Innovation Center

From agglomeration to thermal processing, we offer a variety of testing options for every step of bulk solids process design. Continue Reading →

FEECO-Innovation-Center-Header

Innovation Center

From agglomeration to thermal processing, we offer a variety of testing options for every step of bulk solids process design. Continue Reading →

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 to assist in your R&D efforts. 

Testing 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 optimize an existing one, our process experts can work with you to develop a customized testing program around the answers you need. We can also generate small samples of product for field trials and further testing.

We use the data gathered during testing to scale up the process and manufacture custom equipment, tailored to your exact processing needs.

Bulk Solids Process Development & Optimization for the Fertilizer, Mining, and Chemical Industries

Equipped with unmatched expertise and an extensive array of process equipment, the FEECO Innovation Center is an essential resource for producers looking to develop a process to dry, thermally treat, mix, condition, or agglomerate/granulate their bulk solids. Coating of granular products can also be tested.

The Innovation Center serves nearly every industry, handling a wide range of materials. We regularly test:

  • Adsorbents
  • Animal feed products
  • Carbon products
  • Catalysts
  • E-waste and metal recovery applications
  • Fertilizers (NPK, Potash, MAP, DAP, Phosphates, etc.)
  • Industrial by-products (EAF Dust, Cement Kiln Dust, Fly Ash, Syn Gyp, etc.)
  • Manures and animal bedding
  • Metallic ores and compounds
  • Pulp and paper residuals (paper sludge, etc.)
  • Soil amendments (Limestone, Gypsum, Compost, Recovered wastes and by-products, etc.)

Process Development Stages

Depending on the testing objective(s) and what is already known about the material, testing is typically conducted in the following stages:

Confirm Feasibility (Proof of Concept)

The Innovation Center can confirm feasibility and establish proof of concept of an intended process through batch-scale testing. This type of testing typically consists of an initial, non-witnessed test that explores the possibility of creating a product from a representative sample of the source material. From this, producers can gain an understanding of whether or not the intended process merits further exploration on a larger scale.

Proof of Product 

Proof of product testing consists of a more in-depth batch test in which more time is spent determining whether the source material can be made into a product that meets the desired specifications.

This may include exploration of various binding agents, equipment configurations, pretreatment requirements, as well as other process and equipment variables that influence end product specifications.

Proof of Process

Proof of process testing consists of continuous testing in our pilot plant. This pilot-scale testing aims to establish the viability of the intended process on a continuous basis, as well as the equipment setup and parameters required.  

Process/Product Optimization

Once proof of process has been established, testing moves on to process and product optimization. This stage consists of in-depth testing in our pilot plant, with tests designed to optimize product quality and process efficiency for commercial-scale production. 

PROCESS EQUIPMENT AVAILABLE FOR 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 bulk solids testing needs.

Batch- & Pilot-Scale Testing Equipment:

The following equipment is available for testing. For those interested in testing at their own on-site R&D facility, we also offer a range of rental equipment

AGGLOMERATION: BATCH EQUIPMENT

  • Disc Pelletizer
  • Pin Mixers (2)

AGGLOMERATION: CONTINUOUS EQUIPMENT

  • Disc Pelletizers (2)
  • Rotary Granulator
  • Paddle Mixer/Pug Mill
  • Pin Mixer
  • Hammer Mill
  • Rod Mill
  • Prater Mill
  • Rotex Screen – 2 deck
  • Circular Screen
  • Coating Drum
  • Curing Drum

THERMAL: BATCH EQUIPMENT

  • Rotary Kiln
  • Indirect Kiln
  • Flight Simulator

THERMAL: CONTINUOUS EQUIPMENT

  • Rotary Kiln
  • Indirect Kiln
  • Rotary Dryer
  • Fluid Bed Dryer

MATERIAL HANDLING (ALL CONTINUOUS)

  • Belt Conveyor
  • Bucket Elevator
  • Steep Incline Conveyor
  • Various Feeders

SUPPORT: BATCH EQUIPMENT

  • Muffle Furnace
  • Fluid Bed Sample Dryer
  • Tray Oven

SUPPORT: CONTINUOUS EQUIPMENT

  • Steam Generator with Steam Tanks

BENEFITS TO FEECO r&d TESTING

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 Testing Experience:

FEECO has been a pioneer in material processing since the 1950s, with in-depth knowledge around thousands of materials. Because of this, we are often able to expedite the testing process, with an understanding of what typically works and what doesn’t. 

Complete Process Knowledge:

As experts in process design, FEECO can offer expertise not only in each step in the process, but also in how the process comes together as a whole. This allows us to better understand your project on both a micro and macro level.

Process Scale-up Capabilities:

Once the process configuration has been defined, FEECO can aid in process scale-up, as well as manufacturing the custom equipment needed to build the commercial-scale plant.

