Manganese ore powder rotary drum granulator granulation production line

The conversion of manganese ore powder into granules is processed using a drum granulator granulation production line

       The conversion of manganese ore powder into granules is processed using a drum granulator granulation production line. The core of the manganese ore rotary drum granulation process is to use the mechanical action of the rotating drum to mix fine manganese ore powder with a binder and agglomerate it into uniform particles, providing qualified raw materials for subsequent metallurgical processes (such as sintering and smelting), and solving the problems of ore dust, transportation losses and low smelting efficiency.

1. Core Process Flow

The entire process revolves around "raw material pretreatment → mixing → granulation → drying → sieving", with each step closely linked and directly affecting the quality of the granules.

1. Raw material pretreatment : Grind and remove impurities from manganese ore powder to ensure uniform particle size (usually 80%-90% passing through a 200-mesh sieve), while removing impurities such as stones and metals to avoid wear on equipment or affecting particle purity.

2. Ingredients and mixing : Add manganese ore powder (main material), binder (such as bentonite or water glass, accounting for 2%-5%), and water (for humidity adjustment) to the mixer in proportion, and stir thoroughly until the material is in a state where it can be "formed into a ball by hand and easily dispersed when squeezed", providing the best humidity conditions for granulation.

3. Rotary drum granulation (core process) : The pretreated mixture enters an inclined drum (inclination angle 3°-5°, rotation speed 10-20 r/min). Through the rolling, tumbling and squeezing action generated by the rotation of the drum, the material gradually agglomerates into spherical or near-spherical particles. The particle size can be controlled by adjusting the drum rotation speed, inclination angle and feed rate (usually the target particle size is 3-8 mm).

4. Particle drying : Freshly made wet particles (moisture content 15%-25%) enter a dryer (such as a rotary kiln) and are dried at a temperature of 100-200℃ to reduce the moisture content to below 5%, thereby increasing particle strength and preventing breakage during transportation and storage.

5. Screening and return : The dried granules are screened by a vibrating screen. Those that meet the particle size requirements are the finished product; powders that are too fine or lumps that are too large are returned to the mixer or granulator for reprocessing, so as to realize the recycling of raw materials and improve the yield (usually the yield can reach more than 85%).

2. Key process control parameters

Parameter settings directly determine particle strength, particle size uniformity, and yield; the following three items require close monitoring:

• Material moisture content : The moisture content of the mixed material needs to be controlled between 18% and 22%. Too high a moisture content will cause the particles to clump together, while too low a moisture content will make it difficult for the particles to agglomerate, resulting in loose and brittle particles.

• Drum operating parameters : The drum tilt angle is usually 3°-5°, and the rotation speed is 12-18 r/min. If the tilt angle is too large or the rotation speed is too fast, the material residence time in the drum is short and the particles are small; conversely, the residence time is long and the particles are prone to be too large.

• Binder dosage : The amount of binder (such as bentonite) added is generally 2%-4% of the manganese ore powder mass. If the dosage is too small, the particle strength will be insufficient; if the dosage is too large, impurities will be introduced, affecting the subsequent metallurgical effect.

3. Process Advantages and Precautions

Advantages

• High capacity : The hourly capacity of a single machine can reach 5-50 tons, which is suitable for large-scale production.

• Stable particle quality : The finished particles have good sphericity and uniform particle size, and the strength can reach 10-20N/particle, which meets the requirements of metallurgical transportation and smelting.

• Highly adaptable : It can process manganese ore powder of different grades (such as rhodochrosite and pyrolusite) by simply adjusting the ingredients and parameters.

Precautions

• Raw material impurity removal : Metal impurities in manganese ore powder must be strictly removed to avoid wear of the inner lining of the drum or equipment blockage.

• Environmental control : The drying process generates dust, so it is necessary to use environmental protection equipment such as bag filters to prevent dust pollution.

• Binder selection : Prioritize binders that have minimal impact on subsequent smelting. For example, bentonite should have its silicon content controlled to avoid affecting the purity of the manganese alloy.

4. Main parameters of peat pellet drum granulation production line

Rotary Drum Granulator Frequently Asked Questions (FAQs)

Q:  Could you please specify the hourly output range of your drum granulator?

A:     The standard hourly output of our drum granulator ranges from 1 to 300 tons. If you have higher output demands (e.g., over 25 tons per hour), we can tailor a customized solution based on your specific production needs.

Q: HOW DOES A ROTARY DRUM GRANULATOR WORK?

A:     A drum granulator works by tumbling material in the presence of a liquid binder to encourage granule formation and growth. Feed material and binder are constantly fed through the rotating drum. The rolling action, combined with the stickiness from the binder, causes fines to collect together into particles. These particles continue to pick up additional fines and binder as they tumble in the bed, causing them to densify and pick up additional layers in a phenomenon known as coalescence. Tumbling flights can be incorporated into the unit to increase agitation of the material bed.

