A granulation system for chemical fertilizer with real-time visualization of particle size distribution
Patent Information
- Application Number
- CN202522316313.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-31
- Publication Date
- 2026-09-25
- Estimated Expiration
- 2035-10-31
AI Technical Summary
[0003]当前化肥造粒生产线（如磷铵装置）的粒级分布控制依赖人工现场观察：操作人员通过肉眼判断造粒机出料粒子分布然后调整造粒参数；但人工方式存在主观性强、反馈滞后；且人工反馈易导致主控调整偏差，产生大量不合格料（月均600吨），增加成本；且传统模式无法实现粒级数字化监控，制约生产稳定性和合格率提升
本实用新型提供的粒径分布实时可视化的化肥造粒系统，通过预筛设备按粒径分级筛分造粒设备产出的物料粒子，经至少两个第一筛分出口分别排出不同粒级物料，对应连接的输出称重皮带秤实时获取各粒级物料重量数据并传输至DCS控制系统，系统通过显示界面直观呈现各粒级重量及占比，实现物料粒级的数字化可视化，替代人工主观判断；非所需粒级物料经对应皮带秤直接返回造粒设备，形成即时循环再加工，减少不合格料堆积；DCS控制系统基于实时数据可快速联动调整造粒参数，降低人工干预成本，通过精准控制稳定粒级分布，最终提高产品粒度合格率。
Smart Images
Figure CN224793427U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of fertilizer granulation technology, and in particular to a fertilizer granulation system with real-time visualization of particle size distribution. Background Technology
[0002] In the process of modern agricultural development, chemical fertilizers are key production materials for ensuring high crop yields, and their production quality and efficiency directly affect agricultural economic benefits and food security.
[0003] Currently, particle size distribution control in fertilizer granulation production lines (such as phosphate fertilizer units) relies on manual on-site observation: operators judge the particle distribution of the granulator output by visual inspection and then adjust the granulation parameters; however, the manual method is highly subjective and has a delayed feedback; moreover, manual feedback is prone to causing deviations in the main control adjustment, resulting in a large amount of unqualified material (an average of 600 tons per month), increasing costs; and the traditional model cannot achieve digital monitoring of particle size, which restricts the improvement of production stability and pass rate. Utility Model Content
[0004] The purpose of this invention is to provide a fertilizer granulation system with real-time visualization of particle size distribution, in order to solve the problems existing in the prior art, realize material particle size visualization, reduce waste, reduce labor costs, and improve product particle size qualification rate.
[0005] To achieve the above objectives, this utility model provides the following solution: This invention provides a fertilizer granulation system with real-time visualization of particle size distribution, including a granulation device, a pre-screening device, a DCS control system, and multiple output weighing belt scales. The granulation device is used to prepare material particles. The pre-screening device is used to receive the material particles prepared by the granulation device, and the pre-screening device can classify and screen the material particles according to different particle sizes. The pre-screening device has at least two first screening outlets. Each of the output weighing belt scales is connected to a corresponding first screening outlet. Material particles discharged from the first screening outlet that are not of the desired particle size are returned to the granulation device after being transmitted through the corresponding output weighing belt scale. The DCS control system is communicatively connected to the granulation device, the pre-screening device, and each of the output weighing belt scales, and the DCS control system has a display interface. After the weighing data of each output weighing belt scale is transmitted to the DCS control system, the display interface can display the weight and percentage data of the material particles of each particle size.
[0006] Preferably, the pre-screening device further has a second screening outlet, which is used to discharge the material particles of the largest particle size screened by the pre-screening device; the second screening outlet is connected to a crusher, and the output port of the crusher can be connected to the granulation device.
[0007] Preferably, the granulation equipment includes a granulator, a dryer, and a conveyor belt scale; the output port of the granulator is connected to the input port of the dryer, and the output port of the dryer is connected to the input end of the conveyor belt scale; the output end of the conveyor belt scale can be connected to the input port of the pre-screening equipment; the granulator, the dryer, and the conveyor belt scale are all communicatively connected to the DCS control system.
[0008] Preferably, the granulation equipment further includes a bucket elevator; the output end of the conveyor weighing belt scale is connected to the input port of the bucket elevator, and the output port of the bucket elevator is connected to the input port of the pre-screening equipment.
[0009] Preferably, the input port of the granulation equipment is equipped with a system return belt, which is used to return the material particles from the first screening outlet to the output end of the output weighing belt scale of the granulation equipment. The output port of the crusher is connected to the input end of the system return belt.
[0010] Preferably, the conveyor weighing belt scale and each of the output weighing belt scales are connected to the DCS control system via optical fiber.
[0011] Preferably, there are two first screening outlets; one first screening outlet is used to discharge fine material, and the other first screening outlet is used to discharge qualified material; the second screening outlet is used to discharge coarse material; the particle size of the coarse material is larger than the particle size of the qualified material, and the particle size of the qualified material is larger than the particle size of the fine material.
