Enhancing Efficiency: The Role of Disc Pelletizers in Modern Manufacturing

disc-pelletizers-in-modern-manufacturing

Introduction

The main features of the disc pelletizer are its high degree of automation and less manual operation. The disc pelletizer has obtained a national patent and has low power consumption, which meets the basic needs of current users. Disc pelletizer has been widely used in fertilizer production and processing enterprises, but how can we choose a disc pelletizer that is satisfying to buy and use with confidence? Issues to note when analyzing the role of disc pelletizer in fertilizer production.

Compost turner machine process flow

  • A variety of basic fertilizers and additives are measured in batches according to the process formula requirements. After being stirred evenly by the mixer, they are transported together with the returned materials by the electronic metering belt into the composition turner machine. Sulfuric acid with a concentration of 98% or 93% is purchased from a tank truck and stored in a sulfuric acid storage tank.
  • It is pumped into a sulfuric acid dilution storage tank and measured for granulation needs.
  • The liquid ammonia is evaporated into gaseous ammonia and transported into the composition turner machine through pipelines. Ammonia and sulfuric acid react continuously in the pipeline in the granulator and directly enter the material layer of the composite turner machine for granulation.
  • The materials are agglomerated and granulated in the composition turner machine under the regulation of temperature and steam at 70-80℃. After the granulated wet materials are cooled and hardened on the belt conveyor, they then enter the dryer for drying and dehydration.
  • The dried materials are transported to the screening machine by the elevator.
  • The screened large particles are crushed and returned to the granulator together with the fine materials under the screen for further granulation. Qualified particles are treated with moisture-proof and anti-caking coatings and then air-cooled before entering the finished product for re-screening, measurement and packaging.
  • The packaged finished products are transported to the warehouse by transfer vehicles for storage.
    The exhaust gas generated by the compost turner machine is extracted by the ventilator and sent to the exhaust gas washing device system for cleaning. Dry hot air is provided by a hot air stove through a hot air fan. The dried exhaust gas is dusted by a high-efficiency cyclone dust collector, then sent to the scrubber by the exhaust fan for washing and emptied from the chimney.
  • The washing water from the washing tower is recycled, and part of it is pumped into the sulfuric acid dilution storage tank for dilution and supplementary water. The washed exhaust gas is discharged into the atmosphere.
    NH3+HSO4=NH3(HSO4)+heat

granular compost principle

  • Granular compost technology utilizes the characteristics of molten urea, monoammonium phosphate, and potassium chloride to form eutectic compounds.
  • After heating powdered monoammonium phosphate, potassium chloride, additives, etc., they are added to the molten urea to form a compound through reaction.
  • The NPK eutectic melt with good fluidity is then sprayed into the compound fertilizer granulation tower through a special nozzle, and is cooled and solidified in the air into particles to obtain a compound fertilizer with uniform nutrient distribution and good particle properties.
  • Product specifications include: 24-12-12, 23-11-11, 24-0-24, etc.
    The production process is mainly divided into three parts: raw material processing, granulation, and cooling treatment.
  • High-tower granulation technology mainly utilizes granular compost. This technology was first used in monoammonium phosphate (MAP), ammonium nitrate phosphate (APN), and urea ammonium phosphate (UAP). In these production methods, potassium salt or other solid materials can be added to produce granular nitrogen, phosphorus and potassium compound fertilizer products.
  • According to the different granulation methods, the granular compost compound fertilizer production process can be mainly divided into: granulation tower spray granulation process, oil cooling granulation process, biaxial granulation process, drum granulation process, spray granulation process , disc granulation process, steel belt granulation process, etc. The earliest and most widely used granulation tower spray granulation process is the granulation of single nitrogen fertilizers (such as urea, ammonium nitrate, etc.), and has now been expanded to the granulation of nitrogen, phosphorus and nitrogen, phosphorus and potassium compound fertilizers. Stamikaben Company of the
  • Netherlands used a granulation tower spray granulation process to produce potassium ammonium nitrate phosphate; Norwegian Hydro used a granulation tower spray granulation to produce urea ammonium phosphate and urea ammonium potassium phosphate.
  • A special requirement of this process is that the potassium chloride must be ground finely to prevent the holes of the granulation nozzle from clogging, and it needs to be preheated to a high enough temperature to prevent the melt from cooling during mixing.

Pelletized poultry manure principle

  • The water in the slurry (mixture, solution and solute) (general name for liquids that can be vaporized) is sprayed into a device, and the water in the slurry is vaporized and separated by heating and pressure, and the remaining The process in which solids that do not gasify (under certain conditions) form granular forms is called pelletized poultry manure.
    The main difference from ammoniated granulation is in the granulation method. In pelletized poultry manure, the self-granulated particles form a material curtain in the form of returned material, which is combined with the sprayed slurry and coated layer by layer to form granules.
  • In ammonia granulation, a certain amount of gas ammonia is introduced into the drum to continue neutralization and generate heat to evaporate and take away part of the water. Its granulation method is mainly bonding and granulation.
    Although the processes are very similar, the moisture content of the slurry entering the granulator is different between the two. The pelletized poultry manure is generally about 30%, while the ammoniated granulation is generally about 15%.
    High-tower granulation is mainly the melting and granulation of materials. The moisture content of the materials is very low, about 2%. The granulation method is self-granulation. Generally, the nitrogen content is very high, generally above 20%, so it is instant and quick-acting.
  • As for slow-release fertilizers, there are various types and processing forms. Currently, the two most popular ones are endoplasmic and external. Endoplasmic agents such as urease inhibitors and nitrification inhibitors are added to the endoplasm, or polyaspartate is added to the endoplasm. Acid, etc., there are sulfur coatings, resin coatings, some inorganic coatings like some phosphates, etc., and some chemical controlled release ones such as urinary formaldehyde, etc. The production processes are different.
  • The slurry temperature of pelletized poultry manure is generally only about 110~120 degrees, while the temperature of ammoniated granulation slurry is generally between 220~280 degrees, which is much higher than that of pelletized poultry manure.
  • The main difference between pelletized poultry manure and ammoniated granulation is the granulation method. In pelletized poultry manure, the self-granulated particles form a material curtain in the form of returned material, which is combined with the sprayed slurry and coated layer by layer to form granules. .
    During ammoniation granulation, a certain amount of gas ammonia must be introduced into the drum to continue neutralization and generate heat to evaporate and take away part of the water. Its granulation method is mainly bonding and granulation.