Agglomeration is the process of particle size enlargement and is used throughout a variety of industries to improve handling and product characteristics, among other things. This presentation looks at why it may be desirable to agglomerate a material, as well as some of the basic types of agglomeration.

1. Agglomeration
Experts in process design and material
processing for over 60 years.
An Introduction to

2. Agglomeration is the process of particle
size enlargement.

3. It is commonly used to upgrade material
fines into a granular product, and can
also be used to transform sludge-like
materials into a dry, granular form.

4. Why Agglomerate
Your Material?

5. Common Reasons to
Agglomerate Include:

6. Common Reasons to
Agglomerate Include:
• The material is difficult to
handle or apply

7. Common Reasons to
Agglomerate Include:
• The material is difficult to
handle or apply
• The material is challenging
or costly to transport

8. Common Reasons to
Agglomerate Include:
• The material is difficult to
handle or apply
• The material is challenging
or costly to transport
• The material is not usable
in its current form

9. Common Reasons to
Agglomerate Include:
• The material is difficult to
handle or apply
• The material is challenging
or costly to transport
• The material is not usable
in its current form
• The material is too dusty

10. No matter what the reason, agglomeration
offers an array of benefits…

11. Benefits of
Agglomeration

12. The use of agglomeration to solve material
problems and improve product characteristics
is continually spreading to new industries and
materials.

13. In general, agglomerating a material
offers the following benefits:

14. In general, agglomerating a material
offers the following benefits:
• Significant Dust Reduction

15. In general, agglomerating a material
offers the following benefits:
• Significant Dust Reduction
• Improved Handling & Transportation

16. In general, agglomerating a material
offers the following benefits:
• Significant Dust Reduction
• Improved Handling & Transportation
• More Complete Utilization of Raw Materials

17. In general, agglomerating a material
offers the following benefits:
• Significant Dust Reduction
• Improved Handling & Transportation
• More Complete Utilization of Raw Materials
• Improved Product Characteristics

18. More specifically, there are many facets to
the benefits of agglomeration…

19. End Product Benefits:

20. End Product Benefits:
• Dust-free product handling

21. End Product Benefits:
• Dust-free product handling
• Segregation prevention

22. End Product Benefits:
• Dust-free product handling
• Segregation prevention
• Improved product characteristics

23. End Product Benefits:
• Dust-free product handling
• Segregation prevention
• Improved product characteristics
• Enhanced appearance

24. End Product Benefits:
• Dust-free product handling
• Segregation prevention
• Improved product characteristics
• Enhanced appearance
Example:
The agglomeration of agricultural wastes makes them
easier and less costly to transport, easier to apply, and
capable of being stored. Other improvements include the
opportunity to create a more precise and targeted
fertilizer formula.

25. Raw Material Benefits:

26. Raw Material Benefits:
• Simplified Transportation

27. Raw Material Benefits:
• Simplified Transportation
• Dust loss prevention

28. Raw Material Benefits:
• Simplified Transportation
• Dust loss prevention
• Increased porosity, density, and melting
abilities

29. Raw Material Benefits:
• Simplified Transportation
• Dust loss prevention
• Increased porosity, density, and melting
abilities
Example:
Agglomerating ore fines prior to heap leaching creates a
more uniform particle size distribution. This maximizes the
efficiency of the heap leaching process, allowing for
better percolation of the leaching solution through the
heap.

30. Process Benefits:

31. Process Benefits:
• Elimination of dust and fines

32. Process Benefits:
• Elimination of dust and fines
• Increased process flow effectiveness

33. Process Benefits:
• Elimination of dust and fines
• Increased process flow effectiveness
• Reduced clogging of processing equipment

34. Process Benefits:
• Elimination of dust and fines
• Increased process flow effectiveness
• Reduced clogging of processing equipment
• Increased process efficiency

35. Process Benefits:
• Elimination of dust and fines
• Increased process flow effectiveness
• Reduced clogging of processing equipment
• Increased process efficiency
Example:
In its raw state, glass powder is susceptible to being swept
up in the airflow during processing, resulting in lost product
and skewed formulas. Agglomerating glass reduces
product loss, ensures accurate formulations, and improves
process efficiency.

36. Economic Benefits:

37. Economic Benefits:
• Conversion of a waste material to a
marketable product

38. Economic Benefits:
• Conversion of a waste material to a
marketable product
• Reduced transportation costs

39. Economic Benefits:
• Conversion of a waste material to a
marketable product
• Reduced transportation costs
• Reduced material handling costs

40. Economic Benefits:
• Conversion of a waste material to a
marketable product
• Reduced transportation costs
• Reduced material handling costs
Example:
Agglomeration of previously unsalable limestone fines
transforms them into a marketable product – limestone soil
amendment pellets.

