The equipment configuration of the liquid fertilizer production line needs to be determined according to the production scale, product type (such as foliar fertilizer, flushing fertilizer, drip irrigation fertilizer, etc.), and process requirements. The following is a classification introduction of common core equipment and auxiliary equipment:
1、 Raw material processing and mixing equipment
Ingredient tank (mixing tank)
Function: Used for dissolving solid raw materials (such as urea, potassium dihydrogen phosphate) or mixing liquid raw materials (such as humic acid, amino acids).
Features: Equipped with stirring devices (paddle, anchor, or turbine), some are equipped with heating/cooling jackets to meet the dissolution needs at different temperatures.
Type: Mainly made of stainless steel material, with capacities ranging from several hundred liters to several cubic meters.
Grinding and dispersing equipment
Colloidal mill/sand mill: used to process high concentration or solid particle containing raw materials (such as mineral humic acid, bone meal), ensuring uniform particle size (usually required ≤ 50 microns).
High speed disperser: It crushes agglomerates through high-speed stirring blades and is suitable for emulsifying or dispersing insoluble components.
2、 Reaction and synthesis equipment
Reaction kettle
Function: Used for acid-base neutralization, chelation reactions (such as EDTA chelation of trace elements), fermentation and other complex processes.
Configuration: Equipped with stirring, temperature/pressure control system, some parts require corrosion-resistant materials (such as titanium alloy).
Heating/cooling system
Steam boiler/thermal oil furnace: provides heat source for reaction or dissolution processes.
Condenser/cooling tower: used to control reaction temperature or recover volatile components.
3、 Filtering and refining equipment
Plate and frame filter/membrane filtration equipment
Plate and frame filter: removes impurities (such as undissolved residue) through pressure filtration, with low cost but more manual operation.
Membrane filtration (ultrafiltration/reverse osmosis): used for refining high-purity liquid fertilizers (such as drip irrigation specific fertilizers), removing microorganisms, colloids, and ionic impurities.
Centrifugal filter machine
The use of centrifugal force to separate solid-liquid mixtures is highly efficient and suitable for large-scale production.
4、 Measurement and filling equipment
Metering pump/flowmeter
Used for precise control of the filling volume of finished liquid fertilizers, common types include plunger pumps, gear pumps, electromagnetic flow meters, etc.
Filling production line
Atmospheric pressure filling: suitable for low viscosity liquids (such as water-soluble fertilizers).
Vacuum filling: prevent volatile components from escaping or foam generated during filling.
Supporting equipment: automatic capping machine, labeling machine, weighing and calibration equipment, realizing assembly line automation.
5、 Auxiliary equipment
Raw material storage system
Storage tank: Classify and store liquid raw materials (such as ammonium sulfate solution, phosphoric acid) and solid raw materials (such as potassium chloride), usually equipped with liquid level sensors and anti-corrosion coatings.
Spiral conveyor/bucket elevator: used to transport solid raw materials to the batching tank.
Control System and Instrumentation
PLC control system: Automated control of parameters such as ingredient ratio, mixing time, temperature, etc.
Online detector: Real time monitoring of key indicators such as pH value, conductivity, and specific gravity to ensure stable product quality.
Cleaning and environmental protection equipment
CIP cleaning system: automatically cleans pipelines and tanks to avoid cross contamination.
Wastewater treatment equipment: Treat production wastewater to meet environmental discharge standards (such as neutralization tanks and sedimentation tanks).
6、 Equipment differences in different process routes
Simple production line (small): mainly using manual/semi-automatic equipment, such as small mixing tanks, centrifugal pumps, and manual filling machines, suitable for laboratories or township enterprises.
Medium sized production line: Add automatic batching system, plate and frame filter, semi-automatic filling line, with a production capacity of 5-10 tons per hour.
Large scale fully automated production line: equipped with control system, film processing equipment, robot palletizer, realizing the full process automation from raw material input to finished product storage, with a production capacity of over 20 tons per hour.
Selection suggestions
According to product characteristics: Liquid fertilizers containing a large amount of organic matter require grinding equipment; High purity water-soluble fertilizer requires a membrane filtration device.
Capacity demand: Modular equipment (such as mobile mixing tanks) can be selected for small-scale production, while customized production lines are required for large-scale production.
Environmental requirements: Priority should be given to selecting low-energy equipment (such as energy-saving mixing motors) and supporting wastewater treatment facilities.
If a more specific plan is needed, information on liquid fertilizer types (such as organic/inorganic fertilizers), production capacity targets, etc. can be provided to further refine equipment configuration.
