Solution for Reducing Equipment Wear in Disc Granulation Production Lines
The main wear in disc granulation production lines is concentrated on the granulation scraper, disc liner, conveyor belt, screen, bearings, and spray nozzles. Excessive wear increases spare parts costs and leads to frequent downtime. Comprehensive management can be implemented through four aspects: raw material pretreatment, process control, daily maintenance, and structural optimization.
Proper raw material pretreatment is the key to reducing hard wear. Well-rotted cow dung and straw should be thoroughly pulverized in a semi-wet pulverizer to cut long fibers and remove hard impurities such as stones and bricks beforehand. Hard objects entering the disc granulator will quickly scratch the disc surface and wear down the scraper. The moisture content of the raw materials should be evenly adjusted to 28%-32%. Too high a moisture content results in excessive material sticking to the disc, and the scraper’s continuous, strong scraping will exacerbate wear; too low a moisture content leads to excessive dust, accelerating the accumulation of dust and corrosion in bearings and transmission parts. The addition of binding agents such as bentonite should not be excessive to avoid material hardening and increased frictional wear.
Optimize the granulation operation process to reduce the load on components. Properly adjust the disc tilt angle and rotation speed to avoid prolonged full-load high-speed operation. Excessive speed increases material impact force, accelerating liner wear. Use ultra-fine atomization for spraying to prevent localized water accumulation and the formation of large clumps of mud, reducing the force on the scraper when removing thick material. Regularly fine-tune the gap between the scraper and the disc surface; too small a gap will cause continuous friction against the disc, while too large a gap will result in incomplete cleaning of adhering material. An appropriate gap effectively cleans material while minimizing hard-on-hard wear.
Implement daily preventative maintenance to delay component aging. After each daily shutdown, rinse the disc and scraper, and clean the silos and conveyor belts of accumulated material. Long-term adherence of hardened clumps increases operating resistance. Unclog the spray nozzles daily to prevent uneven water flow and the formation of large material clumps, which increases the overall machine load. Promptly correct belt misalignment to avoid one-sided friction and belt tearing. Use rollers to clean adhering material and prevent localized belt wear.
