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复混肥制作工艺及相应配套设备
(一) 有机肥发酵设备
此工艺是针对目前大量有机废弃物随意丢弃,造成大面积环境二次污染的现状设计,此发酵工艺不同于传统的厌氧发酵(沼气池)采用好氧发酵工艺,添加发酵菌,在控温增氧的条件下实现快速腐熟发酵过程,发酵过程无臭味产生,发酵效率高,可将有机废弃物快速转化为有机肥料,真正实现变废为宝,循环生态。
发酵设备有多齿型翻抛机、链板式翻抛机以及全密闭高温发酵器多种类型,客户需根据实际生产需要自由选择。
优点:全天候运行、运行成本低、设备投资少、转化效率高。
主要配套设备:装载机、翻抛机、移位机、密闭发酵器尾气生物处理器等。
使用原料种类:养殖禽畜粪便(牛、羊、猪、鸡粪等)、工业有机废弃物(甘蔗渣、木薯渣、淀粉渣、糖泥、污泥等)。
产能: 10-15万吨/年。
 
1. Organic manure fermentation process
This process is designed based on the current problems
such as  large amounts of organic waste discarded causing widespread environmental secondary pollution. This fermentation technology is different from the traditional anaerobic fermentation (pool). Using aerobic fermentation, adding bacteria, fermentation under the condition of temperature control and oxygenation it realizes fast rotten fermentation. The fermentation process has no smell, fermentation is high efficiency and can be quickly converted organic waste materials to organic fertilizer. Thus truly recycles waste materials to realize ecological cycles.
    Advantages: All-weather operation, low operation cost, less equipment investment, high conversion efficiency.
    Major equipment: Loaders, turning machine, the displacement car.
    Using raw materials categories:  Breeding livestock feces (cattle, sheep, pigs, chicken manure, etc.), industrial organic wastes (bagasse, cassava dregs, slag starch, sugar mud, sewage sludge, etc.).
    Capacity: A single set can produce 100000-150000 tons/year.
 
(二)圆盘/蒸汽转鼓造粒工艺
圆盘/蒸汽转鼓造粒工艺其实是两种工艺,根据其造粒
机的不同,可细分为圆盘造粒工艺和蒸汽转鼓造粒工艺,也可以根据原料情况组合成转鼓+圆盘双造粒机工艺,主要区别就是在造粒机,后面的烘干、冷却及其他配套设备都是相同的。
1.圆盘造粒工艺:
优点:造粒能力强,产品外观圆润,可适应原料范围广。
弱点:产量小,造粒时需添加辅料,无法生产高养分肥料,多适用于小型肥料生产企业。
2.转鼓造粒工艺:
优点:在添加蒸汽的情况下产量大,生产粉尘小,可生产高养分复混肥。
弱点:原料适应范围窄,不添加蒸汽的情况下造粒能力大幅下降。因为用来生产肥料的原料种类繁多,原料之间的搭配也是多种多样,所以,具体选用哪种造粒机还要看具体原料情况来确定工艺方案。
3.主要配套设备:圆盘造粒机、转鼓造粒机、烘干机、
冷却机、包膜机、皮带输送机、粉碎机、筛分机、混料机、包装机等。
4.适用肥料种类:无机单养分肥、无机多养分复混肥、
有机肥、生物有机肥、有机无机复混肥。
5.产能:单线1-10万吨/年。
 
The compound fertilizer producing process and the corresponding equipments
 
2. The disc/steam drum granulation process
Disk/steam drum granulation process is actually two kinds of process. According to its different granules machine it can be subdivided into disk granulation process and steam drum granulation process. According to the situation of raw material can also be subdivided into drum + double disk granulating process. The main difference is between the granulators, the following processes such as drying, cooling and other auxiliary equipment are the same.
    (1)The disc granulating process
    Advantages: The granulation capability is strong, product appearance is fruity and adaptable to wide range of raw materials.
    Weakness: The production is small, needs add accessories during granulation, unable to produce high nutrient fertilizer. It is more suitable for small fertilizer production enterprises.
    (2) The drum granulating process
    Advantages: The production is large with small dust and can produce high nutrient fertilizer in the case of adding steam.
    Weakness: It adapts to narrow range of the raw material and its granulation ability falls dramatically under the condition of not adding steam. Because of various types of raw materials to produce fertilizer and the collocation between raw materials is also varied, so the specific choice of pelleting machine depends on the determined processing plan with the specific raw material conditions.
    (3)The main equipments 
The granulating disc and drum granulator, dryer,
cooling machine, coating machine, belt conveyor, crusher, screening machine, mixing machine, packaging machine, etc.
    (4) Adaptable fertilizer categories
 The inorganic single nutrient fertilizer, inorganic multiple nutrients fertilizer, organic fertilizer, biological organic fertilizer, organic & inorganic fertilizer.
    (5) Production
One single line can produce1-100000 tons/year.
 
