SAHUT-CONREUR : Experierice Mouse woine s boutela. Ensemble dos Act 2FYeoupes. in 1859, Aled CONREUR established <@ mechanical wekshop in Raises, in the North of France. Since the fist decades of the 20h century, the SAHUFCONREUR company has then specialized in the design and constuction of coal briqueting plans tsing double roll presses. Beginning in the 19508, the company expanded this technology for new fields of apolications concerning @ variely of industries : chemical, food processing, fron ond sicel_metslirgical, nucleor ores and minerals, phormacestcal. and many other powder processing industries: In adalion tothe ouble rll press, the company has developed a range of additional equipments specifically adapted fo the requtements of this technology : mixers, pugs, foke- breakers, hammarmils, granulate, ete After more than a century of existence, SAHUFCONREUR is recognized as one of the world leaders in the engineering and constuction of briqueting and granulation by compaction plants Furthermore in the 1980s, SAHUFCONREUR has expanded the use of roller presses to grinding by double roll. Know-how SAHUTCONREUR’ knowhow wos obtained wih the help ofthe pilot plant, the foll production uni, the engineering department, the manufacturing workshop and the achievement of numerous plants The pilot plant is @ true means of research ‘and development, wih a fll range of lab equipments necessary fo determine the key parametes that will be used in the design of equipments and plants This design work performed through CAD workstations by the engineering department is adapted to the requirements of each user. Equipped with special machinery for the manufacture of presses and ancillary equipments, the workshop meets the reliability and quality standards of production and provides a full autonomy to SAHUFCONREUR,Shaping the future Quality and Service A constant search for technical innovations and a modemization of CAD workstations and machining centers ensure the quality and reliability of the plants installad by SAMUTFCONREUR. With iis engineers and skilled technicians SAHUTCONREUR will assist customers from design through startup of their plant and training of staff and throughout the plant operation. Internationalization The equipments manufactured by SAHUTCONRELR are delivered to all five continents. Export sales ‘account for mere than 80 % of total sales. Annelwork of sales agents and associated companies represent the company in more than 3O countries ‘and are at your service to give information on the know-how and services we can provide and answer your requests We also paricipate in many important international exhibitions of major industies Experience, know-how, service, SAHUT-CONREUR has all the necessary means to propose a global solution and implement it.Compaction - Briqueting (briquettes), and granulation by compacting (granules) processes are technologies of particle size enlagment using a dry process in which duss or powers are formed info shapes. The densification of the product is obtained by machanical compression through at double roll press TECHNICAL SOLUTION © Obtain products of the same size, volume and woight an agglomerate /a compact can represent the exact dose required in a process # Obioin o specified and constant product sizerange * feduce the volume of a powder @ Stobilize midures of powders : during handling and transport, the heterogeneous mixtures of particles lose their uniformity because of the variation in density, shape and size of he particles. The problems of segregation disoppear * Improve the flowabiliy of the powders, hus preventing problems of feed, dosage or packaging * Improve the compactabilly of some powders * Eliminate the problems of dust generation during he * Contol the hardness and skength of products ling © Control the dispersion rate of granules * Solve the problems of powder caking during storage A COMMERCIAL-MARKETING SOLUTION * Increase the sales appeal of a product * Fociltate dosage use : an agglomerate can represent the exact dose required in a process for ease of exact dosageAN ENVIRONMENTAL SOLUTION © Recycle industrial waste © Recycle benaficiated dust in an industial process * Eliminate pollution problems caused by airborne dist: air and ground pollution AN ECONOMICAL SOLUTION *# Replace the wel process of agglo ity in the chokes ‘eration involving costly drying and binder addition techniques fraw materials purchased at the most atractive price ge of mixed fertiizer formulas * Granule products that cannot be granulated by means of other techniques (wet process) * Upgrade byproducts * Reduce the packing, storage and transport costs thanks fo @ volume reduction cand higher density ofthe product # Avoid loss of product in dust form te ev- x 4SAHUFCONREUR designs and manufactures doubler! presses for heavy-duty operation under hard and difficult condltions ; raliable uso. and minimal maintenance are basic crtoria for the design of these prosses The main components of the double roll presses (also called briquottors or compactors) aro FEED SYSTEM OF THE ROLLS The foed system is essonial for ful press effcioncy : SAHUFCONRELR has developed various types of sysiems selected according tothe product processed. 