Agglomeration Handbook

The
AGGLOMERATION
HANDBOOK
PROCESSING | EQUIPMENT | PROCESS CONSIDERATIONS | TESTING
a product of
Contents
INTRO
Introduction 1
Intro to Agglomeration
Types of Agglomeration
Why Agglomerate Your Material
EQUIPMENT & PROCESSING

Agglomeration Equipment Basics
Pelletizing 10
Compaction Granulation
12
Pelletizing Vs. Compaction Granulation
14
A Look at Micro-Pelletizing
16
CONSIDERATIONS IN AGGLOMERATION
Borax pellets created in the

FEECO Innovation Center
Choosing an Industrial Mixer: Pin Mixer Vs. Pug Mill
21
Drum or Disc?
24
Agglomeration or Granulation Drum - Whats the Difference?
25
The Benefits of Pre-Conditioning Your Material
27
Choosing A Binder in the Agglomeration Process
29
The Role of Drying in Agglomeration
30
Testing Particle Characteristics in the FEECO Innovation Center
33
Why Choose FEECO? - The FEECO Commitment to Quality
40
THE
AGGLOMERATION
HANDBOOK
Introduction
FEECO International was founded in 1951 as an engineering and manufacturing company. We quickly became
known as the material experts, able to solve all sorts of material processing and handling problems, and now
serve nearly every industry, from energy and agriculture, to mining and minerals.
As experts in the field of particle size enlargement and tumble growth agglomeration, FEECO has been on
the forefront of the agglomeration industry since the 1950s. Weve helped our customers process hundreds of
materials into value-added products, eliminating handling and transportation problems, improving product
characteristics, and creating marketable products.
This comprehensive resource includes tumble growth agglomeration and pressure agglomeration techniques,
and examines methods, processing considerations, and equipment for both types.
For further information on agglomeration, contact a FEECO expert today.
FEECO US Headquarters
FEECO Australia Testing Facility
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Synthetic Gypsum pellets

created in the FEECO
Innovation Center
An Overview of
AGGLOMERATION
INTRO| TYPES OF AGGLOMERATION| WHY AGGLOMERATE?
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An Intro to Agglomeration
Agglomeration is the process of particle size
available, all of them fall under one of two main
enlargement and most commonly refers to the
categories: pressure agglomeration, or non-pressure
upgrading of material fines into larger particles, such
agglomeration (a.k.a., tumble growth agglomeration).
as pellets or granules. In addition to material fines,

agglomeration is also useful for sludge-like materials,
Pressure agglomeration technologies use mechanical
such as manure or FGD sludge, to transform them into
compression to shape a material into a desired form.
a more usable, more easily handled form.
Very little, if any, moisture is needed.
Long used throughout the iron and steel sector,
Non-pressure agglomeration technologies use a
agglomeration is far from a new technique. However,
tumbling process to grow material into a spherical
it is constantly gaining popularity in an increasing
pellet form. A binder is often used to assist in the
number of industries, particularly in the past few
agglomeration process.
decades, as the numerous benefits it has to offer

become more and more evident.
While there are many agglomeration techniques

available within these two categories, this handbook
There are many types of agglomeration, all offering
will focus on the following:
their own unique advantages and disadvantages, but

in general, they can all offer the following benefits:

Significant dust reduction
Improved handling
More complete utilization of raw materials
Improved product characteristics
Agglomeration continues to evolve as an industry,

becoming ever important in our day-to-day lives as it
finds its way into an increasing number of applications.
This has created a plethora of activity in the field of
particle technology, with new processes constantly
being forged and old ones being improved upon.
Pressure Agglomeration:
Briquetting: Typically a dry process, briquetting uses
pressure to form pillow-shaped briquettes from
material fines.
Compaction: Also a dry process, compaction presses
material fines into a sheet-form, which is then broken
up into jagged granules.
Non-Pressure Agglomeration:
Pelletizing: A wet process whereby material fines are
rolled into uniform pellets with the help of a
binding agent.
Types of
Agglomeration
Micro-Pelletizing: Also a wet process, in which
While there are many agglomeration techniques
agglomerates, or prepare the material for pelletizing.
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material fines are mixed with a binder to form small
AGGLOMERATION HANDBOOK | 3
Image: Various agglomerate samples created in

the FEECO Innovation Center
Conditioning: A process which often refers to the
Product Benefits: Dust-free product handling,
mixing of material fines with a binding agent in order
segregation prevention, and improved product
to reduce dust, and transform the material into a
characteristics and appearance.
more usable form.

Industry Example: Agglomerated agricultural wastes
A variety of elements are considered when
(such as manure or compost) are easier to transport,
determining which agglomeration method should
store, and apply than unprocessed materials. Other
be used. Contributing factors include: equipment
improved characteristics include custom formulations,
capabilities, binder properties, industry standards,
and opportunity for storing.
desired end product characteristics, and raw material

characteristics.
Raw Material Benefits: Simplified transportation, dust

loss prevention, and increased porosity, density, and
Why Agglomerate
Your Material?
melting abilities.
Benefits of Agglomeration
a uniform particle size distribution, which in turn
There are many reasons why it might be desirable to

agglomerate a material. The choice to agglomerate
often stems from a material problem, be it a dust issue,
a waste problem, handling problem, or otherwise.
When a material is agglomerated, you can expect to
Industry Example: Ore agglomeration creates

maximizes the heap leaching process, allowing a
more efficient extraction of minerals from the ore.
Process Benefits: Elimination of dust and fines,
increased process flow effectiveness, and increased
process efficiency.
achieve several of the following benefits:
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Industry Example: Glass powder in its raw state incurs
Environmental Benefits: Potential to eliminate the
a great deal of material loss during processing,
need for landfill, improved cost-efficient recycling
ultimately throwing off glass formulas. Agglomerated
capabilities, potential for waste-to-fuel processes, and
glass powder reduces product losses, increases
improved waste disposal cost efficiency.
process efficiency, and ensures that formulas are not

skewed through the loss of dust.
Industry Example: After agglomeration, previously

landfilled waste paper sludge is recycled into a
Economic Benefits: Conversion of waste to a
usable product.
marketable product, reduced transportation costs,

and reduced material handling costs.
In addition to the benefits listed above, the following

chart identifies specific reasons why agglomeration is
Industry Example: After agglomeration processing,
used in various applications:
previously unsalable limestone fines become a

marketable product (known as limestone soil
amendment pellets).
Reason
Typical Application
To produce useful structural forms
Powder Metallurgy
To provide a defined quantity for dispensing and metering
Agricultural Chemical Granules, Pharmaceutical Tablets
To eliminate dust handling hazards or losses
Agglomeration of Waste Fines
To improve product appearance and/or performance
Food Products
To reduce caking and lump formation
Fertilizers
To improve flow properties for further processing
Pharmaceuticals, Ceramics
To increase bulk density for storage
Detergents
To control dispersion and solubility
Instant Food Products
To control porosity and surface-to-volume ratio
Catalyst Supports
To improve permeability for further processing
Ore Smelting
To create non-segregating blends of powder ingredients
Ore Smelting, Agricultural Chemicals, Pharmaceuticals
Source: Lister, Jim and Ennis, Bryan. The Science and Engineering of Granulation Processes. Boston: Kluwer Academic Publishers, 2004.
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Various potash samples

