Eight Questions That can be Answered Through Agglomeration Testing

This article was co-authored by:

Chris Kozicki
Agglomeration Expert

Carrie Carlson
Technical Writer

Agglomeration is a particle size enlargement technique used to solve a wide array of material problems and improve product performance through controlling particle characteristics. Offering a number of benefits, agglomeration is used in a myriad of ways throughout nearly every industry working with bulk solids. 

With many types and approaches to agglomeration available, and overlap between methods and equipment, the path to the end goal in an agglomeration process is not always clear. This ambiguity, paired with the unpredictability of how a given material will respond to agglomeration, makes testing a critical step in developing or improving an agglomeration production line, no matter what the end goal is. 

Unfortunately, this often leaves those exploring the option as a potential solution with many unanswered questions. As the industry leader in tumble growth (agitation) agglomeration, we’ve put together the most common questions that can be answered through agglomeration testing in the FEECO Innovation Center. 

Will my material agglomerate?

Agglomeration can be used to treat a broad spectrum of materials, but it is not a fit for every material. All materials, and even the same type of material from different sources, will respond

differently to agglomeration. Some materials will readily agglomerate with little assistance, while others simply will not agglomerate, or may require substantial preconditioning to bring them to a point where agglomeration is possible. 


Material before and after agglomeration during testing in the Innovation Center

Process engineers in the Innovation Center use batch-scale tests conducted with small samples of material to assess the feasibility of agglomerating a specific material. These tests reveal whether or not the material is capable of being agglomerated, and therefore, if agglomeration is a potential avenue to the end goal.  

Can agglomeration solve my material problem?

Agglomeration is employed to address a range of problems, some of the most common of which are:

  • Handling challenges
  • Application issues
  • Inferior performance
  • High transportation costs
  • Significant dust
  • Product loss due to dust

To uncover whether or not agglomeration could solve the issue at hand, small samples are produced through batch testing for further assessment. 

What equipment configuration will be required to produce the results I’m looking for?

A variety of agglomeration equipment is available. Depending on the desired end product characteristics, as well as the raw material characteristics and specific process requirements, some types of equipment are likely to be a better fit than others. For example, when working with a feedstock of finely divided solids, a pin mixer is usually a better choice compared to a pugmill mixer. Likewise, if size control and a highly refined product are the goals, a disc pelletizer offers a better option compared to a rotary drum. Equipment is also frequently combined in different configurations to achieve the desired end product specifications. 

Determining the optimal equipment configuration can be challenging and is best carried out by an expert with an extensive background in agglomerating different kinds of materials, and a solid understanding of the different methods of agglomeration. 

Through systematic testing, paired with experience, process engineers in the Innovation Center can reveal the best equipment configuration based on the specific process parameters.

What binder, if any, will work best for my material?

Binders, or binding agents, are used in non-pressure agglomeration processes to facilitate particle formation, maintain pellet integrity throughout processing, and reach the desired end product quality.

Binding agents are an industry of their own, with hundreds of options and variations available. While binder type is often narrowed down based on end product use, there are still many options to explore. 

Testing can be used to evaluate which binder not only performs well, but also whether or not it can produce the desired results in the end product. Here again, experience is an asset. 

Can my product be improved?

Agglomeration testing is frequently used to evaluate the potential improvement of a product, as well as whether or not that improvement is economically viable. 

Testing may focus on the general enhancement of a material through agglomeration, or the improvement of an existing agglomerate product for better performance and handling. 

Since testing assesses the ability to target different product parameters, various determinations can be made. 

How can I optimize my existing process?

There are two ways in which agglomeration testing can be used to optimize an existing process:

Improve upon the agglomeration process itself 

Reaching the desired results in an agglomeration production setting relies on several factors working together. As such, when any one factor falls out of spec, problems may arise. 

Testing can be used as a means of troubleshooting an agglomeration process that produces excess off-spec product, requires frequent shutdowns, or is simply underperforming. 

One of the key benefits to utilizing a testing facility like the Innovation Center is that it allows the problem to be assessed systematically in a controlled setting without interrupting the production facility or imposing unnecessary risk. 

Improve downstream processing by using agglomeration as an intermediary step

Agglomeration is not just a means of producing end products; it can also be used as an intermediary step to improve processing conditions. This might involve controlling the density, meltability, porosity, or other particle parameters to improve downstream processing. 

A classic example of this is iron ore pelletizing in the steel production process. Iron ore fines are pelletized, or “balled,” in order to improve processing in the downstream furnace. 

How much can dust/product loss be reduced??

The challenges associated with a dusty material represent the most common reasons for agglomerating a material. 

Agglomeration significantly reduces, and in some cases eliminates dust, with some techniques providing better results than others. 

Attrition tests performed on pellets or granules produced in the Innovation Center determine the amount of degradation that will occur with the end product. Various techniques can then be used to control the amount of attrition and minimize dust.

Can the product I want to make be produced on a continuous, commercial-scale basis?

Testing may also be used to assess the viability of a process or product as a continuous, commercial-scale operation. 

In this case, continuous tests are conducted in order to obtain the factors necessary for scaling up the process. At the same time, process engineers watch for red flags and potential issues to work around when implementing the process at commercial scale. 

Conclusion

Agglomeration is an incredibly powerful tool in controlling particle characteristics and solving material problems when working with bulk solids, but its flexibility and diversity can make evaluating agglomeration and developing the optimal process around it challenging. 

Testing in a facility such as the FEECO Innovation Center can answer all of the questions listed here and more. With comprehensive testing capabilities, and an unmatched expertise in agglomeration, testing in the Innovation Center is the most efficient way to evaluate an agglomeration process. For more information on our testing capabilities, contact us today!

 

About the Authors . . .


Chris Kozicki is a Process Sales Engineer and agglomeration expert.

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More About Chris

Carrie Carlson is a technical writer and visual designer.

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