New Type Stirring Tooth-Drum Granulator

Equipment Overview

The new type of organic fertilizer two-in-one granulator, also known as the Stirring Tooth-Drum Granulator, is an innovative product in the field of organic fertilizer granulation equipment. This equipment combines the advantages of a stirring tooth granulator and a rotary drum granulator, employing a wet continuous pusher granulation process. It overcomes the shortcomings of traditional disc granulators (low efficiency) and rotary drum granulators (unstable pelletizing rates). Through the combined action of the inner stirring teeth and the outer rotating drum, the material undergoes multiple physical processes within the machine, including mixing, spheroidizing, extrusion, and polishing. The resulting granules are round and firm, with an organic matter content of up to 100%, making it one of the key pieces of equipment in the organic fertilizer industry.

Core Positioning:

1. Combines the dual granulation mechanism of a stirring tooth granulator and a rotary granulator.

2. Employs a new wet continuous pusher granulation process.

3. Capable of granulating various organic materials, especially coarse fibrous materials that are difficult to granulate with conventional equipment.

4. Suitable for cold and hot granulation, as well as large-scale production of high, medium, and low concentration organic-inorganic fertilizers.

5. Organic content can reach up to 100%, achieving pure organic granulation.

Technological Evolution: Traditional organic fertilizer granulation equipment mainly includes single types such as disc granulators, rotary drum granulators, flat die granulators, and stirring tooth granulators. The new two-in-one granulator, through technological innovation, organically integrates the forced stirring granulation mechanism of the stirring tooth granulator with the rolling polishing mechanism of the rotary drum granulator, overcoming the limitations of single equipment—it can produce both organic fertilizer and organic-inorganic compound fertilizer, becoming a representative of low-energy, high-quality granulation equipment.

Equipment Structural Composition

1. Core Component System

2. Five Major Functional Systems

1. Feeding System: A spiral pusher forcibly conveys materials to the granulation chamber.

2. Mixing and Stirring System: High-speed rotating stirring teeth achieve shearing, extrusion, and kneading of materials.

3. Granulation System: Under mechanical force, materials agglomerate, nucleate, grow, and become dense.

4. Polishing System: The rotating cylinder causes the granules to roll and polish, improving sphericity.

5. Control System: PLC touch screen, integrating monitoring of parameters such as mixing time, granulation speed, material moisture, and output.

3. "Two-in-One" Structural Features

"Two-in-One" Core Meaning:

1. Stirring Tooth Granulation Mechanism: Utilizing high-speed rotating mechanical stirring force and aerodynamics, fine powder materials continuously achieve mixing, granulation, spheroidization, and densification processes within the machine.

2. Rotary Drum Granulation Mechanism: The rotating cylinder causes the granules to roll along the cylinder wall under centrifugal force, with fine powder adhering to the outer layer, gradually increasing granule size and polishing.

3. Synergistic effect: The combination of the two granulation methods results in a higher pellet formation rate and more aesthetically pleasing granules, while also saving energy.

Equipment Application Scope

1. Main Application Areas

2. Applicable Raw Material Characteristics

This machine is suitable for granulation of light, fine powder materials, with particularly good granulation effect on organic-inorganic compound fertilizers. The finer the basic particles of the fine powder material, the higher the sphericity of the granules and the better the granulation quality. Generally, the particle size of the material before granulation should be less than 50 mesh (300 mesh).

High Moisture Materials: Livestock and poultry manure with a moisture content of 20%-40% (can be granulated directly without pre-drying)

Coarse Fiber Materials: Crop straw, distiller's grains, mushroom residue, medicinal residue, etc. (difficult to granulate with conventional equipment)

Viscous Materials: Fermented organic materials, humic acid, urban sludge, etc.

Powdered Materials: Carbon black, clay, kaolin, urea-formaldehyde molding powder, etc.

Mixed Materials: Organic-inorganic mixtures of various raw materials in different proportions

3. Typical Application Material List

Core Advantages of the Equipment:

1. Wide Raw Material Adaptability, Breaking Industry Limitations: Exclusively adaptable to coarse fiber and high-moisture organic materials that conventional equipment cannot form, achieving 100% pure organic granulation content, truly realizing granulation without auxiliary materials or binders.

2. High Granulation Quality and Stable Appearance: Spherical granules are round and full, without sharp edges, with extremely low pulverization rate. Compressive strength is superior to traditional disc and drum granulation equipment, with a large granule rate ≤15%, and controllable and adjustable particle uniformity.

3. Precise and Controllable Particle Size, Concentrated Distribution: Utilizing a stepless speed regulation system, particle size is precisely controlled, resulting in uniform particle size distribution, eliminating drastically different particle sizes, and significantly improving the finished product qualification rate.

4. Energy Saving and Low Production Costs: Direct granulation of wet materials eliminates the need for drying processes, significantly reducing drying energy consumption; no binders are required, saving raw material costs; the equipment has low operating energy consumption, suitable for large-scale mass production.

5. Stable operation and high durability: Thickened seamless steel pipe body, alloy wear-resistant stirring teeth, and high-strength reducer make the whole machine wear-resistant, impact-resistant, and less prone to failure, with a service life far exceeding that of ordinary granulation equipment.

6. High production efficiency and suitable for mass production: Continuous wet process operation, high degree of automation, granulation rate ≥90%, stable production capacity, and adaptable to large, medium, and small production lines for large-scale production.