(三) 尿基喷浆造粒工艺
此工艺是将尿素高温熔融以后,将高温的尿素熔液代替造粒水喷洒到造粒机中的物料层上进行造粒,因为尿素熔液自身具有很好的粘性,而且尿素熔液遇冷会逐渐凝固,减少了造粒水的用量,因此,采用此工艺可以提高造粒机的成球效率,增加产量。同时,因为尿素自身是一种高氮肥料,所以,采用此工艺可以生产高含量的复混肥,是一种适应性非常广泛的肥料造粒工艺。
优点:产量高、可生产高养分复混肥、颗粒外观圆润光滑、原料适用范围广。
弱点:生产成本略高
主要配套设备:尿素熔融系统、圆盘或转鼓造粒机、烘干机、冷却机、筛分机、包膜机、包装机等。
适用肥料种类:无机复混肥、有机无机复混肥。
产能:单线3-10万吨
 
3.The urea-based spray granulation process
The process is that we first melt urea with high temperature 
then use the molten urea instead of granulation of water to spray into the granulator to the granulation material layer for granulation. Because urea liquid has very good viscosity and urea liquid will be gradually solidified with cold air thus can reduce the amount of the granulation water, therefore, using this technology can improve the efficiency of granulation of the pelleting machine and increase production. At the same time, because urea is a kind of high nitrogen fertilizer, so adopting this process can produce high content fertilizer. It is a kind of wide adaptability of the fertilizer granulation process.
    Advantages: High yield, can produce high nutrient fertilizer, grain smooth, round shape and material applicable range.
    Weakness:  Slightly higher production cost
    Major equipment: Urea melting system, disc or drum granulator, dryer, cooling machine, screening machine, coating machine, packaging machine, etc.
    Adaptable fertilizer: Inorganic fertilizer, organic inorganic fertilizer.
    Capacity: Single line can produce 30000-100000 tons/year.
 
(四) 氨酸/氨化法造粒工艺
这两种工艺主要用来生产无机复混肥,氨酸法工艺原理是利用液氨与稀硫酸反应生成的高温硫酸铵液浆来代替一部分水及蒸汽的用量,且硫酸铵料浆自身具有一定粘性,可以提高造粒机成粒效率,提高产量,大幅降低生产成本。氨化生产工艺是在氨酸法工艺的基础上增加了一套氯化钾脱氯工艺,可以在一条生产线中直接用氯化钾生产硫酸钾型复合肥,生产成本进一步降低。
优点:产量高,生产成本低,可生产高养分复合肥。
弱点:必须要用到液氨、硫酸,因具有一定危险性,在
部分地区申建审批时会有困难。
主要配套设备:氨站、酸罐、配酸系统、反应器、转鼓造粒机、烘干机、冷却机、筛分机、包膜机、包装机等。
适用肥料种类:无机复合肥。
产能:单线5-15万吨/年。
 
4. Amino acid ammoniating granulation process
The two kinds of process are mainly used for producing 
inorganic fertilizer. The principle of amino acid ammoniating process is to use the method of liquid ammonia reaction with dilute sulfuric acid to generate high temperature liquid ammonium sulfate pulp instead of part of the amount of water and steam, and ammonium sulfate slurry itself has certain viscosity, can significantly improve the efficiency of the granulator’s granulation, increase production and greatly reduce the production cost. On the basis of the method of amino acid process the ammoniating production process is increased a set of potassium chloride dechlorination process so it can directly produce potassium sulfate compound fertilizer within one production line and further reduce the production cost.
    Advantages: High yield, low production cost, it can produce high nutrient compound fertilizer.
    Weakness: Must use liquid ammonia, sulfuric acid so it has a certain risk. It is difficult passed across the examination and approval.
    Major equipment: Ammonia station, acid tank, mixed acid system, reactor, drum granulator, dryer, cooling machine, screening machine, coating machine and packaging machine, etc.
    Adaptable fertilizer: Inorganic compound fertilizer.
    Capacity: A single line can produce 5-150000 tons/year.
 
