Abstract
Fertilizer manufacturing in the chemical industry is closely related with agricultural production. More than a half of raw materials for food products are grown by fertilizing plants. The demand of fertilizers has been constantly increasing along the growth of human population. Fertilizer manufacturers face millions of losses each year due to poor quality products. One of the most common reasons is wrong decisions in control of manufacturing processes. Operator’s experience has the highest influence on this. This paper analyzes the pellet measurement data, collected at the fertilizer plant by using indirect measurements. The results of these measurements are used to construct the model of equipment status control, based on the fuzzy logic. The proposed solution allows to respond to changes in production parameters in a 7–10 times faster manner. On average, a manufacturer with production volumes of up to 80 tonnes/hour could have lost about 8400 tonnes/year of high-quality production. The publication seeks symmetry between human and system decision making.
Highlights
Fertilizers used in agriculture, household, and other fields usually are bulk, spherical, fine particles.The process of chemical fertilizer particle formation can be either wet or dry
This paper evaluates the correlation between fertilizer granules measurement results and other indirect measurements based on thebetween evaluation of particle roundness
Errors are unavoidable in assessing the status of the manufacturing process if it is based on the human factor alone
Summary
Fertilizers used in agriculture, household, and other fields usually are bulk, spherical, fine particles. The process of chemical fertilizer particle formation can be either wet or dry. Depending on the chemical composition of the fertilizer, it may be pelletizing or prilling. One of the most common methods of pelletizing [1] is wet prilling. Molten fertilizers are converted into liquid drops. As they fall through the prilling tower (shot tower), they are cooled and form pellets
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