The FEECO Innovation Center is a state-of-the-art testing facility where we can test both agglomeration and thermal processes at batch and pilot scale. Testing your material in the FEECO Innovation Center allows you to gather valuable material and process data. Whether you’re looking to develop a new product, solve a material problem, develop a new process, or even optimize an existing one, our process experts can work with you to develop a customized testing program around the answers you’re looking for.

 

We can then use the data gathered during testing to scale up the process, as well as engineer and manufacture custom equipment and process solutions, tailored to your exact processing needs.

 

We offer testing services in four categories:

 

Feasibility/Proof of Concept: An initial, non-witnessed batch testing phase in which the possibility of creating a product is explored.
Proof of Product: A more in-depth batch testing phase in which more time is spent determining whether a product can be made to desired specifications.
Proof of Process: A continuous testing phase that aims to establish the equipment setup and parameters required for continuous production of your specific material.
Process/Product Optimization: An in-depth study to optimize your specific material’s characteristics and/or production parameters in an industrial setting.

 

EQUIPMENT TESTING

From testing on a single piece of equipment, to a continuous process loop, we offer a variety of equipment types, as well as support equipment to cover the full range of process testing needs. In addition, we are capable of making on-site, large-scale modifications to our facility in order to accommodate your testing needs.

Lab Equipment:

AGGLOMERATION

Disc Pelletizer 24″

Disc Pelletizer 36″

Disc Pelletizer 4′ 6″

Rotary Granulator 36″ x 9′

Paddle Mixer 14″ x 6′

Batch Pin Mixer 8″

Batch Pin Mixer 15″

Continuous Feed Pin Mixer 10″

SC Roll Compactor / Briquetting

Hammer Mill

Rod Mill

Prater Mill

Rotex Screen – 2 deck

Circular Screen 18″ & 36″

Pipe Reactor

Littleford Day Mixer

Coating Drum 2′ x 6′

THERMAL

Rotary Batch Kiln 18″ x 24″

Continuous Rotary Kiln 20″ x 20′

Indirect Kiln / Dryer

Rotary Dryer with recycle loop 3′ x 20′

Fluid Bed Dryer, Calciner, Cooler

Rotary Dryer 20″ x 8′

Diameter Lifter Test Unit 46″

MATERIAL HANDLING

Belt Conveyor

Bucket Elevator

Steep Incline Conveyor

SUPPORT

Muffle Furnace

Batch Walk-In Oven

Fluid Bed Sample Dryer

Steam Generator with Tanks

Spargers and heat source for hot melt granulation

AGGLOMERATION TESTING

We can convert dusts, bulk powders, and sludges into free-flowing pellets or granules for dust-free handling, or to improve product characteristics. We can also test a complete, continuous process with agglomeration, drying, particle sizing, and product recycle capabilities to create a highly efficient process. The FEECO Innovation Center is equipped to test non-pressure (tumble growth) agglomeration and roll compaction (pressure agglomeration).

 

Through agglomeration testing in the FEECO Innovation Center, we can tell you if your material is capable of agglomeration, which method of agglomeration will best suit your process goals, and what equipment configuration will be required to produce the desired results.

 

When it comes to choosing a binder, we have a wide selection on hand and have a broad knowledge of binder materials, characteristics, and application rates, so we can help you make the best selection for your material.

 

Agglomeration Tests Conducted in the FEECO Innovation Center:

 

Non-Pressure Agglomeration

  • Pelletizing (Disc or Drum)
  • Micro-Pelletizing
  • Mixing
  • Coating
  • Conditioning

Pressure Agglomeration

  • Compaction
  • Briquetting

 

We can also measure and adjust a variety of properties to create a product with ideal characteristics:

 

  • Attrition
  • Bulk Density
  • Compression
  • Crush Strength
  • Flowability
  • Green/Wet Strength
  • Moisture Content
  • Physical Characteristics
  • Particle Size Analysis
  • Solubility
  • Temperature

 

THERMAL TESTING

The FEECO Innovation Center offers a variety of thermal testing capabilities for both drying and high-temperature applications. In addition to rotary dryers, we offer continuous direct-fired and indirect-fired pilot kilns, as well as batch scale direct-fired and indirect-fired kilns.

 

Thermal Processes Commonly Tested:

  • Drying
  • Flight Design & Pattern Simulation
  • Calcination
  • Catalyst Activation
  • Desorption & Combustion
  • Heat Setting
  • Metal Recovery
  • Organic Combustion
  • Reduction
  • Sintering
  • Thermal Desorption
  • Upgrading of Ores

 

Through thermal testing in the FEECO Innovation Center, we can develop a number of data points necessary for commercial kiln or dryer design and process scale-up, including:

 

  • Feed & Product: Physical and Chemical Analyses
  • Burner Fuel Storage
  • Drum Slope
  • Emissions
  • Fan Speed
  • Feed Rate
  • Gas Sampling & Analysis
  • Residence Time
  • Rotational Speed
  • Screen Analysis of Feed & Product
  • Temperature Profiles

WASTE TRANSFORMATION

The FEECO Innovation Center has helped companies around the world to transform waste materials and process by-products into value-added products through agglomeration and thermal processing methods. The list below looks at some of the waste transformations performed in recent years, as well as the processing methods used to transform the material.

