disc granulator – Page 2 – fertilizer production line

Disc Granulator: The Versatile Particle Maker

Written by fertilizer production line on September 2nd, 2025. Leave a comment

In modern industrial production, the disc granulator performs the magical transformation of powder into uniform granules. This seemingly simple yet crucial equipment serves as the heart of NPK fertilizer production technology, where it functions as the primary NPK fertilizer granulato NPK fertilizer granulator. Its unique rotating disc action efficiently blends and forms consistent NPK compound granules, making it an indispensable component in any complete NPK production line. The disc granulator’s versatility and efficiency have established it as a fundamental material transformation tool across multiple industries.

An Indispensable Tool for Fertilizer Production

Walk into any modern fertilizer plant, and you’ll find disc granulators hard at work. They skillfully convert organic waste like livestock manure and straw into granular fertilizer, solving storage challenges while enabling slow, sustained nutrient release. For compound fertilizers, this remarkable machine perfectly blends nitrogen, phosphorus, and potassium to create customized nutrient granules tailored to soil characteristics and crop needs.

The Metallurgy Industry’s Transformation Expert

In blazing metallurgical plants, disc granulators are changing the fate of mineral powders. Iron ore powder, manganese powder, and other raw materials are transformed into uniform, sturdy granules, paving the way for subsequent sintering and smelting processes. This transformation not only improves resource utilization but also significantly reduces production costs, delivering tangible benefits to metallurgical enterprises.

An Innovative Partner for Construction and Chemical Industries

The construction sector also benefits from this technology. Cement raw materials show significantly improved combustion performance after granulation, enhancing final product quality. In the fine chemical industry, various materials—from catalysts to detergents—gain superior flowability and stability through granulation, dramatically improving user experience.

Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines

Written by fertilizer production line on September 2nd, 2025. Leave a comment

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.

Key requirements for choosing granulators in NPK fertilizer production lines

Written by fertilizer production line on August 30th, 2025. Leave a comment

In compound fertilizer production, the granulator is the core equipment of an NPK fertilizer production line. It directly affects pellet quality, production efficiency, and product competitiveness. With the advancement of agricultural modernization, the market demands higher standards for NPK fertilizer granulation.

1.Strong Raw Material Adaptability

A quality NPK fertilizer granulator must handle various raw material ratios.It needs to work with mixes having different proportions of Nitrogen (N), Phosphorus (P), and Potassium (K).It should be able to process functional formulas that include added trace elements.It must handle raw materials with high moisture or high viscosity.

2.High Granulation Rate and Uniform Particles

A professional NPK granulator should achieve a granulation rate above 90%, minimizing recycled material.Particle size must be uniform, with over 85% of pellets sized between 2-4mm.Pellets should be well-rounded with a smooth surface finish.

3.Excellent Energy Efficiency and Environmental Performance

Modern NPK granulators need energy consumption per unit at least 20% below industry standards.They must include dust recovery systems, keeping dust emissions ≤30mg/m³.Noise levels should be controlled below 85 decibels.

4.Durable and Easy to Maintain

A quality granulator’s design should use wear-resistant alloy materials for key parts, ensuring a lifespan of over 5 years.Modular design allows for quick replacement of wear parts.Multiple access points provide ample space for maintenance.The lubrication system should be highly automated.

Granulator Selection Advice

Small lines (1-5 tons/hour): Disc Granulators are suitable.Medium lines (5-15 tons/hour): Rotary Drum Granulators are recommended.Large lines (15+ tons/hour): Prilling tower systems should be considered.

Selecting an NPK fertilizer granulator that meets these requirements will significantly boost production efficiency and product quality.

Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines

Written by fertilizer production line on August 28th, 2025. Leave a comment

The Secrets of the Disc Granulator in an Organic Fertilizer Production Line

Written by fertilizer production line on August 27th, 2025. Leave a comment

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.

Disc granulator: Efficiently processing various livestock manure composts

Written by fertilizer production line on August 22nd, 2025. Leave a comment

In organic fertilizer production, disc granulators are a go-to piece of equipment for handling livestock manure compost. They’re valued for their simple structure, easy operation, and strong adaptability.

Types of Livestock Manure Compost Suitable for Disc Granulator
1.Chicken Manure Compost
Characteristics: High in nitrogen, phosphorus, and potassium; rich in organic matter; but has high viscosity and moisture.
Key points for granulation: Needs full decomposition and moisture adjustment to 40%-50%. Adding conditioning agents like straw powder can improve air flow.
2.Pig Manure Compost
Characteristics: Moderate fiber content, good viscosity, but may contain heavy metals.
Key points for granulation: Mixing with materials like mushroom residue or rice husks is recommended. This reduces stickiness and improves pellet formation.
3.Cow Dung Compost
Characteristics: Coarse fiber texture, loose consistency, stable organic matter content.
Key points for granulation: Requires fine grinding to at least 60-mesh fineness. Adding binding agents may be necessary.

4.Sheep Manure Compost
Characteristics: Fine particles, balanced nutrients, excellent granulation properties.
Key points for granulation: Can be granulated directly, or mixed with materials like phosphate rock powder to make compound organic fertilizer.
5.Mixed Manure Compost
Characteristics: Fermented mix of multiple manures, resulting in more balanced components.
Key points for granulation: Ensure thorough mixing and control the material’s pH value (ideally between 6.5 and 8.0).

In summary, whether it’s chicken, pig, cattle, or mixed manure compost, scientifically processed material can be transformed into high-quality organic fertilizer pellets using a disc granulator.

Comparing granule shapes from different fertilizer granulators: Choosing the best granulation process

Written by fertilizer production line on August 19th, 2025. Leave a comment

In fertilizer production, the choice of granulator directly affects granule shape, strength, and performance. Different granulation techniques produce distinct granule shapes suited for specific fertilizer types and market needs.

1.Rotary Drum Granulator: Spherical granules, smooth surface

Produces typically round, smooth-surfaced granules with uniform size. This shape works well for compound fertilizers, organic fertilizers, and BB blends, offering good flowability and crush strength for mechanical application.

2.Double Roller Press Granulator: Oblate or hemispherical granules

Forms mostly flat-round or half-spherical granules, sometimes with slight burrs on edges. The dense structure resists breakage, making it suitable for high-concentration compound fertilizers or organic-inorganic blends.

3.Flat Die Granulator: Cylindrical granules, varying lengths

Creates short cylindrical pellets with consistent diameter but lengths that may vary. These high-hardness granules fit organic fertilizers, bio-organic fertilizers, and feed additives.

4.Disc Granulator: Near-spherical granules, mixed sizes

Similar to rotary drum granulation but yields less regular, near-spherical shapes with a wider particle size range. Ideal for initial processing of organic or compound fertilizers—cost-effective but less uniform.

In short, selecting the right granulator improves fertilizer quality and production efficiency.

How to improve the granulation rate of the disc granulator

Written by fertilizer production line on August 18th, 2025. Leave a comment

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.