The hydraulic double-roller granulator is an intelligent granulation equipment for dry high-pressure extrusion molding. It is a core piece of equipment for deep processing of powder materials, differing from traditional mechanical double-roller granulators, disc granulators, and rotary drum granulators. Its core technology utilizes hydraulic constant pressure drive + double-roller reverse extrusion, eliminating the need for water, binders, or high-temperature heating. It can achieve one-time granulation of dry powder materials at room temperature, making it a mainstream energy-saving and environmentally friendly granulation equipment in the organic fertilizer, chemical, mining, feed, and building materials industries.
The equipment relies on a high-precision hydraulic control system to achieve precise adjustment of roller pressure and roller gap, solving the pain points of traditional granulation equipment such as uneven particle size, high pulverization rate, low forming rate, high energy consumption, and complex operation. With core advantages such as high forming rate, high particle strength, stable operation, low failure rate, wide material compatibility, high degree of automation, no drying required, and strong adaptability to production lines, the dry powder granulation forming rate can reach over 97%, and the material density can be increased by 1.5-3 times. The finished particles are dense, not easily absorbing moisture, and not easily broken. It is suitable for storage, transportation, and mechanized spreading and feeding operations, making it a core piece of equipment in current powder granulation technology that combines cost-effectiveness and practicality.
The hydraulic roller granulator is an extrusion sliding model. Its working principle is to forcefully extrude and shape the material through a pair of relatively rotating rollers. With the addition of a hydraulic system, the equipment can provide constant and adjustable extrusion pressure, ensuring the consistency of particle hardness, and is particularly suitable for processing heat-sensitive or moisture-sensitive materials.
1. Feeding Section: Typically equipped with a forced feeder (such as a screw feeder) to ensure uniform material entry into the roller extrusion zone.
2. Extrusion Rollers: Core component, forged from high wear-resistant alloy steel. The roller surfaces have spherical grooves; shapes can be customized (spherical, pillow-shaped, sheet-like).
3. Hydraulic System: Composed of an oil pump, hydraulic cylinder, and accumulator. The hydraulic cylinder holds the movable bearing seat, providing strong extrusion force and overload protection.
4. Transmission System: An electric motor drives a reducer, which in turn drives a pair of gears via a coupling to achieve synchronous, counter-directional rotation of the rollers.
5. Crushing and Screening System: The extruded "cake" is broken up by a crusher and then graded by a drum screen or vibrating screen. Qualified particles enter the finished product silo, while the powder is recycled for granulation.
The hydraulic double-roller granulator adopts a purely physical, high-pressure dry extrusion molding principle. The entire process involves no chemical reactions, no high temperatures, and no additives. Its core relies on molecular compression deformation to achieve powder forming. The complete workflow consists of four stages:
1. Quantitative Feeding Stage: Dry powdered material is forcibly and evenly fed into the double-roller extrusion working area via a screw feeder. Frequency conversion control precisely matches the feeding speed with the roller speed, ensuring full and uniform material filling.
2. High-Pressure Extrusion Molding Stage: The hydraulic system drives the movable roller to fit against the fixed roller, forming a constant high-pressure extrusion zone. The double rollers rotate in opposite directions, drawing material into the roller gap. Under ultra-high pressure, the material expels internal air, causing plastic deformation and tightly adhering to the roller surface and die cavity, pressing into uniform sheet and strip-shaped blanks.
3. Crushing and Shaping Stage: After the formed blanks detach from the rollers, they enter the crushing and granulation mechanism. High-speed toothed rollers break down and shape the large blanks into uniformly sized solid particles.
4. Screening and Recirculation Stage: The shaped granules enter a vibrating screen for screening. Granules that meet the standards are discharged as finished products. Fine powder and broken materials are automatically returned to the feeding system for secondary extrusion granulation, achieving closed-loop production with no waste.