Innovation Center
EQUIPMENT &
PROCESSING
EQUIPMENT | PELLETIZING | COMPACTION GRANULATION | PELLETIZATION VS. COMPACTION | MICRO-PELLETIZING
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Agglomeration
Equipment Basics
they are used throughout a variety of industries, they
There are many choices on the market when it comes
their heavy-duty construction, ideal for the demanding
to agglomeration equipment. Additionally, new uses
process needs of the mining industry. Here, they aid in
are being developed all the time, making current
the heap leaching process by promoting optimal ore
equipment options increasingly flexible. Below, weve
extraction through more uniform particle shape and
provided a quick overview of some of the most
size. In addition, agglomeration drums can be used for
common types of agglomeration equipment.
specialty applications such as coating.
Disc Pelletizers
How Agglomeration & Granulation Drums Work
Disc pelletizers are a type of non-pressure (tumble
Similar to disc pelletizers, agglomeration drums tumble
growth) agglomeration equipment. In the world of
material fines in the presence of a binder to promote
agglomeration equipment, the pelletizer is often
agglomeration.
are perhaps most common in the mining industry, due

to their ability to accept variance in feedstock, and
chosen for its ability to fine-tune the product size, the

process of which is a combination of both science
Agglomeration drums can also be valuable when a
and art. The pelletizer offers several variables, all of
chemical reaction is required during agglomeration,
which can be adjusted, and work together to create
such as in the fertilizer industry. Here, agglomeration
the desired pellet product.
drums, referred to as granulation drums (or

granulators), are a valuable tool in producing a
How Disc Pelletizers Work
variety of fertilizer blends. In some cases, they can
Material is fed onto the disc, where it is taken up by
also be fitted with a cross-pipe reactor, where liquid
the rotation of the disc. Both material feedstock and
ingredients are combined and reacted, and then
a binder are continuously fed onto the disc pelletizer,
sparged into the rotating drum as a hot melt. The
making this a continuous process. The binder causes
melt then tumbles and agglomerates as it cools. This
the fines to be tacky, allowing them to pick up more
approach can yield significant energy savings, as the
fines as they tumble. This results in an effect similar to
heat of reaction is captured to aid in the drying effort.
rolling a snowball, referred to as coalescence.
Agglomeration Drums &

Granulation Drums
(Rotary Drums)
Pin Mixers
Pin mixers are industrial mixers used for a variety of
purposes, including: micro-pelletizing, conditioning,
agglomerating, and mixing. These versatile mixers are
Agglomeration drums also fall under the tumble
particularly adept at dealing with fine materials, such
growth agglomeration category. Agglomeration
as powders, and are optimal machines for mixing
drums are valued for their high throughput, and while
these fines with a binder. Pin mixers can act as a
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stand-alone agglomeration unit, or as the precursor to
How Compactors Work
a disc pelletizer or agglomeration drum setup.
Material fines are first fed between two counterrotating rolls, which press the material into a compact
How Pin Mixers Work
sheet. The sheet is then fed through a flake breaker,
Pin mixers use a high-speed spinning action to both
followed by a granulator, which breaks the sheet up
mix and agglomerate materials in the presence of a
into the desired size granules. Though compactors
binder. A single shaft affixed with rods (pins) rotates
can work with a binding agent, with most materials
at a constant speed, creating a densified product
processed in a compactor, a binder is not needed.
through the use of motion.
This is therefore considered a dry process and does

not require a subsequent drying step, though this is not
Pug Mills / Paddle Mixers

Like pin mixers, pug mills, sometimes called paddle
true of all compaction granulation processes.
mixers, are industrial mixers capable of conditioning,
Briquetters
mixing, and agglomerating. Pug mills are also ideal
Similar to compactors, briquetters also use mechanical
solutions for processing material in the presence of a
force to press material fines into a desired shape.
binder, though unlike pin mixers, pug mills are more
Briquetters are typically reserved for instances where
suited for heavy-duty material processing, such as can
larger agglomerates are desired, such as in the
be found in the mining industry.
making of water softener salt briquettes, or charcoal

briquettes. Because small briquettes are difficult
How Pug Mills Work
to make and have a low volume, the smaller the
Pug Mills use dual-shafts with pitched paddles to
briquette, the higher the price of the equipment.
create a kneading and folding over motion inside the
Typically, briquettes are produced no smaller than
mixer. This results in a thorough mixture of ingredients.
roughly a square by thickness.
Here again, pug mills can be used as a standalone agglomeration device, or as part of a larger
How Briquetters Work
processing configuration.
Material fines are fed between two counter-rotating

rolls. Each roll has one half of the desired pillow
Compactors
shape, and as the rolls come together, the halves
Compactors are a type of pressure agglomeration
unite, pressing the material into one complete pillow
equipment that operate on the principle that under
form. Here again, a binder is not necessary, but
extreme pressure, some materials will adhere to
sometimes useful.
themselves. Compactors use mechanical force to

press material fines into a compacted sheet, which
The chart on the following page provides a summary
is then broken up into granules. Compactors are
of the agglomeration equipment discussed here.
frequently used in fertilizer production.
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Equipment
Name
Other
Names
Pressure or
Non-Pressure?
Binder Normally
Required?
Uses
Common
Materials
Disc Pelletizers
Disc Granulators
Non-Pressure
Yes
Pelletizing
Minerals
Rotary Drums
Pan Pelletizers
Chemical Powders
Pan Granulators
Fly Ash
Granulators
Fertilizers
Agglomeration
Drums
Non-Pressure
Yes
Pelletizing
Fertilizers
Granulating with a
Chemical Reaction
Minerals & Ores
Balling Drums
Agglomerators
Coating
Ore Drums
Granulators
Granulation Drums
Pin Mixers
Pug mills
Pin Agglomerators
Paddle Mixers
Non-Pressure
Non-Pressure
Yes
Yes
Micro-Pelletizing
Coal Dust
Mixing
Fly Ash
Conditioning
Minerals
Agglomerating
Clays/Ceramics
Mixing
FGD Scrubber Sludge
Conditioning
Ag Chemicals
Agglomerating
Carbon Powders
Chemical Consumer
Products
Minerals & Ores
Compactors
Roll Press
Pressure
No
Granulation
Double Roll Press
Minerals
Chemicals
Detergents
Fertilizers
Pigments
Catalysts
Briquetters
Roll Press
Double Roll Press
Pressure
No
Briquetting
Coal
Charcoal
Water Softener Salt
Chemicals
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Image: The image above shows the possibilities for a raw material (in this case clay) to be transformed into a variety of agglomerates. From
left to right: raw material, pellets from a pelletizing process, granules from a compaction granulation circuit, and briquettes, from a briquetter.
Pelletizing
Pelletizing is a form of tumble growth agglomeration,
whereby material fines are grown through a
tumbling motion and the addition of water or a
mill. While not all processes utilize a pre-conditioning

step, those that do see many benefits as a result, such
as reduced binder usage, increased production, and
an improved product. For more information on this, see The
Benefits of Pre-Conditioning Your Material on page 27.
binding agent. This process is a non-pressure method

of agglomeration, and instead of pressure, uses a
binder (or simply water) to help material adhere to
itself. Because of this, this type of agglomeration is
categorized as a wet process.
Pelletizing is carried out using either a disc pelletizer
or rotary drum, with disc pelletizers being the most
common choice, and drums being more suited to
specific applications such as heap leaching or fertilizer
production. Note: The choice between a drum and a disc is
discussed more in-depth on page 24.
A typical pelletizing process looks like this:

Material fines are first conditioned in a pin mixer or pug
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Once material has been conditioned, it moves on

to pelletizing. For processes that do not use a preconditioning step, this is where the process begins.
Here, material is fed onto a disc pelletizer at a
continuous rate, where binder is continually added.
The material fines are tacky as a result of the binder,
and as they tumble against themselves while the disc
rotates, they pick up more fines, growing in similar
fashion to a snowball.
Once pellets have reached the desired size, they exit
the disc pelletizer, and are carried via a conveyor belt
to a dryer if moisture removal is necessary.
Flow Diagram of A Typical

Pelletizing Process
The dryer cures the pellets, removing the desired amount of

moisture, and often polishing the pellets into their final form. Drying is
commonly carried out using a rotary dryer, with fluid bed dryers being
an alternate choice.
The diagram above illustrates a simplified pelletizing setup. In situations
where a rotary drum is used instead of a pelletizing disc, the process is
typically the same, with only the drum replacing the disc.
Diagram Key:
1.
2.
3.
4.
5.
6.
7.
8.
Pug Mill/Pin Mixer

Disc Pelletizer
Liquid Spray System
Transfer Conveyor
Rotary Dryer
Vibrating Screen
Oversize Mill
Surge Hopper
Pelletizing on a disc has been likened to an art, with many variables
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affecting the success of the end product. The most
granulation is not an option. But for other materials,
common variables include:
such as salts like potash, it is an extremely effective,
Binder formulation
Binder feed rate
Material feed rate and location
Pan speed
Pan angle
Liquid addition rate and location
Pelletizing is used throughout a variety of industries,

with new applications developing all the time. Some
of the most commonly pelletized materials include:
cost-efficient option.
In the compaction process, because the material
often adheres to itself, typically no binder (or
very minimal binder) is needed to agglomerate
the material fines. Therefore, this is considered a
dry process, and most often does not require an
additional drying step.
Compaction granulation is carried out using a double
roll press, or roll compactor.
EAF Dusts
Chemical Powders
The diagram on the next page illustrates a simplified
Limestone
compaction granulation process, with the addition of
Gypsum
a polishing drum.
Coal
Fly Ash
Minerals and Ores
And more
Compaction granulation operates on the principle
that some materials, when put under extreme
pressure, will bind to themselves. Not
all materials are capable of
this, so in some cases,
compaction
Potash granules created in

