How to use disc granulator to make 10 t/h zeolite pellets

Disc granulator, also known as plate granulator machine, is a widely used fertilizer granulator machine in the production of zeolite pellets. It is a popular choice for making 10 t/h zeolite pellets due to its high efficiency, easy operation, and low cost. In this passage, we will discuss how to use a disc granulator to make 10 t/h zeolite pellets.

Preparation before Granulation

Before using the disc granulator to make zeolite pellets, it is important to prepare the raw materials. Zeolite powder should be mixed with a binder to ensure the pellets have the right consistency and strength. The binder can be water, clay, or any other suitable material that can help the zeolite powder stick together. The mixture should be thoroughly mixed to ensure a uniform consistency.

Setting up the Disc Granulator

Once the raw materials are prepared, the next step is to set up the disc granulator. The granulator should be placed on a flat and stable surface to ensure it operates smoothly. The angle of the disc should be adjusted to the desired level, usually between 40 to 60 degrees. The rotation speed of the disc should also be set according to the manufacturer’s instructions.

disc zeolite pellets making plant
disc zeolite pellets making plant

Feeding the Raw Materials

After setting up the disc granulator, the next step is to feed the raw materials into the machine. The feeding rate should be adjusted to match the capacity of the granulator, which is 10 t/h in this case. The raw materials should be fed evenly and continuously to ensure the pellets are of consistent size and shape.

Granulation Process

As the raw materials are fed into the disc granulator, they are subjected to a combination of centrifugal force, gravity, and friction. This causes the materials to roll and collide with each other, forming small pellets. The size and shape of the pellets can be adjusted by changing the angle of the disc and the rotation speed.

Drying and Cooling

Once the pellets are formed, they need to be dried and cooled before they can be used. The drying process removes any excess moisture from the pellets, while the cooling process helps to harden them. The pellets can be dried using a rotary dryer and cooled using a cooler or by air-drying.

Packaging

After the pellets are dried and cooled, they can be packaged for storage or transportation. The packaging material should be chosen based on the intended use of the pellets. For example, if the pellets are to be used as a feed additive, they should be packaged in food-grade bags.

In conclusion, using a disc granulator to make 10 t/h zeolite pellets is a straightforward process that involves preparing the raw materials, setting up the granulator, feeding the materials, granulating, drying and cooling, and packaging the pellets. By following these steps, you can produce high-quality zeolite pellets for various applications.

How to use disc pelleting machine to make zeolite granules

Introduction to Zeolite Granules

Zeolite granules are a type of natural mineral that has been processed into small, uniform pellets. These granules are commonly used in various industries, including agriculture, water treatment, and air purification, due to their high absorption capacity and ion exchange properties. One of the most efficient ways to produce zeolite granules is by using a disc pelleting machine.

Understanding the Disc Pelleting Machine

The disc pelleting machine, also known as a pan granulator, is a piece of equipment that is designed to convert fine powder or small particles into granules. The machine consists of a large, rotating disc that is angled at a specific degree to create the necessary force to form the granules. The disc is equipped with a scraper to prevent the material from sticking to the surface and to ensure even distribution.

Preparing the Zeolite Powder

Before the zeolite powder can be granulated, it must be prepared to ensure that it is the correct size and consistency. The powder should be sieved to remove any large particles or impurities that could affect the granulation process. It is also important to ensure that the powder is dry, as moisture can cause the granules to become clumpy and uneven.

Setting Up the Disc Pelleting Machine

Once the zeolite powder is prepared, the disc pelleting machine can be set up. The angle of the disc should be adjusted to the appropriate degree, which will depend on the size and density of the zeolite powder. The speed of the disc should also be set to the correct level, as this will affect the size and quality of the granules.

disc zeolite pellets making machine
disc zeolite pellets making machine

Granulating the Zeolite Powder

To begin the granulation process, the zeolite powder is fed into the disc pelleting machine. As the disc rotates, the powder is forced to the edge of the disc, where it begins to form small granules. The scraper helps to ensure that the granules are uniform in size and shape. The process continues until all of the powder has been granulated.

Drying and Cooling the Granules

After the granules have been formed, they must be dried and cooled to ensure that they are stable and ready for use. The granules can be dried using a rotary dryer or a fluidized bed dryer. Once they are dry, they can be cooled using a cooling conveyor or a rotary cooler.

