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複混肥制作工藝及相應配套設備
(一) 有機肥發酵設備
此工藝是針對目前大量有機廢棄物随意丢棄,造成大面積環境二次污染的現狀設計,此發酵工藝不同于傳統的厭氧發酵(沼氣池)采用好氧發酵工藝,添加發酵菌,在控溫增氧的條件下實現快速腐熟發酵過程,發酵過程無臭味産生,發酵效率高,可将有機廢棄物快速轉化為有機肥料,真正實現變廢為寶,循環生态。
發酵設備有多齒型翻抛機、鍊闆式翻抛機以及全密閉高溫發酵器多種類型,客戶需根據實際生産需要自由選擇。
優點:全天候運行、運行成本低、設備投資少、轉化效率高。
主要配套設備:裝載機、翻抛機、移位機、密閉發酵器尾氣生物處理器等。
使用原料種類:養殖禽畜糞便(牛、羊、豬、雞糞等)、工業有機廢棄物(甘蔗渣、木薯渣、澱粉渣、糖泥、污泥等)。
産能: 10-15萬噸/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)圓盤/蒸汽轉鼓造粒工藝
圓盤/蒸汽轉鼓造粒工藝其實是兩種工藝,根據其造粒
機的不同,可細分為圓盤造粒工藝和蒸汽轉鼓造粒工藝,也可以根據原料情況組合成轉鼓+圓盤雙造粒機工藝,主要區别就是在造粒機,後面的烘幹、冷卻及其他配套設備都是相同的。
1.圓盤造粒工藝:
優點:造粒能力強,産品外觀圓潤,可适應原料範圍廣。
弱點:産量小,造粒時需添加輔料,無法生産高養分肥料,多适用于小型肥料生産企業。
2.轉鼓造粒工藝:
優點:在添加蒸汽的情況下産量大,生産粉塵小,可生産高養分複混肥。
弱點:原料适應範圍窄,不添加蒸汽的情況下造粒能力大幅下降。因為用來生産肥料的原料種類繁多,原料之間的搭配也是多種多樣,所以,具體選用哪種造粒機還要看具體原料情況來确定工藝方案。
3.主要配套設備:圓盤造粒機、轉鼓造粒機、烘幹機、
冷卻機、包膜機、皮帶輸送機、粉碎機、篩分機、混料機、包裝機等。
4.适用肥料種類:無機單養分肥、無機多養分複混肥、
有機肥、生物有機肥、有機無機複混肥。
5.産能:單線1-10萬噸/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) 尿基噴漿造粒工藝
此工藝是将尿素高溫熔融以後,将高溫的尿素熔液代替造粒水噴灑到造粒機中的物料層上進行造粒,因為尿素熔液自身具有很好的粘性,而且尿素熔液遇冷會逐漸凝固,減少了造粒水的用量,因此,采用此工藝可以提高造粒機的成球效率,增加産量。同時,因為尿素自身是一種高氮肥料,所以,采用此工藝可以生産高含量的複混肥,是一種适應性非常廣泛的肥料造粒工藝。
優點:産量高、可生産高養分複混肥、顆粒外觀圓潤光滑、原料适用範圍廣。
弱點:生産成本略高
主要配套設備:尿素熔融系統、圓盤或轉鼓造粒機、烘幹機、冷卻機、篩分機、包膜機、包裝機等。
适用肥料種類:無機複混肥、有機無機複混肥。
産能:單線3-10萬噸
 
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/氨化法造粒工藝
這兩種工藝主要用來生産無機複混肥,氨酸法工藝原理是利用液氨與稀硫酸反應生成的高溫硫酸铵液漿來代替一部分水及蒸汽的用量,且硫酸铵料漿自身具有一定粘性,可以提高造粒機成粒效率,提高産量,大幅降低生産成本。氨化生産工藝是在氨酸法工藝的基礎上增加了一套氯化鉀脫氯工藝,可以在一條生産線中直接用氯化鉀生産硫酸鉀型複合肥,生産成本進一步降低。
優點:産量高,生産成本低,可生産高養分複合肥。
弱點:必須要用到液氨、硫酸,因具有一定危險性,在
部分地區申建審批時會有困難。
主要配套設備:氨站、酸罐、配酸系統、反應器、轉鼓造粒機、烘幹機、冷卻機、篩分機、包膜機、包裝機等。
适用肥料種類:無機複合肥。
