In fertilizer production, raw material waste in ring die granulators primarily stems from substandard pellets and die blockage. Targeted measures can increase raw material utilization by 5%-8%.
First, substandard pellets are recycled. After screening in the pelletizer, broken and large particles are collected and crushed to the required particle size (consistent with new raw material) using a dedicated fertilizer crusher. These particles are then mixed with new raw material at a ratio of 1:5 for re-pelletization. Care should be taken to control the moisture content during mixing. If the moisture content of the recycled material exceeds 18%, it should be air-dried to 14%-16% before mixing to prevent moisture absorption and impact on the overall pelletizing effect. Furthermore, the recycled material mix ratio should not exceed 20% to prevent it from affecting the strength of the new pellets.
Secondly, reduce ring die blockage losses. Before each shutdown, empty the pelletizing chamber of any remaining raw material. Then, introduce a small amount of talcum powder (5-8 kg per ton of raw material). Run the ring die granulator at no load for 5 minutes to allow the talcum powder to adhere to the inner wall of the ring die, forming a protective film to prevent residual raw material from solidifying and clogging. During daily production, check the ring die holes for blockage every four hours. If a small blockage is detected, clear it with a special needle (0.5 mm smaller in diameter than the die hole) to prevent further blockage and material waste.
In addition, polish the edges of the ring die holes every 100 hours to remove burrs and minimize material loss caused by material being stuck in the holes. A magnetic separator should be installed at the pelletizer feed inlet to remove metallic impurities from the raw material, preventing them from damaging the ring die and causing pelletizing problems, further reducing material waste.
Before using a cage crusher, it’s crucial to control the moisture content of the material. For materials such as corn, soybean meal, bran, and fish meal used in the feed industry, the ideal moisture content is generally between 10% and 14%. This is because feed pellets need to remain loose. Moisture levels above 14% can cause the material to stick to the cage rotor, hindering the grinding process. Below 10% can easily generate dust, polluting the environment and potentially posing a safety hazard. For example, corn with a moisture content of 9% can be over-crushed into a fine powder due to its brittle texture, exceeding the required particle size for feed pelleting.
Regularly inspect the beater. Manually move the beater. If the beater shakes more than 5mm, or if the bolts securing it are loose or missing, tighten them immediately with a torque wrench. Use a lock washer to prevent further loosening. If a beater is severely worn, replace it with a beater of the same specification to ensure consistent height across all beaters.
Check the cage plate for material buildup. If wet material is not cleaned after crushing, material may stick to the inside of the cage plate, causing the rotor’s center of gravity to shift. Stop the cage crusher and use a scraper to clean it. Reduce operating time when handling wet material. Also, check for cage wear. Measure the diameter of both cage plates with a caliper. If wear exceeds 2mm, replace the cage plates. After replacement, perform a dynamic balancing test on the rotor.
Bearing maintenance is also crucial. After 10 minutes of operation, touch the bearing seat. If the temperature exceeds 70°C or there is a snag during rotation, the bearing may be depleted or damaged.
Only by properly controlling material moisture and performing routine maintenance can you maintain a cage crusher in good operating condition, improve production efficiency, and extend the equipment’s life.
To build an efficient organic fertilizer production line, the proper selection of a disc granulator and its supporting equipment are crucial, directly impacting the overall production efficiency and product quality.
When selecting a disc granulator, the specifications of the disc granulator should be determined based on the production capacity requirements of the fertilizer production line. If the production line has a low capacity, a machine with a moderate processing capacity can be selected. If the production capacity requirements are high, a disc granulator with a high processing capacity should be used to ensure that the granulation process is compatible with the overall production capacity and avoid capacity bottlenecks.
Furthermore, the type of fertilizer being produced, such as organic fertilizer or NPK compound fertilizer, should be considered. Different types of fertilizer raw materials have different characteristics, so an appropriate disc granulator must be selected to ensure optimal granulation results.
The selection of supporting equipment is also crucial. In a fertilizer production line, a disc granulator must work in conjunction with other equipment such as a fertilizer crusher, mixer, screener, dryer, and packaging machine. The pulverizer crushes the raw materials to the appropriate particle size, preparing them for granulation; the mixer ensures that the raw materials are evenly mixed; the screening machine screens the granulated particles and separates unqualified particles; the dryer reduces the moisture content of the particles for easy storage; and the packaging machine completes the final product packaging.
The rational combination of these supporting equipment can form a complete and efficient fertilizer production process, improve the automation level and production efficiency of the entire production line, and create greater value for the enterprise.
In the field of fertilizer size reduction, the cage crusher stands as a master blacksmith among fertilizer equipment. This robust fertilizer machine wields its dual-rotation cages like hammers, expertly designed to tame the most stubborn materials. Whether crushing rock-hard MAP/DAP or breaking apart caking-prone urea, this essential fertilizer production machine effortlessly transforms hardened granules into a uniform, valuable powder, ensuring optimal quality and efficiency in any production line.