Flow Diagram of A Typical

Compaction Granulation Circuit
Material is fed between two counter-rotating roll presses. The rolls apply
extreme pressure to press the material into a sheet-like form. This sheet
Diagram Key:
of material is then fed through a granulator, where it is broken up into

granules. The granules then typically go through screening, where overand under-size granules are separated out from the on-size granules. The
overs are then crushed down to be put back into the process as recycle,
while the unders do not typically require crushing, and can be put back
into the process as-is. While the granules can be considered a final
product at this point, a variety of options exist for further improving them.
Granules may be tumbled in a polishing drum to remove any loose edges.
Or, they may be conditioned in a pug mill or rotary drum where additives
such as coating or anti-caking agents can be added. Additionally, they
1.
Raw Feed Materials
2. Mill
3.
Surge Hopper
4.
Humidificator Mixer
5.
Protecting Screen
6. Compactor
7.
Flake Breaker
8. Granulators
9. Screen
10. Polishing Drum
11. Screen
12. Screw for Recycles
can be wetted in a pug mill and dried in a rotary dryer to fill in surface
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cracks, remove loose edges, and polish the granules.
methods, making the choice clear. Other materials

however, will respond well to both (such as bentonite,
Variables that affect the success of compaction
coal, humate, potash, urea, and others) and will
granulation include:
require further consideration.
Particle size distribution
Distribution of pressure on roll faces
Moisture content of raw material
Consistent feed to roll compactor
Advantages to Pelletizing:
Faster nutrient delivery: Because pellets are not
created through pressure, they are less dense than
their compaction granule counterparts. The less dense
Materials that are commonly processed using
pellets created in pelletizing can withstand handling,
compaction granulation include:
but can still quickly break down upon application,

an ideal characteristic for soil amendments, fertilizers,
Fertilizers
and other applications that benefit from fast material
Chemicals
breakdown.
Detergents
Pigments
Less dust and fines: Compared to compaction
Minerals
granules, pellets produce less fines. Since pellets are
Polymers
round, there are no edges to break off and create dust.
Oxides
Catalysts
Binders can serve as beneficial additives: Pelletization
Clays
offers the opportunity to control formulation, through
And more...
the addition of specially formulated binders, in order
Pelletizing vs. Compaction
to create optimum pellet characteristics.
When it comes to agglomerating material fines,
Lower capital costs: The pelletizing method often
compaction granulation and pelletization are often
requires a lower capital investment than compaction
both investigated.
granulation.
Both methods are an effective solution, but each has
A premium product is produced: The round, smooth
distinct advantages and disadvantages. And while
pellets produced in the pelletizing process are
operating and capital costs are often the deciding
considered a premium product. Additionally, the
factor between the two, there are many things to
pelletizing process offers the opportunity to include
consider when choosing which method best suits
additives to further customize and enhance the
your material and processing needs. Additionally,
end product.
some materials may respond well to only one of these
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Disadvantages to Pelletizing:
Often times, its not clear which method of agglom-
Higher Processing Costs: The use of a binder, and the
eration will produce the desired results, and in these
required drying step results in higher processing costs
cases, testing is recommended, and often required.
when compared to compaction granulation.

Agglomeration Testing
Advantages to Compaction Granulation:
Running testing trials with samples of your material
Lower Processing Costs: Because no binder or drying
in a facility such as the FEECO Innovation Center will
step is needed, processing costs are usually lower
offer a number of benefits; it will not only tell you if your
when compared to pelletizing.
material is capable of agglomeration, but it will also

help to determine the best method of agglomeration
Disadvantages to Compaction Granulation:
to achieve the end product youre looking for. Taking
Attrition: Attrition is the breakdown of granule edges
it a step further, in addition to running batch tests on a
into material fines and dust. This is common with
single piece of equipment, the FEECO Innovation
compaction granules because of the rough, jagged
Center can also do testing in a continuous process
edges. As mentioned, however, there are methods
loop, utilizing many pieces of equipment. This is useful
to aid in reducing attrition, but they can increase
in determining the best equipment configuration and
production costs.
the process variables needed to produce desired

product characteristics. For more information on testing in the
Sometimes, its also sufficient to simply condition or
FEECO Innovation Center, see page 33.
micro-pelletize material in a pin mixer or pug mill,

instead of pelletizing or granulating it. This is common
for applications where the material only needs to be
de-dusted, such as in cases where transportation to
landfill is made difficult because of a dusty product.
Pelletization
Produces round, smooth pellets considered a premium product
Produces coarse granules
Relatively dust-free
Significant amount of attrition likely
Binder usually required
Typically no binder required
Drying required
Usually no drying required
Faster product breakdown
Delayed product breakdown
Lower capital investment
Reduced processing costs
The chart above provides a summary of the differences between pelletizing and compaction granulation.
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A Look at
Micro-Pelletizing
What is Micro-Pelletizing?
Micro-pelletizing is the process of agglomerating
material fines into small pellets, or micro-pellets.
Unlike traditional pelletizing, where slightly larger
pellets are produced, micro-pelletizing produces
pellets around 20-60 mesh.
Micro-pelletizing can be carried out either in a standalone pin mixer (this process is sometimes referred to
as conditioning), or with a pin mixer/disc pelletizer
combination. When a full-scale pelletizing operation is
not necessary, or when only smaller pellets or material
conditioning is needed, the use of a pin mixer to
micro-pelletize material offers a cost-effective
alternative to a full-scale pelletizing operation
and can provide sufficient results.
Why Micro-Pelletize?
Micro-pelletizing is used to process fine materials in
order to make them easier to handle, transport, and
use. There are several reasons why this may be desirable: to improve how a product performs, to reduce
product lost to dust, to condition a material prior to
landfill, or to reduce other issues associated with dust.
Benefits of Micro-Pelletizing
Like all agglomeration techniques, micro-pelletizing a
fine material offers a variety of benefits:
prior to being landfilled to avoid excessive amounts

of wind-blown material. This is commonly seen with fly
ash, a by-product of burning fossil fuels that comes in
the form of an ultra-fine powder. While some fly ash
can be recycled into other products, other fly ash is
not usable, and is therefore micro-pelletized, or conditioned, before it is brought to a landfill, to avoid it
being carried away by the wind.
Dust reduction is also beneficial during processing. If
not well-managed, fugitive dust can easily escape
into the air, which can not only damage equipment if
left unchecked, but can also be a health and safety
hazard. An extreme example of this can be found at
coal-fired power plants, where coal fines are generated. Here, coal fines are micro-pelletized because they
can be combustible if sufficiently aerated.
Dust reduction or elimination is also valuable because
it reduces the amount of product or raw material lost
to waste as dust, a common problem among dusty
materials. This results in more usable material/product,
and a reduction in material waste.
Improved Handling and Transport
As one can imagine, a fine, dusty material can be difficult to move around or haul without losing a significant
amount of material. Micro-pelletizing allows the material to be much more easily handled and transported.
Improved Application and Use
While micro-pelletizing generally focuses on making a
Significant Dust Reduction/Elimination
material less dusty and easier to handle, it also allows
Dust reduction or elimination is beneficial for many
for improved application and performance in many
reasons. Sometimes, materials are micro-pelletized
instances. A good example of this is in the agriculture
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Copper Hydroxide
micro-pellets created
in the FEECO
Innovation Center
industry, where soil amendments are sometimes
choosing micro pellets over larger particle sizes.
micro-pelletized, offering significant benefits, including:

Micro pellets also offer the opportunity to serve as a
More accurate application micro-pellets can move
core for applications that require the pellets to be
through spreading equipment much more efficiently
coated, but still need the pellets to remain in the
than powdered materials, making application more
desired size range.
precise and reliable.