41. Environmental Benefits:

42. Environmental Benefits:
• Potential to eliminate the need to landfill a
material

43. Environmental Benefits:
• Potential to eliminate the need to landfill a
material
• Improved cost-efficient recycling capabilities

44. Environmental Benefits:
• Potential to eliminate the need to landfill a
material
• Improved cost-efficient recycling capabilities
• Potential for waste-to-fuel processes

45. Environmental Benefits:
• Potential to eliminate the need to landfill a
material
• Improved cost-efficient recycling capabilities
• Potential for waste-to-fuel processes
• Improved waste disposal cost efficiency

46. Environmental Benefits:
• Potential to eliminate the need to landfill a
material
• Improved cost-efficient recycling capabilities
• Potential for waste-to-fuel processes
• Improved waste disposal cost efficiency
Example:
Waste paper sludge that was previously considered
unusable and therefore landfilled, can be agglomerated
into a usable product.

47. Methods of
Agglomeration

48. Many types of agglomeration techniques
exist, with all of them falling under one of
two main categories:
• Pressure
• Non-pressure (tumble growth)

49. Pressure Agglomeration:
Pressure agglomeration techniques rely
on pressure to cause a material to
adhere to itself, through the application
of extreme pressure. Not all materials will
adhere to themselves under pressure, so
pressure methods are not always an
option.

50. Non-Pressure Agglomeration:
(Tumble Growth)
Non-pressure agglomeration techniques
use a binding agent to process material
into larger fines. This is done by tumbling
the fines in the presence of a binder,
similar to rolling a snowball.

51. Pressure
Agglomeration
Techniques

52. Briquetting
Briquetting is carried out in a briquetter, and
produces large, pillow-shaped briquettes. This
process is reserved for larger agglomerates,
such as charcoal or water softener briquettes.

53. Briquettes created in a briquetter in the
FEECO Lab.

54. Because briquetting is typically a dry
process (no binder), a drying phase is not
necessary. While a binding agent is typically
not utilized, it can be helpful in some
situations.

55. Compaction
Compaction is carried out using a roll
compactor, and produces small, jagged
granules. This process is used throughout
a variety of industries, including fertilizers
and chemicals.

56. Compaction
Compaction is carried out using a roll
compactor, and produces small, jagged
granules. This process is used throughout
a variety of industries, including fertilizers
and chemicals.
Again, a binder is typically not used, and
therefore a drying step is usually not
necessary.

57. Photo of granules
Granules created in a roll compactor in the
FEECO Lab.

58. Non-Pressure
Agglomeration
Techniques

59. Pelletizing
Pelletizing can be carried out in a disc
pelletizer or agglomeration drum. Both
methods produce round pellets.

60. Pelletizing
Pelletizing can be carried out in a disc
pelletizer or agglomeration drum. Both
methods produce round pellets.
Because a binder is used, pelletizing
methods most often require a drying
step.

61. Pellets created on a disc pelletizer in the
FEECO Lab.

62. Micro-Pelletizing
Micro-pelletizing produces small pellets,
and is commonly used to de-dust
material, as well as to prepare it for
optimal pellet formation on a disc
pelletizer or in an agglomeration drum.

63. Micro-Pelletizing
Micro-pelletizing produces small pellets,
and is commonly used to de-dust
material, as well as to prepare it for
optimal pellet formation on a disc
pelletizer or in an agglomeration drum.
Micro-pelletizing is most often carried out
in a pin mixer.

64. Micro-pellets created in a pin mixer in the
FEECO Lab.

65. Conditioning
Conditioning typically refers to the
simple act of mixing or de-dusting
material in a pin or paddle mixer. This
may be to prepare it for pelletizing, to
reduce dust, or simply to make it easier
to handle and transport.

66. Material being conditioned in a paddle
mixer in the FEECO Lab.

67. Conclusion
The numerous benefits agglomeration has to
offer, combined with increasing flexibility in
applications, has caused this valuable process
to find its way into all sorts of industries. Various
agglomeration techniques are available,
allowing manufacturers to tailor a process to
the exact needs of their material.

68. has been a leader in the agglomeration industry
since the 1950s, helping customers solve material
problems through process & product
development, feasibility testing, and high-quality,
custom agglomeration equipment.
FEECO

69. Want to learn more?
Download our
Agglomeration Handbook
Agglomeration Handbook
Intro to Agglomeration
Processing Techniques
Considerations in Agglomeration
And more…
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