As a highly efficient granulation machine, disc granulators have broad and important applications across multiple industries thanks to their simple structure, convenient operation, and excellent granulation results.
In fertilizer production, disc granulators are essential key equipment. They play a vital role in the production of compound fertilizers, organic fertilizers, and slow-release fertilizers. In compound fertilizer production lines, disc granulators mix various basic fertilizer ingredients in appropriate proportions. The rotating motion of the discs gradually forms uniform granules under the influence of centrifugal force and gravity. The resulting granulated fertilizer is not only easy to store and transport, but also improves fertilizer utilization and reduces nutrient loss. In organic fertilizer production lines, disc granulators ferment organic materials such as livestock and poultry manure and straw before granulating them. This converts loose organic materials into granulated organic fertilizer, improving its physical properties and making it easier for farmers to use. This also promotes the resource utilization of agricultural waste.
The metallurgical industry is also a key application for disc granulators. In the processing of metal ore powder, granulation is often necessary to improve smelting efficiency and utilization. Disc granulators can granulate metal ore powders such as iron ore and manganese ore. The resulting granules are characterized by high strength and good air permeability. Once introduced into smelting equipment such as blast furnaces, they facilitate a more complete smelting reaction, laying the foundation for efficient production in metallurgical enterprises.
In the environmental protection field, disc granulators have demonstrated significant application value in solid waste treatment. Granulating solid wastes such as sludge generated by municipal sewage treatment plants and slag discharged from industrial production using disc granulators not only reduces the volume of solid waste, facilitating subsequent landfill, incineration, or resource recovery, but also reduces the risk of environmental pollution.
Due to its flexible applicability, disc granulators continue to play an important role in various application scenarios. As production requirements continue to increase across various industries, their application prospects will continue to expand.
Bio-Organic Fertilizer Production Line Equipment Maintenance Guide
Bio-Organic Fertilizer production line equipment must cope with the corrosive and sticky nature of mature materials. Scientific maintenance is key to avoiding malfunctions and ensuring product quality. The following summarizes key maintenance points from three perspectives: core equipment maintenance, general maintenance principles, and special precautions.
Core equipment maintenance requires precise implementation. Check the wear of the turning teeth of the fermentation turning machine weekly. Replace any wear exceeding 5mm to prevent uneven turning. Clean the reducer oil and replace the lithium-based grease monthly to prevent damage from high temperatures. Clean residual material from the crushing machine after each shutdown to prevent caking and blockage. Check the hammer gap quarterly to maintain a 1-2mm gap to ensure a consistent particle size. Disc granulators require daily cleaning with soft tools. Bearing grease should be replaced monthly. Liner wear should be inspected annually and replaced if the thickness decreases by 1/3. Clean dust from the heat exchange tubes of the drying and cooling equipment weekly. Check the conveyor belt tension every six months to prevent deviation and slippage.
General maintenance principles must be adhered to throughout the entire process. Before starting up each day, check the motor voltage and current of each device to ensure normal operation. After shutting down, clean the equipment surface and remove any residual material. Tighten the bolts of transmission components monthly to prevent loosening and vibration. Quarterly, inspect equipment seals, such as the crusher feed inlet seal and the dryer door seal, and replace any damaged seals promptly to prevent dust leakage or heat loss.
Special precautions must not be overlooked. Bio-organic fertilizer materials contain microorganisms. After maintenance, equipment must be flushed with a high-pressure water jet to prevent residual material from mold and affecting subsequent production. During the rainy season, electrical cabinets must be protected from moisture, and wiring insulation must be regularly inspected to prevent short circuits. Maintenance records should also be established to record maintenance times and component replacements for each device. This data can be used to predict failures and minimize downtime losses.
In short, maintenance of bio-organic fertilizer production line equipment requires consideration of material characteristics, targeted maintenance of core equipment, adherence to general principles, and attention to specific details to ensure continuous and stable operation of the production line.
Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines
In organic fertilizer production lines, the disc granulator is the core equipment for raw material processing. Its operating condition directly affects product quality and production efficiency. Scientific maintenance can extend equipment life, reduce downtime, and lower costs. The following details maintenance methods from three perspectives: daily, periodic, and long-term.
Daily maintenance requires “cleaning and inspection in tandem.” After each shutdown, promptly clean the discs of residual material to prevent hardening and scratching of the disc surface or increased operating load. Use soft tools to prevent damage to the liner. Also, check the disc’s tilt angle (normally 45°-55°). If offset, correct it using the bracket bolts. Observe the transmission system daily for abnormal noise and check the motor and reducer temperatures. If the temperature exceeds 60°C, shut down the machine for inspection.
