C H R I S K O Z I C K I F E E C O I N T E R N A T I O N A L

Transcription

1 AGGLOMERATING BULK SOLIDS: FROM IDEA TO PRODUCTION C H R I S K O Z I C K I F E E C O I N T E R N A T I O N A L

2 A G G L O M E R A T I O N

3 AGGLOMERATION

4 WHY AGGLOMERATE? RAW MATERIAL BENEFITS Simplified transportation Mitigation of dust issues Increased porosity, density, and melting abilities PRODUCT BENEFITS Dust-free handling Segregation prevention Improved appearance Enhanced performance PROCESS BENEFITS Mitigation of dust Improved process flow and efficiency ECONOMIC BENEFITS Waste is converted into a usable product (in some cases with potential for sale and reduction of waste management costs) Reduced handling and transportation costs ENVIRONMENTAL BENEFITS Reduction in need for landfilling Potential for waste to fuel processes

5 WHY AGGLOMERATE? PROBLEM SOLVING Material entrainment in furnaces Unacceptable product loss Skewed product formulations Inability to effectively meter/dose material Caking during storage or shelf life Hazardous work environment Non user-friendly deliverable Unpredictable application results Uncontrolled product breakdown Flowability issues

6 APPLICATIONS >> Agglomeration has proven to be valuable in numerous applications (and growing), including: Coal Fines De-dusting Fly Ash Conditioning Limestone Pelletizing Gypsum Pelletizing Iron Ore Pelletizing Organic-based Fertilizers Chemical Powders Municipal Sludges EAF Dust Cement/Lime Kiln Dust Compost Flue Dust Animal Feed Foundry Dust Lead Fume Zinc Oxide Diatomaceous Earth Sulfur

7 PRESSURE / NON-PRESSURE PRESSURE AGGLOMERATION This method of agglomeration relies on extreme pressure to force particles together into the desired shape. This includes the following techniques: Compaction Briquetting Extrusion Tabletting Molding NON-PRESSURE AGGLOMERATION Also known as tumble growth agglomeration, this method relies on a binding agent and the phenomenon of coalescence to create agglomerates. This includes: Pelletizing (Disc or Rotary Drum) Micro-Pelletizing (Pin Mixer) Mixing (Pug/Paddle or Pin Mixer) Conditioning (Pug/Paddle or Pin Mixer)

8 ADVANTAGES Non-pressure agglomeration offers many advantages: Porosity voids between particles Improved product breakdown Easily de-dusts a material Less attrition Ability to layer ingredients Produces a premium product for some industries

9 EQUIPMENT The most common non-pressure agglomeration equipment includes: Disc Pelletizers Rotary Drums (Agglomerators/Granulators) Pin Mixers Paddle Mixers/Pug Mills Each of these pieces of equipment can be used as a stand-alone agglomeration device, or in combination with each other to create the configuration needed to produce the desired results.

10 DISC PELLETIZERS Benefits: Allows for fine-tuning product characteristics Less recycle Open system View Interactive Model >>

11 DISC PELLETIZERS Go to Video

12 COMMON APPLICATIONS Limestone & Gypsum Commonly pelletized for use as a soil amendment Improved product handling, applications, and end use Minimal dust Stays where it s needed

13 ROTARY DRUMS Benefits: High capacity Hands-off operation Closed system Ability to inject materials into rotating bed.

14 COMMON APPLICATIONS Iron Ore Commonly pelletized to reduce dust and increase efficiency of the furnaces. Either a disc pelletizer or a balling drum can be used.

15 PADDLE MIXERS Accommodates mixing of solid & liquid feeds Ideal for heavy-duty applications High-torque, kneading motion De-dusting, agglomeration and pre-conditioning View Interactive Model >>

16 PADDLE MIXERS

17 COMMON APPLICATIONS Fly Ash Conditioning: Conditioned for dust-free transportation and landfilling Also pelletized for use in cement products Common Applications: Fertilizers Ore Concentrates Carbon Powders Chemicals And more..

18 PIN MIXERS Accommodates mixing of solid & liquid feeds Ideal for de-dusting & fine material applications Intense spinning action densifies material without additional binder usage De-dusting, agglomeration & pre-conditioning View Interactive Model >>

19 COMMON APPLICATIONS Coal Dust: Conditioned to de-dust coal fines to avoid risk of combustion Also conditioned for ease of adding back into the coal burning process Common Applications: Coal Fines Limestone & Gypsum Clays And more...

20 T H E F E E C O I N N O V A T I O N C E N T E R

21 STAGES OF PROCESS DEVELOPMENT 1. PROOF OF CONCEPT 2. PROOF OF PRODUCT 3. PROOF OF PROCESS 4. PROCESS/PRODUCT OPTIMIZATION

22 STAGES OF PROCESS DEVELOPMENT 1. PROOF OF CONCEPT Assesses feasibility of the intended concept Ultimately confirms or denies the potential of an idea Helps to identify potential challenges

23 STAGES OF PROCESS DEVELOPMENT 2. PROOF OF PRODUCT More in-depth testing at batch-scale to gather more data and more fully assess a project s potential value Explores method of agglomeration Equipment selection Binder selection refinement Determines whether or not a product with desired specs can be achieved targeted specs often include: Attrition/Degradation Bulk Density Compression Crush strength Flowability Green/Wet strength Moisture content Physical characteristics (shape, surface texture, etc.) Particle size analysis Solubility

24 STAGES OF PROCESS DEVELOPMENT 3. PROOF OF PROCESS Confirms the viability of the process on a continuous basis Works to establish equipment configuration and sizing Helps to define parameters required for continuous production

25 STAGES OF PROCESS DEVELOPMENT 4. PROCESS/PRODUCT OPTIMIZATION In-depth testing phase aimed at optimizing the established configuration to produce the product with the desired specifications on a continuous basis at commercial scale Looks at fine-tuning variables to produce as much on-size product as possible Intended to reproduce the successful results achieved earlier Evaluate process stability over a longer period of time Watch for potential situations that could upset a process

26 MOVING FORWARD Plant Layout and Equipment Engineering Drying Technology Evaluation Screening Technology Evaluation Commissioning & Installation Assistance Plant Engineering / EPC Contractor Selection

27 PLANT LAYOUT & EQUIPMENT ENGINEERING Equipment engineering and manufacturing Plant layout P&IDs General arrangement drawings Civil works guide drawings with static and dynamic loads Structural steel and access platform guide drawings Chute and ductwork guide drawings Electrical and control systems engineering Material handling engineering Heat & mass balance CAPEX & OPEX budgets

28 DRYING Because of the addition of moisture (i.e., the binding agent), drying is commonly required in non-pressure agglomeration settings. Options in industrial drying systems include Conveyor Belt Dryers, Fluid Bed Dryers, and Rotary Dryers. When carried out in a rotary dryer, there is an added advantage of polishing the pellets; the tumbling action imparted by the rotating drum further rounds and polishes the pellets. Fluid Bed Dryers and Conveyor Belt Dryers work well when a pellet needs to be handled gently.

29 SCREENING >> Screening is also often required to assist in segregating over-size, under-size, and on-size product.

30 COMISSIONING & INSTALLATION ASSISTANCE Establish one-source contact for all installation procedures Identify sequence of installation Work side-by-side with erection contractor Identify and sort parts Expedite scheduling and issue resolution Inspect final installation Support process and production commissioning Ensure critical inspection hold points are not overlooked, avoiding potential re-work and voided warranties

31 PROCESS FLOW

32 QUESTIONS?

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