Importance of optimizing the tilt angle and speed of the disc granulator

Disc granulators are widely used in fertilizer, feed, and other granule production processes. Tilt angle and rotation speed are two critical parameters that directly affect granulation outcomes. Optimizing these factors can significantly improve production efficiency and product quality.  

Optimizing Tilt Angle

1. Key Factors  

The material's flow behavior is closely linked to the tilt angle. An overly steep tilt angle causes materials to accumulate too quickly at the bottom of the disc granulator, shortening granulation time and resulting in loose, unevenly shaped particles. Conversely, a shallow tilt angle limits proper rolling and mixing of materials, leading to inconsistent granule formation.

2. Optimization Approach  

Determine the ideal tilt angle through repeated trials based on material properties. For example, highly viscous materials may require a smaller tilt angle to ensure sufficient rolling time for proper granule formation. A starting range of 45°–60° is recommended for initial testing. Adjustments can then be made by observing granule shape, size distribution, and other quality indicators.  

Optimizing Rotation Speed  

1. Key Factors  

Rotation speed controls the material's tumbling frequency and centrifugal force. Excessive speed creates strong centrifugal forces that push materials toward the disc edge, causing uneven distribution and premature ejection of underformed particles. Insufficient speed slows material movement, reducing granulation efficiency.

2. Optimization Approach  

Set the rotation speed based on the disc diameter and material characteristics. Larger diameter disc granulators can operate at relatively lower speeds. For example, a 1-meter diameter disc typically starts with a speed range of 10–20 RPM. The optimal speed is achieved when particles roll evenly and produce uniform granules in size and shape. Adjustments should also account for material properties like friction coefficient—higher speeds may suit free-flowing materials.

By applying these optimization methods, manufacturers can better control particle size, enhance product quality, and boost production efficiency, gaining a competitive edge in the market.