What is a compound fertilizer production line?
The compound fertilizer production line refers to the workflow that combines some compound fertilizer facilities orderly to produce chemical fertilizer. Reasonable arrangement of the fertilizer equipment can make your fertilizer production line more efficient. Tongda compound fertilizer production lines are compact, scientific and reasonable. Compound fertilizer production lines are mainly pellet fertilizer production lines. What’s more, the core machine of a chemical pellet fertilizer production line is the fertilizer granulator, and the granulation rate of Tongda fertilizer granulators is above 90%.
If you choose to buy a fertilizer production line from Tongda Heavy Industry, we can also help you to plan your factory site. There are three types of common compound fertilizer production lines: urea fertilizer production line, triple superphosphate fertilizer production line and phosphate fertilizer production line.
Three different types of fertilizer production line solutions from Tongda
The main components of compound fertilizer are nitrogen, phosphorus and potassium, so people also call a compound fertilizer production line as a NPK fertilizer production line sometimes. Some raw materials of compound fertilizer are sticky, and the other are not that sticky. Therefore, if you want to use some less sticky raw materials to make compound pellet fertilizer, you should and some liquid binder in your raw materials. The following are three different fertilizer production lines suggested by Tongda Heavy Industry.
Urea fertilizer production line
The nitrogen content of urea is very high, so urea is one of the common raw materials in compound fertilizer industry. In general, Tongda suggests you should adopt roller compactors to make compound pellet fertilizer in your urea fertilizer production line. The pellet fertilizer made by double roller granulators has the characters of high solidity. What’s more, by employing roller compactors, you don’t need to equip any drying or cooling machines in the fertilizer production line. In this way, you can save s lot of spending.
Phosphate fertilizer production line
If you plan to use phosphate as raw material to produce chemical fertilizer, you can assemble disc granulators in your fertilizer production line. Disc pan granulators require that the moisture content of the raw material should range from 25% to 30%. If your raw material is too dry, you can add some liquid binder in it.
Triple superphosphate fertilizer production line
If triple superphosphate is your raw material, and you want to have a large output production line like 200000 tons per year fertilizer production line. Tongda recommends you employ a roller compactor and a rotary drum granulator in your fertilizer producing line. The combination of these two granulators will greatly improve the production efficiency of the whole fertilizer production line.
Compound fertilizer production process
In sequence, the technological process of a compound fertilizer production line can be divided into:
There might be some agglomeration matters in your raw material, so you should use a crushing machine to crush it into uniform powder material.
Tongda urea crusher
Motor Speed: 1200(r/min)
Overall Size: 1800*1300*1160mm
In the batching process, different raw materials will be batched in appropriate proportion. You need an automatic batching machine or a static batching machine for this process. Honestly, automatic batching machines are more convenient and efficient than static batching machines, but they also cost a little more. You can make a choice according to your needs.
When the raw materials are well-proportioned, they will go through the mixing process next. The purpose of mixing raw materials is to make the compound fertilizer uniform. Notice: This is an inevitable process for all pellet fertilizer production lines.
As for compound pellet fertilizer making, granulating process is the key process. The granulation methods include wet granulation and dry granulation. Compound disc granulators and rotary drum granulators adopt wet granulation method while compound compactor granulators adopt dry granulation method.
Compound Fertilizer Double Roller Granulator
Granule Diameter: 3-10mm
Roller Sheet Size: 150*220mm
Color: red(can be customized)
The compound pellet fertilizer produced in the way of wet granulation needs to go through the drying process. The moisture content of the raw material ranges is a little high. In order to make the compound pellet fertilizer qualified, you should process it in the Tongda fertilizer drying machine.
The dried pellet fertilizer is hot. Through the fertilizer cooling machine, the pellet fertilizer’s temperature will decrease to the room temperature.
The qualified and unqualified compound pellet fertilizer should be separated. At this time, we could use screening machines to help the work. The qualified pellet fertilizer will be conveyed to the next procedure, and the unqualified pellet will be re-granulated.
The aim of the coating process is to cover a “protective layer” on the surface of the compound pellet fertilizer. In general, the protective layer is some powder or grease. With this “protective layer”, the finished compound pellet fertilizer will be lustrous and antisticking.
Compound fertilizer coating Machine
Rotating Speed: 6(r/min)
Installation Angle: 3°-5°
The last process of the whole compound pellet fertilizer production line is packing process. You need an automatic packing scale in this process. Tongda packing scale is very precise and its accuracy can reach 2‰.
For your information, if you use a compactor granulators in your fertilizer production line, you do not need to prepare drying and cooling machines. The compound pellet fertilizer made by a double roller granulator can be coated directly, because the pellet fertilizer is made from fairly dry material.
Raw materials needed for compound fertilizer making
There are a lot of raw materials of compound fertilizer production lines. According to chemical elements that the raw material contains, we could make a classification of the raw materials.
Nitrogen source: ammonium bicarbonate, ammonium sulfate, ammonium chloride, sodium nitrate, calcium nitrate, ammonium nitrate, urea…
Phosphorus source: calcium superphosphate, calcium magnesium phosphate, triple suprphosphate, powdered rock phosphate…
Potassium source: potassium chaloride, potassium sulphate, kainite, monopotassium phosphate(MKP)…
Above all, there are various materials for making compound fertilizers. And sometimes, in order to make the compound fertilizer more nutritious, you can add some bentonite into the materials. For your information, we also has equipment for you to make bentonite pellets. In the following, Tongda will show you the fertilizer facilities used in a compound fertilizer producing line.
