Agglomeration

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

An Introduction to

Agglomeration is the process of particle size enlargement.

It is commonly used to upgrade material fines into a granular product, and can also be used to transform sludge-like materials into a dry, granular form.

Why AgglomerateYour Material?

Common Reasons toAgglomerate Include:

Common Reasons toAgglomerate Include:

• The material is difficult to handle or apply

Common Reasons toAgglomerate Include:

• The material is difficult to handle or apply

• The material is challenging or costly to transport

Common Reasons toAgglomerate Include:

• The material is difficult to handle or apply

• The material is challenging or costly to transport

• The material is not usable in its current form

Common Reasons toAgglomerate Include:

• The material is difficult to handle or apply

• The material is challenging or costly to transport

• The material is not usable in its current form

• The material is too dusty

No matter what the reason, agglomeration offers an array of benefits…

Benefits ofAgglomeration

The use of agglomeration to solve material problems and improve product characteristics is continually spreading to new industries and materials.

In general, agglomerating a material offers the following benefits: 

In general, agglomerating a material offers the following benefits: • Significant Dust Reduction

In general, agglomerating a material offers the following benefits: • Significant Dust Reduction• Improved Handling & Transportation

In general, agglomerating a material offers the following benefits: • Significant Dust Reduction• Improved Handling & Transportation• More Complete Utilization of Raw Materials

In general, agglomerating a material offers the following benefits: • Significant Dust Reduction• Improved Handling & Transportation• More Complete Utilization of Raw Materials• Improved Product Characteristics

More specifically, there are many facets to the benefits of agglomeration…

End Product Benefits:

End Product Benefits:

• Dust-free product handling

End Product Benefits:

• Dust-free product handling• Segregation prevention

End Product Benefits:

• Dust-free product handling• Segregation prevention• Improved product characteristics

End Product Benefits:

• Dust-free product handling• Segregation prevention• Improved product characteristics• Enhanced appearance

End Product Benefits:

• Dust-free product handling• Segregation prevention• Improved product characteristics• Enhanced appearance

Example:The agglomeration of agricultural wastes makes them easier and less costly to transport, easier to apply, and capable of being stored. Other improvements include the opportunity to create a more precise and targeted fertilizer formula.

Raw Material Benefits:

Raw Material Benefits:

• Simplified Transportation

Raw Material Benefits:

• Simplified Transportation• Dust loss prevention

Raw Material Benefits:

• Simplified Transportation• Dust loss prevention• Increased porosity, density, and melting

abilities

Raw Material Benefits:

• Simplified Transportation• Dust loss prevention• Increased porosity, density, and melting

abilities

Example:Agglomerating ore fines prior to heap leaching creates a more uniform particle size distribution. This maximizes the efficiency of the heap leaching process, allowing for better percolation of the leaching solution through the heap.

Process Benefits:

Process Benefits:

• Elimination of dust and fines

Process Benefits:

• Elimination of dust and fines• Increased process flow effectiveness

Process Benefits:

• Elimination of dust and fines• Increased process flow effectiveness• Reduced clogging of processing equipment

Process Benefits:

• Elimination of dust and fines• Increased process flow effectiveness• Reduced clogging of processing equipment• Increased process efficiency

Process Benefits:

• Elimination of dust and fines• Increased process flow effectiveness• Reduced clogging of processing equipment• Increased process efficiency

Example:In its raw state, glass powder is susceptible to being swept up in the airflow during processing, resulting in lost product and skewed formulas. Agglomerating glass reduces product loss, ensures accurate formulations, and improves process efficiency.

Economic Benefits:

Economic Benefits:

• Conversion of a waste material to a marketable product

Economic Benefits:

• Conversion of a waste material to a marketable product

• Reduced transportation costs

Economic Benefits:

• Conversion of a waste material to a marketable product

• Reduced transportation costs• Reduced material handling costs

Economic Benefits:

• Conversion of a waste material to a marketable product

• Reduced transportation costs• Reduced material handling costs

Example:Agglomeration of previously unsalable limestone fines transforms them into a marketable product – limestone soil amendment pellets.

