Background
The controlled-release fertilizer production line of a fertilizer company requires high-temperature heat energy for melting of coating materials, particle coating, drying and curing. The traditional process relies on gas boilers to provide heat energy, which not only consumes a lot of energy, but also generates a lot of carbon emissions and operating costs.
In response to the energy-saving and emission-reduction policy, the company decided to use high-temperature heat pump technology to optimize the process and recycle the waste heat discharged during the production process.
Application link and transformation plan
- Melting of coating materials
- Requirement: Heat the polymer material to 130°C ~ 150°C for particle surface coating.
- Transformation: Introduce high-temperature heat pumps to raise the waste heat (50°C ~ 70°C) discharged during the production process to the required temperature to replace boiler heating.
- Coating and curing
- Requirement: Maintain a constant temperature environment of 100°C ~ 140°C during coating, and the curing stage needs to be controlled at 80°C ~ 120°C.
- Renovation: Use high-temperature heat pumps to provide stable hot air circulation while reducing heat loss.
- Particle drying
- Requirement: The drying tower needs to maintain a hot air temperature of 60°C ~ 90°C to remove excess moisture.
- Renovation: Use high-temperature heat pumps to recover waste heat and heat it directly into the drying tower.
Renovation effect
- Energy saving effect
The energy efficiency ratio (COP) of the high-temperature heat pump system reaches 4.0, the overall energy saving rate is increased by about 40%, and the annual energy consumption cost is saved by about 200,000 yuan (based on the estimated production capacity of 1,000 tons/month). - Reduced carbon emissions
After replacing gas boilers, 300 tons of COâ‚‚ emissions are reduced each year, which meets the requirements of the national energy conservation and emission reduction policy. - Improved product quality
The stable heat supply improves the coating uniformity and curing effect, and improves the release stability and performance of controlled-release fertilizer products. - Return on investment
The system renovation cost is about 1.5 million yuan, and it is expected to pay back within 2 years.
Summary
The application of high-temperature heat pumps in the production of coated controlled-release fertilizers not only improves energy efficiency, but also significantly reduces operating costs and carbon emissions, reflecting the advantages of green manufacturing. This provides a replicable demonstration case for the fertilizer industry to achieve sustainable development.