Materials that are Commonly Processed
More predictable results Because micro-pellets wont Using Micro-Pelletizing
Because micro-pelletizing can benefit nearly any
blow away like a powdered material might, applications stay where they are applied, delivering nutrients
material that comes in the form of a powder, the
where they are needed, and nowhere else.
applications for micro-pelletizing are innumerable

(and growing!). Some of the most commonly
Faster product breakdown smaller pellets are more

quickly broken down than larger ones and thus, in the
case of soil amendments, nutrients reach the
soil sooner.
Reduced visibility micro pellets sink between the
grass blades quickly. This is beneficial because the application does not detract from the beauty of the turf,
a valuable characteristic for applications such as golf
micro-pelletized materials include:

Pigments and Dyestuffs
Carbon Black
Coal Dust
Fly Ash
Specialty Powders
Filter Media
Catalysts
courses and lawns. This is a common reason for
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Agglomerated algae
Innovation Center
Micro-Pelletizing in a Pin Mixer
micro-pellets as the mixture moves through the length
While micro-pelletizing can be done in a pug mill, it
of the pin mixer.
is best carried out in a pin mixer. Pin mixers are the

industry standard for micro-pelletizing, offering an
At this stage, a disc pelletizer could be utilized to
ideal solution for agglomerating material fines into
further grow and/or round the pellets if desired. In this
small pellets. For this reason, pin mixers have been
scenario, the pin mixer prepares the material for
used extensively for decades in both the coal and
optimal pellet formation on the disc. It also allows the
carbon black industries.
target moisture level to be reached prior to the disc

pelletizer, which can increase production, and
Pin mixers utilize a high-speed spinning action that not
decrease the amount of binder required, because
only thoroughly mixes liquid and solid feeds, but also
densification is being carried out in the pin mixer
begins to agglomerate material fines as well, resulting
through motion, instead of on the disc pelletizer
in small, dense pellets. Pin mixers can act as a contin-
with binder.
uous, stand-alone unit to quickly and reliably produce

micro-pellets in a process setting.
After pellet formation is complete, micro-pellets are

then typically discharged from the pin mixer, and
A typical micro-pelletizing setup looks like this:
carried via a conveyor to a rotary dryer, in order to
Raw feed material is fed into the pin mixer at a contin-
reduce the moisture content of the pellets down to
uous rate. Simultaneously, a binder spray system sprays
the desired level. Here, pellets tumble through the ro-
binder into the pin mixer at a continuous, specified rate. tating drum, while flights pick up the material and drop
The material feedstock and binder are thoroughly
it through the stream of drying air, maximizing heat
mixed, and begin to agglomerate, forming
transfer efficiency. A fluid bed dryer is also an industrial
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FEECO Pin Mixer:

Interior View
drying option in this setting.

Pellets are then discharged from the dryer, and taken
by conveyor to their next processing stop (screening),
or to storage or bagging.
In some instances, it may also be desirable to cool the
material prior to bagging or storage. Similar to drying,
this can be carried out in a rotary cooler, or fluid
bed cooler.
Micro-pelletizing offers a host of benefits, including
reduced dust, improved handling, and enhanced
application. Furthermore, when only rough agglomeration is desired, micro-pelletizing in a pin mixer alone
offers a cost-effective alternative to a full-scale disc
pelletizing or drum operation.
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Agglomerated waste paper

sludge created in the FEECO
Innovation Center
Considerations in
AGGLOMERATION
CHOICES IN EQUIPMENT| PRE-CONDITIONING |

BINDER SELECTION | DRYING | TESTING | PARTICLE CHARACTERISTICS
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NPK agglomerates created

in the FEECO Innovation Center
Choices in Equipment
While a pelletizing process or compaction circuit may
follow a basic configuration, many choices often
come up during each of these processes. The same is
true for conditioning and micro-pelletizing processes.
For this reason, weve provided this section to shed
light on some of the common equipment comparisons
faced when developing an agglomeration process
that best suits your requirements.
Choosing An Industrial
Mixer: Pin Mixer Vs. Pug Mill
material. The following information outlines the basics

on each mixers capabilities.
The Pug mill
How It Works: Material undergoes tumbling, kneading,
and medium shear action, resulting in an intimate
mixture of materials.
Typical Use: Mixing, conditioning, or agglomerating.
Processing with a Pug mill
FEECOs pug mill is a U-shaped, horizontal trough.
Inside the trough, a series of pitched paddles are
When considering the use of an industrial mixer, be it
mounted on dual counter-rotating shafts that run the
for pre-conditioning prior to a disc pelletizer, or as a
length of the device. The paddles move material from
stand-alone agglomeration unit, it is often common to
the bottom of the trough, up the middle, and back
run into the question of which mixer will serve the pro-
down the sides, creating a kneading and folding
cess and material best: a pin mixer, or a pug mill. While
effect that intimately mixes the material.
both pieces of equipment are considered industrial

mixers, they each have distinct benefits and capabili-
The pug mill is also used for conditioning or agglom-
ties. Tyipcally, the material itself, along with processing
erating materials. In these instances, a liquid spray
considerations, will help in determining which piece of
system is added to dispense a binder that assists with
equipment will best fit the needs of the process and
the conditioning or agglomerating process.
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Pug mill Applications
hundred RPMs in order to impart agitation forces on
The kneading motion of a pug mill makes this type of
the material. The motion and high rotational speeds
industrial mixer best suited for heavy-duty materials
produced by the pin mixer minimize air and reduce
and applications. Typical pug mill material
water volume between particles in the material. This
applications include:
results in densification many times that of a disc pelletizer. A fluid binder material is added in order to aid in
Mixing: FGD scrubber sludge, fly ash and lime for SO2
the agglomeration process.
neutralization, municipal sludge for composting

facilities, and other processes combining moist and
Pin Mixer Applications
dry feed materials.
Pin mixers are ideal for processing fine materials, such

as powders. Typical pin mixer material applications
Conditioning: Fly ash, cement or lime kiln dust, foundry

dust, iron-oxide, friction material waste, lead fume, iron
ore dust, and zinc oxide.
Agglomeration: Granulation of a variety of materials:
agricultural chemicals, fertilizers, pesticides, coke fines,
chemical consumer products, carbon powders,
cement kiln dust, flue dust from dust collectors,
pigments, and dyes.
include:

Calcium chloride
Sodium aluminum chloride
Mine fines (such as zinc sulfate)
Coal dust
Pigment
Gypsum
Limestone
Other fine particle materials
The Pin Mixer
Pin mixers work well as a stand-alone agglomeration
How It Works: Material undergoes an intense spinning
unit, or as a pre-conditioner in a two-stage agglom-
action, resulting in densification.
eration process involving a disc pelletizer. Pin mixers

are also ideal components in an automated system,
Typical Use: Micro-pelletizing, solids mixing, densifica-
offering precise quality control and accurate
tion, de-dusting, pre-conditioning, conditioning, and
production rates.
granulation.
Processing with a Pin Mixer
The pin mixer is comprised of a stationary cylindrical
shell that houses a high velocity central rotor shaft.
The rotor shaft extends the full length of the mixer,
with numerous rods (or pins) that extend outward. A
constant speed motor spins the rotor shaft at several
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Choosing Between a Pug Mill and

a Pin Mixer
Pug mills and pin mixers both provide a wide array of
benefits and processing capabilities. When choosing
which industrial mixer to use, the material may help
in determining which equipment should be selected.
Processing system requirements and facility
FEECO Pug Mill/Paddle Mixer
FEECO Pin Mixer
considerations are also used to determine the best
see any damage. This is also true when working with
equipment solution. However, the best way to choose
large particle sizes. Large particles could lodge be-
between a pug mill and a pin mixer is to evaluate
tween the pin tips and the interior wall of the pin mixer.
the raw material and decide what type of outcome
In a pug mill, however, the clearance between the
is preferred; the equipments capabilities will lead to
trough and paddles is greater, decreasing opportunity
choosing one device over the other.
for this. There is also typically enough torque in a pug

mill to dislodge particles as well, in the event that any
For example, a pug mill tends to handle sticky and/or
do get stuck.
abrasive materials a little better, because of its slower

speed. It also offers a significantly higher throughput
When looking to densify a material, the high-speed
over a pin mixer, making it an attractive option for
spinning action that occurs in a pin mixer can offer
high capacity operations. Pin mixers would likely get
much better results than a pug mill. Pin mixers also
bogged down when trying to process a sticky
excel in working with ultra-fine materials, such as pig-
material, and would not stand up as well to severely
ments and dyes. The pin mixers ability to effectively
abrasive materials, due to the mixers high
micro-pelletize a fine powder is tough to beat.
rotational speed.
As can be seen, both pin mixers and pug mills are
A pug mill is also more forgiving than a pin mixer, an
effective industrial mixers, with each offering their own
ideal characteristic when working with tougher ma-
advantages and disadvantages.
terials, or where tramp could possibly enter the mixer.

