Granulation and mass exchanging equipment
GRAULATION UNIT OF MELT OF NITRIC AND COMPLEX FERTILIZERS
Production and mounting of vibration-granulators are the main activities of Turbomash (granulation units of melt of nitric and complex fertilizers).
Vibration-granulators and filters of melt of nitric and complex fertilizers, that are the part of granulation units, are developed by the laboratory of granulation and mass-exchanging in the Sumy State University (Ukraine,Sumy). Nowadays it is widely applied in production.
Specialists of our company in association with the Sumy State University (with the laboratory of granulation and mass-exchanging equipment of the Sumy State University) carry out all works of production and commissioning of granulation equipment. It allows us to realize complicated and often innovation aims, apply the last achievements of science and technology in a practical production.
The laboratory of granulation and mass-exchanging equipment of the Sumy State University was created according to the joint order of the Ministry of Chemical Industry of USSR and the Ministry of Education of USSR No 450 from 26.12.1978. (OLHO SF KhpI)
The Sumy State University is the applicant and consequently the owner of more than 80 author’s certificates and patents for methods and mechanization of the granulation processes of various substances (including 40 for vibration-granulators and filters of melt of nitric fertilizers).
Design documentation and equipment are certificated by the Certification Center of pumping and refrigerating equipment (NP”SCTs NASTKhOL”) No ROSS UA.АЯ45.А01112 from 22.08.2006, No ROSS UA.АЯ45.А01260 from 24.04.2008. They are allowed for application by the Federal Service of Ecological, Technological and Atomic Inspection No RRS 00-22575. The laboratory of granulation and mass-exchanging equipment is certified complying with the standards ISO 9001:2000; certificate HU 08/3130 from 28.03.2008.
The modern rotating vibration-granulators of ammonium nitrate and urea designed by the Sumy State University are applied at dozens granulation towers. It provides receiving the most quality pellets in Odessa, Severodonetsk, Gorlovka, Nevinnomyssk, Grodno, Navoi, Fergana, Chirchik (CIS), and also in Pulava, Vlotslavek (Poland), Stara Zagora (Bulgaria) and at other factories. Among the customers was the company “Urea Casale S.A. Our equipment was dispatched through Poland to Qatar.
Specialists of our company in association with the Sumy State University (with the laboratory of granulation and mass-exchanging equipment of the Sumy State University) carry out all works of production and commissioning of granulation equipment. It allows us to realize complicated and often innovation aims, apply the last achievements of science and technology in a practical production.
The laboratory of granulation and mass-exchanging equipment of the Sumy State University was created according to the joint order of the Ministry of Chemical Industry of USSR and the Ministry of Education of USSR No 450 from 26.12.1978. (OLHO SF KhpI)
The Sumy State University is the applicant and consequently the owner of more than 80 author’s certificates and patents for methods and mechanization of the granulation processes of various substances (including 40 for vibration-granulators and filters of melt of nitric fertilizers).
Design documentation and equipment are certificated by the Certification Center of pumping and refrigerating equipment (NP”SCTs NASTKhOL”) No ROSS UA.АЯ45.А01112 from 22.08.2006, No ROSS UA.АЯ45.А01260 from 24.04.2008. They are allowed for application by the Federal Service of Ecological, Technological and Atomic Inspection No RRS 00-22575. The laboratory of granulation and mass-exchanging equipment is certified complying with the standards ISO 9001:2000; certificate HU 08/3130 from 28.03.2008.
The modern rotating vibration-granulators of ammonium nitrate and urea designed by the Sumy State University are applied at dozens granulation towers. It provides receiving the most quality pellets in Odessa, Severodonetsk, Gorlovka, Nevinnomyssk, Grodno, Navoi, Fergana, Chirchik (CIS), and also in Pulava, Vlotslavek (Poland), Stara Zagora (Bulgaria) and at other factories. Among the customers was the company “Urea Casale S.A. Our equipment was dispatched through Poland to Qatar.