Regular maintenance focuses on “component maintenance and lubrication.” Perform a comprehensive weekly inspection, focusing on the meshing of the transmission gears. Adjust and replace any wear or excessive clearance. Inspect the bearing seals to prevent dust intrusion. Replace the bearing grease monthly. Choose a high-temperature, dust-resistant lithium-based grease, filling it to fill 2/3 of the bearing’s internal space. Disassemble and inspect the scraper blade quarterly. If the blade wear exceeds 3mm, polish or replace it. Ensure a 1-2mm gap between the blade and the liner to prevent material adhesion.
For long-term maintenance, maintain “equipment inspection and record keeping.” Perform a comprehensive annual disassembly and inspection. If the liner thickness decreases by 1/3, replace it entirely. Perform a flaw inspection on the frame to identify any weld cracks and repair them. Maintain a maintenance log, recording maintenance times, details, and replaced parts. Use data analysis to predict failures and plan maintenance in advance.
In short, disc granulator maintenance should adhere to the principle of “prevention first, prevention combined.” This involves combining daily cleaning, regular maintenance, and ongoing inspections to ensure optimal equipment operation and a stable and efficient organic fertilizer production line.
Analysis of the unique advantages of disc granulator fertilizer production technology
As a classic fertilizer granulation device, the disc granulator plays an essential role in producing compound fertilizers, organic fertilizers, and bio-fertilizers. Compared to traditional granulation methods, its unique process characteristics make it widely popular among small and medium-sized fertilizer manufacturers.
Core Features of the Disc Granulation Process:
1.Unique Tilted Rotating Design
The disc granulator features an adjustable tilt angle (15-55°) and a rotational speed of 2.2 to 6 rpm. This allows materials to roll and form granules naturally under gravity. This design ensures uniform granule size while preventing breakage caused by excessive pressure.
2.Open and Visible Operation
Unlike enclosed granulation equipment, the disc granulator operates completely openly. Operators can visually observe the entire granulation process in real-time, allowing them to adjust parameters like water spray volume and feed rate accurately, significantly improving process control precision.
3.Low Energy Consumption and High Efficiency
The disc granulator requires no complex drive system. Its power consumption is only 60%-70% of that of a drum granulator with equivalent output. This makes it especially suitable for areas with unstable power supply, significantly reducing production costs.
As demand grows for organic and specialty fertilizers, the disc granulator is gaining wider use in small-scale, high-end fertilizer production due to its process flexibility and cost-effectiveness.
Fertilizer Processing Process with a Disc Granulator
The disc granulator is the core equipment in a fertilizer production line, and its standardized processing flow is crucial for producing high-quality fertilizer.
The first step is raw material preparation. Raw materials include organic materials such as animal manure and plant residues, as well as inorganic materials such as urea and ammonium phosphate. These raw materials must be crushed to reduce particle size for subsequent mixing and granulation. Furthermore, they must be accurately weighed according to the formula to ensure an accurate nutrient ratio, and the humidity must be adjusted to 20%-30% to facilitate granule formation.
The second step is raw material loading. The disc is driven by a motor, and the speed can be set according to the raw material characteristics and the desired particle size. The raw material is evenly distributed on the disc, spread toward the edges due to centrifugal force, and then rises along the inner wall due to friction. After reaching a certain height, it falls back due to gravity, forming a circular motion.
The third step is the application of a binder. As the raw materials circulate, a nozzle above the disc sprays the binder onto the raw materials. The binder is usually a natural polymer or inorganic substance. When it comes into contact with water, it develops viscosity, causing the fine particles to bind together. The spraying rate must be precisely controlled: too much will result in oversized and dense granules, while too little will make them difficult to form.
The fourth step is granule growth. As the disc rotates continuously, the already bonded small granules continuously absorb the raw materials, growing larger as they rotate. The collision and friction between the granules also make them more compact. The operator must observe the granule state and adjust the rotation speed and tilt angle promptly. The rotation speed affects the residence time and granule size, while the tilt angle changes the movement trajectory and helps shape the granules.
The fifth step is discharge. When the granules reach the desired size and quality, they overflow from the edge of the disc. Freshly formed granules contain moisture, which requires drying to reduce the moisture content and improve stability and storage performance.
