I. Project Background
This project is located in Uzbekistan. The client plans to construct an NPK compound fertilizer production line with a capacity of 6 t/h, primarily to produce granular fertilizers suitable for crops such as cotton, wheat, fruits, and vegetables. Raw materials include urea, ammonium phosphate, potassium chloride, potassium sulfate, and some fillers; the nitrogen, phosphorus, and potassium ratios can be adjusted according to local soil and crop requirements.
Considering the client’s desire to reduce energy consumption, streamline the production process, and minimize equipment investment in the drying stage, we designed a double-roller extrusion granulation solution for this project.
II. Production Line Configuration
The entire 6 t/h NPK compound fertilizer production line primarily consists of an automatic batching system, a urea crusher, a horizontal mixer, feeding equipment, multiple double-roller extrusion granulators, a rotary screening machine, a return conveyor, a coating machine, and an automatic packaging machine.
Due to the production line’s high designed capacity, multiple double-roller granulators operate in parallel during the granulation process. This configuration not only meets the production requirement of 6 t/h but also allows for easy adjustment of the number of machines in operation based on order volume, thereby reducing wear and tear caused by long-term full-load operation of the equipment.
III. Production Process
During production, the automatic batching system weighs various raw materials according to the preset NPK formula. Granulated urea is crushed and then fed into the mixer along with phosphate fertilizer, potash fertilizer, and additives to ensure a more uniform distribution of nutrients. The mixed powder is then steadily fed into the double-roller granulators via conveying equipment.
The material is compressed between two counter-rotating rollers to form compact flakes, which are then crushed and shaped into granules. A rotary screening machine separates qualified granules from fine powder and oversized particles; the fine powder is returned to the granulation process via a recirculation system, while oversized particles are crushed and rescreened to improve raw material utilization. After coating, the qualified product is weighed, bagged, and sealed by an automatic packaging machine.
IV. Project Advantages
The double-roller granulator employs a dry extrusion process, which typically does not require the addition of large amounts of water during the granulation stage. Consequently, the production line can eliminate the need for conventional dryers and coolers, featuring a short process flow, a small footprint, low energy consumption, and rapid start-up. The finished particle size can be adjusted based on the die holes in the roller shells and the screen specifications; the commonly used particle size range is 2–5 millimeters.
Given Uzbekistan’s dry climate and significant diurnal temperature fluctuations, the project incorporates rational designs for raw material storage, sealed conveying, and electrical protection to minimize moisture absorption and caking of hygroscopic raw materials such as urea.
V. Project Outcomes
Following installation and parameter commissioning, this NPK compound fertilizer production line in Uzbekistan has achieved continuous operation encompassing batching, mixing, double-roller granulation, screening, recirculation, and packaging. Actual output and granulation yield are influenced by raw material fineness, moisture content, formulation cohesiveness, and roll pressure; however, after targeted adjustments, the entire line is capable of consistently meeting the designed production capacity, providing a reliable guarantee for the customer to produce NPK granular fertilizers in a variety of formulations.
Post time: Aug-27-2026
