What are the differences between dry granulation and wet granulation in fertilizer production?

Granulation is a crucial step in the fertilizer production line, directly affecting product form, application effectiveness, and production efficiency.Dry granulation and wet granulation, as two mainstream processes, differ significantly in technical logic, production conditions, and applicable scenarios. Understanding these differences is crucial for fertilizer companies in selecting the appropriate process.

The core differences lie in the process principles and raw material requirements. Dry granulation does not require additional water, relying on the inherent binding properties of the fertilizer raw materials or a small amount of binder. Granulation is completed through extrusion, crushing, and screening.  The raw material moisture content must be strictly controlled at 8%-12%; excessive moisture can lead to clumping and equipment blockage. Wet granulation requires adding water or a binder solution to the raw materials to create a plastic state, which is then rolled into granules by a granulator. The initial moisture content of the raw materials can be relaxed to 15%-20%, but subsequent drying is required to reduce moisture.

Production energy consumption and equipment costs differ significantly. Dry granulation equipment has a simpler process, primarily consisting of an extrusion granulator and a screening machine, and does not require a drying system. Initial investment is low, and the unit energy consumption is only 1/3 of that of wet granulation. Wet granulation requires a granulator, dryer, cooler, etc., resulting in higher equipment investment. The drying process consumes a large amount of heat energy, leading to high energy costs, and requires exhaust gas treatment, further increasing environmental protection costs.

Product characteristics and application scenarios have different focuses. Dry granulated products have high hardness and irregular shapes, with uniform nutrient distribution, making them suitable for long-distance transportation and mechanized fertilization, and ideal for arid regions. Wet granulated products are spherical, with good fluidity and rapid dissolution, suitable for quick-acting fertilization. However, they have low hardness and are prone to dusting, making them more suitable for local application and fertigation scenarios.

In summary, dry granulation is suitable for low-cost, low-energy consumption requirements, while wet granulation better meets the requirements of high adaptability and superior application experience. Companies need to scientifically select the process based on raw material characteristics, product positioning, and cost budget to achieve a precise match between production efficiency and market demand.

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