Four Common Problems in NPK Fertilizer Production Lines and Solutions

NPK fertilizer production lines involve complex processes and are susceptible to problems due to factors such as raw materials, processes, and equipment. These problems not only affect product quality and production capacity, but can also pose environmental risks and require precise solutions.

Impurities and agglomeration are prominent issues. Stones and metal fragments mixed in with the raw materials can wear the lining of the granulator and clog the screens of the screening machine, causing equipment downtime. Urea and monoammonium phosphate absorb moisture and agglomerate, forming lumps, resulting in uneven mixing and fertilizer nutrient content deviations exceeding 5%. Solutions: Install a magnetic separator and vibration screener machine at the outlet of the raw material silo to separate impurities; equip a pre-crushing system to crush agglomerated materials to 80-100 mesh; and control the humidity in the raw material silo to less than 60% to prevent moisture absorption.

Pelletization and drying are prone to quality problems. Improper moisture content during granulation (less than 15% results in loose granules, while above 18% results in sticking to the pellet wall), as well as imbalanced rotation speed and inclination angle, can lead to uneven granule size and poor roundness (less than 80%). Excessively high drying temperatures (>160°C) can cause nitrogen volatilization (loss rate exceeding 10%), while too low drying temperatures can easily lead to granule agglomeration. Solutions: Install an online moisture meter before granulation to adjust binder dosage in real time; use a frequency converter system to optimize granulator parameters; and equip the drying process with an automatic temperature control system to maintain a stable temperature between 120-150°C.

Dust and wastewater treatment can easily fail to meet standards. Mixing and screening processes generate a lot of dust. If the dust removal equipment's filter bags become clogged or air volume is insufficient, dust emission concentrations can easily exceed 20mg/m³. Drying condensate and equipment wash water contain nitrogen and phosphorus, which can be directly discharged into water bodies and pollute. Solutions: Clean dust removal filter bags weekly and optimize fan air volume. Establish a wastewater recycling system for treated and reused in granulation to achieve "zero discharge."

Wear and aging reduce efficiency. Wear and tear of vulnerable components like granulator scrapers and dryer lift plates (e.g., a gap exceeding 15mm between the scraper and the disc) can cause material to stick to the wall and reduce drying efficiency. Oil depletion or aging in the drive system can cause abnormal noise and speed fluctuations. Solutions include establishing a regular inspection system, checking vulnerable parts weekly and replacing them promptly. Lubricate the drive system monthly with specialized lubricant, and perform comprehensive maintenance and calibration quarterly.

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