A Dry Granulation Method Manufacturing of Double Roller Granulator
Are you looking for a machine to make compound fertilizers? It is profitable to set up a complete line of compound fertilizers. Which granulator is the right fit? Here we recommend to you a machine suitable for compound fertilizer granulation. Of course, you can use the double roller granulators to make powdered granules for other industries, such as metallurgy and the chemical industry, not just for the granulation of fertilizers. This is one of the reasons why it is so popular. Our double roller extrusion granulators form pellets by the extrusion of two rollers. The roller extrusion granulator has become one of the most popular models in our company last year. This is not only because of its special granulation principle, but also because of some of its special designs.
What is the Unique Design of Our Double Roller Granulator?
Like other companies, our double roller fertilizer granulator is also consists of driving device, feed port, roller, discharge port, etc. But what is the uniqueness between the double roller press granulator produced at our factory? The answer is that we have higher demands on the design and materials of our machines. It is precisely for these reasons that our roller extrusion granulator has become the preferred granulation equipment for compound fertilizers in recent years.
The rollers of our granulator are made by specific roller making machines. It mainly includes two parts: roller and roller sheet. You can customize the shape and size of the ball socket on the roller sheet according to your needs. Generally it is a flat spherical shape. The material of our roller sheet is 20 CrMnTi, which is a well-performing carburized steel. It is highly hardenable and can withstand high loads and impact forces. In addition, it is the material of many parts of automobiles and airplanes. To ensure the quality of granulation, you should replace the roller sheet every six months. To be fair, the quality of our roller extrusion granulator is excellent, which is a great benefit to the overall operation of the equipment and to the granulation.
All the working bodies of the double roller granulator are installed on the fixed frame. The material of our machine is boiler steel, Q235. Passed strict quality control and specific process requirements. The part of granulation and crushing are in a closed environment, which avoids the flying of powder during granulation. There are hoisting holes in the middle of the four corners of the rack for use in loading and unloading transportation.
Feed Port and Discharge Port
The feeding port is on the top of the main machine, which is convenient for feeding. There are two types of discharge ports: side discharge ports and front discharge ports. Generally, there are many side discharge ports. Secondly, we use a grading discharge device, including qualified discharge ports and unqualified discharge ports. Qualified discharge ports directly produce finished products, and unqualified discharge ports enter the granulator for granulation.
The driving device of our granulator uses electric motor and reducer with low power consumption. We can save the cost to the greatest extent for you. When purchasing a granulator, the motor power consumption are also a factor that you should consider. Therefore, in the selection of our motors, we use well-known brand motors, which have low power consumption and stable operation.
Why Most Fertilizer Manufacturers Choose Our Double Roller Extrusion Granulators?
High Granulation Rate
Roll extrusion granulation is a dry granulation process. The advantage of dry granulation is that it can granulate without drying or humidification. Because using two pairs of rollers for extrusion granulation, the strength of the granules is greatly improved. During the granulation process, the working surface of the pressing roller is 100%. Therefore, the granulation rate is higher than other granulators.
No Need for Additional Adhesive
The convenience of the roller extrusion granulator lies in its granulation method – dry granulation. You can granulate powdered granules directly without additional binders. The common wet granulation needs to add water or steam to the material for bonding. And you should dry the granulated granules with a dryer due to excessive moisture. That’s quite troublesome. On the other hand, the double roller granulator simplifies the process, saves the drying process, and reduces energy consumption.
Unlike disc granulation, the technical requirements for operators are relatively high. The double roller press granulator only needs to put the mixed material into the feeding port. It can achieve automatic granulation without other operations. And the equipment is easy to operate and maintain. You can use multiple granulators in compound fertilizer granulation lines.
Flexible Raw Materials
The raw materials of the roller extrusion granulation are wide. It is fitting for the granulation of various powdery raw materials such as compound fertilizer, medicine, chemical industry, feed, etc. The most suitable is the granulation of compound fertilizers. Therefore, if your raw materials are powdered raw materials, you can use the roller extrusion granulator for granulation.
Double Roller Granulator for Sale in Different Volumes
Capacity 1-1.5 t/h, its motor power is 15 KW,
Capacity 1.5-2.5 t/h, its motor power is 18.5 KW
Capacity 2-3 t/h, its motor power is 22 KW
The granule diameter is between 3-10 mm. Material moisture is between 2%-5%.