While a stray rock or tramp bolt may cause a few pins
to break off in a pin mixer, the pug mill would likely not
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Recycle
There are many differences between a drum and a
disc, but whether the differences are an advantage
or a disadvantage is often dependent upon the material. This is clear when looking at the amount of recycle
in a process.
Overall, a pelletizer results in far less recycle than a
rotary drum does. This is ideal in situations where the
material goes from a pelletizer to a dryer, because the
less recycle that has to be dried, the more efficient the
process will be (i.e. the more recycle that needs to be
dried, the more energy spent on drying).
While rotary drums may result in a higher amount of reFEECO Disc Pelletizer
Drum or Disc?
cycle, this recycle can also be beneficial to a process.

For example, when utilizing a rotary drum agglomerator, the higher amount of recycle can act as a buffer
in the process. If there is any upset in conditions, there
When it comes to agglomerating a material via tum-
is enough recycle in the process to help even things
ble growth agglomeration, people are often faced
out. However, with a pelletizer, there is such little
with the decision of choosing between a rotary drum
recycle, that when there is an upset in conditions, the
agglomerator and a disc pelletizer. Though the choice
output is almost immediately affected.
may seem overwhelming at first, there are many things

to take into account that will help you make the right
Additionally, some material processes require a certain
decision for your material.
amount of recycle to function efficiently, and whether

using a drum or disc, extra recycle is advantageous.
Many times, the choice between a rotary drum and a
Such is often the case when a pin mixer is introduced
disc pelletizer is dependent upon historical preference. into the process. Some materials require a certain
amount of recycle to be mixed in with the feedstock
Throughout various industries, one or the other has
been used for generations, and there is no need for
going into the pin mixer, in order for the feedstock to
change. Taking a look at the pros and cons of each
mix efficiently before going onto the pelletizer. For this
can help to make an informed decision, whether
reason, it is often a requirement to have a little more
youre a start-up company, or a plant looking to
recycle on hand.
optimize your process.
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System Considerations
Another aspect to consider when choosing between
a rotary drum agglomerator and a disc pelletizer, is
the throughput. When it comes to running a very high
capacity, rotary drums are often the equipment of
choice. Typically, a rotary drum can handle a much
higher throughput than a pelletizer can. Where it might
take a few pelletizers to get to the desired capacity, it
may only take a single drum. While rotary drums allow
for a higher throughput, pelletizers are the equipment
FEECO Agglomeration Drum
of choice when a tight window of size range is desired

for the output product.
Maintenance
In terms of maintenance, pelletizers typically require
Creating pellets on a pelletizer has been likened to a
less maintenance than a rotary drum. Though pel-
form of art, allowing for customization and fine-tun-
letizers do need to be properly maintained in order
ing of the end product. Pan speed, pan angle, feed
to function efficiently, there are fewer parts to be
location, and binder location, are all things that can
replaced - usually only scrapers and spray nozzles.
be adjusted to zero-in on the size range (among other
With rotary drums, there are many parts that not only
qualities) of the pellets that youre looking for. Howev-
require regular maintenance, but that also need
er, this also means a pelletizer requires a much more
replacing now and then. It is important to note that
watchful eye than a rotary drum. Where one operator
the performance of either piece of equipment is
would be capable of watching several drums, one
severely hindered if not properly maintained.
operator should only watch a few pelletizers. Rotary

drums are far more limited in terms of customization,
offering fewer variables for adjusting end product, but
subsequently requiring less monitoring.
Another side to consider in the choice between a
Agglomeration or
Granulation Drum:
Whats the Difference?
When looking for versatile manufacturing equipment
rotary drum and disc pelletizer, is whether or not a
capable of producing agglomerates, an agglomer-
closed system is desired. Rotary drums are consid-
ator or granulation drum will predictably turn up in
ered a closed system, because the agglomeration
your search. Because drums are flexible and capable
happens within the drum, meaning the vessel can be
of processing large throughputs, they are extensively
sealed to help control dust and odor. The disc pelletizer
used in many different industries. Unfortunately, the
is considered an open system, meaning the operation
pervasive use of these drums has created a multitude
happens in a less sealed atmosphere than a drum.
of naming opportunities and, along with it, the
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potential for confusion. Agglomeration drums, rotary
applications being in mining and fertilizers. Drums used
granulators, and balling drums are just a few of the
for fertilizer purposes are usually considered granu-
names used to label drum equipment. The following
lation drums, while drums used for mining are usually
goes over some of the common nomenclature used
considered agglomeration drums. Specialty applica-
to refer to agglomeration drums.
tions also use agglomeration or granulation drums to

process material into pellets or apply a coating to
Typical Drum Characteristics
a material.
Due to their robust design and ability to handle material fluctuation, drums are considered workhorses in
Granulation Drums
many industries. They enhance product characteris-
Granulation drums are most often used for fertilizer
tics, improve material handling qualities, and reduce
production in the agriculture industry. The tumbling
waste associated with dust issues. Most drums utilize:
motion inside a granulation drum creates blended,

A tumbling, cascading motion on the
intended granule.
uniform fertilizer granules that are easy to handle and

apply. Granulation drums often include a lining as a
protective measure against corrosive and/or sticky

An inclined drum capable of handling a large
capacity.
materials. Common names for a granulation drum
Granulator
Granulation Drum (Drum Granulator, Granulator
Pre-moistened feed material or liquid spray
within the drum.

The ability to run large recycles of undersized
and crushed oversized granules.

The (potential) use of flights, or if necessary,
scrapers, to move material through the drum.

A rubber lining for sticky/abrasive materials.
Additionally, drums are the preferred equipment

choice when an application combines a chemical
reaction process with agglomeration, such as in the
formation of many traditional fertilizers.
Drum Applications and Categories
Granulator and agglomeration drum equipment is
include:
Drum, etc.)

Rotary Granulator
Rotary Drum Granulator
Rotary Drum Fertilizer Granulator
Agglomeration Drums
Agglomeration drums used in mining applications are
designed to handle high capacities. Compared to
other drum equipment, the size of an agglomeration
drum tends to range from medium to large in order
to handle the high throughputs associated with ore
mining and processing. Agglomeration drums also
often include a lining as a protective measure against
abrasive and/or corrosive materials.
used in a number of industries, with the most common
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Potash: Before & After Pelletizing
While most of the naming confusion for agglomeration
Specialty Drums
drums is contextual, some of it stems from unique
While specialty drums are technically either agglom-
processes undertaken by customized drum equip-
eration drums or granulation drums, they merit their
ment. Balling drums, for instance, are designed to
own category, as they process material in capacities
agglomerate iron ore into rolled balls (pellets).
outside typical mining and agricultural processes. In
Additionally, heap leaching drums improve the
addition to forming material into granules or pellets,
extraction of usable metal from ore.
specialty drums are also used to coat material and/

or mix material with various components. Common
Common names for an agglomeration drum include:

Agglomerator
Agglomerator Drum (Drum Agglomerator,
Agglomeration Drum, etc.)

