CHAPTER-3.

1
SIZE ENLARGEMENT/
AGGLOMERATION
Size Enlargement
 Size enlargement : is any process whereby small particles are
gathered into larger, relatively permanent masses in which the
original particles can be distinguished.
 It can be said the opposite process of size reduction.

 In the broadest sense the term agglomeration includes all processes

in which fine particles which are dispersed in either gas or liquid,

aggregate to form a coarser product. The collection of particles that
results is called an agglomerate or granule. Eg. Cheese/butter
 In most cases, the preferred particle shape is spherical, because it is

the shape least subjected to breakage and abrasion.

 In many processes the product is a cylindrical section such as a

tablet or some other regular geometrical shape.

Size Enlargement
 Why particle size enlargement is required?
 Dust and sludge can be recycled or disposed of without
pollution.eg. Brick from shaving dust, Particle board from
sagatura.
 Improve handling and storage characteristics. Eg. Cereal bagas for
animal food( fagullo, geleba)
 Increased bulk density and lower bulk volume.
 Improved appearance.
 Defined shape and sometimes defined weight of each agglomerate.
eg. Bread from wheat powder.
 Removal of Particles from liquid. Eg. Industrial waste treatment.
 Increase product value.
 Reduce caking and lump formation.
 Solubility, dispersability, porosity and surface to volume ratio can
be controlled. Eg. Pharma tablets
Desired and Undesired Agglomeration
 During production and processing of solid matter in disperse
systems, adhesion phenomena become more and more important
with decreasing particle size, causing aggregation, agglomeration,
coating, caking, and build-up.
 Adhesion: the property of sticking together (as of glue and wood)
or the joining of surfaces of different composition.
 Cohesion: the intermolecular force that holds together the
molecules in a solid or liquid of the same composition.
 Adhesion of finely divided material takes place during all
operations of mechanical process engineering and can be either
desired or undesired.
 During grinding, agglomeration is always undesirable because it
reduces the grinding effect, lengthens the grinding time, and
increases the energy requirement.
Desired and Undesired Agglomeration
 Powder mixtures often tend to segregate during handling and
storage; then, a controlled agglomeration of the final mix may be
desirable prior to further processing.
 Because fine powders possess a large bulk volume, generate dust,
and exhibit unfavorable transport, storage, and feeding
characteristics, their particle size is sometimes enlarged by
agglomeration.
 In some cases it is necessary to further treat the agglomerate with
"anti-caking" compounds to avoid clustering during storage.
 Conglomerates can result in clogging of feeders, prevent discharge
from silos, and cause incorrect metering. The prevention or
destruction of such conglomerates often requires considerable
technical efforts.
Agglomerate Bonding and Strength
 Binding Mechanisms
 To obtain agglomerates from particular matter, binding forces
must act between the individual particles.
 According to Rumpf who first published a classification, the
possible mechanisms can be divided into five major groups.
1. Solid bridges.
2. Interfacial forces and capillary pressure at freely
movable liquid surface(liquid bridge).
3. Adhesion and cohesion forces at not freely movable
binder bridges.
4. Attraction forces between solid particles.
5. Form-closed bonds (interlocking).
Agglomerate Bonding and Strength
 Binding Mechanisms (According to Pietsch)

 Matrix Binder
 Solid Bridge  Capillary Forces
 Sintering (conglomerates saturated with
 Crystallization of soluble substances liquid)
 Hardening of melted substances

 Chemical Reactions  Interlocking

 Adhesion Forces  Form Closed Bonds
 Highly Viscous Binders
 Adsorption Layers
 Cohesion Forces

 Molecular Forces
 Liquid Bridges
 Electrical Forces
 Capillary Pressure
 Magnetic Forces
 Interfacial Forces
Agglomerate Bonding and Strength
 Alternative classification of binding mechanisms
Agglomerate Bonding and Strength
 The most important characteristic of all forms of the agglomerates is
their strength. For the determination of agglomerate strength, real
stresses are often simulated experimentally.
 In addition to the usually applied crushing, drop, and abrasion tests,
methods for the determination of impact, bending, cutting, or shear
strength are employed.
 All values obtained by these methods are strictly empirical and
cannot be predicted by theory, since it is not known which stress
component causes the agglomerate to fail.
 Strength of agglomerates derives from:
 The action of binding forces, acting either at the coordination
points between the particles or
 The interfaces between a matrix binder and the particulate
solids or
 By the capillary pressure of a liquid filling the pore volume.
 Attractive Forces

