Fig. 7.

1
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.1


Size Enlargement,

Agglomeration


7. Particle formulation by agglomeration,
7.1 Fundamental agglomeration principles
7.2 Agglomerate strength
7.3 Pelletizing of moist powder
7.4 Press agglomeration
7.4.1 Powder compression and compaction behaviour
7.4.2 Briquetting and tabletting
7.4.3 Roller press





Fig. 7.2
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.2


Processes or unit operations of mechanical process engineering
according to RUMPF




separation

combination

without
change
of
particle size
mechanical
separation (filters,
separators,
screens, sifters)
powder mixing
and
blending
particle

size

analysis with change
of
particle size
size reduction
(crushing and
grinding)

size enlargement
(agglomeration)

transport and storage of bulk
materials



Fig. 7.3
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.3


Agglomeration - Size Enlargement



7.1 Fundamental agglomeration principles:

a) tumble agglomeration (growth or agitation agglomeration)
pelletizing







b) press agglomeration (compaction)
continuous sheets
solid forms (tablets, briquettes)
c) sintering (thermal process)

A feed material (for agglomeration),
Q

heat flow


Fig. 7.4
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.4


Different Types of Pellets and Granulates


Cellets
Pelletizing
Pharma

Micropellet < 500 m
Coating
Pharma
Micropellet < 500 m
(Cross-Section)
Coating
Pharma

Instant-Tee
Agglomeration
Food

Aromas
Encapsulating
Food
Sweetener
Agglomeration
Food

Amino acid
Coating
Feeding stuff
Polymer
Agglomeration
Fine chemistry
Detergent component
Spraying granulation
Fine chemistry


Quelle: www.glatt.de




Fig. 7.5
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.5

7.2 Tensile Strength of Agglomerates


Approximation of the theoretical tensile strength of agglo-
merates versus primary particle size, porosity = 0.35
(according to RUMPF)


Fig. 7.6
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.6


Compressive strength of agglomerates
(according to RUMPF)

pellets
25 mm
diameter
dried
dried
with
2 - 3 %
of salt
green dried pellets
20 mm diam.
green pellets
20 mm diam.
green pellets
50 X 50 mm
ore briquettes
lignite briquettes
calcinated
pellets of
25 mm
diameter


Fig. 7.7
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.7

7.3 Tumble Agglomeration (Pelletizing)

Species of the genus Scarabaeus, which occur throughout Southern Europe and Northern Africa,
are fairly typical of the dung - rolling scarabs:













Scarabaeus sacer adult beetle rolling its ball of dung
(actual size 25 30 mm long) to a suitable place for burial

Scarabaeus sacer, natures pelletizer


Fig. 7.8
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.8

7.3 Tumble Agglomeration (Pelletizing)

1. Balling drum and balling pan

a) balling drum












b) balling pan











A feed material
P green pellets
W water


Fig. 7.9
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.9

Models of pellet nucleation and pellet
formation mechanism









a) Pellet nucleation mechanism













b) Embedding of small feed particles at the surface of wet
agglomerates (acc. to Pietsch, Aufbereitungstechnik 7 (1966) 177-191)
liquid
solid


Fig. 7.10
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.10

Balling pan pelletizer


















Inclined pan pelletizer
1. pan 5. device for changing the
2. pan drive pan angle of inclination
3. water supply (tilt angle to the horizontal)
4. bottom share



Fig. 7.11
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.11



n
crit
=

1
D 2
sin g


















Figure shows conditions to determine the critical rotation speed of
pan

pan bottom angle of inclination (tilt angle to the horizontal)

b
dynamic angle of repose of the material to be granulated
angular velocity
D pan diameter
g gravitational acceleration
m mass in the pan
n
crit
critical number of revolutions


Fig. 7.12
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.12

Movement of the charge in a pelletizing pan at different
rotational speeds















Qualitative relationship between moisture, residence time or
throughput and average pellet size for balling pan
f moisture content


