Agglomeration

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

Equipment Basics

Agglomeration is the process of particle size enlargement. This process transforms material fines that were previously dusty and difficult to work with, into a dry, granular product offering ease of use, reduced dust, and improved product characteristics.

There are many types of agglomeration equipment available.

There are many types of agglomeration equipment available.

Furthermore, the constant discovery of new applications for agglomeration have made existing equipment options increasingly flexible.

What follows is a brief overview on some of the most common types of agglomeration equipment available. In general, they all fall under one of two main categories: pressure agglomeration, or non-pressure agglomeration.

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. 

Pressure Agglomeration

Equipment

CompactorsCompactors use pressure to form dense, jagged granules from material fines. Compactors are frequently used in the fertilizer industry to produce fertilizer granules.

CompactorsCompactors use pressure to form dense, jagged granules from material fines. Compactors are frequently used in the fertilizer industry to produce fertilizer granules. Compactors are also called:• Roll Compactors• Roll Press• Double Roll Press

Sahut-Conreur Compactor

How Compactors WorkMaterial is fed between two counter-rotating rolls. The rolls use mechanical force to press the material into a sheet, which is then fed through a flake breaker and granulator, breaking the sheet up into the desired size granules.

Because this process utilizes pressure instead of a binding agent, it is considered a dry process, and most often does not require an added drying step.

BriquettersSimilar to compactors, briquetters also use mechanical force to press material into a desired shape. Briquetters produce larger, pillow-shaped agglomerates, called briquettes. They are commonly used to process water softener salt and charcoal into briquettes for consumer use. 

BriquettersSimilar to compactors, briquetters also use mechanical force to press material into a desired shape. Briquetters produce larger, pillow-shaped agglomerates, called briquettes. They are commonly used to process water softener salt and charcoal into briquettes for consumer use. Briquetters are also called:• Roll Press• Double Roll Press

Sahut-Conreur Briquetter

How Briquetters WorkMaterial fines are fed between two counter-rotating rolls. Each roll has one half of the desired shapes, and as the rolls come together, the halves unite, pressing the material into the complete pillow form.

Non-Pressure Agglomeration

Equipment

Disc PelletizersDisc Pelletizers produce uniform, round pellets. They are often chosen for their ability to fine-tune the end product size, creating a premium pelletized product. 

Disc PelletizersDisc Pelletizers produce uniform, round pellets. They are often chosen for their ability to fine-tune the end product size, creating a premium pelletized product. Disc Pelletizers are also commonly called:• Pan Pelletizers• Pan Granulators• Disc Granulators• Granulators

FEECO Disc Pelletizer

How Disc Pelletizers WorkMaterial feed and binder are fed onto the disc at a constant rate. Material fines become tacky in the presence of the binder, allowing them to pick up more fines as they tumble on the rotating disc. This process is similar to rolling a snowball, and is considered a continuous process. Because the disc pelletizer is not enclosed, this is an open system.

Agglomeration DrumsAgglomeration drums are also a type of non-pressure agglomeration equipment. This type of equipment is chosen for its heavy-duty construction, high capacity capabilities, and its ability to be insensitive to variations in feedstock. For these reasons, agglomeration drums are frequently used in the mining industry. 

Agglomeration Drums are also commonly referred to as:

• Rotary Drums• Granulation Drums• Agglomerators• Granulators• Ore Drums• Balling Drums 

FEECO Agglomeration Drum

How Agglomeration Drums Work:Material and binder are fed into the drum at a constant rate. As the drum rotates, material fines get tacky in the presence of the binder, picking up more fines as they tumble against themselves.  

Agglomeration drums can also be used when a chemical reaction is required during the agglomeration process, such as when producing inorganic fertilizer products. This is considered a closed process, because processing is contained within the drum.

Pin MixersPin mixers are industrial mixers used for a variety of agglomeration processes: micro-pelletizing, mixing, agglomerating, and conditioning. Pin mixers can be used as a stand-alone agglomeration unit, or as a pre-cursor to a disc pelletizing or agglomeration drum setup.

Pin MixersPin mixers are industrial mixers used for a variety of agglomeration processes: micro-pelletizing, mixing, agglomerating, and conditioning. Pin mixers can be used as a stand-alone agglomeration unit, or as a pre-cursor to a disc pelletizing or agglomeration drum setup. Pin Mixers Are Also Called:• Pin Agglomerators

FEECO Pin MIxer

How Pin Mixers WorkPin mixers consist of a central rotor shaft affixed with rods (pins) inside a stationary housing. The shaft rotates at a constant, high speed, creating an intense spinning action within the mixer. This thoroughly mixes the material, creating tiny, dense agglomerates.

Paddle MixersPaddle mixers are another type of industrial mixer. These robust mixers are also capable of conditioning, mixing, and agglomerating. Similar to pin mixers, they are adept at processing a liquid and solid feed. Again, paddle mixers can be used as a stand-alone agglomeration device, or as part of a disc pelletizer or agglomeration drum setup.

Paddle MixersPaddle mixers are another type of industrial mixer. These robust mixers are also capable of conditioning, mixing, and agglomerating. Similar to pin mixers, they are adept at processing a liquid and solid feed. Again, paddle mixers can be used as a stand-alone agglomeration device, or as part of a disc pelletizer or agglomeration drum setup. Paddle Mixers Are Also Called:• Pug Mills

FEECO Paddle Mixer

How Paddle Mixers WorkPaddle mixers are comprised of two counter-rotating shafts affixed with pitched paddles to create a kneading and folding over motion. Paddle mixers create an intimate mixture of materials, and are particularly adept at processing more demanding materials.

Equipment Tips

Choosing quality equipment will go a long way in providing for an efficient, long-lasting operation that produces a premium product. 

Choosing quality equipment will go a long way in providing for an efficient, long-lasting operation that produces a premium product. Instead of a one-size-fits-all approach, equipment should be designed around a material’s unique characteristics for best results.  

Feasibility testing is a valuable component in the process of choosing which type of agglomeration equipment (or what combination of equipment) will best suit your processing needs. 

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.

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