Core Principle: Wet Agglomeration Granulation
Scale Types: Small, Medium, Large
Daily Production Capacity: 5-10t/d, 10-50t/d, 50-100t/d
Floor Area: 150-350m2, 200-500m2, 500-1000m2
Product: Granular Organic Fertilizer
Applications: Family farms, small cooperatives, organic fertilizer pilot plants, large-scale livestock operations, large-scale organic fertilizer production bases, environmentally friendly sludge treatment projects, etc.
1. Pretreatment System
● Pulverizer: Grinds bulky raw materials to 80-100 mesh, ensuring uniform material fineness;
● Mixer: Mixes raw materials and additives to ensure uniform composition;
● Screener: Removes impurities from the raw materials to prevent damage to subsequent equipment.
2. Core Granulation System
● Disc Granulator: Core granulation equipment, agglomerates the material into granules using rotating discs;
● Spray Conditioning System: Precisely controls the amount of water sprayed/binder applied, adjusts the moisture content of the material, and ensures a high granulation rate.
3. Post-Processing System
● Dryer: Uses hot air to reduce the moisture content of wet pellets from 20%-25% to below 10% to prevent clumping.
● Cooler: Cools the dried hot pellets to room temperature to prevent moisture during storage.
● Product Screener: Separates oversized pellets (which return to the crusher) from substandard fines (which return to the granulator), ensuring uniform particle size in the finished product.
● Coating Machine (optional): Coats the pellets with a waterproof/anti-caking film to improve storage stability.
4. Auxiliary Systems
● Conveyor Belt: Connects various equipment to ensure continuous material transport.
● Hot Air Furnace/Hot Air Blower: Provides stable hot air for the dryer.
● Dust Removal Equipment: Collects dust generated during the production process to reduce pollution.
The essence of disc granulation is the agglomeration granulation process, relying on the synergistic effect of the material's inherent properties (such as moisture content and cohesiveness) and the machine's motion. The specific process can be divided into three stages:
1. Nucleation Stage: Bulk raw materials with a moisture content of 15%-25% are fed into the inclined rotating disc. Friction at the disc's bottom drives the material along with its rotation. Simultaneously, a small amount of water or binder is sprayed onto the material through a spray system, allowing the fine particles to absorb the water/binder, forming "nuclei" with a diameter of 1-2mm.
2. Particle Growth Stage: After the "nuclei" rise to a certain height as the disc rotates, they roll down due to gravity, continuously absorbing the surrounding bulk materials and moisture, gradually growing like a "snowball." The disc's tilt angle and rotational speed precisely control the material's rolling speed, ensuring evenly packed particles and preventing oversized or undersized particles.
3. Particle forming and separation stage: When the particles grow to the target particle size, the centrifugal force is greater than the friction force, and the particles automatically overflow from the edge of the disc and enter the subsequent drying and screening stages; the fine powder that does not meet the standards is screened and returned to the disc for re-granulation, forming a "closed loop".
Advantages of a disc granulation line:
1. High Granulation Quality:
The granules are round or oval, highly rounded, and have good flowability, making them easy to package, transport, and spread in the field.
2. Low Equipment Cost:
Compared to extrusion granulators and agitator granulators, disc granulators have a simpler structure and a 30%-50% lower equipment purchase cost, making them suitable for initial investment by small and medium-sized enterprises.
3. Easy Operation and Maintenance:
The equipment is easy to disassemble and clean. Routine maintenance only requires checking disc wear and lubricating bearings, resulting in low labor costs.
4. Wide Compatibility with a Wide Range of Raw Materials:
It is suitable not only for organic fertilizers, but also for compound fertilizers, biofertilizers, and humic acid fertilizers. Adjustments to the moisture content and binder are sufficient.
5. Low Energy Consumption:
The disc requires less power to rotate, resulting in a high granulation rate and less rework. Overall energy consumption is lower than that of extrusion granulation.
Scale Type | Small production line | Medium production line | Large production line |
Daily processing capacity | 1-5 tons | 5-20 tons | 20 tons and above |
degree of automation | There are many manual operations, such as manual feeding, manual adjustment of equipment parameters, etc. | Partial automation, such as automatic adjustment of disc inclination angle through the hydraulic system and speed control by variable frequency motor. | Fully automated, the PLC system enables real-time monitoring and automatic control of the entire production line, such as automatic adjustment of feed volume, temperature, humidity, and other parameters. |
Floor space | 150-350m2 | 200-500m2 | 500-1000m2 |
What raw materials can a disc pelletizing line process? What are the raw material moisture requirements?
It can process organic and inorganic materials such as livestock and poultry manure (after fermentation), straw powder, humus, slag, and fly ash. The recommended raw material moisture level is typically 20%-35%. If the humidity is too high, the disc will stick, while if it is too low, pelletization will be difficult. Therefore, moisture adjustment is necessary.
What is the shape and size of the finished pellets produced by disc pelletizing? Can it meet different fertilization requirements?
The finished pellets are generally elliptical or nearly spherical. The particle size can be controlled by adjusting the disc speed, inclination angle, and scraper position, typically ranging from 3-10mm. Fine particles are suitable for seedlings and potted plants, medium particles are suitable for fruit, vegetable, and tea plantations, and coarse particles are suitable for field crops, making them suitable for a variety of applications.
How many workers are needed to operate a disc pelletizing line?
Are specialized skills required? A production line with an hourly output of 1-5 tons requires only 2-3 people, whose duties include feeding, inspecting the pelletizing process, and packaging the finished products. The equipment's operation is simple, and the manufacturer provides 1-2 days of on-site training. Once workers master basic startup and shutdown techniques and parameter adjustments (such as disc speed), they can begin work. No professional skills certification is required.
Do impurities in the raw materials (such as small stones and plastic fragments) affect the disc pelletizer? Do they require pretreatment?
Yes, stones can wear the liner and scraper, and plastic fragments can entangle the scraper, affecting pelletization. Pretreatment is necessary. We recommend using a vibrating screen and manual sorting (to remove plastic and fiber) to ensure a raw material purity of ≥95%.
What daily maintenance is required for a disc pelletizing line? What is the maintenance interval?
Daily maintenance requires cleaning the disc of residual material, inspecting the liner for wear, and lubricating the transmission components. Weekly maintenance (tightening bolts and checking scraper clearance) is performed, while monthly maintenance (cleaning the gearbox and calibrating the disc inclination) is performed. Lubricant should be changed quarterly.
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