Disk pelletizer

Types of Disk Pelletizers

A disk pelletizer is a piece of equipment used to make pellets from a range of materials. It works by agglomerating fines into granules through controlled rolling and klassing on a sloped, rotating disk or pan. This machine was initially designed for making pellets in the chemical, mineral, and metallurgical industries. Still, it is now widely used in the fertilizer, feed, and food industries. The devising of pellets is reliant upon various factors, including characteristics of the material, equipment design, and operational parameters. It is also employed in numerous sectors, like pharmaceuticals, plastics, and waste management.

Different types of disk pelletizers are available, which can be categorized based on size:

• Laboratory-scale pelletizers: These are small pelletizers used for research and development purposes. They are ideal for testing new formulations or processes on a small scale before moving to large-scale production. Laboratory-scale pelletizers are commonly found in academic institutions and R&D centers.
• Bench-top pelletizers: These pelletizers are slightly larger than laboratory-scale ones and are often used for pilot plant studies. Bench-top pelletizers allow users to generate pellets in a bench-top-sized unit for trials before investing in a full-scale production plant.
• Production-scale pelletizers: These are larger pelletizers used for mass production of pellets. They typically have a higher capacity and are built for continuous operation. Production-scale pelletizers come in different models, depending on the working mechanism. Models using the same working principle that utilizes rotation to generate friction between particles and the wall of the chamber include the disc-type and drum-type. Though they vary slightly in specifications, both serve the same purpose. Drum pelletizers have a larger capacity as compared to disk pelletizers. Drum pelletizers can also be referred to as agglomerator, pan granulator, and rotary granulator.

These are just some examples of different models available on the market. The specific types and configurations may vary depending on the manufacturer.

Functions and features

Functions

A disk pelletizer is mainly used in the fertilizer industry to convert powdered material into pellets of uniform size. The pellets produced in this process have increased strength and are easier to handle, store, and transport. Additionally, the pellets can be distributed evenly when applying them to the soil. This increases the chances of good infiltration and reduces the chances of fertilizer burn on the plants. Using a pelletizer, fertilizer can be compacted and made into pellets for use. Different types of fertilizers can be mixed and pelletized together so that they can be applied in a single uniform application. The pelletization process also helps to enhance the quality and increase the shelf life of the fertilizer. Fertilizer disk pelletizers can also be used to grind the fertilizer if it is not in a fine powder form before adding it to the pelletizing chamber. Moreover, the disk pelletizer can be used to produce animal feed pellets. Feed for livestock can be made into pellets for easier feeding and for boosting the growth of the animals. Feed pellets are more cost effective and provide a uniform nutritional value to the livestock. In addition to this, using a pelletizer can help manufacture wood or biomass fuel pellets that are suitable for use in stoves or boilers for heating. Wood waste can be turned into fuel pellets through the process of pelletization.

Features

• Variable speed controller: A disk pelletizer has a variable speed controller that can control the rate at which the material is discharged to suit the specific requirements of a pelletizing operation.
• Water addition: The water addition feature allows the pelletizing operator to control the amount of water added to the material in the pelletizing chamber. The amount of water added is essential for pellet formation. It also determines the hardness and durability of the final pellets produced.
• Discharge chute: Disk pelletizers are fitted with a discharge chute through which the final pellets are discharged after they have been formed. The discharge chutes are designed to ensure that there are no blockages and the pellets are continuously and smoothly discharged.
• Stainless steel construction: Disk pelletizers are usually made of stainless steel, which makes them corrosion resistant. This improves the pelletizers' durability and makes them ideal for use in industrial applications where they are subjected to wear and tear. Stainless steel is also simple to clean and maintain.
• Compact size: Disk pelletizers are smaller than ring die pelletizers. This makes them more economical and easier to maintain. Their compact design suits small-scale pelletizing operations.
• Integrated cyclone separator: Cyclone separators are often integrated into disk pelletizers to separate fine particles from the exhaust air. The separator improves the quality of the pellets produced and ensures that the dust generated is minimal.

