DH series double roller granulator
The importance of powder granulating technology as one of the most important branches of powder particles processing treatment is increasingly clear with the demand of environment protection and improvement of automation of the production process. “Powder products will become granules” has become the necessary trend of powder-after-processing technology in the world.
1) Reduce dust pollution and improve working conditions of operation.
2) Meet the requirements of production processes, such as increasing porosity & specific surface area, improving thermal transmission and so on.
3) Improve the physical properties of the products (such as fluidity, Breathability, bulk density) and avoid the bad influences of segregation, pulsing, agglomeration, bridging etc. appearing in the follow-up operations (drying, screening, measurement) and the use of the process (measurement, ingredients, etc.), improving the appearance and fluidity, being convenient for storage and transportation, controlling solubility, controlling porosity and specific surface area and so on. Create the conditions for enhance the production and use of process automation and confined operations.
DH series dry roll press granulator adopts dry rolling technology to compress the powdery materials with moisture content ≤ 5% into pieces or tablets, then going through the processes of breaking into granules and screening to make the lump materials into granules that meet the requirements of application. Dry roll press granulator mainly depends on the manner of external pressure to force the material going through the gap between two relatively turning rollers to compress into laminar particles. During course of roller pressing, the real density of materials can increase 1.5~3 times thus reaching certain demands of granular strength.
Working principle:
DH series dry roll press granulator machine adopts dry rolling technology to compress the powdery materials with moisture content ≤ 1% into pieces or tablets, then going through the processes of breaking into granules and screening to make the lump materials into granules that meet the requirements of application. Dry roll press pelletizer mainly depends on the manner of external pressure to force the material going through the gap between two relatively turning rollers to compress into laminar particles. During course of roller pressing, the real density of materials can increase 1.5~3 times thus reaching certain demands of granular strength.
◆Without any additives, dry powders are granulated directly.
◆Granular strength can be adjusted by adjusting the pressure of roller, control strength of final products.
◆Cycle operations to achieve continuous production.
◆High yield of finished products.
◆Materials are force to compress molding by mechanical pressure, without any additives, the product's purity is guaranteed.
◆Dry powders are granulated directly without follow-up drying process, the existing production process is easy to convergence & transformation.
◆Granular strength is high, compared with other granulating methods, the improvement soft bulk density are significant，especially for the occasion where increase the proportion of product accumulation.
◆A wide range of raw materials can be used, granular strength can be freely adjusted according to different materials.
◆Compact structure, easy maintenance, simple operation, short process, low energy consumption, high efficiency, low failure rate.
◆Control environmental pollution, reduce waste and powder packaging costs, and improve product transport capacity.
◆Feeding device adopts frequency adjustment control, high automation ,one can control multi-machine, has the features of low labor intensity and long term continuous operation, etc.
◆Major transmission components use high quality alloy material. Stainless steel, titanium, chromium and other surface alloys which greatly improved wear resistance, corrosion resistance, high temperature and pressure capabilities, so that this machine has one long service life.
• Advanced driving system
Adopting increased double shafts output dedicated reducer and drum gear shaft coupling effectively protects the rolls and the main bearing from damage, increasing the driving efficiency and further improving the production of products.
• Optimized frame structure
The new type frame designed through optimized calculation according to human engineering is equipped with a working platform at the top which has a large door structure near the rollers and which is convenient for the operators. It fully meets the requirements of the customers to reliability of the equipment safety and overhaul convenience.
• High efficient, durable alloy steel rollers
The roller matrix is wholly forged with high quality alloy steel, which can widely adapt to all kinds of complicated material conditions. In the design of the wearing layer of the roll surface, have held the rules of the max. Mechanical stress effect depth according to the HZ contact theories and pure elastic theories assembled the materials of tear-proof layer, interlayer, wearing layer, arranged hardness, and improved heat treatment process scientifically so that the crack-proof and wearing properties have been improved greatly. The finally case-hardened patterns of the roll surface after repeated tests, compared and profiting from the technical improvement of other components (such as the feeding unit) can make the pull-in angle of the materials more equipoise, stable, and can effectively remove the axial action of the rolls at the same time to make the equipment working more stable.
