What are the common malfunctions in fertilizer production lines?

The stable operation of a fertilizer production line directly affects product quality and production efficiency. In actual production, various malfunctions often occur due to raw material characteristics, equipment wear, or improper operation. Mastering the troubleshooting methods for core malfunctions can effectively reduce downtime and minimize production losses. The following are three of the most typical malfunctions in production line operation and practical troubleshooting solutions.

Uneven granulation is the most frequent malfunction in compound fertilizer and organic fertilizer production lines, manifested as large variations in particle size, clumping, or low granulation rate. There are three main causes: first, unbalanced raw material ratio, with excessively high or low moisture content (the suitable moisture content is usually 20%-30%); second, abnormal granulator speed or wear of internal paddles; and third, insufficient material mixing. During troubleshooting, first check the raw material moisture content and ratio, and adjust it to a reasonable range by drying or adding water; then check whether the granulator speed meets the equipment parameters and check the paddle wear, replacing or repairing them as needed; finally, confirm the mixer's operating status to ensure that the materials are evenly mixed before entering the granulation process.

Inadequate drying can lead to excessive moisture content in the fertilizer, making it prone to clumping and deterioration. The core reasons include improper temperature control of the dryer, insufficient hot air volume, and insufficient material residence time in the machine. During troubleshooting, first calibrate the temperature sensor to ensure that the drying temperature is stable at 80-120℃ (adjusted according to the type of fertilizer); secondly, check the combustion status of the hot air furnace and whether the air ducts are blocked, and clean accumulated dust to ensure sufficient airflow; finally, adjust the dryer drum speed to extend the material residence time, and check whether the internal baffles of the drum are intact to ensure sufficient contact between the material and the hot air.

Low screening efficiency results in excessive impurities in the finished product and excessive recirculation of unqualified particles, often caused by screen blockage, insufficient screen vibration amplitude, or screen damage. During troubleshooting, first stop the machine and clean the screen blockage; for sticky materials, a pre-screening step can be added; then check the operating status of the vibrating motor and adjust the eccentric block angle to increase the amplitude; finally, check whether the screen is damaged or loose, and replace or tighten it in time to ensure that the screen mesh size meets the finished product requirements. 

In addition, performing daily equipment inspections and maintenance, regularly lubricating transmission components, and cleaning accumulated material from the equipment can reduce the occurrence of malfunctions at the source. If malfunctions occur repeatedly, further optimization of process parameters based on production data is necessary to ensure the stable and efficient operation of the fertilizer production line.

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