In comparison to the static, centrifugal, acoustical and other granulators used in industry, our rotation vibration-granulators provide:
- Increasing agronomic value of fertilizers;
- High operation reliability;
- Receiving more competitive uniform pellets;
- Exclusion of sticking in towers;
- Intensification of heat exchange in towers.
| Companiesparameters | Centrifugal granulator of «Kreber» |
Acoustical granulator of NIIIKHIMMASh | Proposed rotation vibration granulator |
| Capacity, t/h | 25-70 | 7-18 | 20-100 |
| Granulometric composition, %1-4 mm2-4 mm2-3 mm2,0-2,5 mmless than 1 mm | 97-99 83-92 75-90 40-50 0,8-2,5 |
98-99 85-95 80-90 45-65 0,8-1,5 |
more than 99 90-97 more than 90 more than 80 0,5-1,0 |
DESCRIPTION OF MAIN EQUIPMENT
Rotating vibration-granulator
The rotating vibration-granulator is applied in chemical industry and is intended for dispersion of melt of nitric fertilizers on uniform drops in the granulation tower, with subsequent cooling and crystallization to firm pellets during free fall in ascendant flow of cool air.
The rotating vibration-granulator is intended to produce monodisperse granulated nitric (ammonium nitrate, urea) and complex fertilizers. It represents a system of compactly located main and additional equipment, pipelines.
Using monodispersion process improves the technology of producing fertilizers. Applying uniform (monodisperse) pellets in agriculture allows distributing evenly fertilizers on the fertilized area and thereby receiving additional yield increase up to 10 per cent.
Vibration-granulators allow obtaining strong monodisperse pellets with a smooth glossy surface (degree of monodisperse is 99%). It results the intensification of granulation process and significantly increases agronomical value of fertilizers.
The principle of work of the vibration-granulator for receiving granulated mineral fertilizers from their melt is based on the ability of liquid jets to break up into droplets of equal size; if on its surface regular disturbances (waves) are created at the same distance from each other.
Elastic waves are extended in a mass of melt that fills the vibration-granulator. Periodically they change their speed of melt discharge when reach the discharge orifice, creating disturbance on the surface of jets in the form of constrictions. In places of constrictions the melt jet break up into strictly equal droplets by surface tension force which falling into the cavity of granulation tower against the stream of cold air. Then they harden into spherical granules.
Rotation of the vibration-granulator promotes the dispersal of pellets along different trajectories thus improving the conditions of heat transfer in the granulation tower. Also it increases monodispersity of the product.
Depending on demanded diameter of jet, the shape of perforated bottom of the basket can be spherical or toroidal (bowl-shaped cupped).
The vibration-granulator is simple in construction and in maintenance, reliable and durable. It has long-term running between maintenance inspections.
Abiding the service conditions provides the required granulometric composition
MECHANISM OF VIBRATION-GRANULATOR AND HOW IT WORKS
Image 1 – the scheme of vibration-granulator, type VVG: a) with torroidal bottom; b) with spherical bottom; c) fast-rotating.
The vibration-granulator consists of the basket with perforated bottom 1, distributor 2, rod 3 with transmitter, hollow shaft 4, bearing unit 5, vibrator 6 is installed on the top of the pellet and connected with the rod 3. The metal cap 7 is fixed on the bearing unit 5. The bearing unit 5 is installed on the cap 9, which has the pipe branch 8 and 10 correspondingly for melt and steam entering before starting and stopping the granulator. The pulley 11 is applied to transmit rotation from the motor reducer to the hollow shaft (the drive system is not shown). In the heated-up rotating vibration-granulator cleared filtered melt moves through pipe branch 8, which passes through the distributor 2 and goes to the basket holes 1 and expires in the form of laminar jets in volume of the granulation tower.
Vibration is transmitted from the oscillator 6 through the rod 3 with the transmitter in melt that is in the basket 1 and on jets. It assists the fragmentation into uniform droplets.
