TONGLI Dry Briquetting compaction compound fertilizer production are to first extrude the material into large pieces, and then use a crusher to break the large pieces into finished product size. The strength of Briquetting particles is about 20% higher than that of traditional particles.

PRODUCTION LINE EQUIPMENT LIST

Dry roll press granulator

Dry roller granulator is a kind of equipment that squeezes powdered materials into granules through high-pressure rollers. This equipment does not need to add liquid binders or water, thus avoiding the drying step required in wet granulation, thus greatly saving energy and costs.

Dry roller press coating machine

After being squeezed and crushed, the material enters the drum coating machine and is evenly coated with a layer of protective film. This avoids the negative impact of moisture on the particles, prevents agglomeration and improves the strength of the particles.

Roller Compaction Fertilizer Produciton Line ADVANTAGES

The briquetting dry type compaction special-shaped particle extrusion production line has a 30% reduced floor space, optimizing the space utilization of the factory

Large particle extruders have higher output, up to 10 tons per hour

30% less floor space, optimized factory space utilization

Integrated high-frequency vibration feeding device, feeding error does not exceed 0.5%

Automatically adjust the pressure to adapt to different material characteristics, improve production flexibility and efficiency.

Flexible configuration according to demand, optional polishing and coating processes

The roller surface is coated with a nano-ceramic layer, which increases the wear resistance by 60%

The roller spacing adjustment accuracy reaches 0.01 mm, ensuring the consistency and accuracy of the particle shape.

Briquetting Dry Compaction Granulation PROCESS

zhejiang tongli heavy machinery dry type briquetting roller press fertilizer production line solution process flow

Raw material preparation

This irregular large particle extrusion granulation process is particularly suitable for raw materials containing metal elements, such as potassium chloride (KCl) and potassium sulfate (K₂SO₄) fertilizer production. Conventional roller extrusion granulators usually consume a large amount of stainless steel roller skins due to the presence of metal elements in the raw materials. The large particle extrusion method has a higher output of up to 10 tons per hour due to less wear. In addition, this method can also handle single-element fertilizers with insufficient viscosity. The raw materials are squeezed into particles by the pressure between the two rollers, which greatly improves the pelletization rate.

Automatic-Batching Process

Whether an automatic quantitative batching system for raw materials is required depends on the type of product produced. If only single-element fertilizers such as potassium chloride or potassium sulfate are produced, a batching system is not required. However, if NPK compound fertilizers are produced, multiple raw materials are required. Therefore, a high-precision batching scale is required to weigh the raw materials before entering the mixing process.

Mixing and conveying

After weighing, the raw materials are fed into a twin-shaft mixer for mixing. The mixer not only makes the raw material composition more uniform, but also handles the return material from the screening process. The unqualified materials after screening are returned to the mixer through the return belt or return scraper for remixing. Water pipes are added during the mixing process to ensure that the moisture content of the raw materials is kept at around 2% to increase the ball formation rate.

Agglomeration And Compaction

The mixed raw materials enter the large-particle extrusion granulator through the feeding system. Compared with conventional small-particle extruders, large-particle extruders have higher output and can process 10 tons of materials per hour. Through the pressure of the oil cylinder, the material is extruded into strips or blocks in two stainless steel molds. The specific shape is determined by the mold texture, and the finished product enters the crushing process.

Crushing

The strength of the extruded material is already high and needs further processing. The extruded strips or blocks are about 3-5 cm in size and are crushed by the impact crusher. After pre-crushing, the block material is 1-2 cm in size. After the second crushing, the size is 0.5-0.7 cm, forming small particles. These small particles will enter the screening equipment, and the unqualified products will be returned for reprocessing.

Screening

Screening is a key link in the production line. After the first hammer crushing, the material enters the drum screen or vibrating screen. Qualified particles enter secondary crushing, and unqualified particles return to the twin-shaft mixer for reprocessing. After secondary crushing, fine screening is carried out, and the qualified finished products screened out enter the next process, and unqualified particles return for re-granulation.

Polishing (optional)

The polishing process depends on customer needs. If the customer wants the particles to be more rounded, a rotary polishing device can be used to process the surface of the particles. If the customer accepts irregular particles, this process can be omitted, and the main function is aesthetics.

Coating (optional)

The coating process depends on customer needs. The screened materials can enter the automatic quantitative feeding scale and belt scale, and coating oil and anti-cleaning agent are added through the DCS system. Coating can enhance the color of the particles and the stability of the product, and extend the storage time. If there are no special requirements, this process can be omitted to save costs.

Dust removal

The dust removal system is equipped with a bag dust collector, which is suitable for low-humidity dust. The system includes a centrifugal fan and a fiberglass chimney to effectively collect dust from the raw material feeding and screening process, and control the emission to less than 30 mg per cubic centimeter.

Packaging and Palletizing

The final step is automatic quantitative packaging and palletizing. The finished product can be packaged into 25 kg or 50 kg bags. The fully automatic APP robot palletizing system, including all stainless steel conveyor belts and robot grippers, can produce up to 1,000 bags per hour. The automatic packaging scale uses advanced servo motor technology and has an output of between 800 and 1,000 bags per hour.