Through this series of rigorous processes, the disc granulator machine transforms various raw materials into high-quality granular fertilizers, providing strong support for agricultural production.
Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines
In organic fertilizer production lines, the disc granulator is the core equipment for raw material processing. Its operating condition directly affects product quality and production efficiency. Scientific maintenance can extend equipment life, reduce downtime, and lower costs. The following details maintenance methods from three perspectives: daily, periodic, and long-term.
Daily maintenance requires “cleaning and inspection in tandem.” After each shutdown, promptly clean the discs of residual material to prevent hardening and scratching of the disc surface or increased operating load. Use soft tools to prevent damage to the liner. Also, check the disc’s tilt angle (normally 45°-55°). If offset, correct it using the bracket bolts. Observe the transmission system daily for abnormal noise and check the motor and reducer temperatures. If the temperature exceeds 60°C, shut down the machine for inspection.
Regular maintenance focuses on “component maintenance and lubrication.” Perform a comprehensive weekly inspection, focusing on the meshing of the transmission gears. Adjust and replace any wear or excessive clearance. Inspect the bearing seals to prevent dust intrusion. Replace the bearing grease monthly. Choose a high-temperature, dust-resistant lithium-based grease, filling it to fill 2/3 of the bearing’s internal space. Disassemble and inspect the scraper blade quarterly. If the blade wear exceeds 3mm, polish or replace it. Ensure a 1-2mm gap between the blade and the liner to prevent material adhesion.
For long-term maintenance, maintain “equipment inspection and record keeping.” Perform a comprehensive annual disassembly and inspection. If the liner thickness decreases by 1/3, replace it entirely. Perform a flaw inspection on the frame to identify any weld cracks and repair them. Maintain a maintenance log, recording maintenance times, details, and replaced parts. Use data analysis to predict failures and plan maintenance in advance.
In short, disc granulator maintenance should adhere to the principle of “prevention first, prevention combined.” This involves combining daily cleaning, regular maintenance, and ongoing inspections to ensure optimal equipment operation and a stable and efficient organic fertilizer production line.
The Secrets of the Disc Granulator in an Organic Fertilizer Production Line
At the heart of an organic fertilizer production line, the disc granulator, with its unique operating principle, transforms loose organic raw materials into uniform granules, becoming a key piece of equipment connecting fermentation and finished products. While its seemingly simple operation requires precise control of material properties and mechanical movement, the disc granulator’s core structure consists of a tilted circular disc, the angle of which can be adjusted according to the characteristics of the raw materials. When fermented and pulverized organic materials (such as a mixture of livestock and poultry manure and straw) are fed into the disc, the disc rotates at a constant speed, causing the materials to slide upward along the disc wall under the combined effects of centrifugal force, friction, and gravity. Once they reach a certain height, they fall due to gravity, forming a continuous material circulation.
The key to the granulation process lies in the proper ratio of water to material. As the disc rotates, a spray system evenly applies an appropriate amount of water to the material, forming a moist film on the surface of the organic granules. As the materials collide and squeeze each other during this circulation, the moistened surfaces of the granules attract surrounding fine particles, gradually expanding like a snowball. The operator monitors the granulation process and adjusts the water spray rate and disc speed in real time to ensure uniform particle size.
The disc granulator‘s advantage lies in its adaptability to organic materials. Organic fertilizer raw materials are complex and high in fiber. The gentle rotation of the disc reduces material loss while preserving the activity of beneficial microorganisms. For materials with high humidity, the disc’s tilt angle can be adjusted to reduce the material’s residence time within the disc, preventing sticking and clumping. For dry materials, the disc’s rotation speed can be slowed to prolong agglomeration.
Organic fertilizer granules processed by the disc granulator are not only easy to store and transport, but also enable a slow release of nutrients upon application. With its simple and efficient design, this equipment bridges the gap between raw materials and finished product in the industrial production of organic fertilizer, providing solid technical support for the large-scale development of organic agriculture.
Diverse options for bio-organic fertilizer production line configuration: Meeting different production needs
A bio-organic fertilizer production line usually includes several core sections. This basic setup ensures organic waste gets systematically processed into high-quality organic fertilizer.
What Mainly Affects the Configuration Differences
1.Raw Material Type: Different materials like livestock manure, crop straw, or food waste need different pre-processing equipment.
2.Production Scale: Smaller lines might simplify some steps, while large-scale ones need high automation.
3.Final Product Requirements: Powdered or granulated fertilizer need different finishing equipment.
