NPK Granular Factory for Making Potassium Sulfate Fertilizer in Indonesia
A director of a chemical company told us his plan to set up a 15 t/d NPK granular fertilizer factory in Indonesia and engaged in potassium sulfate fertilizer production. Considering this is a new business for him, he expected us to offer him the production technology to make good-quality potassium sulfate fertilizer and guidance to improve the efficiency of his NPK granular fertilizer factory in Indonesia.
Then, let’s start with the potassium sulfate fertilizer production process first.
The Extrusion Granulation for the Production of Potassium Sulfate Chemical Fertilizer
When it comes to the manufacturing of potassium sulphate as fertilizer, there are 2 methods adopted by most NPK fertilizer makers, namely extrusion granulation (dry granulation) and wet granulation. Though the latter has a wide application in NPK compound fertilizer factories, the former is more advisable for the customer.
Usually, potassium sulfate is in the form of dry powder, which makes it harder to round it into granules in the process of steam granulation without dolomite or bentonite, two binding materials. The client has no intention of using any binding agent in the procedure of manufacturing potassium sulfate fertilizer granules. Hence, dry granulation should be the first resort. In fact, the technique of dry granulation has lots of advantages. For example, the steps of dry granulation are easy and simple, requiring a few machines. Therefore, the outlay of an NPK fertilizer production line with machines used for dry granulation is affordable for most small investors.
What is the Dry Granulation Process for Potassium Sulfate Fertilizer roduction?
Then, what is dry granulation? How can you make potassium sulfate fertilizer granules from NPK fertilizer powder? Let us expatiate on dry granulation method steps in layman’s terms.
The technique of dry granulation has been the mainstream for most fertilizer potassium sulfate plants. Its working principle is much more accessible than wet granulation.
First, you should know the design of the double rollers pressing granulator. It has two rollers rotating anticlockwise, with many ball sockets of the same size and shape. After the pan mixing machine feeds well-blended NPP fertilizer powder into the double roller press for granulator, the rollers press the powder with huge extrusion force. With the help of ball sockets, potassium sulfate fertilizer is formed into small granules. Then, how does the dry powder stick together by extrusion?
After the potassium sulfate fertilizer is crushed by extrusion force, there is a rearrangement of its structure. The air between fertilizer particles is extruded, and these grains are forced against each other closely. Therefore, an intermolecular force is generated, holding these litter particles together tightly. Even when external force is gone, it can help granules form into a specific shape. In general, you can get compact potassium sulfate fertilizer granules, if the compression ratio is close to 2.5:1 and the air in the raw materials is less than 40%.
Affordable Potassium Sulfate Granulator for NPK Fertilizer Production
As one of the potassium sulfate fertilizer plant manufacturers, we offer an efficient dry roller press granulator for sale. It is inclusively designed for making NPK compound fertilizer granules. As one of the dry granulator machines in the fertilizer industry, it uses extrusion force to press potassium sulfate fertilizer into granules.
How to Choose the Right Model of the Potassium Sulfate Granulator?
Like other potassium sulfate granulator suppliers, we have more than one model of granulators. Then, how to choose the right one for the client’s NPK granular fertilizer factory in Indonesia? These are some tips.
Looking at the Capacity
According to the client’s project, his fertilizer potassium sulfate plant needs to manufacture 15 tons of fertilizer granules in a day. Then, it is proper for him to choose the SXDG-2T. NPK granulators are able to meet his needs if the plant runs 8 hours a day.
Generally, it is more costly to buy a double rollers pressing granulator with a larger output. Therefore, we advised the customer to choose the SXDG-1T when we knew his price range. He can prolong the working time.
What Kinds of Potassium Sulfate Fertilizer Can it Produce?
The customer plans to make 6 mm fertilizer granules in a round shape. There are ready roller press granulators for him to produce the granules he wants. But, if you have special requirements for the size and shape of the NPK fertilizer granules, it will take some time to customize rollers. Yes, customization of the NPK fertilizer granulator is available. We can manufacture the rollers with ball sockets in the shape and size you want. There is a wide range of options for you. Contact us now to get an NPK granulator and produce the potassium sulfate fertilizer granules you like!
Factors for Increasing the Potassium Sulfate Production Efficiency During the Manufacturing Stage
There is an influence of 4 factors on the efficiency of potassium sulfate production equipment, namely water content of raw materials, the size of the potassium sulfate, granulation speed of the potassium sulfate granulator and crushed pellets for re-granulation.
The Water Content of Raw Materials
In dry granulation, water, as a blending agent, helps potassium sulfate powder hold together when the roller press granulator presses them into small granules. Actually, it plays a big role in the efficiency of making potassium sulfate fertilizer. If there is too much water, your raw materials tend to stick to the rollers and block the ball sockets. Accordingly, there is nothing you can get but big problems with cleaning and maintaining the granulator.