The entire process changes the material's form solely through physical pressure, fully preserving the material's original physicochemical properties. The resulting granules have high density, good strength, and good storage resistance, representing the most mature technology principle for dry powder granulation.
The equipment is suitable for dry powder, fine crystalline, and non-sticky/weakly sticky materials. It has extremely low requirements for material moisture content. The core compatibility parameter is: material moisture content ≤5%. No drying is required; granulation can be performed directly. Compatible material categories cover multiple industries:
1. Organic Fertilizer/Bio-fertilizer Raw Materials: Chicken manure, sheep manure, cow manure, straw powder, mushroom residue, biogas residue, humic acid, peat, organic fertilizer powder, bio-fertilizer, amino acid powder, and other fermented dry powder materials.
2. Chemical Raw Materials: Compound fertilizer powder, urea powder, potash fertilizer, phosphate fertilizer, magnesium sulfate, ammonium sulfate, inorganic salts, chemical waste residue, powder additives, dye auxiliaries, etc.
3. Mining/Building Material Raw Materials: Mineral powder, iron powder, coal powder, lime powder, bentonite, kaolin, fluorite powder, metallurgical powder, tailings powder, and other industrial powders.
4. Feed/Supplement Raw Materials: Feed additives, premix powders, veterinary drug powders, grain processing tailings, etc.
Material Contraindications: High moisture content (>8%), high viscosity, and large particle/lumpy materials must be pre-treated and crushed before use to avoid clogging and roller sticking.
The hydraulic double-roller granulator adopts a pure dry extrusion granulation process, which differs from traditional wet granulation equipment.
Process Features:
1. Room Temperature Granulation: The entire process is carried out at room temperature, without the need for heating.
2. No Additives Required: No binders or wetting agents are added. Dry powder is granulated directly. Even if a small amount of dry powder binder is added, the proportion is ≤3%.
3. No Drying Required: Eliminates the expensive dryers and coolers used in traditional processes, directly utilizing the material's own crystal water or a very small amount of moisture for forming.
4. Circulating Operation: Unqualified fine powder is returned to the elevator feed port via a return auger, mixed with fresh material, and added to the pre-feeding hopper for the next round of process flow. This achieves continuous production.
5. Adjustable Particle Strength: The strength of the finished product can be controlled by adjusting the pressure of the rollers.
6. Significantly Increased Density: The actual density of the material can increase by 1.5 to 3 times.
1. Daily Maintenance: Before starting and after each day's operation, carefully inspect the roller surfaces for wear, scratches, dents, etc. Tighten any loose bolts or nuts promptly.
2. Roller Maintenance: Regularly check the roller surfaces for wear. Repair any wear or scratches promptly. Replace rollers if wear is severe. It is generally recommended to check every six months or quarterly, depending on usage frequency.
3. Hydraulic System Maintenance: Regularly check the hydraulic oil level and sealing. Change the hydraulic oil every 3-6 months. Inspect the hydraulic lines and address any leaks promptly. Clean and inspect the hydraulic cylinders regularly.
4. Lubrication System Maintenance: Regularly check the condition of the lubricating grease to ensure proper lubrication of all components. Clean the lubricating grease and add new grease if necessary.
5. Electrical System Maintenance: Regularly check electrical wiring and components for aging, loosening, or short circuits.
6. Equipment Cleaning: After each shutdown, promptly clean the roller surfaces, feed hopper, and any residual material in the crushing and screening system. Clean using compressed air or a vacuum cleaner. Prevent material from clumping and sticking, which could affect subsequent runs.
