Process Flow Design for Manufacturing Humic Acid-Enhanced SOP Fertilizer
- Efat Elahi
- 5 days ago
- 4 min read
Table of Contents
Introduction: The Need for an Engineered Process Flow
Stage 1: Raw Material Reception & Pre-Processing
Stage 2: Precision Dosing & Homogeneous Blending
Stage 3: Granulation: Creating the Composite Granule
Stage 4: Drying, Cooling, & Final Processing
Stage 5: Coating, Screening, and Packaging
The LANE Advantage: Benefits of an Integrated Line
FAQ on Process Design for SOP with Humic Acid
Conclusion
1. Introduction: The Need for an Engineered Process Flow
SOP also known as sulfate of potash is essential for high-value crops due to its low chloride content. humic acid is a high-efficiency additive that boots fertilizer efficiency and soil-improving effects. An integrated production line is essential to create a stable, homogeneous granule where SOP fertilizer additive humic acid is uniformly distributed.
LANE Heavy Industry, a leading fertilizer machinery manufacturer, offers tailored production line solution for SOP fertilizer additive humic acid. This article guides you through the optimized process flow design of LANE's SOP fertilizer production line.
2. Stage 1: Raw Material Reception & Pre-Processing
The first step of the process is the preparation of base materials. Solid SOP and the and high-quality powdered humic acid are stored in separate storage area to prevent any kind of contamination. The raw materials are fed into a LANE Semi-Wet Crusher to create fine powder. It is necessary for uniform distribution of granules. the materials then pass through a pre-mixing screen to remove any foreign matter or clumps.
3. Stage 2: Precision Dosing & Homogeneous Blending
The SOP powder and humic acid are conveyed to the separate batching system. LANE dynamic batching system can accurately measure weight and scale to release predetermined ratio of each component (e.g., 90% SOP, 10% humic acid) with accuracy. These raw materials are mixed in LANE Horizontal Paddle Mixer. The intensive, counter-current mixing action of the intermeshing paddles ensures a perfectly homogeneous dry blend in seconds. This creates a uniform powder where every particle of SOP is mixed with the humic acid additive.
4. Stage 3: Granulation: Creating the Composite Granule
in the next stage of SOP fertilizer additive humic acid production line, the powder blend is transported to the granulation unit. he recommended solution is a LANE Rotary Drum Granulator. The powder is fed into the rotating drum with a controlled spray of liquid binder. As the drum rotates, the fine particles form dense, spherical granules. This process physically locks the SOP and humic acid together into a single, composite granule. this prevents any future nutrient segregation.
5. Stage 4: Drying, Cooling, & Final Processing
The green granules from the drum have high moisture content and are too soft for handling. They are conveyed to a LANE Rotary Dryer. here a stream of hot air reduces the moister into a stable level (<2%). The temperature of the dryer is carefully controlled to protect the bioactivity of the humic acid. The hot granules then enter a LANE Rotary Cooler, which uses ambient air flow to solidify their structure. It prevents caking and prepare them for coating.
6. Stage 5: Coating, Screening, and Packaging
The cooled granules pass over a LANE Rotary Screening Machine. On-spec granules (typically 2-4mm) proceed. oversizer granules and undersize fines are sent back to the crusher to be recycled back into the production. The on-spec product enters a LANE Coating Drum, where a light application of anti-caking or dust-suppression agent is applied to enhance shelf-life and flowability. Finally, the finished SOP fertilizer additive humic acid is sent to automated LANE packaging machine for bagging.
7. The LANE Advantage: Benefits of an Integrated Line
Designing the entire process flow with compatible LANE Heavy Industry machinery offers key benefits:
Seamless Integration: Equipment is designed to work harmoniously, minimizing transfer points and bottlenecks.
Process Control: Automated dosing and PLC control ensure consistent product formulation and quality.
Energy & Material Efficiency: Closed-loop recycling of fines and undersize maximizes yield and reduces waste.
Scalability: The modular design allows for production line expansion to meet growing demand.
8. FAQ on Process Design for SOP with Humic Acid
Q1: What is the main process design challenge when adding humic acid?
A: The primary challenge is achieving and maintaining homogeneity. The process flow must include precision dosing and high-shear mixing before granulation to ensure each final granule contains the correct ratio of SOP to humic acid.
Q2: Can this process flow be retrofitted into an existing SOP production line?
A: Yes, in many cases. Existing lines can often be upgraded with key LANE units like the precision dosing system, high-intensity mixer, and coating drum. A full audit is recommended to determine integration feasibility.
Q3: How does this dry granulation process protect humic acid quality?
A: By using controlled, lower-temperature drying, the process preserves the organic molecular structure and bioactivity of the humic acid additive, which can be degraded by the high heat of other production methods.
Q4: What is the typical output capacity of such a designed line?
A: LANE Heavy Industry designs complete lines with capacities ranging from 10 to 50 metric tons per hour, customized to specific raw material characteristics and market requirements.
9. Conclusion
LANE Heavy Industry's SOP fertilizer additive humic acid production line optimizes every step of the production to save costs. A well-designed process flow is the blueprint for manufacturing a superior, market-differentiating fertilizer.
Its intelligent, eco-friendly machinery guarantees efficient, high-quality production, supporting modern agriculture's demand for high-efficiency fertilizers and promising broad application prospects. LANE Heavy Industry transforms raw SOP and humic acid into a uniform, stable, and highly effective composite granule with our machines
Email: sales@lanesvc.com
Contact number: +86 13526470520
Whatsapp: +86 13526470520
Comments