidity of the material can enhance the viscosity between particles, thereby producing fertilizer particles with higher strength.

The disc fertilizer granulator, with its unique granulation method and many advantages, plays an irreplaceable role in fertilizer production lines, providing strong support for the production of high-quality and uniform fertilizers, and meeting the requirements of agricultural production for the physical form and quality of fertilizers.