021 Operation Manual

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S h a n g h a i R e s e a r c h JOB NO : 6119-SP-BTG-08

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NPK Fusion Granulation Plant DATE BY CHKD APVD

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

FUSION GRANULATION PLANT
Part 1
Technological Process for PKT’s 2x100000 TPY

NPK Compound Fertilizer Production Unit
Operation Manual
Shanghai Research Institute of Chemical Industry
April 2009
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Contents
Chapter I Finished Products 4
1.1 The Properties, Uses and Technical Documents 4
1.2 The Analysis and Sampling Methods 5
1.3 Product Packaging 7
Chapter II Raw material 9
Chapter III Description of the Production Process 11
Chapter IV The Main Equipment 20
Chapter V Process Details and the Main Points of the Technical Operation 23
Chapter VI Startup and Shutdown Sequence and Method 29
6.1 Startup Sequence 29
6.1.1 Startup Sequence of the main production plant
6.1.2 Startup Sequence of the Preparation Unit of Liquid Urea
6.2 The Normal Shutdown Sequence 33
6.2.1 The Normal Shutdown Sequence of the Preparation Unit of Liquid Urea
6.2.2 The Normal Shutdown Procedure of the Main Production Units
6.3 Long-term Shutdown 36
6.4 Emergency Shutdown and Power Outage 36
6.5 Blow the Liquid Urea Pipelines and Atomizers 37
Chapter VII Technical Operation Specifications, Control Analysis, Sampling and Analysis
Items 39
7.1 Specifications of the Technical Operations 39
7.2 Analysis Points and Test Items 41
7.3 Chemical Analysis Sampling Points and Analysis Items 42
Chapter VIII Example of Process Calculation (mass basis) 44
8.1 Calculation Conditions 41
8.2 Material Ratio Calculation 45
8.3 Hourly Rate of Material 49
Chapter IX Consumption Norms 50
9.1 Consumption Norms of Raw material and Utility 50
9.2 Production Manning Level 50
Chapter X Common Failures, the Causes and Handling Methods 53
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Chapter I Finished Products
1.1 The properties, Uses, and Technical Documents
Liquid urea – ammonium phosphate (hereafter as ammophos) – potassium

chloride is a granular compound fertilizer containing multi-elements like N, P, and K.
According to the requirements of the varying crops and soil nutrients on the fertilizer,
the manufacturing plant can produce special fertilizers of different ratio of N: P2O5:
K2O. The typical specifications (in ratio of N: P2O5: K2O) of the finished product are:
15-15-15, 12-12-12, 16-20-0, 6-9-15, 20-10-10, and 13-6-27-4 Mg-0.65B, with the
total nutrient content of 30 ~ 45%, and the fertilizer looks off-white in appearance (or
close to the appearance color of the filler materials, if introduced), in spherical
granule. The fertilizers are characterized by mixed nutrients in neat and uniform size
of granule, good physical properties, and they are not susceptible to agglomerate,
and convenient to apply to crops, with high efficiency, and satisfy the requirements of
mechanical fertilization.
Liquid urea –ammophos – potassium compound fertilizer has the main

makeup materials of: urea, ammophos , potassium chloride (potassium) and other
inorganic salts, and, if the filler materials are introduced, such as the ammoniated
superphosphate and clay, then the compound fertilizer also contains monocalcium
phosphate, dicalcium phosphate, calcium sulfate, the iron and aluminum silicate.
（ 1 ） The main physical and chemical properties of the liquid urea – ammophos –
potassium compound fertilizers are as follows:
Stacking angle ~ 31°
Bulk density ~ 0.75
Shoot density ~ 0.88
Critical relative humidity (30℃) ~ 44.5%
Specific heat ~ 0.30 cal/gram.℃
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PH value 4.5 ~ 6.5 (varying with the makeup materials)
（2） Products and the specifications:
Product specifications: N－P2O5－K2O 20－10－10 & 13-6-27-4Mg-0.65B
Other specifications: water ≤2%
Granule size (-4.5 +2 mm) ≥90%`
1.2 Analysis and sampling methods
Detailed method of analysis is referred to in the ‘Compound fertilizer Production

Analysis Specifications’, and the conventional analysis items of the product are the
total nitrogen, effective P2O5, water soluble P2O5, K2O, free water, granule strength
and size, and so on. The PH value and total P 2O5 content of the products shall be
analyzed, when necessary.
Production plant sampling methods: Sampling packages of fertilizer: from the fertilizer
packages of varying packaging lots, the random sampling shall be following the
requirements as below:
The total
The minimum number Total number of The minimum number
number of
of bags to be sampled bags of bags to be sampled
bags
1～10 All bags 182～216 18
11～49 11 217～254 19
50～64 12 255～296 20
65～81 13 297～343 21
82～101 14 344～394 22
102～125 15 395～450 23
126～151 16 451～512 24
152～181 17
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Where the number of bags involved is more than 512, the sampling result shall
be determined using the following equation:
3
The number of sampling bags = 3 × √N
Where: N – the total number of bags for each lot of product.
Based on the above table or the calculation results, randomly select and sample
a number of bags, by inserting the sampler from the longest diagonal and into the
three-quarters depth of a bag, and take out not less than 100 g of sample, and the
total amount of sample to take for each lot of product shall not be less than 2 kg.
The samples taken shall be evenly blended in a timely manner, and, using the
sample splitting device or quartering method, split and prepared to 1000 g, before
they are respectively packed into two 500mL clean and dry glass bottles with wide
mouth and ground stopper, or polyethylene bottles, and the bottles shall be sealed
and labeled properly to indicate the name of the product manufacturer, product name,
the lot number, the sampling date, and the sampling person’s name. One of the two
bottles shall be used for analysis of the product quality, and the sample in the other
bottle is retained for future reference or test, with a preservation period of two
months.
Sampling fertilizer in bulk
Fertilizer in bulk of varying tonnage shall be sampled by sampling lots in line with
the rules as follows:
Tonnage The number of sampling lots
<1 ton 4～6
1～2 5～8
2 to 6 tons 6～10
5 ~ 10 tons 8～15
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> 10 tons 15～20
The sampling points shall be evenly distributed to ensure the representativeness of

the sample. The methods for splitting and retaining sample remain the same as
above.
1.3 Packaging Finished Product
1． The product packaging woven bag shall be lined with polyethylene film bag or PP
(polypropylene) film. The net weight per bag shall be (50 ± 0.5) Kg, (40 ± 0.4)
Kg, (25 ± 0.25) Kg, or (10 ± 0.1) Kg, and the average net weight per bag of each
lot of product may not be less than 50.0Kg, 40.0Kg, 25.0 Kg, and 10.0Kg.
2. The packaging bags shall be marked with: the granular compound fertilizer or
special compound fertilizer for some crops, and the manufacturing factory
name, registered trademark, N- P2O5- K2O nutrient specifications (such as 15-
15-15), the lot number, and the production date.
3. Where the product contains nitrate nitrogen, the packaging container shall be
marked “nitrate N”; where the product is based calcium and magnesium
phosphate fertilizer, and other citrate-soluble phosphate fertilizer, the packaging
container shall be marked with “citrate-soluble P”; where the product has the
mass fraction of chloride ions greater than 3.0%, the packaging container shall
be marked with “containing chlorine”.
4. The packaging bag shall be placed with the product test certificate which is
marked with the ex-works date, the certificate specific marks, and the seal of the
quality control supervisor. Meanwhile, each bag of product shall be placed with
a brief statement of the fertilizer use and application.
5. At the time of product ex-works delivery in bulk, the product specification and
instructions shall be provided as well, along with the product analysis certificate.
6. The net content of the specified range of bag products have additives must be
mixed with the raw material are not allowed to form small packaging bag.
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7. NPK granular compound fertilizer is susceptible to moisture, so in the course of
transportation and storage measures shall be taken to avoid moisture, heat, and
broken packages.
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Chapter II Raw material
The specifications of the basic fertilizer and supplementary materials used in the
production line are as follows:
1. Specifications of the raw material
（1）Urea
Spec: N 46%, H2O 0.5%, granule size 1 ~ 2mm, in loose granular, and non-
agglomeration.
Biuret ≤ 1%
（2） Ammonium sulfate
Spec: N 21%, H2O ≤ 1%
（3） MAP (in powder, loose and non-agglomeration)
Spec: N 18%, effective P2O5 46%, H2O 1.5%, in powder, loose and non-
agglomeration.
（4） Diammonium Phosphate (in powder, loose and non-agglomeration)
agglomeration.
（5） Potassium Chloride
Spec: K2O 60%, H2O ≤ 1%, in white or red fine shape, loose and non-
agglomeration.
（6） Potassium
Spec: K2O 50%, H2O ≤ 1%, in white color, loose and non-agglomeration.
（7） Phosphate rock
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Spec: total P2O5 30%, H2O ≤ 4%, in powder, loose and non-agglomeration.
（8） Filler material
Spec: dolomite, kaolin, gypsum powder, fineness: 100-200 mesh, and H2O ≤
8%.
2、 Specifications of supplementary materials
（1） Coating oil
Spec: anti-agglomeration agent coating oil
（2） Bag
Spec: woven bag lined with plastic film, 50Kg load per bag
（3） Diesel
Spec: calorific value: 9,600KCal/Kg
（4） Steam
Spec: low pressure steam, P = 0.6-0.8Mpa (gauge),
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Chapter III Process Description
3.1 Process Flow Block Diagram
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Potassium Phosphate Di-ammonium Phosphate
Magnesium oxide Boric acid
Clay Chloride Rock powder
(metering) (metering) (metering) (metering) (metering)

