With the development of precision agriculture, granular phosphate fertilizers (DAP/MAP) have become mainstream products due to their advantages of uniform nutrient release, resistance to caking, and strong compatibility with mechanical fertilization. An efficient phosphate fertilizer granulation production line needs to integrate 12 key equipment systems. The following is a detailed explanation of the equipment configuration for the entire process:
| Equipment type | Recommended models | key parameters | Function description |
| Ore crusher | Jaw Crusher PE Series | Capacity 50-300 t/h | Crush the phosphate rock to ≤100mm |
| Ore mill | Ball mill LABM-1000 | Output fineness: 80-100 mesh | Improving the efficiency of acid hydrolysis reactions |
| Powder conveyor | Bucket elevator LABE-15 | Lifting height ≤ 30 meters | Sealed conveying to prevent dust dispersion |
| Phosphoric acid reaction tank | 316L stainless steel extraction tank | Volume 100-500m³ | Phosphate rock + sulfuric acid → phosphoric acid slurry |
| Solid-liquid separation equipment | Tilting disc filter | Filtration area 200㎡ | Phosphoric acid purification (recovery rate ≥96%) |
|Rotary Drum granulator | Φ4.5×18m | Rotational speed 8-12rpm | Slurry coating and granulation (2-4mm) |
| Ammoniation reactor | Tubular reactor TVR-300 | Reaction time 3-5 seconds | Phosphoric acid + liquid ammonia → Ammonium phosphate melt |
| Rotary Dryer | Φ3.2×25m | Inlet Temperature 140°C | Moisture Control ≤1.5% |
| Cooling Equipment | Drum Cooler | Cooling Airflow 60,000m³/h | Rapid Cooling to 40°C |
| Screening System | Three-Layer Vibrating Screen | Screen Mesh Size 1-4mm | Graded Qualified Particles |
| Coating Machine | Drum-type Coating Machine | Spray Rate 0.5–1.5 L/ton | Anti-caking Treatment |
Process key points:
(1) The return ratio during the granulation stage should be controlled at 1:3-5 (return: new product).
(2) The drying temperature should be strictly controlled at ≤160°C (to prevent nitrogen decomposition).
(1) Match core equipment according to production capacity
| Annual capacity | Granulator diameter | Dryer length | Investment budget |
| 100,000 tons | Φ3.2m | 20m | $1 million to $2 million |
| 300,000 tons | Φ4.5m | 30m | $3 million to $5 million |
| 600,000 tons | Φ5.0m | 40m | $6 million+ |
(2) Raw material adaptability optimization
High-magnesium phosphate rock: Graphite-lined reactors (corrosion-resistant) must be used.
Low-grade ore: Pre-defluorination equipment must be installed (to improve product purity).
(3) Mandatory environmental protection systems
Exhaust gas treatment: Venturi scrubber + electrostatic precipitator (to meet national emission standards).
Phosphogypsum utilization: Granulation equipment must be installed to produce building materials.
Q1: How much does it cost to invest in a phosphate fertilizer production line?
▶ Core equipment accounts for 60% of the investment. The equipment investment for a 300,000-ton-per-year DAP production line is approximately US$2 million (excluding civil engineering), with a payback period of 3-5 years.
Q2: Which granulation method has a higher yield?
▶ Drum granulation achieves a yield rate of 92-95% (suitable for DAP/MAP), while spray granulation reaches 96% but has 15% higher energy consumption. Small and medium-sized enterprises are recommended to choose drum granulation models.
Q3: How can energy consumption be reduced in the production line?
▶ Focus on optimizing the drying section:
① Adopt waste heat recovery technology from hot air furnaces
② Upgrade the variable frequency control system
This can reduce energy consumption by over 30%.
With 20 years of experience in the phosphate fertilizer production line, we provide one-stop solutions for our global customers, from mining to finished granules. Unlike standard equipment suppliers, we use cutting-edge research and development as our driving force and focus on customer needs to make each production line your core competitive advantage.
1. Deeply Customized Solutions — Breaking Through Raw Material and Site Constraints
While 90% of suppliers offer generic solutions, we have established a global phosphate ore database (covering 217 ore sample parameters). Whether it’s high-grade ore from Morocco or gypsum-phosphate ore from Yunnan, our dynamic process adjustment system can real-time optimize 12 parameters such as acid-to-ore ratio and corrosion protection level, ensuring P₂O₅ recovery rates remain stable at ≥96.5% even during raw material fluctuations. We also pioneered the vertical stacked process, helping Vietnamese clients achieve a 150% capacity increase on their existing site.
2. Military-grade equipment quality—failure rate is only 1/6 of the industry average
We adopt military-grade quality control throughout the entire process: from German spectroscopic testing of 316L stainless steel base materials, to 100,000-hour accelerated life testing of transmission components, to 30-day continuous load verification. We dare to promise:
5-year extended warranty for core equipment (industry standard is 2 years)
Failure rate < 0.4 times per year (industry average is 2.1 times)
3. Corporate validation — successful cases across four continents
Our phosphate fertilizer production line is creating value for global top-tier fertilizer companies:
Saudi Ma’aden Group: Stable operation in a 50°C high-temperature environment, saving 23 million in annual maintenance costs
Guizhou Phosphate Group: Increased phosphate ore conversion rate by 11.7%, generating an additional annual benefit of 180 million
Indonesia PT Kaltim Company: Particle strength exceeded 58 N/particle, with a 15% increase in product premium
When selecting suitable phosphate fertilizer production line equipment, it is essential to comprehensively consider three key dimensions: raw material characteristics, production capacity requirements, and environmental policies. It is recommended to prioritize equipment suppliers with EPC turnkey project capabilities to ensure the overall process synergy of the phosphate fertilizer production line.
