The equipment configuration of the compound fertilizer production line with an annual output of 100000 tons may vary slightly depending on the granulation process (such as disc granulation, high tower granulation, etc.), but the core revolves around raw material processing, granulation molding, post-treatment, and auxiliary support. The following is a list of commonly used equipment covering the entire process, while distinguishing special configurations for different processes:

Raw material pretreatment equipment

Automatic batching system: including electronic measuring scales, silos, belt feeders, etc., it can accurately control the ratio of various raw materials such as urea, ammonium phosphate, potassium chloride, etc., matching the continuous production demand of 100000 tons per year, avoiding the impact of mixing errors on fertilizer efficiency. Its power can usually meet the stable feeding of multiple raw materials at the same time.

Crusher: A commonly used semi wet material crusher or chain crusher is used to crush agglomerated or large materials, ensuring uniform particle size (generally ≤ 0.5mm), facilitating subsequent mixing and granulation, and avoiding poor granulation effect due to differences in raw material particle size. The power is mostly around 30KW, suitable for this production capacity.

Horizontal/disc mixer: Fully mix the prepared and crushed raw materials to solve the problem of layering caused by different densities of raw materials, and improve the uniformity of fertilizer particle efficiency. The mixer power matched with this production capacity is about 11KW, which can achieve continuous and uniform mixing of raw materials and transport them to the granulation process.

Core granulation equipment

Conventional granulation equipment: If traditional processes are used, disc granulators or drum granulators are often chosen. The disc granulator has a simple structure and low cost, suitable for small and medium-sized production capacity; The rotary drum granulator operates stably, has good granulation uniformity, and is suitable for continuous production of 100000 tons/year, with a supporting power of about 15KW.

Special equipment for tower granulation: If the tower spraying granulation process is used, a granulation tower of about 96 meters, a dedicated spraying nozzle, and a urea melting system need to be equipped. The melting system melts urea into a slurry, which is sprayed into droplets through nozzles. The droplets then condense into particles through heat exchange with air in the tower. This process does not require additional drying equipment, but requires insulation and material conveying devices related to the tower.

Particle post-treatment equipment

Rotary dryer: for drying wet particles after conventional granulation, reducing the moisture content of particles to below 2%, improving particle strength, and avoiding moisture absorption and agglomeration during storage. The most suitable for this production capacity are rotary drum dryers with specifications such as φ 2.4 × 24m, with a power of about 30KW.

Cooling machine: After drying, the temperature of the particles is relatively high and needs to be cooled by a rotary cooling machine. After the temperature drops to near room temperature, it is convenient for subsequent screening and packaging. A common cooling machine with a diameter of 2.2 × 20m and a power of about 22KW can match the discharge speed of the dryer to ensure production continuity.

Drum screening machine: Some production lines will be equipped with primary and secondary screening. First level screening removes particles that are too large or too small after granulation, and returns to the crushing stage; Secondary screening re grades the cooled particles to ensure a finished particle size of 3-5mm, with an equipment power of approximately 4KW. Unqualified particles after screening can be recycled to reduce raw material waste.

Rotary coating machine: coating qualified particles by spraying coating agent to increase particle roundness and brightness, while preventing moisture absorption and agglomeration. For example, the powder coating machine with a diameter of 1.6 × 6m is suitable for this production capacity and can improve the storage and transportation performance of finished products.

Finished product packaging and auxiliary equipment

Automatic packaging equipment: including electronic quantitative packaging scales, sewing machines, and some production lines are also equipped with palletizing robots to achieve quantitative bagging, sealing, and palletizing of finished particles, reducing labor costs and adapting to the batch packaging needs of 100000 tons of production capacity. The packaging machine has a power of about 2.2KW.

Environmental protection supporting equipment: Bag dust collectors, cyclone dust collectors, etc. need to be equipped to collect dust generated during feeding, screening, and drying processes. The dust can be recycled and reused in production; If equipped with a hot blast stove, additional desulfurization and denitrification devices need to be added, such as urea denitrification and limestone wet desulfurization equipment, to meet environmental emission requirements.

Conveyor equipment: The belt conveyor and bucket elevator run through the entire production line, responsible for the transportation of raw materials, semi-finished products, and finished products between various equipment. For example, the mixed raw materials are transported to the granulator, and the coated finished products are transported to the packaging machine, achieving the continuous conveying goal of "zero" material dropping.