7–8 T/H Urea Compound Fertilizer Granule Manufacturing Plant in Morocco

A Quick Look Before Going Deeper

The 7–8 t/h urea compound fertilizer granule manufacturing plant in Morocco runs on a single-shift schedule, about 8 hours per day, 330 days per year. With this rhythm, the plant maintains a steady output without overloading equipment.

Another thing worth mentioning: the plant doesn’t rely on complicated automation. It’s semi-automatic, but operators can quickly adjust feed ratios and moisture levels. During commissioning, the first batches were slightly uneven—some granules too soft, some too brittle. After a few parameter tweaks, it stabilized.

Project Overview

What this plant really is

The 7–8 t/h urea compound fertilizer granule manufacturing plant in Morocco is a compact extrusion granulation system built for medium-scale fertilizer blending and shaping.

It processes nitrogen, phosphorus, and potassium-based raw materials into uniform granules mainly used for:

• Field crops (wheat, maize)
• Vegetable farming
• Orchard fertilization

Why extrusion instead of drum granulation?

The client didn’t want a drying system. That was clear from day one.

Extrusion granulation works at low temperature, which means:

• Lower energy consumption
• Less ammonia loss
• Simpler environmental control

And honestly, for 20,000 t/year, going with a full rotary drum system would’ve been overkill.

Customer Background (Why Morocco?)

The client operates in central Morocco, where agriculture is shifting toward higher-efficiency fertilization. Imported fertilizers dominate the market, but there’s growing demand for custom-formulated blends.

What they had:

• Access to bulk urea and ammonium chloride
• Distribution network in regional farming zones
• Existing industrial building (unused warehouse)

What they needed:

• A moderate-capacity production line
• Flexibility in formulation
• Low operating cost

That’s how the 7–8 t/h urea compound fertilizer granule manufacturing plant in Morocco came into the picture.

Raw Materials

In Morocco, fertilizer raw materials are a mix of imports and regional supply. Storage and humidity control became an early design consideration—especially for urea.

Before listing them, one detail: the client initially underestimated how hygroscopic urea can be. During early trials, it absorbed moisture faster than expected. We added tighter storage control after that.

Raw Material Consumption

Utility Consumption

The plant avoids heavy thermal systems, so energy use stays relatively low.

Most water is used in moisture conditioning, not washing or cooling.

Equipment Configuration

One thing we adjusted during design: instead of fewer large machines, we used multiple smaller granulators. This gives flexibility—if one unit needs maintenance, the line doesn’t stop completely.

Main Equipment List

Process Flow (How It Actually Runs)

Instead of overcomplicating things, the flow is straightforward. But small details matter.

