The granulation drying process is a commonly used method in the production of NPK fertilizer, DAP fertilizer, etc. Below are the key steps in this process:
- Raw Material Preparation: Mixing key ingredients main components such as Ammonia (NH₃), Phosphoric Acid (H₃PO₄), Potassium (KCl), Urea (CO(NH₂)₂), and Limestone (CaCO₃) in the desired ratio to create the appropriate fertilizer formulation (e.g., NPK 16-16-8, 20-10-10).
- Preliminary Granulation: The mixed materials are fed into a Drum Granulator, where they form small granules with initial compression and size.
- Granule Drying: The freshly formed fertilizer granules contain high moisture content (15-20%). A Rotary Dryer is used to reduce the moisture content below 5%, ensuring the required hardness and stability.
- Cooling and Classification: The granules are cooled and screened to classify them according to standard size requirements.
- Packaging: The qualified fertilizer granules are packaged for storage and transportation.
This process ensures uniform fertilizer quality, meeting nutritional and size standards.
Below is a compiled list of all the essential measurement equipment commonly used in the granulation drying production line. These instruments help control product quality, optimize operational processes, and save energy:
1.Temperature Measurement Equipment
- Temperature Sensors (RTD, Thermocouple): Monitor temperature inside the dryer.
- PID Temperature Controller: Automatically regulates the drying temperature.
2.Air humidity and Product Moisture Measurement Equipment
Air humidity Sensor: Measures the supply air to dryer.
Near-Infrared (NIR) Moisture Analyzer: Provides rapid, non-contact moisture measurement.
3. Pressure Measurement Equipment
Pressure Sensors and Pressure Gauges: to monitor pressure in the dryer, compressed air system, and exhaust fan.
4. Flow Measurement Equipment
Gas flowmeter: Measures the flow rate and totalizer of hot gas entering the drying chamber, compressed air, LPG/CNG, steam.
Liquid flowmeter: to measure the flow rate and totalizer of water, liquid-form materials (for dosing or controlling).
5. Level Measurement Equipment
- Continuous Level Sensor: to monitor material levels in silos and mixing tanks.
- High/Low Level Sensor: to alarm when the material is reaching empty or full level.
6. Rotational Speed Measurement Equipment
Rotational Speed Sensor: to monitor the speed of the dryer.
7 .pH Measurement Equipment
Online pH Sensor: to measure the pH of raw materials or mixing solutions.
8. Oxygen and Emission Measurement Equipment
- O₂ Concentration Sensor: to monitor oxygen levels in the flue gas, to check and adjust for optimizing furnace efficient.
- Concentration of Emission Gas Analyzer (CO, CO₂, NOx, SOx): to track the exhaust gases to environment.
9. Vibration Measurement Equipment
Vibration Sensor: Monitors the operational condition of machinery
10. Weight Measurement Equipment (Belt Scale)
- Dynamic Belt Scale: Measures the mass of materials passing through the conveyor.
- Load Cell: Measures the weight of materials in silos or storage tanks.
11. Pneumatic or Electrically Actuated Linear Control Globe Valve
- Controls the flow of hot gas or steam in the dryer.
12. Data Logger
- Used to collect, store, and monitor data from measurement sensors in the industrial system.
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