• Bran-new feeding unit
Bran-new designed feeding unit equipped with regulating valve plate can conveniently realize on-line adjustment. The increased air expansion chamber can make the air carried in materials discharged smoothly and improve the occlusion of the materials between the rollers. The technical improvement of the feeding unit also results in the improvement of the patterns of the roller surface directly.
• Simple, safe hydraulic system
In the design of the hydraulic system, we do not only consider it as the source of proving power, but also make it having the function of protecting the equipment. We designed multiple automatic protecting functions, and the optimized hydraulic system makes the motion flexibility of the dynamic rollers more strong and be able to reject the iron lumps mixed in unexpectedly and protect the equipment to run safely. Modularized and integrated design of the hydraulic system does away with the cumbersome, redundant pipelines. It takes less area and makes the whole equipment look simple, beautiful and highly efficient.
• Intelligent control system
Roller press use on-line control operation, can set the device operating parameters easily & intuitively, on-line detection, control equipment operating status, to provide operator decision-making information. With its help, roll granulator work more stability.
• High-efficient crushing &granulating system
The crusher is divided into two levels, can crush the materials of block twice, and has three rooms, greatly increases the broken area, so this crusher improve crushing efficiency & rate of final products.
• Superior screening system
This machine has the advantage of small vibration, low noise, and low strength requirements, and combine the advantages of circular motion, elliptical motion, and reciprocating linear motion, and has cleaning devices for screen surface, so it has large production, high screening efficiency , small power consumption, flexible installation, convenient for screening.
| Raw material | Model | Size of granules（mm） | Output（Kg/h） |
| KCL、Russia potash | DH360、DH450、DH650、DH850、DH1050、DH1500、DH1700 | 2.0~4.75 | 1000~1500、2000~2600、3200~4500、6000~8000、11000~18000、14000~55000、25000~85000 |
| Potassium Sulfate | DH360、DH450、DH650、DH850、DH1050、DH1500、DH1700 | 2.0~4.75 | 1000~1300、2000~2500、3000~4500、6000~8000、11000~18000、14000~55000、25000~85000 |
| NPK compound fertilizer | DH360、DH450、DH650、DH850、DH1050、DH1500、DH1700 | 2.0~4.75 | 900~1500、1800~2600、3000~4500、6000~8000、11000~18000、14000~55000、25000~85000 |
| Cryolite | DH360、DH450、DH650、DH850、DH1050、DH1500、DH1700 | 2.0~4.75 | 1000~1500、2000~2600、3200~4500、6000~8000、11000~18000、14000~55000、25000~85000 |
| Ammonium Chloride、Ammonium Sulfate | DH360、DH450、DH650、DH850、DH1050、DH1500、DH1700 | 2.0~4.75 | 800~1000、1800~2500、3100~4600、6000~8000、11000~18000、14000~55000、25000~85000 |
| Antioxidant | DH360 | 0.3~2.0 | 300~400 |
| Zinc oxid | DH360 | 1.5~2.5 | 350~500 |
| Sodium cyanide | DH360 | 1.5~6.0 | 800~1000 |
| Steel making flux | DH360 | Olive shape | 1000~1200 |
| Snow melt agent | DH360 | 2.0~7.0 | 800~1000 |
|
Bromine chlorine hydantoin |
DH240 | 1.5~6.0 | ~300 |
| Medical intermediate | DH240 | 0.5~2.0 | ~200 |
| Environment protection | DH240 | 8.0~15.0 | ~500 |
Technical parameters:
| Model | DH240 | DH360 | DH450 | DH650 |
| Roller diameter（mm） | φ240 | φ360 | φ450 | φ650 |
| Valid usable width（mm） | 300 | 170-230 | 190-280 | 290-330 |
| Roller speed (rpm) | 50-100 | 10-25 | 10-25 | 10-25 |
| Max forming pressure(KN) | 1100 | 800 | 1300 | 2100 |
| Max rolled sheet output(mm) | 10 | 8 | 12 | 16 |
| Rolled sheet output(Kg/h) | 300 | 1600 | 3000 | 6000 |
| Final product output(kg/h) | 2000-2500 | 900-1300 | 1800-2500 | 3500-4000 |