Solid Bridges Vander walls

1.Sintering
2.Hardening binder
Mechanical Interlocking
3. Crystallization Electrostatic force

Liquid Bridges
1. Capilary
2. Droplet

Attractive Forces On Size Enlargements

11
Methods of Size Enlargement by agglomeration

 A common classification of methods for the size

enlargement of particulate matter distinguishes between
two types of processes:
1. Growth/tumble agglomeration (no external
forces)
2. Pressure agglomeration (low, medium, and high
external forces)
 Two techniques:
 Agglomeration with the addition of binders
 Binder-less agglomeration
Growth/Tumble agglomeration
Mechanism of growth/tumble agglomeration
 The particles to be agglomerated are larger, the particle-to-particle
adhesion must be enhanced by the addition of binders mostly
water and other liquids.
 The collision probability must be increased by providing a high
particle concentration. Such conditions can be obtained in
inclined discs, rotating drums, any kind of powder mixers and
fluidized beds.
 These wet agglomerates are temporarily bonded by the effects of
surface tension and capillary forces of the liquid binder.
 With increasing size and mass of the particles to be agglomerated
by growth/tumble methods, the forces trying to separate newly
created bonds during agglomerate growth become larger until size
enlargement by tumbling is no longer possible.
Growth/Tumble agglomeration

Dry Particles

Wet Particles

Effective Collision

Forming of Liquid Bridge

Growth/Tumble agglomeration
 Theoretically, no specific piece of equipment is necessary for this
phenomenon to occur; as long as the solid particles are kept in
irregular, stochastic motion, the probability for collision and
coalescence exists.
 Micron and sub-micron particles (approx. <5 to 10 mm) will adhere to
form an agglomerate even if they are dry.
 Van der Waals forces are high enough to cause coalescence.
Agglomeration of larger particles necessitates the addition of binders.
 If very large amounts of solids must be agglomerated and the fine
particulate form is also required for other reasons, for example, the
concentration of valuable constituents of ores, tumble agglomeration is
a preferred technology. In those cases the main binder is normally
water.
Growth/Tumble agglomeration
 Other reasons for the application of tumble agglomeration, even at
small capacities, may be the high porosity of the agglomerates
with other attendant beneficial characteristics such as large surface
area (e.g., for catalyst carriers) and easy solubility [e.g., for food
(drink) and pharmaceutical products]. Eg. Powdered juices.
 Drawbacks of all tumble agglomeration methods are the limitation
to small dimensions of the particles forming the agglomerate and
that, in most cases, only temporarily bonded conglomerates are
formed.
Growth/Tumble agglomeration
 Major mechanisms of growth/tumble agglomeration:
 Nucleation:
 The binding together of particles to form a small granule.
 This mechanism reduces the number and mass of particles in the system
while increasing the number and mass of granules.
 Coalescence:
 Two granules successfully collide to form one granule.
 After collision, the two granules form a dumb-bell shaped intermediate.
 The collision is only successful if the net forces on the intermediate are
sufficient to hold the newly formed granule together.
 Coalescence reduces the total number of granules but has no effect on their
total mass.
 Abrasion transfer:
 occurs when material is transferred from the surface of one granule to
another.
 This mechanism changes neither the total number nor the total mass of
granules and very little work has been reported on abrasion transfer; its
effects are often discounted.
 Growth and layering
Growth/Tumble agglomeration

Different processes taking place during tumble agglomeration

Formal representation of mechanisms of size change in size
enlargement by agglomerate growth.
Growth/Tumble agglomeration
 In a broad sense, equipment for tumble agglomeration
itself can be divided into:
1. Solids-dense phase agglomeration: apparatus producing
movement of a densely dispersed bulk mass of particulate.
2. Fluid-suspended solids agglomeration: apparatus keeping
solid particulate matter suspended and loosely dispersed in a
suitable fluid.