Common Differences in Setup Options
1.Fermentation System Choice: Trough-type turners suit small to medium production, while tower fermenters are better for large-scale, continuous operation. Choosing between aerobic and anaerobic fermentation systems also changes the overall setup.
2.Granulation Process Differences: The choice between disc granulators or rotary drum granulators depends on the raw material and the required granule type. Each granulation method needs matching drying and cooling equipment.
3.Automation Level: From semi-automatic to fully automatic lines, the setup of control systems and monitoring equipment varies a lot. This directly impacts investment costs and labor needs.
4.Environmental Equipment Setup: The level of bio-deodorization systems and wastewater treatment equipment depends on how sensitive the factory location is. Plants near cities usually need more complete environmental protection facilities due to regulations.
In short, bio-organic fertilizer production lines need custom setups based on the specific situation. This ensures the line is both cost-effective and meets environmental standards, turning organic waste into a resource for sustainable goals.
How to improve the granulation rate of the disc granulator
The granulation rate of the disc granulator directly affects the production efficiency and quality of organic fertilizer. When processing organic fertilizer raw materials containing high fiber and impurities, the disc granulator can take the following measures to ensure the uniformity and granulation rate of the particles:
Pretreatment of raw materials: For raw materials with high fiber and many impurities, it is necessary to first remove large impurities and long fibers through crushing and screening to make the material texture more uniform, provide high-quality basic materials for granulation, and reduce granulation failure caused by uneven raw materials.
Adjust the disc parameters: According to the characteristics of the material, reasonably adjust the disc inclination angle and speed. If the angle is too small, the material is easy to accumulate; if the angle is too large, the material residence time is short. Too fast speed will cause the material to be thrown out due to excessive centrifugal force, and too slow speed will make it difficult to fully roll and agglomerate. By repeatedly debugging and finding the appropriate parameters, the material can form a stable rolling track in the disc and promote uniform growth of particles.
Adding binder: By increasing the spraying amount and uniformity of the binder, the bonding of the material can be improved, thereby improving the strength and uniformity of the particles.
Install screening device: Install drum screener machine in the fertilizer production line to separate unqualified particles and impurities in time, return them to the granulator for reprocessing, form a closed loop, reduce the waste of raw materials, and ensure the uniformity of the output particles.
Clean the equipment regularly: Clean the disc and the inside of the disc granulator regularly to prevent the accumulation of impurities from affecting the granulation effect.
Through these methods, the disc granulator can stably maintain a high granulation rate, improve the quality and efficiency of organic fertilizer production, and help produce high-quality granular fertilizer.
How to choose between a rotary drum granulator and a disc granulator?
In the fertilizer, feed and other industries, disc granulators and rotary drum granulators are both common granulation equipment, playing a key role in fertilizer production lines. Understanding their differences can help companies choose the right equipment and achieve efficient production. From the working principle, when the disc granulator tilts the disc and rotates, the material continues to roll and agglomerate under the action of gravity, centrifugal force and friction. First, small particles are formed at the bottom of the disc, and then they continue to roll, absorbing the surrounding powder and gradually become larger. After reaching a certain size, they overflow from the edge of the disc to complete the granulation. The material of the rotary drum granulator rolls continuously in the rotating drum, and through water or steam, the basic fertilizer and other materials are fully reacted chemically in a wet environment, and the particles are agglomerated into balls under the extrusion force generated by the rotation of the cylinder.
In terms of equipment structure, the disc granulator is relatively simple. The core component is the tilted granulation disc, which is driven to rotate by the drive device. There are also disc inclination adjustment mechanisms, racks, feeding pipes, liquid sprayers, hanging plates, etc. The rotary drum granulator has a complex structure. The main body is a huge rotating cylinder, which is driven by a drive device. In addition, there are feeding systems, steam or gas supply systems, discharging systems, and complex control systems and auxiliary equipment such as temperature and humidity sensors.
The two have different focuses in their application areas. The disc granulator has a small investment and is easy to operate. It is a powerful assistant for small production plants and is widely used in small compound fertilizer plants, feed processing plants and small biomass fuel enterprises. The rotary drum granulator is like an industrial giant with high output and is suitable for large-scale production. It performs well in large-scale compound fertilizer and feed production enterprises and industrial raw material granulation processing.
Disc granulators and rotary drum granulators have their own advantages and disadvantages. Enterprises must make comprehensive considerations and careful choices based on their own production scale, material characteristics, product quality requirements and budgets to win development opportunities in the fierce market competition.