How to Troubleshoot NPK Fertilizer Granulator Malfunctions

The granulator is the core equipment in NPK fertilizer production, and its operational stability directly affects product quality and capacity. In actual production, granulators often experience malfunctions such as poor granulation, abnormal equipment vibration, and discharge blockage.  Troubleshooting requires a precise approach based on process characteristics. The following are common troubleshooting methods and key solutions.

Poor granulation is a typical malfunction of NPK fertilizer granulators, manifested as loose granules and uneven particle size. First, check the raw material ratio. If the moisture content of nitrogen, phosphorus, and potassium raw materials is too high or too low, it will lead to insufficient binding. The moisture content should be adjusted to a reasonable range of 20%-30%. Second, check the mixing uniformity. If the raw materials are not evenly mixed, resulting in insufficient binder content in some areas, the mixing blades should be inspected to ensure that the mixing time meets the requirements. In addition, too fast or too slow granulator speed will also affect granulation, and the speed needs to be fine-tuned according to the characteristics of the raw materials.

Abnormal equipment vibration is mostly caused by mechanical component problems. First, check whether the foundation bolts are loose. Long-term operation can easily lead to loose bolts, which need to be tightened in time. Then, check the bearing condition. If the bearing is overheating or making abnormal noises, it may be due to insufficient lubrication or wear. Lubricating oil should be added or the bearing should be replaced. At the same time, if the material distribution inside the granulator is uneven, it will cause the machine body to vibrate due to uneven weight distribution. The feeding speed needs to be adjusted to ensure uniform material distribution.

Discharge blockage is mostly related to process parameters and equipment cleaning. First, check whether there is any debris accumulation at the discharge port. The discharge channel needs to be cleaned regularly. If the material temperature is too high, causing caking and blockage, the heating device should be checked and the temperature parameters adjusted. In addition, if the screen mesh size is too small or blocked, it will hinder the discharge of granules. A screen with a suitable mesh size should be replaced, and residual materials should be cleaned promptly.

Troubleshooting should follow the principle of "process first, then mechanics; simple first, then complex." In daily production, establishing a regular equipment inspection system and recording operating parameters can help predict malfunctions in advance. By accurately troubleshooting the root cause of the malfunction and promptly adjusting process parameters or repairing components, the operational stability of the granulator can be effectively improved, ensuring the continuity of the NPK fertilizer production line and product quality.