Conclusion

Using a disc pelleting machine to make zeolite granules is an efficient and effective way to produce high-quality granules for various industries. By following the steps outlined above, manufacturers can ensure that their granules meet the necessary specifications and are ready for use.

What factors affect the cost of npk fertilizer granulator

Introduction

NPK fertilizer granulator is a machine used to produce granules of NPK fertilizer from raw materials. It is an essential equipment for fertilizer production. The cost of an NPK fertilizer granulator can vary greatly depending on various factors. In this passage, we will discuss the factors that affect the cost of an NPK fertilizer granulator.

Material Quality

One of the primary factors that affect the cost of an NPK fertilizer granulator is the quality of the materials used to make the machine. High-quality materials such as stainless steel or carbon steel are more expensive than lower-quality materials. The quality of the materials used will also affect the durability and longevity of the machine.

Size and Capacity

The size and capacity of the NPK fertilizer granulator also play a significant role in determining the cost. Larger machines with higher capacities will cost more than smaller machines with lower capacities. The size and capacity of the machine will depend on the production needs of the fertilizer manufacturer.

Technology and Features

The technology and features of the NPK fertilizer granulator can also affect the cost. Machines that are equipped with advanced technology and features such as automatic control systems, high-efficiency motors, and energy-saving designs will be more expensive than basic models. These advanced features can improve the efficiency and productivity of the machine, which can justify the higher cost.

npk compound fertilizer granulator
npk compound fertilizer granulator

Brand and Manufacturer

The brand and manufacturer of the NPK fertilizer granulator can also impact the cost. Well-known brands with a good reputation for quality and reliability may charge more for their machines. Additionally, manufacturers that offer better after-sales services such as installation, training, and maintenance may also charge more for their machines.

Market Demand and Supply

The market demand and supply of NPK fertilizer granulators can also affect the cost. When there is high demand for the machines and a limited supply, the cost may increase. Conversely, when there is low demand and an oversupply of machines, the cost may decrease.

Conclusion

The cost of an NPK fertilizer granulator is influenced by various factors including material quality, size and capacity, technology and features, brand and manufacturer, and market demand and supply. It is essential for fertilizer manufacturers to consider these factors when purchasing an NPK fertilizer granulator to ensure they are getting a machine that meets their production needs and budget.

How to make zeolite pellets in double roller granulator

Zeolite pellets are widely used in a variety of industries, including agriculture, water purification, and petrochemical processing, due to their high adsorption and ion exchange capacities. Making zeolite pellets involves pressing fine zeolite powder into a dense, uniform shape that is easy to handle and use. A double roller granulator is an equipment that can efficiently produce zeolite pellets through a dry granulation process without the need for binders or additional liquid. Below is the detailed process for manufacturing zeolite pellets using a double roller granulator.

Initial Preparation of Zeolite Powder

Sourcing and Milling Zeolite

The first step in the pellet-making process is to obtain zeolite in its raw form. The natural zeolite rocks are then milled into a fine powder, ensuring that the powder has the necessary particle size for granulation. Proper milling is crucial as it determines the flowability and compressibility of the material.

Preparing for Granulation

Once the zeolite powder is prepared, it’s important to ensure that the powder is free from moisture and any other impurities that might affect the integrity of the pellets. The powder can be dried in an oven or using a flash dryer to achieve an optimal moisture content that is suitable for dry granulation.

Setting Up the Double Roller Granulator

Equipment Calibration

Before starting the granulation process, it is essential to calibrate the double roller granulator machine. This involves adjusting the gap between the rollers to achieve the desired pellet size, as well as setting the correct pressure and roller speed. These parameters directly influence the pellet quality and should be carefully controlled.

Ensuring Uniform Feeding

For consistent pellet quality, the zeolite powder must be fed uniformly into the granulator. A feeder mechanism can be used to regulate the flow of powder between the rollers. This prevents overloading or insufficient feeding, which can lead to uneven pellet sizes or poor compaction.

The Granulation Process

Dry Granulation Method

The double roller granulator operates using a dry granulation process method, which does not require any additional binders or liquid. The zeolite powder is fed into the hopper and then conveyed into the compression zone between two rotating rollers.