(metering)
Urea Granule
(metering)
Fines bolow2.5mm
Pump Urea Melter

Granulator
vent
steam
Scrubber No.1 Cyclone Dryer No.1 Combustion Furnace Diesel
Air
Cyclone Fines Screen
Granule smaller than 2.5mm
Cyclone Dryer No.2
Cyclone Cooling Large Granule Crusher
Granule larger than 4.5mm
Screen
Settling pond Scrubber No.2 Coating Machine
Venting Product packaging
Product
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3.2 Process Flow Description
The production plant comprises units for 2 × 100,000 tons/year production of

urea-based compound fertilizers, and the system-wide process consists of four parts:
1. ammophos crushing system (equipment number: 02 × ×), 2. The preparation of
liquid urea (equipment number: 12 × ×, 22 × ×), 3. raw material feeding zone
(equipment number: 01 × ×), and 4. the main production units (equipment number: 11
× ×, 21 × ×).
1. Flow process description of the ammophos crushing system (equipment number:

02 × ×)
The ammophos crushing system is in intermittent operation, where the

ammophos granule are lifted by the elevator (L-0201) up to the crusher or mill
(M-0201) for crushing, and the crusher discharging materials shall meet the
required fineness (usually meeting -2mm fineness, accounting for about 85%;
and that meeting -1.0mm fineness, accounting for about 60%.) before falling into
a closed room; when the closed room is holding appropriate amount of the
crushed materials, the elevator (L-0201) shall stopped hoisting and feeding
materials, and the crusher (M-0201) stops as well, where the closed room shall
open, and the ammophos powder is delivered to the elevator (L-0101E) for
adding into the main production plant. The crusher operates at high speed for
colliding and crushing the material granule, with the generation of the gaseous
stream containing a large flow of powder. In order to improve the operating
environment and the loss from the crushing process, fan (C-0201) shall be used
to pump the material into the pulse bag filter (X-0201) for ‘dust removal’ before
the venting to atmosphere while meeting the exhaustion standards. The fine
powder resulting from the ‘dust removal’ shall be automatically discharged into
the closed room.
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2. Process flow description of the liquid urea and preparation (equipment number: 12
× ×, 22 × ×)
IF the liquid urea and preparation equipment is numbered 12 × ×, the

prepared liquid urea shall be delivered to the granulator (M-1101). If the liquid
urea and preparation equipment is numbered 22 × ×, and the prepared liquid
urea is delivered to the granulator (M-2101).
Solid urea is dumped into the urea hopper (V-1201AB) through the urea
metering belt weigher (W-1201AB), and the measured urea is delivered into the
elevator (L-1201AB) by which the urea is forwarded into the Urea Melting Device
(E-1201AB), where the solid urea gets contact with the steam pipes of the
Melter, and quickly melted into liquid urea flowing into the liquid urea transition
tank (V-1202), and then the liquid urea is sent by the liquid urea pump (P-
1201AB) to the granulator ( M-1101).
The process flow of the liquid urea and preparation equipment numbered 22
× × is the same as the equipment numbered 12 × ×, so the latter’s process flow
is no longer described.
Note: The relationship between the measurement of solid urea and the
individual raw material of the main production plant, shall be adjusted in
accordance with the mix ratio of nutrients for the production of products.
3. The process flow description of the raw material feeding zone (equipment number:
01 × ×)
The trace elements to add to the product compound fertilizer shall be

lifted by the elevator (L-0101A) up to the raw material hopper (V-0101A), which
features two hoppers, and the discharging ports of the two hoppers are
respectively projecting to the inlets of the belt weight meter (W-1101A and W-
2101A). The filler materials are lifted by the elevator (L-0101B) up to the hopper
(V-0101B) with two hoppers, and the discharging ports of the two hoppers are
respectively projecting to the inlets of the belt weight meter (W-1101B, W-
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2101B). The potassium chloride is lifted by the elevator (L-0101C) up to the
hopper (V-0101C) with two hoppers, and the discharging ports of the two
hoppers are respectively projecting to the inlets of the belt weight meter (W-
1101C, W-2101C). The phosphate rock power shall be lifted by the elevator (L-
0101D) up to the hopper (V-0101D) with two hoppers, and the discharging ports
of the two hoppers are respectively projecting to the inlets of the belt weight
meter (W-1101D, W-2101D). The ammophos powder from (M-0201) is lifted by
the elevator (L-0101E) up to the hopper (V-0101E) with two hoppers, and the
discharging ports of the two hoppers are respectively projecting to the inlets of
the belt weight meter (W-1101E, W-2101E). The elevator (L-0101F), hopper (V-
0101F) of raw material, and the belt weight meter (W-1101F, W-2101F) are used
as backup equipment.
4. The process flow description of the main production plant (equipment number: 11
× ×, 21 × ×):
The main production plant has the equipment numbered 11 × ×, and the process
flow is described as follows:
According to the product specification requirements on the mix ratios, the