Environmental Benefits:

Environmental Benefits:

• Potential to eliminate the need to landfill a material

Environmental Benefits:

• Potential to eliminate the need to landfill a material

• Improved cost-efficient recycling capabilities

Environmental Benefits:

• Potential to eliminate the need to landfill a material

• Improved cost-efficient recycling capabilities• Potential for waste-to-fuel processes

Environmental Benefits:

• Potential to eliminate the need to landfill a material

• Improved cost-efficient recycling capabilities• Potential for waste-to-fuel processes• Improved waste disposal cost efficiency

Environmental Benefits:

• Potential to eliminate the need to landfill a material

• Improved cost-efficient recycling capabilities• Potential for waste-to-fuel processes• Improved waste disposal cost efficiency

Example:Waste paper sludge that was previously considered unusable and therefore landfilled, can be agglomerated into a usable product.

Methods ofAgglomeration

Many types of agglomeration techniques exist, with all of them falling under one of two main categories:

• Pressure• Non-pressure (tumble growth)

Pressure Agglomeration:Pressure agglomeration techniques rely on pressure to cause a material to adhere to itself, through the application of extreme pressure. Not all materials will adhere to themselves under pressure, so pressure methods are not always an option.

Non-Pressure Agglomeration: (Tumble Growth)

Non-pressure agglomeration techniques use a binding agent to process material into larger fines. This is done by tumbling the fines in the presence of a binder, similar to rolling a snowball.

PressureAgglomeration

Techniques

BriquettingBriquetting is carried out in a briquetter, and produces large, pillow-shaped briquettes. This process is reserved for larger agglomerates, such as charcoal or water softener briquettes.

Briquettes created in a briquetter in the FEECO Lab.

Because briquetting is typically a dry process (no binder), a drying phase is not necessary. While a binding agent is typically not utilized, it can be helpful in some situations.

CompactionCompaction is carried out using a roll compactor, and produces small, jagged granules. This process is used throughout a variety of industries, including fertilizers and chemicals.

CompactionCompaction is carried out using a roll compactor, and produces small, jagged granules. This process is used throughout a variety of industries, including fertilizers and chemicals.  Again, a binder is typically not used, and therefore a drying step is usually not necessary.

Photo of granules

Granules created in a roll compactor in the FEECO Lab.

Non-PressureAgglomerationTechniques

PelletizingPelletizing can be carried out in a disc pelletizer or agglomeration drum. Both methods produce round pellets.

PelletizingPelletizing can be carried out in a disc pelletizer or agglomeration drum. Both methods produce round pellets.

Because a binder is used, pelletizing methods most often require a drying step.

Pellets created on a disc pelletizer in the FEECO Lab.

Micro-PelletizingMicro-pelletizing produces small pellets, and is commonly used to de-dust material, as well as to prepare it for optimal pellet formation on a disc pelletizer or in an agglomeration drum.

Micro-PelletizingMicro-pelletizing produces small pellets, and is commonly used to de-dust material, as well as to prepare it for optimal pellet formation on a disc pelletizer or in an agglomeration drum.

Micro-pelletizing is most often carried out in a pin mixer.

Micro-pellets created in a pin mixer in the FEECO Lab.

ConditioningConditioning typically refers to the simple act of mixing or de-dusting material in a pin or paddle mixer. This may be to prepare it for pelletizing, to reduce dust, or simply to make it easier to handle and transport.

Material being conditioned in a paddle mixer in the FEECO Lab.

ConclusionThe numerous benefits agglomeration has to offer, combined with increasing flexibility in applications, has caused this valuable process to find its way into all sorts of industries. Various agglomeration techniques are available, allowing manufacturers to tailor a process to the exact needs of their material.

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

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Agglomeration Handbook

Agglomeration Handbook

Intro to AgglomerationProcessing TechniquesConsiderations in AgglomerationAnd more…

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