Disc granulator

The disc granulator—also known as a pelletizing disc, disc-type granulator, or disc pelletizer—is a granulation device that utilizes a rotating disc to transform powdery materials into granules. It is widely used for granulating organic fertilizers, compound fertilizers, animal feed, and chemical raw materials, and is also suitable for continuous, uniform feeding and proportioning in industries such as pharmaceuticals, food processing, ceramics, iron and steel, and mining.

The granulator features a disc body with an arc-shaped design, typically lined with high-strength fiberglass-reinforced plastic (FRP) or stainless steel. It is characterized by uniform granulation, a high pelletization rate, stable operation, robust construction, and a long service life. Capable of achieving a pelletization rate exceeding 93%, it serves as a core piece of equipment for the granulation of powdery materials.

Structural Composition of the Disc Granulator

The disc granulator is primarily composed of the following major components:

(I) Granulating Disc: This is the core working component of the equipment. It is fabricated from welded steel plates of varying thicknesses; the disc bottom is reinforced with a radial steel plate structure, and the disc rim features an integrated arc design. The interior of the disc is lined with high-strength fiberglass-reinforced plastic (FRP) for corrosion resistance and durability.

(II) Transmission System: This includes the electric motor, speed reducer, pulleys, pinion gear, and main gear. A flexible belt drive connects the motor and reducer, ensuring smooth startup and shock absorption. The main gear is specially mounted on the main shaft—which is fixed to the frame's adjustment plate—to support the operation of the entire granulating disc. The main gear undergoes high-frequency quenching treatment, effectively doubling its service life.

(III) Frame and Base: Constructed from welded channel steel, the base features a thickened, weighted, and robust design, allowing for stable operation without the need for anchor bolts.

(IV) Scraper System: Comprising a non-powered composite scraper, a bottom-cleaning scraper, and a rim-cleaning scraper, this system removes material adhering to the disc bottom and rim.

(V) Angle Adjustment Mechanism: Flexible adjustment of the disc's inclination angle is achieved via an adjustment screw rod and locking nut; the adjustment range is typically between 35° and 55°.

(VI) Electrical Control System: This includes electrical components such as a power distribution box, switches, contactors, and relays, used to control the equipment's startup, shutdown, and operational parameters.

Application Scope of Disc Granulators

Disc granulators have an extremely wide range of applications. In the fertilizer industry, they serve as core granulation equipment for producing organic, bio-organic, inorganic, compound, and blended fertilizers. In the cement industry, they are used to form raw meal powder into pellets before calcination in vertical kilns. In the metallurgy sector, they enable the pelletizing of materials such as iron concentrate for subsequent smelting. In the chemical industry, they are used to granulate various powdered chemical raw materials. Additionally, they are widely employed in sectors such as construction materials, animal feed, pharmaceuticals, food processing, and ceramics.

What raw materials can the disc granulator process?
The disc granulator is capable of processing a wide variety of raw materials. In organic fertilizer production, these include livestock and poultry manures (such as chicken, pig, and cattle manure) as well as organic wastes like municipal refuse, sludge, crop straw, and peat. For compound fertilizer production, raw materials include nitrogen sources (such as urea, ammonium chloride, ammonium sulfate, and ammonium bicarbonate), phosphorus sources (such as single superphosphate, triple superphosphate, monoammonium phosphate, diammonium phosphate, and calcium-magnesium-phosphate fertilizer), and potassium sources (such as potassium chloride). Additionally, the machine can process non-sticky powdery materials such as coal dust, cement, clinker, limestone, mineral powder, iron concentrate, and titanium dioxide.

Working Principle of the Disc Granulator
The working principle of the disc granulator is based on the combined motion of the material within the rotating disc. Upon entering the inclined granulating disc, the material moves along a parabolic trajectory under the combined influence of centrifugal force, friction, and gravity generated by the disc's rotation. As the material moves, it continuously tumbles and adheres to itself, forming initial seed granules; with the continuous addition and rolling of material, these granules grow by gradually accumulating surrounding fine powder. During this process, water or a binding agent is evenly sprayed onto the material to facilitate agglomeration into spheres. Once the granules reach the desired size, they naturally spill over the edge of the disc under the action of centrifugal force, enabling continuous discharge.
Core Advantages of the Disc Granulator
The disc granulator offers several outstanding advantages: first, it achieves a high pelletization rate with uniform, spherical granules and minimal material recycling, resulting in a finished product yield exceeding 93%; second, the equipment features a streamlined structure, an intuitive operating interface, and easy maintenance; third, it is highly adaptable and capable of processing various types of powdery materials; fourth, the investment cost is relatively low, offering savings of approximately 30% compared to other granulation processes; and fifth, it operates with low energy consumption, prevents dust emissions during production, and ensures a favorable working environment.
Who are the target users for disc granulators?
The primary target audience for disc granulators includes equipment procurement and technical personnel from organic fertilizer manufacturers; production managers at compound and blended fertilizer plants; investors in livestock manure treatment projects; operators of urban sewage sludge and food waste resource recovery projects; process engineers from cement and metallurgical enterprises; and entities requiring powder processing capabilities in sectors such as feed processing, chemical manufacturing, and pharmaceuticals.