trace elements, ammophos, potassium chloride, and filler materials, shall be
respectively discharged from the raw material feeding zone, through the
accurate measurement by the belt weight meter (W-1101A-F), onto the 1# Belt
Conveyor (L-1101) of raw material, and then transported to the 2# Belt Conveyor
(L-1102). The returning material and that resulting from the cyclone shall also be
discharged to the 2# Belt Conveyor (L-1102), and, together with the individual
raw material, be lifted to the granulator by the raw material general elevator (L-
1103). The above raw material, together with the liquid urea, shall enter the
granulator (M-1101) in specified mix ratio for granulation. The materials in the
granulator are formed into mechanically fluidized bed under the rotation of the
cylinder, which is flowing continuously. Steam nozzles are buried in the rolling
bed of material, which are projecting appropriate amount of steam into the
materials, and the steam condenses into water while raising the temperature of
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the materials, thus supplying some of the water required for granulation of the
materials. Above the bed of material, there is liquid urea atomizer and water
adding pipe, where the liquid urea is sprayed from the atomizer onto the material
bed, giving off the crystallization heat, and raising the granulation temperature.
When the material reaches a certain temperature and liquid volume, the
resultant surface tension shall lead to agglomeration, and the agglomerated
material is ‘rolled’ into spherical granule with the extrusion pressure and friction
of the rolling bed of materials.
The granular materials from the granulator (M-1101) shall send, via the
curing belt conveyor (L-1104), into the inlet shute of the 1# Dryer (M-1102) which
shall slide the material to the shoveling plate section of the dryer. Under the
action of the spiral shoveling plate, the heat-sensitive and wet granular material
are removed from the high-temperature zone and thrown into the heating
section, where the elevating type shoveling plate shall lift and throw the granular
material into the space of the dryer, and this lifting and throwing process repeats
so that a number of material ‘screens’ are formed, and this gives the granular
material a full contact with the hot furnace gas, resulting in quick transfer of heat,
and thereby completing the drying and dewatering process of the granular
material.
The Hot-air stream of the Dryer 1# (M-1102) for drying the material shall be
supplied from the 1# Hot-air furnace system which is composed of the Hot-air
furnace (F-1101), 1# drafting jet (X-1101) and 1# jet blower (C-1101), where
diesel combustion generates hot furnace gas. The 1# furnace (F-1101) has the
furnace temperature at about ~ 800℃, and the discharging flue gas temperature
at ~ 500℃, and the discharging pressure at around the 30mm H 2O column, and
the suction of the 1# drafting jet (X-1101) shall give the pumping power of low
negative pressure. The high-temperature furnace gas through the 1# jet draft fan
(X-1101) shall remix with the cold air from the 1# jet blower (C-1101) to lower the
temperature to the drying temperature as required, and sent into the dryer as the
drying medium. The temperature of gas entering the dryer can be maintained at
a certain level of drying temperature, by adjusting the volume of the combustion
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diesel oil. The drying medium and the material to be dried shall flow in parallel
currents during the drying process.
The material from the outlet of the Dryer #1 shall flow under the gravity onto
the 1# Semi product Belt Conveyor (L-1105), and is delivered to the 1# semi
product elevator (L-1106), whereby it is lifted up to the fines screen (M-1103AB)
for screening separation, where the granular material with granule less than
2.5mm shall fall back to the Cyclic material Belt Conveyor (L-1112) and then to
the 2# Raw Material Belt Conveyor (L-1102), while the material with granule
greater than 2.5mm shall be sent by the 2# Semi product Belt Conveyor (L-
1107) into the Dryer 2# (M-1104).
The Hot-air stream for Dryer 2# (M-1104) needed for drying the material
shall be supplied from the 2# Hot-air furnace system which is composed of the
2# Hot-air furnace (F-1102), 2# Drafting Jet (X-1102) and the 2# jet Blower (C-
1102). The theory and principle of drying is same as the Dryer1#.
The dry material discharging from Dryer 2# (M-1104) flows under gravity
onto the 3# semi product Belt Conveyor (L-1108), and then delivered to 2# semi
product elevator (L-1109) which lifts it to the inlet of the Cooler (M-1105). The
dry material in the cooler is in counter-current contacting with the air flow
introduced into the cooler, thus cooling the material down to ~ 45℃, and at the
mean time the material water can continue to disperse for dewatering. In order to
prevent that the temperature of the finished product in the cooler becomes too
low, which can result in moisture absorption by the material, it’s required to
control the cooling air flow rate, so that the temperature of the material shall not
drop below 40℃, and the cooler discharging material shall enter the 3# semi
product elevator (L-1110), and be lifted to the screen (M-1106) for screening
large granule, where the granule remaining on the screen that is sized greater
than 4.5mm shall flow under gravity to large granular crusher (M-1108), and the
crushed materials shall be discharged onto the cyclic material belt conveyor (L-
1112), while the granule under the screen that is sized smaller than 4.5 mm shall
flow under gravity to the product screen (M-1107) for further screening and
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separation. The granular material on the finished screen (M-1107) that is sized
4.5 mm and 2.5 mm shall become the finished product, and flow under gravity to
the coating machine (M-1108) for anti-caking treatment, while the granular
material under the product screen (M-1107) that is sized smaller than 2.5mm
shall flow directly onto the cyclic material belt conveyor (L-1112), and then be
delivered to the 2# raw material belt conveyor, together with the crushed
material from the large granular crusher (M-1108).
The granule of the finished product shall undergo the anti-caking treatment
in the coating machine (M-1109), and the required coating oil comes from the oil
tank (M-1101AB) whose temperature is controlled by the use of steam heating
coil, so that the coating oil can be maintained with a certain level of fluidity, with
the addition of anti-caking agent (the weight ratio of oil to the anti-caking agent =
9:1); after the anti-caking agent is dissolved under agitation, it is measured by
the coating oil metering pump (P-1102) before it is pumped into the coating
machine (M-1109). The finished product discharging from the coating machine
shall be lifted by the Product Elevator (L-1111) into the product hopper (V-1101),
where it is measured and packaged by the automatic packing machine (W-
1102AB) before being sent into warehouse.
In order to maintain a good operating environment for the Granulator (M-

1101), a small amount of granular dust contained in the off-gas shall be
scrubbed by the Venturi Scrubber (X-1107), and the scrubbed stream shall go
through the gas-liquid separator (X-1108), where the off-gas shall be delivered
by the granulator waste gas fan (C-1103) to the 2# scrubber (T-1102) for another
scrubbing so as to meet the environmental exhaustion standards for venting
from the stack concerned. The scrubbing fluid discharging from the gas-liquid
separator (X-1108) shall flow to the settling pond (V-1102).
In order to maintain a good operating environment in the plant, and the

partial vacuum, air suction points shall be provided over the fines screen (M-
1103AB), larger granule screen (M-1106), product screen (M-1107), cyclic
material belt conveyor (L-1112), and the 1# raw material belt conveyor (L -
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1101). The gas from the dust collection point shall be suctioned by the dedusting
waste gas fan (C-1105) and pumped to the cyclone (X-1106), and the dust
removed gas stream flows into the 1# Scrubber (T-1101), and joins with 1# dryer
off-gas for scrubbing so as to meet the exhaustion requirements.
The off-gas of Dryer 1# contains a small amount of fertilizer dust and soot,
and a large amount of water vapor. The off-gas shall go through the cyclone (X-
1103AB), and the dust removed gas stream delivered by the 1# dryer waste gas
fan (C-1104) to the 1# scrubber (T-1101) for scrubbing and exhaustion.
The off-gas of Dryer 2# contains a small amount of fertilizer dust and soot,
and water vapor. The off-gas shall go through the cyclone (X-1104), and the dust
removed gas stream is delivered by the 2# dryer waste gas fan (C-1106) into the
2# scrubber (T-1102) for scrubbing and exhaustion.
The off-gas of the cooler shall go through the cyclone (X-1105), and the
dust removed gas stream is delivered by the cooler waste gas fan (C-1107) into
the 2# scrubber (T-1102) for scrubbing and exhaustion.
The wash liquor discharging from the scrubber shall go into the settling
pond (V-1102). Some of the wash liquor used for recycle, and the rest used as
the granulator process water. Clean water is introduced to the settling pond
periodically.
The equipment numbered 21 × × for the main production plant has the
same process flow as the equipment numbered 11 × ×, so its process
description is not repeated.
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Chapter IV Dimensional Specifications of Major Equipment
4.1 Ammophos crushing system (equipment number: 02 × ×)
1. Elevator: HL300 hopper upgrade the speed of 1.25m/s, N = 5.5KW.
2. DAP Crusher: DMT80, N = 55 +7.5 +1.1 KW, Q = 25 ~ 30 ~ 35t/h
4.2 The preparation of liquid urea (equipment number: 12 × ×, 22 × ×)
1. Elevator: HL300, elevating hopper at the speed of 1.25m/s, and N = 5.5KW.
2. Belt weight meter for urea: B = 650, L = 2.7M, measurement range: 2 ~ 8t/h, N =
2.2KW
3. Urea melter: Q = 4t/h
4. Liquid urea pump: Q = 15M3/h, H = 80M and N = 18.5KW
4.3 Raw material feeding zone (equipment number: 01 × ×)
1. Elevator: HL300, TH315, elevator hopper at the speed of 1.25m/s, and N = 5.5 ~
7.5KW.
2. Belt weight meter for Raw material: B = 650, L = 2.7 or 4.2M, measurement range:
2 ~ 8t/h, and N = 2.2KW
4.4 The main production plant (equipment number: 11 × ×, 21 × ×).
（1） The dimensional specifications of major equipment (equipment number: 11 ×

×)
1. Belt Weight Meter for Raw material: B = 650, L = 2.7 or 4.2M, and the
measurement range: 2 ~ 10t/h, and N = 2.2KW
2. Belt Conveyor: B = 800, 1200 mm, in groove type, V = 0.6m/s, N = 7.5 ~

17.5KW.
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3. Elevator: TH500, TH800, elevating hopper at the speed of 1.5m/s, N = 15
~ 22KW.
4. Large granule crusher: DMT80, N = 55 +7.5 +1.1 KW, Q = 25 ~ 35t/h
5. Granulator: 2.4 × 10M, n = 8.88rpm, α = 2.5°, N = 45KW, driving on the

left
6. 1# Dryer: 3.0 × 30M, n = 4.2rpm, α = 2.5°, N = 110KW, driving on the

right
7. 2# Dryer: 2.8 × 28M, n = 3.2rpm, α = 2.5°, N = 75KW, driving on the left
8. Cooler: 3.0 × 30M, n = 5.9rpm, α = 2.5°, N = 90KW, driving on the left
9. Coating machine: 1.6 × 6M, n = 8.2rpm, α = 2.5°, N = 11KW, driving on

the right
10. Vibrating Screen: F = 10.0M2, N = 2 × 2.2KW
（2） The dimensional specifications of major equipment (equipment number 21 ×

×)
1. Belt Weight Meter for Raw material: B = 650, L = 2.7 or 4.2M, and the
measurement range: 2 ~ 10t/h, and N = 2.2KW
2. Belt Conveyor: B = 800, 1200 mm, in groove type, V = 0.6m/s, N = 7.5 ~