[0012] The present invention achieves the following technical advantages over the prior art: This utility model provides a real-time visualized fertilizer granulation system for particle size distribution. The system uses a pre-screening device to classify and screen the material particles produced by the granulation equipment according to particle size. Different particle sizes are discharged through at least two first screening outlets. Correspondingly connected output weighing belt scales acquire the weight data of each particle size in real time and transmit it to the DCS control system. The system displays the weight and proportion of each particle size intuitively through a screen interface, achieving digital visualization of the material particle size and replacing manual subjective judgment. Undesirable particle sizes are directly returned to the granulation equipment via the corresponding belt scale, forming an immediate cycle for reprocessing and reducing the accumulation of substandard materials. Based on real-time data, the DCS control system can quickly and dynamically adjust granulation parameters, reducing manual intervention costs. Through precise control and stable particle size distribution, it ultimately improves the product particle size qualification rate. Attached Figure Description
[0013] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0014] Figure 1 A schematic diagram of the overall structure of the fertilizer granulation system for real-time visualization of particle size distribution provided by this utility model.
[0015] In the diagram: 1-granulator; 2-dryer; 3-conveyor weighing belt scale; 4-bucket elevator; 5-pre-screening equipment; 6-output weighing belt scale; 7-crusher; 8-system return belt; 9-fine material; 10-qualified material; 11-coarse material. Detailed Implementation
[0016] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0017] The purpose of this invention is to provide a fertilizer granulation system with real-time visualization of particle size distribution, in order to solve the problems existing in the prior art, realize material particle size visualization, reduce waste, reduce labor costs, and improve the product particle size qualification rate.
[0018] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0019] Example 1 This embodiment provides a fertilizer granulation system with real-time visualization of particle size distribution, such as... Figure 1As shown, the system includes a granulation device, a pre-screening device 5, a DCS control system, and multiple output weighing belt scales 6. The granulation device is used to prepare material particles. The pre-screening device 5 is used to receive the material particles prepared by the granulation device, and the pre-screening device 5 can classify and screen the material particles according to their particle size. The pre-screening device 5 has at least two first screening outlets. Each output weighing belt scale 6 is connected to a corresponding first screening outlet. Material particles that are not of the desired particle size are returned to the granulation device after being transmitted through the corresponding output weighing belt scale 6. The DCS control system is communicatively connected to the granulation device, the pre-screening device 5, and each output weighing belt scale 6, and the DCS control system has a display interface. After the weighing data of each output weighing belt scale 6 is transmitted to the DCS control system, the display interface can display the weight and percentage data of each particle size.
[0020] The material particles produced by the granulation equipment are graded and screened by the pre-screening device 5 according to particle size. Different particle sizes are discharged through at least two first screening outlets. The corresponding output weighing belt scale 6 acquires the weight data of each particle size in real time and transmits it to the DCS control system. The system displays the weight and proportion of each particle size intuitively through the display interface, realizing the digital visualization of the material particle size and replacing manual subjective judgment. Undesirable particle size materials are directly returned to the granulation equipment through the corresponding belt scale, forming an immediate cycle for reprocessing and reducing the accumulation of unqualified materials 10. The DCS control system can quickly adjust the granulation parameters based on real-time data, reducing the cost of manual intervention. By accurately controlling the stable particle size distribution, it ultimately improves the product particle size qualification rate.
[0021] Specifically, the output weight and proportion of each particle size obtained through the DCS control system provide real-time data for precise control of the granulation process; early deviation correction reduces defective material by 10%; it reduces reliance on manual labor, replacing manual visual observation and feedback; and the DCS control system digitally monitors particle size trends, preventing system crashes and enhancing production stability.
[0022] The following are the relevant setup instructions for the granulation equipment: Among the optional solutions in this embodiment, the more preferred one is as follows: Figure 1 As shown, the granulation equipment includes a granulator 1, a dryer 2, and a conveyor weighing belt scale 3; the output port of the granulator 1 is connected to the input port of the dryer 2, and the output port of the dryer 2 is connected to the input end of the conveyor weighing belt scale 3; the output end of the conveyor weighing belt scale 3 can be connected to the input port of the pre-screening equipment 5; the granulator 1, the dryer 2, and the conveyor weighing belt scale 3 are all connected to the DCS control system.
[0023] Among the optional solutions in this embodiment, the more preferred one is as follows: Figure 1As shown, the granulation equipment also includes a bucket elevator 4; the output end of the conveyor weighing belt scale 3 is connected to the input port of the bucket elevator 4, and the output port of the bucket elevator 4 is connected to the input port of the pre-screening device 5.
[0024] Specifically, the weight and percentage data of the material particles corresponding to the second screening outlet displayed on the DCS control system's display interface are obtained by subtracting the data from each output weighing belt scale 6 (each first screening outlet) from the total weight obtained by the conveyor weighing belt scale 3.
