Common Problems with NPK Fertilizer Granulator Machines

During the granulation process of NPK compound fertilizer production lines, various problems can arise due to factors such as raw material characteristics, operating procedures, and equipment maintenance, directly affecting the quality of fertilizer granules and production efficiency. This article summarizes four common problems with granulation machines and, considering the diverse NPK fertilizer formulations and the need to prevent nutrient loss, provides simple and easy-to-implement solutions to help farmers and fertilizer plants achieve efficient production.

Uneven and inconsistent granule size is the most common problem, often caused by improper raw material matching or unreasonable parameter adjustments. The moisture content of NPK mixed raw materials needs to be controlled between 15% and 25%.  Too high moisture content can lead to clumping and oversized granules, while too low moisture content makes granulation difficult.  Simultaneously, extrusion granulators require adjustment of roller pressure, disc granulators require control of rotational speed, and rotary drum granulators require adjustment of feeding speed to prevent uneven mixing of raw materials leading to granule size variations. Solution: Mix nitrogen, phosphorus, and potassium raw materials evenly before starting the machine, precisely control the moisture content, gradually adjust parameters during trial runs, and use a screening device for secondary screening to ensure consistent granule size.

Loose and easily broken granules are primarily caused by insufficient granulation pressure or improper binder addition. The nitrogen, phosphorus, and potassium components in NPK fertilizers can affect granule cohesion, especially in high-concentration formulations. If the roller pressure is insufficient, the granulation chamber is worn, or the amount of binder added is insufficient or the wrong type is used, it will lead to insufficient granule strength. Solution: Check easily worn parts such as rollers and granulation chambers, and replace worn parts promptly; add an appropriate amount of suitable binder according to the raw material formula, avoiding excessive amounts that lead to nutrient dilution, and insufficient amounts that affect molding.

The equipment not producing granules or a sudden drop in granule output mainly stems from feed blockage, excessive raw material impurities, or equipment malfunction. If the NPK raw materials contain stones or metal impurities, they can easily block the feed port; unbalanced moisture content and clumping of raw materials can also affect the smoothness of feeding; in addition, abnormal motor speed and loose transmission components can also lead to abnormal granule output. Solution: Screen the raw materials before feeding to remove impurities and crush clumped raw materials; regularly clean the feed port and granulation chamber, and check the motor and transmission components to ensure normal equipment operation. Sudden increases in energy consumption and equipment overheating are often due to improper operation or inadequate maintenance. Prolonged overloading and insufficient lubrication can lead to increased friction between equipment components and higher energy consumption; excessive moisture in raw materials increases the operating load on the equipment, causing overheating. Solutions include: scheduling work time reasonably to avoid overloading; regularly adding lubricant to the equipment and cleaning dust and residual raw materials from components; and strictly controlling the moisture content of raw materials to reduce equipment operating pressure.

In summary, common problems with NPK fertilizer granulator machines are mostly related to raw materials, operation, and maintenance. By properly screening raw materials, adjusting parameters, and maintaining the equipment during daily production, most problems can be effectively avoided, ensuring that the nutrients in the NPK fertilizer are not lost, while also improving production efficiency and extending the equipment's service life.

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