産能:單線5-15萬噸/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)高塔造粒工藝
該工藝最适合用來生産高濃度無機複混肥,工藝原理是利用尿素熔液遇冷快速凝固的特點,将尿素顆粒加溫熔化後,按照一定量的配比,将磷、鉀等原料加入到尿素熔液中,混合均勻後通過造粒機噴灑到塔體内,料漿液滴在從塔頂部下落的過程中遇冷凝固,從而形成圓形顆粒,經收集、篩分、包膜等一系列工序後制得成品包裝。
優點:産量大、生産成本低、産品養分含量高、外觀漂亮且易于識别。
弱點:必須要用尿素、投資大、不适合生産高磷養分的複混肥。
主要配套設備:塔體、熔料罐、提升機、造粒機、冷卻機、篩分機、包膜機、包裝機等。
适用肥料種類:高養分無機複混肥。
産能:單塔8-15萬噸/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)、脲甲醛工藝生産線:
本工藝是用尿素和甲醛在PH8條件下生産二甲基脲,然後在PH4.75條件下逐步添加尿素進行縮聚反應,甲醛和尿素的摩爾比為1:3,最後生産脲甲醛,将反應好的脲甲醛溶液作為造粒料漿噴入複合肥造粒機内的物料層上,在造粒機的滾動作用下成粒,後經過烘幹、冷卻及篩分等工序,最終成品包裝入庫。
優勢:是一款化學緩釋複合肥,産量大,顆粒強度高,商品性好,國内知名度高。
主要設備:脲甲醛配制系統、造粒機、烘幹機及冷卻機等
主要原料:甲醛、尿素、磷酸一铵、硫酸鉀等
産能:5-15萬噸/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)硫酸脲生産工藝:
本工藝是将尿素、硫酸按一定比例進行反應生成性質穩定的硫酸脲溶液,再将硫酸脲料漿噴到造粒機料床表面,靠溶液高黏性與造粒機内的其它氮、磷、鉀基礎原料粘結成粒,經幹燥、篩分、冷卻、包裹等正常生産工序,最終形成複合肥産品。
硫酸脲複合肥工藝是我公司獨家研發的複合肥生産方法,利用該工藝可以進行普通複混肥生産裝置的升級,該技術具有節能、環保效果好、投資低、産量高、運轉成本低、産品肥效好、産品品種多樣化、工藝适應性強等優點。
同時在生産廠現有生産設備的基礎上也可以進行升級改造,隻需要新增硫酸脲配制系統、輸送設備及附屬管道、閥門、儀表即可。
優勢:是一款化學緩釋複合肥,産量大,顆粒強度高,商品性好。
主要設備:硫酸脲配制設備、轉鼓造粒機、烘幹機、冷卻機等
主要原料:硫酸、尿素、磷酸一铵、硫酸鉀等
産能:5-15萬噸/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)、全水溶肥生産線:
全水溶性肥是随着當前滴灌、噴灌的大面積普及,以及水肥一體化理念的發展而快速發展的一種新型肥料,這類肥料多為粉狀産品,具有養分含量高(也叫大量元素肥)、全水溶、肥效快等顯著特點,同時這類肥料因為原材料的原因極容易吸潮,因此在生産過程中需要全密閉,夏季濕度大的天氣下生産時,還需要額外添加除濕機來防止肥料吸潮結塊。
主要設備:電子配料機、密閉輸送器、高效混合機、電子包裝秤等。
主要原料:尿素、磷酸二氫鉀、磷酸二胺、硫酸鉀等
産能:1-5噸/時
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)擠壓造粒工藝
此工藝原理是将一種或多種粉狀原料,通過模具,利用
強大的擠壓力擠壓成顆粒,工藝原理簡單,配套設備較少。
優點:占地面積小、投資少。
弱點:相對生産成本高、顆粒外觀差、産量低。
主要配套設備:擠壓造粒機、篩分機、輸送機、包裝
機等。
适用肥料種類:無機複混肥、有機肥、有機無機複混
肥。
産能:單台1-3噸/時。
 
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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