17.5KW.
3. Elevator: TH500, TH800, elevating hopper at the speed of 1.5m/s, N = 15

~ 22KW.
4. Large granule crusher: DMT80, N = 55 +7.5 +1.1 KW, Q = 25 ~ 35t/h
5. Granulator: 2.4 × 10M, n = 8.88rpm, α = 2.5°, N = 45KW, driving on the

right
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6. 1# Dryer: 3.0 × 30M, n = 4.2rpm, α = 2.5°, N = 110KW, driving on the left
7. 2# Dryer: 2.8 × 28M, n = 3.2rpm, α = 2.5°, N = 75KW, driving on the right
8. Cooler: 3.0 × 30M, n = 5.9rpm, α = 2.5°, N = 90KW, driving on the right
9. Coating machine: 1.6 × 6M, n = 8.2rpm, α = 2.5°, N = 11KW, driving on

the left
10. Vibrating Screen: F = 10.0M2, N = 2 × 2.2KW
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Chapter V Process Description and Technical Operation Key Points
5.1 Production methods and process technology
Using solid fertilizer as the raw material, the compound fertilizer manufactured by
agglomeration process can be described as: The powder, crystal or fine granular
basic fertilizer is agglomerated into granule or grains, and the granule is dried,
screened for separation, cooled, and processed for granule coating, so as to obtain
the multi-nutrient granular fertilizer with nutrients uniformly distributed. The key steps
of the production process are the materials batching, and granulating and drying
operations. In using liquid urea as the nitrogen source for the production of the NPK
ternary compound fertilizer, the original production technology of agglomeration
method can used with appropriate improvements.
Agglomeration of the powder fertilizer into granule is achieved by that, into the
solution of the fertilizer salts is introduced the appropriate salt solution as well as the
water vapor, and this wets the surface of the powder granule which, under the
constant rotation of the granulator, the materials are kept in a state of fluid, where
there is friction, turning, and squeezing actions between the materials, and, with the
appropriate amount of liquid phase (which means the amount of the fertilizer salt
solution under a certain level of temperature), the materials are agglomerated and
adhered into granule.
The process of using liquid urea as the nitrogen source for production of NPK
ternary compound fertilizer can be described as: the granular urea is rapidly melted in
the melter into a liquid fluid, and the liquid urea is sprayed onto the moving bed of the
granulator with a rotating drum, thus mixing with ammonium sulfate, potassium
chloride, Di-ammonium phosphate, and other basic fertilizers as well as the returning
materials, and agglomerating into granule, and the granular material is dried,
screened, cooled and coating processed, so as to obtain the granular multi-nutrients
fertilizer with nutrients uniformly distributed, thereby the products of high
concentration compound fertilizer are manufactured. The process of using liquid urea
as the nitrogen source for production of NPK ternary compound fertilizer is
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technologically characterized by that: As the raw material of urea features great
solubility, therefore the concentration of liquid urea can be made as high as 99% at a
certain degree of temperature, and the solution with low content of water can be
favorable for maintaining the water balance of the whole plant of production, and
there is a large amount of crystallization heat released from the granulation of the
liquid urea; this heat can not only increase the granulation temperature, but also
reduce the amount of steam input into the granulator, as well as the drying load,
thereby a coating process occurs in the granulation, which makes the appearance of
the product granule look round and full, with high strength.
The process of ‘molten’ liquid urea has the characteristics of both agglomerating
into granule and a certain level of coating action, and the amount of liquid phase is
the major controlling factor in the process of granulation; an appropriate amount of
liquid phase can result in high rate of granulation as well as good appearance of the
product granule. The liquid urea is sprayed onto the materials in the granulator,
forming a uniform and thin slurry film on the surface of the returning material, and, at
the same time, as a result of adding salts into the scrubbing liquid and steam, the
material surface gets wet, facilitating the agglomeration of granule. Agglomeration
and coating actions take places in the granulation process, so the appearance of the
product looks good, with high compressive strength. The amount of liquid phase is
the main controlling factor in the process of granulation; an appropriate amount of
liquid phase can result in high rate of granulation as well as good appearance of the
product granule. Figure (1) shows the granulation curve line of urea, DAP, and
potassium chloride, and provides the right temperature for granulation, the
appropriate amount of granulation material, and the moisture content of material.
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Figure (1) Granulation Curve of the Urea—Ammonium Phosphate—Potassium chloride
5.2 Analysis of the Drying Process
The material drying operation is one of the key features of the production
process. Drying process is a kind of chemical process unit operation, where heat is
applied to vaporize the water in the wet material, thus reducing the moisture in the
material to the specified level. In accordance with the mode of heat transfer, drying
forms can generally be classified into drying conduction, drying convection, and
drying radiation, where the convective drying is the most common of industrial drying
applications, by which heat is transferred by convection of heat from high-
temperature gas directly to the surface of wet material, and the heat disperses from
the surface further into the material, which is a typical process of heat transfer.
Moisture transfers from the inside of the material to the surface, in the form of liquid
or gaseous water, and then the water vapor spreads from the surface of material
through the gaseous ‘film’ to the main flow of heating gas, which is a process of mass
transfer. Nevertheless, the two processes of transfer are not independent, instead
they are closely linked. The condition to carry out the drying process is that the water
vapor pressure from the surface of material is greater than the vapor partial pressure
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of the Hot-air furnaceeous stream; the greater the differential pressure, the more
rapidly the drying process proceeds. On the other hand, the rise in the vapor pressure
of the material needs the increase in temperature of the material, as the vaporization
of water needs the absorption of heat from the Hot-air furnaceeous stream to obtain
the latent heat for vaporization, so the drying process is actually a combination of the
above two processes.
Urea and DAP have a high point of melting, typically Hot-air furnace flow at 150~
180℃ is used for the drying process; if the drying temperature is too low, the driving
force of heat transfer decreases, and the size of the drying equipment becomes
bigger; on the contrary, if the drying temperature is too high, the materials will get
melted, resulting in the adverse effect of the material getting stick to the equipment
wall. Figure (2) is the drying curve of urea ammonium, DAP, and potassium chloride.
It can be seen from the curve that the temperature of drying material is controlled at ~
75℃, and the water content of raw material gets close to 1.5% in 30 minutes. Under
these conditions of process, the phenomena like melting and decomposition does not
occur.
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Figure 2. Drying curve
In drying the materials, the temperature is an important indicator of the

performance, the water content of the granulator discharging material also has a role
to play; if the water content is too high, the drying load increases, and but the
materials get stick to the equipment wall; in order to ensure the safe operation of the
system, the granulation process shall be such that “dry is preferred over wet”, and the
drying process shall be operated by following the principle of “low-temperature with
high flow of air”.
5.3 The product cooling process facilitates the continuation of dispersing the moisture from
the hot granule, and overcomes the problem of water vapor condensation from the
packaging process without cooling, and this result in material agglomeration. However,
excessive cooling results in the material’s absorption of moisture; therefore, NPK urea
fertilizer shall undergo the anti-agglomeration processing of the product following the
cooling step, and additionally, the whole process shall be controlled in strict
accordance with the process conditions and the actual situation in the production.
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Chapter VI Startup and Shutdown Sequence and Procedure
6.1 Startup Sequence
In order to ensure the good functioning of all equipment, a smooth flow of