Applications of Disk Pelletizers

Applications of the disk pelletizer are widespread and cover many industries. The industries include agriculture, pharmaceuticals, mining, and chemicals. The following applications are the main uses of pelletizers:

• Fertilizer Production: To produce diammonium phosphate pellets and NPK, disk pelletizers are used in the fertilizer industry.
• Animal Feed Manufacturing: Animal feed producers use pelletizers to convert raw materials like corn and soy to pellets for ease of handling, feeding, and storage.
• Biomass Pelletizing: Biomass resources like sawdust, straw, and wood chips are turned into pellets by disk pelletizers. Biomass can be converted into pellets for energy generation or as a renewable fuel source.
• Pharmaceuticals: Pelletization is a common practice in the pharmaceutical industry used to manufacture the majority of solid oral medications. Disk pelletizers are used to make small, uniform pillery masses from drug powders.
• Mineral Processing: Mineral processing uses pelletizers to turn metal powders into pellets. The metal pellets can be used for blast furnaces or further refinement to get pure metal.
• Chemical Industry: Disk pelletizers are used to convert powdered raw materials into uniform chemical industry pellets. These pellets are then used as catalysts or as feedstock during chemical reactions.
• Compost Production: Compost made from organic material like yard waste or food waste is produced using pelletizers. The compost helps to enhance soil by adding nutrients.

How to Choose Disk Pelletizers

For buyers of disk pelletizers, several important factors should be taken into account before making a purchase. The factors are as follows;

• Define requirements: The first step is to clearly define the current and future pelletization needs. Consider parameters like pellet size, production capacity, raw materials, and specific application. This will help in selecting the right model and configuration.
• Research reputable suppliers: Look for suppliers with a proven track record in the pharmaceutical industry. Read reviews, case studies, and customer testimonials to gauge the reputation and reliability of different suppliers. For a better understanding of the suppliers, visit the suppliers' website and compare the offers and services of different suppliers.
• Service and support: Choose suppliers who offer excellent after-sales support, including installation, commissioning, troubleshooting, and maintenance. A supplier who provides prompt technical support can help resolve issues quickly and minimize downtime.
• Customization and flexibility: Consider suppliers who can customize pelletizers to meet specific requirements. Flexible disk pelletizers with adjustable features and configurations can accommodate changing production needs.
• Cost of pelletizer: While the initial cost of the disk pelletizer is an important consideration, it is necessary to evaluate the total cost of ownership (TCO) over the lifespan of the equipment. This includes maintenance costs, energy consumption, and potential production losses due to equipment failure. Select a cost-effective option that offers good value in the long run.
• Compliance with regulations: Ensure that the chosen disk pelletizer complies with relevant industry regulations and standards, such as Good Manufacturing Practices (GMP). This is crucial for maintaining product quality, safety, and regulatory compliance during the pelletization process.
• Offers spare parts: Select a supplier that readily offers replacement parts for their equipment. This is important for repairing equipment when it is damaged or malfunctions.

Disk pelletizer Q&A

Q1 What else besides iron ore can disk pelletizers process?

A1. Disk pelletizers can process a variety of materials apart from iron ore fines. They are versatile and can help in producing pellets from other minerals like nickel, copper, and various metal hydroxides. In the chemical industry, disk pelletizers are used to create uniform pellets from alkaline earth metal carbonates and other hydroxide salts. They also agglomerate powdered raw materials used in refractory and ceramic production.

Q2 What is the difference between a disc and a drum pelletizer?

A2. The main difference between a disc and a drum pelletizer is the shape of the working apparatus. A pelletizing disc is flat and circular while a pelletizing drum is cylindrical. Both can produce pellets of similar sizes and serve the same basic function. However, pelletizing discs allow for better control of pelletization parameters, facilitating adjustment of operating conditions like moisture levels and pellet size. On the other hand, pelletizing drums have a higher throughput since they can process a larger amount of material in a single batch. This makes them more suitable for larger pelletizing operations. While both can produce pellets, the choice between the two may depend on factors like required throughput, budget, and the degree of control needed over the process.

Q3 How does a pelletizer work?

A3. To begin with, the material is ground to an appropriate size before being mixed with water or a binding agent. Then, the mixture is pressed through a series of rollers to form uniform pellets. After that, the pellets are dried or cooled, depending on the desired final temperature. Finally, the finished pellets are stored or transported.

Q4 How are pellets produced?

A4. Different kinds of raw materials are first prepared by grinding them to a suitable size. Then, these ground materials are mixed either with water or some type of binding agent. The mixture is then pumped through a series of screw augurs where it is continuously rotated. This pumping action creates both friction and pressure which helps in forming uniformly sized pellets. Lastly, the pellets produced are either dried or cooled depending on what the final temperature needs to be.

Q5 What is a pelletizing machine?

A5. A pelletizing machine uses a pelletizer, which is a type of granulator, to convert loose powdery material into small, spherical pellets. These pellets are also referred to as granules or ball-shaped aggregates. The pelletizing process enhances properties such as flow and pack density, making them easier to handle and transport. The term 'pellet' and 'granule' are often used interchangeably, but the appropriate one depends on the specific industry.