CO-NELE Intensive Granulator (integrated mixer-granulator) is a professional, high-efficiency core equipment independently developed by CO-NELE for the production of petroleum ceramic proppant (bauxite ceramsite). It integrates high-shear mixing, uniform humidification and precise spherical granulation in one unit, specially designed for manufacturing high-strength, high-roundness and high-density ceramic proppants used in oil and gas hydraulic fracturing projects. Compared with traditional disc granulators, the CO-NELE intensive granulator solves the pain points of unstable pellet quality, low bulk density and high breakage rate, and is the preferred equipment for high-end petroleum proppant production lines.
The CO-NELE intensive granulator adopts an optimized eccentric rotor composite motion structure, combining an adjustable inclined drum and high-speed shear rotor to form a three-dimensional turbulent granulation environment:
Against traditional disc granulators, the CO-NELE intensive granulator has comprehensive advantages in product quality, production efficiency, operation cost and environmental protection, which fully meets the strict standards of deep well and ultra-deep well fracturing proppants:
| Comparison Item | CO-NELE Intensive Granulator | Traditional Disc Granulator |
|---|---|---|
| Pellet Roundness | ✓ ≥0.95, ultra-smooth surface | 0.85–0.90, irregular shape |
| Pellet Density & Strength | ✓ Bulk density ≥1.8 g/cm³, crush loss ≤5% (52 MPa), compact internal structure | Low density, high voidage, easy to break under high pressure |
| Production Mode | ✓ Fully sealed batch production, dust-free operation | Open-type operation, serious dust pollution |
| Automation Level | ✓ CO-NELE independent PLC intelligent control, adjustable rotor speed, drum tilt and automatic water spraying | Simple manual adjustment, poor parameter consistency |
| Wear Resistance & Service Life | ✓ Tungsten carbide (HRC 65) coated liner, blades and scrapers, service life 18–24 months | Ordinary liner, easy to wear, service life only 6–12 months |
| Production Cycle | ✓ 3–8 minutes per batch, high efficiency | 20–40 minutes per batch, low output efficiency |
3. CO-NELE Equipment Core Technical Parameters
4. Proppant Production Process with CO-NELE Granulator
CO-NELE intensive granulator perfectly matches the standard petroleum ceramic proppant production line, with the complete process as follows:
CO-NELE provides complete gradient models to meet the needs of formula research, pilot test and industrial mass production:
As a professional brand of proppant granulation equipment, CO-NELE intensive granulator has broken through the technical bottlenecks of traditional granulation equipment. With intelligent control, high wear resistance, excellent granulation quality and environmental protection advantages, it has become the core supporting equipment for global high-end petroleum ceramic proppant production, serving high-standard hydraulic fracturing projects of oil and gas fields worldwide.
CO-NELEceramic powder granulator is a high-performance integrated system combining mixing, wetting, granulation, and densification. Specifically designed for fine ceramic powders, it is suitable for processing:
- Alumina (Al₂O₃)
- Silicon Carbide (SiC)
- Zirconia (ZrO₂)
- Mullite
- Silicon Nitride (Si₃N₄)
- Porous Ceramics / Electronic Ceramic Powders
Based on the principle of intensive mixing and granulation, this equipment achieves a high granulation rate, a narrow particle size distribution, and excellent flowability.
·An inclined mixing pan
·An eccentric high-speed rotor
·A stationary scraper
✔Rapid and homogeneous dispersion of powders
✔Precise liquid addition and wetting control
✔Stable nucleation and particle growth
✔Formation of high-strength, dense granules
Application Fields: Oxide ceramics, non-oxide ceramics, refractory materials, sanitary ceramics, structural ceramics, etc.
Compared to traditional spray drying or inefficient mixing equipment,CO-NELE granulatorsoffer significant advantages in terms of particle size control, granulation rate, and uniformity, making them a critical piece of equipment for the preparation of high-end ceramic powders.
Can serve as an alternative to certain spray granulation processes, reducing energy consumption by over 30%.
| Parameter | Data |
| Granulation Rate | ≥90%–98% |
| Proportion of Qualified Particles | ≥85% |
| Particle Size Range | 0.1–5 mm (Adjustable) |
| Particle Size Deviation | ≤ ±0.2 mm |
A: We offer a full range of models, spanning from laboratory-scale testing to industrial-scale production:
Laboratory Models: 0.05-25kg/batch
Mid-scale Production Models:50-300kg/h
Large-scale Industrial Models: 500kg–5t/h
The CO-NELE granulator series covers a volume range of 1 liter to 7,000 liters; models can be customized and selected based on the client's actual production capacity requirements.
A:Yes. By employing a proportional structural design combined with identical process logic, linear scalability is achieved:
✔Consistent granulation rate
✔Stable particle size distribution
✔Low scale-up risk
At theCO-NELETesting Center, experienced engineers collaborate with users to optimize process steps, ensuring a high degree of consistency in both granulation rate and particle size distribution from the laboratory stage to full-scale production, thereby significantly mitigating scale-up risks.
A:Yes.CO-NELEintensive mixers demonstrate exceptional performance in the preparation of fibrous materials; they are suitable for the fiber separation and coating processes involved in the production of carbon ceramics and fiber-reinforced ceramics.
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