Tongda Complete fertilizer equipment for compound fertilizer production lines
In a compound fertilizer production line, different processing steps require different fertilizer facilities. In the following content, Tonda Heavy Industry will show you more details about these facilities used in chronological order.
Crushing machines for sale
Tongda Heavy Industry manufactures several kinds of crushing machines, and vertical crushers and chain crushers are hot sale products of our company. You can choose the most suitable crusher machine for your fertilizer plant according to your raw material. In addition, not all kinds of raw materials should be crushed. If you have no idea about this, you can contact us and our engineers will provide you professional suggestions.
Batching machine for sale
When your raw material is fine enough, the next step you should do is batching. Tongda Heavy Industry has two kinds of batching machines. They are dynamic automatic batching machines and static batching machines. Compared with static batching machines, dynamic automatic batching machines are more high-efficiency. Commonly, Tongda suggests you prepare a spare batch bin. That is to say, if you have three kinds of materials, you should choose a batching machines with four batch bins.
Mixing machine for sale
The proportioned materials will be conveyed to a mixing machine. If you have a small compound fertilizer production line, we recommend you should choose a disc mixer. If your compound fertilizer production line is of large output, Tongda advises you should use a single shaft mixer or a double shaft mixer.
Low-cost Horizontal Mixer
Spindle Speed: 46(r/min)
Overall Size: 2350*1200*1000mm
Granulating machine for sale
Here comes the key machine of the whole production line, compound fertilizer granulating machine. There are three Tongda compound fertilizer pellet machines for you to refer: disc pelletizers,rotary drum granulators and fertilizer compactor roller. Double roller granulator employs dry granulation method while disc granulators and rotary drum employ wet granulation method. If you want to adopt a double roller granulator for your fertilizer production line, you won’t need to buy drying machines and cooling machines. If you choose the other two kinds of granulating facilities, it’s a must to equip dryer machines and cooling machines in your fertilizer production line.
Drying machine for sale
The compound pellet fertilizer made by disc granulators and rotary drums should be dried in Tongda drying machine. Through this dryer, the moisture content of the granulated pellet will decrease.
Cooling machine for sale
When the pellet fertilizer comes out of the drying machine, its temperature is around 70℃. It is too hot and you need to cool down it. Therefore, you should assemble a cooling machine after the drying machine.
Screening machine for sale
Next, a belt conveyor will transport the processed fertilizer pellets to a screening machine. The pellet fertilizer will be selected out and conveyed to the next procedure while the unqualified products will be re-granulated. Tongda Heavy Industry has two kinds of screening machines, namely vibrating screening machines and rotary screening machines.
Coating machine for sale
In order to avoid that the pellet fertilizer agglomerates together, you should coat the pellet fertilizer with some nutrient chemical components. Tongda coating machine is perfectly designed for this purpose. According to the intended usage, our experts have made a special design of the inner structure which is covered with stainless steel.
Packing machine for sale
When all the above-mentioned work is done, next, the coated pellet fertilizer could be packed in bags and stored. Tongda automatic packing scale machines are of two kinds: single bucket automatic packing scale and double buckets automatic packing scale. You can choose the packing scale machine according to your needs.
Price of compound fertilizer production lines
What is the price for a compound fertilizer production line? This must be the question that all the investors want to know. Here, we are going to make a general description of the prices.
Price of compound pellet fertilizer production lines
Relatively speaking, double roller granulator production line costs less, because there is no need of drying machine and cooling machine. If all the other compound fertilizer facilities are the same, a rotary drum fertilizer production line will cost more than a disc pan fertilizer production line.
In addition, the price of compound fertilizer production lines also has something to do with configuration and models of the fertilizer equipment.
Space needed by a compound fertilizer production line
Certainly, floor space is also an important factor that you should consider for establishing a compound fertilizer plant. If you want to buy compound pellet fertilizer production lines, it will be a totally different situation. The following is the detailed analysis.
In general, double roller granulator fertilizer production line has smallest demand of space. On the one hand, double roller granulators cover a small area. On the other hand, you don’t need to install drying machine and cooling machine for this compound fertilizer production line, so you can save cost on renting or buying a factory site.
In the second place, it is the disc pan fertilizer production line. Though you must assemble a dryer and cooler for this fertilizer production line, the disc granulator itself is not bulky. Therefore, this fertilizer production line is of medium size.
Obviously, rotary drum compound fertilizer production lines require that you have a large factory site. Apart from a drying machine and cooling machine, the long rotary drum pellet making machine also covers a large area. This fertilizer production line demands that the length of the factory should be over 100m and the width of the factory should be tens of meters.
Proposal on starting a compound fertilizer production line
First of all, you should make sure your investment is sufficient. When you are choosing a compound fertilizer production line, you should be scrupulous. Tongda suggests you buy compound fertilizer facilities from reputed factory. Tongda Heavy Industry has abundant experience in manufacturing compound fertilizer equipment. If you have any demand of fertilizer machines, please contact us.
After you’ve bought a compound fertilizer production line, you should install the whole line correctly and orderly. Next, you ought to do the run-in test. If there is no problem, you can put this fertilizer line in to production.
At the sales stage, you’d better do a good job to promote your compound pellet fertilizer to the public, because market promotion is necessary for every business .
Good preparation is the start of success, and Tongda Heavy Industry is always here for providing good service and compound fertilizer facilities to you.