The term bulk solids processing encompasses an array of different types of materials, processing techniques, and objectives; soil amendments and fertilizers, minerals and ores, chemical compounds and more, all fall under the umbrella of bulk solids. And while the goals and equipment differ across operations, there are several factors that are universal to the success of any given bulk solids processing operation.
As a pioneer in bulk solids processing technology ranging from agglomeration and granulation to drying and high-temperature thermal processing, we’ve outlined some of the key aspects required for success in any bulk solids process setting.
Proof of Concept, Proof of Product, Proof of Process, and Process Optimization
Testing to illustrate process feasibility is a valuable tool in de-risking any investment, particularly when working with a novel process or material source. In fact, even when working with a well-established process, the natural variation of material characteristics across different sources and deposits makes testing a necessity to avoid the potential pitfalls of an unverified process.
By conducting batch- and pilot-scale testing, producers can work through initial feasibility of their intended process, problem solving issues and gathering the data necessary for a smooth scale-up.
A process that reaches its rated production shortly after start-up and that reliably and efficiently produces the desired product quality is no accident; it is developed through comprehensive testing, first showing proof of concept, then proof of product, proof of process, and finally, optimizing the process.
Consistent Feedstock
Though not always the case, in most settings, producers working with bulk solids are looking to reach a specific set of characteristics in the processed material, whether that material will serve as a finished product, or as an intermediary material necessary for downstream processing.
In such cases, it is desirable for all material, or as much material as is possible, to meet those characteristics. One of the most influential aspects of producing a consistent product is a consistent feedstock.
Feedstock should be tightly controlled to maximize uniformity across parameters such as particle size distribution, moisture content, chemical composition, and more; the more uniform the feedstock, the more uniform the product.
Trained Operators
The value of a trained operator is often overlooked in bulk solids processing operations. However, trained operators are an invaluable asset, with influence extending to nearly every measure of success.
Trained operators not only know what they’re doing, but why they’re doing it, giving them the foundation to troubleshoot issues, fine-tune process variables, and optimize the process for maximum efficiency. They often mean the difference between minimal upsets and extensive downtime.
Training is especially important in pelletizing operations utilizing a disc pelletizer (also known as a pan granulator), as there are many process variables that can be adjusted during processing to respond to changes in feedstock or production.
Appropriately Designed Equipment
Employing equipment suited for the specific demands of the process is essential to efficiency and long-term reliability, particularly for those operations working in high-demand, high-capacity markets.
One-size-fits-all equipment may offer reliable performance in the short term, but incurs greater costs in the long run in the form of reduced efficiency, excessive downtime, unexpected maintenance costs, and often, premature replacement.
Equipment not suited to the rigors of its specific duty will almost always fail; it’s just a matter of when.
It’s important to note that this principle extends to the bulk solids handling equipment as well; even the best process equipment cannot be effective if feeding and offtake aren’t up to par.
Parts & Service Support
Well-designed and properly maintained equipment provide a reliable processing solution. However, even well-designed equipment is not immune to issues.
When problems do arise, having parts and service support, whether from the original equipment manufacturer (OEM), or a third-party service provider, is essential for expediting issue resolution.
As part of their preventative maintenance plan, plant operators should have a reputable provider at the ready in the event of an issue or repair that cannot be resolved by in-house personnel. This will help to minimize the amount of time to resume normal production.
Service providers can also be used as an extension of the maintenance team, assisting in preventative maintenance inspections and replacements.
An Inventory of Wear-Critical Parts
Similarly, plant managers should keep an inventory of wear-critical or parts with a long lead time. Having replacement parts for process equipment at the ready can mean the difference between days and weeks of downtime, depending on the component.
Automation
While process equipment automation is certainly not required in any bulk solids processing operation, the value these capabilities add cannot be overlooked and will only continue to gain importance as the industrial internet of things (IIOT) takes hold.
Through automation, capabilities such as data collection, trending, and reporting provide process transparency that can help operators to predict and prevent potential issues, reduce troubleshooting and issue resolution time, and even identify potential gains in efficiency.
Conclusion
Despite the diverse nature of bulk solids processing, there is some commonality among those working with bulk solids. Six factors are essential in the success of a bulk solids processing operation, including proving the process and product, maintaining a consistent feedstock,
training operators, choosing well-designed equipment, having a service provider, and considering automated equipment.
In business since 1951 and serving some of the largest companies in the world, FEECO is an industry leader in bulk solids processing equipment, testing services, and parts and service support. We serve every industry from mining and minerals, to chemicals and fertilizers, pulp and paper products, and so much more. For more information on our bulk solids processing, contact us today!