Drum Pelletizer
Rotary Agglomerator
Rotary Drum Agglomerator
Heap Leaching Drum
Ore Drum
Ore Agglomerator
Balling Drum
specialty drums include coating drums and

conditioning drums.
The Benefits of
Pre-Conditioning
Your Material
When considering an industrial agglomeration solution
for a material, most focus is placed on what agglomeration process and equipment will yield the greatest,
and most cost-effective final product. While these
are vital primary considerations, an equally important
concern should be how to pre-condition a material for
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the desired agglomeration process. Pre-conditioning is
Pre-Conditioning Equipment
essential, because it prepares material for other
Once the final product result is determined, the
processing steps, and in doing so, assists in creating
required level of pre-conditioning should be evaluated
the best final product possible.
in order to ensure a material can achieve the desired

results. The following list examines common methods
Pre-Conditioning Benefits
used to pre-condition material.
Many different materials benefit from pre-conditioning,

even materials that do not undergo agglomeration (in
Rotary Dryers
this case, the process would be referred to as simply
Rotary dryers reduce moisture in a material using a
conditioning). Besides creating an optimal final
rotating drum with customized lifting flights. As mate-
product, pre-conditioning provides a variety of other
rial travels down the drum, it cascades off the flights
advantages as well
and comes in direct contact with a heated air stream,

which effectively dries the material. Because moisture
Each step in the agglomeration process works to make is critical to the agglomeration process, material at or
the next step easier. Pre-conditioned material provides
near its critical moisture requires drying before being
an early advantage to the entire process, resulting in
agglomerated. Using a rotary dryer to reduce moisture
easier handling for all subsequent steps.
allows for the addition of a binder and improves the

desired tackiness necessary for pellet formation.
Pre-conditioned material enhances size control and

the ability to create a uniform product. In fact, numer-
Pug mills
ous issues can be avoided by gaining greater control
Pug mills use paddles to create a kneading and
of the overall size of the material. For example, size
medium shear action as material travels through the
control can reduce excessive recycle of small (unders)
barrel-shaped trough. These mixers provide pre-con-
or large (overs) pellets.
ditioning benefits such as wetting, standard mixing,

granulating, and back mixing dried material (recycle)
By creating an easy to handle material, pre-condi-
into the process.
tioning creates a consistent feedstock that permits

increased production rates versus unconditioned
Pin Mixers
material.
Pin mixers use pins mounted on a rotor shaft to deliver

pre-conditioning benefits such as standard mixing,
Pre-conditioning allows for more control during
granulating, and back mixing dried material into the
agglomeration, which in turn creates a better
process. As the pins rotate at a high velocity, the
final product.
turbulent agitation forces imparted on the material

also deliver densification. Both pin mixers and pug mills
are ideal for use when wet and dry feedstock must
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AGGLOMERATION HANDBOOK |28
Calcium Aluminate pellets

Innovation Center
be thoroughly mixed as part of the pre-conditioning
Why Use A Binder?
process.
There are three main reasons for using a binder in the

agglomeration process:
Vacuum Deaeration
Some compaction granulation circuits utilize a
1. To achieve the desired final dry pellet crush strength
vacuum system to extract air from a material in order
Achieving the appropriate dry crush strength is
to pre-condition the material for ideal processing in
necessary to ensure the pellets are durable enough
the roll-compactor.
to survive all handling points prior to and during end

product use. From screening and packaging, to
Pre-conditioning a material, by any method, offers a
shipping, distribution, and application, product break-
variety of benefits. These benefits can be seen both
age and dust needs to be kept to a minimum. A dry
during processing, as well as in the final product results. pellet crush strength that is too low will break up too
easily, while a dry pellet crush strength that is too high
Choosing a Binder in the

Agglomeration Process
wont break up easily enough, or will take too long
Choosing the right binder for your material is one of
crush strength.
to dissolve. Adjusting binder concentration, or testing

different binders, can help to hit the target dry
the most important aspects of the agglomeration

process. A binder not only aids in pellet formation, but
2. To achieve the desired green strength
can also be used to optimize product characteristics
Green strength refers to the strength of a pellet in its
and performance.
wet state, prior to drying. Oftentimes, materials need

to be able to hold up as they move throughout the
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process before they are dried. A material with a green
binders, however, not only function well as binders for
strength that is too low has the potential to break up
fertilizer products, but also allow the product to break
as it drops off of conveyors or goes through chutes.
down quickly, and can even add micro-nutrients to
Achieving the appropriate green strength will help the
the soil.
product to stay intact through the end of the process.

Some industries, such as the steel industry, may require
3. To assist in the actual agglomeration process
that the binder be able to withstand high amounts of
A binder helps to achieve the tackiness needed for a
heat, in order to hold up in rotary kilns, or other thermal
material to stick to itself. Though some materials may
processing equipment.
agglomerate without a binder, most materials require

some sort of binding agent to pull and hold particles
Another important factor in binder selection is choos-
together while forming the pellets. And while ideally
ing a binder that is cost-effective. Binders vary greatly
water will do the job, many times it does not have the
in price, with water typically being the least costly.
tackiness to give the pellet enough wet strength to
Additionally, not all binders are available in all areas.
hold up to the rolling, tumbling, and dropping that a
You may find that a binder works perfectly for what
pellet is exposed to during processing.
youre looking to achieve, but the cost of getting it to

your area may override these benefits.
Selecting A Binder
Binders are available by the hundreds, from waxes, to
There are many aspects to consider when choosing
starches, latexes, and even plastics. Choosing a binder a binder in the agglomeration process. Industry, use,
can seem overwhelming with all of the choices avail-
cost, and availability will all have an effect on which
able, but often times, industry and end use will help to
binder will work best for the job.
decide which binder will be the best solution.

One example of how industry and end use can
quickly narrow down the choice between binders is in
the fertilizer industry. Though coal tar might function as
The Role of Drying in

Agglomeration
Drying plays a critical role in the agglomeration
a perfect binder for other industries, coal tar contains
process. When used prior to agglomeration, drying
toxins that could be passed to the soil and plants, and
prepares material feedstock for agglomerate forma-
therefore would be unacceptable to use in a fertilizer
tion, and has a direct effect on how material will
product. The same holds true for a cement binder. A
perform during agglomeration. Used after agglomera-
cement binder may work well during the agglomer-
tion, drying cures pellets into their final, strong form. In
ation process, and achieve desired strength charac-
both applications, drying is vital to producing a
teristics, but would not break down, and would leave
premium end product.
cement in soil. Molasses, starches, and other organic
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FEECO Rotary Dryer
Pre-Drying
the end product. In pelletizing, drying essentially cures
In order for agglomeration to occur, feedstock must
the green (wet) pellet into its final, hardened form.
be in the preferred moisture range. As such, it can be
This is done by removing moisture to bring the pellet
necessary to dry material prior to the actual agglom-
down to the desired moisture level of the end product.
eration stage of processing.
This improves handling, as well as end product characteristics by creating a strong pellet that is capable of
Implementing a drying stage prior to agglomeration
withstanding further handling and transportation, but
brings material feedstock down to the level of mois-
can still break down when needed. When carried out
ture needed for optimum agglomeration to occur. This
in a rotary dryer, the drying stage has the added
reduction in moisture also helps to improve subsequent benefit of polishing the pellets further rounding
processing steps, by reducing the potential for issues
them as they tumble through the drum.
like clumping, which can be common with hygroscopic materials, such as potash. If not dried first, materials
With some materials, a co-current air-flow serves to
such as these can quickly clog subsequent processing
flash off residual moisture as material enters the drum.
equipment, causing processing issues, inefficiencies,
This creates a hardened, re-crystallized surface on the
and even problems with the end product.
pellet or granule.
Drying in the Pelletizing Process
To reduce potential caking issues during the drying
As a post-agglomeration step, drying helps to refine
stage, knocking systems are often utilized to dislodge
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AGGLOMERATION HANDBOOK |31
any material that may be sticking to the interior of the

drum. Again, this may be needed in situations where
hygroscopic materials are being processed.
Drying in the Compaction Process
Because compaction is a dry process, typically not
requiring a binder, drying is often not needed.
However, a drying stage is sometimes added in order
to improve resistance to attrition. As mentioned,
granules formed in the compaction process can be
wetted and then dried, a process which serves to fill in
any surface cracks and dissolve loose edges. Again,
when carried out in a rotary dryer, this breaks off any
loose edges, polishing the granules.
For materials that do utilize a binder during the
compaction process, and therefore require a drying
Diagram: The diagram above illustrates how flights in a rotary

dryer pick up material, carry it over, and drop it through the
stream of drying air, creating what is called a curtain of
material, a technique which maximizes heat transfer efficiency.
stage, a dryer may be added to reduce the moisture
Rotary dryers work by tumbling agglomerates in a
content down to the desired level to produce the
drum for a set retention time. As the drum rotates,
final agglomerate.
flights pick up material, carrying it over, and showering

it through the drying air. This maximizes heat transfer
How Drying Works
between the material and drying air, and offers a
With most materials, reaching a target moisture range
uniform, efficient drying solution.
(or even an exact percentage) is required for the final