materials in the production equipment system shall be assured all the time from the
startup to the planned shutdown. Prior to the plant startup, inspected shall all be the
pipelines, conveyors, electrical equipment, instrumentation items, and the mechanical
equipment, and obstructions found in the pipeline shall be immediately removed.
Additionally, the driving devices shall be checked of the application of lubricating oil,
ensuring the required oil level is maintained. Notification shall be made to the steam
boiler for steam production and transmission, with condensed water in pipelines
concerned to be drained and cleaned, ensuring the steam pressure satisfy the
process requirements. The main equipment: granulator, drying machine, cooler, and
the coating machine, shall be manually barred or turned for more than 1/2 turns,
ensuring they are rotating normally. After the inspections and/or checks are
completed, and it is confirmed that all equipment, pipelines, valves, instrumentation
items, and electrical equipment are in normal working conditions, the equipment can
start in a forward order, downstream first and then upstream, in accordance with the
following sequence.
6.1.1 The procedure for startup of the main production plant – Equipment No. 11 × ×
1. 1# and 2# Hot-air furnace system is ignited to heat up, when the flue gas is vented
to atmosphere from the auxiliary stack (which shall not be shut down unless all
equipment of the whole system have been started and in normal operation).
2. Start up the scrubbing pump (P-1101AB), and open the spray valves for scrubbing
the stack, and the scrubbing fluid is pumped into the 1# and 2# scrubbing stack (T-
1101, T-1102) for spraying and scrubbing operation.
3. Start up the 1# drying off-gas fan (C-1104), and check the indications of the
individual points of pressure measurement.
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4. Start up the 2# drying off-gas fan (C-1106), and check the indications of the
individual points of pressure measurement.
5. Start up the product elevator (L-1111).
6. Start up the coating machine (M-1109).
7. Start up the product screen (M-1107).
8. Start up the large granule screen (M-1106).
9. Start up the large granule crusher (M-1108).
10. Start up the cooler off-gas fan (C-1107).
11. Start up the cooler (M-1105).
12. Start up the 2# semi-product elevator (L-1109).
13. Start up the 3# semi-product belt conveyor (L-1108).
14. Start up the 2# dryer (M-1104).
16. Start up the fines screen (M-1103AB).
17. Start up the 1# semi-product elevator (L-1106).
19. Start up the 1# dryer (M-1102).
20. Start up the curing belt conveyor (L-1104).
21. Start up the granulator (M-1101).
22. Start up the granulator off-gas fan (C-1103).
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23. Start up the raw material general elevator (L-1103).
24. Start up the 2# raw material belt conveyor (L-1102).
25. Start up the 1# raw material belt conveyor (L-1101).
26. Start up the cyclic material belt conveyor (L-1112).
27. Start up the belt weight meter (W-1101A-F).
28. Start up the raw material elevator (L-0101A-F).
29. Start up the 1# jet blower (C-1101), regulate the air flow rate, and close the valve
of the auxiliary stack, so as to gradually raise the gas temperature at the inlet and
outlet of the dryer concerned, until the process requirements are satisfied.
30. Start up the 2# jet blower (C-1102), regulate the air flow rate, and close the valve
of the auxiliary stack, so as to gradually raise the gas temperature at the inlet and
outlet of the dryer concerned, until the process requirements are satisfied.
Now all equipment of this system have been started up (except for the equipment
of the liquid urea system), recheck shall be carried out to all the equipment, ensuring
they be operating properly, and all conditions be meeting the process requirements;
following the checks and inspections, if there is no problem being identified, the solid
material can be introduced for production startup. After the normal production is
achieved, start up the system equipment for liquid urea preparation for the
changeover of the solid urea.
6.1.2 The startup sequence of the liquid urea preparation
The preparation of liquid urea: in accordance with the batching ratio required, the
solid urea is steadily introduced by the urea belt weight meter into the melting device
in which steam coil pipe is installed, and the solid urea is heated and molten by the
0.8-1.0Mpa steam into the liquid urea (99%).
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Liquid urea is driven through a filter into the granulator by the special pump of
liquid urea.
The measurement of liquid urea is used to control the amount of liquid urea, by
controlling the liquid level of the buffering tank of liquid urea.
When the material enter the system, the operators of the operating posts shall
make another round of inspection of the equipment, the electrical and instrumentation
items, checking their functioning with loads, and adjusting the flows of the materials,
ensuring uniform feed is achieved, with strict control of the various process
parameters.
1. Startup sequence (the valve numbering is referred to in the process flow diagram)
(1) Close 3# valve. Open 1#, 2#, 4#-valve, deliver the steam to V-1204.
(2) put all the equipment and piping as required in a Trap hydrophobic state, to
check whether the intact hydrophobic state.
(3) Open the valves – 5#, 6#, 7#, 8#, 9#, 10#, 11#, 12#, and 13#, and warm up
the insulated pipelines of liquid urea and equipment concerned.
(4) Check and close the valve 14#, and start up the urea elevator L-1201AB (L-
2201AB), and then start the W-1201AB (W-2201AB).
(5) In accordance with the process requirements, add to V-1201AB (V-2201AB)

the solid urea, and start up the urea melter, open the valve of compressed air.
Then observe the liquid level of V-1202 (V-2202); when the liquid urea
reaches a certain level (60% or so), it’s ready to start the pump of liquid urea.
(6) Check the valves – 17#, 18#, 20#, 21#, 22#, 26#, 27#, 28#, 29#, and 30#,
ensuring they be closed (when using P-1201A), and that the valves – 15# ,
16#, 19#, 23#, 24# and FV1201 (FV2201) are all fully open, and the valve 25#
is semi-open.
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(7) Open the 14# valve, and then slowly open the 21# valve, and do not close the
21# valve until the liquid urea is fully filling the liquid urea pump.
(8) Start up the P-1201A (P-2201A), and observe the pressure of P-1210 (P-
2210); when the pressure reaches the normal level, slowly open the 21#
valve.
(9) Open the valves 27#, 28#, and 29#, and purge the pipeline of liquid urea, and
do not close the 27# and 29# valves until the granulator M-1101 (M-1201) is
seen with blowing out steam.
(10) Close the 25# valve by 1/3 of the full openness, and close the FV1201
(FV2201) to the 50% or so openness, and then open the valve 26# to
introduce liquid urea to the granulator M-1101 (M-1201).
(11) Observe the liquid urea transporting conditions, and accordingly set the
FV1201 (FV2201) in the mode of automatic control.
6.2 The procedure for normal shutdown
Prior to the normal shutdown, the liquid urea preparation shall be stopped firstly,
thus stopping the introduction of solid urea into the V-1201AB (V-2201AB), and turn
to use the liquid urea in the tank V-1202 (V-2202), and then stop dosing other raw
materials, and wait for the cyclic material of the system to reach the minimum limit,
carry out the shutdown process in the following sequence.
6.2.1 Normal shutdown of the urea melting system
(1) Close 26# valve, at the same time automatic control valve FV1201 (FV2201) to the
largest, open 27#, 29# valve to purge liquid urea pipe to the Granulator until clean.
(2) Slowly close the valves 21# and 28#, and shut down the pump P-1201A (P-2201A),
before closing the valve 14#.
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(3) Open the valve #26, blow the V-1202 (V-2202) through the UR1213 (UR2213)
pipeline, and then close the valves – 15#, 23#, and 25#, and open the valve 30#
to drain urea in the V-1202 (V-2202) into the V-1203 (V-2203).
(4) Open the valves – 15#, 17#, 18#, 20#, 21#, and 22#, blow out the liquid urea
remaining in the pipelines.
(5) Close the valves 27# and 29#, stop running the equipment, and turn off the steam
supply to all the insulation.
6.2.2 Normal shutdown of the main production unit plant – equipment number: 11 × ×
1. Stop refueling the 1# and 2# Hot-air furnace, and, at the same time, reduce the
primary and secondary air flows, and open the butterfly valve of the auxiliary stack.
2. Stop the 1# jet blower (C-1101).
3. Stop the 2# jet blower (C-1102).
4. Stop the raw material elevator (L-0101A-F).
5. Stop the belt weight meter (W-1101A-F).
6. Stop the cyclic material belt conveyor (L-1112).
7. Stop 1# raw material belt conveyor (L-1101).
8. Stop 2# raw material belt conveyor (L-1102).
9. Stop raw material general elevator (L-1103).
10. Stop the granulator (M-1101). Firstly, close the steam and water valves to the
granulator, and then shut down the granulator.
11. Shut down the granulation off-gas fan (C-1103).
12. Stop the curing belt conveyor (L-1104).
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13. Shut down the 1# dryer (M-1102), and, at the same time, open the emergency
discharging door of the unloading chamber of the dryer, and unload the materials
from the inside of the dryer and dump the materials to the ground, which shall be
packaged up following the natural cooling, and retained for putting into the system
at the next startup.
14. Shut down the 1# semi-product belt conveyor (L-1105).
15. Shut down the 1# semi-product elevator (L-1106).
16. Shut down the fines screen (M-1103AB).
18. Shut down the 2# dryer (M-1104), and, at the same time, open the emergency
discharging door of the unloading chamber of the dryer, and unload the materials
from the inside of the dryer and dump the materials to the ground, which shall be
packaged up following the natural cooling, and retained for putting into the system
at the next startup.
20. Shut down the 2# semi-product elevator (L-1109).
21. Shut down the cooler off-gas fan (C-1107).
22. Shut down the cooler (M-1105).
23. Shut down the large granule crusher (M-1108).
24. Shut down the large granule screen (M-1106).
25. Shut down the product screen (M-1107).
26. Shut down the coating machine (M-1109).
27. Shut down the product elevator (L-1111).
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28. Shut down the 2# dryer off-gas fan (C-1106).
29. Shut down the 1# dryer off-gas fan (C-1104).
30. Shut down the wash liquor pump (P-1101AB), meanwhile, close the spray valve
of the scrubbing stack.
6.3 Long-term shutdown
Long-term shutdown is necessary due to the preparation for equipment overhaul

