The application prospects of disc granulation mechanism particles

Improving resource utilization: The disc granulator can reprocess ore tailings into granular form, making them better used in fields such as building materials, fillers, and roadbeds, thereby improving resource utilization.

Reducing environmental pollution: By making ore tailings into granules, the occupation and pollution of waste residue on the environment can be reduced. Meanwhile, the disc granulator produces less dust during the granulation process, which is beneficial for improving the working environment and reducing air pollution.

The promotion of sustainable development: The disc granulation mechanism has a positive significance for achieving sustainable development of mining, which can reduce the negative impact of mining waste on the environment and promote the recycling of resources.

Application scenarios of disc granulation mechanism granules

Metallurgical industry: In the metallurgical industry, the disc granulator can convert metallurgical waste into granular materials with certain strength, which are used for the production of building materials, roadbed fillers, and smelting auxiliary materials.

Pharmaceutical industry: The production process of the pharmaceutical industry generates a large amount of waste residue and wastewater. Through the disc granulation mechanism, these waste materials can be made into particles with certain shapes and sizes, which are convenient for transportation and storage, while reducing environmental pollution.

Chemical industry: In the chemical industry, disc granulator can convert chemical waste and waste liquid into granular materials with certain uses, such as catalysts, adsorbents, fillers, etc.

For fertilizer manufacturers, there are various granulators to choose from. According to the different forms of granulation, it can be roughly divided into the following five types.

There are four types of granulators with lower investment costs for fertilizer processing equipment:

1. Disc granulator: suitable for cold granulation of raw materials in industries such as bio organic fertilizers, compound fertilizers, and feed. The inclination of the disc can be adjusted as needed to control the particle size. High ball forming rate, beautiful particle shape, wide range of particle diameter selection, and relatively low equipment investment cost.

2. Double roll extrusion granulator: mainly suitable for granulation of more than 20 types of raw materials such as urea, ammonium chloride, ammonium sulfate, calcium phosphate, superphosphate, potassium chloride, potassium sulfate, etc., without drying process, granulation at room temperature, one-time molding, low investment and quick effect.

3. Organic fertilizer wet stirring toothed granulator: urban household waste such as poultry manure, compost, green manure, sea manure, cake fertilizer, peat, soil and miscellaneous fertilizer, three wastes, microorganisms, etc. It can be naturally dried in the later stage, eliminating the need for drying and cooling.

4. Drum granulator: With beautiful appearance, simple operation, low energy consumption, long service life, uniform drying, and convenient maintenance, it is one of the more advanced granulator equipment in China. This product is suitable for large-scale production of cold and hot granulation, as well as high, medium, and low concentration compound fertilizers.

The organic fertilizer granulator consists of several parts. First, it’s the collection part of the device. Secondly, it is the most important transmission component and also a bracket device with special technology. Finally, there are conveyor belts and auxiliary wheels, and different granulators have different granulation characteristics.

1. The principle of rotary drum granulator is that the material relies on the surface tension, an appropriate amount of liquid phase, and the extrusion force generated by the rolling between the materials.

2. The processing operation of the double roller granulator equipment adopts the non-drying and normal temperature process, the particle strength is high, and the bulk specific gravity increase is more obvious than other granulation methods, especially suitable for occasions where the product bulk specific gravity increases.

3. The new organic fertilizer granulator uses the high-speed rotating mechanical stirring force and the generated aerodynamic force to continuously realize the mixing, granulation, spheroidization, densification and other processes of fine powder materials in the machine, so as to achieve the purpose of granulation.

4. The control of water content, material quality and water temperature in the operation of the disc granulator of organic fertilizer equipment.

How to reduce the noise of the organic fertilizer granulator in the npk manufacturing process, there are the following suggestions:

1. There may be a problem with the bearing of a certain part of the organic fertilizer granulator, which makes the machine work abnormally, the working current fluctuates, and the working current is too high.

2. The ring die is blocked, or a part of the die hole is detached from the material. If the ring die enters the foreign body, the ring die is out of the circle, the gap between the roller and the die is too tight, the roller is worn or the roller bearing is damaged and cannot rotate, which will cause the vibration of the granulator.

3. The coupling correction is unbalanced, the height and height are deviated, the granulator vibrates, and the gear shaft oil seal is easily damaged.

