Binder

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

Choosing A

In the Agglomeration Process

Choosing a binder for your material is one of the most critical steps in developing an effective agglomeration process.

 A binder not only aids in pellet formation, but can also be a valuable tool in optimizing product characteristics and performance. 

Why UseA Binder?

There are many reasons why a binder is desirable and most often necessary in the agglomeration process.

There are many reasons why a binder is desirable and most often necessary in the agglomeration process.  1. To achieve the desired final crush

strengthAchieving the desired crush strength will help to ensure that a pellet performs as needed – capable of withstanding handling, transportation, and the like, but still able to break down when needed.

A pellet crush strength that is too low would result in the pellet breaking down before its intended use, resulting in an excess of fines.

A pellet crush strength that is too low would result in the pellet breaking down before its intended use, resulting in an excess of fines.  A pellet crush strength that is too high would not break down quickly enough, or would take too long to dissolve. 

A pellet crush strength that is too low would result in the pellet breaking down before its intended use, resulting in an excess of fines.  A pellet crush strength that is too high would not break down quickly enough, or would take too long to dissolve. Testing different binders, or adjusting binder concentration can help to hit the target dry crush strength.

2. To achieve desired green strengthGreen strength is the strength of a pellet in its wet state, prior to drying. Most materials need to fall within a certain range of green strength in order to withstand processing. The appropriate green strength allows pellets to remain intact, despite drops from conveyors, or moving through chutes. The right binder can help to reach the desired green strength for the material.

3. To Aid in the Agglomeration ProcessPerhaps most importantly, a binder helps the actual agglomeration to occur, by causing the material to be tacky, allowing it to pick up more fines. While some materials can agglomerate without a binder, most materials require some sort of binding agent to aid in pellet formation.

SelectingA Binder

Choosing a binder can easily become overwhelming, with hundreds of options available.

However, binder choice is often made easier by looking at a few key factors. 

Industry/MaterialBinder choice is often quickly narrowed down by looking at the industry and end use of the material.

Industry/MaterialBinder choice is often quickly narrowed down by looking at the industry and end use of the material. For example, while coal tar is a highly effective binder in many industries, it would not be a suitable binder for the fertilizer industry. This is because coal tar contains toxins that would likely be passed to the soil and plants.

Similarly for cement binders, cement functions effectively as a binder in the actual agglomeration process, but as a fertilizer product, the pellets would not break down, and would likely leave cement particles in the soil.

However, a variety of organic binders, such as starches and molasses exist, providing a binder that is both effective during agglomerate processing, and functions well in the end product.

However, a variety of organic binders, such as starches and molasses exist, providing a binder that is both effective during agglomerate processing, and functions well in the end product.

Some industries that utilize high temp thermal processing, such as the steel industry, will often require the binder be able to withstand extreme temperatures.

CostCost is another factor that plays into binder choice. Binders can vary greatly in price, and not all binders are available in all areas.

CostCost is another factor that plays into binder choice. Binders can vary greatly in price, and not all binders are available in all areas.

You may find that a binder works great for your process, but the cost of getting it to your area far outweighs the benefits.

Product OptimizationAnother factor to consider is the opportunity to enhance your product.

Product OptimizationAnother factor to consider is the opportunity to enhance your product.

Many binders can offer improved product performance. This is particularly true in the soil amendment industry, where binders can add beneficial nutrients to the product.

ConclusionWhile choosing a binder may seem overwhelming, the choice can be narrowed down by looking at the industry, end use, effectiveness, and cost.

Working with an agglomeration expert to test your material in a feasibility lab can help to figure out the best binder for your application. 

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

Want to learn more?Download our

Agglomeration Handbook

Agglomeration Handbook

Intro to AgglomerationProcessing TechniquesConsiderations in AgglomerationAnd more…

Download Now