AGGLOMERATION

Combining the resources of

K-G

RIETZ

SCHUGI TT

STRONG-SCO

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Outline
Introduction Binder Overview Pressure Agglomeration / Compaction Wet Agglomeration Overview Tumbling Agglomeration / Instant Mixing Extrusion Agglomeration Thermal Agglomeration Batch vs Continuous Processing Selection of an Agglomeration System

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Defining Agglomeration

The process of transforming finely divided particles into particles of a larger size by the introduction of outside forces.

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Reasons For Agglomeration

Minimize or eliminate dust Improve flowability Improve storage and handling characteristics Improve metering and dosing characteristics Formulation stability, prevent segregation

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Reasons For Agglomeration

Increase or control bulk density Defined shape, size, or weight Solubility control, dispersability Improved appearance Increased product value

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Industrial / Consumer Applications

Salt Pellets, Charcoal Briquettes Laundry / Dishwasher Detergents Agricultural Chemicals Feed Supplements Instant Drink Mixes Nutraceuticals / Functional Foods Many others
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(According To Pietsch)

Binding Mechanisms

- Solid Bridges - Chemical Reactions - Liquid Bridges - Sintering - Adhesion Forces -Capillary Pressure -Crystallization of Soluble - Highly Viscous Binders - Interfacial Forces Substances - Adsorption Layers -Hardening of melted subs. -Cohesion Forces

- Matrix Binder - Interlocking - Capillary Forces -Form Closed Bonds (conglomerates saturated with liquid)

- Molecular Forces - Electrical Forces - Magnetic Forces

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Agglomeration Methods
Pressure Agglomeration - Briquetting - Tableting - Compacting - Piston Press

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Agglomeration Methods
Tumbling Agglomeration - Mechanical Tumbling High/Low Speed Pneumatic

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Agglomeration Methods
Extrusion Agglomeration - Low Pressure Extruder - Gear Pelletizing - Pellet Mill - High Pressure Extruder

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Agglomeration Methods

Thermal Agglomeration Hot Melting/Forming - Flakes/Pastilles - Prilling Sintering - Rotary Kiln - Traveling Grate

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Pressure Agglomeration
Application of High Pressure to: Densify powder feed material Partially crush incoming particles Force particles into close proximity Rely on interparticular forces Rely on particle molding

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Advantages of Pressure Agglomeration

Little or no binders required Drying or curing post treatment not required High capacity with low energy input Wide range of feed sizes acceptable High product density achieved Robust design promotes extended equipment life
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Pressure Agglomeration Product Characteristics

Densify powder feed material High density products High strength Uniform shape and size Large product size possible Possibility for no binder addition Limited dispersability

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Double Roll Compaction

Material drawn between counter rotating rolls Force feeders usually used High pressure applied in the nip Roll surface dictates product shape End product: Briquettes, or sheets for granulation

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Feed Limitations for Double Roll Compaction

Aerated Aerated feed materials require special features to deaerate or minimize vibration Only Only dry feed acceptable Abrasiveness, Abrasiveness, elasticity, plasticity, and brittleness need to be considered Heat Heat and pressure sensitive materials not compatible Toxic Toxic materials are difficult to contain

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Double Roll Compactors

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Products Produced In Roll Compactors

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Wet Agglomeration Process

Dry Particles Wet Particles Effective Collision Forming of Liquid Bridge

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Wet Agglomeration Model

Less liquid

Small agglomerates

More liquid

Larger agglomerates

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Influence of Moisture on Particle Size

Particle Size

Mixing

Agglomeration

% Liquid

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Increasing Solid:Liquid Ratio

Very little liquid powder coating More liquid agglomerates A lot of liquid paste Mainly liquid slurry

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Wet Agglomeration General Flow Sheet

Solids Feed PreMix Liquid Feed Agglomeration Conditioning

Size Reduction Final Product

Oversize Sizing

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Tumbling Agglomeration
Feedstock must be a fine powder Binder or moisture must be added Typical for capacity to be high Good alternative for dedusting / disposal Capital and operating costs are low (without post-drying)

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Tumbling Agglomeration Product Characteristics