product. Choosing a dryer that is designed around the
Fluid bed dryers work by suspending agglomerates
unique requirements of the material to be processed
in an air stream, causing the material to behave in a
will produce the best results.
fluidized state. This too, is an efficient drying solution

for agglomerates.
Characteristics such as a materials angle of repose,

bulk density, particle size distribution, specific heat,
A quick note on choosing an industrial dryer
and more, will all have an effect on how the material
When it comes to drying bulk solids and agglomerates,
will behave in a dryer, and subsequently, how that
the choice often comes down to a rotary dryer or
dryer should be designed to work with the material to
fluid bed dryer. The choice is sometimes dictated by
produce the desired results.
the industry or material, with fluid bed dryers typically

serving the pharmaceutical and food industries, and
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rotary dryers serving more industrial applications such
sometimes both, of different sizes, shapes, solubility, and
as fertilizers and minerals. Its worth noting too, that
densities, among other things. Similarly, within each
fluid bed dryers are less suited for heavy materials such
method of agglomeration, manufacturers are often
as ores, because it requires so much energy to fluidize
targeting a set of parameters that will ensure their
them. Generally speaking, however, both dryers are
agglomerates perform as intended. The variety of
a sufficient industrial drying option, with each offering
processing methods gives manufacturers control over
their own advantages and disadvantages.
how they want their agglomerated materials to look,

feel, and behave during commercial use.
Rotary dryers are valued for their high throughput

capacities, their heavy-duty build, and their ability to
FEECO process experts often perform tests prior to
accept variance in feedstock.
processing a material, during processing, and after

agglomerates are produced. These tests are crucial
Fluid bed dryers offer a smaller footprint, increased
to process and product development, and help us
exhaust gas flow, and improved opportunity for
create agglomerates to meet each customers unique
operational growth, since they are modular in design.
needs. Testing helps predict potential behavior in the

field by gathering information on characteristics
It is also worth mentioning that cooling is sometimes
ranging from shape, to crushing behavior, and even
desirable after drying. Cooling agglomerates is useful
attrition, to help manufacturers determine if the
when material will need to be immediately packaged, agglomerates will fit their anticipated application.
or stored in a silo. Cooling helps to prevent caking
issues during storage. Similar to the choice between
Listed here are some of the most commonly
rotary dryers and fluid bed dryers, the same principles
performed tests in the FEECO Innovation Center.
typically apply when choosing between a rotary

cooler and fluid bed cooler.
Attrition
These tests are used to determine the amount of
Testing Particle
Characteristics in the
attrition that will occur during handling - that is, the

amount of product that will break down into fines.
As one can imagine, the least amount of attrition is
desirable, as it causes product loss, as well as dust-re-
The following article examines particle characteristic
lated issues. Testing during product development can
testing and gives an in-depth look at testing agglomer-
help process experts make adjustments to the process,
ates in the FEECO Innovation Center.
such as a formulation change, or addition of binder, in

order to reduce the occurrence of attrition.
Each agglomeration method tested in the FEECO

Innovation Center can produce pellets or granules,
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This test is accomplished with an attrition tester, a
Potash pellets on a conveyor in

machine that simulates the conditions under which
Reaching a target crush strength is particularly
granules rub against each other, causing edges to
essential to the fertilizer industry; fertilizer pellets must
break off into fines. On-size pellets are put into the
be strong enough to withstand processing, baggage/
machine, agitated, and then measured to see what
storage, transportation, and even spreading without
portion of the sample is still on-size. Tests are typically
breakage. Yet, the pellets must still be capable of
done on granules, as opposed to pellets, since
breaking down in standard field conditions.
granules are far more likely to have attrition issues.

Green/Wet Crush Strength
Crush Strength
Green/wet strength tests are essentially crush strength
Crush strength tests are used to determine the crush
tests, but performed on a wet pellet prior to drying.
strength of an agglomerated pellet, or in other words,
Pellets need a certain amount of strength to withstand
how much pressure it takes to crush the pellet com-
the number of drop points during processing, such as
pletely. If crush strength is low, it takes little pressure
when moving from one conveyor to another. Green/
to break pellets during normal handling, but if crush
wet strength tests are frequently done to confirm that
strength is high, then the pellet is stronger and can
the pellets are ready for the next processing steps,
withstand more handling without premature degrada-
or to determine if the agglomeration process needs
tion. Crush tests are performed on a single pellet, using
adjustment.
metal plates to gradually apply increasing pressure to

the pellet.
Compression
Similar to crush strength, compression tests look at how
Target crush strength is an important characteristic in
the agglomerated material behaves under stress, but
creating a pellet that will perform as needed.
as a whole, instead of just as a single pellet. FEECO
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process experts use a controlled product amount and a hydraulic press to perform these tests. This type of test is most commonly
utilized on kiln products, and more specifically, on proppants.
Proppants must be able to endure extreme amounts of pressure
to hold open rock fissures, allowing natural gas or oil to flow out. If
proper strength were not attained, proppants would crush under
pressure, defeating their purpose. They would also subsequently
clog veins to the main wellbore, inhibiting extraction. Furthermore,
compression is important when it comes to materials like frac sand,
or concrete additives, which are required to stand-up to heavy
loading, not as an individual particle, but as a unit.
Heres how the test works: the material sits in the bottom of a cylinder, and a smaller, solid cylinder enters the larger one. The smaller
cylinder is then pressed onto the material, crushing it at a specified
rate of pounds per square inch.
Bulk Density
As the name suggests, bulk density tests determine the density of
agglomerates. This is measured by taking a container of known
volume, filling it with agglomerates, and then weighing it. The
weight/volume reveals the materials bulk density.
Bulk density is significantly important in sizing equipment according
to material and processing needs (i.e. tons per hour of production). An operation producing paper sludge at 10 tons/hour and
weighing 20 pounds per cubic foot would look much different
than a limestone operation with product weighing 60 pounds
per cubic foot, for example. Certain products may also require a
specific bulk density for a variety of reasons, such as packing or
shipping purposes, consumer use, or maintaining pellet integrity
during use. As with other particle characteristics, the ability to test
agglomerate density ensures a product will meet the needs of its
Crush Strength Test being
performed in the FEECO
Innovation Center
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intended application.
Physical Characteristics
Sieve Analysis
Agglomerate shape is crucial in many industries where
Sieves are used to measure particle size distribution,
the end-product will go directly to market. Many
specifically what percentage of on-size pellets are
companies and industries want spherical or oblong
produced from the agglomeration process, as well as
particles, whereas other customers request different
the amount of over- and under-size particles.
shapes to match their needs. While agglomerate

shape can be determined simply by viewing the final,
Sieves are made up of a circular, metal frame with a
overall product, it can be evaluated in greater detail
screen-like wire mesh in the bottom. Various sieves,
using a microscope. FEECOs state-of-the-art micro-
each with different standardized mesh sizes, are
scope and software program from Nikon captures
available to measure the particle size distribution of
detailed particle images, allowing us to further eval-
agglomerates.
uate the agglomerate shape, in addition to surface

quality and other features unbeknownst to the naked
Flowability
eye. This in-depth view provides tangible confirmation
Flowability tests reveal how agglomerates move, or
of the agglomeration processes, and ensures that
flow, as a unit. Flowability is measured by pouring
our customers agglomerates have met their precise
material onto a makeshift chute positioned at various
expectations.
angles, and observing how the material moves from

point A to B. In this test, the angle of repose is exam-
Solubility
ined: the steepest angle, from 0-90, of descent in
Also referred to as a dissolving test, solubility tests
relation to the horizontal surface to which the material
indicate how a material will dissolve in water. These
can be piled without falling.
tests often require nothing more than a simple beaker

of water, and, of course, the product to be tested.
Flowability is particularly imperative in regards to the
Several items are recorded and analyzed in solubility
design of material handling equipment. A conveyor
tests, including:
transporting pellets may be designed differently than
1) Time
2) Temperature
3) If the material dissolves
4) How much of the material dissolves
one carrying compacted granules, for example. A

round, smooth pellet cannot be piled as steeply compared to a rougher, more jagged granule, because of
the angle of repose.
These tests are extremely valuable for fertilizer and
Moisture Content
soil amendment products, ensuring that the product
Moisture content is measured by using a moisture ana-
breaks down at the optimal rate under standard field
lyzer tool to record the amount of free moisture pres-
conditions. In addition, solubility tests are useful in
ent in agglomerates. With most materials, reaching a
testing how well coating agents perform.
target moisture range, or even an exact percentage,
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Sulfur granules created in

is required for the final product. This ensures agglomerates perform

as desired, and do not result in clumping or breakdown issues.
The analyzer uses heated coils to withdraw moisture from the agglomerate sample. The device tracks the initial moisture content, the
temperature and duration of the heat, and the final moisture content.
Temperature
Temperature is often recorded during testing, especially in thermal
applications. Process experts measure the inlet temperature of the
rotary dryer, the gas, air, and material, for example all necessary
to know while configuring the most effective drying process.
Temperature is also recorded for kiln tests, as process temperatures
are an integral part of controlling chemical reactions or phase
changes that take place in the kiln.
Testing: Prior to, During, and

