Disc granulation is a widely used granulation technology in chemical, fertilizer, and building materials industries. It transforms powdered materials into uniform granules through the rotation of a disc. Its high efficiency and stability have made it a core process in industrial production.
The core principle of this process is based on the synergistic effect of the material's adhesive properties and mechanical force. During operation, powdered raw materials are fed into an inclined rotating disc, while a suitable binder (such as water, slurry, or a special binder liquid) is sprayed through a spray system. The rotation of the disc generates centrifugal force, gravity, and friction, propelling the material through complex rolling motions within the disc. The powdered particles gradually absorb the binder and agglomerate, growing from tiny particles into uniformly sized spherical particles. When the particles reach the set size, they overflow from the edge of the disc due to gravity, completing the granulation process.
The disc granulator is a key piece of equipment in the process, and its structural design directly affects the granulation effect. The equipment mainly consists of a disc body, a transmission system, an inclination angle adjustment device, and a spraying system. The disc inclination angle is typically adjustable between 30° and 55°, and the rotation speed is controlled by frequency converter to adapt to the granulation requirements of different materials. High-quality disc granulators also feature wear-resistant liners and uniform material distribution to ensure equipment lifespan and stable particle quality.
Compared to other granulation processes, disc granulation has significant advantages: First, it offers high particle formation rates, exceeding 85%, with good particle strength and uniform size, resulting in low subsequent screening load; second, it has low energy consumption, with minimal energy loss during operation, leading to more cost-effective production; third, it is flexible in operation, allowing for rapid adaptation to different material characteristics by adjusting the disc inclination angle, rotation speed, and binder dosage; and fourth, it has a simple structure, is easy to maintain, has a low failure rate, and is suitable for large-scale continuous production.
Currently, disc granulation technology is widely used in fertilizer production, mine tailings treatment, and new building material processing industries. In the fertilizer industry, it can process powdered raw materials into granular fertilizer, improving fertilizer utilization. In the environmental protection field, it can treat industrial waste residue, realizing the resource utilization of waste. With continuous technological upgrades, disc granulation technology is developing towards intelligence and high efficiency, providing solutions for the granulation needs of more industries.