Mineral powder granulation
Mineral Powder Granulation is a process that converts mineral powder into granular material. It is widely used in chemical, building materials, metallurgy and other fields. Common granulation methods include drum granulation, spray granulation and extrusion granulation. Drum granulation uses a rotating drum and a binder to form powder, which is suitable for large-scale production. Spray granulation uses a nozzle and hot air flow combined with a binder to form particles, which is suitable for heat-sensitive materials. Extrusion granulation is formed by high-pressure extrusion, which is suitable for the production of larger particles. Mineral powder granulation can effectively improve powder fluidity, reduce dust, and improve transportation and storage efficiency.
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Mineral powder granulation technology and its importance in modern industry
Mineral powder granulation is a key technology in modern industrial production. It greatly improves the handling, transportation and use performance of materials by converting fine mineral powders into granular substances. This article discusses the basic principles, main process methods and applications of mineral powder granulation in various industries, and analyzes the important role of this technology in improving production efficiency, reducing environmental pollution and enhancing product performance.
In modern industry, mineral powders are widely used in many fields such as metallurgy, building materials, chemical industry and agriculture. However, materials in powder form usually have problems such as difficult handling, poor fluidity and serious dust pollution. Mineral powder granulation technology effectively solves the above problems by converting these powders into granular substances, providing a more efficient and environmentally friendly solution for industrial production.
Basic principles of mineral powder granulation
The basic principle of mineral powder granulation is to aggregate powder particles into larger and dense particles under certain process conditions through mechanical force or chemical bonding. This process not only improves the fluidity and handling performance of the powder, but also enhances the physical strength and stability of the particles. Common granulation methods include drum granulation, spray granulation and extrusion granulation, each of which has its unique advantages and application scenarios.
Main granulation process methods
Drum granulation: Drum granulation is a method of mixing powder and liquid binder by rotating drum, and gradually forming particles by the rotation and gravity of the drum. This method is suitable for large-scale production, with good granulation uniformity and high physical strength of particles.
Spray granulation: Spray granulation sprays powder and liquid binder at the same time, and quickly evaporates excess liquid through hot air flow or other drying means to quickly form particles. This method is suitable for the treatment of heat-sensitive materials and can produce products with uniform particle size.
Extrusion granulation: Extrusion granulation extrude powder materials into shape through high pressure, and then forms particles by cutting or crushing. This method is suitable for the production of larger particles with high granulation efficiency, but has high requirements on the physical properties of the material.
Application of mineral powder granulation in various industries
Metallurgical industry: In the metallurgical industry, mineral powder granulation technology is widely used in the production of sintered ore and pelletized ore. Granulation can improve the permeability and reaction efficiency of ore in blast furnaces, thereby improving the overall efficiency of the smelting process.
Chemical Industry: In the chemical industry, mineral powder granulation is used to produce catalysts, fertilizers and other products. Granulation not only improves the physical properties of the products, but also greatly improves the convenience of storage and transportation of the products.
Building Materials Industry: In the building materials industry, mineral powder granulation is used to produce building materials such as cement and gypsum. The granulation process improves the strength and durability of the materials and reduces dust pollution during the production process.
Environmental and Economic Benefits of Mineral Powder Granulation Technology
The wide application of mineral powder granulation technology not only significantly reduces dust pollution and improves the working environment, but also improves the utilization rate of materials and reduces resource waste. At the same time, the high fluidity and easy handling characteristics of granulated products reduce transportation and storage costs, bringing significant economic benefits.
Conclusion
As a core technology in modern industrial production, mineral powder granulation technology is of great significance to improving production efficiency, improving environmental quality and enhancing product performance. In the future, with the further development and innovation of process technology, mineral powder granulation will play an irreplaceable role in a wider range of fields.
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Analysis and comparison of commonly used mineral powder granulation processes
Mineral powder granulation processes occupy an important position in modern industry. By converting fine mineral powders into granular substances, these processes significantly improve the handling, transportation and application performance of materials. This article will discuss in detail several commonly used mineral powder granulation processes, including drum granulation, spray granulation and extrusion granulation. By comparing and analyzing the principles, characteristics and applicability of these processes, this article provides a theoretical basis for optimizing granulation processes and equipment design.
In metallurgy, chemical industry, building materials and other industries, the wide application of mineral powder as a raw material makes its processing technology particularly important. The mineral powder granulation process converts fine powder into particles with a certain strength and particle size, which not only improves the handling performance of the material, but also improves its application value. This article will analyze several commonly used mineral powder granulation processes in detail, in order to provide a reference for research and practice in related fields.
Drum granulation process
Process principle
Drum granulation process is to mix powder material with binder and put it into a rotating drum. Under the rotation of the drum, the powder gradually gathers into particles. This process relies on the friction, collision and gravity of the material in the drum, so that the particles gradually increase in size while having good uniformity and mechanical strength.
Process characteristics
- Advantages: Suitable for large-scale continuous production, high production efficiency. Uniform particle size and high yield rate. Mature process equipment and simple maintenance.
- Disadvantages: High energy consumption of equipment, especially when dealing with high viscosity materials. Strict requirements on the initial particle size and moisture content of the material. Dust may be generated, and dust removal equipment is required.
Scope of application
Drum granulation is widely used in the production of fertilizers, feeds, mineral particles and other products, especially for granular products that require high strength and good fluidity.