 In both cases, binder is sprayed into the turbulently

agitated bed of particles.
Growth/Tumble agglomeration
Selection of an agglomeration system based on end product
characteristics
 Dispersability
 Dissolution rate
 Flowability
 Compressibility
 Density
 Strength
 Size
 Shape
 Size distribution
 Formulation
Pressure agglomeration
 Relatively uniformly shaped and sized agglomerates can be
obtained by low- to medium-pressure agglomeration whereby the
feed mixture must still be made up of fine particles and low
binders.
 The moist, often sticky mass of particulate solids and a liquid
binder is extruded through holes in differently shaped screens or
perforated dies.
 Agglomeration and shaping occur by the pressure forcing the
material through the holes and by frictional forces during passage
of the mass.
 Depending on the plasticity of the feed mix, short "crumbly,"
elongated "spaghetti-like," or cylindrical "green extrudates" are
produced.
 In most cases a post treatment (typically drying and cooling) is
required to obtain final, permanent strength.
Pressure Agglomeration
 Application of High Pressure to:
 Densify powder feed material
 Partially crush incoming particles
 Force particles into close proximity
 Rely on inter-particle forces
 Rely on particle molding
Advantages of Pressure Agglomeration
 Little or no binders required
 Drying or curing post treatment not required
 High capacity with low energy input
 Wide ranges of feed sizes acceptable
 High product density achieved
 Robust design promotes extended equipment life
Pressure agglomeration
 Pressure Agglomeration Product Characteristics
 High density products
 High strength
 Uniform shape and size
 Large product size possible
 Possibility for no binder addition
 Limited dispersability
Pressure Agglomeration Methods

 Pressure Agglomeration includes operation such as:

 Briquetting
 Compacting
 Piston Press
 Tableting
Pressure Agglomeration Methods

Schematic representation of equipment for high-pressure

agglomeration
Pressure Agglomeration Methods

Schematic representation of equipment for low (a)-

and medium (b)-pressure agglomeration
Pressure Agglomeration Methods

 Extrusion Agglomeration: Squeezing out by applying pressure to

characterize its own shape.
 Low Pressure Extruder: Form or shape by forcing through an
opening
 High Pressure Extruder
 Gear Pelletizing
 Pellet Mill
Pressure Agglomeration Methods

 Extrusion Agglomeration Product Characteristics

 Medium density product.
 Medium dispersability.
 Good for time release dispersion.
 Product is cylindrical, with constant cross
section.
 Typical diameter 1 to 10 mm.
 Uniform particle size and shape.
 Product very resistant to breakdown.
 Binder may need to be added.
Pressure Agglomeration Methods
 Double Roll Compaction
 Material drawn between counter rotating rolls.
 Force feeders usually used.
 High pressure applied in the nip.
 Roll surface dictates product shape.
 End product:
 Briquettes: A block made from charcoal or
coal dust and burned as fuel or
 sheets for granulation.
Pressure Agglomeration Methods
 Feed Limitations for double roll compaction are:
 Aerated feed materials require special features to
deaerated or minimize vibration.
 Only “dry” feed acceptable.
 Abrasiveness, elasticity, plasticity and brittleness
need to be considered.
 Heat and pressure sensitive materials not
compatible.
 Toxic materials are difficult to contain.
Granulation Influence of Moisture on Particle Size

 Granulation is particle size

enlargement by sticking together
smaller particles using agitation to
impart energy to particles and
granules.
 Agglomeration is the formation of

Particle Size
agglomerates or aggregates by sticking Mixing Agglomeration
together of smaller particles and
granulation is agglomeration by
agitation methods.
 Very little liquid: powder coating
 More liquid: agglomerates
 A lot of liquid : paste (An
adhesive made from water and
flour or starch; used on paper % Liquid
and paperboard)
 Mainly liquid: slurry
Granulation
 Wet Granulation
liquid binder is
distributed over the bed to
initiate granule formation.
The resulting assembly of
particles is called a
’granule‘ and consists of
the primary particles
arranged as a three-
dimensional porous
structure.
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