A Look at the Pelletizing Process
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The document discusses the pelletizing process which involves conditioning materials through mixing, forming pellets using a disc pelletizer or drum, and drying the pellets using a rotary or fluidized bed dryer. Pelletizing is used in various industries to process materials like dust, chemicals, limestone, coal, and minerals. Choosing the right binder and equipment is important for efficient pellet production.
A Look at the Pelletizing Process
- 1. Pelletizing Process Experts in process design and material processing for over 60 years. A Look at the
- 2. Pelletizing is a non-pressure (tumble growth) agglomeration method used throughout a variety of industries to process all sorts of materials.
- 4. Common pelletizing applications: • EAF Dust
- 5. Common pelletizing applications: • EAF Dust • Chemical Powders
- 6. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone
- 7. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone • Gypsum
- 8. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone • Gypsum • Coal
- 9. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone • Gypsum • Coal • Fly Ash
- 10. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone • Gypsum • Coal • Fly Ash • Minerals and Ores
- 11. Common pelletizing applications: • EAF Dust • Chemical Powders • Limestone • Gypsum • Coal • Fly Ash • Minerals and Ores • And more….
- 12. Pelletizing produces uniform, round pellets through the use of either a disc pelletizer, or agglomeration drum. Disc pelletizers are a more common choice for the pelletizing process, with agglomeration drums being reserved for more specific applications requiring a robust, high capacity solution.
- 13. What follows gives an overview of the disc pelletizing process.
- 14. What follows gives an overview of the disc pelletizing process. In an application using an agglomeration drum, the process would be similar, with only the replacement of the disc with the drum.
- 15. Pre-Conditioning
- 16. Material fines are first conditioned in a pin or paddle mixer. Not all processes utilize a conditioning step, but in many cases, those that do see many benefits from it, including reduced binder costs, increased production, and an improved product.
- 17. FEECO Pin Mixer
- 18. Conditioning a material helps to prepare it for optimal pellet formation, and ultimately creates a more refined product.
- 19. Pelletization
- 20. Once material has been conditioned, it can be fed to the disc pelletizer.
- 21. Once material has been conditioned, it can be fed to the disc pelletizer. For processes that do not utilize a conditioning step, this is where the process begins.
- 22. Material fines and binder are fed onto the rotating disc at a continuous rate. The material fines become tacky through the addition of the binder, allowing them to pick up more fines as they tumble on the disc, similar to rolling a snowball.
- 24. Once pellets have reached the desired size, they exit the disc pelletizer, and are most commonly carried via a conveyor belt into a dryer to bring the pellets down to the desired moisture level.
- 25. Drying
- 26. Drying essentially “cures” the pellets into their final, hardened form, allowing them to be durable enough to withstand further handling, but still capable of breaking down as needed.
- 27. Drying essentially “cures” the pellets into their final, hardened form, allowing them to be durable enough to withstand further handling, but still capable of breaking down as needed. The drying step can be carried out using either a fluid bed dryer, or a rotary dryer, with rotary dryers being the more robust choice.
- 28. In a rotary dryer, pellets tumble through the drum, with flights picking up the material and showering it through a stream of hot air or combustion gas. This efficiently dries and hardens the pellets into their final form.
- 29. FEECO Rotary Dryer Dried pellets then typically go through a screening process, where on-size pellets are separated out to move on to packaging or transport, under-size pellets are put back into the process as recycle, and over-size pellets are broken down to be put back into the process as recycle.
- 30. It is also sometimes desirable to cool pellets prior to bagging or storage. In this case, a rotary cooler is often used, offering the same advantages as a rotary dryer. Again, fluid bed coolers are also an option.
- 31. Simplified Pelletizing Diagram 1. Paddle/Pin Mixer 2. Disc Pelletizer 3. Liquid Spray System 4. Transfer Conveyor 5. Rotary Dryer 6. Vibrating Screen 7. Oversize Mill 8. Surge Hopper
- 32. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics:
- 33. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation
- 34. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation • Binder feed rate
- 35. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation • Binder feed rate • Material feed rate
- 36. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation • Binder feed rate • Material feed rate • Material feed location
- 37. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation • Binder feed rate • Material feed rate • Material feed location • Pan speed
- 38. The process of pelletizing fines on a disc pelletizer has been likened to a form of art. Many variables affect the success of the end product, and can be adjusted to fine-tune end product characteristics: • Binder formulation • Binder feed rate • Material feed rate • Material feed location • Pan speed • Pan angle
- 39. Gypsum fines are fed into the pin mixer, with the addition of a binder. Pelletizing results in a durable pellet that can withstand handling, but still break down quickly under standard field conditions.
- 40. While there are many things to consider in a pelletizing operation, two of the most important factors are:
- 41. While there are many things to consider in a pelletizing operation, two of the most important factors are: - Binder
- 42. While there are many things to consider in a pelletizing operation, two of the most important factors are: - Binder - Equipment
- 43. Binder
- 44. A binder aids in pellet formation and also helps to achieve the desired end product crush strength.
- 45. A binder aids in pellet formation and also helps to achieve the desired end product crush strength. Consulting an agglomeration expert can help in deciding which binder will best suit your needs.
- 46. Equipment
- 47. Choosing quality equipment will go a long way in providing for an efficient, long-lasting operation that produces an optimum product.
- 48. Choosing quality equipment will go a long way in providing for an efficient, long-lasting operation that produces an optimum product. Instead of a one-size-fits-all approach, equipment should be designed around the material’s unique characteristics for best results.
- 49. Choosing quality equipment will not only aid in process efficiency, but will also typically require less maintenance and down time, and will often result in prolonged equipment life.
- 50. 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
- 51. Want to learn more? Download our Agglomeration Handbook Agglomeration Handbook Intro to Agglomeration Processing Techniques Considerations in Agglomeration And more… Download Now