or for other reasons. Following the shutdown, immediately remove and clean the
equipment and pipelines, and the removed materials shall be properly packaged and
placed aside as returning material for the next startup; the removed materials shall
not be piled on the ground, so as to avoid moisture absorption causing material
melting and loss. The procedure for the shutdown remains the same as for the
normal shutdown. The residual liquid urea in the pipelines and equipment needs to be
flushed and blown for clean-up.
6.4 Emergency shutdown and power outage
1. Emergency shutdown
During the course of production, equipment failure or other accident would occur
sometimes when an emergency shutdown is necessary, where followed shall be
a principle by which the power supply to the failure equipment shall be firstly
turned off, before the other equipment are shut down, and the appropriate
actions shall be taken, depending on the situation of the accident and the length
of shutdown time.
If failures occurs unexpectedly, and the production cannot continue, then

emergency shutdown is necessary; if the problem is found to be with the main
workshop, the repair time is short, then the liquid urea and preparation can be
handled in the following procedure: close the valve 26#, and open to the most the
valve on the reflux pipeline, and, at the same time, open the atomizers of 27#
and 29#, and stop feeding.
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Where the maintenance shall take a long time, then the shutdown is treated as
normal one; if the failure occurs with the liquid urea, then failure equipment shall
be shut down first, and then followed by handling in line with the specifications.
2. Power outage
Due to a sudden outage of power, all the equipment stop operation automatically,
then immediate shut down shall be the power supply button of the general power
distribution room as well as all the electrical motors of the rotary equipment, and
open the butterfly valve of the auxiliary stack. Close the oil atomizer and other oil
valve, so that the Hot-air furnace is turned off. Open the sight hole of the material
loading and unloading chamber of the dryer, and the door of the material
unloading chamber, so that natural convection is established with cold air in the
dryer, where the dryer shall be barred or turned periodically (at an interval of 15
minutes, with each barring of 1/3 turn; the barring shall continue at the interval
until the temperature in the dryer falls below 60℃), so as to avoid the otherwise
uneven heating of the dryer and deforming the cylinder; after the power supply is
restored, the normal procedure shall be followed for the startup sequence.
If the production plant or workshop experiences a sudden power outage, the 14#,
21# and 26# valves shall be closed quickly for the liquid urea preparation, and
open the valve #30, in order to drain the slurry in the pipelines into V-1203 (V-
2203), and followed by the steam blowing of all the pipelines.
6.5 Blow the liquid urea pipelines and atomizers
1. Close the 14# valve, open the 27#, 28# and 29# valves, and blow the atomizers
toward the granulator, until clean steam is blowing out of the granulator.
2. Close the 28# slurry valve, and open the valves of 15#, 16#, 17#, 18#, 19#, 20#,
21#, 22#, 23#, 24#, 25#, and 26#, and also open to the most the FV1201
(FV2201) valve, blowing for 2 ~ 3 minutes.
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Upon the completion of blowing all the pipelines and equipment, turn off the steam
supply to all the insulations, and, at the same time, all the valves are restored to the
status the next startup requires.
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Chapter VII Technical Operation Specifications, Control Tests,
Sampling and Analysis Items
7.1 Technical Operation Specifications
1. Raw Material
In order to meet the production operating requirements for material batching,

metering, transmission and so on, all kinds of raw materials shall have good
physical properties. Ammonium phosphate to be used shall be of a granular
powder; if granular ammonium phosphate is to be used as raw material, it shall
be crushed in the warehouse for pre-processing, and the crushed material of a
fineness of 2mm shall account for about 85% in general, while those of 1.0mm
accounts for about 60%. Urea and potassium chloride shall be non-
agglomeration, and the moisture content shall be consistent with the applicable
standards. The filler material shall have the granules sized between 100-200
mesh accounting for more than 80%, with water content lower than 8%.
2. Batching of raw materials
According to the product’s specification of N- P2O5- K2O, and the raw materials to
be used, the analysis data of raw materials shall be based on to determine the
batching ratio of the various raw materials, the hours, and the charges in lots.
Through accurate measurement by using electronic belt weight meter, the raw
materials shall be evenly introduced into the production system and onto the
granulator. At the same time, following the ratio measurement, the liquid urea
shall also be introduced into the granulator.
3. Granulation
(1) Granulation material temperature 60 ~ 70℃
(2) The ratio of cyclic material to the finished product 1 ~ 2.5 times
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(3) Moisture of the granulation material 2.5 ~ 4.5% (about 3.5% when using
liquid urea for the granulation)
4. Drying the granulation materials
(1) Furnace gas temperature at the inlet of Dryer 1# 150 ~ 180℃
(2) Off-gas temperature at the outlet of Dryer 1# 70 ~ 75℃
(3) Temperature of the material discharging from Dryer 1# 65 ~ 70℃
(4) Moisture content of the material discharging from Dryer 1# ≤2.5%
(5) Furnace gas temperature at the inlet of Dryer 2# 150 ~ 180 ℃
(6) Off-gas temperature at the outlet of Dryer 2# 70 ~ 75℃
(7) Temperature of the material discharging from Dryer 2# 65 ~ 70℃
(8) Moisture content of the material discharging from Dryer 2# ≤1.5%
5. Cooling finished product
(1) Air temperature at the cooler inlet – Less than ambient temperature
(2) Material temperature at the cooler inlet ~ 65℃
(3) Material temperature at the cooler outlet 40 ~ 50℃
(4) Off-gas temperature at the cooler outlet ~ 55℃
7.2 Test points and test items
List of the major test points of temperature and pressure in production
Temperature measurement:
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Test
S/N Location of Test Point Test Range Test Pattern Note
Medium
1 Hot-air furnace chamber Gas 0～1200℃ Continuously Centrally
2 Hot-air furnace outlet Gas 0～100℃ Continuously Centrally
3 Dryer inputting gas Gas 0～400℃ Continuously Centrally
4 Dryer discharging gas Gas 0～200℃ Continuously Centrally
5 Dryer discharging material Granule 0～100℃ Intermittently Locally
6 Cooler discharging gas Gas 0～100℃ Continuously Centrally
7 Cooler discharging material Granule 0～100℃ Intermittently Locally

Granulator discharging
8 Granule 0～100℃ Intermittently Locally
material
Pressure measurement:
S/N Location of Test Point Test Medium Test Range Test Pattern Note
0 ～ 100mm
1 Granulator discharging gas Gas Continuously Locally
Water column
Hot-air Furnace discharging 0 ～ 200mm
2 Gas Continuously Locally
pipe Water column
0 ～ 100mm
3 Dryer feeding chamber Gas Continuously Locally
Water column
0 ～ 100mm
4 Dryer unloading chamber Gas Continuously Locally
Water column
0 ～ 500mm
5 Jet Blower outlet Gas Continuously Locally
Water column
Cooler off-gas discharging 0 ～ 200mm
6 Gas Continuously Locally
pipe Water column
0 ～ 300mm
7 Cyclone outlet Gas Continuously Locally
Water column
0 ～ 500mm
8 Scrubbing stack inlet Gas Continuously Locally
Water column
9 Steam pipe to the granulator Steam 0～1.0Mpa Continuously Locally
10 Steam pipe to the workshop Steam 0～2.0MPa Continuously Locally
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7.3 Analysis sampling points and analysis items
List of sampling points for chemical analysis