After Processing
Its significant to note that these tests are either completed prior to
processing, during, or after test work has been completed. In some
cases, all tests, or a combination, can be performed at each of
the testing stages. The chart on the next page highlights tests we
often conduct at FEECO, and when they are most likely to occur.
Each of the tests noted here are done for multiple purposes: to
help determine the material handling components, agglomerate and end product characteristics, equipment selection, and
to gather data necessary for process scale-up. Furthermore, the
overall goal of these tests is to produce an end product which
meets the customers unique needs. Thus, testing a sample prior to
processing, then during processing, and on the produced agglomerate essentially helps us help you. By analyzing a sample at
various stages of processing, sometimes during all stages, process
experts are able to fine-tune process variables, and make the
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Potash pellets in a dryer in the

necessary adjustments. All tests are recorded and
motor control centers, programmable logic controllers,
provide a recipe for success, if you will, on the
and data collection systems with advanced technolo-
process used to create agglomerates unique to
gies for reporting.
your application.
The FEECO Innovation Center features a Rockwell
Automation
Automation PLC/MCC system, which utilizes current
FEECO is a Rockwell Automation partner, providing
technologies for optimizing testing operations. During
integrated process control solutions, both as a ser-
the testing process, this provides for optimal process
vice in the Innovation Center, and as part of a system
transparency; various data points can be monitored,
purchase. FEECO and Rockwell Automation process
trended, and adjusted in real-time, all from a single in-
control solutions are provided with current technology,
terface or mobile device. This includes everything from
Prior to Processing
During Processing
After Processing
Attrition
Crush Strength
Green/Wet Strength
Compression
Bulk Density
Physical Characteristics
Sieve Analysis
Flowability
Moisture Content
Temperature
Solubility
X
X
*Note: This is not an exhaustive list, and may vary per discretion of the process expert. Misc. / additional tests may be performed, depending on the unique
material, processing requirements, and desired end product.
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current (amps), feed rate, and flow rate, to
To learn how agglomeration can benefit your material,
horsepower, speed, and torque, and just about
or for further information on processing equipment or
everything in between.
material testing, contact a FEECO expert today!
The system in the Innovation Center allows for

unparalleled reporting capabilities. Customers can
select only the variables they want to see, from the
exact timeframe theyre looking for, to generate
the reports they need. This especially gives returning
customers a big advantage, allowing them to pick up
exactly where they left off.
Conclusion
Agglomeration is a valuable process in all forms,
capable of turning difficult to handle materials into
easily handled agglomerates, and adding value along
the way. There are many types of agglomeration,
each suited for unique applications, with the choice
between them often depending on desired end product characteristics, the material to be processed, and
the most cost-effective solution.
Despite the variety that exists within the agglomeration
industry, one thing is clear: the benefits that agglomeration can offer continue to extend into more and
more industries, prompting increased focus on turning
material problems into solutions, through developing
better processes, and optimizing existing ones.
FEECO has been an agglomeration expert since the
1950s, and can offer customers the best in material
testing, process design & optimization, product
development, and custom agglomeration systems
and equipment.
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THE FEECO COMMITMENT TO QUALITY

With 65+ years of experience, FEECO International has provided full-scale process solutions for thousands of
satisfied customers (including some of the worlds largest corporations, engineering firms, and start-ups). Cited
in over 250 US patents, the name FEECO has become synonymous with innovation and the reimagining of
efficiency. As the leading manufacturer of processing and handling equipment in North America, no company
in the world can move or enhance a concept from process development to production like FEECO
International, Inc.
The choice to work with FEECO means a well-rounded commitment to quality. From initial feasibility testing, to
engineering, manufacturing, and aftermarket services, we bring our passion for quality into everything we do.
FEECO International is in the process of working towards ISO 9001:2008 quality management system
compliance, with the goal of achieving ISO 9001:2008 Certification within the next calendar year.
Innovation
The FEECO Innovation Center can
aid in everything from feasibility
testing, to process design and
product development.
+
Aftermarket
Our Aftermarket
Engineering Team is
ready to serve, from
routine maintenance,
to emergency
service.
Engineering
Since 1951
We engineer custom
solutions to meet
your unique needs.
Manufacturing
We manufacture the best
heavy-duty processing
equipment around.
www.FEECO.com
3913
Algoma Rd. Green Bay, WI 54311, USA Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com www.FEECO.com
sales@feeco.com
Factory 4, 4 Bormar Drive, Pakenham, Victoria, 3810, AU Phone: 03 59404994 Fax: (920) 469-5110 Email: ausales@feeco.com www.FEECO.com.au
For more information on agglomeration, material testing, custom

equipment, or for help with your agglomeration operation or problem
material, contact FEECO International today!
FEECO US Headquarters
3913 Algoma Road | Green Bay, WI 54311 USA
Phone: 920-468-1000
Australia Testing Facility
Factory 4, 4 Bormar Drive | Pakenham, Victoria 3810 AU
Phone: 03 59404994
sales@feeco.com
Copyright 2016 | FEECO International, Inc.

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What are the main types of agglomeration discussed?

What are the main types of agglomeration discussed?

What are some benefits of agglomeration listed?

What are some benefits of agglomeration listed?

The

Why Agglomerate Your Material

EQUIPMENT & PROCESSING

Pelletizing Vs. Compaction Granulation

Borax pellets created in the

Choosing an Industrial Mixer: Pin Mixer Vs. Pug Mill

Agglomeration or Granulation Drum - Whats the Difference?

The Benefits of Pre-Conditioning Your Material

Choosing A Binder in the Agglomeration Process

The Role of Drying in Agglomeration

Testing Particle Characteristics in the FEECO Innovation Center

Why Choose FEECO? - The FEECO Commitment to Quality

For further information on agglomeration, contact a FEECO expert today.

FEECO Australia Testing Facility

3913 Algoma Rd. Green Bay, WI 54311, USA

Factory 4, 4 Bormar Drive, Pakenham, Victoria, 3810, AU

Synthetic Gypsum pellets

available, all of them fall under one of two main

enlargement and most commonly refers to the

categories: pressure agglomeration, or non-pressure

upgrading of material fines into larger particles, such

agglomeration (a.k.a., tumble growth agglomeration).

as pellets or granules. In addition to material fines,

Pressure agglomeration technologies use mechanical

such as manure or FGD sludge, to transform them into

compression to shape a material into a desired form.

a more usable, more easily handled form.

Very little, if any, moisture is needed.

Long used throughout the iron and steel sector,

Non-pressure agglomeration technologies use a

agglomeration is far from a new technique. However,

tumbling process to grow material into a spherical

it is constantly gaining popularity in an increasing

pellet form. A binder is often used to assist in the

number of industries, particularly in the past few

decades, as the numerous benefits it has to offer

While there are many agglomeration techniques

There are many types of agglomeration, all offering

will focus on the following:

their own unique advantages and disadvantages, but

Significant dust reduction

More complete utilization of raw materials

Improved product characteristics

Agglomeration continues to evolve as an industry,

Micro-Pelletizing: Also a wet process, in which

While there are many agglomeration techniques

agglomerates, or prepare the material for pelletizing.

material fines are mixed with a binder to form small

Image: Various agglomerate samples created in

Conditioning: A process which often refers to the

Product Benefits: Dust-free product handling,

mixing of material fines with a binding agent in order

segregation prevention, and improved product

to reduce dust, and transform the material into a

characteristics and appearance.

more usable form.