 

Beginning Material Final End Product Agglomeration Drying Blending Thermal Roll Compaction
Sulphur Stack Emissions Granulated Fertilizers x x x
Calcium Sulfate Fertilizer Pellets x x x
Ash (Wood, Fly) Fertilizer Pellets x x
Bentonite Clay Cat Litter Granules x x x
Calcium Chloride Ice Melt Pellets x x
Calcium Carbonate Fertilizer Pellets x x
Carbon Black Dust De-dusted Pellets x x
Cement Kiln Dust Calcium Fertilizer Pellets x x
Cell Phone Batteries Lithium, Zinc Metal Recovery x
Clay Cat Litter, Oil Dry Granules, Encapsulate Seeds x x x
Coal Dust De-dusted Coal Pellets x x x
Composts (Yard Waste) Fertilizer Pellets x x x
Copper Dust Metal Recovery Pellets x x x
Corn Cobs Cat Litter, Oil Dry Pellets x x x
Clay Proppants x
Dredge Sludges Non-leaching Granules x x x
Electric Arc Furnace (EAF) Dusts Metal Recovery x x x
Ethanol Plant Waste (DDG) Animal Feed x x x
Foundry Dust Metal Recovery x x x
Gold Ore Dust Precious Metal Recovery x x x
Grain Dust Non-explosive Pellets x x x
Gypsum Wallboard Waste Fertilizer, Cat Litter Pellets x x x
Humate Fertilizer Pellets x x x
Iron Oxide Metal Recovery Pellets x x x
Lime (Waste Water Treatment Sludge) Calcium Fertilizer Pellets x x x
Limestone Calcium Fertilizer Pellets x x x
Talc Ore Sterilized Baby Powder x
Manure – Cattle/Chicken/Hog Fertilizer Pellets x x x
Soda Bottles Recycled Plastic x
MAP Fertilizers Fertilizer Pellets x x x
Municipal Wastes Fertilizer, Fuel Pellets x x x
Nitrogen Fertilizers Fertilizer Pellets x x x
NPK Blends Fertilizer Pellets x x x x
Paper Sludge Fertilizer, Cat Litter x x x
Petroleum Coke Dust Fuel Pellets x x x x
Phosphates Powder Fertilizer Pellets x x x
Potassium Chloride Fertilizer Pellets x x x x
Saw Dust Cat Litter, Fuel Pellets x x x x
Soy Flour Animal Feed x x x
Steel Dusts and Sludges Metal Recovery Pellets x x x x
Sugar Sugar Pellets x x x
Sulphur Dust Non-explosive Pellets x x x
Tar Sands Waste Sludge Substitute Fuel Pellets x x x
Titanium Metal Shavings Metal Recovery x x x
Iron Ore Metal Recovery Pellets x x
Glass Batch Glass Blend x x x
Ceramic / Aluminum Refractory x x
Paper Sludge Bright White Clay x
Gypsum Fertilizer Pellets x x
Zinc Oxide Metal Recovery Pellets x x x
Nickel Ore Metal Recovery Pellets x x
Kaolin Clay Coating Paper x x
Tungsten Oxide Metal Recovery Pellets x x x
Raw Coal Purified Coal x
Bone Meal Fertilizer x x
Ammonium Sulfate Fertilizer x
Diatomaceous Earth Filter Agent x x
Titanium Dioxide Pigment Pellets x x x
Urea Fertilizers Coated to prevent moisture absorption x x x

AUTOMATION

FEECO is a Rockwell Automation Partner, providing integrated process control solutions, both as a service in the Innovation Center, and as part of a system purchase.

 

During testing, we can monitor, trend, and adjust various data points in real-time, all from a single interface or mobile device, giving you an aerial view of your process and equipment performance.

 

This also provides unmatched data collection and reporting capabilities.

BENEFITS TO TESTING WITH FEECO

The FEECO Innovation Center provides a valuable opportunity to test your material or process in a controlled environment. Some of the many advantages to testing with FEECO include:

 

Material Experience:

FEECO has been a pioneer in material processing since the 1950s, and has extensive knowledge around thousands of materials and material samples. This experience allows us to better understand your project on both a micro and macro level and deliver a custom processing solution that contributes to your company’s bottom line.

 

Complete Process Knowledge:

As experts in process design, FEECO is familiar with each aspect of a process, from agglomeration and kiln processing, to drying and cooling, allowing us to look at how the process will function as a whole, instead of each individual portion.

 

Process Scale-up:

Once the process configuration has been defined, FEECO can aid in process scale-up, as well as manufacturing the custom equipment needed to get the job done.

 

Virtual Lab:

FEECO offers a unique Virtual Lab: a secure portal customers can log into and view their material being tested in real time, without having to come to the FEECO facility.

Material Testing in the FEECO Lab

Testing & Waste Transformation Articles