Size Enlargement

Fig. 7.
1
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
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_MPE_7 VO Mechanical Process Engineering - Particle Technology Agglomeration Dr. W. Hintz/Prof. Dr. J. Tomas 07.05.2012
Figure 7.1
Fig. 7.2
Processes or unit operations of mechanical process engineering

according to RUMPF
without
separation
mechanical
combination
powder mixing
change
separation (filters,
and
of
separators,
blending
particle size
screens, sifters)
with change
size reduction
of
(crushing and
particle size
grinding)
particle
size
analysis
size enlargement
(agglomeration)
transport and storage of bulk

materials
Figure 7.2
Fig. 7.3
Agglomeration - Size Enlargement

1. Agglomeration processes:
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
Figure 7.3
Fig. 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
Figure 7.4
Fig. 7.5
Tensile Strength of Agglomerates
Approximation of the theoretical tensile strength of agglomerates versus primary particle size, porosity = 0.35
(according to RUMPF)
Figure 7.5
Fig. 7.6
Compressive strength of agglomerates

(according to RUMPF)
lignite briquettes
calcinated
pellets of
25 mm
diameter
ore briquettes
green pellets
50 X 50 mm
dried
with
2-3%
of salt
pellets
25 mm
diameter
green
green pellets
20 mm diam.
dried pellets
20 mm diam.
dried
Figure 7.6
Fig. 7.7
Species of the genus Scarabaeus, which occur throughout Southern Europe and Northern Africa,
are fairly typical of the dung - rolling scarabs:
Scarabaeus sacer
(actual size 25 30 mm long)
adult beetle rolling its ball of dung

to a suitable place for burial
Scarabaeus sacer, natures pelletizer

Figure 7.7
Fig. 7.8
Tumble Agglomeration (Pelletizing)

1. Balling drum and balling pan
a) balling drum
b) balling pan
A
P
W
feed material
green pellets
water
Figure 7.8
Fig. 7.9
Models of pellet nucleation and pellet

formation mechanism
solid
liquid
a) Pellet nucleation mechanism
b) Embedding of small feed particles at the surface of wet

agglomerates (acc. to Pietsch, Aufbereitungstechnik 7 (1966) 177-191)
Figure 7.9
Fig. 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
Figure 7.10
Fig. 7.11
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
pan diameter
gravitational acceleration
mass in the pan
ncrit =
1 g sin
2D
ncrit critical number of revolutions
Figure 7.11
Fig. 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
Figure 7.12
Fig. 7.13
Deep dish or pan pelletizer

1 disc
2 screw conveyor
3 water supply
A feed
P green product
Figure 7.13
Fig. 7.14
Flow sheets for pelletizing systems

a) with balling drums
1 mixer
2 balling drum or pan
3 screen
4 mill
b) with balling pan
A feed
Z additives
P green pellets
Figure 7.14
Fig. 7.15
Different material flow patterns during revolution of balling drums
material is sliding,
material is rolling,
material is cataracting,
rotational speed too
rotational speed is
rotational speed too fast
slow
optimal, 8 14 rpm,
6 10 drum angle
Figure 7.15
Fig. 7.16
Press Agglomeration
Operation principles of press agglomeration :
a)
a) in a closed die
b) in a open die
c) by roller pressure
B agglomerate
FP compaction or press force
b)
FR wall friction force in the die

channel
h punch stroke length
l
filling level (not compacted)
thickness of compacted
material
k
c)
compaction (k=l/s)
1 half of nip angle

1 punch
2 pressing die
Figure 7.16
Fig. 7.17
Isentropic Powder Compression

Adiabatic gas compression:
dV
1 V
=
dp ad p
(1)
Isentropic powder compression:

b
bulk density b
d b
b = n
b,0
M ,st
d M ,st
M ,st + 0
(2)
n = 1 ideal gas compressibility index
0 < n < 1 compressible

b,0
isostatic
0
tensile
strength -0
n = 0 incompressible
M,st n
b = b,0 (1 +
)
0
centre stress during consolidation
or steady-state flow M,st
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
Figure 7.17
Fig. 7.18
Powder Compression
b,0
1-n
) -1
0<n<1
p
b = b,0 (1 +
0
b
db
= n
p + 0
dp
isostatic
tensile
strength -0
specific compression work Wm,b
b,0
n
0
p
(1 +
0
compression rate db/dp
bulk density b
Wm,b = n . 0 .
1-n
b,0
average pressure p
Figure 7.18
Fig. 7.19
Compression and Preshear Work

preshear
FN
pre, YL3
FS
shear force FS
pre, YL2
pre, YL1
Wb,
specific compression and

preshear work Wm,b, Wm,b,pre
spre
pre
= FS(s) ds
displacement s
M,st 1-n
spre. sin 2st 0
Wm,b,pre = 2 . hSz
b,0 (1 + 0 )
spre. sin 2st 0
b,0
2 . hSz
isostatic
0
tensile
strength -0
Wm,b = n . 0 .
1-n
b,0
0<n<1
M,st 1-n
(1 + ) 0
average pressure at steady-state flow M,st
Figure 7.19
Fig. 7.20
Microprocesses and deformation mechanism at

