How Drying Enables Better Agglomeration
The behavior of the material during the agglomeration process is heavily affected by a plethora of factors. Amongst them, drying is one of the most impactful. Preliminarily dried material agglomerates much faster and smoother. The product dried after the agglomeration process is more robust and sustains better both transportation and handling.
For agglomeration to happen, the material must be prepared and its liquid content must be adjusted to the level where it will be optimal for further processing. Agglomeration requires the material to be dry enough, but not too much.
In order to achieve perfectly balanced conditions for agglomeration to occur smoothly and without hiccups, it is imperative to carefully prepare the material. In the vast majority of cases, incorporating the drying process in the production is a good idea. Preliminary drying is the key to reducing various undesired effects such as clumping, accretion, and slow agglomeration from happening. Various materials may quickly clump and significantly reduce the efficiency of production if not prepared correctly. There is no better way to enhance the overall quality of your products than simply implementing drying process prior to agglomeration.
Maximizing peletization effectiveness with drying
Generally, peletization follows agglomeration. Drying makes the product much better after agglomeration. Pellets lose their last bits of unnecessary wetness and become robust. In order to achieve this hardened and convenient form, product must be additionally dried. Liquid contents will be equalized with the most optimal level for the end product. Removing liquid contents significantly improves mechanical properties of the material. Pellets are easier to handle, move around, and transport. Pellets also receive additional treatment in rotary dryers since rotation forces pellets to stir against the walls of the vessel. This process polishes the surface of pellets making it smoother.
Additional effects can be achieved by properly setting up the air flow. For example, co-current system will immediately remove wetness and make pellets even harder effectively crystalizing the surface of the material.
There are types of liquid absorptive materials that tend to clog and stick to the interior of the vessel. In order to reduce undesired clumping and remove sticky bits from the shell, we recommend using various knocking systems. This will greatly improve your drying process.
Compaction Improvements with drying
Granules may not need additional drying since compaction is often a process applied to materials that have been preemptively dried.
There are certain scenarios when drying is beneficial. For example, drying out pellets and granules that go through additional processing such as surface smoothing. In order to make granules smoother and remove undesired cracks and deformations, the material is often intentionally wetted and then dried again.
In such cases, drying also additionally polishes the granules and makes product better for further compaction and distribution. Some materials also use binder for compaction and will need drying in order to regulate wetness.
The Drying Process
Any product needs materials that are prepared. Equalizing moisture levels with production requirements is pivotal in the vast majority of production processes. Depending on the type of the production, requirements may differ greatly. In order to follow these requirements, one needs to pick the right type of the dryer.
There are various product properties that should be accounted for when choosing the most optimal drying equipment. Amongst the most important material characteristics: bulk density, processing heat level, repose angle, etc. With proper equipment, drying is a highly efficient process that can enhance your production.
The process is fairly simple. The vessel is filled with materials through the inlet. The drum starts rotating powered by the drive. Hot gases from the burner flows through the material and dries it. In order to improve drying efficiency, lifters constantly shuffle and move the material. This setup ensures both energy usage efficiency and even drying.
To improve agglomeration, fluid bed setups can be used. These dryers force the material to be dried in a fluid state by keeping in airborne. This solution is ideal for agglomeration.
How to choose the best industrial dryer
Picking between fluid bed and rotary dryer is a hard task when it comes to processing the material. Generally, the most optimal choice is determined by the industrial standards. For example, pharmaceutical companies would definitely prefer to use fluid bed variants. On the other hand, companies that manufacture fertilizers and work with various ores and minerals may find rotary dryers way more useful. Note that fluid bed setups are not efficient when working with heavy materials and will not be good enough for processing minerals and ores. This is an important issue to consider.
There are distinct benefits in using Rotary Dryers:
- Heavy-duty durable wear-resistant construction;
- Works well with a great variety of feedstock;
- Incredible capacity and processing speed.
Fluid bed dryers also have apparent advantages:
- Gentle handling of the material with less intimate contact of material bits with each other and the walls of vessel;
- Better suited for agglomeration;
- Allows more room for operational growth.
Important takeaways: drying is a pivotal part of various industrial processes from preparing the feedstock for further agglomeration or drying the product in order to achieve better properties. Note that post-agglomeration drying is not required, but can significantly improve the quality of product in many cases. For agglomeration purposes, both bed fluid and rotary setups are sufficient, but rotary dryers are better suited for heavy industrial purposes.