Integrated equipment
Automatic Feeder
Meters carbon black powder into the line at a stable rate and isolates the first dust release point.
01 · Complete production solution
Carbon Black Granulation Line
Turns dusty carbon black powder into dense, low-dust granules through binder mixing and double roller compaction, with closed-loop screening and packing sized to your target mesh.
02
Project definition
Quick answer
Carbon black is compacted, not pelletised in a drum: the whole route is built around roll pressure, binder ratio and dust control.
SolutionCarbon Black Granulation Line
Primary feedCarbon black powder, binder system, process water
Finished productDust-free carbon black granules
Process routeFeeding & de-dusting → Binder mixing → Double roller compaction → Crushing & screening → Drying → Packing
CapacityProject-specific; confirmed by mass balance
VoltageConfirmed for the destination country
AutomationManual-assisted, coordinated automatic or integrated
Project scopeProcess, equipment, controls, layout and service as agreed
One connected process, not isolated machines
Roll pressure, binder ratio and screen cut are set as one system; changing one of them changes the whole mass balance.
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Feedstock readiness
Suitable raw materials
Fine powders behave differently from fertilizer granules. These are the inputs we ask you to characterise before sizing the line.
01
Furnace carbon black powder
N220, N330, N550 or similar grades; bulk density, oil absorption and sieve residue confirmed before design.
02
Recovered carbon black
Material from pyrolysis or tyre recycling, screened and de-ironed before batching; ash content verified.
03
Binder system
Water, lignin, molasses or starch-based binder, selected against target granule strength and end use.
04
Process water
Used for wet mixing, granule formation and dust suppression; hardness and suspended solids checked.
05
Optional additives
Dispersants, humectants or conductivity additives where the application requires them.
06
Material condition
Moisture, particle size, lump content and abrasiveness are measured per batch, not assumed from the grade name.
04
Market output
Target finished product
The line is configured backward from the granule specification and the packing format your customers accept.
Target product
Dust-free carbon black granules
Granule size, crush strength, dust index, moisture and packing density
Representative material reference. Replace with an approved finished-product photograph.
Product formCompacted carbon black granules
Typical size1–5 mm, set by screen cut and confirmed on your sample
Quality basisSize distribution, crush strength, dust index, moisture, bulk density
Main applicationsRubber and tyre masterbatch, pigment and dye, conductive compounds, carbon-based fertilizer carrier
Packaging25 kg bag, big bag, bulk or filling format by project
TraceabilityRecipe, roll pressure and batch records when configured
Design priorities
- Dust containment at every transfer point
- Stable granule size across shifts
- Predictable binder consumption
- Safe operator and maintenance access
- Expansion-ready interfaces when required
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Production sequence
Process flow
Every stage is sized against its inlet, outlet and recycle duty; oversize granules always return to the press, never to the bin.
01
Feeding & de-dusting
Meter powder under negative pressure
02
Binder mixing
Knead to a compactable mass
03
Double roller compaction
Press the mass into a dense sheet
04
Crushing, screening & packing
Cut to mesh size and pack dust-free
StagePurposeInputEquipmentOutputCritical control
1. Feeding & de-dustingBreak lumps and stop dust escaping at the first transferCarbon black powder in bags, bulk bags or siloAutomatic FeederMetered, de-lumped powderFeed rate, negative pressure, filter condition
2. Binder mixingHold the binder ratio that decides granule strengthPowder plus binder and process waterDouble-Shaft MixerUniform, compactable massBinder-to-powder ratio, mixing time, moisture
3. Double roller compactionDensify the mass into a sheet at controlled pressureMixed mass at target moistureDouble Roller Extrusion GranulatorCompacted sheet or flakeRoll pressure, gap, roll speed, sheet thickness
4. Crushing, screening & packingCut to size, return oversize and pack the productCompacted sheetRotary Drum Screener, Fertilizer Packing MachineFinished granules in the agreed packingScreen cut, recycle ratio, dust, bag weight
Process balance rule
Final throughput is limited by the complete mass balance — binder and water addition, oversize recycle, drying load and packing rate — not by the nominal capacity of a single press.
06
Line architecture
Equipment configuration
Open each machine page for its role and selection boundary.
Integrated equipment
Double-Shaft Mixer
Blends powder with binder and water to a homogeneous, compactable mass; the paddles handle dense carbon mixes.