4. If the main shaft is not tightened, the loosening of the main shaft will cause axial movement before and after the movement, the roller swings obviously, the granulator is noisy, and the granulation is difficult.

5. The wear of the big gear and the pinion, or the replacement of a single gear, will also produce a lot of noise.

The treatment of ore tailings has always been an important challenge in mining processing. In order to better utilize resources and reduce environmental pollution, many companies are seeking innovative methods to treat and utilize these wastes. Among them, the disc granulation mechanism is a promising solution.

Disc granulation mechanism is a process method that utilizes rotating disc granulation to produce spherical or nearly spherical particles by controlling parameters such as rotation speed, material residence time, and material layer thickness. Compared with traditional granulation methods, the disc granulation mechanism has higher production efficiency, lower energy consumption, and better particle quality.

Advantages of disc granulation mechanism particles

High yield: The disc granulator granulation equipment has high production efficiency and can continuously and stably produce high-quality particles.

Good particle quality: By controlling process parameters, the disc granulator can produce spherical or nearly spherical particles with high particle density and strength, which meet the needs of various application scenarios.

Simple process: The disc granulation machine granulation process is relatively simple, easy to operate, easy to maintain, and produces less waste during the production process, reducing production costs.

The disc granulator has obvious advantages and application prospects in the treatment of ore tailings. By making ore tailings into granular form, resource utilization efficiency can be improved, environmental pollution can be reduced, and it has the advantages of high yield, good particle quality, and simple process. With the increasing demand for sustainable development in the future, the application prospects of disc granulator in the field of mining waste treatment will be even broader.

The organic fertilizer pellet production line project is a process that uses organic waste fermented by microorganisms to produce organic fertilizer through granulation.

Process flow of a daily production line for 500 tons of straw granular organic fertilizer

1. Mainly, raw materials containing organic matter (such as sheep manure, pig manure, sludge, chicken manure, duck manure, cow manure) with a moisture content of about 70% are mixed with crushed organic waste (such as straw, corn straw and branches, mushroom residue) and then added with a biological fermentation agent for fermentation.

2. Use a forklift to load the mixed (sheep manure, pig manure, sludge, chicken manure, duck manure, cow manure) and other plant straw into a fermentation and maturation tank, and evenly add fermentation bacteria for maturation.

3. Fermented raw materials can be directly transported to the organic fertilizer crusher for crushing through an automatic material system using a belt conveyor. The crushed materials can be directly transported to the screening machine using a belt conveyor. The screening machine screens out impurities that are not fully decomposed or crushed, and then uses a belt conveyor to transport them to the waste disposal site for processing;

4. After fermentation and crushing, the raw materials are accurately proportioned (bentonite, humic acid) with a forklift into the automatic batching bin and other raw materials (adding nitrogen, phosphorus, and potassium with a total nutrient content of less than 25%) to produce organic and inorganic fertilizer compound fertilizers. After proportioning, they are quickly and evenly stirred by a mixer.

5. It enters the organic fertilizer granulator through a belt conveyor, and a small amount of water is added to the inlet for granulation. The particles formed by the granulator are then transported by the belt conveyor to the rounding machine for shaping

6. After drying and cooling, the particles are sieved by a belt conveyor through a powder screening machine for final product screening. The particles that do not meet the requirements are transported to the waste crusher by a (finished particle 2-4mm) belt conveyor for thorough crushing, and then returned to the granulator for further granulation by the return material belt conveyor.

7. After sieving the powder, the particles are coated by a coating machine and can be added (functional bacteria can produce bio organic fertilizers)

8. After adding functional bacteria to the coating machine, the particles are transported by a belt conveyor to the second screening machine for particle size screening. The particles (2mm and 4mm) can be separated and packaged separately, making them more beautiful,

Advantages of double roller granulator:

1. Low energy consumption and energy saving road roller extrusion granulation is a kind of material granulation at room temperature. Compared with other methods, it does not require drying measures such as fuel and gas.

2. The low investment is due to the saving of the drying process, the low rate of return (about 15% of the total feed of the extruder), the simple process flow and the low investment.

3. The consumption capacity of extrusion granulation is only electricity, and there is no three waste discharge for environmental protection.