However, that does not mean that you should remove all the water from your potassium sulfate. It costs more money to dry your raw materials. Most importantly, water is a sort of adhesive in the process of manufacturing potassium sulphate as fertilizer granules, as we said. Without it, even the most efficient potassium sulfate granulation equipment will fail to turn your potassium sulfate into NPK fertilizer granules. Then, what is the ideal moisture content of potassium sulfate?
According to the study, it should be within the range between 0.9% and 1.1 %. If your NPK fertilizer powder is too dry, install a water sprayer on the fertilizer conveyor belt that aims to feed raw materials to the double roller granulating machine.
The Size of Potassium Sulfate
Potassium sulfate has the feature of absorbing water. Therefore, you will inevitably find some lumps in it. Don’t neglect them. These lumps will bring the granulation rate down, and even stall the whole production. Theoretically, your potassium sulfate should be at an ideal particle size, namely 1.00 mm-2.00 mm. Any larger NPK fertilizer clumps needs several times of granulation, which is a waste of money and time. Then, what should you do with these big pieces of your raw materials?
Use a fertilizer crusher machine! As a manufacturer of NPK fertilizer making machines, we offer hot types of fertilizer crushing machines, such as the urea crusher and the chain crusher for fertilizer. Before the process of granulating, you can use these fertilizer grinders to process your caked NPK fertilizer powder. They will grind all the lumps and clumps in your potassium sulfate, turning them into fine particles that are the same in size.
The Granulation Speed of the Potassium Sulfate Granulator
In general, the capacity of an NPK fertilizer granulator depends on the speed of granulation. In a short, higher speed, higher output. However, it is not proper to blindly prefer a large capacity. You know, there is an inverse correlation between the granulation speed and the granulation time. In other words, the procedure of granulation finishes quickly when the rollers rotate fast. Does that have something to do with the quality of NPK fertilizer pellets?
Of course! Our experiment found that the granulation speed is a huge factor influencing the strength and shape of the potassium sulfate fertilizer granules. As the granulation speed of the extruder pelletizer increases, the fertilizer granules have coarse surfaces, and they are smashed into pieces easily because of external pressure, even if it is weak. In contrast, moving slowly, the rollers will press the potassium sulfate powder into the ball sockets tightly. Therefore, the granules have compact structures and perfectly round shapes. They are unlikely to break or cake, even during long-time storage and transportation.
However, that does not mean that a roller press granulator with a small capacity is better. After all, the slower the granulation speed is, the higher production costs are. After several times of experiments, our team found the most ideal granulation speed. As the speed is 35 r/min, the potassium sulfate granulation equipment works efficiently and makes high-quality NPK fertilizer granules without too much waste or powder.
Crushed Pellets for Re-granulation
After screening your NPK fertilizer granules with a rotary drum screener, there will be some granules that are not up to the national standard as a product sold on the market. Don’t be in a haste to discard them. In fact, they are of great value. Granulated once, these potassium sulfate fertilizer pellets have some changes in their structure and granularity. There are more interstices among them, which allow small particles to fill. Therefore, you can grind them into power again with a chain crusher for NPK, and put the power into the NPK granulator machine again.
Of course, the client doesn’t need to do it manually. According to the design of his 10 t/h NPK fertilizer plant layout, there are fertilizer conveyor belts connecting the NPK fertilizer making machines. When the fertilizer screener discharges substandard potassium sulfate granules, the conveyor belt will send them into the NPK fertilizer mill. Then, another belt will feed crushed granules into the double roller extrusion granulator. The process of re-granulation is totally automatic.
Reasons to Start Potassium Sulfate Fertilizer Production in Indonesia
Why should the client set up an NPK granular fertilizer factory in Indonesia and make potassium sulfate fertilizer? Is there any profit the client can get from the manufacturing of potassium sulphate as fertilizer in the local market? Of course! In recent years, the demand for this type of NPK fertilizer granules has been growing extraordinarily in Indonesia, according to our market research. The primary factors are as follows:
It is an element that improves plants’ ability to make food from sunlight and contributes to the formation of starch and sugar. Besides, it helps plants absorb nitrogen and, therefore, makes them more resistant to disease.
As a micro-nutrient, it is the building block of plants and a participant in important chemical reactions in the plant. The lack of sulfate entails the consequence of your plant shriveling, or dying.
Make it Easier to Fertilize
In Indonesia, the potassium sulfate fertilizer on the market is in the form of powder. When it is fertilized in the field, there is a large possibility of dust pollution. However, potassium sulfate fertilizer granules make it easier for the farmer to fertilize with a commercial machine.
Release Nutrients Slowly
Potassium sulfate fertilizer granules stand out for their impressive feature of solving in the water. Fertilized in the soil, they will release nutrients for a long time, like 30 days. That is much longer than fertilizer power. Hence, these fertilizer granules meet plants’ needs for nutrients during the fast growing phase.
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