How to assess the energy consumption of a granulator?

Granulator Energy Consumption Assessment Methods

1. Power Input and Operating Time

The total energy consumption E=Pxt is obtained by measuring the actual motor power (kW) of the equipment during operation and combining it with the production cycle (h).

The key is to distinguish between the extruder power and the pelletizing motor power; the sum of the two is the baseline power of the entire machine.

2. Air/Fluid Injection Power

Airflow or water flow is often used for pelletizing during the granulation process. Excessive air injection power leads to unnecessary energy consumption, while insufficient air injection affects particle size uniformity. Literature indicates that optimizing air input power is the main means of reducing energy consumption.

3. CFD-DEM Numerical Simulation

The two-way coupled CFD-DEM method is used to simulate the interaction between particles and fluids, which can predict the energy consumption distribution under different process parameters. By comparing the simulation results with actual power measurements, the energy consumption model can be corrected and a refined assessment can be achieved.

4. Energy Consumption Index System

Common indicators include energy consumption per unit output (kWh/ton) and energy intensity (kW/kgh). These indicators facilitate horizontal comparison of energy efficiency levels across different models or under different process conditions.

5. Process Monitoring and Data Acquisition

Power meters, flow meters, and temperature sensors are installed on the actual production line to record key parameters in real time. Data is aggregated through a PLC/HMI system, enabling online assessment and alarm of energy consumption.