fertilizer production line

How to balance efficiency and energy consumption when choosing a fertilizer grinder

fertilizer granulator Aug 23, 2024

When choosing a fertilizer grinder, balancing efficiency and energy consumption is a key decision point as it directly affects production costs and environmental impact. Here are some strategies to help you find the best balance between efficiency and energy consumption:

Choose high-efficiency and energy-saving equipment: There are specialized crushers on the market designed to improve energy efficiency, which typically use advanced technologies such as optimized mechanical design, energy-saving motors, intelligent control systems, etc., to reduce energy consumption while maintaining high crushing efficiency.

Material pretreatment: Proper pretreatment of materials, such as pre drying, pre screening, etc., before entering the crusher can reduce energy consumption during the crushing process. Pre processed materials are easier to crush, thereby reducing the load and energy consumption of the crusher.

Adjust operating parameters: Based on material characteristics and production needs, adjust the operating parameters of the crusher, such as speed, feed rate, etc., to optimize crushing efficiency and energy consumption. Usually, higher rotational speeds can improve crushing efficiency, but they can also increase energy consumption and require finding the optimal balance point.

Maintenance and optimization: Regular maintenance and optimization of fertilizer crushers, such as cleaning, lubrication, and replacement of worn parts, can maintain the optimal operating state of the equipment and avoid energy consumption increases caused by equipment failures or performance degradation. Regular performance checks and adjustments are conducted to ensure that the equipment operates in an efficient and energy-saving state.

Adopting energy-saving technologies: By utilizing energy-saving technologies such as variable frequency speed regulation and heat recovery systems, energy consumption can be further reduced. For example, variable frequency speed regulation technology can adjust the motor speed according to actual needs to avoid energy waste.

Life cycle cost analysis: In the decision-making process, in addition to considering initial investment costs, a life cycle cost analysis should also be conducted, including equipment operating costs, maintenance costs, and energy consumption costs. Choose equipment with high initial investment but low long-term operating costs and energy consumption.

Environmental and safety standards: Ensure that the selected equipment complies with local environmental and safety standards, avoiding additional costs or fines due to non-compliance.

Through the above strategies, it is possible to effectively control energy consumption while ensuring the crushing efficiency of fertilizer crushers, achieving dual benefits of economy and environment. Continuous monitoring and optimization are key when selecting and using crushers to adapt to changes in production conditions and maintain optimal equipment performance.

How to adjust the speed of fertilizer granulator to improve granulation efficiency

fertilizer granulator Aug 23, 2024

The speed regulation of fertilizer granulator is one of the key factors to improve granulation efficiency and particle quality. The correct speed setting can optimize the granulation process, but too low or too high a speed can affect the granulation effect. Here is a guide on how to improve granulation efficiency by adjusting the speed of the granulator:

Understand the relationship between rotational speed and granulation efficiency:

When the speed is low, the mixing and rolling effect of materials inside the fertilizer granulator is poor, which may lead to slow particle formation and low granulation efficiency.

When the rotation speed is high, although it can accelerate the rolling and mixing of materials, excessive rotation speed may lead to increased wear between particles, affecting the integrity and strength of particles, and increasing the energy consumption and wear of equipment.

Determine the optimal speed range:

Determine the optimal speed range suitable for specific material characteristics and production needs through experiments or reference to equipment manufacturers’ recommendations. This usually requires consideration of factors such as material particle size, humidity, and adhesion.

Some granulators, such as drum granulators, may have an optimal speed between 60% and 70% of the critical speed, which helps the material form the best parabolic motion inside the granulator and promotes particle formation.

Gradual adjustment:

During the production process, the speed of the granulator can be gradually adjusted to observe changes in particle quality and production efficiency. By fine-tuning the speed, find the speed point that can improve granulation efficiency without affecting particle quality.

When adjusting, it is recommended to only increase or decrease the speed by a certain proportion each time to avoid significant changes that may have adverse effects on the granulation process.

Monitoring and feedback:

Real time monitoring of the operating status of the fertilizer granulator using sensors and monitoring systems, including parameters such as speed, temperature, pressure, as well as quality indicators such as particle shape, size, and density.

Adjust the speed in a timely manner based on monitoring data and production requirements to maintain the stability and efficiency of the granulation process.

Consider changes in material characteristics:

The characteristics of materials, such as humidity and particle size, may change during the production process. Therefore, the adjustment of speed should take into account these changes to adapt to different batches or types of raw materials.

Regular calibration and maintenance:

Regularly inspect and calibrate the speed control device of the granulator to ensure its accuracy and reliability.

Regularly maintain the granulator, inspect and replace worn parts to avoid unstable speed caused by equipment failure.