TECHNICAL SPECIFICATIONS OF VIBRATION-GRANULATOR
Productivity of vibration-granulator according to melt is 10-100 t/h (at request).
| Substance | urea,ammonia nitrate, etc. |
| Load according to melt, t/h | at request |
| Granulometric composition | at request |
| Revolving frequency of basket, rev/min | 35-150 |
| Jet’s diameter, m | 4,0-15,0 |
| Drive*: | |
| – performance | explosion and flameproof |
| – current | AC, three-phase |
| – frequency, Hz | 50 |
| – voltage, V | 380 |
| – energy input, kWt, not more than* | 4,0 |
| Service life of granulator, years | 10 |
| Service life of basket, years | 5 |
| Weight, kg | 67±3 |
Note: required granulometric composition and productivity are regulated by diameter and quantity of baskets’ holes of the vibration-granulator.
Application of the melt filters before using the vibration-granulator is obligatory because it eliminates the possibility of frequent clogging of holes of granulator’s bottom.
Mechanism and principle of work of electromagnetic granulator
The electromagnetic vibrator consists of control unitand electromechanical chopper. The control unit is applied as transmitter of signal of given frequency and amplitude on the vibration-transformer. Received signal is sent to the vibration-transformer where reorientation of crystal lattice of float core material happens under influence of magnetic field. It results the change of length of the core. The vibration radiator of the granulator is connected to the bottom of the core. Blasting of cold air is provided to cool the chopper. The vibration system has input and output signal. It is 4-20 mA. It allows operating the frequency of vibration depending on changes of the level of melt in granulator. The control unit of vibration system is mounted on CPU.
Parameters of electromagnetic vibrator:
- operating frequency range, Hz – 120-1200
- current input, mA – 5-20
- amplitude, um – 0-100
- fixed power, kW – not more than – 1,5
Installation of the vibration system allows:
- to regulate frequency of jets’ collapse depending on load (melt level) in granulator;
- if necessary the system allows to control vibration frequency with the help of PC;
- to receive more qualitative fractional structure of the finished product
- to simplify the maintenance of granulator vibration system;
- to use more reliable vibration system.
SYSTEM OF MELT FILTRATION
The melt filter is installed before the granulator in the line of supply of melt of nitric and complex fertilizers as the technological equipment of the unit of melt granulation
The filter is applied to break up large particles, homogenization of similar components and filtration of melt of nitric fertilizers before sending it into the granulator. The principle of work of the granulator is like autogenous milling of particles containing in melt.
Application of the filter reduces three to four times the quantity of stops of the granulator for clearing from inclusions that are in melt. Also it allows transferring clear melt into the granulator that simplifies its maintenance, improves granulometric composition of received product by reducing clogging of the holes of the granulator basket.
FGP Filter
Image 2 – The scheme of the melt filter FGPNote: * Overall sizes are specified while preparing technical proposals on the basis of the questionnaire filled by the customer.TECHNICAL SPECIFICATIONSSubstancemelt of nitric fertilizerLoad according to melt, t/hat requestConcentration of hard inclusions, % mass., not more than10*Note: *Permitted work operation of the filter with the concentration of powdery admixture up to 20% mass2. FPTs filters
TECHNICAL SPECIFICATIONSProductivity according to melt of nitric fertilizer with powdery admixture, m3/h, not more than*55Admixture added into melt, % mass, not more than20Melt temperature, C, not more than195Drive*: – performanceеexplosion and flameproof– currentAC, three-phase– frequency, Hz50- voltage, V380- energy input, kWt, not more than *15,0Overall sizes, length x width x height, mm´mm´mm*2580´1100 ´2115Mass of the filter, kg390±20Mass with drive, frame and lifting device975±65Note: Note: productivity according to melt, drive power, overall sizes are specified while preparing technical proposals on the basis of the questionnaire filled by the customer.DELIVERY SET*GRANULATORVibration-granulator of melt with basket;Removable basket;Measuring system of melt level;Motor-reducerFrequency converter for induction motors (for changing rotation speed of granulator)VIBRATION SYSTEM:control unit;chopper;cooling system;cord.SYSTEM OF MELT FILTRATIONNote: *Complete set can be changed according to the customer’s orderWARRANTYWarranty period is 12 months from the date of starting the melt granulation unit into operation if service conditions specified in user manual are followed.