NPK Compound Fertilizer Production Line

1) Raw materials: The first step in selecting an NPK production line is to determine the type and material characteristics of the raw materials. NPK production lines have a variety of granulation methods such as steam drum granulation, disc granulation, extrusion granulation, and high tower melting granulation. If the raw material has a high organic matter content, drum granulation and disc granulation are more suitable. If the raw material is a single component such as potassium chloride or potassium sulfate, extrusion granulation and high tower melting are more suitable.

2) Output: Tongli Heavy Machinery provides a variety of NPK compound fertilizer production lines with different outputs. For example, the calculation method of Tongli for a production line with an annual output of 200,000 tons is: 22.8t/h * 365d/y *24h/d = 200,000 tons per year. Different algorithms will lead to different annual outputs, so it is very important to confirm the output with the customer.

3) Confirmation of process routes: NPK production lines have a variety of process routes. Customers can send their requirements for the particle size and strength of the finished product to Tongli, and Tongli's engineers will check the process of the entire production line.

As China's earliest and currently the largest manufacturer focusing on NPK compound fertilizer drum production line, Tongli has started the research and development and production of fertilizer equipment since 1958. After 65 years of development, Tongli has grown from the earliest annual output of 10,000 tons and 20,000 tons to the current annual output of 300,000 tons or even 500,000 tons, and has accumulated rich experience and technology.

Secondly, Tongli cooperates with internationally renowned brands such as BASF, Krupp, Yaruan Group, etc. The choice of these major customers proves that Tongli's quality has been recognized by the world's top companies.

Third, Tongli has advanced processing equipment and technology, covering the entire process from steel casting, plate welding, assembly to packaging and painting, and can control product quality from the source, which makes Tongli stand out in the industry.

Finally, since 1998, Tongli has served more than 100 customers, covering many countries around the world, including Thailand, Indonesia, the United States, Canada, Africa, Jordan, etc., and has rich experience and extensive international cases in the compound fertilizer industry.

1) Efficient granulation technology: The drum granulation production line adopts advanced granulation technology, which is a technology optimized by Tongli after years of practice and customer feedback in compound fertilizer projects.

2) The internal design of the granulator optimizes the flow path of the material, prolongs the residence time of the material inside the drum, and achieves efficient and uniform granule formation by adjusting the speed, inclination angle and humidity of the drum. This process can effectively improve the ball formation rate, while controlling the particle size distribution of the particles, ensuring that the produced particles have consistent quality and performance.

3) The production line is equipped with a DCS automatic batching system, which realizes precise monitoring and adjustment of the fertilizer production process through PLC and DCS, and can adjust the production parameters of the batching part in real time, so as to achieve the production of compound fertilizers with different formulas at the fastest speed.

4) Energy-saving and environmental protection technology: The drum granulation production line incorporates an efficient heat recovery system and tail gas treatment device in its design. Unlike traditional compound fertilizer production lines, the emission of the Tongli compound fertilizer production line can reach 30mg/cm3, which fully meets the emission requirements of developed countries. At the same time, the operating environment of the workshop has also been significantly improved.

1) Improve the pelletizing rate of the granulator: Improving the particle size, humidity and adhesion of the raw materials can increase the output. By reasonably adjusting the raw material ratio and adding an appropriate amount of adhesive, the pelletizing rate of the material in the drum can be improved. In addition, pre-treating the raw materials to ensure that their humidity is moderate can help reduce agglomeration and wall sticking during the granulation process and improve granulation efficiency.

2) Adjust the speed of the granulator: Reasonable adjustment of the speed and inclination angle of the drum can optimize the movement path of the material, extend the residence time of the material in the drum, and make the material collide, roll and aggregate more fully to form uniform particles, but it is necessary to avoid excessive retention of raw materials and reduce efficiency.

3 In the granulation process, the temperature control of the material is crucial. Improving the heat recovery system of the production line, such as increasing the heat recovery efficiency of the hot air furnace, can better maintain the granulation temperature, reduce energy consumption and increase the overall output of the production line. Ensuring the matching of the drying system and the granulation system can maintain stable humidity and temperature during the granulation process.

First of all, the equipment uses wear-resistant rubber lining, which not only has excellent wear resistance, but also can reduce the adhesion of materials on the inner wall of the drum, reduce the cleaning frequency and realize automatic cleaning function. Tongli's drum granulator has a high balling ratio, which ensures that the material is fully formed in a short time, and the particles are uniform and strong.

Tongli has a patented granulator steam injection system, which saves more energy than traditional granulators.

In terms of materials, all castings of Tongli are cast by Tongli's own foundry, made by three-phase electric arc furnace cast steel and resin sand process, and equipped with German spectrometer to measure the composition of castings. After the heat treatment of the castings, ultrasonic flaw detection and magnetic particle flaw detection are required to ensure the quality of the castings.

In terms of processing technology, Tongli uses automatic welding technology to ensure the quality of the welds, and is equipped with high-precision processing machine tools to ensure the overall roundness and straightness.

1) Tongli dryer has many technical advantages, which effectively improves the drying efficiency of compound fertilizer. First, the dryer adopts an optimized lifting plate to ensure that the material is fully turned and evenly distributed during the drying process, maximizing the contact area between the material and the hot air, thereby improving the heat exchange efficiency.

2) Secondly, the hot air system of Tongli dryer has been carefully optimized, and can achieve uniform distribution of hot air by adjusting the hot air temperature, flow rate and wind direction, ensuring the consistent drying effect of the material throughout the drying process.

3) In addition, the equipment has excellent sealing performance, effectively preventing hot air leakage and humidity fluctuations, maintaining a stable drying environment, thereby improving the overall drying efficiency and energy saving effect.

These design and technical improvements enable Tongli dryer to provide stable and efficient drying effects during long-term operation, ensure the uniformity of compound fertilizer drying, and meet the needs of high-capacity production.

Tongli's NPK compound fertilizer production line is equipped with an advanced DCS control system, which has significant advantages in the measurement of raw materials and finished products.

First, in terms of accurate measurement of raw materials and control of fertilizer formula, the DCS system can monitor and adjust the input ratio of various raw materials in real time, ensure that the supply of each ingredient meets the formula requirements, avoid unstable product quality due to raw material deviation, and quickly switch from one formula to another.

Secondly, in terms of finished product measurement, the DCS system uses automatic control and sensors to achieve real-time monitoring of finished products. The factory manager can observe in real time how much raw materials enter the NPK production line and how many tons of finished products are output.

Coating is a key step in compound fertilizer production. Its function is to enter the coating machine for surface treatment after the finished product passes through the rotary screening machine and the cooler.

The coating system is relatively complex. In addition to the coating machine, it also includes an oil storage tank for coating oil and an automatic batching scale to control the amount of material entering the coating machine.

Since the amount of coating oil needs to be accurately matched with the proportion of the finished material, the DCS control system is used to adjust the batching speed and the amount of coating oil to ensure accurate supply.

At the same time, the anti-caking agent is quantitatively added to the coating machine through a screw conveyor to prevent the compound fertilizer particles from agglomerating or flying during the coating process. The supply of anti-caking agent is also precisely controlled by the DCS system to ensure that the coating oil and anti-caking agent are evenly distributed.

After coating, the strength of the compound fertilizer particles can usually reach about 20 Newtons, and the coating can also change the color and appearance of the finished product, making it have different color effects such as blue.