Compound fertilizer equipment
Compound fertilizer equipment is a kind of equipment that uses ammonia and ammoniated spray granulation to make chemical fertilizer.
brief introduction
Compound fertilizer equipment: drum steam granulation technology for producing high-concentration compound fertilizer, disc non-steam granulation technology for producing high, medium and low-concentration compound fertilizer, anti-caking technology for compound fertilizer, high-nitrogen compound fertilizer production technology, urea melt gunning granulation technology for producing organic and inorganic compound fertilizer, etc. Filled the gap in China.
At present, there are ammonia method and ammoniated shot blasting granulation method in the compound fertilizer equipment market, which are suitable for the domestic market and more suitable for large, medium and small enterprises in China.
parameter
craftsmanship
Fermentation process flow
The production process of organic fertilizer is mainly to mix organic solid waste with water content below 60% with auxiliary materials (plant straw, etc.). ) and microbial starter, which are fully decomposed, sterilized, deodorized and dehydrated by aerobic continuous fermentation in the tank. The moisture content of decomposed materials is generally in the range of 30-35%. After screening and magnetic separation, it can be directly used for pelletizing to produce spherical organic fertilizer or further drying to produce powdery organic fertilizer.
Granulation process flow
The technological process of compound fertilizer can be divided into: raw material batching, raw material stirring, raw material granulation, particle drying, particle cooling, particle grading, finished product coating and finally finished product packaging.
1, raw material composition:
Raw materials such as urea, ammonium nitrate, ammonium chloride, ammonium sulfate, ammonium phosphate (monoammonium phosphate, diammonium phosphate, superphosphate) and potassium chloride (potassium sulfate) are prepared according to a certain proportion (according to market demand and soil testing results in various places).
2, raw material mixing:
Stir the prepared raw materials evenly to improve the uniform fertilizer efficiency content of the whole fertilizer particles.
3, raw material granulation:
The evenly stirred raw materials are sent to a granulator for granulation (which can be converted into strands or extruded for granulation).
4, particle drying:
The granules made by the granulator are sent to the dryer to dry the moisture contained in the granules, which increases the strength of the granules and is convenient for storage.
5, particle cooling:
After drying, the temperature of fertilizer particles is too high, which is easy to agglomerate, and after cooling, it is convenient to bag, store and transport.
6, particle classification:
Grading the cooled particles, crushing and re-granulating the unqualified particles, and screening out qualified products.
7. Finished film:
Coating qualified products to increase the brightness and roundness of particles.
8, finished product packaging:
Coated granules, that is, finished products, are bagged and stored in a ventilated place.
trait
1. Wide application range of raw materials: it is suitable for direct granulation of crude fiber organic wastes with water content of about 30%, such as fermented livestock manure, sugar mill sludge, municipal sludge, paper sludge, distiller's grains, straw and peat, and can produce spherical pure organic fertilizer, organic inorganic fertilizer and bio-organic fertilizer.
2. High balling rate and survival rate of biological bacteria: the new technology can make the balling rate reach above 90-95%, and the new technology of low temperature and large air volume drying can make the survival rate of microbial bacteria reach above 90%.
3. Short process flow: low operating cost. The organic raw materials used in this process do not need pretreatment such as drying and crushing, and the process flow is short and the running cost is low (if the traditional disc or drum granulation process is adopted, the organic raw materials with water content of about 30% after fermentation should be dried to below 13% and crushed to more than 80 meshes, and the addition amount of organic materials should not be greater than 30%).
technology
Tubular reactor technology
This NPK production equipment chooses to introduce the world's advanced patented technology of "tubular reactor" from Norway Hydro Company, including hardware and process software package. Compared with the traditional neutralization reaction tank+ammoniation granulation process, this patented technology has great advantages in product quality. Characterized in that:
● Advanced granulating technology.
According to the nutrient requirements of compound fertilizer products, all kinds of liquids and Guyuan materials measured by microcomputer are synthesized into compound fertilizer by chemical reaction in granulator and tubular reactor, and completely spherical particles are obtained by continuous wrapping in ammoniation granulator. All kinds of nutrient ratios can meet the standard, which is stable and guaranteed.
● The nutritional components of the product granules are equally balanced.
Due to chemical synthesis and granulation, the nutrient content of granular fertilizer is the same as that of the label, which can provide nitrogen, phosphorus, potassium and other nutrients for crops at the same time according to a certain proportion to ensure the balanced growth of crops.
● The product has good physical properties.
The particle size distribution of the product is uniform, and 90% is 2-4 mm particles; The particles have high strength and good fluidity, and are not easy to break during transportation, storage and stacking. The third design institute of the Ministry of Chemical Industry also absorbed the advanced technology of French AZF company and Spanish INCRO company in the engineering design, and further optimized the design performance of the device.
Granulation technology of molten urine
The device adopts molten urine granulation technology, which can meet the requirements of producing various high-nitrogen nutrient compound fertilizers; On the other hand, the granulation quality can be further improved, so that the nitrogen content of fertilizer particles is more balanced, the surface is smooth and the gloss is high.
New technology of spray granulation in tubular reactor of amino acids
The new technology of amino acid tubular reactor spray granulation has solved the common problems in urea-based compound fertilizer production, such as equipment scarring, poor production environment, poor adaptability of raw materials, poor product appearance and nutrient uniformity, product caking, poor long-term stable operation and so on. This technology makes full use of public works such as steam, urine, ammonia, air, circulating water and electricity. And can greatly reduce the investment and operating costs of fixed assets.