WASTE RECOVERY & REUSE EXPERTISE

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

Beginning MaterialFinal End ProductAgglomerationDryingBlendingThermalRoll Compaction
Sulphur Stack EmissionsGranulated Fertilizersxxx
Calcium SulfateFertilizer Pelletsxxx
Ash (Wood, Fly)Fertilizer Pelletsxx
Bentonite ClayCat Litter Granulesxxx
Calcium ChlorideIce Melt Pelletsxx
Calcium CarbonateFertilizer Pelletsxx
Carbon Black DustDe-dusted Pelletsxx
Cement Kiln DustCalcium Fertilizer Pelletsxx
Cell Phone BatteriesLithium, Zinc Metal Recoveryx
ClayCat Litter, Oil Dry Granules, Encapsulate Seedsxxx
Coal DustDe-dusted Coal Pelletsxxx
Composts (Yard Waste)Fertilizer Pelletsxxx
Copper DustMetal Recovery Pelletsxxx
Corn CobsCat Litter, Oil Dry Pelletsxxx
ClayProppantsx
Dredge SludgesNon-leaching Granulesxxx
Electric Arc Furnace (EAF) DustsMetal Recoveryxxx
Ethanol Plant Waste (DDG)Animal Feedxxx
Foundry DustMetal Recoveryxxx
Gold Ore DustPrecious Metal Recoveryxxx
Grain DustNon-explosive Pelletsxxx
Gypsum Wallboard WasteFertilizer, Cat Litter Pelletsxxx
HumateFertilizer Pelletsxxx
Iron OxideMetal Recovery Pelletsxxx
Lime (Waste Water Treatment Sludge)Calcium Fertilizer Pelletsxxx
LimestoneCalcium Fertilizer Pelletsxxx
Talc OreSterilized Baby Powderx
Manure – Cattle/Chicken/HogFertilizer Pelletsxxx
Soda BottlesRecycled Plasticx
MAP FertilizersFertilizer Pelletsxxx
Municipal WastesFertilizer, Fuel Pelletsxxx
Nitrogen FertilizersFertilizer Pelletsxxx
NPK BlendsFertilizer Pelletsxxxx
Paper SludgeFertilizer, Cat Litterxxx
Petroleum Coke DustFuel Pelletsxxxx
Phosphates PowderFertilizer Pelletsxxx
Potassium ChlorideFertilizer Pelletsxxxx
Saw DustCat Litter, Fuel Pelletsxxxx
Soy FlourAnimal Feedxxx
Steel Dusts and SludgesMetal Recovery Pelletsxxxx
SugarSugar Pelletsxxx
Sulphur DustNon-explosive Pelletsxxx
Tar Sands Waste SludgeSubstitute Fuel Pelletsxxx
Titanium Metal ShavingsMetal Recoveryxxx
Iron OreMetal Recovery Pelletsxx
Glass BatchGlass Blendxxx
Ceramic / AluminumRefractoryxx
Paper SludgeBright White Clayx
GypsumFertilizer Pelletsxx
Zinc OxideMetal Recovery Pelletsxxx
Nickel OreMetal Recovery Pelletsxx
Kaolin ClayCoating Paperxx
Tungsten OxideMetal Recovery Pelletsxxx
Raw CoalPurified Coalx
Bone MealFertilizerxx
Ammonium SulfateFertilizerx
Diatomaceous EarthFilter Agentxx
Titanium DioxidePigment Pelletsxxx
Urea FertilizersCoated to prevent moisture absorptionxxx

PROCESS DATA COLLECTION

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. Depending on the type of testing being conducted, tracked data might include:

  • Current (Amps)
  • Feed Rate
  • Flow Rates/Product Flow
  • Fuel Usage
  • Horsepower
  • System Pressure
  • Temperature
  • Torque
  • Gas Sampling & Analysis (Oxygen, Carbon Monoxide, Nitric Oxide, Nitrogen Dioxide, Sulfur Dioxide, and combustibles discharged from various thermal

These capabilities provide unmatched data collection and reporting capabilities.

Ready to Test Your Process? 

Contact us today to discuss your batch- or pilot-scale testing needs!

RESOURCES

TESTING PROFILES

Synthetic Gypsum Lab Profile
Potash Lab Profile

MATERIAL TESTING & TRANSFORMATION ARTICLES

Batch Rotary Kiln Testing to Detailed Kiln Design

From Batch Rotary Kiln Testing to Detailed Kiln Design

Since 1951, FEECO International has built a reputation as the leader in rotary kiln design and manufacturing. Part of our success …

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Fluid Bed Dryer Testing in the FEECO Innovation Center

Fluid Bed Dryer Testing & Process Development in the Innovation Center

One of the most challenging aspects buyers face in the purchase of capital equipment is ensuring the equipment can meet their …

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BROCHURES

Innovation Center Brochure
Batch Kiln Brochure

PHOTOS

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