Compacting
Rethinking
Compaction
Technology
Efficient compaction
technology for the fertilizer
industry
Compaction is a proven method for producing granules, which compresses fine-grained solids between two counter-rotating rollers and is used particularly in the production of fertilizers. This produces a solid strand of material, known as a shell, which is then broken up and sieved to produce high-quality granules.
- uniform particle size distribution
- improved flowability
- storage stability
- Conservation of resources through reduction of dust and material losses
As specialists in roller presses and compacting systems, we not only supply individual machines, but also complete system solutions, thereby optimizing the entire process.
Take contact us and benefit from our innovative compaction solutions.
Process technology
Customized Process
engineering
A granulation process for fertilizers consists of the process steps of dosing, mixing, compacting, crushing, classifying, and post-treatment.
The raw materials used in compaction are usually salts. Depending on the grain size and shape, pre-crushing and moistening may be necessary. Some raw materials come from a drying process. The increased temperature often has a favorable effect on compactability. The decisive factor is the optimal interaction of raw material type, grain size, moisture content, and temperature—meaningful results from pilot plant tests form the basis for this.
Our compacting press compresses the mixture of fresh and recycled material under high pressure to form a solid shell of uniform thickness. Köppern offers various types of roller presses for this purpose, tailored to the material properties and throughput. Thanks to precise material feeding, roll gap control, and robust roll design, our presses impress with their long service life, uniform flake quality, and reliable throughput—even with demanding materials.
The compacting press produces a continuous flake. By selecting the optimum press pressure, a defined density is achieved across the entire width of the flake. This ensures the consistently high quality of the granulate.
The Köppern shell crusher reduces the shells to a size that allows them to be transported in conveyor units and adjusts the feed size for the subsequent crushers. The crushing result can be optimized by selecting the operating gap and the crushing discs.
The screen separates the crushed shells into several fractions. The undersize material is fed back into the press. The oversize fractions are fed into the respective crushers and the product fraction is discharged.
The screening process takes place in several stages with different mesh sizes. Graduated screening intervals allow the product quality to be specifically controlled and material loss to be minimized.
The return material is the material separated from the screen with a smaller particle size than the desired granulate product. This material flow is returned to the press and mixed with the fresh material. Mixing the return material and fresh material improves the feed material properties for the compacting press.
The Köppern GranuGrinder® produces the final product size while minimizing the proportion of fine material.
The pre-crushed, screened shell pieces are crushed by a crusher.
Storage and post-treatment ensure the stability and durability of the granulate—e.g., through moistening, drying, and coating with coating agents—and prepare it optimally for transport and further processing. Constant conditions are important in order to specifically control post-curing or moisture absorption or loss. Our technologies enable gentle material handling, which benefits both granulate quality and operational efficiency.
Applications
Advanced Technology
for the Fertilizer Industry
Maximum productivity through efficient process design
Lower energy costs per ton
Our efficient compaction technology ensures high-performance production while reducing energy costs. Optimized roller surfaces, precise pressure control, and efficient material feeding reduce specific energy requirements while maintaining consistently high product quality. Köppern thus guarantees high performance and high output while reducing energy costs.
Improved handling (transport, storage, dosing)
High system availability
Test facilities
Maximize efficiency
with our cutting-edge
test facilities
In order to work out the right design for your compacting pelletizing system, we offer to carry out simulations and tests in our test facilities. In addition to various roller presses, Köppern also has extensive process technology available for this purpose.
Contact us
Contact us for your
customized solution
Would you like to learn more about our compaction solutions? Our experts will be happy to advise you and work with you to develop a solution that is precisely tailored to your production requirements.
