Bentonite Granulation Process

Settings

• Ability : 1 has 20 t/h
• Cost : $100 000 -500 000 $
• Equipment material: Q235 carbon steel, stainless steel
• Application : Bentonite treatment, Production of cat litter, Valorization of mining residues

Raw bentonite feeding and crushing

To start the valorization of bentonite and facilitate the manufacture of granules, It is advisable to first crush the rocks and bentonite blocks into small particles and an easy-to-process powder. For that, you need to feed the raw bentonite into a feeder, then send it to a crusher. Jaw crusher and cage crusher are both suitable choices.

Moisture adjustment and mixing with binders/additives

Ensuite, crushed bentonite powder enters a dosing and mixing system. At this stage, when you mix bentonite with additives to produce cat litter or mineral fertilizer, dosing machine becomes necessary in order to ensure accurate ratio. As for the mixture, it is important to obtain bentonite materials with balanced nutrients and required humidity. These conditions help produce excellent bentonite pellets.

Bentonite granulation : disc/tray granulator, drum or extrusion

Ensuite, the prepared bentonite mixture enters the pellet manufacturing stage. For continuous large-scale bentonite pellet production, many factories choose rotary drum granulator. If you want to get hard pellets with lower investment, you can use a double roller compactor-granulator. For small-scale production of round pelleted cat litter or spherical bentonite fertilizer pellets, a disc granulator gives you a better experience.

Drying and cooling of granulated bentonite

Finished wet bentonite pellets, with approximately 20 % humidity, pass through a rotary dryer, where a flow of warm air reduces humidity to a safe level for storage and transport, generally less than 10 %. After drying, a rotary cooler lowers the temperature, which improves the resistance of granulated bentonite fertilizer, reduces caking and prepares product for screening and packaging.

Screening and particle size classification of bentonite granules

Rotary drum screens classify granular bentonite fertilizer into three categories : oversized, consistent and fine. Compliant pellets become finished commercial mineral pellets, while the oversized pellets return to the crusher, and the fines return to the bentonite granulator. This closed loop helps you produce uniformly sized bentonite pellets and increase the rate of qualified pellets.

Coating granulated bentonite with PVA or paraffin wax

To achieve higher added value and better bonding resistance, you can send the granulated bentonite into coating machine. In mineral fertilizer manufacturing projects, you coat the bentonite pellets with PVA or acrylic polymers to reduce moisture absorption and caking. In bentonite cat litter granulation lines, you spray anti-dust agents, fragrances or colored coatings to meet market demands.

Packaging and storage

Finally, coated or uncoated bentonite granules pass to automatic packaging scales. You can package them in bags of 10 has 50 kg for industrial customers, or in smaller retail bags for the cat litter market. Palletizing systems, conveyors and storage silos facilitate your bagging process in bentonite granulation system, so you can respond quickly to customer orders.

Thanks to the continuous rotation of the drum, you can quickly granulate bentonite rock powder. The maximum capacity can reach 30 TPH, which means it can fully meet your needs to set up an industrial bentonite granulation plant with an annual output of up to 200 000 tons.

What's more, through the use of wet granulation technology, you can freely choose to produce bentonite pellets from 3 has 6 mm, provided the humidity is well controlled. For that, YUSHUNXIN offers customized drum granulation systems with precise liquid spraying device.

On the one hand, no liquid is involved in the process. Therefore, there is no drying in this bentonite granulation process. In this way, you can reduce the costs associated with purchasing a drying system and the energy consumption required for drying.

On the other hand, the system mainly transforms bentonite into pellets by pressing the material between rollers. This physical pressure allows the bentonite to form high hardness fertilizer granules, of 15 has 20 N.

Why does a disc bentonite pelletizing line produce round pellet cat litter ? Because the system mainly forms bentonite cat litter granules by natural rolling under the effect of disk rotation, instead of using physical extrusion.

What's more, in the manufacturing process of bentonite cat litter, disc granulation line works efficiently due to specific designs. The cat litter granulation process is closely related not only to humidity adjustment, but also to adjust the inclination of the disc. The lower the inclination, the larger the pellet size.

With this investment of 500 000 dollars, you can equip it with a complete set of bentonite processing machines, including bentonite sprayer, an automatic dosing machine, two double shaft mixers, a rotary drum granulator SXZGZ-3210, a screening system 2080, a rotary dryer 2424, a cooler 2424, a coating machine and an automatic packaging scale.

These equipment can fully meet your large-scale granular bentonite manufacturing needs for fertilizer, production of cat litter and processing of mineral waste. The capacity can reach 20 TPH, either 100 000 has 150 000 tons per year.

For the production of bentonite cat litter pellets 10 TPH, you can also buy a complete tray granulation line, from crushing to packaging.

However, for large-scale bentonite pellet manufacturing, For example 20 TPH, the budget 300 000 dollars only allows for simpler configuration. For example, you can only buy a system including bentonite powder making, material feeding, two disc granulators, drying and cooling, as well as the packaging. In the future, you can plan a gradual upgrade.

In general, and budget 100 000 dollars can easily allow you to purchase a bentonite pellet making system of 5 TPH, with equipment ranging from crushing rocks to bagging granulated bentonite fertilizer. This is particularly suitable when you plan to adopt a roller extrusion granulation system.

However, if you require production of 10 TPH or the manufacture of spherical granules for the transformation of bentonite, a simpler configuration will be more appropriate.