Materials endure 10-15 crushing cycles between high-speed steel bars
Dynamic Classification
Properly sized powder exits through cage gaps, preventing over-grinding waste
Self-Cleaning
Centrifugal force automatically removes adhered materials
“Traditional crushers wear out quickly processing MAP—requiring monthly hammer replacement—while our cage crusher’s alloy bars last 2000 hours, reducing maintenance costs by 70%. This is the economic solution for hard fertilizer crushing.” — Equipment Supervisor, Compound Fertilizer Plant
Four Unmatched Advantages
Advantage
Technology
Value
Hard Material Specialist
Special alloy bars + high-speed design
Crushes mineral fertilizers ≤Mohs 5 hardness
Uniform Fineness
Dual counter-rotation + dynamic grading
90% product in ideal 0.2-0.5mm range
Energy Efficient
Precise impact replaces full-power grinding
30-40% energy saving vs traditional models
Low-Dust Operation
Fully enclosed structure + negative pressure
Workspace dust ≤10mg/m³
Typical Applications
High-hardness Fertilizers: Pre-processing MAP, DAP, CAN etc.
Specialty Fertilizers: Providing base powder for CRFs
Within a complete suite of equipment required for biofertilizer production, the cage crusher plays a vital preparatory role. This robust machine is tasked with the primary size reduction of organic raw materials, ensuring a uniform, fine powder. This optimal particle size is critical for the subsequent mixing, composting, and granulation stages, making the cage crusher a fundamental piece of equipment for efficient and high-quality biofertilizer manufacturing.
Fertilizer manufacturing technology to be used to produce the organic fertilizer and compound fertilizer granulator.In the biofertilizer manufacturing process,what type fertilizer machines are used to produce the bio organic fertilizer granulator?
The biofertilizer production line is designed for producing the bio organic fertilizer granulator,in the line,it is equipped with different type fertilizer production line,we are mainly equipped with different type fertilizer machines to produce the bioorganic fertilizer granulator.So what type fertilizer machines we can use to produce the bioorganic fertilizer granulator?
In the bio fertilizer manufacturing process,the main equipment are mainly included:
1.Automatic batching system:the automatic batching system is mainly composed of feeding system,weighing device,bin and conveyor belt.And the static batching system has the speed of dynamic batching and the accuracy of ordinary static batching(0.2%).
2.New type organic fertilizer granulator machine:It is designed and manufactured by the new technology of wet continuous pusher granulation.This machine can not only granulate a varity of organic matters,especially for coarse fiber materials which are difficult to be granulated by conventional equipment.What’s more,this type fertilizer granulator machine is always to be used in the organic fertilizer production line to produce the organic fertilizer granulator.
3.Horizontal mixer:this series of horizontal mixer is a new generation of mixing equipment developed by our company,which has high mixing degree and less residue,and it is suitable for mixing organic fertilizer and inorganic fertilizer.
4.Roller screen:the machine adopts combined screen,which is easy to maintain and replace.It has simple structure,convenient operation and stable operation.It is an ideal fertilizer equipment in the production of compound fertilizer.
5.Conveyor:it is suitable for coal,metallurgy,mining,chemical industry,building materials,wharf,warehouse,construction site,etc. to transport bulk materials or box bags,especially suitable for using in chemical fertilizer plant,cement plant and other environments requiring manual loading,saving a lot of personnel.
6.Dryer:It has the characteristics of beautiful appearance,simple operation,low engery consumption,long service life,even drying convenient maintenance,etc.It is an advanced compound fertilizer drying equipment.
7.Hot blast furance:The hot blast furance adopts the technology of return water injection to solve the problems of shell bioler,such as tube plate crack,drum at the bottom of the drum,water-cooled wall burst,low thermal efficiency,insufficient output,poor adaptability of coal,etc.
8.Packing scale:the packing scale is mainly composed of automatic quantitative packing scale(composed of storage hopper,feeder,weighing bag hopper,kneading mechanism,computer control,pneumatic executive part,etc.)and optional part(conveyor,seam sewing machine/heat sealing machine)
These series machines are also different type and model,when producing we can choose the different type and model according to the raw materials and the production yield per hour.As the professional fertilizer machine manufacturers,we are not only produce all types of fertilizer equipment,we also designed different type fertilizer production lines to produce the biofertilizer granulator.In the npk fertilizer manufacturing process,it is equipped with different type fertilizer machines to produce the npk,compound fertilizer granulator.
We can produce the bio fertilizer granulator using the fertilizer manufacturing technology,in the fertilizer manufacturing process it is equipped with different type fertilizer equipment to finish the bio fertilizer production.For finishing the biofertilizer production,the fertilizer machine manufacturers designed complete fertilizer production line to finish the biofertilizer production lines.
In the biofertilizer production line,it is equipped with fertilizer granulator machine to finish the fertilizer granulator producation.The bioorganic fertilizer granulator is a new kind of organic fertilizer granulator,the fertilizer manufacturing process smoetimes it has some differences from the organic fertilizer production line.
Why we produce the bioorganic fertilizer granulator?The function of the bio organic fertilizer:
The function of bio organic fertilizer the function of bio organic fertilizer is also due to the different types of microorganisms which can be summarized as follows.