[0025] The following are the relevant settings instructions for the pre-screening equipment 5: Among the optional solutions in this embodiment, the more preferred one is as follows: Figure 1 As shown, the pre-screening device 5 also has a second screening outlet, which is used to discharge the material particles of the largest size screened by the pre-screening device 5; the second screening outlet is connected to a crusher 7, and the output port of the crusher 7 can be connected to the granulation equipment.
[0026] Among the optional solutions in this embodiment, the more preferred one is as follows: Figure 1 As shown, there are two first screening outlets; one first screening outlet is used to discharge fine material 9, and the other first screening outlet is used to discharge qualified material 10; the second screening outlet is used to discharge coarse material 11; the particle size of coarse material 11 is larger than the particle size of qualified material 10, and the particle size of qualified material 10 is larger than the particle size of fine material 9.
[0027] Specifically, fine material 9 consists of material particles with a particle size ≤ 3.0 mm, qualified material 10 consists of material particles with a particle size between 3.0 mm and 4.5 mm, and coarse material 11 consists of material particles with a particle size ≥ 4.5 mm. The specific particle size classification can be set according to actual needs, including but not limited to the classification methods mentioned above.
[0028] Specifically, the first screening outlet is connected to the corresponding output weighing belt scale 6 by setting a suitable discharge chute.
[0029] Regarding other related settings: Among the optional solutions in this embodiment, the more preferred one is as follows: Figure 1 As shown, the input port of the granulation equipment is equipped with a system return belt 8 (i.e., belt conveyor), which is used to return the material particles from the first screening outlet to the output end of the granulation equipment. The output end of the weighing belt scale 6 and the output port of the crusher 7 are both connected to the input end of the system return belt 8.
[0030] In the optional schemes of this embodiment, it is more preferred that the conveyor weighing belt scale 3 and each output weighing belt scale 6 are connected to the DCS control system via optical fiber.
[0031] Specifically, all equipment (including but not limited to granulator 1, dryer 2, weighing belt scale (including output weighing belt scale 6 and conveying weighing belt scale 3, the same as the existing belt scale), pre-screening equipment 5 (a screening machine that screens according to different particle sizes of materials), bucket elevator 4, etc.) are existing equipment, and their specific structures and operating principles will not be described in detail.
[0032] This utility model uses specific examples to illustrate its principles and implementation methods. The above description of the embodiments is only for the purpose of helping to understand the method and core idea of this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the idea of this utility model. In summary, the content of this specification should not be construed as a limitation of this utility model.
Claims
1. A fertilizer granulation system with real-time visualization of particle size distribution, characterized in that: Includes granulation equipment, pre-screening equipment, DCS control system and multiple output weighing belt scales; The granulation equipment is used to prepare material particles; The pre-screening device is used to receive the material particles prepared by the granulation device, and the pre-screening device can classify and screen the material particles according to different particle sizes; the pre-screening device has at least two first screening outlets. Each of the output weighing belt scales is connected to the first screening outlet in a one-to-one correspondence; and the material particles discharged from the first screening outlet that are not of the required particle size are returned to the granulation equipment after being transported by the corresponding output weighing belt scale. The DCS control system is communicatively connected to the granulation equipment, the pre-screening equipment, and each of the output weighing belt scales, and the DCS control system has a display interface; after the weighing data of each of the output weighing belt scales is transmitted to the DCS control system, the display interface can display the weight and percentage data of the material particles of each particle size.
2. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 1, characterized in that: The pre-screening device also has a second screening outlet, which is used to discharge the material particles of the largest particle size screened by the pre-screening device; The second screening outlet is connected to a crusher, and the output port of the crusher can be connected to the granulation equipment.
3. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 1, characterized in that: The granulation equipment includes a granulator, a dryer, and a conveyor belt scale. The output port of the granulator is connected to the input port of the dryer, and the output port of the dryer is connected to the input end of the conveyor weighing belt scale. The output end of the conveyor weighing belt scale can be connected to the input port of the pre-screening equipment; The granulator, the dryer, and the conveyor weighing belt scale are all communicatively connected to the DCS control system.
4. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 3, characterized in that: The granulation equipment also includes a bucket elevator; The output end of the conveyor weighing belt scale is connected to the input port of the bucket elevator, and the output port of the bucket elevator is connected to the input port of the pre-screening equipment.
5. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 2, characterized in that: The granulation equipment is equipped with a system return belt at its input port, which is used to return the material particles from the first screening outlet to the output end of the output weighing belt scale of the granulation equipment. The output port of the crusher is connected to the input end of the system return belt.
6. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 3, characterized in that: The conveyor weighing belt scale and each of the output weighing belt scales are all connected to the DCS control system via optical fiber.
7. The fertilizer granulation system with real-time visualization of particle size distribution according to claim 2, characterized in that: The number of the first screening outlets is two; one first screening outlet is used to discharge fine material, and the other first screening outlet is used to discharge qualified material; the second screening outlet is used to discharge coarse material; the particle size of the coarse material is larger than the particle size of the qualified material, and the particle size of the qualified material is larger than the particle size of the fine material.