Good dispersability Medium to low density and strength Rounded shape Small, uniform size Binder required

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Tumbling Agglomeration Mixers

Rotary Type Mixers Low Energy
DRUM DEEP DISH

CONE

STEPPED PAN

Agitator Type Mixer Medium Energy

PAN or DISC PIN MIXER
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Turbulizer Mixer / Agglomerator

Solids Inlet Liquid Injection Points

Adjustable Paddles
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Tumbling Agglomeration for Instant Mixing

Combine Combine powder and liquid streams with high shear High High level mixing quality required High High production capacity Value Value added products Agglomerate Agglomerate Qualities:
Relatively porous Particle size range 0.1 to 1.5 mm Easily dispersed, compressed, dissolved

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Advantages of Instant Mixing

High capacity, short residence time High speed contact yields smaller, more uniform particles Capacity to handle sticky products Atomized liquid injection system Liquid/steam addition in series

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Instant Mixing Agglomerator

Instant mixing
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Water Dispersible Granule Plant Flow Diagram

Extrusion Agglomeration
Feedstock as fine powder, wet cake, or paste Moisture or binder may be added Curing or post drying may be required Improve the drying efficiency of wet cakes Capacity to handle sticky and high viscosity products Optional temperature control for high fat or waxy products Further processing possible (spheres)

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Extrusion Agglomeration Product Characteristics

Medium density product Medium dispersability Good for time release dispersion Product is cylindrical, with constant cross section Typical diameter 1 to 10 mm Uniform particle size and shape Product very resistant to breakdown Binder may need to be added
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Extrusion Process

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Extrusion Agglomeration Product

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Extrusion Process
1. Powder Weigh Feeder 2. Premixer 3. Liquid Metering System 4. Extruder 5. Continuous Fluid Bed Dryer

1 2 3 4

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Extrusion Agglomeration Further Processing by Spheronization

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Thermal Agglomeration
Uses heat transfer processes Difficult to generalize product properties Examples include:
Prilling Drum Flaker Sintering Rotary Kiln Nodulizing

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Prilling
Can produce particles up to 1,500 um diameter, 300 um diameter is more common Product is spherical, not ideal sphere Hollow sphere in turbulent mixing, indented sphere in laminar mixing Usually followed by Vibratory Fluid Bed to cool product

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Drum Flaker
Rotating Drum chills product Product hardens on surface Product is scraped off to form flakes Feed material must be in liquid form

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Batch vs Continuous Processing

BATCH Bad lots easily identified More labor with switching batches Low production rates Intermittent production Frequent product changeover Frequent system clean out

CONTINUOUS More uniform product Less labor required High production rates Few shutdowns Few different product specifications Seldom need to stop and clean out

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Selection of an Agglomeration System

Any agglomeration method can be applied to most materials
May need to modify feed materials

first

End product functionality requirements dictate method

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Selection of an Agglomeration System End Product Characteristics Dispersability Strength Dissolution rate Shape Flowability Size Compressibility Size Density Distribution Formulation
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End Product Types

Multi stage spray drying Disc granulation Powder clustering by instant mixing Form granulation by mechanical force

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Product Comparison
Product Form / Product Properties Flowing Properties Bulk Density Dispersability Instant Characteristics Particle Size Onion Skin Clusters Extrudate Hollow Sphere 2-3 1 3 1-2 < 200 m Compacted Granule 4 4 2 1 0.1-5 mm Briquette 4 3-4 1 1 1-5 mm 4 2-3 4 4 0.2-1.2 mm 3 3 2-3 1-2 0.3-5 mm 2 3 1 1 5 mm+

4 Very good / excellent 3 good 2 moderate 1 - poor

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Selection of an Agglomeration System

Raw material limitations Upstream process Downstream process Formulation flexibility Product changeover Equipment maintenance Capital vs Operating costs
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Examples of Machine Selection

Charcoal Briquetting on Double Roll Compactor Instant Drink Mix Turbulizer and Fluid Bed Stearic Acid Prilling Tower

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Conclusions
Agglomeration equipment is the key part of a total agglomeration system Various options exist for most feed materials Desired product characteristics will dictate the method to use
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