The granulation performance of disc pelletizers is affected by a combination of material properties, equipment parameters, operational conditions, and environmental factors. A detailed breakdown is as follows:

I. Material Characteristics

1. Particle Size and Distribution
   • Fine powder materials have a large specific surface area and strong nucleation ability, but excessively fine particles may increase the demand for binders.
   • Uniform particle size distribution promotes dense granule formation and reduces breakage risks.
2. Moisture Content and Binders
   • Moisture levels must be balanced: insufficient moisture leads to loose granules, while excessive moisture causes agglomeration.
   • Binder properties (e.g., wettability, surface tension) and spray rates influence granule strength and size distribution. For example, low-surface-tension binders enhance wettability, but excessive spray rates may form lumps.
3. Solubility and Composition
   • Highly soluble materials reduce solvent requirements, but active ingredients may migrate to granule surfaces during drying.
   • Material composition (e.g., organic matter, inorganic salts) affects binder adhesion and granule stability.

II. Equipment Parameters

1. Disc Structure
   • Diameter and Inclination Angle: Larger diameters increase throughput; inclination angles (typically 40°–60°) that are too small cause material retention, while steep angles reduce granule size.
   • Rotational Speed (10–50 RPM): Balances nucleation and breakage. Insufficient speed causes uneven binder distribution; excessive speed hinders large granule formation.
   • Edge Height and Material: Edge height influences material rolling paths; stainless steel or carbon steel discs with anti-corrosion linings (e.g., dual-layer衬里) extend service life.
2. Scrapers and Spray Systems
   • Scraper position and shape prevent wall adhesion and ensure uniform material rolling.
   • Spray systems must evenly distribute binders to avoid localized over-wetting or drying.

III. Operational Conditions

1. Feeding Method and Rate
   • Continuous, uniform feeding prevents localized overload. Feeding rates must match rotational speed to maintain dynamic equilibrium.
2. Granulation Time
   • Insufficient time results in underdeveloped granules; excessive time increases breakage risks.
3. Drying and Cooling
   • Post-granulation drying affects granule hardness and storage stability. Temperature and humidity must be controlled to prevent cracking or agglomeration.

IV. Environmental Factors

1. Temperature and Humidity
   • High temperatures accelerate binder drying, but high ambient humidity may cause material moisture absorption and agglomeration.
2. Dust Control
   • Ventilation systems must effectively control dust to maintain operational safety and product quality.

V. Integrated Influence Mechanisms

• Material-Equipment Synergy: Fine powders require lower rotational speeds and moderate binder amounts; disc inclination and speed must adapt to material flowability.
• Operational Coordination: Feeding rates and binder spray volumes directly impact granule uniformity and yield.
• Environmental Indirect Effects: Humidity and equipment corrosion indirectly influence granulation by altering material properties.

Optimizing these factors enhances granulation efficiency, granule strength, and size uniformity, meeting diverse application needs (e.g., organic fertilizers, chemical raw materials).