High-speed intensive mixing granulator:

Principle:The three-dimensional countercurrent intensive mixer rotates at high speed in a closed container,violently mixing,shearing,and agglomerating the powder and the injected binder into granules.

High-speed intensive mixing granulator Advantages:

The mixing and granulation are completed in one piece,with high efficiency and short single batch time(several minutes to more than ten minutes).

The sphericity of the particles is good and the fluidity is usually good.

Enclosed operation,good dust control,and relatively convenient cleaning.

The equipment is compact and occupies a small area.

High-speed intensive mixing granulator Disadvantages:

The particle density is relatively low and the porosity is high.

The particle strength may not be as good as the extrusion type.

It is not ideal for sticky materials or applications requiring high-density particles.

Applicable:The particle strength requirements are not too high,and the efficiency and fluidity are pursued,such as the granulation of powders such as electronic ceramics,some structural ceramics,and catalyst carriers.Commonly used in small laboratories and pilot plants.

Extrusion granulator:

Principle:First,mix the powder and binder evenly(a separate mixer may be required)to form a plastic mud mass,then extrude it into strips through a mold(screen),and then cut it into short cylindrical particles by a rotating cutter.

Extrusion granulator Advantages:

High particle density and good strength,suitable for subsequent dry pressing.

Regular particle shape(short cylinder)and uniform particle size(controlled by the screen aperture and cutter speed).

It has a wide adaptability to materials and can handle slightly sticky materials.

Extrusion granulator Disadvantages:

Usually requires a pre-mixing step(the equipment may only be responsible for extrusion granulation).

The granulation speed is relatively slow.

The screen is easy to wear and needs to be replaced regularly.

Cleansing the mold and the interior is relatively complicated.

The particle shape is limited to cylindrical.

Applicable:Occasions with high requirements for particle strength and density,such as refractory materials,structural ceramics,grinding media,catalysts,etc.Small equipment is suitable for small-batch high-quality production or research and development.

Fluidized bed granulator:

Principle:The powder is blown up by the air flow in the fluidized bed to fluidize,the binder solution is sprayed into atomization,the droplets wrap the powder particles and collide with each other to agglomerate and grow.The drying function can be integrated(one-step granulation).

Fluidized bed granulator Advantages:

The particles have high sphericity and excellent fluidity.

The particle size distribution is narrow and can be precisely controlled.

Drying can be completed simultaneously to obtain dry particles in one step.

Closed operation and good dust control.

Fluidized bed granulator Disadvantages:

The equipment is relatively complex and the price is usually high(even for small ones).

The control requirements of operating parameters(airflow,temperature,spray speed,etc.)are high.

There are certain requirements for the particle size and density of the initial powder(it needs to be fluidized).

The output is relatively small(small equipment).

Applicable:High-end applications with extremely high requirements for particle sphericity,fluidity,and particle size uniformity,such as precision ceramics,medicine,high-end catalysts,etc.Small equipment is mainly used for research and development and small batch production