Fig. 7.13
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.13



Deep dish or pan pelletizer














1 disc
2 screw conveyor
3 water supply

A feed
P green product



Fig. 7.14
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.14

Different material flow patterns during revolution of balling drums












material is sliding,
rotational speed too
slow
material is rolling,
rotational speed is
optimal, 8 14 rpm,
6 10 drum angle
material is cataracting,
rotational speed too fast


Fig. 7.15
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.15

Flow sheets for pelletizing systems

a) with balling drums



b) with balling pan



1 mixer
2 balling drum or pan
3 screen
4 mill

A feed
Z additives
P green pellets


Fig. 7.16
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.16

7.4 Press Agglomeration
Operation principles of press agglomeration :

a)








b)










c)








a) in a closed die
b) in a open die
c) by roller pressure

A feed
B agglomerate
F
P
compaction or press force
F
R
wall friction force in the die
channel
h punch stroke length
l filling level (not compacted)
s thickness of compacted
material
k compaction (k=l/s)

1
half of nip angle

1 punch
2 pressing die



Fig. 7.17
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.17

b
u
l
k

d
e
n
s
i
t
y

b,0

b
=
b,0
(1 + )

M,st

0
n
centre stress during consolidation
or steady-state flow
M,st
isostatic
tensile
strength -
0
0
n = 0 incompressible
0 < n < 1 compressible
n = 1 ideal gas compressibility index
Isentropic Powder Compression
Adiabatic gas compression:
p
V 1
dp
dV
ad

=
(1)
Isentropic powder compression:

st , M
b
0 , b
0
0 st , M
st , M
b
b
d
n
d
(2)

Compressibility index of powders, semi-empirical estimation
index n evaluation examples flowability
0 0.01 incompressible gravel free flowing
0.01 0.05 low compressibility fine sand
0.05 - 0.1 compressible dry powder cohesive
0.1 - 1 very compressible moist powder very cohesive


Fig. 7.18
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.18

b
u
l
k

d
e
n
s
i
t
y

b,0
average pressure p
isostatic
tensile
strength -
0
0
0 < n < 1
Powder Compression

b
=
b,0
(1 + )
p

0
n
c
o
m
p
r
e
s
s
i
o
n

r
a
t
e


d

b
/
d
p

b
p +
0
= n
d
b
dp
W
m,b
= . . (1 + ) - 1
p

0
1-n
n
1 - n

b,0
s
p
e
c
i
f
i
c

c
o
m
p
r
e
s
s
i
o
n

w
o
r
k

W
m
,
b

b,0

0
n



Fig. 7.19
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.19

average pressure at steady-state flow
M,st
isostatic
tensile
strength -
0
0
0 < n < 1
Compression and Preshear Work
W
m,b
= . . (1 + ) - 1

M,st

0
1-n
n
1 - n

b,0
s
p
e
c
i
f
i
c

c
o
m
p
r
e
s
s
i
o
n

a
n
d
p
r
e
s
h
e
a
r

w
o
r
k

W
m
,
b
,

W
m
,
b
,
p
r
e
W
m,b,pre
= (1 + )

M,st

0
1-n
s
pre
.
sin 2
st
2
.
h
Sz

b,0
displacement s
s
h
e
a
r

f
o
r
c
e



F
S
preshear
s
pre

pre, YL3
W
b, pre
= F
S
(s) ds

pre, YL2

pre, YL1
F
N
F
S
s
s
pre
.
sin 2
st
2
.
h
Sz

b,0



Fig. 7.20
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.20

Microprocesses and deformation mechanism at
powder press agglomeration (compaction)

p p
d) Plastic deformation
of particles to create
large contact areas
f) Plastic deformation
of entire tablet
e) Breakage of
edges, particle
breakage, pore filling
p
p
b) Elastic-plastic
contact deformation

a) Feed of loose
packing

c) Pore filling
by fine particles

p
h
0


h(t)

h(t)

h(t)

h(t)

h(t)



