Disc Granulator

Feature

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High Granulation Rate

The disc adopts a full arc structure without dead corners. Materials roll smoothly inside the disc. The granulation rate can exceed 93%, reducing recycle load and improving production efficiency.

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Reinforced Disc Structure

Multiple radial steel plates strengthen the bottom of the disc. This design prevents deformation and ensures long-term mechanical stability.

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Anti-Scaling Lining

Wear-resistant rubber lining can be installed inside the disc. It prevents fertilizer materials from sticking and forming scale during operation.

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Adjustable Disc Angle and Speed

The disc inclination angle can be adjusted between 35° and 55°. With variable frequency speed control, the machine can quickly adapt to different fertilizer formulas.

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Automatic Particle Classification

Optimized disc angle and rotation speed allow qualified granules to overflow naturally from the disc edge. This improves production efficiency and reduces manual intervention.

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Uniform Spray System

The atomized spray system distributes water as fine droplets. Moisture spreads evenly across the material surface. This prevents over-wet zones and ensures stable granule formation.

Structure

Granulation Disc

The disc is the core working area of the disc pan granulator. Materials roll and grow layer by layer inside the disc. The height of the disc edge determines material capacity and particle residence time.

Support Frame

A heavy-duty steel frame supports the granulation disc and maintains a stable inclination angle during operation.

Scraper Device

The scraper removes materials attached to the disc bottom and edges. This keeps the disc surface clean and ensures smooth material movement.

Drive System

The drive system includes a motor and reducer. It provides stable rotational power and supports variable speed control.

Feeding and Spray System

The feeding device delivers powder materials continuously into the disc. The spray system adds water or binder to create the proper liquid phase for granulation.

Principle

The pan granulation process is based on rolling agglomeration. Powder fertilizer materials are fed into the rotating disc granulator, where a small amount of water or binder is sprayed onto the material bed.

As the disc rotates, materials move upward along the inclined surface and then roll back under gravity. During this repeated motion, fine particles gradually adhere and form granules.

Small particles remain in the disc for further agglomeration, while granules that reach the required size overflow from the disc edge automatically. This natural classification helps produce fertilizer particles with uniform size.

Application

Compound Fertilizer Production

The disc fertilizer granulator is widely used for producing high, medium, and low concentration NPK compound fertilizers.

Organic and Bio Fertilizers

Suitable for granulating fermented organic materials such as livestock manure, filter mud, municipal sludge, straw, and peat.

Single Nutrient Fertilizers

Applicable to ammonium sulfate, potassium chloride, potassium sulfate, urea, ammonium chloride, and monoammonium phosphate.

Mineral Pelletizing

Used for pelletizing powder materials such as coal powder, limestone, cement clinker, shale, clay, and mineral fines.

Other Industrial Applications

The disk granulator can also process feed additives, chemical powders, desulfurization gypsum, and fly ash for resource recycling.

Advantage

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Smooth and Stable Operation

The belt drive system provides smooth startup and reduces mechanical shock on the reducer and motor.

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Energy-Efficient Design

Optimized transmission structure reduces power consumption per ton of fertilizer produced.

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Long Service Life

Key components are treated with high-frequency quenching. This improves wear resistance and extends service life.

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Stable Machine Structure

The balanced base structure allows the machine to operate smoothly with low vibration.

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High Roundness of Granules

Materials roll continuously inside the disc and naturally form spherical particles with smooth surfaces.

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Easy Operation and Maintenance

The pan granulator design is simple. Routine maintenance mainly involves checking the disc lining, scraper, and drive components.

Technical Specifications

Model	Capacity (tph)	Size (mm)	Power (kW)	Rotation Speed (rpm)	Pan Diameter (mm)	Tilt Angle (°)
SYM-500	0.05-0.1	650600800	0.75	32	500	35-55
SYM-1500	0.4-0.6	220018002050	4	20	1500	35-55
SYM-2500	1.5-2	263026002800	7.5	16.2	2500	40-50
SYM-4000	4-5	450033004000	15	12.3	4000	45
SYM-6000	6-10	640050006000	75	8.9	6000	45

Deep Customization: Solutions are available from laboratory-scale testing to large-scale industrial production. The system supports precise control of granule hardness, size, and density.

FAQ

1. How is moisture controlled during pan granulation?

Moisture acts as the binding phase in the pan granulation process. The disc granulator uses an adjustable atomizing spray system. Operators can regulate water addition based on material condition to reach the ideal granulation point.

2. How do disc angle and rotation speed affect granule size?

Higher speed and larger disc angles shorten the residence time of particles, producing smaller granules. Lower speed and smaller angles allow particles to stay longer and grow larger. Typical fertilizer particle size is 2–5 mm.

3. Can the disc granulator process high-temperature materials?

Processing hot materials is not recommended. Excessive heat may cause rapid moisture evaporation and weaken particle bonding. Materials should be cooled before granulation.

4. Is drying required after granulation?

Yes. The moisture content of freshly formed granules is usually 12–20%. A rotary dryer is normally used to reduce moisture below 5% for safe storage and transportation.