Twin roll granulator is famous in the fertilizer production industry for dry granulation. It requires the moisture content of the material to be less than 5%. In addition, the roller press granulator is suitable for the production of special compound fertilizers of high, medium and low concern, such as the production of diammonium phosphate, nitrogen, phosphorus and potassium, and urea fertilizers.
In general, a twin roll granulator includes 4 main components.
• The frame part is an integral structure made of high-quality carbon steel plate. All other parts need to be assembled in the rack section. Also, there are holes around the machine. Easy to unload and transport.
• The transmission part refers to the motor drive pulley, V-belt and reducer. This part mainly provides force when the double-roller granulator is working.
• The extrusion granulation part is the key part of the drum granulator. In a complete twin roll granulator there are two rolls which compress the powdered material into large pieces.
• The crushing and separation part is to crush the extruded large flakes into uniform particles. The off-spec fertilizer granules are then separated and need to be returned to the granulation section.
Why choose a twin-roller granulator to produce granular fertilizer?
•Widely applicable to various raw materials. You can not only use twin roll processing machines on npk fertilizer production lines. But it is very applicable in pharmaceutical, chemical, metallurgy, coal, feed and other industries.
• Reduced investment. Extrusion granulators make fertilizer granules at room temperature. So you don’t buy fertilizer dryers and coolers.
• No waste pollution discharge. Our drum granulator uses electricity as the main power. Therefore, the pollution to the environment will be reduced.
• High granulation rate. The ball forming rate of the double-roll granulator is over 90%.
Non-drying granular fertilizers include urea, ammonium phosphate, compound fertilizer, potash fertilizer granules, etc., fertilizer granulation is one of the development trends of fertilizers. Compared with powdered fertilizers, granular fertilizers have good physical properties, no dust, long-term storage and no agglomeration, good fluidity, easy to spread fertilizer, and can realize aircraft sowing. At the same time, it can also play a slow-release effect and improve fertilizer performance. Utilization rate. There are three common methods for processing this kind of non-drying granular fertilizers: disc granulation, recrystallization and extrusion granulation. After long-term practical experience, we recommend using a pair-roll extrusion granulator to process non-drying granular fertilizers. , This kind of processing using a pair of roll extrusion granulator is more practical.
Dry powder-free processed granular fertilizers are mainly used for processing compound fertilizers and compound fertilizers. As the raw material of compound fertilizer, powdery is suitable, but as fertilizer for direct use, granular fertilizer is better than powdery products. The common processing methods of dry granular fertilizer include disc granulation, recrystallization and extrusion granulation. The three granulation methods have their own characteristics.
Comparison of three methods of non-drying granular fertilizer processing
Disc granulation. Disc granulation requires adding a binder to the powder, and at the same time it is obtained by drying and sieving. This method requires the addition of ineffective ingredients such as binder (usually clay) and water to reduce the nutrient content of the product.
Recrystallization method. The powder is dissolved in water, cooled, crystallized and separated into crystals and then crushed and sieved. The method has a complicated process, high cost, high consumption, and low market competitiveness.
Extrusion granulation method. A tablet press or an extrusion granulator is used to forcibly squeeze the powdered potassium fertilizer into tablets, which are then made into granules through processes such as slicing, granulating, and sieving. There are two types of extrusion granulation: roller type and wheel roller type. The roller type extrusion is firstly pressed into large pieces and then crushed into particles. In this way, the device has large capacity, high particle strength and low energy consumption. The wheel rolling type is to directly squeeze the material into a cylindrical strip in the laminating film, and then cut it into columnar particles. Most of the extrusion granulation methods currently used in China are wheel pulverization, and the production scale is small. A single double roller granulator machine can only reach 3~5t/h, and the granulation strength is limited, the mold is damaged, and the production is cylindrical granules. , Poor flow performance and other characteristics.
