Disc granulators, with their unique operating principle, play a crucial role in the pelletizing process in industries such as fertilizer, metallurgy, and building materials. They utilize the rotating tilted disc to cause the material to tumble and agglomerate under the combined effects of centrifugal force, gravity, and friction, ultimately forming uniform granules. However, their performance is not perfect, and their advantages and disadvantages contrast sharply.
Disc granulators have significant advantages. First, their structure is simple and easy to operate. The core components are the tilted disc, transmission mechanism, and frame, making assembly and maintenance easy. Even ordinary workers can master them after a short training session, reducing labor costs. Second, they offer stable granulation results. By adjusting the disc speed, tilt angle, and material moisture content, the particle size can be precisely controlled, achieving a particle size uniformity of over 85%, meeting the quality requirements of most industries. Third, they offer low energy consumption and cost. Compared to equipment such as extrusion granulators, disc granulators utilize a lower motor power, consuming only 60%-70% of the energy consumed per unit of output. Their low purchase cost makes them suitable for small and medium-sized enterprises.
However, disc granulator machines have limitations that cannot be ignored. On the one hand, there is a significant conflict between energy consumption and efficiency. While their unit energy consumption is low, the processing capacity of a single machine is relatively small. To meet large-scale production needs, multiple units must be connected in parallel, which increases overall energy consumption and floor space. On the other hand, pellet strength and compatibility are limited. The finished pellets have low density and weak compressive strength, making them prone to breakage during transportation. Furthermore, materials with excessive viscosity or poor flowability are prone to sticking to the wall and clumping, making proper pelletization difficult. Furthermore, the production environment requires strict control, and material humidity must be maintained within a specific range (typically 20%-30%). Excessive humidity fluctuations can lead to pelletizing failure, placing high demands on temperature and humidity control in the operating environment.
Overall, disc granulators have clear advantages in small and medium-sized production scenarios and for applications requiring medium- and low-strength pellets. However, there is still room for improvement in large-scale production requiring high pellet strength. Future technological upgrades, such as optimizing the disc structure and improving the material distribution method, are expected to further enhance their advantages, address shortcomings, and expand their application.