Profitable Dry Powder Extrusion Granulation Production Line
If you want to produce compound fertilizers and make a profit, just a few double roller granulators are not enough. Granulation is just a critical step in fertilizer production. A complete production line also needs supporting equipment. However, compared with the production of organic fertilizer, the dry powder extrusion granulation production line is more suitable for the production of compound fertilizer. In view of its working principle – dry granulation, the moisture content of the raw material must be around 1.2%. However, although you have turned the poultry manure, the water content is still high. So the production of organic fertilizer is mostly fitting for wet granulation.
The dry powder extrusion granulation production line is fitting for the production of single-element fertilizers and multi-element compound fertilizers. The production capacity of dry powder extrusion granulation production line depends on the number of counter-roll granulators. The minimum is 4 sets, and the maximum depends on your production capacity requirements. So what is the process of a complete dry powder extrusion granulation line? What other machines do you need in your production line?
Dynamic Batching Machine
When making compound fertilizer, you should mix a variety of raw materials. The dynamic batching machine is mainly fitting for mixing, batching and feeding of 3-8 kinds of materials. First of all, our dynamic batching machine can choose the number of bins. The most common is the four-bin batching machine. If you want to make compound fertilizer of several elements, you can choose several warehouses. Secondly, you can customize the size of our silo. Again, in terms of material, the contact part between the silo and the material is stainless steel. Finally, the dynamic batching machine is automatically controlled by a computer. And a pneumatic door is used to control the quantitative feeding of the main silo. After the material is mixed in the mixing bin, it is automatically sent out by the belt conveyor.
Double Shafts Horizontal Mixer
Why do you need to add a blender? This is because the material coming out of the batching machine is unevenly distributed. If you granulate directly, the distribution of nutrients in fertilizer granules is uneven. Some elements are abundant, and some are even missing. So the mixer is an indispensable step. Our double shafts horizontal mixer uses a double-shaft design to make the material more evenly mixed. Generally, after the dynamic batching machine, it is transported to the mixing tank by the belt conveyor. Homogeneous agitation is carried out by means of helical blades mounted on double shafts. It is worth mentioning that the spiral blades on the double shafts rotate in opposite directions, so that the machine can mix the material more evenly. The stirring blade is high-strength wear-resistant material, which has a longer service life.
Rotary Screening Machine
The granules made by the roller extrusion granulator have different shapes and sizes. The function of the screening machine is to sieve out the powder particles and the particles whose shape is not up to standard. The screen of our screening machine is stainless steel, which prevents the material from corroding the screen. And with hitting anti-stick net device. The overall structure of the screening machine is 150 seamless tubes as the legs, 3 mm iron plate as the box, channel steel as the frame, and 130 thick-walled seamless tubes as the shaft. In terms of material, it is tough and wear-resistant, and has a long service life. The powder screening machine has two discharge ports, one for finished products and one for waste products. The waste products are re-entered by the belt conveyor into the extrusion granulator for granulation. The finished product goes directly to the packaging process.
Belt conveyor is an indispensable equipment for granulation production line. Mainly play the role of transport and connect each link. The belt of our conveyor is 4 layers canvas rubber belt with thickness 10 mm. The frame part adopts 10 mm international channel steel.
The sieved particles can enter the final packaging process. Our packaging machines have an integrated design and are compact. Automatic packaging, quantitative weighing. The special design is that it can be fed and has bucket metering. The packing speed is fast and the packing precision is high.Using imported sensors, the measurement accuracy is plus or minus two thousandths.
Things You Should Know When You Use Our Double Roller Extrusion Granulator
The feeding should be uniform, and there should be no shortage of materials. Do not feed too much, and the feeding speed should be appropriate. Otherwise, it will affect the quality of the particles.
Before installation and use, you should smear butter on the easy-to-wear parts such as bearings, which is conducive to the maintenance of the machine.
Pay attention to the temperature and speed of the machine. When the fuselage is unstable, you should pay attention to check whether the gap between the couplings is too tight, and adjust it in time.
The granulator should run forward and avoid reverse. The granulator must be fed and run.