powder press agglomeration (compaction)
p
p
h(t)
h(t)
h0
a) Feed of loose
packing
b) Elastic-plastic
contact deformation
h(t)
d) Plastic deformation
of particles to create
large contact areas
c) Pore filling
by fine particles
h(t)
h(t)
e) Breakage of
f) Plastic deformation
edges, particle
of entire tablet
breakage, pore filling
Compaction function of cohesive Powder
10 -3
T = f(p)
uniaxial compressive strength c
compact strength lg(T in MPa)
Tablet, briquette or ribbon strength T
For hopper design
c = a 1 1 + c,0
0 consolidation stress 1
com paction pressure lg(p in M Pa)
Figure 7.20
Fig. 7.21
Density in cylindrical compacts

panels a) g):
pressure of isobars given in MPa
panel h):
agglomerate density of isodensity lines in % of pure solid
density (according to ORR)
Figure 7.21
Fig. 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
Figure 7.22
Fig. 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
Figure 7.23
Fig. 7.24
Compaction mechanism in a ram press

pressure
filling
begin of back stroke
begin of compaction
back expansion
begin of stroke
begin of pre-filling
Sequence of events during a briquetting cycle in the ram press

(according to KEGEL and RAMMLER)
Figure 7.24
Fig. 7.25
Schematic representation of the decrease in elastic recovery and increase of density of a

briquette during consecutive press cycles in a ram press
Figure 7.25
Fig. 7.26
Ram extrusion press for coal briquetting (ZEMAG, Zeitz, Germany)
1 briquette die
2 ram
3 ram holder
4 press top cap
5 thrust piece
6 coal ejector channel
7 slipping dog
8 connecting rod
Figure 7.26
Fig. 7.27
Vacuum
Ram Press
Vakuumstrangpresse
product
Breitenbach
Fabrikat Breitenbach
Typ VAS
56b56b
type
VAS
Zylinder-: 560 mm
cylinder-dia.
560 mm
Leistung: max. 50 to./
press
force: 240
max.
Antriebsmotor:
KW500 kN
drive: 240 kW
Figure 7.27
Fig. 7.28
Roller press machines

Types of roller press machines:
a) roller compacting machine
b) roller briquetting machine
Figure 7.28
c) ring roller press
Fig. 7.29
Compaction zones and angles of a roller press
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 vb < vu = .D/2 = .n.D
< g velocity advance of compacted material sheet
(ribbon) compared to roller tip speed vb > vu
V angle of elastic release (recovery) zone after passing the

minimum roller gap, the ribbon (compacted sheet) gets
thicker s2 > s1 than the roller gap for roller angle = 0 to -V
Figure 7.29
Fig. 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
Figure 7.30
Fig. 7.31
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
Figure 7.31

Size Enlargement

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Fig. 7.

Particle formulation by agglomeration,

Processes or unit operations of mechanical process engineering

transport and storage of bulk

Agglomeration - Size Enlargement

b) press agglomeration (compaction)

Different Types of Pellets and Granulates

Micropellet < 500 m

Micropellet < 500 m

Tensile Strength of Agglomerates

Compressive strength of agglomerates

adult beetle rolling its ball of dung

Scarabaeus sacer, natures pelletizer

Tumble Agglomeration (Pelletizing)

Models of pellet nucleation and pellet

a) Pellet nucleation mechanism

b) Embedding of small feed particles at the surface of wet

Balling pan pelletizer

Inclined pan pelletizer

5. device for changing the

pan angle of inclination

(tilt angle to the horizontal)

Figure shows conditions to determine the critical rotation speed of

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

b dynamic angle of repose of the material to be granulated

mass in the pan

ncrit critical number of revolutions

Movement of the charge in a pelletizing pan at different

Qualitative relationship between moisture, residence time or

Deep dish or pan pelletizer

Flow sheets for pelletizing systems

Different material flow patterns during revolution of balling drums

rotational speed too

rotational speed too fast

FR wall friction force in the die

filling level (not compacted)

1 half of nip angle

Isentropic Powder Compression

Isentropic powder compression:

n = 1 ideal gas compressibility index

0 < n < 1 compressible

Compressibility index of powders, semi-empirical estimation

specific compression work Wm,b

compression rate db/dp

Compression and Preshear Work

specific compression and

average pressure at steady-state flow M,st

Microprocesses and deformation mechanism at

Compaction function of cohesive Powder

compact strength lg(T in MPa)

Tablet, briquette or ribbon strength T

For hopper design

com paction pressure lg(p in M Pa)

Density in cylindrical compacts

Punch - and - Die - Presses

b) Rotary tabletting machines

ram extrusion or plunger press

pelleting machine with flat die and muller-type press rollers

pelleting machine with one solid and one hollow roll

pelleting machine with two hollow rolls

pelleting machine with internal press roll

Compaction mechanism in a ram press