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FAQ

1. What are the main advantages of the roller-pressed shaped pellet extrusion line?

The main advantage of the roller-pressed shaped pellet extrusion line is that it can effectively handle raw materials containing metal elements, such as potassium chloride (KCl) and potassium sulfate (H2SO4) fertilizers. These raw materials usually cause great wear on the machine, but the roller pressing process greatly reduces the wear rate by using stainless steel rollers and dies.

In addition, compared with the traditional drum granulation line, the roller pressing process can also effectively handle single-element fertilizers with insufficient viscosity, ensuring the quality and ball formation rate of the pellets. The production capacity of the line can reach 10 tons per hour, which is suitable for large-scale production. Through roller pressing, the raw materials are pressed into pellets between two rollers, which greatly improves the uniformity and stability of the finished product.

2. How does automatic batching work in a roller-pressed shaped pellet extrusion line?

Automatic batching systems are particularly important when producing compound fertilizers with multiple raw materials. The system uses a high-precision batching scale to accurately weigh different raw materials to ensure the accuracy of the mixing ratio.

For single-element fertilizers, such as potassium chloride or potassium sulfate, automatic batching systems are usually not required because the raw materials are simple and do not require complex mixing. However, when producing NPK compound fertilizers, the automatic batching system can be adjusted according to the type and quantity of raw materials to ensure that the proportion of each raw material is accurate and the quality of the finished product is consistent.

3. How does the mixing affect the efficiency of roller-pressed compaction fertilizer pellet line?

In the mixing and conveying stage, the twin-shaft mixer is responsible for uniformly mixing and conveying the weighed raw materials. This stage not only ensures the uniformity of all raw materials, but also handles the return material, making the entire process more efficient.

During the mixing process, the moisture addition system keeps the moisture content of the raw materials at around 2%, which is crucial for the subsequent extrusion process. Without the proper moisture content, the pelletization rate will be severely affected, resulting in a decrease in production efficiency. Therefore, the mixing and conveying stage is the key to ensure the efficient operation of the entire production line.

4. What is the process of dry roller granulation of compound fertilizer?

The extrusion process is the core of the production line, which involves feeding the raw materials into the large particle extrusion granulator through the feeding system. Compared with the traditional small particle extruder, this equipment can produce up to 10 tons per hour.

The material is pressed into particles of a specific shape in the stainless steel mold by applying pressure through the oil cylinder. The grain on the mold determines the shape of the particles, which can be strips or blocks.

This process not only increases the output, but also ensures the physical strength and consistency of the particles, laying the foundation for the subsequent crushing and screening links.

5. Why is crushing important for the dry type briquetting fertilizer line?

Crushing is to further process the extruded strip or block material (about 3-5 cm) into small particles (0.5-0.7 cm). The impact crusher plays a key role in this process. It first performs pre-crushing by rotating hammers to break the material into blocks (1-2 cm), and then performs formal crushing to obtain the final required small particle size. This link not only improves the uniformity and quality of the particles, but also ensures that the final product is suitable for market demand, making the entire production process more complete and efficient.

6. How to ensure the product quality of roller-pressed shaped pellet extrusion production line?

1) The first is the selection and proportion of raw materials, which are controlled by high-precision batching scales. Secondly, the mixing and extrusion process needs to be stable to prevent uneven particles or reduced ball formation rate.

2) Crushing and screening are key links to ensure that the particle size and shape meet the standards.

3) Finally, polishing and coating processes are carried out as needed to improve appearance and durability. Strict quality monitoring and data analysis are required throughout the process.

Dry TYPE Briquetting Compactor FERTILIZER PLANT TECHNICAL PARAMETERS

Equipment NamePressure/PowerProduction Capacity/EfficiencyKey ParametersEquipment Highlights
Briquetting CompactorPressure: 15-40 MPa2-12 tons/hourRoller diameter: 450-900 mmHigh-strength double rollers, suitable for various fertilizer formulations, wear-resistant materials
Motor power: 30-90 kWRoller material: Wear-resistant alloy steelLong lifespan design, reducing maintenance frequency
High-Speed CrusherPower: 15-75 kWCrushing capacity: 0.3-1.5 mmFeeding size: ≤25 mmEfficient crushing for various hardness materials, ensuring consistent particle size
High-Precision Vibrating ScreenPower: 5-18 kWScreening area: 1.5-12 m²Screen size: 1-8 mmLarge screening area, supports large-scale production, reducing failure rates
Horizontal MixerPower: 11-30 kWMixing time: 3-10 minutesCapacity: 1000-5000 litersHigh-efficiency mixing ensures material uniformity
High-Efficiency Rotary DryerPower: 20-60 kWProcessing capacity: 3-15 tons/hourTemperature range: 80-250°COptional gas, steam, or electric heating, precise temperature control
Fully Automatic Packaging MachinePower: 5-12 kWPackaging speed: 400-800 bags/hourPackaging spec: 25-50 kgHigh-speed packaging reduces manual intervention, increases packaging efficiency
Intelligent Electrical Control SystemPLC automated systemReal-time monitoring and fault diagnosisTouchscreen interface, supports remote operationProvides accurate production data, improves equipment efficiency
Modular Material Conveyor SystemPower: 3-10 kWConveyor speed: 0.2-3.0 m/sConveyor width: 500-1500 mmBelt, chain, or roller conveyor ensures damage-free material transport