Chemical mixer SOP

Ver 0.1 - draft

The chemical mixer purpose is to mix and melt fertilizers together at the correct rate
with water dilution so the fertilizer solution would be ready at the tank to be pumped to
the water system and further to the field.
The mixer is a 600 liters tank with a pump for transferring the solution from the mixer to
each tank.
After the mixer output there is a filter and a 4-way distribution manifold to choose
which tank is to be filled.
Amounts and rates for each tank are placarded on a sticker and on a sign near the mixer
– go to Fertilizer rates table.
Recommendation on the chemical mixing system
The priority is for a small mixing tank 1000L-600L to dissolve the fertilizer and the
accuracy of the concentrates. The dissolved material is then transferred with a pump to
the required 5 cubic meter tank. Under the weather conditions in Indonesia the tank can
be a tank without a mixer. The tank will have an input of the dissolved material of 1.5"-
2", and an output to the fertilizer system with 1.5-2" pipe with overflow prevention
system.

Pump operation
switch

Dissolving
valve (#2) Water input
valve (#1)

Drain valve
Mixer pump

Fig. 1 – Chemical mixer

Wash
Mixer cleaning is an option. Due to very high dilution of the solution residues it is not
necessarily needed to clean the mixer.
Mixer cleaning is required after dissolving chemicals (pesticide, herbicide, etc.).

Procedure:
1. Rotate the water input valve to the open position (Fig. 1).
2. Drain valve can be switched to fully open position or closed position according to the
washing operation (Fig. 1).
3. When finish – close the water input valve.
4. Drain the mixer – go to Drain procedure.

Drain
Drain line of the chemical mixer is connected to the draining line of all other fertilizer
tanks.

Procedure:
1. Verify the solution within the mixer require draining.
2. Rotate the drain valve to the open position (Fig. 1).
3. When mixer is empty – rotate the drain valve to the close position.

Solution transfer
Solution transfer comprises of:
- Mixer pump mounted at the bottom of the chemical mixer.
- Solution output valve.
- Solution transfer filter.
- Distribution manifold with 4 valves.
- Solution pipelines from the manifold to each tank.
- Tank solution input valves for each tank.

Solution Distribution
transfer filter manifold
valves
Tank solution
input valve

Distribution
manifold

Fig. 2 – Distribution manifold

 Fertilizer rates table
Amounts for Amounts for
100 liters 600 liters
Mixer (0.6 cube) 100 Liter water 600 Liter water Product
Tank 1 (5 Cube) Kg Kg
Potassium nitrate (KNO3) 11.8 70.8 PN Crystal
Monoammonium phosphate (M.A.P) 3.3 19.8 ULTRADAP
Micro Mix 0.27 1.62 Meroke VITAFLEX
Tank 2 (5 Cube)
Calcium nitrate (CaNO3) 10 60 Calnit
Magnesium nitrate (MgNO3) 10 60 MgNO - Magnit

Refill fertilizer tank using the chemical mixer:

Refill for the fertilizer tanks is performed using the chemical mixer and the solution
transfer assembly.
Solution transfer filter should be opened and cleaned once a week.

Equipment
- Protective mask
- Chemicals/fertilizers
- Fertilizers rate table

Procedure
1. Decide which tank to fill and verify all the valves are set to Off.
2. Check the relevant tank and verify that there is enough volume to fill 600 liters (this
is the amount to be filled by the chemical mixer).
3. Check the amounts of required fertilizers and verify no lack of materials (see
Fertilizer rates table).
4. Verify the mixer is clean.
5. NOTE: Always fill the mixer with water before adding chemicals.
6. CAUTION: Use protective mask when operating the chemical mixer.
7. Rotate the blender operation switch to On. The blender should stay in the On
position until the end of this procedure.
8. Fill the mixer with 200 liters of water by rotating the water input valve (#1) to the
open position. Close the valve when it reaches 200 liters (Fig. CMO).
9. Add the chemicals throw the upper mixer door (Fig. UMD) using the amounts
written on the placard/sign according to the desired tank. Start by adding only 25-50
kg of chemicals (according to the chemical product packing size).
10. Make sure to close the upper mixer door while not using it.
11. Wait for chemicals to dissolve in the water.
12. Open water input valve again to fill additional 200 liters of water, close water input
valve.
13. Add additional doze of chemicals (25-50 kg) from the upper mixer door.
14. Wait for chemicals to dissolve in the water.
15. Repeat steps 12-14 until the mixer is full of 600 liters and the chemicals dissolved.
16. If the chemicals did not dissolve and more chemicals should be inserted to the mixer
– use the following steps (17-22) to dissolve the solution.
17. Open jets valve (#3) and start pump operation using the spring-loaded pump
operation switch (Fig. CMO). To operate the pump, the switch must be held
continuously.
18. Gently open the dissolving valve (#2) while checking no drops and spills are exiting
the mixer. The blending process in the mixer can be aggressive.
19. Wait for the chemicals to dissolve.
20. If needed (according to the fertilizer rate table) - add more chemicals to the mixer
basket while continue to run the pump.
21. When reaching a proper dissolvement, close the dissolving valve (#2).
22. After the chemicals have been dissolved in the tank, start mixer operation using the
pump operation switch with only the jest valve (#3) open. The water begins to swirl
and spin for additional 10 minutes with the jets. The jets suck and dissolve the
fertilizer (close to the bottom of the mixer).
23. Stop the pump after 10 minutes of operation.
24. Close all valves in the mixer.
25. Rotate the blender operation switch to Off position.
26. The chemical solution is ready for transfer.
27. Select the desired tank by open the equivalent valve at the distribution manifold and
verify the solution input valve (Fig. 2) at the tank is open.
28. Open the solution output valve (#4).
29. CAUTION: If the pump runs for half a minute without water - it may burn!
30. Start the mixer pump using the pump operation switch.
31. When the mixer is almost empty (approximately 70 liters left) – stop the mixer pump
and close the solution output valve (#4).
32. Rotate the solution transfer valves to the Off position (distribution manifold valve
and tank solution input valve).
33. If planning to add another doze of the same solution - repeat the full process (no
mixer cleaning is required).
34. If another mix of chemicals is required or mixer operation is finished – drain and
wash the mixer - go to chemical mixer Drain and Wash procedure
 Dissolving
Solution output
Pump operation valve (#2)
valve (#4)
switch

Water input
valve (#1)
Jets valve (#3)

Fig. CMO – Chemical mixer operation

Upper mixer
door Mixer basket

Inspection
door

Fig. UMD – Upper mixer door

Blender operation
switch

Fig. BOS – Blender operation switch