Through the above methods, the speed of the granulator can be effectively adjusted to improve granulation efficiency and particle quality, while reducing energy consumption and equipment wear, achieving optimization of the production process. During the adjustment process, it is recommended to collaborate with equipment suppliers or industry experts to obtain more professional guidance and advice.

Organic fertilizer granulator commonly used for processing fertilizers in breeding farms

fertilizer granulator Aug 23, 2024

 Organic fertilizer granulation equipment is the primary and necessary granulation equipment in feed processing and production and processing of organic fertilizer and compound fertilizer. And in the processing of raw materials, granulator can normal task production, which directly affects the economic benefits of production enterprises is directly related, so the accurate operation of granulator is very important.

NPK fertilizer granulator with high degree of automation has extrusion granulation equipment, and then the organic fertilizer wet granulation machine, rotary drum granulator and other equipment also meet the processing needs of different people in different aspects, and the granulation equipment in organic fertilizer processing equipment is becoming more and more abundant.

Flat die extrusion granulator, the representative product of extrusion granulation process, has a large market. It can be formed at room temperature without drying, and can realize automatic production without manual operation, which is highly praised by most users. Flat die pellet mill has also rapidly become a star product in the organic fertilizer production and processing industry.

The important principle of compound fertilizer production by rotary drum granulator is to reduce the addition of water during granulation as much as possible, and moderately increase the temperature and solubility of materials, so as to reduce the heat consumption, improve the qualified rate of pelletizing, increase the output and reduce the production cost.

As an important molding process in the production and processing of organic fertilizer, fertilizer granulator has a great impact on the production of complete sets of organic fertilizer equipment. The strength, uniformity and size of finished organic fertilizer particles are affected by the granulation equipment. Therefore, we will pay special attention to the selection of granulator when applying organic fertilizer granulation equipment to produce organic fertilizer. We need to pay attention to the market In order to make the right choice, we must have a thorough understanding of the basic equipment.

How to ensure the stability and reliability of the crusher in the NPK fertilizer production line

fertilizer granulator Aug 23, 2024

Ensuring the stability and reliability of the crusher in the NPK fertilizer production line is crucial for maintaining production efficiency and product quality. Here are some key measures to ensure the stable operation and long-term reliability of fertilizer crushers:

Select appropriate model and specifications: Choose the appropriate crusher type and specifications based on the material properties (such as hardness, humidity), yield requirements, and particle size requirements of the fertilizer production line. Ensure that the processing capacity of the crusher matches the production line, avoiding overload or insufficient capacity.

Quality control: Choose crushers from reputable and experienced manufacturers to ensure the manufacturing quality and material durability of the equipment. Check whether the structural design, manufacturing process, and materials of the equipment meet the requirements for long-term stable operation.

Regular maintenance: Establish a regular maintenance plan, including cleaning up dust and residual materials inside and outside the equipment, inspecting and fastening all connecting parts, lubricating rotating parts, inspecting and replacing worn hammer heads, screens, and other vulnerable parts. Regular maintenance can extend equipment lifespan and reduce failure rates.

Monitoring and adjustment: Install a monitoring system to monitor the operating status of the crusher in real time, such as temperature, vibration, current and other parameters, and promptly detect abnormalities and make adjustments or maintenance. Adjust the feed rate, speed, and other parameters of the crusher in a timely manner according to production needs to ensure that the equipment operates at its optimal state.

Operation training: Provide professional training to operators to ensure they understand the operating procedures, safety precautions, and basic fault diagnosis and handling methods of the equipment. Proper operation can reduce abnormal wear and failure of equipment.

Spare parts management: Establish a spare parts inventory to ensure timely replacement of critical vulnerable parts such as hammers, screens, bearings, etc. Establish good cooperative relationships with suppliers to ensure rapid supply of spare parts in emergency situations.

Environmental control: Keep the working environment clean and avoid the impact of dust, moisture, etc. on equipment. For crushers that handle materials with high humidity, appropriate moisture-proof measures should be taken to avoid material clumping or corrosion inside the equipment.

Through the above measures, the stability and reliability of fertilizer crushers in NPK fertilizer production lines can be effectively improved, ensuring the continuity of the production process and the stability of product quality.

How to improve granulation efficiency of NPK fertilizer production line for processing fertilizers

fertilizer granulator Aug 23, 2024

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.

The granulation process and application scope of organic fertilizer granulator

fertilizer granulator Aug 23, 2024

 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.

What are the commonly used fertilizer crushers in NPK fertilizer production lines

fertilizer granulator Aug 23, 2024

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.

What equipment is needed for NPK fertilizer production line to process fertilizers

fertilizer granulator Aug 23, 2024

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.

How to process organic materials in an organic fertilizer production line to produce fertilizers

fertilizer granulator Aug 23, 2024

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.

What are the common faults of rotary drum granulator in NPK fertilizer production line

fertilizer granulator Aug 8, 2024

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.