The moisture of the material is the primary control index for the pelletizing process. For one thing, dry granulation manufactures fertilizer pellets with relatively low material moisture. In general, the moisture content is less than 10% as a critical value, and there are very few materials can reach 16%.
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For instance, extrusion granulators (flat die granulator and roller extrusion granulator) apply this method for the production of pellets in variable shapes. Compared with the wet granulation, it has lower energy consumption and equipment cost. Besides, it doesn’t require the dryers or binders to affect the nature of the materials.
For another thing, wet granulators are equipped with sprinkle system. Moreover, we greatly recommend conditional fertilizer plants to utilize steam humidification for better granulation effect. Then, the following way is hot water granulation, which is superior than cold water granulation.
More importantly, wet granulation refers to the production of fertilizer particles containing 20-40% moisture, which are mostly in the form of balls. Furthermore, wet granulation has a variety of equipment: new type organic fertilizer granulator, rotary drum churning granulator, disc granulator and rotarydrum granulator.
If the output is 1-3 tons per hour, we suggest to choose flat die granulator or rotary roller extrusion granulator. If you require high effect of granules, you may choose the latter one.
For small production lines with an output of 4-8 tons per hour, we recommend choosing churning granulator or disc granulator. If you want better effect on the granules, you should choose the former. If you prefer high production efficiency, we advise you to install more than two disc pelletizers because of the low cost.
The drum pelletizer is generally ideal for professional medium and large organic fertilizer manufacturing plants with output requirements ranging from 9 to 30 tons per hour. If you require high capacity and good shape of the pellets, you can choose the rotary drum churning granulator.
In other words, if you own a small or medium scale fertilizer factory with an annual capacity of 5,000-20,000 tons, we propose a high-quality, low-cost flat die granulator and disc granulator. Furthermore, if you run a large fertilizer plant with an annual output of more than 50,000 tons, we recommend purchasing a rotary drum granulator directly. Because it is specifically designed to produce fertilizer granules on a greatly large scale and is more time-saving, efficient, and energy-efficient than several churning granulators working at the same time.
We strongly recommend you to choose flat die pelletizer and roller extrusion pelletizer because they are small in size, save civil construction cost and have good economic efficiency. They produce pellets in room temperature, without dryer and cooler, and have no environmental pollution. Meanwhile, they have high granulation density, high organic matter content and good fertilizer efficiency.
If you do not have a large budget and have severe environmental protection standards, we recommend that you choose a disc pelletizer, which has a low cost, low civil construction cost, a specific output, and can work more than one at the same time.
A rotary granulator is a type of granulation equipment used to produce uniform and consistent granules from powders or other raw materials. and rotary granulator also named as basket granulator. The equipment consists of a cylindrical vessel or "basket" with a rotating impeller or agitator located at the bottom of the basket. The impeller rotates at high speeds, causing the materials inside the basket to be lifted and thrown against the walls of the basket.
The walls of the basket have holes or perforations of a specific size, which allows the granules to pass through while retaining any oversized particles. This process of granulation is known as wet granulation, as it involves adding a liquid binder to the raw materials to create a granulated product.
ZL series basket granulator is usually the key equipment of the wet granulation production line. The pellet production line includes the following equipment: CH saga mixer or GHJ high shear mixer, YK series oscillating granulators or ZL series basket granulator, dryer (such as vibrating fluidized bed dryer, static fluidized bed dryer, vertical fluid bed dryer, or hot air oven), and vibration sieve. This production line can make the dry powder into uniform and instant granules. If the customer wants to make the final pellets into a ball shape, the wet pellets will be sent to the QL pelletizer to obtain wet pellets and dried by a dryer. For example, this production line is used for instant tea granules, additive granules, etc.
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The process of granulation in a rotary granulator can be divided into several steps:
Preparation: The raw materials are mixed together and a liquid binder is added to form a wet mass.
Loading: The wet mass is loaded into the rotary granulator.
Granulation: The impeller at the bottom of the basket rotates at high speeds, causing the wet mass to be lifted and thrown against the walls of the basket. The binder acts as an adhesive, causing the particles to stick together and form granules.
Screening: The granules pass through the holes in the walls of the basket, while any oversized particles are retained.
Drying: The granules are dried to remove any remaining moisture. it can use our fluid bed dryer, such as vibrting fluid bed dryer, vertical fluid bed dryer.
Discharge: The granules are discharged from the rotary granulator and collected for further processing or packaging.
There are several advantages to using a rotary granulator:
Rotary granulators produce granules of a consistent size and shape, which is important in industries such as pharmaceuticals, where product quality and consistency are critical.
Rotary granulators can produce large quantities of granules quickly and efficiently, making them ideal for large-scale production.
Rotary granulators can handle a wide range of materials and can be easily adjusted to produce different granule sizes.
Rotary granulators are relatively easy to maintain and clean, with few moving parts that require regular servicing.
There are also some disadvantages to using a rotary granulator:
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Rotary granulators are typically limited in capacity compared to other types of granulation equipment.
Rotary granulators can be more expensive than other types of granulation equipment, especially for larger production capacities.
Rotary granulators rely on the addition of a liquid binder to create granules, which can make the process more sensitive to variations in moisture content.
When choosing a rotary granulator, there are several factors to consider:
The capacity of the rotary granulator should be appropriate for your production needs.
The size of the granules produced by the rotary granulator should be appropriate for your application.
The rotary granulator should be compatible with the materials you are using, including the binder and any other additives.
The rotary granulator should be easy to maintain and clean, with few moving parts that require regular servicing.
The cost of the rotary granulator should be within your budget, taking into account both the initial purchase price and any ongoing maintenance costs.
There are several types of rotary granulators available, including:
These have a stationary basket and a rotating impeller.
These have a pivoting basket that can be tilted to facilitate loading and unloading.
These have a horizontal rotating cylinder that oscillates back and forth, causing the materials to be granulated.
To ensure the longevity and efficiency of your rotary granulator, it is important to perform regular maintenance and cleaning. This includes:
Regular inspection of the impeller and basket for wear and damage.
Lubrication of any moving parts.
Cleaning of the basket and impeller to remove any residual materials.
Replacement of any worn or damaged parts.
Rotary granulators are used in a variety of industries, including:
Rotary granulators are commonly used in the production of tablets and capsules.
Rotary granulators can be used to granulate ingredients for food products such as seasoning blends.
Rotary granulators can be used to produce granules for fertilizers, detergents, and other chemical products.
In conclusion, rotary granulators are a versatile and efficient type of granulation equipment that can be used in a variety of industries. When choosing a rotary granulator, it is important to consider factors such as capacity, granule size, and material compatibility, as well as the maintenance and cleaning requirements and overall cost.
Rotary granulators can handle a wide range of materials, including powders, crystals, and other solid materials.
The maximum capacity of a rotary granulator will depend on the specific model and manufacturer. Capacities can range from a few kilograms to several hundred kilograms per hour.
Rotary granulators should be cleaned regularly to remove any residual materials that could affect product quality. The frequency of cleaning will depend on the specific application and production schedule.
Rotary granulators are primarily used for wet granulation, but some models can also be used for dry granulation.
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