Compound fertilizer equipment
Compound fertilizer equipment, is a kind of ammoniacal, ammonia slurry granulation method to make fertilizer equipment.
Introduction
Compound fertilizer equipment: rotary drum steam granulation production of high-concentration compound fertilizer process, disc without steam granulation production of high, medium and low concentration of compound fertilizer technology, compound fertilizer anti-caking technology, high nitrogen compound fertilizer production technology, urea melt slurry granulation production of organic and inorganic compound fertilizer technology, etc. had filled the gaps in the country.
Now on the market of compound fertilizer equipment and the emergence of ammonia, ammonia slurry granulation method, they are suitable for the domestic market, the domestic large, medium and small enterprises are more applicable.
Parameters
Process
Fermentation process
Organic fertilizer production process is mainly the moisture content of less than 60% of the organic solid waste and auxiliary materials (plant straw, etc.), microbial fermentation bacterial agent mixed well, through the pool-type aerobic fermentation to make it fully putrefied, sterilized, deodorized, de-watered. The moisture content of the ripened material is generally within the range of 30-35%, and after screening and magnetic separation, it can be directly used for granulation to produce round ball organic fertilizer, or after further drying to produce powdered organic.
Pelleting process
The process of compound fertilizer can be divided into: raw material batching, raw material mixing, raw material pelletizing, pellet drying, pellet cooling, pellet grading, finished product coating, and finally finished product packaging.
1, raw material ingredients:
Urea, ammonium nitrate, ammonium chloride, ammonium sulfate, ammonium phosphate (monoammonium phosphate, diammonium phosphate, heavy calcium, calcium), potassium chloride (potassium sulfate) and other raw materials according to a certain ratio (according to market demand and soil testing results).
2, raw material mixing:
Mix the raw materials to improve the overall uniformity of the fertilizer particles fertilizer content.
3, raw material granulation:
The evenly stirred raw materials will be sent to the granulator granulation (can be used to rotary granulation, can also choose extrusion granulation).
4, granule drying:
The granule will be sent to the dryer to dry the water contained in the granule, increase the strength of the granule, easy to save.
5, particle cooling:
The temperature of the dried fertilizer particles is too high, easy to caking, after cooling, easy to bag and save, and transportation.
6, particle grading:
The cooled particles are graded, unqualified particles are crushed and re-granulated, and qualified products are sieved out.
7, finished film:
The qualified products will be coated with film to increase the brightness and roundness of the particles.
8, finished product packaging:
The film-coated granules, that is, the finished product, are bagged and stored in a ventilated place.
Features
1, the applicability of raw materials and its wide range: for the fermented livestock and poultry manure, sugar mill filter sludge, city sludge, paper sludge, wine lees, straw, charcoal and other coarse fiber organic waste containing about 30% of moisture, direct granulation, the production of spherical particles of pure organic fertilizers, organic inorganic fertilizers, bio-organic fertilizers.
2, high rate of pelletizing and bio-bacteria viability: the new process can make the pelletizing rate reach more than 90-95%, and the new technology of low-temperature and large-air volume drying can make the microbial bacteria viability reach more than 90%.
3, short process: low operating costs of the organic raw materials used in the process does not require drying, crushing and other pre-processing, short process, low operating costs (if the use of disc or drum and other traditional granulation process, you need to ferment the moisture content of about 30% of organic raw materials to dry to 13% or less, crushed to 80 mesh or more, and the amount of organic materials can not be added more than 30%).
Technology
Tubular reactor technology
This set of NPK production plant chooses to introduce the world's most advanced Norwegian Hydro "tubular reactor" patented technology, including hardware and process software package. This patented technology has greater advantages in product quality than the traditional neutralization reaction tank + ammonia granulation process. Its characteristics are:
●Advanced granulation process
According to the nutrient requirements of compound fertilizer products, all kinds of liquid and solid raw materials measured by microcomputer batching are synthesized into compound fertilizers through chemical reaction in granulator and tube reactor, and continuously wrapped up in ammonia granulator to obtain completely spherical particles, and the ratio of all kinds of nutrients can be up to the standard, and it's stable and guaranteed.
●The product particles have equal and balanced nutrients
Because of chemical synthesis granulation, the nutrient contents of the granular fertilizers are the same as those marked, and they can provide nitrogen, phosphorus, potassium and other nutrients to the crops according to a certain ratio at the same time, which ensures balanced growth of the crops.
●Good physical properties of the product
The size of the product particles is uniformly distributed, 90% of which are particles with a diameter of 2-4mm; the particles are of high strength, with good fluidity, and are not easy to be broken during transportation, storage and stacking. The Third Design Institute of the Ministry of Chemical Industry has also incorporated the advanced technologies of France's AZF and Spain's INCRO in the engineering design, further optimizing the performance of the plant design.
Molten urine granulation technology
●The plant adopts molten urine granulation technology, which on one hand can meet the requirements for the production of various compound fertilizers with high nitrogen nutrients; on the other hand, it can also further improve the quality of the granulation, so that the fertilizer particles are more balanced in terms of nitrogen nutrients, with a rounded and smooth surface and a high glossy finish.
Acid tube reactor slurry granulation technology
Acid tube reactor slurry granulation technology, the technology solves the urea-based compound fertilizer production of equipment scarring, poor production environment, poor adaptation to raw materials, product appearance and nutrient uniformity of the product, product agglomeration, the long cycle of stability and operation of poor and other issues, the process makes full use of urea enterprises, steam, urine, gas ammonia, air, recycled water, power and other issues. The process makes full use of steam, urine, gas ammonia, air, circulating water, electricity and other public works, which can greatly reduce the investment in fixed assets and operating costs.
