A disc granulator is a molding machine that processes powdered material into specific-shaped granules. Here is a detailed introduction to its features and applications.

1. Structural Components

1. Granulating Disc: This is the core component of the disc granulator. It typically features an integral arc structure with a high-strength fiberglass liner, providing excellent wear and corrosion resistance. The disc consists of a main body and adjustable sections along the edge, which can be moved up and down. The ends of these sections have an edge flange to ensure the pellets are not damaged or torn as they exit the disc.
2. Drive Section: This includes the electric motor, reducer, pulleys, and gears. The reducer is connected to the motor by a flexible belt drive, which ensures smooth startup, reduces impact force, and extends the equipment's service life. The reducer's input shaft is equipped with a pulley, and the output shaft has a small gear that drives the rotation of the granulating disc.
3. Frame and Base: The frame supports the granulating disc and the drive section. The base is designed to be extra thick and heavy for enhanced sturdiness and durability, eliminating the need for anchor bolts. This design ensures stable and smooth operation of the equipment.
4. Scraper Device: This device consists of a non-powered combined scraper and a corner scraper. The combined scraper is used to clear the edges and bottom of the disc, while the corner scraper cleans the corners. This, combined with the disc's unique surface treatment, effectively removes material buildup and clumping, ensuring optimal granulation results.
5. Inclination Adjustment Device: This mechanism, often using angle shims, allows for flexible adjustment of the granulating disc's tilt angle to accommodate different materials and granulation requirements.

2. Working Principle

Various dry powder materials are fed from the top of the machine. The powder first passes through a pre-wetting mixer to form uniform spherical cores, or it can be added directly to the granulating disc with a suitable amount of water sprayed on top. As the disc rotates, the cores move in a parabolic path under the influence of centrifugal force, friction, and gravity. Due to the material's adhesion and plasticity, the cores stick together and gradually grow into granules. As the granules roll toward the edge of the disc due to centrifugal force, they continuously pick up more powder, growing into spherical pellets. Once they reach the desired diameter, the finished spherical granules are discharged from the disc.

3. Key Features

1. High Granulation Rate: The granulation is uniform, with a particle formation rate of over 93%. It consistently produces spherical granules with uniform particle size.
2. Easy Operation and Maintenance: The structure is relatively simple, making operation intuitive and maintenance straightforward. This reduces labor intensity and overall maintenance costs.
3. Flexible Process Layout: The new disc granulator models are lighter and have a lower profile, allowing for a flexible and convenient process layout, making them suitable for upgrading older facilities.
4. Low Power Consumption: The unique integrated design of the non-powered combined scraper reduces auxiliary power consumption. Additionally, the large disc is composed of a main body and sections, which helps reduce the main motor's power requirements.

4. Scope of Application

The disc granulator is widely used in industries such as bio-organic fertilizer, compound fertilizer, medicine, chemicals, feed, coal, and metallurgy. It can process powdered, granular, or small lump materials like pulverized coal, cement, clinker, limestone, shale, coal gangue, clay, livestock manure, straw, and sludge.

5. Components of the Disc Granulator

5.1 Power Transmission System

1. Electric Motor: Provides the power source for the disc granulator, converting electrical energy into mechanical energy through rotation. An appropriately sized motor is selected based on the granulator's operational needs.
2. Reducer: Connects the motor to the pinion gear. It reduces the motor's high rotational speed to a speed suitable for the granulator's operation while increasing torque, providing enough power for the disc to granulate the material.
3. Belt Drive: Generally consists of pulleys and a belt, used to connect the motor and the reducer's input shaft to transmit power. This type of drive ensures smooth startups and reduces impact force, protecting components like the motor and reducer and extending the equipment's service life.
4. Pinion and Main Gear: The pinion on the reducer's output shaft meshes with the main gear fixed to the bottom of the disc, further transmitting power to drive the disc's rotation.

5.2 Granulating Disc System

1. Disc: The core component of the granulator, typically featuring an integral arc structure with both right-angle and rounded types. The disc is usually made of high-strength steel plates, with multiple reinforcing ribs on the bottom to increase its durability and rigidity, preventing deformation. Some discs are lined with high-strength fiberglass or stainless steel to provide corrosion protection.
2. Main Shaft: Supports the entire granulating disc. One end is fixed to the center of the disc's bottom, while the other is mounted on the frame or a movable section via a bearing seat. This ensures the disc's stability and concentricity during rotation.
3. Roller Bearings: Mounted on the main shaft within the bearing seat, they reduce friction between the shaft and the seat, allowing for smooth rotation. They also bear the weight of the disc and material, as well as the centrifugal force generated during rotation.
4. Bearing Seat: Used to hold the roller bearings and transfer the weight of the main shaft and disc to the frame. It is typically made of high-strength cast iron or cast steel, providing sufficient strength and rigidity.

5.3 Auxiliary Device System

1. Scraper Device: Consists of a scraper frame and a non-powered scraper, installed above or at the edge of the disc. The scraper's function is to clean material sticking to the disc walls and bottom, preventing buildup and ensuring proper rotation and granulation. It also helps to uniformly distribute the material across the disc.
2. Inclination Adjustment Device: Common structures include screw rods or reverse pull rods. By adjusting the angle between the disc and the horizontal plane, you can change the material's rolling path and residence time, thereby controlling the size and shape of the granules to suit different materials and process requirements.
3. Automatic Cleaning Device: Generally installed above the granulating disc in a "lower box" shape with an automatic cleaning plate. During production, this device can promptly clean material sticking to the disc walls, further extending the equipment's lifespan, saving labor, and improving the quality and efficiency of granulation.
4. Frame and Base:
   • Frame: Typically welded from high-quality carbon steel channels, it serves as the supporting structure for the entire granulator. It holds and secures the power transmission, granulating disc system, and other auxiliary devices. It must have sufficient strength and rigidity to handle the various loads during operation.
   • Base: Usually welded from steel plates or H-beams, it is located at the bottom of the frame and stabilizes the entire unit. A thick, heavy, and sturdy base design allows the machine to operate smoothly without the need for anchor bolts, ensuring stability and preventing shaking or vibration during operation.

