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    Size Enlargement Equipment

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    Keena Angeles
    This document discusses various size enlargement techniques including granulation and compaction. It describes common granulation methods like tumbling granulation using disc or drum granulators and mixer granulators. High-speed mixers, fluidized bed granulators and other specialized granulation methods are also outlined. The document also briefly covers compaction techniques for size enlargement including piston molding presses, tableting presses, roll presses and pellet mills.

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    Size Enlargement Equipment

    Uploaded by

    Keena Angeles
    1K views43 pages
    This document discusses various size enlargement techniques including granulation and compaction. It describes common granulation methods like tumbling granulation using disc or drum granulators and mixer granulators. High-speed mixers, fluidized bed granulators and other specialized granulation methods are also outlined. The document also briefly covers compaction techniques for size enlargement including piston molding presses, tableting presses, roll presses and pellet mills.

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    This document discusses various size enlargement techniques including granulation and compaction. It describes common granulation methods like tumbling granulation using disc or drum granulators and mixer granulators. High-speed mixers, fluidized bed granulators and other specialized granulation methods are also outlined. The document also briefly covers compaction techniques for size enlargement including piston molding presses, tableting presses, roll presses and pellet mills.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    1K views43 pages

    Size Enlargement Equipment

    Uploaded by

    Keena Angeles
    This document discusses various size enlargement techniques including granulation and compaction. It describes common granulation methods like tumbling granulation using disc or drum granulators and mixer granulators. High-speed mixers, fluidized bed granulators and other specialized granulation methods are also outlined. The document also briefly covers compaction techniques for size enlargement including piston molding presses, tableting presses, roll presses and pellet mills.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 43

    Size Enlargement Equipment

    By: ANGELES, Katrina ZARRAGA, Christina

    Size Enlargement
    Process where small particles are brought together to form lumps of a desired size

    Original particles can still be distinguished


    To improve handling properties

    To reduce caking and lump formation


    To improve flow properties To increase bulk density for storage and tableting feeds To control solubility, porosity, surface-to-volume

    Size Enlargement
    Agglomeration: fomation of aggregates through the sticking together of feed and/or recycle material Granulation (Agitative Agglomeration) Compaction (Compressive Agglomeration)

    GRANULATION
    Size Enlargement

    Tumbling Granulators
    Particles are set in motion by the tumbling action caused by gravity and centrifugal forces

    Continuous feed
    Generally produce 1-20 mm granules, not suitable for making granules less than 250m Can run at large scale Disc granulators, drum granulators

    Disc Granulator
    o also: pelletizer (iron ore

    industry), pan granulator agricultural chemical industry)


    o Made of a rotating tilted

    disc or pan with a rim

    Disc Granulator
    Solids are introduced to the disc by volumetric/gravimetric feeders

    Coating of feed material builds up on disc

    A plow or scrapers oscillate and control the thickness of the coating Wetting fluids that promote growth are applied by a series of single-fluid spray nozzles distributed across the bed

    Disc Granulator

    Disc Granulator
    Size classification/segregation:
    Small granules, ungranulated feed are thrown high on the disc by centripetal forces Large granules remain in the eye and exit as product

    Drum Granulator
    Used for large-scale productions

    Common in metallurgical, fertilizer industries No output size classification high recycle rates of offsize product

    Drum Granulator
    Consists of inclined cylinder (Drum) Open-ended or Fitted with annular retaining rings Usually tilted 0-10 from horizontal Length: 2-5 times diameter

    Drum Granulator
    Scrapers control buildup of the drum wall

    Feed

    Premoistened by mixers to form granule nuclei Liquid sprayed on tumbling bed via nozzles or distributor pipe systems

    Power and capacity are proportional to drum volume

    Drum Granulator

    Tumbling Granulators
    Size classification Low equipment cost Disc Granulator Sensitivity to operating controls
    Greater capacity Longer retention time Drum Granulator Produces denser granules

    Mixer Granulators
    Contain an agitator to mix particles and liquid to cause granulation
    Agglomerate size and density are controlled by amount of liquid phase, intensity & duration of mixing High-intensity mixers are the only ones that can produce small, high density granules (< 2 mm)
    Granules produced are not as spherical, more dense than those by tumbling granulators

    Equipment can be divided into low- and high-shear mixers

    Low-Speed Mixers

    Rotation rate / Impeller speed: < 100 rpm

    Consist of horizontal troughs where central shafts with attached mixing blades rotate

    Rotating blades throw material forward and to the center: kneading, mixing action

    Vessel may be single- or doubletrough design

    Low-Speed Mixers
    Ribbon/Paddle Blenders
    Batch and continuous applications