(五)高塔造粒工艺
该工艺最适合用来生产高浓度无机复混肥,工艺原理是利用尿素熔液遇冷快速凝固的特点,将尿素颗粒加温熔化后,按照一定量的配比,将磷、钾等原料加入到尿素熔液中,混合均匀后通过造粒机喷洒到塔体内,料浆液滴在从塔顶部下落的过程中遇冷凝固,从而形成圆形颗粒,经收集、筛分、包膜等一系列工序后制得成品包装。
优点:产量大、生产成本低、产品养分含量高、外观漂亮且易于识别。
弱点:必须要用尿素、投资大、不适合生产高磷养分的复混肥。
主要配套设备:塔体、熔料罐、提升机、造粒机、冷却机、筛分机、包膜机、包装机等。
适用肥料种类:高养分无机复混肥。
产能:单塔8-15万吨/年。
 
5. The tower granulation process
This process is most suitable for producing high
concentration inorganic fertilizer. The principle of this process is using the characteristics of rapid solidification of urea liquid   when it meets cold, after urea particle heating melting, according to a certain amount of proportioning adding phosphorus, potassium and other raw materials to molten urea after mixing sprayed to tower body by granulator and let the material slurry droplets cold solidification in the process of falling from the top of the tower, thus forming a circular particles. Through the collection, screening, coating and a series of process get made products after packing. 
    Advantages: High yield, low production cost, high nutrient content, beautiful appearance and easy to identify.
    Weakness: Must use urea, large investment, not suitable for high phosphorus nutrient of compound fertilizer production.
    Major equipment: The tower body, the melting pot, hoisting machine, granulating machine, cooling machine, screening machine, coating machine, packaging machine, etc.
    Adaptable fertilizer types: High nutrient inorganic fertilizer.
    Capacity: A single tower can produce 80000-150000 tons/year.
 
