Compaction agglomeration

Pressure agglomeration (compaction) methods for size enlargement of solid fertilizers... 

Fig. 6.1-13 Block diagram of a powder granulation system by pressure agglomeration (compaction/granulation) for general applications also showing various optional features...

Agglomerates compacted together as in Fig. 9.32 sinter like larger particles of diameter D and so shrink more slowly than expected from the primary particle size. Additionally, agglomerates can act like foreign inclusions which inhibit... 

As pointed out earlier (Section 3.5), certain shapes of hysteresis loops are associated with specific pore structures. Thus, type HI loops are often obtained with agglomerates or compacts of spheroidal particles of fairly uniform size and array. Some corpuscular systems (e.g. certain silica gels) tend to give H2 loops, but in these cases the distribution of pore size and shape is not well defined. Types H3 and H4 have been obtained with adsorbents having slit-shaped pores or plate-like particles (in the case of H3). The Type I isotherm character associated with H4 is, of course, indicative of microporosity. 

A fundamental requirement in powder processing is characterization of the as-received powders (10—12). Many powder suppHers provide information on tap and pour densities, particle size distributions, specific surface areas, and chemical analyses. Characterization data provided by suppHers should be checked and further augmented where possible with in-house characterization. Uniaxial characterization compaction behavior, in particular, is easily measured and provides data on the nature of the agglomerates in a powder (13,14). 

H. H. Hausner, "Compacting and Sintering of Metal Powder Without the Apphcation of Pressure," International Symposium Agglomeration, Apr. 12-14,1961. 

The success of the compaction operation depends pardy on the effective utilization and transmission of appHed forces and pardy on the physical properties and condition of the mixture being compressed. Friction at the die surface opposes the transmission of the appHed pressure in this region, results in unequal distribution of forces within the compact, and hence leads to density and strength maldistribution within the agglomerate (70). Lubricants, both external ones appHed to the mold surfaces and internal ones mixed with the powder, are often used to reduce undesirable friction effects (71). For strong compacts, external lubricants are preferable as they do not interfere with the optimum cohesion of clean particulate surfaces. Binder materials maybe used to improve strength and also to act as lubricants. 

Pellet Mills. Pellet mills differ from roU briquetting and compacting machines in that the particulates are compressed and formed into agglomerates by extmsion through a die rather than by squeezing as they are carried into the nip between two roUs. Several types of equipment that use the extmsion principle are available. The die may be a horizontal perforated plate with rollers acting on its upper surface to press material through the plate. 

Free-swelling tests are commonly used to measure a coal s caking characteristics. A sample of coal is packed in a cmcible or tube, without compaction, and heated at a fixed rate to about 800°C. Infusible coals distill without changing appearance or state of agglomeration. The fusible coals soften, fuse, and usually sweU. The profile of the resultant coke is compared to a series of reference profiles so that a swelling index can be assigned. The profiles represent indexes between 0 and 9. The best cokes come from coals having indexes between 4 and 9. 

The surface of the coal particles oxidizes or weathers resulting in cracks, finer particles, and reduced agglomeration all of which may destroy coking properties. If spontaneous heating takes place, the calorific value of the coal is reduced. Hot spots must be carefully dug out and used as quickly as possible. Without spontaneous heating and with good compaction, calorific value losses below 1%/yr have been recorded. 

FIG. 20-71 Classification of agglomeration processes by agitation intensity and compaction pressure. Relative density is with respect to primary particle density and equals (1 — e) where e is the solid volume fraction. Reprinted from Granulation and Coating Technologies for High-Value-Added Industties, Ennis and Litster (1996) with permission of E G Associates. All rights reserved. 

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