Capacity: 5-20 tons/hour
Granulation Type: Dry Granulation
Pellet Characteristics: High hardness, uniformity, and roundness
Pellet Formation Rate: 95%
Suitable Materials: Suitable for processing materials with high fiber content (such as straw compost) or less viscous materials. High adaptability to raw materials, especially dry, loose materials (such as straw charcoal, weathered coal, and organic fertilizer).
Granulating Disc: This disc is tilted and has an adjustable tilt angle. It's typically made of carbon steel. The inner surface can be coated with wear-resistant ceramic or polyurethane to improve wear resistance and reduce adhesion. Some models use stainless steel. The disc's rim is slightly raised (15-30 cm) to prevent material spillage.
Drive System: The disc is driven by a motor and a reducer via gears or belts. The speed can be adjusted using a frequency converter, and the rotational speed affects the granulation speed and pellet strength.
Feed and Water Spray System: The feed port is located above the disc, and the mixed material is fed to the bottom of the disc via a screw conveyor or chute. The water/slurry spraying system uses pipes installed along the edge or top of the disc to spray the material with an appropriate amount of water through nozzles, providing humidity for material agglomeration.
Discharge and Scraping Device: A discharge port is located at the bottom of the disc. Particles that have reached the target size fall by gravity and enter the subsequent drying and screening processes. Some models feature a fixed scraper installed on the inside of the disc to remove material adhering to the disc wall, preventing accumulation. This also assists in material agitation, promoting uniform particle growth.
Support and Adjustment Structure: The disc is supported by a frame equipped with an angle adjustment mechanism, allowing for flexible adjustment of the disc's tilt based on the desired granulation result.
Working principle of Disc Granulator：
The disc granulator uses an inclined rotating disc to force the material to roll along its inner surface under the combined effects of centrifugal force, friction, and gravity.
At the same time, an appropriate amount of water or binder is sprayed onto the material, allowing fine particles to gradually adsorb and agglomerate, forming uniform spherical granules. When the particles reach a certain size, gravity overcomes the centrifugal force and they are ejected from the edge of the disc, completing the granulation process. Its core principle is to combine mechanical rotation with the material's characteristics to achieve a "snowball"-like granulation process.
Advantages of Flat Die Granulator:
1. High Granulation Rate:
The disc granulation method produces highly spherical granules (roundness ≥ 85%), smooth surfaces, and uniform particle size. The granules also have a loose, porous internal structure, facilitating subsequent drying and nutrient release.
2. High Adaptability:
It can process a variety of fertilizers, including organic fertilizers such as composted livestock and poultry manure and straw powder; compound fertilizers such as urea, monoammonium phosphate, potassium chloride, and other chemical fertilizer blends; and mixtures of organic and chemical fertilizers.
3. Flexible Operation:
The disc granulator has no complex internal components. Granulation quality can be quickly adjusted by adjusting three parameters: tilt angle (to control particle size), rotation speed (to control granulation speed), and water spray volume (to control bonding). This makes it suitable for small-batch, multi-specification granule production.
Model | Diameter of Disc(mm) | Edge Height(mm) | Rotary Speed(r/min) | Motor Power(kw) | Capacity(t/h) | Reducer Model | Dimensions(mm) |
ASLYZ-500 | 500 | 200 | 32 | 0.55 | 0.02-0.05 | BWYO-43-0.55 | 650×600×800 |
ASLYZ-600 | 600 | 280 | 33.5 | 0.75 | 0.05-0.1 | BWYO-43-0.55 | 800×700×950 |
ASLYZ-800 | 800 | 200 | 21 | 1.5 | 0.1-0.2 | XWDA-71-1.5 | 900×1000×1100 |
ASLYZ-1000 | 1000 | 250 | 21 | 1.5 | 0.2-0.3 | XWDA-71-1.5 | 1200×950×1300 |
ASLYZ-1200 | 1200 | 250 | 21 | 1.5 | 0.3-0.5 | XWDA-71-1.5 | 1200×1470×1700 |
ASLYZ-1500 | 1500 | 300 | 21 | 3 | 0.5-0.8 | XWD5-71-3 | 1760×1500×1950 |
ASLYZ-1800 | 1800 | 300 | 21 | 3 | 0.8-1.2 | XWD5-71-3 | 2060×1700×2130 |
ASLYZ-2000 | 2000 | 350 | 21 | 4 | 1.2-1.5 | XWD5-71-4 | 2260×1650×2250 |
ASLYZ-2500 | 2500 | 450 | 14 | 7.5 | 1.5-2.0 | ZQ350 | 2900×2000×2700 |
ASLYZ-2800 | 2800 | 450 | 14 | 11 | 2-3 | ZQ350 | 3200×2200×3000 |
ASLYZ-3000 | 3000 | 450 | 14 | 11 | 2-4 | ZQ350 | 3400×2400×3100 |
ASLYZ-3600 | 3600 | 450 | 13 | 18.5 | 4-6 | ZQ400 | 4100×2900×3800 |
What materials are suitable for processing? What are the raw material requirements?
It is suitable for organic fertilizers (such as fermented livestock and poultry manure and composted straw), inorganic fertilizers (such as compound fertilizers and phosphate fertilizers), metallurgical powders, and ceramic raw materials. Raw materials must meet the following requirements: uniform particle size (recommended ≤2mm), a moisture content of 20%-30% (a higher moisture content will cause caking, while a lower moisture content will make it difficult to form), and no large impurities (such as stones or metal). For organic fertilizer raw materials with high fiber content, they must be crushed in advance to prevent entanglement that affects granulation.
"Is particle size adjustable? How?
Yes, particle size can be adjusted. Particle size can be controlled primarily by adjusting the disc inclination angle (the larger the inclination, the smaller the particles, typically in the range of 30°-50°), varying the disc speed (the higher the speed, the smaller the particles, typically 15-30 rpm), controlling the material feed rate (excessive feed can lead to oversized and uneven particles), and adjusting the moisture or binder content (increasing the amount promotes particle growth). By adjusting these parameters in combination, particles between 0.5-10mm can be produced. "
"What is the pelletizing efficiency? How many pellets can be produced per hour?
Pelletizing efficiency varies depending on equipment specifications. Small disc pelletizers (1-2 meters in diameter) have an hourly output of 0.5-3 tons, medium-sized equipment (2-3 meters in diameter) 3-10 tons, and large equipment (over 3 meters in diameter) can reach 10-20 tons. Actual efficiency also depends on the characteristics of the raw material. Materials with good fluidity and easy agglomeration (such as decomposed manure) are more efficient, while light, loose materials (such as straw powder) are relatively inefficient. "
"What faults are common during operation, and how can they be resolved?
Common faults include:
① Uneven pellet size (due to unstable feed or improper moisture control). This requires stabilizing the feed rate and precisely adjusting the water spray volume;
② Material sticking to the disc (excessive moisture content or too small disc tilt angle). Reduce the moisture content or increase the tilt angle, and clean the disc promptly;
③ Abnormal equipment vibration (loose anchor bolts or worn bearings). Tighten the bolts or replace the bearings; ④ The motor is overloaded (too much material or stuck), so reduce the feed and check the transmission system.
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