Formation of Zeolite Pellets

As the powder passes through the rollers, it is compacted under high pressure, causing the particles to fuse together and form a sheet or ribbon of compressed material. The force applied must be sufficient to overcome the natural repulsion between particles and bind them together without any additives.

Sizing and Refining

Breaking Down Into Pellets

The sheet of compacted zeolite that emerges from the rollers is then broken down into smaller pellets. This is commonly achieved using a milling machine or a crushing system that is adjusted to produce pellets of the specified size.

Sizing and Classification

Once crushed, the pellets are classified using a series of screens to separate the correctly sized pellets from the fine powder and oversized particles. The correctly sized pellets are collected for further processing, while the fines can be recycled back into the granulation process.

Quality Enhancement

Polishing and Smoothing

To enhance the quality of the zeolite pellets and ensure a smooth surface, the pellets can undergo a polishing process. This step can also help to create a more uniform appearance and improve the flowability of the pellets for packaging and application.

Coating for Added Benefits

Depending on the intended use, zeolite pellets can be coated with specific materials to provide additional benefits, such as dust reduction, moisture protection, or to facilitate controlled release in certain applications.

Packaging and Storage

Packing for Distribution

Once the pellets have reached the required quality standards, they are packaged in appropriate containers or bags. Packaging must be sturdy enough to prevent damage during transportation and storage.

Optimal Storage Conditions

Zeolite pellets should be stored in a dry environment to preserve their structural integrity and adsorption properties. Proper storage conditions help in maintaining the efficacy of the zeolite pellets for extended periods.

Conclusion and Application

Final Product Ready for Use

The zeolite pellets produced by the double roller granulator are now ready for various applications. These pellets can be used in agriculture for soil amendment, in water treatment for removing contaminants, in the petrochemical industry for catalysis, or in any other application that exploits the unique properties of zeolites. And we can also make zeolite pellets in disc pelletizer.

In conclusion, producing zeolite pellets in a double roller granulator is an efficient and environmentally friendly process. It eliminates the need for wet granulation, reduces the need for binders, and allows for the production of high-quality pellets suited for a wide range of industrial and commercial uses. And if you want to setup  a zeolite granulation plant, we can also provide you with the best solution.

How to make zeolite pellets

Subtitle 1: Introduction to Zeolite Pellets

Zeolite pellets are highly porous, crystalline structures that possess remarkable adsorption properties. These pellets find applications in various industries, such as water purification, gas separation, and catalysis. This comprehensive guide will walk you through the step-by-step process of making zeolite pellets, providing insights into the materials required and the key stages of production.

Subtitle 2: Materials Required

Before delving into the production process, gather the following materials:

  1. Zeolite Crystals: Select a zeolite type suitable for your application. Common choices include clinoptilolite, mordenite, or faujasite.
  2. Binder: Choose a binder that can withstand high temperatures and effectively bind the zeolite crystals. Sodium metasilicate or sodium aluminate are often suitable choices.
  3. Water: Pure, distilled water is essential for creating a homogenous mixture.
  4. Pelletizer: Invest in a pelletizing machine capable of forming the zeolite-binder mixture into uniform pellets.
  5. Drying Equipment: You will need an oven or a rotary dryer to remove moisture from the formed pellets.

Subtitle 3: Production Process

Step 1: Zeolite Activation

Begin by activating the zeolite crystals to remove any existing water content. Place the zeolite in an oven or heat source at temperatures ranging from 300 to 500 degrees Celsius for a specified duration, typically a few hours.

Step 2: Mixing Zeolite and Binder

Combine the activated zeolite crystals with the chosen binder in the desired ratio. Gradually add distilled water to the mixture, ensuring a consistent blend. The goal is to create a paste-like consistency that facilitates pellet formation.

Step 3: Pellet Formation

Use a pelletizer to shape the zeolite-binder mixture into pellets of the desired size. The pelletizer applies pressure to the mixture, forcing it through a die to form uniform pellets. Adjust the machine settings to achieve the desired pellet size and density.  Pan granulator machine and drum granulator equipment are the best choice for you.