7. Flexible process and strong adaptability: Supports cold and hot granulation, high and low concentration fertilizer production, and is adaptable to the production of various organic fertilizer formulas, making it extremely versatile.

Working Principle of the Equipment

I. Principle of Granulation by Stirring Teeth

The stirring tooth granulator is an organic fertilizer production equipment that uses strong mechanical force to granulate materials. Its working principle is based on the high-speed rotating stirring teeth applying shearing, extrusion, and kneading forces to the material, causing fine powdery raw materials to agglomerate into granules.

Four-stage workflow:

Feeding and pushing → Mixing and stirring → Extrusion and nucleation → Rolling polishing and growth → Screening and discharge

1. Feeding and pushing: The material is fed through the feed inlet and forcibly conveyed into the granulation chamber by a screw conveyor. The moisture content of the material usually needs to be controlled between 20% and 40%.

2. Mixing and stirring: The pre-treated raw material enters the rotating cylinder. The stirring teeth strongly stir, shear, and mix the material through rotation, causing the material to be evenly distributed and initially agglomerated.

3. Extrusion and nucleation: Under the mechanical force of the stirring teeth, the wet material is extruded and kneaded, gradually forming tiny particles ("nuclei"). The material repeatedly collides and kneads between the stirring teeth and the cylinder wall, and the fine powder gradually agglomerates into small particles under mechanical force.

4. Rolling Polishing and Growth: As the cylinder rotates, the particles roll along the cylinder wall under centrifugal force, with fine powder continuously adhering to the outer layer, and the particles gradually increase in size to 2-8mm. The stirring teeth intermittently stir to prevent particle adhesion and ensure uniform particle size.

5. Screening and Discharge: The formed particles are separated through the screen at the discharge port. Particles that are too small or too large are screened and returned for re-granulation.

II. Rotary Drum Granulation Principle The main working method of the rotary drum granulator is wet granulation. A certain amount of water or steam is used to moisten the base fertilizer inside the cylinder, allowing for a full chemical reaction. Under certain liquid phase conditions, the rotational motion of the cylinder causes the material particles to agglomerate into spheres due to compressive force.

III. Two-in-One Synergistic Working Principle The new two-in-one granulator integrates the pressing functions of stirring tooth granulation and rotary drum granulation:

1. Stirring Tooth Section: Utilizing the mechanical stirring force of high-speed rotation and the resulting aerodynamics, fine powder materials undergo continuous mixing, granulation, balling, and densification processes within the machine. The granules are spherical with a sphericity ≥0.7, a particle size generally between 0.3-3 mm, and a granulation rate ≥90%.

2. Rotary Drum Section: The drum body uses a special rubber plate lining or acid-resistant stainless steel lining, achieving automatic descaling and nodule removal, eliminating the need for traditional scraper devices. The granules are polished by rolling under centrifugal force, resulting in a smooth and round surface.

3. Synergistic Effect: The combination of these two granulation methods results in a higher balling rate and more aesthetically pleasing granules, while also saving energy and increasing efficiency.

Organic Fertilizer Production Process (Fermentation + Granulation Full Process)

I. Fermentation Process

1. Pre-fermentation Preparation

Raw Material Ratio: Livestock manure and straw are mixed at a ratio of 3:1 to 4:1.

C/N Ratio Adjustment: The C/N ratio is controlled at 25:1 to 30:1.

Moisture Adjustment: Initial moisture content is 50-60%.

Inoculum Addition: Inoculate with EM bacteria, lactic acid bacteria, and other fermentation agents.

2. Fermentation Process Flow

Raw Material Mixing → Stacking Fermentation → Turning and Aeration → Heating and Deodorization → Maturation and Decomposition → Post-Maturation and Aging → Crushing and Sieving

3. Key Control Points in Fermentation

4. Advantages of Direct Granulation After Fermentation

One of the core advantages of the new two-in-one granulator is that the fermented organic matter does not need to be dried; the raw material moisture content can be 20%-40% for direct granulation.

This greatly saves the energy costs of traditional granulation processes that require drying to below 15% before granulation. The output moisture content is around 30%, reducing the load on subsequent drying processes.

II. Granulation Process of the Equipment

1. Granulation Process Flow

Raw material preparation (moisture content 20-40%) → Feeding and mixing → High-speed stirring and nucleation → Rolling polishing and growth → Sieving and discharging

2. Key Process Parameters

3. Key Points of Granulation Process for Different Materials

Common Equipment Problems and Solutions

If the machine jams or the power load is too high during production, the material supply should be reduced in time and the machine should be stopped for inspection. The material stuck to the inner wall of the machine should be cleaned.

Application Value of the Equipment in Organic Fertilizer Production Lines

This equipment is the core forming hub of the organic fertilizer production line, connecting the front-end fermentation and crushing stage with the rear-end cooling and screening stage. It directly determines the appearance, quality, and commercial value of the finished fertilizer, making it the most cost-effective and practical core equipment in the entire production line.

Compared to traditional single granulation equipment, the two-in-one granulator can replace the functions of two machines: a stirring tooth granulator and a rotary drum granulator. This reduces equipment investment, saves space, and lowers energy and labor costs. It is suitable for standardized, large-scale, and low-cost production in organic fertilizer production lines. Simultaneously, the granulated fertilizer produced by the equipment has good water solubility, uniform fertility, and is not prone to caking, significantly enhancing the market competitiveness of organic fertilizer. It is widely applicable to nationally supported industries such as the resource utilization of livestock waste, ecological agriculture, and green fertilizer processing.
Target Customers for the Equipment