6. How to Choose a Disc Granulator

Choosing a disc granulator requires a comprehensive evaluation of material properties, production needs, equipment performance, auxiliary systems, and the manufacturer's reputation. Here are the key selection criteria:

1. Select Based on Material Characteristics The physical and chemical properties of different materials have a significant impact on the granulator's requirements. For sticky materials (e.g., clay, sludge), you need a granulator with strong anti-sticking capabilities. Look for a disc with a special wear-resistant, anti-stick coating (like polyurethane). The disc's tilt angle and speed should also be adjusted to prevent material from sticking to the walls. For granular materials (e.g., crushed ore), focus on the disc's ability to compress and agglomerate the material. Choose a disc surface with high hardness and wear resistance (like high-manganese steel) to extend the equipment's life. For corrosive materials (e.g., fertilizer raw materials), the disc and all contact parts must be made of corrosion-resistant materials (like stainless steel) to prevent damage.
2. Determine Parameters Based on Production Needs
   • Output Requirements: The granulator's output is directly related to the disc's diameter. Generally, a larger diameter means higher output. Common diameters are 1.5, 2, and 3 meters. A 1.5-meter disc has an output of about 1-3 tons per hour, while a 3-meter disc can reach 10-15 tons per hour. Choose the appropriate diameter based on your production scale.
   • Particle Size: If you need to produce a specific particle size (e.g., 2-5mm, 5-10mm), pay attention to the disc's tilt angle and speed. The disc's angle is usually between 30° and 50°. A smaller angle means the material stays on the disc longer, resulting in larger particles. The speed affects the intensity of the material's rolling. A speed that is too high will cause granules to be thrown off, while one that is too low will make it difficult to form qualified granules. A variable-speed drive allows for precise control of particle size.
3. Focus on Core Equipment Performance
   • Structural Stability: The granulator frame should use a heavy-duty steel structure to ensure it won't shake or deform during long-term operation, which would affect granulation quality. The connection points between the disc and the frame must be secure, and the bearings and other transmission parts should be high-quality to ensure smooth operation.
   • Transmission System: Prioritize equipment that uses gear drives or cycloidal pinwheel reducers. These drive systems are reliable, have low power loss, and are easy to maintain. Avoid belt drives, as they can slip and affect speed stability.
   • Adjustment Flexibility: The disc's tilt angle and speed should be easily adjustable. A variable-speed control feature is highly recommended, as it allows for quick adjustments to meet the needs of different materials and quality requirements, improving production efficiency.
4. Emphasize Auxiliary System Configuration
   • Feeding and Spraying System: Uniform feeding and water spraying are crucial for consistent granule quality. Choose equipment with a screw feeder or belt feeder to ensure the material is evenly distributed on the disc. The spraying system should use atomizing nozzles to evenly mist the water onto the material, preventing localized over- or under-wetting.
   • Dust and Environmental Control: The granulation process, especially with dry materials, can generate dust. The machine should be equipped with a dust collection system (like a baghouse filter) to reduce dust pollution and meet environmental regulations. For materials with odors, consider adding a waste gas treatment device.
5. Evaluate Manufacturer's Reputation and Service Choose a manufacturer with a proven track record and a certain production scale, as this generally guarantees higher equipment quality. You can check the manufacturer's certifications, past projects (e.g., collaborations with large fertilizer or wastewater treatment plants), and customer reviews. The manufacturer's after-sales service is also crucial. Confirm that they provide installation, commissioning, staff training, maintenance services, and have a reliable supply of spare parts to prevent production downtime in case of a breakdown.
6. Consider Cost and Value While meeting your production needs, compare the equipment's purchase price, operating costs (e.g., energy consumption, maintenance), and lifespan. Don't simply look for the lowest price. A cheaper machine might use lower-quality materials and have unstable performance, leading to high maintenance costs in the long run. Choose a machine with high value to ensure a good return on your investment over time.

In summary, when selecting a disc granulator, you need to thoroughly analyze your own needs, and then evaluate material properties, production parameters, equipment performance, and the manufacturer's reliability to ensure the equipment operates stably and efficiently to meet your production requirements.

7. Disc Granulator Pricing

Pricing is determined by customer requirements, including product specifications, material of construction, and capacity. Please contact our sales team for a specific quote.

8. About Our Company and Products

Founded in 1997, Tai'an Hongxin Environmental Protection Technology Co., Ltd. is located at the foot of Mount Tai, one of China's most famous mountains. Our facility spans 100,000 square meters, with 66,000 square meters of floor space. We hold an A2 pressure vessel manufacturing license and are ISO9001 certified. We are a high-tech enterprise in Shandong Province, a strategic partner of the Shandong Academy of Agricultural Sciences, and a member of the National Fertilizer Industry Technology Innovation Alliance.

Our team consists of 216 technical staff and over 100 sets of large, precision, and specialized processing equipment. Our professional technical and manufacturing teams provide comprehensive services, including technical consultation, process design, installation, commissioning, personnel training, and full turnkey project solutions. We also guarantee excellent after-sales service. Our products are sold both domestically and internationally, with exports to countries like Indonesia, the UAE, Malaysia, Vietnam, Bangladesh, and Myanmar.