The double-roll extrusion granulator has obvious advantages in processing non-drying granular fertilizers
The roller squeezing granulator adopts rolling molding and crushing into granules. Extrusion granulation production has a wide range of raw material routes. At present, there are more than 20 kinds of materials that have been successfully used for extrusion granulation: ammonium nitrate, urea, ammonium chloride, calcium nitrate, potassium chloride, potassium sulfate, etc. In addition, the extrusion granulation process can flexibly realize the replacement of product formulas in a very short time, and a set of equipment can produce products with more than 30 formulas.
The design of the roller extrusion granulator is very reasonable, very practical, and low energy consumption. It can be continuously produced without drying at room temperature and once rolled and formed. The ball and socket on the roller can be manufactured according to the size and shape of the customer’s needs. At present, we There are spherical, pillow-shaped, semi-circular grain, rod, pill shape, walnut shape, oblate shape, and square shape. It is now used as a new energy-saving product in the compound fertilizer and organic fertilizer industry.
Organic fertilizer equipment manufacturers not only provide equipment products, but also provide technical services. The intervention of equipment manufacturers is inseparable from the preparation of the pig manure organic fertilizer processing production line from the early stage to the later stage of production, from ground infrastructure guidance, process design, equipment customization, equipment installation, customer technical personnel training, after-sales technical guidance, etc. , All need the service and support of the equipment manufacturer. A company with a good reputation, good service and good reputation is the consideration for choosing a pig manure organic fertilizer equipment manufacturer.
The roller extrusion granulator belongs to the extrusion slip model. Its working principle is: the belt and pulley are driven by the motor, transmitted to the driving shaft through the reducer, and synchronized with the driven shaft through the split gear, and work in opposite directions. The material is added from the hopper, formed by the pair of rollers, demoulded and pelletized, and then sent to the crushing screen studio through a pair of chains, where the finished product particles (balls) are screened and separated, and then the returned material is mixed with the new material. Then granulate. With the continuous rotation of the motor and the continuous entry of materials, mass production can be realized.
The double-roller extrusion granulator produced by FPC is green and environmentally friendly and has no three wastes emissions during the production process. FPC is one of the companies that have passed the environmental assessment certification. With an annual output of more than 1,000 pairs of roll granulators, they are sold to all regions of the country, and even all over the world. Choosing FPC will give you no worries.
Process introduction of inorganic organic fertilizer extrusion granulation production line:
Add the qualified raw materials into the mixer according to the ratio requirements and mix them evenly.
Transport to the disc feeder, and remove the ferrous materials from the material during the transportation process.
The material in the disc feeder evenly enters the extrusion granulator.The material is forced to pass between the two pressure rollers to be squeezed into flakes. The flakes are broken into pieces by the coarse crusher under the pressure rollers. Screening; the materials on the screen continue to be crushed and screened.
The semi-finished products are transported to the finished product screening machine; the fine particles after screening are directly returned to the disc feeder,the large particles are crushed by the crusher and then returned to the disc feeder.
The production of compound fertilizer by extrusion granulation process has the following advantages and disadvantages
Extrusion granulation does not require heating and humidification of the materials, which saves investment and energy, and can also be adapted to the granulation of ingredients containing heat-sensitive materials, such as ammonium bicarbonate and certain organic fertilizers.
No waste water or waste gas is discharged outside during the production process, and it will not pollute the environment.
There are no special requirements on the properties and particle size distribution of the raw materials, so the source of raw materials is relatively wide.
The production is more flexible, and the product plan can be changed at any time, which is conducive to the production of special fertilizers in small batches.
The product has uniform particle size distribution, no segregation or agglomeration.
The shape of extrusion granulation products is not as round as the particles produced by traditional methods such as drum granulation and slurry granulation; if chemical reactions occur between the ingredients in the product particles, the particles may collapse.
With the development of environmental protection and organic agriculture, the use of organic wastes to produce organic fertilizers through biological fermentation has been rapidly developed, making the treatment of organic wastes harmless and resourceful. However, most of the organic fertilizer obtained by biological fermentation is coarse powder or irregular small lumps, which is very inconvenient to use, and is particularly unfavorable for large-area machine sowing. Making the coarse powder or irregular small pieces of organic fertilizer obtained by biological fermentation into spherical granular organic fertilizer is the key to solving the problem of large-scale popularization and use of organic fertilizer.