Core equipment
Double Roller Extrusion Granulator
Compacts the mixed mass between two counter-rotating rolls; roll pressure and gap set granule density and strength.
Integrated equipment
Rotary Drum Dryer
Removes the water added with the binder when the wet route is used; thermal duty is calculated from the moisture balance.
Integrated equipment
Rotary Drum Screener
Classifies granules to the target mesh and separates oversize for recycle back to the press.
Integrated equipment
Fertilizer Packing Machine
Weighs and fills 25 kg or big bags with dust extraction at the filling spout.
07
Scalable planning
Capacity & operating options
Use these as planning bands only. Final capacity follows the verified mass balance and operating schedule.
Planning band 1
≤1 T/H planning band
Single press, manual bag feeding and a compact screening loop.
- Confirm inlet and finished-product basis
- Balance utilities, labor and buffers
- Reserve only validated expansion interfaces
Planning band 2
1–5 T/H planning band
Coordinated line with buffer silos, closed conveying and automatic packing.
- Confirm inlet and finished-product basis
- Balance utilities, labor and buffers
- Reserve only validated expansion interfaces
Planning band 3
≥5 T/H planning band
Parallel press trains or larger rolls with central dust collection and silo-based logistics.
- Confirm inlet and finished-product basis
- Balance utilities, labor and buffers
- Reserve only validated expansion interfaces
08
Site engineering
Plant layout
Concept arrangements show the route; final 2D and 3D drawings require the actual site and approved equipment schedule.
01Feeding & de-dusting
02Binder mixing
03Double roller compaction
04Crushing, screening & packing
Material flow →
Dimensions, elevations, aisles, foundations and utilities are issued only after site engineering.
Illustrative production-line view. A project-specific 3D model has not been supplied.
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Dust zoning
Keep the powder reception bay under negative pressure and away from packing.
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Recycle path
Route oversize material back to the press without crossing the finished-product line.
✓
Maintenance access
Leave roll-change space and lifting points at the press frame.
✓
Explosion precaution
Carbon black dust is combustible; electrical classification and venting follow the local standard.
09
Operating boundary
Utility requirements
Utilities are calculated from the final equipment schedule and local conditions.
01
Electricity
Voltage, frequency, connected load and transformer margin
02
Water
Binder dilution, cleaning and dust suppression
03
Heat source
Fuel and hot-air system when the wet route needs drying
04
Compressed air
Pulse cleaning, valves and instruments
05
Workshop
Clear height, foundations, access, ventilation and drainage
06
Operators
Shift staffing based on automation and local handling
10
Stable production
Quality & environmental control
Carbon black is a dust and housekeeping problem before it is a granulation problem; controls are designed together.
✓
Binder dosing
Ratio recorded per batch and tied to granule strength results.
✓
Roll pressure log
Pressure and gap trended so density drift is caught early.
✓
Dust capture
Bag filters at feeding, transfer, screening and bag filling.
✓
Product sampling
Size distribution and dust index checked at agreed intervals.
✓
Cross-contamination
Grade changes sequenced with purge and line cleaning.
✓
Production records
Recipe, batch and operating data retained where configured.
11
Buyer questions
Frequently asked questions
These answers define the next engineering step without inventing fixed specifications.
Can carbon black powder be granulated without a binder?
Some grades can be compacted dry, but most routes use a small amount of water or binder to reach the target strength. The ratio is fixed by trial on your material, not by a catalogue value.
Why a double roller press instead of a drum granulator?
Carbon black is a fine, low-density powder. A drum needs rolling and layering to build granules, while a roller press densifies the powder mechanically, which suits carbon black and keeps the product dust-free.
What granule size can the line produce?
1–5 mm is the usual band, set by the screen cut. The exact distribution is confirmed on your sample during the trial run.
Is drying always required?
No. It is required when water is added for mixing or dust suppression; a low-moisture compaction route can go straight to screening and packing.
Can recovered carbon black be used?
Yes, after screening and de-ironing. Ash and residue levels are checked first because they change both binder demand and granule strength.
How is the final capacity confirmed?
Capacity follows the mass balance, operating hours, recycle load and the slowest connected stage.
Is the dust a safety issue?
Carbon black dust is combustible. The layout, electrical classification and venting are defined against the local standard for your site.
What is needed for a quotation?
Send the carbon black grade and bulk density, binder preference, target granule size, capacity, site, utilities and packing.
12
Start the engineering study
Get a customized production line design
Required project fields are standardized for engineering review and lead routing.
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