The double roller granulator has the characteristics of low energy consumption, high energy saving, low investment, simple operation, and no pollution of equipment emissions. Before the production of the npk fertilizer production line, the installation of the roller extrusion granulator needs to be debugged. Take the right approach:

1. Adjustment of the roller gap: In the npk manufacturing process, sometimes it is necessary to increase the output or bite angle, at this time, the distance between the two compression shafts can be increased, and the distance between the active shaft and the passive shaft can be increased. The steps are as follows: stop the machine, remove the upper rack of the two bearing seats, adjust the adjustment plate between the two bearing seats to the required thickness, the rollers cannot collide between the two rollers, and the minimum should be kept between 0.3-1mm.

2. The alignment adjustment of the ball socket. The ball socket is formed by the dimples on the main roller surface, so there are problems of axial alignment and circumferential alignment:

1) The axial alignment has been adjusted during installation. Generally speaking, it is not possible to adjust. When adjustment is required, tighten or loosen the glands on both sides of the passive bearing seat, thereby pushing the displacement of the eccentric sleeve to be in line with the drive shaft roller. correspond.

2) Align the ring direction, loosen the six connecting bolts between the driven gear and the adjusting sleeve, so that the adjusting device and the driven gear are slightly separated. Since the ball seat adjustment is considered in the design and two adjustment bolts are installed, the dislocation can be adjusted regardless of the dislocation.

Wet stirring tooth granulator, also known as organic fertilizer stirring tooth granulator, is a commonly used organic fertilizer granulation equipment. It is composed of spiral stirring teeth arranged and welded inside, and its biggest advantage is that it is suitable for organic fertilizer raw materials with high moisture content or other similar materials. It is mainly used for granulation of organic fertilizer raw materials and can also be used for granulation of other chemical raw materials.

The wet stirring toothed granulator mainly has models with a diameter of 600-1000MM, and suitable models can be selected according to production requirements. The shell is made of thickened seamless steel pipes, which have high overall strength and are not easily deformed. The base is welded with thickened steel, which is sturdy and durable, runs smoothly, and has a good granulation effect.

Working principle of wet stirring toothed granulator:

The wet stirring toothed granulator equipment is powered by an electric motor, which drives the internal spiral stirring toothed shaft to rotate at high speed. Air force is generated inside the machine body, which drives the material to flip back and forth and generate friction, thereby merging into balls to achieve the granulation process. The particle shape is spherical, with a sphericity of ≥ 0.7 and a particle size generally between 0.3-3mm. The sphericity rate is above 90%. The size of the particle diameter can be adjusted by adding more auxiliary materials and the spindle speed. The more auxiliary materials are added, the lower the spindle speed. The larger the particle, the less auxiliary materials are added, the higher the spindle speed, and the smaller the particle.

Applicable fields of wet stirring toothed granulator:

From the perspective of material status, it is suitable for lightweight fine powder materials. The finer the material particles, the higher the sphericity of the particles, and the better the quality.

From the perspective of material variety, it is suitable for various livestock and poultry manure, such as chicken manure, cow manure, pig manure, sheep manure, etc.

The organic fertilizer factory in a breeding farm is an equipment that uses chicken and pig manure as the main raw materials, adds a certain amount of nitrogen fertilizer, phosphorus fertilizer, potassium fertilizer, magnesium sulfate, ferrous sulfate and other substances, ferments rice bran, yeast, soybean meal and sugar for a certain period of time as biological bacteria, and under the action of sulfuric acid, mixes and ferments to produce biological fertilizers. It has not only created economic benefits for enterprises, but also made significant contributions to human environmental protection projects.

The equipment of the organic fertilizer plant in the breeding farm is divided into powder organic fertilizer production line and granular organic fertilizer production line:

The processing equipment for powdered organic fertilizer production line mainly includes: fermentation turner, organic fertilizer crusher, drum screening machine, and other equipment.

The granular organic fertilizer production line equipment is equipped with multiple types of equipment on the basis of the powder line, including a mixing mixer, organic fertilizer granulator, rotary drying machine, cooling machine, drum screening machine, coating machine, automatic weighing and packaging machine, etc.

