Explore the Customized Phosphate Fertilizer Pilot Plant with Control System: Lane's Solution for Efficient MAP Production!

 Hello everyone! We are Henan Lane Heavy Industry Machine Technology Co., Ltd. (Lane), a professional manufacturer with over 20 years of experience in fertilizer machinery in China. Today, we're excited to share how our customized phosphate fertilizer pilot plant with control system can help you develop and produce premium Monoammonium Phosphate (MAP) fertilizer. MAP is one of the most widely used phosphate-based fertilizers, delivering high phosphorus content (typically 52-61% P₂O₅) and nitrogen (11-12%) in a highly water-soluble form that promotes strong root systems and vigorous early-season growth in crops.

With increasing focus on precision agriculture and sustainable nutrient management, many researchers, startups, and established producers need flexible pilot-scale facilities to test new formulations, optimize reaction conditions, and validate processes before committing to full-scale production. Our customized phosphate fertilizer pilot plant with control system is the ideal solution—tailored specifically for MAP production, offering precise automation, safety features, and easy scalability.

customized phosphate fertilizer pilot plant with control system

Why a Customized Phosphate Fertilizer Pilot Plant with Control System Is Essential for MAP Production

The production of MAP involves reacting phosphoric acid with ammonia in a controlled exothermic neutralization process to form a slurry, which is then granulated, dried, and finished. Achieving the desired granule size, strength, purity, and N:P ratio requires accurate parameter control. A full-scale plant is expensive and risky for experimentation, but our customized phosphate fertilizer pilot plant with control system allows you to run trials at 0.5-5 tons/hour safely and efficiently.

The integrated PLC-based control system provides real-time monitoring of critical variables like temperature, pressure, pH, flow rates, and ammonia addition, ensuring reproducible results and preventing issues like over-ammoniation or crystallization problems. Many of our clients use this setup to fine-tune MAP grades (e.g., 11-52-0 or 12-61-0) and test additives before moving to commercial volumes.

How Lane's Customized Phosphate Fertilizer Pilot Plant with Control System Works for MAP Production

We fully customize each pilot plant to match your raw material specifications, target capacity, and process preferences. For MAP production, we emphasize equipment suitable for the acidic, corrosive slurry. Here's the detailed process flow with our key equipment:

Step

Process Description

Key Lane Equipment

Benefits with Our Control System

1. Raw Material Preparation

Precise metering and storage of phosphoric acid and gaseous/liquid ammonia

Automatic Batching System + Corrosion-Resistant Storage Tanks

Accurate ratio dosing via PLC for optimal neutralization

2. Neutralization/Reactor

Controlled ammoniation reaction to form MAP slurry

Pipeline Reactor or Dedicated Ammoniator-Granulator

Automatic pH/temperature regulation to maintain reaction stability

3. Granulation

Extrude or press slurry into dense, uniform granules

Lane Double Roller Press Granulator (Counter-Roller Granulator)

Dry granulation option available; high pressure ensures strong, dust-free pellets with adjustable size

4. Drying & Cooling

Remove residual moisture and cool product

Rotary Dryer + Rotary Cooler

Energy-saving control loops for precise moisture endpoint (≤2%)

5. Screening & Coating

Classify granules and apply anti-caking or slow-release coating

Vibrating Screener +Fertilizer Polishing Machine

Automated size separation and optional functional coatings

6. Monitoring & Packaging

Full oversight and final packing

Centralized PLC/SCADA Control System + Automatic Packaging Scale

Data logging, remote monitoring, alarms, and traceability

Our customized phosphate fertilizer pilot plant with control system excels particularly with the double roller press granulator, which is ideal for phosphate compounds like MAP. This dry granulation method (or with minimal binder) produces high-strength granules without excessive drying energy, achieving formation rates above 90% even in pilot scale.

customized phosphate fertilizer pilot plant with control system

Advantages of MAP Granules Produced in Lane's Pilot Plant

Compared to powdered or lower-quality alternatives:

Feature

Lane Pilot-Produced MAP Granules

Powdered or Basic MAP

Granule Strength

High crushing strength, low breakage

Prone to dusting and abrasion

Solubility

Excellent water solubility, rapid availability

Good but often uneven

Handling & Storage

Anti-caking, free-flowing, long shelf life

Higher caking risk

Process Flexibility

Easy adjustment for different grades

Limited formulation testing

Energy Efficiency

Lower drying needs with roller press

Higher energy for wet methods

Clients regularly produce premium granular MAP suitable for direct application, blending, or specialty uses.

Who Benefits from Our Customized Phosphate Fertilizer Pilot Plant with Control System?

This pilot plant is perfect for:

· R&D centers developing new phosphate fertilizer technologies

· Emerging manufacturers validating MAP production processes

· Established companies improving efficiency or testing raw material variations

· Universities and institutes conducting fertilizer research

The data and experience gained from our customized phosphate fertilizer pilot plant with control system make scaling to full production lines seamless and low-risk.

Why Partner with Lane for Your Customized Phosphate Fertilizer Pilot Plant with Control System

At Henan Lane Heavy Industry Machine Technology Co., Ltd., our 20+ years of specialized experience in compound and phosphate fertilizer equipment set us apart. Our professional engineering team collaborates closely with you to design a customized phosphate fertilizer pilot plant with control system that perfectly fits your technical and budgetary requirements.

Our core product range supporting MAP pilot production includes:

· Pilot-scale Compound Fertilizer Production Lines specialized for phosphates

· NPK and Phosphate-Specific Lines

· High-performance Double Roller Press Granulators (key for MAP)

· Robust Pipeline Reactors, Dryers, Coolers, Screeners, and Packaging Systems

· Advanced PLC/SCADA Control Systems with touch-screen interfaces and data analytics

We provide complete one-stop service: from feasibility studies and custom engineering, to manufacturing, delivery, on-site installation, commissioning, operator training, after-sales support, spare parts, and future expansions. All equipment complies with ISO9001 quality standards and CE safety certifications.

customized phosphate fertilizer pilot plant with control system

With Lane, your customized phosphate fertilizer pilot plant with control system becomes a reliable platform for innovation, quality assurance, and business growth in the phosphate fertilizer sector.

Ready to start testing and producing high-quality MAP fertilizer on a pilot scale? Contact Henan Lane Heavy Industry Machine Technology Co., Ltd. today for a no-obligation consultation. We're eager to customize the ideal solution for you—let's advance your phosphate fertilizer projects together!

Feel free to reach out or leave a comment with any questions. We're here to help!

For more details, please feel free to contact us.

Henan Lane Heavy Industry Machinery Technology Co., Ltd.

Email: sales@lanesvc.com

Contact number: +86 13526470520

Whatsapp: +86 13526470520

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