S/N Sample Sampling Sampling Method Analysis Analysis Item
Name Point Frequency
1 Liquid urea Site At field sampling point, take Once a day, Biuret
liquid urea sample in 500ml increase or
wild-mouth bottle. decrease
depending
on the
situation
2 Clay Warehouse Take multi-point samples from Once per lot Water, and fineness
different layers, or unpack,
take samples, mix the
samples, and put into 500ml
wild-mouth bottle.
3 Di- Warehouse Take multi-point samples from Once per lot Water-soluble P2O5,
ammonium different layers, or unpack, citrate-soluble P2O5,
phosphate take samples, mix the N, moisture, and
samples, and put into 500ml granule size
wild-mouth bottle.
4 Rock Warehouse Take multi-point samples from Once per lot Water-soluble P2O5,
Phosphate different layers, or unpack, citrate-soluble P2O5,
take samples, mix the moisture, and
samples, and put into 500ml granule size
wild-mouth bottle.
5 Potassium Warehouse Take multi-point samples from Once per lot K2O, moisture,
chloride different layers, or unpack, granule size
take samples, mix the
samples, and put into 500ml
wild-mouth bottle.
6 Granule Granulator Take sample and put into Irregularly Moisture, granule
material outlet 500ml wild-mouth bottle size
7 Dryer outlet Dryer outlet Take sample and put into Once per Moisture
material 500ml wild-mouth bottle shift
8 products Warehouse Following the sampling Once per N, biuret, P2O5,
of finished specifications, take sample shift ,water-soluble P2O5,
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S/N Sample Sampling Sampling Method Analysis Analysis Item
Name Point Frequency
product and put into 500ml wild-mouth citrate soluble P2O5,
bottle K2O, granule size,
moisture, and
granule strength
9 Dryer off- Dryer Constant speed sampling Irregularly Dust, wet and dry
gas bulb temperature
10 Wash liquor Settling Take sample and put into Irregularly N, P2O5, K2O, PH,
pond 250ml narrow-mouth bottle suspended solids
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Chapter VIII Example of Process Calculation (mass basis)
8.1 Calculation conditions
1. Product specifications: N- P2O5- K2O = 13-6-27-4Mg-0.65B
Product moisture content: H2O = 1.5%
2. The composition of basic raw materials
(1) Urea
Spec: N 46%, H2O 0.5%, granule size of 1 ~ 2mm, loose granular and
non-agglomeration.
Biuret ≤ 1%
(2) Ammonium sulfate
Spec: N 21%, H2O ≤ 1%
(3) Monoammonium phosphate (in powder, loose and non-agglomeration)
agglomeration.
(4) Diammonium phosphate (in powder, loose and non-agglomeration)
agglomeration.
(5) Potassium Chloride
Spec: K2O 60%, H2O ≤ 1%, in white or red fine crystal, loose and non-
agglomeration.
(6) Potassium sulphate
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Spec: K2O 50%, H2O ≤ 1%, in white crystal, loose and non-
agglomeration.
(7) Rock Phosphate powder
Spec: total P2O5 30%, H2O ≤ 4%, in powder, loose and non-
agglomeration.
(8) Filler materials
Spec: dolomite, kaolin, gypsum powder, and so on, with fineness of: 100-
200 mesh, H2O ≤ 8%.
(9) Magnesium oxide
Spec: Mg 54% H2O ≤ 1% powder
(10) Boric acid
Spec: B 17%, H2O ≤ 1% in powder

8.2 Batching ratio calculation
1. K2O is fully supplied from potassium chloride, the required amount of potassium
chloride shall be:
270/60%＝450.00Kg
H2O 450.00×1%=4.50Kg
2. 50% of P2O5 is supplied from diammonium phosphate, and the other 50% from
phosphate rock powder.
(1) The required amount of diammonium phosphate
30/46%＝65.22Kg
N： 65.22×18%＝11.74Kg
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H2O： 65.22×1.5%＝0.98Kg
(2) The required amount of phosphate rock powder
30/30%＝100.00Kg
H2O 100.00×4%＝4.00Kg
3. In addition to the N supplied from diammonium phosphate, the rest shall be

provided by urea, so the required amount of urea is:
(130－11.74)/46%=257.09Kg
H2O： 257.09×0.5%=1.29Kg
4. Mg is supplied from magnesium oxide, so the required amount of magnesium

oxide is:
40/54%=74.07Kg
H2O： 74.07×1%=0.74Kg
5. B is supplied from boric acid, so the required amount of boric acid is:
6.5/17%=38.24Kg
H2O: 38.24×1%=0.04Kg
The total amount of the materials to add:
450.00+65.22＋100.00＋257.09+74.07+38.24=984.62Kg
H2O: 4.50+0.98+4.00+1.29+0.74+0.04=11.55Kg
N%=130/984.62×100%=13.20%
P2O5%=60/984.62×100%=6.09%
K2O%=270/984.62×100%=27.42%
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Mg%=40/984.62×100%=4.06%
B%=6.5/984.62×100%=0.66%
H2O%=11.55/984.62×100%=1.17%
In order to lower the product’s N, P2O5, K2O, Mg, and B nutrients down to 13%, 6%,
27%, 4%, and 0.65%, it’s necessary to add the filler materials of X Kg, as below:
130/(984.62-11.55+92%X)/98.5%=13%
X=12.97 Kg
H2O=12.97×8 %=1.037 Kg
The total amount of materials: 984.62 +12.97 = 997.59Kg
Total H2O: 11.55 +1.037 = 12.587 Kg
Let 1.5% of moisture is contained in the finished product, and Y kg of moisture is

required to add during the production process, then amount of finished product is:
(12.587+Y)/(997.59+Y)=1.5%
Y=2.41Kg
The amount of finished product: 1004.18 +2.41 = 1000.00Kg
Water content of finished product: 12.59 +2.41 = 15.00Kg
Nutrient contents in the finished product:
N%＝130/1000×100%=13.00%
P2O5%＝60/1000×100%=6.00%
K2O%＝270/1000×100%=27.00%
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Mg% =40/1000×100%=4.00%
B% =6.5/1000×100%=0.65%
H2O% =15.00/1000×100%=1.50%
15 tons/hour is the production yield of the urea-based NPK granular fertilizer plant
(100,000 tons/year). The theoretical hourly inputs of the materials are as follows:
Potassium chloride： 450.00×15=6750.00Kg H2O：67.50Kg
Diammonium phosphate： 65.22×15=978.30Kg H2O：14.68Kg
Rock Phosphate powder： 100.00×15=1500.00 H2O：60.00Kg
Urea： 257.09×15=3856.35Kg H2O：19.28Kg
Magnesium oxide： 74.07×15=1111.05 H2O：11.11Kg
Boric acid： 38.24×15=573.60 H2O：5.74Kg
Filler: 12.97×15=194.55Kg H2O：2.92Kg
Total amount of materials ：

6750.00+978.30+1500.00+3856.35+1111.05+573.60+194.55=14963.85Kg
Water entrained ：
67.50+14.68+60.00+19.28+11.11+5.74+2.92=181.23Kg
8.3 Hourly inputs of materials
Hourly inputs of the major materials of 13-6-27-4Mg-0.65B compound fertilizer
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Name of Material Hourly Input (Kg)

Potassium chloride 6852.79
Diammonium phosphate 993.20
Phosphate rock powder 1522.84
Urea 3915.08
Magnesium oxide 1127.97
Borax 582.34
Filler 197.51
Total amount of the makeup materials 15191.73
Hourly input of material includes the material loss from the system off-gas
exhaustion, and mechanical losses of the system-wide materials, while the total
amount of material loss is counted as 1.5% of the finished products.
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Chapter IX Consumption Norms
9.1 Consumption norms of raw materials and utilities: (for each tone of 13-6-27-4Mg-
0.65B product)
Consumption Norm
Items (tone/tone)
1. Potassium chloride，K2O 60% H2O 1% 0.4569
2. Diammonium phosphate， N18%P2O5 46% H2O 1.5% 0.0662
3. Phosphate rock powder， P2O5 30% H2O 4% 0.1015
4. Urea，N 46 % H2O 0.5% 0.2610
5. Magnesium oxide，Mg 54% H2O 1% 0.0752
6. Boric acid B 17% H2O 1% 0.0388
7. Filler material， H2O 8% 0.0132
8. Steam P ＝0.6Mpa (gauge) 0.13
9. Process water P＝0.3Mpa（gauge） 0.10
10. Woven bag lined with plastic bag, 50kg/bag 20.5 (piece)
11. Electricity 525V/220V 50Hz 50 kWh/t
12. Diesel oil 0.032
9.2 Production manning level
The following table is only about the manning level of the production plant, excluding
the persons required for handling the raw materials from the warehouse to the
storage hoppers, and for loading the finished products in lorry for ex-works transport.
The table of the manning matrix for the urea-based NPK granular fertilizer plant
(100,000 tons/year)
Number of Total
Number
S/N Description Staff for Number of Notes
of Shifts
Each Shift Staff
(1) Material supply, and batching 4 6 24 Including the
materials solid material
supply and
preparation of the
liquid urea
(2) Granulation system 4 2 8 Including one
person for the
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control room
(3) Granular DAP crusher 4 2 8
(4) Hot-air furnace 4 2 8
(5) Preparation of liquid urea 4 2 8
(6) Screening system and 4 2 8
crushing large granule of
material
(7) Finished product packaging 4 2 8
(8) Analysis 2 1 2
(9) Crews for mechanical, 4 2 8
electrical and instrument
maintenance and repair
(10) Shift leader or chief operator 4 1 4 Give attention to
off-gas
processing
system as well as
the tour
inspection
(11) Statistician 1 1 1
(12) The director and deputy 1 2 2
director of the plant
Total 89
The urea-based NPK granular fertilizer plant (100,000 tons/year) is manned with: 89
persons for the production.
The urea-based NPK granular fertilizer plant (2× 100,000 tons/year) is manned with:
178 persons for the production.
Note: This line production is operating continuously in the system of three shifts per
day. The table listed system of four rotating shifts is provided for the reference by the
plant owner.
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Chapter X Common Failures, Causes and Handling Methods
Failure Causes Handling Methods