I, ammonia slurry granulation compound fertilizer production process:
1, the use of tubular reactor and gas ammonia ammonia technology, to improve the characteristics of the granulation material and granulation conditions, granulation temperature of 70-80 ℃, the granulation rate of 70-80% of the ball.
2, the use of a section of high-efficiency drying technology, improve the drying intensity, product moisture to ≤ 1.5%.
3. The hot air furnace adopts clean fluidized bed combustion technology to improve the heating effect, and the coal consumption per ton of fertilizer is ≤15kg.
4. The system return material adopts the technology of hot screening and hot large grain crushing to make full use of the system heat.
5, improve screening efficiency and product particle uniformity, φ2.0-φ4.0mm particles ≥ 98%.
6.Cooling adopts unique new technology of high efficient cooling to reduce the packing temperature as much as possible.
Two, ammonia slurry granulation compound fertilizer production process of the new operating characteristics:
1, the product does not caking. Product moisture ≤ 1.5%, product packaging temperature ≤ 40 ℃, product particle strength ≥ 25N, product appearance smooth and rounded, uniform particles φ2.0-φ4.0mm particles ≥ 98%, the product can be achieved by a simple anti-caking membrane treatment for half a year without caking.
2, the product nitrogen content adjustment range, nitrogen content can reach ≥ 30%, you can produce ternary compound fertilizer (such as 30:5:5), but also the production of unit fertilizers (such as particles of nitrogen fertilizer 25:0:0) and binary compound fertilizer (such as 30:0:5).
3, product variety switching is convenient, can produce multiple varieties and types of compound fertilizer products, can produce urine-based, chlorine-based, sulfur-based and nitro type.
4, the production system is flexible and adaptable to raw materials.
5. Expanding the variety of raw materials, low-cost raw materials such as wet ammonium chloride, wet potassium chloride, calcium chloride, calcium and magnesium phosphate fertilizer, calcium phosphate and other low-cost raw materials can be used in large quantities.
6, the equipment does not scar, not clogging, can realize the long cycle of continuous and stable operation.
7, the process is simple, maintenance and operation and production management is convenient, the production environment is good, can achieve the standard discharge and clean and civilized production.
8, investment, operation of the most economic. Compared with the same type, the investment in fixed assets is reduced by more than 30%, the floor space is reduced by 50%, the coal consumption is reduced by 50%, the electricity consumption is reduced by 25%, and the cost of fertilizer ton is reduced by 50-75 yuan.
Three, the practical situation
Most of the technology in the process has been successfully put into operation in a number of sets of urea-based compound fertilizer production units in China, and highlights the distinctive and obvious advantages. The process is very suitable for urea enterprises on the new urea-based compound fertilizer projects, but also suitable for non-urea enterprises and the existing compound fertilizer production unit upgrading.
DCS control technology
●According to the production characteristics of this plant, the control room for phosphoric acid and NPK is set up, and a decentralized control system (DCS) is adopted. Centralized monitoring and control of grinding, phosphoric acid, sulfuric acid/phosphoric acid tank area, NPK and other devices are carried out through the dynamic screen of the whole process. The CRT in the control room can display all kinds of process parameters and the operation status of the machine pumps; automatic control of important process parameters, start and stop of the main machine pumps can be carried out in the control room; the powerful function of the DCS can be used to print a variety of specifications of the production report at regular intervals or in a timely manner; timely display of parameter overruns, production accidents or system failures; the ability to store and display the historical trend, and to provide a wealth of operation and guidance information; easy to operate and maintain. It is easy to operate and maintain.
Main functions of DCS operation station:
-Display of process parameters and alarm for overrun;
-Control circuit can be operated conveniently, such as adjusting the set value;
-Real-time record and trend record of important parameters;
-Operation and display of operating equipment;
-Switching and position display of valves;
-Switching and position display of valves;
-Throughout the process, it is easy to operate and maintain the system.
-Self-diagnosis of system failure;
-Process flow screen display;
-Screen display of control circuit;
-Timely printing of reports.
DCS control technology is adopted in the whole process of raw material dosage and production process adjustment and control, which significantly reduces the deviation of nutrient ratio and unstable production operation caused by inaccurate dosage of manual or mechanical measurement and human error. This ensures stable production of the plant and accurate and standardized nutrient ratio of the product.
Film coating and wrapping technology
The film coating and wrapping system of the device adopts the latest scientific research results of the National Engineering Research Center of Fertilizer Catalyst - active wrapping agent, and selects high-quality wrapping powder, which makes the product, after coating and wrapping, effectively prevent moisture absorption and particles from binding each other with clumps, and has good fluidity, which makes it easy to apply the fertilizer, and the quality of the appearance is further improved, which meets the requirements of users not only in terms of intrinsic quality, but also in terms of quality of the product. The quality of appearance is further improved to meet the quality requirements of users, who not only demand the inner quality to meet the standard, but also pursue the outer beauty of the quality requirements.
Benefits
Social Benefit Analysis
How to make full use of the resources of organic waste is the establishment of a resource-saving society in China, to promote the circular economy and the development of organic agriculture is an important issue. China is a large consumer of fertilizers, the production of fertilizers to consume a large amount of non-renewable resources such as coal, electricity, natural gas, etc., the project developed the use of solid organic waste to produce round ball-type particles of organic fertilizers, to achieve the purpose of saving non-renewable resources and protecting the environment, the social benefits are huge, in line with China's energy saving and emission reduction of industrial policy.
Ecological and environmental benefits
Increase the application of organic fertilizers, can effectively solve the livestock and poultry farming and other industries organic waste pollution caused by the environment, reduce the nitrate content of fertilizers to groundwater, reduce surface pollution caused by surface water eutrophication, is conducive to improving the safety and quality of agricultural products, prevention and treatment of input pollution, the ecological and environmental benefits are extremely significant.