Fertilizer granulators are widely used in the fertilizer industry, and disc granulators are particularly common. What are some common problems with disc granulators in fertilizer production? If problems such as material sedimentation and clumping occur during granulator operation, how can you resolve them? Below, we will guide you through resolving these issues.

Precipitation can occur during fertilizer production. Some materials cannot be mixed; when they are mixed and dissolved in water, precipitation occurs. Some fertilizers are soluble in certain proportions, but above a certain concentration, salting out occurs, causing another material to precipitate. Some materials, such as metal salts, are easily soluble in acidic media, but will precipitate. Other materials, such as humic acid, are easily soluble in alkaline media, but will precipitate when dissolved in acidic solutions.

The main methods to prevent precipitation are to properly adjust the pH of the solution, add cosolvents, and increase the solubility of insoluble substances. The raw materials used in NPK fertilizer production lines should be properly proportioned to prevent salting out and oversaturation. Appropriate additives should be added to protect the reaction materials and prevent precipitation. Appropriate raw materials should be selected to prevent precipitation caused by reactions between them.

Bloating in fertilizer production is caused by the release of gas from the reaction of two or more materials. Materials that may cause bloating during fertilizer production include borax, ammonium salts, and fillers. To effectively prevent bloating, the following points should be noted when using a disc granulator to produce pellets: When sourcing qualified raw materials, avoid blindly pursuing low costs; and ensure that raw materials are properly combined to prevent chemical reactions between them.

Clumping in fertilizer production: This problem is primarily related to the raw materials, humidity, temperature, external pressure, and storage time. Organic fertilizer production equipment requires the proper selection of raw materials, meaning those that are less prone to caking.

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.

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.