Granulation

Granulation1Presented by:Syed Waqas HaiderProcess Engineer

DefinitionGranulation is the process of collecting particles together by creating bonds between them. Bonds are formed by compression or by using a binding agent

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Types of Granulation3Dry Granulationwithout using a liquid solution

Wet Granulationaddition of a liquid solution (with or without binder)

Dry Granulation4Primary powder particles are aggregated under high pressureDry granulation

Wet Granulation5This class of process includes Fluid beds, tumbling drums & pans, and mixer-granulators

Mechanism

Wetting, nucleation and binder distributionConsolidation and growthAttrition and breakage

Fluidized bed Granulation6Granulation and drying in the same equipmentGranulation is controlled by moisture content of the bedToo high moisture content will defluidize the bed and in too low moisture, no agglomeration will occurGranules obtained are more porous than those obtained from shear mixers

Fluidized bed Granulator7

Spray Arrangements

Tumbling Granulation8Particles are set in motion by the tumbling action caused by the balance between gravity and centrifugal forces Includes discs, drums, pans and a range of similar equipment

Characteristics of tumbling granulators9Product granule size in the range of 2 to 20mmNot suitable for producing very small granulesGood for producing high density balls or palletsCapable of handling very large throughputsExtensively used in mineral processing and fertilizer granulation

Disc Granulator10Rotating disc with a rim to hold the tumbling granulesPowder feed continuously fed to the disc, typically at the edge of the rotating granulator bedLiquid binder is added through a series of single fluid nozzles distributed across the face of the bed

Drum granulator11Typically used for high capacity applications and usually requires some type of recycle depending on the product specificationGranulation where the only feed or the majority of the feed is a liquid or melt such as urea granulationFeeds may be either pre-moistened by mixers to form granule nuclei or liquid may be sprayed onto the tumbling bed via nozzles or distributor pipe systemScrapers are often but not always used to limit build up on the drum wall

Drum Granulator12

Mixer-Granulator13The High Shear Mixer-Granulator is a multi-purpose processor equally suitable for high speed dispersion of dry powders, and aqueous or solvent granulations

Melt Granulation: Melt agglomeration is a process by which agglomeration is obtained through the addition of either a molten binder liquid or a solid binder which melts during the processAgglomerates are formed by agitation of the mixtureThe mechanism of melt granulation is similar to that of wet granulation

Mixer-Granulator14

Double shaft paddle Mixer-Granulator15Dual counter-rotating shafts run the length of the deviceThe paddles move material from the bottom of the trough, up the middle, and back down the sides creating a kneading and folding effect that intimately mixes the materialTypical Use: Mixing, conditioning, or agglomerating

20-Apr-14Granulators in different Industries

References17The Science and Engineering of granulation-(books.google.com)Granulation - (books.google.com)http://www.slideshare.net/NAMDEOSHINDE15/granulation-ppthttp://www.fertilizermachine.org/rotary-drum-granulator.htmlhttp://www.slideshare.net/svpv14/characterization-of-granuleshttp://feeco.com/2013/12/27/choosing-industrial-mixer-pin-mixers-paddle-mixers/http://www.scribd.com/doc/113643719/PPT-Wet-Granulation