How Does a Double Roller Granulator Work? The No-Dry Principle Explained

The core innovation of the Double Roller Granulator lies in its simplicity. It transforms dry, fine powder into uniform, high-density granules without adding liquid. The process involves three key stages:

1.Feeding & Compaction

Pre-mixed dry raw materials are evenly fed into the gap between two parallel, counter-rotating rollers. These rollers exert extreme mechanical pressure (ranging from tens to hundreds of tons).

2.Dry Pressing & Flake Formation

Under this immense pressure, the powder particles are compressed, expelling air and creating solid bonds through molecular forces (van der Waals forces, crystal bridging). The output is not yet a granule, but a thin, solid sheet or “flake.”

3.Crushing & Screening

This compacted flake is then fed into a gentle crusher or flake breaker, where it is fragmented into smaller pieces. These pieces are subsequently screened to separate the desired particle size (finished granules) from over-sized pieces (re-crushed) and fine powder (recycled back to the feeder).

This “dry compaction” method bypasses the entire liquid addition, mixing, and drying cycle, which is the source of its massive efficiency gain.

Detailed Analysis: How It Achieves 40-60% Energy Savings

The claimed 40-60% energy saving is not an exaggeration but a calculated comparison between a traditional wet granulation line (e.g., using a rotary drum or disc granulator) and a dry compaction line. The savings are systemic:

The primary saving comes from completely eliminating the dryer. Traditional wet processes require massive thermal energy to evaporate every kilogram of water added during mixing and granulation. Our Double Roller Granulator uses a purely mechanical process, consuming electricity only for driving the rollers and ancillary equipment. This removes the largest single energy consumer from your production line.

Additional efficiency gains are realized across the board:

• No heating, minimal cooling: Without a dryer, there is no need for subsequent energy-intensive cooling of hot granules.
• Simplified exhaust management: The system deals with dry dust only, avoiding the large, humid air volumes that require powerful and expensive scrubbing systems.
• Reduced auxiliary load: A more compact process flow with fewer machines (no mixer, dryer, or complex conveyors for wet material) lowers the overall plant energy footprint.

Beyond Energy: Key Operational Advantages

• High-Density, Low-Dust Granules: Produces strong, abrasion-resistant granules ideal for storage, long-distance transport, and automated spreading.The granules produced meet high-quality specifications, aligning with official fertilizer regulations in key markets.
• Wide Material Compatibility: Excellent for heat-sensitive materials (e.g., certain nitrogen sources) where traditional drying would cause degradation or nutrient loss.
• Simplified Process Flow: Fewer units of equipment mean lower capital investment (CAPEX), reduced maintenance points, and easier operation.
• Environmental Benefits: No process wastewater, minimal volatile emissions, and easier dust control contribute to a greener production profile.

Engineered for Performance: Henan Lane’s Technical Commitment

Henan Lane Heavy Industry designs and manufactures a range of Double Roller Granulators to meet diverse production capacities, from pilot-scale projects to high-tonnage industrial lines. Our focus is on delivering reliable, customizable solutions.

Our Technical Commitment Includes:

• Robust Construction & Premium Materials: Critical components like rollers are engineered for extreme pressure and wear resistance, ensuring long-term durability and consistent output.
• Precise Process Control: Our systems allow for fine-tuned adjustment of key parameters like roller pressure and feed rate, enabling optimization for various material characteristics.
• Proven Global Expertise: With installations worldwide, we provide solutions backed by practical experience across different climates, raw materials, and production standards.

Ideal Applications in Fertilizer & Chemical Production

• The Double Roller Granulator is the optimal choice for a wide range of materials, including:
• NPK Compound Fertilizers
• BB Fertilizer (Bulk Blend) Base Granules
• Organic-Mineral Compound Fertilizers
• Potassium Chloride, Sulfate, and Other Single-Nutrient Fertilizers
• Limestone, Dolomite, and Soil Amendment Powders
• Industrial & Chemical Powders (e.g., catalysts, pigments, ceramics).

Why Partner with Henan Lane for Your Granulation Upgrade?

• Choosing Henan Lane means more than buying a machine; it’s investing in a total productivity solution.
• Data-Backed Recommendations: We offer no-obligation granulation tests using your actual raw materials to verify feasibility and expected results before you invest.
• Turnkey Project Support: From initial design and engineering to installation, commissioning, and operator training, we ensure a smooth project lifecycle.
• Long-Term Partnership: Our commitment is backed by comprehensive support to keep your operation running efficiently.

Take the First Step Toward Efficient Production

• If your goals include slashing energy costs, simplifying your process, and producing superior-quality dry granules, the Double Roller Granulator technology is your definitive answer.
• Contact Henan Lane Heavy Industry today to discuss your project, request detailed technical documentation, or schedule a free material granulation test. Let us demonstrate how our “No-Dry Process” can transform your profitability and operational efficiency.
• Email: sales@lanesvc.comContact number: +8613526470520

  Whatsapp: +8613526470520