Working Principle

1. Feeding & Extrusion
   Powdery or granular raw materials enter the gap between two counter-rotating rollers via a feeding device. Under intense pressure and shear force, the material deforms and aggregates, gradually compressing into dense cakes.

2. Compression Molding
   As the roller gap narrows, pressure increases continuously. The material is extruded through roller surface molds (e.g., circular, oval, square) into continuous strips.

3. Cutting & Screening
   The strips are cut into preset lengths by a knife to form regular particles (e.g., flat spherical, almond-shaped). Target-sized particles are then separated via a screening system.

4. Molecular Binding Forces
   Particle cohesion relies on molecular forces such as van der Waals forces, adsorption, crystal bridges, and embedded connections, eliminating the need for binders.

Technical Advantages

1. Energy Efficiency & Cost Reduction

• Dry-Process Ambient Temperature Technology: Eliminates drying steps, reducing subsequent drying costs by 30%-50%.
• Optimized Transmission System: Uses high-efficiency motors and gear structures, lowering energy consumption per unit output by 30% compared to traditional equipment.
• Low Reflux Ratio: Reflux material accounts for only ~15% of feed, minimizing waste.

2. Environmental Benefits

• Zero Waste Emissions: Sealed design reduces dust pollution, complying with environmental regulations.
• Binder-Free Process: Avoids exhaust emissions from drying binders, simplifying workflows.

3. Productivity & Flexibility

• High Throughput: Capacity ranges from 1-5 tons/hour, supporting 24/7 continuous operation (e.g., monthly output increased from 800 to 1,200 tons in one plant).
• Wide Raw Material Adaptability: Compatible with over 20 materials (e.g., ammonium nitrate, urea, potassium chloride), enabling rapid formula switching (30+ product combinations).
• Adjustable Particle Specifications: Customizable via mold replacement, pressure adjustment, and knife positioning to meet diverse demands (e.g., organic fertilizers, compound fertilizers, biofertilizers).

4. Equipment Reliability & Cost

• Compact Design: Low failure rate and maintenance costs (key components like rollers and knives are easily replaceable).
• Low Investment: Simplified process skips drying and reflux steps.
• Long Service Life: Built with high-strength alloy steel for wear and corrosion resistance.

5. Product Quality

• High-Quality Particles: Uniform shape and strength, with a qualification rate exceeding 95%.
• Multi-Industry Application: Widely used in fertilizers, pharmaceuticals, chemicals, and feed industries, particularly suitable for rare earth and potassium fertilizer granulation.

Comparison with Other Equipment

Application Cases

• Organic Fertilizer Production: A plant processed kitchen waste into 500 tons/year of premium organic fertilizer, generating an additional $300,000 annual revenue.
• Biomass Energy: Corn straw converted into granular fuel, boosting annual capacity by 300% with products exported globally.
• Chemical Industry: Successfully applied to granulate over 20 materials (e.g., ammonium nitrate, urea), filling domestic gaps in rare earth compound fertilizer production.

Summary

The double-roller extrusion granulator stands out in fertilizer, organic waste, pharmaceutical, and chemical sectors due to its efficiency, energy savings, environmental compliance, and flexibility. It is ideal for enterprises prioritizing low costs, high output, and premium-quality granules.