Russia, large agricultural country, has rich reserves of raw materials for mineral fertilizers, such as potassium and apatite. Our client runs a mineral fertilizer company. However, the company faced such problems, low adaptability of equipment, insufficient production capacity and unstable product quality. The company is faced with a dilemma: “inability to accept orders and deterioration of the product’s reputation”. At the same time, equipment often breaks down, and maintenance costs remain high.
In an effort to modernize your equipment, they turned to us for help. After purchasing our custom disk granulator for mineral fertilizers and its introduction into production, we have finally achieved a double breakthrough in productivity and production quality. Take back the initiative in the market. Are you also worried about such problems?, such as reduced production and high equipment maintenance costs? Contact us, and we will help you solve this problem.
Why the Russian client ultimately chose a disc granulator for the production of mineral fertilizers?
The Russian customer ultimately chose disc granulator for the production of mineral fertilizers. The key factor was its adaptability in three key parameters: raw material compatibility, cost control and quality of finished products. Our disc granulator accurately solves the company's production problems and fully meets customers' needs.
Raw material: Main raw materials (potassium and apatite), used by a Russian customer for the production of mineral fertilizers, has high moisture absorption and hardness. The special design of the disc granulator solves these problems. The disc granulator uses variable frequency motor to adjust the speed (potassium: 18–22 rpm, apatite: 22–25 rpm), which allows you to quickly change the recipe without replacing equipment. This increases equipment utilization to 95%, eliminating the need for excess investment in “one machine for one raw material”.
Price: Previously, the Russian customer faced frequent equipment breakdowns, high energy consumption and high labor costs. Our disc granulator has a simple structure and requires 40% less investment, than an extrusion granulation line of the same capacity. Moreover, Custom-made wear liners extend wear part replacement cycles. Maintenance frequency reduced from 8 to 2 once a month. Variable speed motor (with Efficiency transmission ≥95%) and waste heat recovery system reduce overall operating costs for 15%.
Finished product: The customer had previously lost orders due to “high rates of pellet breakage and uneven quality.”. Precise granulation control of the disc granulator ensures uniform, seamless appearance. This significantly improves the quality of the finished product. Rounding machine design + return of the drum screen" made it possible to increase the shelf life of finished products from 75% to 92%. By adjusting the dosage of spray liquid (with an accuracy of ±0.1%) and disk rotation speed. The strength of apatite fertilizer granules can be stabilized at 2.0–2.5 N. The percentage of destruction during transportation can be reduced with 10% to less 3%.
What optimizations have we made to the disk granulator for mineral fertilizers, taking into account the characteristics of the raw materials of Russian customers??
Due to high production volume requirements, the customer ultimately purchased two disk granulators: one for the production of potash fertilizers, and the other for the production of apatite fertilizer granules. We have optimized our disc granulator specifically for two main raw materials, used by our clients:
- Suitable lining material: The potassium fertilizer granulation unit is equipped with a rubber lining (excellent surface elasticity and non-stick properties). The apatite granulation plant uses stainless steel lining 304 (wear resistance coefficient in 3 times higher, than carbon steel). In this case, the edge of the disk is thickened to 12 mm, to withstand exposure to highly hard materials.
- Frequency conversion + precise spray: equipped with a powerful motor with frequency converter 30 kW. Speed is smoothly adjustable in the range of 12–28 rpm (18–22 rpm for potash granulation to avoid sticking; 22–25 rpm for apatite granulation to improve molding efficiency). Equipped with a ring spray system, controlled by PLC, the dosage error of the sprayed liquid is ±0.1%. Considering, that potassium salt easily absorbs moisture, Especially for our Russian customers we have added a “low temperature preheating and tempering” module (50°C). Reduce raw material humidity to 12–15 %, to further reduce sticking.
Raw material testing service + customized equipment solutions. Targeted solutions to your problems.
If you also have problems with granulation, you can send raw materials (10-20 kg) to our factory. We will conduct a free granulation test at our facility. Record the entire granulation process for yourself. (molding speed, particle uniformity, equipment operating parameters). We also provide you with particle samples and strength/uniformity test reports, to help you intuitively understand the suitability of your equipment. Based on test results, as well as the characteristics of your raw materials, requirements for production capacity and site size, we will draw up an equipment layout diagram. And clearly indicate the lining material, engine power, auxiliary equipment (such as a crusher, bolt) and other configurations. Prices are clearly stated, no hidden fees.
If you encounter such problems, as rapid wear and tear of equipment, severe pellet clumping or poor performance. Or are you planning to purchase equipment?, For example, mineral fertilizer granules production line or disk granulator for mineral fertilizers, Contact us. Click the "Consult" button below or leave a message "Test Machine + Your type of raw material", and our technical consultant will contact you within 1 hours. Solve your mineral fertilizer granulation problems with targeted services!
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