In the core process of NPK compound fertilizer production, the choice of granulation technology directly determines product quality, production costs, and market competitiveness. As a key decision point in the production process, drum granulation and twin-roll extrusion granulation represent two different technical routes, each suitable for different production scenarios. This article will systematically analyze the core characteristics and applicable boundaries of these two technologies based on industry practical experience, providing enterprises with clear technical logic and decision-making basis for selection.
I. Drum Granulation: A Mature Solution for Large-Scale Production
Drum granulation technology, with its stability, reliability, high capacity flexibility, and wide product applicability, has become the mainstream choice for large-scale compound fertilizer production enterprises.
Technical Advantages:
High Capacity and High Pelletizing Rate: Capacity range covers 1-20 tons/hour, with a pelletizing rate of over 90%, making it particularly suitable for large-scale continuous production.
Strong Raw Material Adaptability: Compatible with various basic raw materials such as urea, ammonium sulfate, diammonium phosphate (DAP), and potassium chloride, allowing for flexible formula adjustments.
Excellent Product Quality: High granule roundness and strength (typically ≥15N), not easily pulverized, suitable for long-term storage and long-distance transportation.
High Process Maturity: A complete supporting drying, cooling, and screening process system ensures good production stability.
Typical Application Scenarios: Suitable for large-scale production enterprises primarily producing general-purpose NPK compound fertilizers and pursuing economies of scale. For example, a Southeast Asian customer adopted Huaqiang Heavy Industry’s 20-ton/hour drum granulation production line, and through optimized automatic rubber liner cleaning technology, reduced equipment maintenance downtime and increased annual production capacity by 40%.
II. Twin-Roll Extrusion Granulation: An Innovative Path to Energy Saving and Customization
Twin-roll extrusion granulation technology, with “room temperature molding” as its core feature, breaks through the energy consumption bottleneck of traditional processes, providing a new technological option for small and medium-sized enterprises and specialty fertilizer production.
Technical Advantages:
Significant Energy Saving Effect: No drying stage required; overall energy consumption is reduced by approximately 40% compared to drum granulation, resulting in significant operating cost advantages.
Simple raw material processing: It has relaxed requirements on raw material particle size; coarse materials can be directly granulated without fine crushing, reducing investment in pretreatment equipment and energy consumption.
Suitable for heat-sensitive materials: Its room-temperature molding characteristics make it particularly suitable for adding trace elements (boron, zinc, iron, etc.) and certain easily decomposable organic components.
Flexible production organization: Suitable for flexible production of multiple varieties and small batches, with convenient product changeover.
Typical application scenarios: Particularly suitable for small and medium-sized enterprises in areas with high electricity costs, primarily producing specialty fertilizers/formulated fertilizers. For example, after adopting a 5-ton/hour double-roller extrusion production line, an Algerian customer not only met the local demand for specialty fertilizers but also controlled the raw material loss rate to below 3%, achieving a dual improvement in economic benefits and resource efficiency.
III. Selection Decision Matrix: Technology Matching Based on Corporate Strategy
When selecting granulation technology for an NPK compound fertilizer production line, enterprises should conduct a comprehensive evaluation based on the following four dimensions: If the product is positioned as a standardized product such as general-purpose NPK compound fertilizer, and the goal is large-scale continuous production (capacity typically higher than 5t/h), with raw materials mainly consisting of conventional inorganic materials requiring drying treatment, and higher energy consumption acceptable to achieve economies of scale, then roller granulation technology is more suitable. If the enterprise focuses on producing customized special-purpose or formula fertilizers containing trace elements, with capacity requirements of small to medium scale, multiple batches (1-10t/h), raw materials containing heat-sensitive components or uneven particle size, and is sensitive to electricity costs and prioritizes initial investment control, then double-roller extrusion granulation technology has advantages in system simplicity and energy saving, but roller wear needs to be closely monitored during operation.
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IV. Technology Integration and Customized Solutions
It is worth noting that the two technologies are not entirely contradictory. Leading equipment suppliers such as Huaqiang Heavy Industry are able to provide hybrid process solutions or modular designs based on specific customer needs. For example, companies that produce both general-purpose fertilizers and develop specialty fertilizers can design a “dual-line parallel” or “flexible switching” production layout to maximize equipment utilization.
Granulation Technology in NPK Manufacturing
This analysis of drum versus roller press granulation highlights the critical technology choice within the broader npk fertilizer manufacturing process. Regardless of the chosen method, the process begins with precise formulation, typically using a npk blending machine or a fertilizer mixer machine to create a homogeneous powder blend. The core of the npk fertilizer production line is the npk granulation machine. The specific npk granulation machine technology selected—whether a rotary drum (wet) or a roller press (dry)—fundamentally defines the energy profile and product characteristics of the entire npk manufacturing process.
The entire suite of npk fertilizer granulator machine equipment, including the chosen npk fertilizer granulator, dryers, and coolers, must be configured to support the selected technology. For operations focused on physical blending rather than chemical granulation, a npk bulk blending machine may be the primary equipment. This underscores that npk fertilizer production technology is not a single path but a spectrum, where the selection of granulation equipment is the pivotal decision that aligns the production system with strategic business goals of scale, product type, and operational cost.
Therefore, investing in a deep understanding of these granulation technologies and their corresponding equipment requirements is essential for designing an efficient, competitive, and profitable NPK fertilizer production facility.
Conclusion: From Technology Selection to Value Creation The choice of granulation technology is essentially a technological interpretation of a company’s development strategy. For companies producing general-purpose fertilizers on a large scale, drum granulation remains a proven and reliable choice; while for companies focusing on niche markets and pursuing differentiated competition, twin-roller extrusion granulation offers a more cost-effective and flexible innovation path. It is recommended that companies, before making decisions, not only conduct techno-economic analysis but also consider their own resource endowment, market positioning, and development vision to choose a technology route that can truly support long-term competitiveness. Deep cooperation with equipment suppliers with rich project experience and conducting pilot-scale verification will be an important guarantee for reducing investment risk and ensuring the successful implementation of technology.