This way of forming agglomerates is a type of agitation agglomeration also known as wet granulation, balling, or pelletizing.

Q: WHAT TYPES OF MATERIALS CAN A ROTARY DRUM GRANULATOR PROCESS?

A:     Generally speaking, drum granulators can process any bulk solid in the form of a dry, fine powder. This flexibility lends well to a host of industries, processing materials ranging from specialty chemicals and fertilizers, to minerals and ores, and everything in between.

In some cases, the feedstock may require pretreatment in the form of crushing, grinding, or drying to be a suitable feed for the granulator and produce the characteristics desired in the end product.

Q: WHAT’S THE ADVANTAGE OF A ROTARY DRUM GRANULATOR OVER A DISC PELLETIZER?

A:     In choosing between a drum granulator and a disc pelletizer, the drum is often chosen because it offers a higher throughput than the disc pelletizer. The rotary drum also has the advantage of being a “closed” system, meaning that granulation occurs inside a contained environment, so fugitive material is limited.

WHAT CAPACITIES CAN A GRANULATION DRUM ACCOMMODATE?

A:     Granulation drums can be customized to nearly any size, accommodating capacities ranging from 500 lb/hr – 3500 TPH+.

ARE DRUM GRANULATORS BATCH OR CONTINUOUS?

A:     Rotary drum granulators are typically employed in a continuous setting, though they may function as a batch device in some R&D environments, such as the TIANCI Innovation Center.

Q: WHAT IS THE RETENTION TIME OF A ROTARY DRUM GRANULATOR?

A:     Retention time is one process parameter used to control the characteristics and quality of the material exiting the drum, so it can vary significantly depending on the process and product goals. In general, retention time in a granulator may fall anywhere between 30 seconds and 60 minutes.

Q: WHAT ARE THE TYPICAL WEAR ITEMS?

A:     Rotary drum granulators are generally low maintenance, but some items can become worn, depending on the operating conditions, and particularly if the drum falls out of alignment. The most common wear items for a drum granulator typically include the liner (where applicable), tumbling flights (where applicable), and potentially trunnion wheels, tires, and thrust rollers.

Rotary drum alignment is an important aspect of drum maintenance to prevent wear of the tires and trunnion wheels. When a drum falls out of alignment, it puts added stress on all components, encouraging undue wear.

Q: DOES THE PRODUCT EXITING THE GRANULATOR REQUIRE DRYING?

A:     Since the granulation process relies on a liquid binder to form and layer granules, the product exiting the granulator is wet and must be dried unless it is moving immediately to a downstream process that does not require drying (such as in the case of iron ore balling, where pellets go to a grate kiln).

Drying is typically carried out in a rotary dryer, which further rounds and “polishes” the granules as a result of the tumbling action that occurs as the drum rotates.

Q: HOW DO I KNOW IF A ROTARY DRUM GRANULATOR IS RIGHT FOR MY APPLICATION?

A:     Whether or not a rotary drum granulator is the right fit for a given project depends on specific process and product goals, such as capacity, level of control over particle characteristics, product parameters, and more.

When it is not clear if a drum granulator will be able to meet the project objectives, testing can be carried out in the TIANCI Innovation Center to evaluate the process and identify the most suitable equipment configuration.

Q: IS ANY OTHER EQUIPMENT REQUIRED TO SUPPORT A ROTARY DRUM GRANULATOR?

A:     Drum granulators require a feeding and offtake system to convey material into and away from the drum. They also typically require screens and a recycle circuit to recover overs and unders and recycle them back into the process

Drum granulators are also typically followed by a rotary dryer and in some cases, may be preceded by a mixer for providing a homogeneous feedstock to the unit.

Q: WHAT DOES THE DESIGN PROCESS LOOK LIKE?

A:     Rotary drum granulator design typically begins with testing to assess the feasibility of granulating the intended material and to gather key process data such as percent fill, retention time, drum speed and slope, spray system design, and more.

Once the data has been gathered, engineers work off of this to size the drum and incorporate any necessary features or modifications needed to produce the desired product at the intended capacity.

Q: WHAT DATA IS NEEDED TO DESIGN A ROTARY DRUM GRANULATOR?

A:     A variety of data points are necessary to design the granulator. Along with a process description, the follow data is typically required:

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We are committed to providing our customers with comprehensive support and reliable services. Our company offers free process design drawings tailored to your needs, as well as free trial testing services to ensure optimal machine performance. Every machine comes with a one-year warranty for worry-free operation. In addition, we provide free installation and professional training services, helping your team quickly master the equipment and achieve efficient production.