Detailed Step-by-Step Process

1. Raw Material Reception and Pre-Screening
   • All incoming raw materials (urea, DAP, KCl, ammonium chloride, ammonium sulfate) are inspected for moisture content and purity
   • Bagged materials are manually loaded into the raw material bins; bulk materials are pneumatically conveyed
   • Each material passes through a preliminary screen to remove foreign matter and oversized particles
   • Urea is stored in a climate-controlled section to prevent moisture absorption (humidity kept below 60%)
2. Batching and Weighing
   • Five belt weighing scales operate simultaneously, each dedicated to a specific raw material
   • Formulations are programmed into the control system; recipe changes take less than 5 minutes
   • Each scale has ±0.5% accuracy, ensuring consistent nutrient ratios across batches
   • Micro-ingredients (trace elements) are added via a separate manual dosing station
3. Mixing and Moisture Conditioning
   • Weighed materials discharge into the humidifying mixer
   • A precisely measured amount of water (typically 1.5–2.5% of total weight) is sprayed during mixing
   • Mixing duration is 45–90 seconds depending on batch composition; target is uniform color and moisture distribution
   • Moisture content is monitored continuously; operator can adjust water addition in real time
   • Proper moisture is critical: too low causes weak granules, too high causes sticking and equipment buildup
4. Extrusion Granulation
   • Conditioned material is distributed to 28 double roller granulators via distribution bins
   • Each granulator compresses material between two counter-rotating rollers at pressures up to 200 tons
   • Material forms into compact flakes which are immediately broken by built-in flaking knives
   • Granule size is controlled by roller gap and knife speed; typical output is 2–5 mm diameter
   • No heat, no binders — pure mechanical compaction ensures good hardness without chemical additives
   • If one granulator needs maintenance, production continues with the remaining 27 units
5. Primary Screening
   • Granules from all granulators converge on a single primary screening drum
   • Rotary drum screen with two mesh sections: 2 mm under-sieve, 5 mm over-sieve
   • Undersized particles (<2 mm) are collected and returned to the mixing stage for re-granulation
   • Oversized particles (>5 mm) are crushed and fed back into the granulator input
   • On-size granules (2–5 mm) proceed to polishing
6. Polishing
   • Granules enter the polishing machine — a rotating drum with internal lifters
   • Gentle tumbling action rounds off sharp edges and removes surface dust
   • Polishing improves visual appearance and reduces dust during handling and application
   • Dust generated during polishing is captured by integrated suction and recycled
7. Coating (Optional)
   • Polished granules flow into the coating drum where a fine mist of anti-caking oil or liquid coating is applied
   • Coating prevents granules from sticking together during storage and improves flowability
   • For products destined for humid regions, coating is applied; for immediate local delivery, it may be skipped
8. Secondary Screening
   • Final classification step ensures product uniformity before packaging
   • Secondary screening drum has tighter tolerance (2.5 mm and 4.5 mm mesh)
   • Only granules within the target range proceed to packaging; off-spec material is returned for re-processing
9. Quality Control Sampling
   • Samples are taken every 30 minutes from the finished product bin
   • Tests include: moisture content (Karl Fischer method), granule hardness, nutrient analysis (N-P-K), and particle size distribution
   • Results are logged and any deviation triggers immediate adjustment to batching or mixing parameters
10. Packaging and Dispatch
    • Automatic packaging machine fills 50 kg polywoven bags with inner liner
    • Bags are weighed, sealed, labeled with batch number and nutrient analysis
    • Palletized bags are stretch-wrapped and staged in the finished goods area for truck loading
    • Daily packaging capacity matches production output; no intermediate storage bottlenecks

Environmental Control Measures

Dust was the main concern here—not wastewater.

• Closed belt conveyors reduce dust leakage
• Bag filter systems (99% efficiency) installed at key points
• Localized suction hoods with ~95% collection efficiency
• Indoor storage to avoid rain contamination

No process wastewater is generated. That simplified things quite a bit.

Workshop Layout Notes

The layout wasn’t just about fitting machines.

We arranged the plant like this:

• Raw material zone → Production → Finished goods
• Linear material flow (minimal backtracking)
• Office placed upwind of production

One thing learned on-site: Operators prefer shorter walking distances between control points. We adjusted control panel locations after installation.

Investment & Cost

The client didn’t want a high upfront cost. We kept things practical.

• Equipment cost: around $180,000 – $220,000
• Total project investment stayed relatively moderate

Labor costs in Morocco helped balance the budget, so automation didn’t need to be extreme.

Shipping & Delivery

All equipment was shipped from Qingdao Port (China) to:

• Casablanca Port, Morocco

From there, inland transport to the project site.

A Few Real Observations from Commissioning

• First batches had uneven moisture—normal for extrusion lines
• Roller pressure adjustment took a few days to stabilize
• Once stable, output stayed consistent
• Dust control worked better than expected after sealing improvements

Market Outlook in Morocco

Demand for compound fertilizer in Morocco is quietly growing.

Farmers are shifting from single-nutrient fertilizers to balanced formulations. This opens opportunities for plants like this one.

The 7–8 t/h urea compound fertilizer granule manufacturing plant in Morocco fits right into this transition:

• Flexible formulations
• Moderate investment
• Scalable capacity

Final Thoughts from an Engineering Perspective

Projects like this aren’t about building the biggest system. They’re about building the right-sized system.

The 7–8 t/h urea compound fertilizer granule manufacturing plant in Morocco shows that:

• You don’t always need drying systems
• Simpler processes can still deliver stable output
• Good layout saves more cost than expensive automation

For anyone considering a similar setup, the first thing we usually ask is simple: “What raw materials do you actually have access to?”

That answer shapes everything else.