1.Nitrogen fixation,such as nodules and nitrogen fixing bacteria,it can fix nitrogen in the air and provide nitrogen nutriention for growth under suitable environmental conditions.It is estimated that the amount of biological fixed nitrogen in the world can reach 101 million tons per year.
2.Nutrient releasing microorganisms decomposes some substances in soil that are difficult to be absorbed and utilized by crops into effective nutrients that can be absorbed and utilized by crops.For example, silicate bacteria can not only decompose the refractory minerals such as potassium feldspar and mica in the soil,release the fixed potassium,but also promote the insolible phosphorus in the soil to be converted into the form that can be used by crops.
3.The effect of microbial fertilizer on the growth of the soil not only increase the nutrient content of the soil,but also promotes the synthesis of various vitamixs,enzymes and other substances conducive to the growth of growth of crops,stimulates the growth of crop,and help crops absorb nutrients.
4.After inoculating some microorganisms in the resistant soil,they propagate in the roots of crops in large numbers,and become the dominant bacteria in the rhizosphere of crops in a period of time,which inhibits or reduces the breeding opportunities of pathogenic microorganisns,and some microorganisms also have resistances to pathogenic microorganisms.Although microbial fertilizer can provide nutrients for crop growth and stimulate and promote crop growth,its role is limited after all.In crop production,organic fertilizer and chemical fertilizer,which it can beproduced in the npk fertilizer manufacturing process,are mainly used to provide nutrients for crop growth.
5.There are many benefical microorganisms in many natural materials,but once these materials are applied to the soil,the microorganisms in them will be eaten by countless microorganisms in the soil.Therefore,it can not survive stably in the soil,and its effect is difficult to show.However,if the benefical bacteria are added to the fermented organic fertilizer,the fermented organic fertilizer itself to expand the culture medium,so as to make a large number of bacteria proliferation.At this time,the microbial organic fertilizer is applied to the soil to form a dominant population in the soil,which can play a good role in the root system of crops.Fermented organic fertilizer has a good effect on microbial activity.
In this article,brief introduction of complete equipment and process of compound fertilizer production line of Zhengzhou Huaqiang Heavy Industry Technology Co.Ltd.The npk fertilizer manufacturing process production of compound fertilizer is the general process of compound fertilizer production,which is of great significance for users to incest and fully understand the production of compound fertilizer.
The fertilizer manufacturing process of npk,compound fertilizer is roughly as follows:raw material proportioning,mixing,and stirring,agglomeration and crushing,material granulation,primary screening,particle drying,particle cooling,secondary grading of particles,coating of finished particles,quantitative packaging of finished particles,etc.
The following is a detailed introduction to each link of the production process of npk, compound fertilizer and in different producing parts it is equipped with different type fertilizer equipment:
The production process of npk,compound fertilizer includes raw material promoting,mixing,crushing and agglomeration,granulation,primary screening,particle,drying,particle cooling,secondary screening,particle coating of finished products and quantitative packaging of finished products.
1.Raw materia ingredients:generally the raw materials can be the urea,ammonium nitrate,ammonium chloride,ammonium sulfate,potassium chloride and other raw materials can be selected and prepared in a certain proportion.
2.Mixing parts:Minx the prepared raw materials evenly to improve the overall uniform fertilizer efficiency content of the fertilizer particles,and use the horizontal mixer or disc mixer to mix the raw materials.
3.Agglomerate crushing:the raw materials with uniform mixture are crushed to facilitate the subsequent granulation processing,mainly using chain crusher,etc.
4.Material granulation:evenly stirred and crushed materials are sent to the granulator by belt conveyor for fertilizer granulator machine(drum granulator,disc granulator and roller press granulator can be used),which is an essential and most important step in the production process of compound fertilizer.
5.Primary screening:preliminary screening of semi-finished particles.Unqualified particles are returned to the mixing and mining link for reprocessing.Generally,roller screener is used to sceeen the granulator.
6.Particle drying:the particles made by the granulator and screned by the first stage are sent to the dryer to dry the moisture contained in the particles,so as to increase the particle strength and facilitate the storage.Generally,the rotary dryer is used in the fertilizer manufacturing process.Sometimes,the series of fertilizer dryer is also equipped in the organic fertilizer production line.
7.Particle cooling:the dried fertilizer particles are easy to agglomerate due to their high temperature.After cooling,they are easy yo be stored and transported in bags and stored by a cooler.
8.Secondary grading of particles:The cooled particles are graded,the unqualified particles are crushed and regranulated,and the qualified products are screened out,which can be screened by the secondary drum screener machine.
9.Finsihed paticle coating:coating the qualified products to increase the brightness and roundness of the particles,so as to make the appearance more beautiful.Generally,the coating machine is used for coating.
10.Quantitative packaging of finished particles:the coated particles,which is to easy,the finished particles are sent to the silo by the belt conveyor for temporary srotage,and then connected to the electronic quantitative packaging scale,sewing machine and other automatic quantitative packaging and sealing bags,placed in the ventilation place for storage,so as to realize full automation.
Then production process of compound fertilizer is simple,the production process of npk, compound fertilizer production line is small,the floor area is small,the operation is simple,and the technical requirements are not high.
