Compaction Granulation

Experts in process design and material processing for over 60 years.

A Look at

Compaction granulation is a method of pressure agglomeration used to turn material fines into a granular product.

This method relies on the principle that under extreme pressure, some materials will adhere to themselves without the use of a binder.

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals• Polymers

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals• Polymers• Oxides

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals• Polymers• Oxides• Catalysts

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals• Polymers• Oxides• Catalysts• Clays

Compaction is used throughout a variety of industries, to process all kinds of materials. Common applications include:

• Fertilizers• Chemicals• Detergents• Pigments• Minerals• Polymers• Oxides• Catalysts• Clays• And more…

How it Works

Compaction granulation is carried out in a compactor, or double roll press.

Material fines are fed between two counter rotating rolls. The rolls use extreme pressure to press the fines into a form.

Material fines are fed between two counter rotating rolls. The rolls use extreme pressure to press the fines into a form.

This form is then broken up into the desired granule size.

After this, the granules typically go through a screening process, where on-size material is separated out to move on to packaging or transport, and under-size and over-size are put back into the process as recycle, with over-size first being broken down.

Granules are sometimes conditioned after compaction, in order to help reduce the opportunity for attrition.

This can be carried out in paddle mixer, or a coating/conditioning drum. This step can also accommodate the addition of desirable additives, such as anti-caking additives and the like.

Simplified Compaction Diagram1. Raw feed2. Mill3. Surge Hopper4. Humidificator Mixer5. Protecting Screen6. Compactor7. Flake Breaker8. Granulators9. Screen10. Polishing Drum11. Screen12. Screw for Recycles

While many factors affect the success of the compaction process, two key factors that can influence this are:

While many factors affect the success of the compaction process, two key factors that can influence this are:

• The Feeding Mechanism

While many factors affect the success of the compaction process, two key factors that can influence this are:

• The Feeding Mechanism• Particle Size Distribution

The Feeding Mechanism

An even, steady pressure across the face of the rolls is necessary.

An even, steady pressure across the face of the rolls is necessary.

Uneven pressure is often the result of an inadequate feeding system.

Particle SizeDistribution

Variance in particle size distribution for the material feedstock will produce the best results. This is because smaller particles will fill in the spaces between larger ones.

In addition, a particle size distribution that is either too fine or too coarse, can cause processing problems or produce poor end product results.

ConclusionWhile not all materials will respond well to the compaction granulation process, for those that do, this pressure agglomeration technique is a cost-effective means of transforming material fines into an easy to use, granular product.

has been a leader in the agglomeration industry since the 1950s, helping customers solve material problems through process & product development, feasibility testing, and high-quality, custom agglomeration equipment.

FEECO

Want to learn more?Download our

Agglomeration Handbook

Agglomeration Handbook

Intro to AgglomerationProcessing TechniquesConsiderations in AgglomerationAnd more…

Download Now