EMCC Drum Granulator
Spray granulation process
Process principle
Spray granulation is a technology that converts fine powder materials into granular materials. It is widely used in metallurgy, building materials, chemicals and agriculture. The process sprays a slurry containing a binder onto the powder material, so that the powder particles are combined and aggregated under the action of the binder to form uniform particles. This technology can effectively improve the physical properties of the material and improve its fluidity, stability and ease of handling.
Process characteristics
- Advantages: By controlling the spraying amount and mixing time, products with relatively uniform particle size can be produced. The spraying granulation process is suitable for various types of powder materials, whether it is metal mineral powder or non-metallic mineral powder, it can be granulated by this process. The type and amount of binder can be adjusted according to different production needs, with strong flexibility. The spraying granulation process can effectively reduce the generation of dust, improve the production environment, and contribute to environmental protection.
- Disadvantages: The energy consumption of spray granulation is relatively high due to the need to spray the slurry and dry it. Spray granulation equipment is usually more complicated, involving spraying system, mixing system and drying system, and has high maintenance and operation requirements. Some binders may remain in the particles, which may affect some products with high purity requirements.
Scope of application
The spray granulation process is widely used in many industrial fields. The specific application scope includes: Mainly used for the granulation of iron ore powder, manganese ore powder, nickel ore powder and other mineral powders to produce sintered ore or pelletized ore to improve the utilization rate of ore in blast furnaces. Commonly used in the production of compound fertilizers, trace element fertilizers, catalysts, etc., products that require control of particle size and uniformity. Used in the granulation production of cement, gypsum, ceramics and other materials to improve the physical properties of these materials and improve the convenience of construction. Used in the production of feed pellets and agricultural fertilizers to improve the storage stability and application efficiency of the products.
Extrusion granulation process
Process principle
The extrusion granulation process extrude powder materials through a die under high pressure and then form particles by cutting or crushing. This process directly forms through mechanical force and can produce larger and more regular particles.
Process characteristics
- Advantages: The granulation process is simple and easy to control. It can produce high-density and high-strength particles. It is suitable for a variety of materials, especially those with high plasticity requirements.
- Disadvantages: The viscosity and plasticity of the material are required to be high. The mold wears quickly and needs to be replaced and maintained regularly. It is relatively difficult to control the particle size and shape.
Scope of application
Extrusion granulation is mainly used for the production of fertilizers, ceramic particles, feed, etc., and is suitable for the production of large particles or particles of special shapes.
EMCC Roller Granulator
Process comparison and selection
Different granulation processes have their own advantages and disadvantages. The selection of a suitable granulation process requires consideration of material characteristics, product requirements, production scale and economy. Drum granulation is suitable for the production of large-scale, uniform particles; spray granulation is suitable for the control of fine particles and the processing of heat-sensitive materials; extrusion granulation has advantages when large particles or particles of special shapes are required.
Conclusion
Mineral powder granulation process plays an important role in modern industrial production. Through the detailed analysis and comparison of drum granulation, spray granulation and extrusion granulation, it can be seen that different processes are suitable for different application scenarios and material characteristics. In the future, with the development of technology, various granulation processes will play their unique role in a wider range of fields and will further promote the efficient and sustainable development of industrial production.
EMCC has been the industry’s preferred supplier of mineral powder granulation equipment for over 10 years. Our granulation equipment is rugged, reliable and manufactured to the highest quality standards. We also offer unparalleled feasibility testing and granulation process development services in our test facilities, as well as comprehensive parts and service support. To learn more about our mineral powder granulation equipment or services, contact us today!
WE NOT ONLY PROVIDE RELIABLE PRODUCTS, BUT MORE IMPORTANTLY WE PROVIDE RELIABLE PROCESS DESIGN AND EXPERIMENTATION
HERE ARE THE COMMON STEPS INVOLVED IN MINERAL POWDER GRANULATION:
Raw material preparation: Firstly, the mineral powder needs to undergo appropriate raw material preparation. This may involve steps such as screening, grinding, mixing, or proportioning to ensure the quality and composition of the raw materials meet the requirements.
Wet granulation: Wet granulation is one of the common methods used in mineral powder granulation. In this process, the mineral powder is mixed with a certain proportion of water or other liquids and undergoes wet granulation through equipment such as stirring, spraying, or drumming. The mixture forms granules in the stirring or drumming process and is solidified into granules through drying or curing. Generally, rotary drum granulation production lines and disc granulation production lines are used.
Drying: After granulation, the granules usually need to undergo drying to enhance their stability and strength. This may involve steps such as drying, adding curing agents, or heat treatment to solidify or harden the granules.
Screening and packaging: Finally, the granulated mineral powder particles need to undergo screening to remove particles that do not meet the size requirements. They are then packaged and stored.
It is important to choose a suitable granulation process based on the specific properties, requirements, and applications of the mineral powder. Different mineral powder granulation processes can be adjusted and optimized as needed to achieve the desired granular products. EMCC company can provide you with suitable solutions for your specific requirements.
WHY CHOOSE EMCC AS YOUR PARTNER?
Shanghai Exceed Industry Co., Ltd (China EMCC) is a manufacturing enterprise specializing in high-tech fertilizer machinery. For many years, we have devoted to producing inorganic and organic fertilizers granulator equipments. By consistently creating values for our customers around the world, we have become one of the leading suppliers in global agricultural fertilizers industry. With China EMCC, you may get comprehensive services of consulting, design, equipment, installation, training, emergency assistance, field assistance, spare parts and routine maintenance to save fertilizer plants cost.