(六)、脲甲醛工艺生产线:
本工艺是用尿素和甲醛在PH8条件下生产二甲基脲,然后在PH4.75条件下逐步添加尿素进行缩聚反应,甲醛和尿素的摩尔比为1:3,最后生产脲甲醛,将反应好的脲甲醛溶液作为造粒料浆喷入复合肥造粒机内的物料层上,在造粒机的滚动作用下成粒,后经过烘干、冷却及筛分等工序,最终成品包装入库。
优势:是一款化学缓释复合肥,产量大,颗粒强度高,商品性好,国内知名度高。
主要设备:脲甲醛配制系统、造粒机、烘干机及冷却机等
主要原料:甲醛、尿素、磷酸一铵、硫酸钾等
产能:5-15万吨/年
6.Urea formaldehyde process production line
This process is with urea and formaldehyde under the condition of pH8 production dimethyl urea, then in PH4.75 under the condition of gradually adding urea condensation reaction and the molar ratio of formaldehyde and urea is 1:3, after drying, cooling and sieving processes of the production of urea formaldehyde and the reaction of urea formaldehyde solution as granulation material slurry is injected into compound fertilizer granulator material layer and in the granulator rolling under the action of grain, and the final product packaging warehousing.
Advantages: it is a chemical compound fertilizer with high yield, high grain strength, good commercial property and high reputation in China.
Main equipment: urea formaldehyde preparation system, granulation machine, drying machine and cooling machine, etc.
Main raw materials: formaldehyde, urea, ammonium phosphate, potassium sulfate, etc.
Capacity: 5-15 million tons / year
(七)硫酸脲生产工艺:
本工艺是将尿素、硫酸按一定比例进行反应生成性质稳定的硫酸脲溶液,再将硫酸脲料浆喷到造粒机料床表面,靠溶液高黏性与造粒机内的其它氮、磷、钾基础原料粘结成粒,经干燥、筛分、冷却、包裹等正常生产工序,最终形成复合肥产品。
硫酸脲复合肥工艺是我公司独家研发的复合肥生产方法,利用该工艺可以进行普通复混肥生产装置的升级,该技术具有节能、环保效果好、投资低、产量高、运转成本低、产品肥效好、产品品种多样化、工艺适应性强等优点。
同时在生产厂现有生产设备的基础上也可以进行升级改造,只需要新增硫酸脲配制系统、输送设备及附属管道、阀门、仪表即可。
优势:是一款化学缓释复合肥,产量大,颗粒强度高,商品性好。
主要设备:硫酸脲配制设备、转鼓造粒机、烘干机、冷却机等
主要原料:硫酸、尿素、磷酸一铵、硫酸钾等
产能:5-15万吨/年
7.Sulfuric acid urea production process
This is the process of the urea and sulfuric acid according to a certain proportion of reaction stability properties of urea sulfuric acid solution, then the sulfuric acid urea material slurry spray to granulating machine bed surface, by high solution viscosity and granulating machine of other nitrogen, phosphorus, potassium based materials bonded into particle by drying, sieving, cold but, package, and other normal production process, and ultimately the formation of compound fertilizer products.
Urea sulfuric acid compound fertilizer process is my company exclusive development of compound fertilizer production method, and the process can be utilized for ordinary complex mixed fertilizer production device upgrade, the technology has energy saving, good environmental protection effect, low investment, high yield, operation has the advantage of low cost, good fertilizer products, diversification of product variety, process adaptability is strong.
At the same time on the basis of existing production equipment can also be carried out on the basis of upgrading, only need to add urea sulfuric acid preparation system, transport equipment and ancillary pipes, valves, instrumentation can be.
Advantage: it is a chemical compound fertilizer with high yield, high grain strength and good commercial property.
Main equipment: urea sulfate preparation equipment, drum granulator, drying machine, cooling machine etc.
Main raw materials: sulfuric acid, urea, ammonium phosphate, potassium sulfate, etc.
Capacity: 5-15 million tons / year
(八)、全水溶肥生产线:
全水溶性肥是随着当前滴灌、喷灌的大面积普及,以及水肥一体化理念的发展而快速发展的一种新型肥料,这类肥料多为粉状产品,具有养分含量高(也叫大量元素肥)、全水溶、肥效快等显著特点,同时这类肥料因为原材料的原因极容易吸潮,因此在生产过程中需要全密闭,夏季湿度大的天气下生产时,还需要额外添加除湿机来防止肥料吸潮结块。
主要设备:电子配料机、密闭输送器、高效混合机、电子包装秤等。
主要原料:尿素、磷酸二氢钾、磷酸二胺、硫酸钾等
产能:1-5吨/时
8.Whole water soluble fertilizer production line
Water soluble fertilizer is with the popularity of a large area of the drip irrigation, sprinkler irrigation and fertilizer integration of the concept of development and the rapid development of a new type of fertilizer, the fertilizer for powder products, with nutrient content high (also called a lot of elements fertilizer, water soluble and quick fertilizer effect and so on the remarkable characteristic, also this type of fertilizer because of raw materials is extremely easy to absorb moisture, so in the production process need full closed, summer humidity weather production, also need to additional dehumidifiers to prevent fertilizer absorb moisture caking.
Main equipment: electronic batching machine, closed conveyor, high efficiency mixer, electronic packaging scale etc..
The main raw material of urea, potassium dihydrogen phosphate, phosphoric acid, potassium sulfate and two amine
Capacity: 1-5 tons / time
(九)挤压造粒工艺
此工艺原理是将一种或多种粉状原料,通过模具,利用
强大的挤压力挤压成颗粒,工艺原理简单,配套设备较少。
优点:占地面积小、投资少。
弱点:相对生产成本高、颗粒外观差、产量低。
主要配套设备:挤压造粒机、筛分机、输送机、包装
机等。
适用肥料种类:无机复混肥、有机肥、有机无机复混
肥。
产能:单台1-3吨/时。
 
9. Extrusion granulation process
The principle of this process is that one or more powder
raw materials can be squeezed into particles through the mould, with powerful extrusion pressure. The principle is simple and less equipment used.
    Advantage: Cover an area small, less investment.
    Weakness: Relatively high production cost, poor grain appearance and low yield.
    Major equipment: Extrusion pelleting machine, screening machine, conveyor, packing machine, etc.
    Adaptable fertilizer: Inorganic fertilizer, organic fertilizer, organic inorganic compound mixing fertilizer.
    Capacity: One set can produce 1-3 tons/hr.

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