Description
1. Elevator 1. Machinery chain becomes 1. Adjust downward the lower rolling wheel, so
plugging loose, grow in length, and skid. that the chain gets tight to prevent slipping; if
2. Elevator discharging pipe is this method fails, take off a few links of the
plugged by materials. chain.
3. Too much material input, 2. Remove of the pipe plugging materials.
exceeding the capacity of the 3. Uniformly feeding the materials.
elevator. 4. Check and clean up.
4. Elevator is jammed by blocks Note: The above methods shall not be taken
of materials. before the materials in the equipment are
cleaned up.
2. The efficiency The crusher chain is worn, Replace the chain.
of crusher is low. resulting in too large gap of The replaced chain can be remedied of its
chains. The driving belt grows length, and used as a backup chain.
in length, thus slipping. The Replace the triangle driving belt.
material agglomeration in the Clean up the material agglomeration in the
crusher is not cleaned up crusher.
timely.
3. The belt 1. Material gets stick to the belt Eradicate the sticky material, and align the rear
conveyor is rollers, resulting uneven stress roller.
moving offset on the belt. Align the rear roller.
2. The front and the rear rollers
are not parallel in installation.
4. Excessive 1. Too much inputs of steam or Adjust the flux of steam input. After the
granulation by the water. occurrence of this phenomenon, in order to
granulator 2. The sudden interruption of avoid plugging the feeding shute of the dryer,
raw material supply. and material gets stick to the dryer cylinder wall
as well as shoveling plate, the excessively wet
materials shall have been discharged to the
ground; only after the materials gets normal
inside the granulator, can the wet material be
gradually introduced to the granulator.
5. The granulator 1. The amount of steam and Adjust the amount of steam and the PH value.
is giving a low rate the temperature are too low. Adjust the formula.
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Description
of granule 2. The formula is not correct.
formation.
6. The dryer 1. The gas temperature at the Check and ensure that blower air flow is
discharging inlet and outlet of the dryer is normal, and the burner or furnace is in normal
material has water low. operation.
content exceeding 2. The material input is too Ensure that the flow of the dryer discharging
the specification. high, exceeding the dryer materials, and the gas temperature, are
capacity. meeting the process targets or specifications;
3. Insufficient heat. increase the amount of coal for the burning
4. The water content of the furnace, or temporarily reduce the input amount
granulator discharging material of raw material.
is high. Regulate the input of steam and water into the
granulator.
7. Vibration 1. The screening body has Immediate reporting shall be made to the
screening loosening fasteners and other squad or shift leader or to the maintenance staff
efficiency is reasons, the screen gives off for inspection; where as necessary, temporary
lowered unusual noise, and the exciting shutdown may be carried out for inspection and
force is reduced. maintenance of the screen.
2. The water content of material Increase the temperature of the dryer
is high, or the material batching discharging gas, and the material temperature,
is improper and blocking screen or make due adjustment of the makeup
holes. materials.
3. The shaking screen is Check and ensure the direction of motor
rocking unevenly, so imbalance rotation is as specified, and electric motor’s
occurs. eccentric block has consistent scale.
8. The finished 1. The materials are Tools like wire brush can be used for brush
product has excessively wet, and the cleaning of the screen in a timely manner, so as
excessive vibration screen holes are to ensure that the holes are open and through,
entrainment of fine plugged. and, at the same time, the drying post shall be
powder 2. Too much material is informed of the excessively wet material,
handled, exceeding the needing corrective actions to be taken.
capacity of the equipment. Notification shall be made of the posts of raw
material supply to suspend the input of raw
material, and then open the dryer discharging
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bypass to deal with the failure by unloading or
dumping the materials on the ground, and
recharge the materials into the system when
the amount of materials gets normal, and then
notify the posts of raw material supply to feed
the system.
9. The granule out The cooler fan flow of air is too Appropriately reduce the air flow into the
of the cooler has high. cooler.
too low
temperature and
too wet surface.
10. High Off-gas pipe is plugged. Identify the causes, and do the cleanup.
differential
pressure as
indicated by the
U-type pressure
gauge of the
various points of
the off-gas
system.
11. Fan is 1. Material agglomeration or To the fan add a small quantity of water to
vibrating corrosion occurs on the fan scrubbing and dissolve the material
abnormally blade, resulting in an agglomeration; if this fails to solve the problem,
imbalance. shut down the equipment for inspection and
2. Mechanical reasons. rectification.
Maintenance personnel shall be invited to make
checks and repair.
12. Dryer feed 1. Excessive air flow of the Reduce the air flow of the blower.
chamber is blower. Check the pressure of the individual points of
blowing out gas 2. The off-gas system has the dryer off-gas pipe, and identify the points of
pipes locally blocked, and the blockage, and get it cleaned up.
off-gas suction flow is reduced
13. Too much The granule generation rate of Reduce the input of material, and use for the
material is the granulator is low. time being the returning feed for granulation.
returned When the returning feed is meeting the process
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requirements, start to increase the input of
material, and gradually restore to normal.
14. Liquid urea Debris and garbage are Take off the atomizer, cleaning, and flush the
atomizer is entrained in the liquid urea. liquid urea pipe (from the pump outlet to the
plugged atomizer).
15. The liquid urea 1. There is residual water in the 1. Lower the pump outlet temperature of the
pumping pipes. liquid urea, as appropriate.
performance is 2. Filter has foreign matters 2. Drain the residual water in the liquid urea
poor, or unable to inside, and the pump depletion pipes.
deliver the liquid occurs. 3. Remove the filter and clean the screen.
urea 3. Pump seal damaged. 4. Replace the sealing ring
Page 54 of 56

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OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

Technological Process for PKT’s 2x100000 TPY

Shanghai Research Institute of Chemical Industry

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

1.1 The properties, Uses, and Technical Documents

Liquid urea – ammonium phosphate (hereafter as ammophos) – potassium

Liquid urea –ammophos – potassium compound fertilizer has the main

Stacking angle ~ 31°

Bulk density ~ 0.75

Shoot density ~ 0.88

Critical relative humidity (30℃) ~ 44.5%

Specific heat ~ 0.30 cal/gram.℃

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

（2） Products and the specifications:

Product specifications: N－P2O5－K2O 20－10－10 & 13-6-27-4Mg-0.65B

Other specifications: water ≤2%

Granule size (-4.5 +2 mm) ≥90%`

1.2 Analysis and sampling methods

Detailed method of analysis is referred to in the ‘Compound fertilizer Production

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

Where: N – the total number of bags for each lot of product.

Sampling fertilizer in bulk

<1 ton 4～6

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

The sampling points shall be evenly distributed to ensure the representativeness of

1.3 Packaging Finished Product

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

1. Specifications of the raw material

（2） Ammonium sulfate

Spec: N 21%, H2O ≤ 1%

（3） MAP (in powder, loose and non-agglomeration)

（4） Diammonium Phosphate (in powder, loose and non-agglomeration)

（5） Potassium Chloride

（7） Phosphate rock

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

（8） Filler material

2、 Specifications of supplementary materials

（1） Coating oil

Spec: anti-agglomeration agent coating oil

Spec: calorific value: 9,600KCal/Kg

Spec: low pressure steam, P = 0.6-0.8Mpa (gauge),

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

3.1 Process Flow Block Diagram

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

(metering) (metering) (metering) (metering) (metering)

Pump Urea Melter

Scrubber No.1 Cyclone Dryer No.1 Combustion Furnace Diesel

Cyclone Fines Screen

Granule smaller than 2.5mm

Cyclone Dryer No.2

Cyclone Cooling Large Granule Crusher

Granule larger than 4.5mm

Settling pond Scrubber No.2 Coating Machine

Venting Product packaging

OPERATION MANUAL FOR NPK May 23’ 09 DL RBN AGP

The production plant comprises units for 2 × 100,000 tons/year production of

1. Flow process description of the ammophos crushing system (equipment number:

The ammophos crushing system is in intermittent operation, where the