7. Roller Gap Adjustment
Control the roller gap using manual bolts or a hydraulic system. Increase the gap for materials with high hardness/large particle size, and decrease it conversely. After adjustment, a no-load test run is required to verify the output particle size.
| Common Fault Phenomenon | Core Fault Causes | Corresponding Solutions |
|---|---|---|
| Low pellet forming rate & severe pulverization | Insufficient hydraulic pressure, excessive roller gap, high material moisture content, severe roller surface wear | Increase hydraulic system pressure and slightly narrow roller gap; dry materials to cut down moisture; polish or replace worn roller shells |
| Material blockage & machine jamming | Excessively fast feeding speed, agglomerated materials, too small roller gap, foreign hard objects entering extrusion zone | Stop machine immediately for pressure relief and clear blocked materials; lower feeding frequency; pre-crush caked materials; inspect and remove hard foreign impurities |
| Hydraulic oil leakage & unstable pressure | Loose pipeline joints, aging sealing parts, insufficient hydraulic oil, clogged filter element | Tighten oil pipeline joints and replace sealing gaskets; add qualified hydraulic oil; clean or replace hydraulic filter element, readjust and stabilize pressure |
| Uneven pellet size | Deviated double roller parallelism, uneven feeding, partial roller surface wear, mismatched rotating speed | Calibrate double roller parallelism; adjust spiral feeder for uniform feeding; repair worn roller surface areas; calibrate transmission speed ratio |
| Abnormal noise & strong vibration during operation | Loose frame bolts, lack of bearing grease, worn gears, excessively hard materials | Tighten all machine bolts and fill lubricating grease; replace worn gears and bearings; sieve out hard materials |
| Overheated motor & overload trip | Long-term overload operation, blockage stall, poor motor heat dissipation, unstable voltage | Reduce feeding load and clear blockages; clean dust on motor heat dissipation components; stabilize power supply voltage and overhaul circuits |
1. Advanced Technology and Low Cost: Pure dry physical molding eliminates the need for water, binders, and drying equipment, significantly reducing equipment investment and operating energy consumption. The process is simple, and labor costs are low.
2. Excellent Molding Effect: Hydraulic constant pressure extrusion produces uniform, high-density, high-strength particles that are less prone to pulverization and have better storage resistance. The granulation rate far exceeds that of traditional granulation equipment.
3. Wide Applicability: Suitable for multiple industries and materials, with strong dry and wet compatibility. Direct granulation of dry powder makes it suitable for various powder deep processing scenarios.
4. Intelligent, Stable, and Durable: PLC fully automatic control ensures simple operation and a low failure rate. Wear-resistant and durable core components result in a long machine lifespan and extremely low maintenance costs.
5. Environmentally Friendly, Efficient, and Waste-Free: Closed-loop production eliminates material waste, dust pollution, wastewater, and exhaust gas, meeting environmental production standards and adapting to various compliant production lines.
Hydraulic roller granulators, as efficient, energy-saving, and environmentally friendly dry granulation equipment, directly compress powdery materials with a moisture content of ≤5%-10% into granules using high-pressure extrusion (50-300MPa) provided by a hydraulic system. No binders or moisture are needed, and no subsequent drying process is required. This equipment achieves a granulation rate of ≥85%, high particle strength (≥10-30N), and can increase bulk density by 1.5-3 times. It is widely used in compound fertilizers, organic fertilizers, chemicals, pharmaceuticals, environmental protection, and many other fields.
Whether you are building a new organic fertilizer/compound fertilizer/feed production line and need a complete equipment solution, upgrading an existing production line and need equipment selection advice, or encountering difficulties in granulating high-moisture, sticky, or coarse-fiber materials and need technical support—we are always ready to provide you with professional and sincere service.
| Size | DGZ-1 | DGZ-2 | DGZ-3 | |
| Capacity | 1-1.5t/h | 2-3t/h | 3-4.5t/h | |
| Granulator rate | ≧85% |
≧85% |
≧85% |
|
| Power | 15kW | 30kW | 37kW | |
| Material moisture | 2%-5% | |||
| Granulation temperature | Normal temperature | |||
| Particle | Diameter | 4-10（mm） | ||
| Strength | 6-20N(Compression crushing) |
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| Shape | Oblate sphere | |||
