Case Study: Fertilizer Batching Plant with Deagglomeration System
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The Challenge: Precision Dosing of Agglomerated Raw Materials
A fertilizer production facility faced significant challenges with material flow consistency. Several raw ingredients, stored in Big Bags, were prone to compaction and lumping (agglomeration), which caused standard Φ150 mm dosing screws to seize or provide inconsistent volumetric flow. The project required a system that could not only dose five different ingredients with high accuracy but also ensure that any lumps were broken down before reaching the weighing stage to maintain recipe integrity.
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Our Solution: Integrated Deagglomeration and Automated Batching
Our team designed a heavy-duty automated dosing and weighing line specifically for difficult-to-handle bulk solids:
- 5 x FIBC Bulk-Bag Discharging Stations: Five dedicated intake points for bulk raw materials.
- Active Agitator & Deagglomerator Systems: At each intake point, we integrated a mechanical agitator and deagglomerator. This system breaks down compacted material and “bridge-building” at the source, ensuring a free-flowing stream into the conveyors.
- Precision Dosing Screws (Φ150 mm): Five high-torque augers transport the de-lumped material to the central weighing unit.
- 1500L Automatic Weigh Scale: A central weighing hopper equipped with high-precision load cells and an automated control system. The ingredients are weighed sequentially with high accuracy before being discharged into the downstream process.
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The Result: Consistent Flow and Guaranteed Recipe Accuracy
Our fertilizer batching system eliminated the facility’s flow-rate bottlenecks:
- Continuous Material Flow: The integrated deagglomeration technology ensured that the Φ150 mm screws operated at peak efficiency without blockage or mechanical strain.
- Precision Recipe Control: The automated weighing system provides 100% repeatable accuracy for every batch, essential for the chemical balance of high-grade fertilizers.
- Reduced Maintenance Downtime: By solving the lumping issue at the discharge station, the plant significantly reduced the wear and tear on the dosing augers and the need for manual intervention.