Raw materials and auxiliary materials for organic fertilizer factories in aquaculture farms

1. Organic main raw materials: organic solid waste such as livestock and poultry feces, sludge and garbage

2. Inorganic main raw materials: urea, phosphorus, superphosphate, heavy calcium, potassium sulfate and other trace element additives account for about 10% of the formula; Y bio organic compound fertilizer requires the addition of 5% bio bacterial powder. 10% may also use raw materials as needed, such as peat, oil residue, fly ash, etc

1. Fermentation equipment enables materials to fully ferment and mature under the action of bacterial strains, eliminating harmful substances such as insect eggs in the raw materials.

2. Crushing equipment, which crushes materials into powder.

3. Screening equipment screens out materials that meet size requirements through a sieve and re crushes them.

4. A granulator is used to make crushed materials into spherical or long cylindrical shapes through a granulator.

5. Drying machine, drying the prepared particles with water to make the material more compact and not loose.

6. Packaging machine for bagging and stacking.

The development of large-scale farms can be said to be in the ascendant, which greatly meets the needs of the people for meat, eggs and milk. The subsequent harmless treatment of a large number of livestock and poultry manure is also imminent. The production and processing of livestock and poultry organic fertilizer is one of the good ways to use it. one. Use the scientific and reasonable production technology of the livestock manure organic fertilizer production line to promote the development of the local livestock and poultry organic fertilizer industry and the transformation and upgrading of the livestock breeding industry.

The organic fertilizer production line is composed of fermentation system, drying system, deodorization and dust removal system, special pulverizer for organic fertilizer, batching system, mixing system, organic fertilizer granulator and finished product packaging machine. To produce granular organic fertilizers, organic fertilizer granulators must be used. In addition to the common disc granulator  machine, double roller granulator and rotary drum granulator, let’s talk about organic fertilizer collision granulators.

The chicken manure organic fertilizer production line adopts the organic fertilizer collision granulator working principle: this model adopts the two-way spiral countercurrent collision granulation technology, and the horizontally opposed auger is driven by the motor, so that the material can obtain continuous, High-speed, reciprocating mixing and shearing, thus forming a colliding flow of high-pressure fluid state, changing the molecular structure and granulation of the material, and significantly enhancing the heat transfer, fluidization, and extrusion processes between materials. The organic fertilizer collision granulator has the following characteristics: heating granulation, strong production capacity; novel design, unique structure, small volume; high spheroidization rate, uniform, smooth, round, and high strength.

It is recommended to be equipped with an automatic return system for organic fertilizers. The unqualified large and small granular materials are divided, transported out through the belt elevator, re-crushed and sent to the granulator to continue granulation, which helps to improve the continuous operation capacity of the production line.

The organic fertilizer production line process basically includes: organic material inoculation fermentation (pre-fermentation), main fermentation, crushing, compounding and mixing, drying, granulation (double roller granulator), cooling, screening, metering and packaging, etc. craft.

(1) The process of small chicken manure organic fertilizer equipment is composed of raw material pretreatment system for continuous feeding, fermentation system, and fertilizer processing system, which can be flexibly combined according to the processing volume.

(2) The fermentation system adopts forced ventilation dynamic fermentation to ensure the adaptive supply of oxygen during the fermentation process and maintain the high activity and efficiency of microorganisms. The organic fertilizer equipment tumbler is the core equipment of aerobic dynamic composting, which is conducive to improving product quality. Stable, the general cycle is 15 days, and the aging cycle is 20 days. Compared with the traditional composting cycle of 60 days, the efficiency is higher;

(3) The low configuration of the chicken manure organic fertilizer production line only needs a pulverizer, a mixer, a granulator, a screening machine and a packaging machine. This is a basic configuration, and equipment is added according to the actual needs and requirements of customers. High configuration chicken manure organic fertilizer equipment: chicken manure dehydrator, fermentation stacker, semi-wet material grinder, horizontal mixer, rotary drum granulator, dryer, cooler, trommel screen, coating machine, packaging equipment , belt conveyors, etc.

The chicken manure organic fertilizer production line project has a high degree of harmlessness, the removal rate is over 99%, and it is completely decomposed. At the same time, the characteristics of raw materials are used to develop special products and market-specific fertilizers according to local characteristics. The chicken manure organic fertilizer production line can be processed into refined fertilizer, increase output and increase efficiency, and implement pollution-free production. If chicken manure can be processed into organic fertilizer, it will not only effectively utilize chicken manure resources, but also not worry about sales.