    Planetary Mixers
    Batch Planetary Mixers Typical batch size: 100-200 kg Long mixing times: 20-40 mins. Pharmaceutical applications: for powder granulation

    Low-Speed Mixers

    Orbiting Screw Mixers Sigma Blade Mixers

    Low-Speed Mixers

    Double-Cone Blenders
    V Blenders

    High-Speed Mixers
    Continuous Shaft Mixers Batch High-Speed Mixers

    Schugi mixer (vertical shaft)

    Eirich mixer

    Pin mixers (horizontal shaft)

    Lodige mixer

    Peg mixers (horizontal shaft)

    Fielder mixer

    Diosna mixer

    Continuous Shaft Mixers


    Consist of blades/pins rotating at high speed on a central shaft

    Operate at high speeds of 200-3500 rpm


    Produces granules of 0.5-1.5 mm

    Granulated product is generally fine, irregular, with low bulk density


    Applications: detergents, agricultural chemicals, clays, ceramics, foodstuffs, carbon black

    Continuous Shaft Mixers

    Schugi mixer
    Capacity: up to 200 tons/h Power reqt: up to 200 kW

    Pin mixer
    Capacity: up to 200 tons/h Power reqt: up to 200 kW

    Peg mixer
    Capacity: 10-20 tons/h

    Batch High-Speed Mixers


    Plow-shaped mixers rotate on a horizontal shaft at 60-800 rpm

    Most have an off-center high-speed cutter/chopper rotating at 500-3500 rpm breaks down overwetting powder mass and limits the maximum granule size
    Granulation times range from 5-10 min

    Batch High-Speed Mixers


    Lodige horizontal plough shear design Gral designs

    Batch High-Speed Mixers


    Fielder designs Diosna designs

    Batch High-Speed Mixers


    Eirich mixer granulator Both chopper and impeller blades rotate on eccentrically mounted vertical shafts, cylindrical bowl also rotates Hybrid of mixer and tumbling granulation More spherical granules are produced than

    Batch High-Speed Mixers

    Fluidized Bed Granulator


    Particles are set in motion by air rather than mechanical agitation

    Produces high-porosity granules and highstrength, layered granules

    Fluidized Bed Granulator


    Disadvantages Advantages

    Batch Fluid-Bed Granulator


    Air handling unit dehumidifies and heats inlet air Liquid binder is sprayed through an air atomizing nozzle

    Heated fluidization air enters the processing zone through a distributor

    Other fluidization gases are used with or to replace air to avoid potential explosion hazards due to fine powders

    Batch Fluid-Bed Granulator

    Continuous Fluid-Bed Granulator

    Near-size granules are recycled to control the granule-size distribution

    Dust is recycled by first remelting or slurrying in liquid feed

    Spouted-Bed Granulator
    Consists of a central high-velocity spout surrounded by a moving bed annular region Particles entrained in the spout are carried to the bed surface and rain down on the annulus as a fountain Air enters through the orifice at the base of the spout

    Granules grow by layering only

    Spouted-Bed Granulator

    Good for coating applications

    Not suitable for weak granules, due to high attrition rates

    Nonspherical particles are more suited for spouted beds than fluid beds

    Particle circulation is better controlled in a fluidized bed

    Centrifugal Granulators
    A horizontal disc rotates at high speed, causing the feed to form a rotating rope of tumbling particles at the vessel walls Particle motion depends on disc speed, peripheral air velocity, presence of baffles, frictional properties of the feed

    Drying air enters through a small gap around the edge of the spinning disc

    Used for spheronization (rounding) of pellets, coating of pellets by liquid feeds

    Centrifugal Granulators
    Yield denser, more spherical granules or powder layers High capital cost

    Capacity: 3-80 kg

    Rotor Speed: 45-360 rpm

    Centrifugal Granulators

    COMPACTION
    Size Enlargement

    Piston & Molding Press


    Used to create uniform and intricate compacts

    Consists of a mechanical/hydraulic press


    Due to pressure and heat, the particulate charge causes it to flow and take the shape of the mold

    Tableting Press
    Used for applications with strict specifications for weight, thickness, hardness, density, appearance of agglomerate Produces simpler shapes at higher production rates than molding presses

    Roll Press
    Compresses raw material as it is carried into the gap between two rolls rotating at equal speeds Size and shape of agglomerates are determined by the geometry of the roll surfaces Can produce large quantities of materials at low cost Product is less uniform

    Pellet Mills
    Moist plastic feed is pushed through the holes in dies of various shapes Friction of material in the die holes provides the resistance needed for compaction Adjustable knives shear the product into pellets of desired length

    Screw and Other Paste Extruders


    Uses a screw to force material in a plastic state continuously through a die Shape of the die hole determines the shape of the compact
    Round hole: rodshaped Thin slit: film/sheet

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