| Granular size(mm) | 3-10 | 0.5-6 | 0.5-6 | 0.5-6 |
| Main unit power(KW) | 45 | 30-37 | 55-75 | 90-110 |
| Total installed capacity(KW) | 75 | 55 | 90 | 175 |
| Dimension(L.W.H.) | 2300×1700×1900 | 2000×2350×4600 | 2200×2600×5600 | 2800×3900×6300 |
| Total weight(t) | 13 | 10 | 15 | 25 |
| Model | DH850 | DH1050 | DH1500 | DH1700 |
| Roller diameter(mm) | φ850 | φ1050 | φ1500 | φ1700 |
| Valid usable width(mm) | 420 | 450 | 500 | 650 |
| Roller speed(rpm) | 9-16 | 8.5-14.5 | 6-13 | 6-13 |
| Max sheet output(kg/h) | 12000-16000 | 22000-38000 | 36000-50000 | 64000-200000 |
| Final product output(kg/h) | 6000-8000 | 12000-16000 | 18000-25000 | 35000-50000 |
| Granular Size(mm) | 2-5 | 2-5 | 2-5 | 2-5 |
| Main unit power(KW) | 220-250 | 400 | 630 | 400*2 |
| Total installed capacity(KW) | 400 | 850 | 1000-1200 | 1500-1800 |
| Dimension(L.W.H) | 5000*3800*4100 | 5500*6400*4800 | 7500*6500*5200 | 9700*5600*7700 |
| Total weight(t) | 46 | 98 | 100-120 | 120-150 |
Note: Rolled sheet output, finished product outputs are just for reference and the screen is determined according to the nature of materials.
1、Single set flow diagram
This process is DH650 and the following models of the conventional process
The process is the basis process for the design of the company's dry granulation, In the process raw material will be lifted by bucket elevator to prepare granulation bin, and then into the granulator, material roll forming directly into the crushing system, after crusher broken into screen, The particles divided into qualified granules and unqualified particles by screen net of screen, qualified particles can be directly into the next process, or direct packaging, and unqualified particles will be returned to the raw material bucket elevator, and then re granulation process.
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This process is DH850 and the above model of conventional process
In the process, due to the material after roller press income of finished products of granulation is in a strip shape is not conducive to the transportation, so in the granulator outlet installation of pre crushing device, followed by impact crusher, according to customer demand can have chosen polishing, envelope, sieve processing, product particles can be directly weighing and packing.
2、Multiple sets of processes
This process is the process of multiple sets of equipment, can be designed according to the site and customer demand, single bucket elevator can be used for loading and granulating, or lifting to the feed hopper, use hopper to feed. After the process of crushing and screening, the materials are crushed and screened.
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"Mixing - granulation - pre crushing - concentrated crushing - Screening - polishing - second screen - packaging", After the screening ,fine powder material to return to the raw material mixing again into the granulation system to form a granulation cycle, improve the granulation efficiency of the granulation process.
According to the demand, the granulation of the preceding paragraph can be added batching or drying system,in this process, due to the larger strip produced by the tablet, the lower end of the granulation machine is equipped with a pre crushing machine, pre crushing and then concentrated crushing. The qualified material produced by the screening enters into the next polishing, second screening and the packing process, and the screening out of the unqualified large particles are returned to the impact crusher for re broken, the unqualified fine powder is returned to the raw material place to carry on the re granulation.
Automation control
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