The core solution logic for abnormal pellet quality in disc pelletizers is "first identify the type of anomaly, then adjust materials, equipment parameters, and processes accordingly." The following are specific measures:

1. Uneven particle size (large lumps / excessive small particles / high proportion of fine powder)

• Optimize raw material pretreatment: Crush the raw material to 80-100 mesh, remove oversized particles and excessive fine powder through screening to ensure uniform particle size.

• Adjust the equipment parameters: Set the disc rotation speed to 18-22 r/min (a higher speed may generate fine powder, while a lower speed may cause caking). Adjust the tilt angle to 45-55° (an excessive tilt angle may cause particles to slide off, while a smaller angle may lead to accumulation).

• Improve the spray method: Adopt multi-point atomization spraying to avoid excessive local moisture causing clumping, ensuring uniform humidity distribution of the material.

2. Insufficient particle strength (prone to breakage/fracturing)

• Control moisture ratio: Adjust the materials water content to 15%-25% (fine-tune based on material viscosity, reducing moisture for highly viscous materials) to prevent excessive dryness or wetness from affecting bonding strength.

• Add binder: For materials with poor adhesion (such as fly ash or phosphogypsum), incorporate 2%-5% of binders like bentonite, starch, or cement to enhance particle cohesion.

• Optimize the drying process: Maintain the drying temperature at 80-120°C, extend the drying time to 1-2 hours, ensure thorough moisture evaporation within the particles, and enhance hardness.

3. Abnormal particle humidity (excessive moisture causing adhesion / excessive dryness preventing ball formation)

• Excessive wet adhesion: Reduce spray water volume, increase disc rotation speed to promote moisture evaporation, or incorporate 5%-10% dry recycled material into the feedstock to adjust humidity.

• Over-drying prevents ball formation: Gradually increase the spray water volume (1%-2% increment each time), and use warm water spraying (30-40°C) to enhance material viscosity, aiding in ball formation.

4. Low pellet formation rate (large amounts of material cannot be formed into pellets)

• Check the material ratio: Ensure that the viscous component accounts for no less than 30% of the materials, and non-viscous materials must be mixed with viscous materials.

• Adjust the disc structure: Install hanging plates on the inner wall of the disc to extend the rolling time of materials within the disc, promoting the growth of ball nuclei; replace wear-resistant linings (such as rubber linings) to enhance material adhesion.

• Control the feed rate: The feed volume must match the disc specifications (e.g., for a φ2.2m disc, the feed rate should be controlled between 1-1.5t/h) to prevent excessive feeding speed, which may result in insufficient material retention time within the disc.

Key Preventive Measures

1. Establish a parameter ledger: Record parameters such as rotation speed, inclination angle, and water spray volume corresponding to different materials, enabling direct reuse for similar materials in the future.

2. Regular equipment inspection: Clean the inner wall deposits of the disc weekly, check for clogging in the atomizing nozzles monthly, and replace worn liners and hanging plates quarterly.

3. Real-time Quality Monitoring: After granulation, an online screening process is implemented to promptly separate substandard particles (returned to the disc for re-granulation), preventing batch quality issues.