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Comprehensive Guide to Agglomeration Methods and Objectives in Particle Processing

Understand agglomeration mechanisms, study key rate processes, and explore various equipment types in particle processing. Learn the objectives of agglomeration, such as improved product appearance, dust elimination, and increased bulk density. Discover compression and agitation methods, ideal for creating structured forms for various applications. The text covers factors like heat transfer, solubility control, and particle removal from liquids. Ideal resource for professionals in pharmaceuticals, ceramics, food, and more.

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Comprehensive Guide to Agglomeration Methods and Objectives in Particle Processing

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  1. Particle Agglomeration Objectives • To understand the mechanism of agglomeration • To study key rate processes of agglomeration • To illustrate the different types of agglomeration equipments

  2. What is Agglomeration?

  3. Agglomeration Agglomeration happens when small particles stick together, forming aggregates which are of larger sizes.

  4. Scaled up agglomerates (Source: NIZO food research)

  5. What are the Objectives of Agglomeration?

  6. Objectives of Agglomeration • Production of useful structural forms  For eg. in pressing of intricate shapes in powder metallurgy • Provision of a defined quantity for dispensing and metering  Agricultural chemical granules or pharmaceuticals tablets • Elimination of dust handling hazards or losses  Briquetting of waste fines • Improved product appearance  Food • Reduced caking and lump formation  Fertilizer • A briquette (or briquet) is a block of flammable matter used as fuel to start and maintain a fire.

  7. Objectives of Agglomeration • Improved flow properties  Pharmaceutics, ceramics • Increased bulk density for storage  Detergents • Control of solubility • Control of porosity and surface-to-volume ratio • Improvement of heat transfer • Removal of particles from liquid

  8. 1) Agglomeration by Agitation Methods • Will be referred to as granulation, where a particulate feed is introduced to a process vessel and is agglomerated to form a granulated product • Liquid binder used to form interparticle bonds • Agitation of “wet mass” to promote liquid binder dispersion and granule growth

  9. 1) Agglomeration by Agitation Methods • Feeds: a mixture of solid ingredients (formulation), which includes an active or key ingredient, binders, diluents, flow acids, surfactants, wetting agents, lubricants, fillers or end-use aids (e.g. sintering aids, colors or dyes, taste modifiers) • Induction: solvents addition; heat (lead to controlled sintering) • Include fluid-bed, pan, drum, and mixer granulators • Spray drying is an extreme case with no further, intended agglomeration taking place after granule formation

  10. P=(p1, p2,..., pj) Y=(y1, y2,..., yn) X=(x1, x2,..., xn) Product Feed Compression vessel % % (x or y) = (size, voidage, strength, surface properties, quality metric) x y 2) Agglomeration by Compression Methods • Where the mixture of particulate matter is fed to a compression device which promotes agglomeration due to pressure. • Usually dry, sometimes liquid as lubricant.

  11. 2) Agglomeration by Compression Methods • Products: briquette or tablet • Induction: heat or cooling; carrier fluids (wet extruded) • Processes: • Continuous: roll presses; briquetting machines; extrusion • Batch: tabletting • Semi-continuous: Ram extrusion

  12. 2) Agglomeration by Compression Methods • This is a forming process controlled by mechanical properties of the feed in relationship to applied stresses and strains • Mechanical processes controlled by microlevel processes such as friction, hardness, size, shape and elastic modulus • Particles deform and break during compaction • Compaction processes give the highest density agglomerates and can operate without liquid binder

  13. Size-Enlargement methods and Application(Adapted from Table 20-36 in Perry’s Handbook)

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