FPC will explain to you how the organic fertilizer production line makes organic fertilizer into pellets. The coarse powder or irregular small pieces of organic fertilizer after biological fermentation are characterized by high water content (30-40%) and looseness ( The bulk density is 0.3～0.4t/m3), and the fiber is much. The existing organic fertilizer in the form of coarse powder or irregular small pieces after biological fermentation is made into spherical granular organic fertilizer.
Some manufacturers use traditional discs or drums to granulate, and need to dry coarse powder or irregular small pieces of organic fertilizer (moisture content <15%) and crush them into very fine powder (greater than 100 mesh) . Then add the binder and inorganic fertilizer, and the addition amount of the binder and inorganic fertilizer in the organic fertilizer cannot be greater than 30%. Although this method can be made into spherical particles, the organic fertilizer in the processing process will be crushed by sufficient precipitation, then be granulated by adding water and then dried, repeated many times, so the processing cost is quite high. Moreover, due to the low density of organic fertilizer, the particle strength is low, which is not conducive to storage, transportation, and machine seeding.
There are also some manufacturers who first dry coarse powder or irregular small pieces of organic fertilizer until the moisture content is only 20-25%. Then, a flat die extrusion granulator or a pair-roll extrusion granulator is used to squeeze the dried organic fertilizer into columnar or oblate spherical particles. Although this method is more convenient to use, the fluidity is still not good, it is not suitable for machine broadcast, and the appearance is poor and the appearance is not good.
Some manufacturers first use flat die extrusion granulatorto squeeze the coarse powder or irregular small pieces of organic fertilizer into short columnar particles (due to high water content and high fiber content, columnar particles also have a certain degree of plasticity). Then, it is polished to form spherical particles, and then the spherical particles are dried, cooled and sieved to obtain qualified particles. In this method, the raw materials do not need to be processed, the moisture sequence is reduced in steps, and the production cost is greatly reduced. However, this method also has some fatal weaknesses, that is, organic fertilizer is easy to arch, easy to block and easy to bond equipment, and at the same time, the output is small and the power consumption of the extrusion process is high.
Therefore, in summary, the organic fertilizer industry urgently needs to introduce a large-yield, low-energy compression granulating equipment to overcome the easy arching, easy blocking, easy bonding equipment, and small output of the traditional granulator. And the shortcomings of high power consumption in the extrusion process.
The roller extrusion granulator machine is the main equipment for making compound fertilizer, compound fertilizer and organic fertilizer compound fertilizer. It adopts the normal temperature extrusion process to extrude various raw materials at one time, with high ball formation rate and very little return material, so it is widely used. Moreover, the roller granulation equipment has reasonable design, simple operation, convenient maintenance, and stable operation. The most important thing is that its investment cost is the lowest compared to other pelletizers. The roller extrusion granulator is also suitable for a wide range of materials. It can not only process materials in the dry powder state such as ammonium chloride, urea, and ammonium phosphate, but also process other raw materials for organic fertilizer machines. It has a significant effect in reducing production costs and efficiency. And the price of such a practical double-roller extrusion granulator is about several thousand dollars.
Use dry hair granulation technology to realize the granulation process of various organic fertilizers and compound fertilizers, eliminating the need for drying equipment in wet granulation.
Compared with the traditional wet granulation process, this process will reduce your investment cost by more than 30%.
The granulation success rate is as high as 98%, and there is almost no material return, which saves production costs.
The organic fertilizer compound fertilizer particles produced by this equipment have high strength and high density, which are more conducive to transportation and storage.
Special abrasive tools can be customized according to user needs. The shapes of abrasive tools are diversified and suitable for various industries.
There are a variety of specifications for the roll extrusion granulator, which are mainly determined according to your annual output requirements. Our company has always adopted the factory direct sales model. We are not only selling equipment, but more importantly, solving various production technical problems for customers. We have experienced fertilizer production technical engineers throughout the planning and guidance, you are welcome to consult in detail at any time, let me be your free technical consultant.