Despite granular limestone’s ubiquity, variation in limestone sources, combined with the mineral’s sometimes-challenging behavior, can make pelletizing limestone into a soil amendment product challenging. And while anyone can sell limestone pelletizing equipment, there is a significant distinction between a vendor that solely manufactures the equipment versus one that can also support the process.
Having a pelletizing expert available as a resource is an invaluable tool to minimizing downtime, managing operating costs, and maximizing efficiency. Here are six ways limestone producers can benefit from relying on FEECO for process expertise.
Benefits of FEECO’s Limestone Pelletizing Expertise
FEECO has been supporting soil amendment producers with process development services, custom equipment, and parts and service offerings since 1951, giving us unmatched expertise in the industry. As the world’s leading limestone pelletizing expert, FEECO can offer the following benefits to soil amendment producers:
1. Complete System Expertise
The limestone pelletizing process consists of several components, primarily raw material preparation, preconditioning, pelletizing, and drying. Bulk material handling equipment, as well as screening and a recycle circuit are weaved into the process to create a continuous loop.
The problem that many limestone producers run into is that most OEMs can only provide one part of that process, and often only the equipment at that; when it comes to fitting those components together and reaching rated plant capacity, producers are left to figure it out on their own. This is especially challenging given that these components don’t simply connect together for a plug-and-play production line; there are many nuances to creating a seamless operation, and figuring them out by trial and error can be costly, time consuming, and full of headaches.
FEECO offers a distinct advantage to producers in that in addition to supplying individual components, we can supply the complete pelletizing line, along with the expertise to put it all together seamlessly.
A simplified process flow diagram (PFD) of a typical limestone pelletizing operation utilizing a pin mixer and disc pelletizer setup.
2. Improved Troubleshooting
This process expertise also allows us to better troubleshoot pelletizing plant issues.
While most OEMs are only able to offer assistance around their specific piece of equipment, FEECO brings a birds-eye view of the entire process to the table, allowing us to expedite the path to identifying and resolving the problem in the most efficient approach possible.
Clumped pellets, also known as “raspberries,” are often a sign of imbalance in the pelletizing process
3. Maximized Process Efficiency
One of the most valuable benefits granular limestone producers gain from working with FEECO is the opportunity to maximize process efficiency and product quality through our pelletizing process audits.
Even pelletizing plants performing as designed can often be further optimized to reduce operating costs, increase production, improve product quality or on-size yield, and more. And with the high tonnages limestone producers work with, even small gains in efficiency can quickly add to the bottom line.
This expertise also extends to evaluating potential changes to the production line.
Material prior to and after pelletizing
4. Feasibility Testing and Process Development Services
Limestone’s diversity in physical and chemical composition, paired with its unique material characteristics, makes feasibility testing and process development around a representative sample essential to building a successful limestone pelletizing line.
The FEECO Innovation Center offers both batch- and pilot-scale testing programs in which limestone producers can evaluate the feasibility of their intended process, as well as work out process and equipment variables needed for equipment design and scale-up.
This de-risks the path to commercialization, identifying potential issues early in the process so they can be worked around through plant design.
A process expert evaluates material on a disc pelletizer in the FEECO Innovation Center
5. Operator Training
Operators play a significant role in the success (or downfall) of a pelletizing operation. Their understanding of agitation agglomeration (wet granulation) fundamentals, the material they are processing, and their unique pelletizing line can mean the difference between producing quality product in a stable operation, and frequent process upsets and lost product.
FEECO offers training programs to limestone soil amendment producers in which we educate operators on the pelletizing process and work with them during live production right on the line.
6. Parts & Service Support
Another major advantage to FEECO process expertise is our ability to address identified issues through parts and service support. Whether the process requires equipment modification or a retrofit, or simple process adjustments, the FEECO Customer Service Team is available to assist. The ability to work with a single party to both identify and resolve production issues significantly simplifies the process.
Through working with FEECO, limestone soil amendment producers can gain an added layer of process expertise and support, helping them with everything from minimizing downtime to evaluating process changes and increasing plant efficiency. From new to existing plants, contact us today for more information on how we can assist with your limestone pelletizing operation!