Agitator Granulator (new type organic fertilizer granulator)

The new organic fertilizer granulator is a core piece of equipment designed to process powdered organic raw materials into granular fertilizer. Utilizing a novel wet-process continuous ram-extrusion granulation technique, the machine is capable of granulating a wide range of organic materials; it offers distinct advantages, particularly when processing coarse-fiber materials that are difficult to granulate using conventional equipment. It is primarily used to granulate various fermented organic materials, overcoming the limitations of traditional granulation processes.

The granules produced are spherical, with an organic matter content of up to 100%. Unlike traditional granulators, this new model eliminates the need for pre-drying or pulverizing raw materials; fermented organic matter can be processed directly after batching. It accommodates raw material moisture content ranging from 20% to 40% and operates without binders, relying instead on the inherent ability of organic particles to interlock and grow under applied force. The resulting granules are solid and can be screened immediately after granulation, effectively reducing energy consumption during the drying stage.

The machine body is constructed from carbon steel, while the forming components are made of wear-resistant alloy steel. The unit features an all-welded structure, and critical components undergo quenching treatment to ensure durability and long-term stable operation.

Structural Composition of the New Type of Organic Fertilizer Granulator

The new organic fertilizer granulator is composed of a frame, a drum, an internal stirring-tooth granulation mechanism, internal and external drive mechanisms, and other components.

Frame: Constructed from welded heavy-duty channel steel, the frame is stable and reliable, capable of effectively supporting the full load during equipment operation.

Drum: Fabricated from welded heavy-duty steel plate, the drum features a rotary design with an internal granulation chamber. The outer shell utilizes thick-walled seamless steel piping, ensuring durability and resistance to deformation.

Granulation Mechanism: Employs a stirring-tooth granulation method; specially designed stirring/granulating teeth are mounted on the rotor to mix, agitate, and granulate the material through high-speed rotation.

Drive Mechanism: Consists of two systems—internal and external drives. The internal drive utilizes a flexible coupling connection, while the external drive employs cast-steel gear meshing. Powered by a motor and a gearbox, the drive system ensures stable and reliable rotational power for the granulation rotor.

The entire unit features a robust base design, ensuring smooth and stable operation.

Operating Instructions

Pre-start Preparation: Conduct a thorough inspection of the equipment before startup. Check that all component connections are secure and that no screws are loose; specifically, verify the belt tension of transmission parts and check for any signs of chain looseness or wear. Ensure bolts are tight and that grease has been applied to the rollers, idler wheels, pinions, and large gear rings. Inspect the interior for foreign objects or residual material and clear them away promptly. Check the internal mixing and granulating teeth for entangled debris or excessive material buildup. Proceed with startup only after confirming the lubrication system is functioning correctly.

Startup and Operation: Before starting the machine, verify the correct direction of rotation (the drum and main shaft must rotate in the same direction). Once started, feed material evenly; inconsistent feeding rates will compromise granulation quality and reduce the motor's service life. During granulation, strictly control material coarseness, mixing ratios, viscosity, and moisture content. Note that granule size is directly proportional to material moisture content. Operators must continuously monitor the granulator's operating status, including motor current, equipment temperature, and noise levels.

Shutdown Procedure: Stop feeding material before shutting down the machine; cut the power only after all material inside has been fully discharged. At the end of a shift, ensure all material is cleared from the machine's interior to prevent caking or adhesion. Perform cleaning and maintenance after shutdown.

Maintenance and Care Procedures

Daily Maintenance: After each production run, thoroughly remove residual material from the interior and exterior of the granulation tank, clean up any material spilled or splashed onto the equipment, and wipe down exposed machined surfaces. Keep the work area clean to prevent dust contamination. Periodically check for loose bolts across the equipment and ensure that rotating and rolling parts are properly lubricated.

Periodic Maintenance: Change the gearbox oil every six months. Regularly inspect the inner wall of the cylinder for material buildup and promptly remove any material adhering to the tips of the mixing paddles. Periodically check the clearance between the cylinder wall and the mixing paddles; this gap should be maintained between 3 mm and 6 mm. If the gap is too wide, granulation will fail, requiring timely adjustment of the paddle tips. After 300 hours of operation, clean the bearings and change the oil; the oil level should fill one-third of the bearing housing cavity and must not exceed one-half. Proper bearing lubrication is critical to equipment longevity; ensure that the lubricant is clean and the seals are intact.

Wear Part Management: Monitor the wear levels of components prone to abrasion and replace them as necessary. Promptly replace mixing paddle tips if they show significant wear. Newly installed retaining rings are prone to loosening and require frequent inspection. Monitor the operation of all machine components to ensure they are functioning correctly.

Common Issues and Solutions

Issue 1: Failure to form granules. Possible causes include unbalanced material moisture content or unsuitable viscosity. The solution is to maintain the material's moisture content within an optimal range; excessively low moisture (<25%) results in insufficient adhesion, while excessively high moisture (>35%) causes the material to stick to the die and clump. For materials with low viscosity, an appropriate amount of binder (such as humic acid or starch) may be added.

Issue 2: Equipment blockage preventing granule discharge. Possible causes include rust or poor surface finish in the die holes, or an excessive gap between the die and the rollers. The solution is to shut down the machine, remove the die for cleaning, and manually clear the holes using a drill bit slightly smaller than the hole diameter or by back-flushing with a high-pressure water jet; in cases of severe adhesion, soak the die in 50°C water for one hour to soften the material before cleaning.

Issue 3: Excessive gap between the cylinder and the mixing paddles. This prevents proper granulation. The solution is to adjust the position of the mixing paddle tips to ensure the gap remains within the 3mm–6mm range.

Issue 4: Rise in bearing oil temperature. Stop the machine immediately to investigate and rectify the cause.