1. Main features of the new technology for producing compound fertilizer by amino acid spray granulation;
1. tubular reactor and gas ammoniation technology were adopted to improve the characteristics and working conditions of granulated materials. The granulation temperature is 70-80℃, and the pelletizing rate is 70-80%.
2. Adopt efficient drying technology to improve the drying strength, and the moisture content of the product reaches ≤ 65438 0.5%.
3. The hot blast stove adopts clean fluidized bed combustion technology to improve the heating effect, and the coal consumption per ton of fertilizer is ≤ 15kg.
4. The system returns materials through thermal screening and thermal large particle crushing technology, making full use of the heat of the system.
5, improve the screening efficiency and product particle uniformity, φ2.0-φ4.0mm particles ≥98%.
6. Cooling adopts unique and efficient new cooling technology to reduce the packaging temperature as much as possible.
Second, the operation characteristics of the new production process of ammonia acid spray granulation compound fertilizer:
1, the product is not caked. The moisture content of the product is less than or equal to1.5%, the packaging temperature of the product is less than or equal to 40℃, the particle strength of the product is more than or equal to ≥25N, the appearance of the product is smooth and round, the particles are even, and the particles of φ2.0-φ4.0mm are more than or equal to 98%. After simple anti-caking coating treatment, the product does not agglomerate for half a year.
2. The nitrogen content of the product has a wide adjustment range, and the nitrogen content can reach ≥30%, and it can produce ternary compound fertilizer (such as 30: 5: 5), unit fertilizer (such as granular nitrogen fertilizer 25: 0: 0) and binary compound fertilizer (such as 30: 0: 5).
3. The product variety is convenient to switch, and various types of compound fertilizer products can be produced, namely, urea-based, chlorine-based, sulfur-based and nitro-based.
4. The production system is flexible and adapts to raw materials.
5, expand the variety of raw materials, wet ammonium chloride, wet potassium chloride, calcium superphosphate, calcium magnesium phosphate, calcium hydrogen phosphate and other low-priced raw materials can be used in large quantities.
6. The equipment is not scarred or blocked, and can run continuously and stably for a long time.
7. The process flow is simple, the maintenance and operation and production management are convenient, and the production environment is good, which can realize standard discharge and clean and civilized production.
8. Investment and operation are the most economical. 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 power consumption is reduced by 25%, and the cost per ton of chemical fertilizer is reduced by 50-75 yuan.
Third, the actual situation.
Most of the technology of this process has been successfully put into operation in several sets of urea-based compound fertilizer production devices in China, highlighting its distinct advantages. This process is very suitable for urea enterprises to build new urea-based compound fertilizer projects, and it is also suitable for non-urea enterprises and the upgrading of existing compound fertilizer production devices.
DCS control technology
● According to the production characteristics of this plant, phosphoric acid and NPK control rooms are set up and distributed control system (DCS) is adopted. Through the dynamic picture of the whole process, centralized monitoring is carried out for grinding, phosphoric acid, sulfuric acid/phosphoric acid tank farm, NPK and other devices. The CRT in the control room can display various process parameters and the running state of the pump; The automatic control of important process parameters and the start and stop of main pump can be carried out in the control room; Using the powerful function of DCS, you can print production reports of various specifications regularly or in time; Can timely display parameter overrun, production accident or system failure; Ability to store and display historical trends and provide rich operational guidance information; Easy to operate and maintain.
Main functions of DCS operation station:
Process parameter display and over-limit alarm;
The control loop is easy to operate, such as adjusting the set value;
Real-time recording and trend recording of important parameters;
Operation and display of running equipment;
Switch operation and position display of the valve;
Self-diagnosis of system fault;
Process flow screen display;
Picture display of control loop;
Print the report regularly.
DCS control technology this production device adopts DCS microcomputer control technology in the whole process of raw material batching, production process adjustment and control, which significantly reduces the phenomenon of large deviation of nutrition ratio and unstable production operation caused by inaccurate manual or mechanical batching and human operation errors. The stable production of the device is ensured, and the nutritional ratio of the product is accurate and qualified.
Coating wrapping technology
The coating system of the device adopts the latest scientific research achievement of National Fertilizer Catalyst Engineering Research Center-active coating agent, and selects high-quality coating powder. After coating, the product can effectively prevent moisture absorption and particle adhesion and agglomeration, and has good fluidity, which is convenient for fertilization operation, further improves the appearance quality and meets the quality requirements of users for internal quality and external beauty.
profit
Social benefit analysis
How to make full use of organic waste resources is an important issue in building a resource-saving society, promoting circular economy and developing organic agriculture in China. China is a big consumer of chemical fertilizers, and the production of chemical fertilizers consumes a lot of non-renewable resources such as coal, electricity and natural gas. Using the solid organic waste developed in this project to produce spherical granular organic fertilizer has achieved the purpose of saving non-renewable resources and protecting the environment, which has great social benefits and conforms to China's industrial policy of energy conservation and emission reduction.
Ecological environmental benefits
Increasing the application amount of organic fertilizer can effectively solve the environmental pollution caused by organic waste in livestock and poultry breeding and other industries, reduce the nitrate content of chemical fertilizer in groundwater and reduce the eutrophication of surface water caused by non-point source pollution, which is conducive to improving the safety and quality of agricultural products and preventing input pollution, and has extremely significant ecological and environmental benefits.