Step 4: Drying the Pellets

Transfer the freshly formed pellets to a drying apparatus. This can be a rotary dryer or a controlled-temperature oven. The drying process is crucial for removing excess moisture and solidifying the pellets. Maintain a temperature appropriate for the chosen binder to ensure optimal drying without compromising the zeolite structure.

Subtitle 4: Quality Control and Testing

After the pellets are dry, conduct thorough quality control checks. Inspect the pellets for uniformity, density, and structural integrity. Perform adsorption tests to verify the effectiveness of the zeolite pellets for the intended application.

Subtitle 5: Application Considerations

Understand the specific requirements of your intended application. Whether it’s water purification, gas adsorption, or catalysis, tailor the zeolite pellet production process to meet the performance criteria of your end-use.

Subtitle 6: Conclusion

Creating zeolite pellets involves a meticulous process that combines science and engineering. By following these steps and considering the specific needs of your application, you can produce high-quality zeolite pellets with consistent performance. Experiment with different zeolite types and binders to optimize your production process and contribute to advancements in diverse industries. So how to setup a zeolite pellets plant? SX can give you a answer.

What Organic Materials Can Be Used in Disc Granulator?

Shunxin will shed light on the diverse array of organic materials that can be harnessed as valuable resources through the transformative power of disc granulators. Join us as we hold the versatile disc granulation machine which is suitable for organic materials, and they play the pivotal role in promoting sustainable agricultural practices and environmental stewardship.

Pan Granulation Machine
Pan Granulation Machine

Flexible Applications of Disc Greanulator

A pan granulator is a versatile machine designed to process a wide range of organic materials, transforming them into valuable organic fertilizer granules. Some of the organic materials that can be effectively used in a disc granulator include:

Disc Granulator for Organic Fertilizer Production
Disc Granulator for Organic Fertilizer Production

1. Livestock Manure

Livestock manure, deriving from animal husbandry operations, serves as a cornerstone of organic fertilizer production through disc granulation. Whether originating from cattle, poultry, pigs, or other livestock, the nutrient-rich composition of livestock manure renders it a prime candidate for conversion into organic fertilizer granules, enriching the soil with essential nutrients and organic matter.

2. Agricultural Residues

The residues of agricultural activities, encompassing straw, hay, stalks, and other crop by-products, can be repurposed in pellitizing disc, breathing new life into what would otherwise be considered agricultural waste. Disc granulation of agricultural residues yields organic fertilizer granules that contribute to the enrichment of soil nutrients, fostering sustainable agricultural practices.

3. Food Waste

Organic waste generated from food processing facilities, restaurants, and households can find a second life through the transformative capabilities of this granulator. By converting food waste into nutrient-dense organic fertilizer granules, disc granulation machine offers a sustainable solution for the management of organic waste, reducing environmental impact and promoting circular economy principles.

4. Green Waste

Biomass in the form of green waste, including grass clippings, leaves, and plant trimmings, can undergo a metamorphosis in pan pelletizer. Through this process, green waste is transformed into organic fertilizer granules, contributing to sustainable waste management while enhancing soil fertility and vitality.

5. Sewage Sludge

In some contexts, treated sewage sludge can be repurposed through disc granulation, culminating in the production of organic fertilizer granules. This sustainable utilization of sewage sludge as a raw material underscores the environmentally conscious approach to waste management and resource recovery.

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The Valuable Finished Products

The finished products from disc granulation of organic waste extend beyond mere waste reduction:

Pan Pelletizer
Pan Pelletizer

    1. Organic Fertilizers:

    Granular organic waste is rich in nutrients, making it an excellent source for organic fertilizers. These fertilizers enhance soil fertility, promote plant growth, and contribute to sustainable agriculture practices.

    2. Biomass Energy:

    The granular biomass from organic waste can be utilized as a renewable energy source. Whether for direct combustion or bioenergy production, the biomass output holds the key to cleaner and more sustainable energy generation.

    3. Soil Amendments:

    The organic matter present in the granules improves soil structure and water retention. As a result, these granules serve as effective soil amendments, enhancing the overall health of agricultural and garden soils.

    By processing these organic materials in disc granulator, these machines help to harness the nutrient potential of organic waste, transforming it into high-quality organic fertilizer that can be used to enhance soil fertility and support sustainable agricultural practices. Visit this website: https://www.fertilizerproductequipment.com/pelletizing-disc/ for more information.