Granulation Method for Uniform Fertilizer Granules
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Solution Overview
Problem
Existing granulation methods face challenges in producing uniform fertilizer granules with improved hardness, durability, and coatability, as they often result in segregation of materials due to varying particle sizes and irregular shapes, which complicates transportation and storage.
Innovation Solution
A granulation method involving a graded powder mix with specific particle size distributions and a liquid binder, combined in a pan granulator, to form 'concrete granules' with enhanced bonding and smooth surfaces, reducing segregation and improving handling characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If different materials having dissimilar particle sizes are blended, then the mixture can be formed, but segregation occurs where smaller and denser particles move toward the bottom while larger and less dense particles move toward the top
Solution Approach 1:
The patent changes the particle size parameter of the materials to be blended by using granulated materials with controlled size distributions. By ensuring all materials have similar particle sizes through granulation, the segregation tendency is reduced while maintaining mixture uniformity.
2Quantity of substance
If materials with small particle sizes and irregular shapes are used, then the material composition can be achieved, but flowability deteriorates making transportation and storage difficult
Solution Approach 1:
The patent changes the particle size and shape parameters by granulating small irregular particles into larger, more uniform granules. This transformation improves flowability and ease of handling while maintaining the required material composition through controlled granulation processes.
3Productivity
If conventional granulation methods are used, then granules can be formed, but manufacturing precision deteriorates resulting in non-uniform granules with poor hardness, durability, and coatability
Solution Approach 1:
The patent changes multiple parameters including feedstock particle size distribution, granulation process conditions, and binder characteristics to produce granules with superior uniformity, hardness, and surface quality while maintaining production efficiency.
Solution Approach 2:
The patent uses composite feedstock materials with specific particle size distributions and combines them with carefully selected binders to create granules that exhibit enhanced mechanical properties and surface characteristics for improved coatability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces fertilizer granules with superior hardness, durability, and coatability, enabling efficient blending and coating, while reducing segregation and energy consumption in the granulation process.
Implementation Method 1
The smaller particles may be bonded by compression and/or using a bonding agent
Implementation Method 2
The smaller particles may be bonded by compression and/or using a bonding agent
Implementation Method 3
A drying unit may be positioned downstream of the screening unit and configured to dry at least a portion of the wet granule material
Data Source
AI summary
A granulation method may include feeding a graded powder into a granulator. The powder may have a particle size distribution (PSD) of at least 98% −115 mesh and at most 50% −200 mesh. The powder may have a PSD of at least 98% less than or equal to 4.2% of a median product particle size and at most 50% less than or equal to 2.5% of the median product particle size. The powder may have a PSD of between 40% and 80% between 3% and 6% of the median product particle size, between 5% and 30% between 2% and 4% of the median product particle size, and between 10% and 40% between 1% and 3% of the median product particle size. A liquid binder may be fed into the granulator. Wet granules may be discharged from the granulator and may have a moisture content of between 7% and 12%.