Compaction function of cohesive Powder
c
o
m
p
a
c
t

s
t
r
e
n
g
t
h


l
g
(

T


i
n

M
P
a
)
compaction pressure lg(p in MPa)
10
-3
Tablet, briquette or ribbon strength
T
u
n
i
a
x
i
a
l

c
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

c
consolidation stress
1
0

c
= a
1

1
+
c,0
For hopper design

T
= f(p)


Fig. 7.21
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.21

Density in cylindrical compacts
panels a) g):
pressure of isobars given in MPa
panel h):
agglomerate density of iso-
density lines in % of pure solid
density (according to ORR)


Fig. 7.22
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.22

Punch - and - Die - Presses

a) Reciprocating piston and die (excenter) press

1 excenter drive
2 upper punch
3 lower punch
4 rotating table with inwrought dies
5 feed shoe with hopper
A feed
B tablets


b) Rotary tabletting machines














B


Fig. 7.23
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.23

Pelletizing machines
1 cutter A feed B briquettes

a) ram extrusion or plunger press
b) screw extruder
c) pelleting machine with flat die and muller-type press rollers
d) pelleting machine with one solid and one hollow roll
e) pelleting machine with two hollow rolls
f) pelleting machine with internal press roll
g) gear-type pelletizer


Fig. 7.24
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.24


Compaction mechanism in a ram press

Sequence of events during a briquetting cycle in the ram press
(according to KEGEL and RAMMLER)
pressure
filling filling
begin of stroke
back expansion begin of compaction
begin of pre-filling
begin of back stroke



Fig. 7.25
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.25

Schematic representation of the decrease in elastic recovery and increase of density of a
briquette during consecutive press cycles in a ram press



Fig. 7.26
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.26

Ram extrusion press for coal briquetting (ZEMAG, Zeitz, Germany)














1 briquette die 5 thrust piece
2 ram 6 coal ejector channel
3 ram holder 7 slipping dog
4 press top cap 8 connecting rod



Fig. 7.27
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.27

Vakuumstrangpresse
Fabrikat Breitenbach
Typ VAS 56b
Zylinder-: 560 mm
Leistung: max. 50 to./
Antriebsmotor: 240 KW
Vacuum Ram Press
product Breitenbach
type VAS 56b
cylinder-dia. 560 mm
press force: max. 500 kN
drive: 240 kW



Fig. 7.28
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.28

Roller press machines

Types of roller press machines:

a) roller compacting machine b) roller briquetting machine c) ring roller press


Fig. 7.29
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.29

Compaction zones and angles of a roller press

o
feed angle of roller

E
grip angle of roller (angle of compaction)

g
nip angle or neutral angle (sign of friction forces changes)
>
g
velocity lag of compacted (compressed) powder
compared to roller tip speed v
b
< v
u
=
.
D/2 =
.
n
.
D
<
g
velocity advance of compacted material sheet
(ribbon) compared to roller tip speed v
b
> v
u

V
angle of elastic release (recovery) zone after passing the
minimum roller gap, the ribbon (compacted sheet) gets
thicker s
2
> s
1
than the roller gap for roller angle = 0 to -
V



Fig. 7.30
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure 7.30

Feeder design for roller press machines (KPPERN,
Hattingen, Germany)

a) gravity feeder with adjustable tongue (or plate)








b) screw feeder for filling and pre-compaction




Fig. 7.31
Prof. Dr. J . Tomas, chair of Mechanical Process Engineering
Fig_MPE_7 VO Mechanical Process Engineering - ParticleTechnology Agglomeration Dr. W. Hintz/Prof. Dr. J . Tomas 23.06.2014 Figure7.31

Roller press (KPPERN, Hattingen, Germany)


1 rollers with replaceable rings or sleeves as pressing tools 4 hydraulic reservoir
2 roller core with integral journals 5 hydraulic pump
3 hydraulic cylinder 6 automatic grease lubrication