4) The hopper Feeding the rolls by gravity, this system can, if necessary, be fited with inclined flaps the postion of which is manually or automaticaly adjusted, b) The distributor and feed-box This paienied system provides a uniform dlshibution of material across the roll wich «this condition Is essental in order to obtain the same agalomercie quality ¢) The force-feeder equipped with one or two conical screws Predonsiving the product and feeding the rol. For very aevaied products, the forcefeeder i equipped with @ daaeration device [vacuum pump] to remove the air contained in the product All hese foed systems can be equioped wh spectal floating cheek plates feducing the powder leakage on the rol! sides and providing a beer ‘efficiency in the compaction area. ROLLS The press is composed of two rolls : one is fixed in the press frame (aed (ol) whereas the other call can move perpendicular tots ex's (mobile cll The size of a press is characterized among ahher features by the rail ameter tom 250 mm i 1400 mm) and the rofl widh from 40 mm to 1600 mm The tangential speed ofthe rolls detemnnes the compression time which has a noticeable influence on the qualiy ‘of the densified product : the compression time should inceaso as the ratio cf the apparent densty 1 the fue density ofthe feod decreases, io whon the quantly of air contained in the product increases. The roll speed can go up fo 25 Rpm and even higher in particular cases ; tt corresponds fo a tangential rll speed up to 1 mere per second 4Roll Press Four lechnologieal solutions are possible forthe working surface of the rolls * shafts wth pocketed tyres (steel rings heatshrunk on the shat) * shafts with profled tres * shafs with boted segments * profled monobloc shafts A number of specticaly treated materiak are used (alloy steel, stainless steel, cast tron, ..) are used forthe manufacture of res and segments. Their selection is dicated by the product abrasveness, is corrosive effect and the condiions of agglomeration {product temperature, compaction pressure]. The pattems on the roll suface has an effect on the perfermance and the ihoughput of the press and several paatiems are proposed : pocketed, smooth, knurled, comugated, chevron, The pockets are machined by miling or eecrochemical machining [ECM The rolls are mounted on dovbleiow self aligning rollerbearings, manually or automaticaly lubricaied by grease or oil am poorery ROLLS DRIVE Most of the presses are equipped wih a special doublecufput gearbox and infernal gear couplings able fo witksiand ihe axial misalgnement caused by the mobile ro movement, The coupling of the mobi roll can be ited with @ device for crcumierential adjusiment ofthe rol that provides a perfect synchronization betweon the fixed roll pockats and those of the mobile raf tn paricuar cases igh torque, resticted space, ...) other dive systems (planetary gearbox, hycraulc mois) can be used, HYDRAULIC SYSTEM The press is equipped with an hydraulic system able fo apply a force on the mobile roll by means of jacks This force can be diferent in certain cases on each bearing block of the mobile roll thanks to @ double ycraule ctcult, This system also includes safely devices and nirogen accumulators fo dampen the movement and quick retun of the mobile rll and protect the press when tramp material is Inadvertenly fed to the rol The force applied on the product can vary fom T to 1.50 KN per linear centimetre of oll width and even higher in particular instances CONTROL - AUTOMATION The press is equipped with sensors and a contol system which ensure @ continuous production of compacts of constant quality without the need for operator. This system can bo * either the conirol between the power consumed by the oll drive and the forcefeeder screw speed ; * or the conto! between the gap measurement fdisiance between the roll] and the forcefeeder roll speed ; SAHUFCONREUR can propose a complete range of presses : from lab presses fo industrial presses of high capacty, each one is spectically adapted to one application 5Fields of application * Chemicals bod sulphate, sodium chloride, carbonates, sodium cyanide, potassium cyanide, iron sulphate, palssum bromide, boric cid ure, calcium hypochlorite.) * Minerals lumina, bei, line, dolomite, china doy, mognsi, uorspar, pnt pigments, sulphur...) * Gypsum from power station flue gas esuphurisation * Minerals (chromium, cobok copper, ion, mangones, kod zn.) * Sponge ron + Metalic oxides (Woelz oxides, rare eorth oxides, zirconium hydroxide, feroaloys, molybdenum roxie, zicon sand...) * Steal turnings * Coal: preduation of briquetes for home heating or industrial purpose {paral coke oven charge, briquetes treated to obtain fermeoke, briquettes for gosfeation). * Coal for production of ectvted carbon * lignite, pot, * Charcoal * Grophite, carbon block * Coke poste * Phosphate {foo cold briqueting) *Clay * Detergents * Frozen food * Sugar * Gloss batch « Sealworks wost materia and by - prodbet (sludge, nil ds snring fines, mil cal, cole fs...) * Died sewage shdge IP R The briqueting units shape fine materials into fauger forms of varied shapes, sizes and volumes {from a Few ce up to 600 cc and more): these characteristics are defined according to the product end use. IF the cohesive forces [particulate cohesion, valence forces, recrystalization, van Der Waals forces...) between the particles are low, a binder has fo be used before agglomeration. The physical properties of the feed material, the end use of the briquettes and the cost of binder addition have to be taken inio account before a selection is made A large variety of fiquid or solid) binders is offered : starch, bentonite, bitumen, me, cement, water, flour ignosulphonates, molasses, polymet, ‘esin, sodium silicate, et.. The briquetes are obtained at a low or high pressure and can undergo mechanical or thermal teaimen! according to the characteristics of the processed material, the binder used and the desired end product Considering the large variely of products to be processed and the binders used, the range of mixers designed end proposed by SAHUTCONREUR is specifically adapted to each ype of briquetingF © vettical mixers or pug mills, for instance for briquating of coal wih bitumen twin screw mixers, for instance for briqueting of some chemicals with water ; these mixers can be equipped with heating or cooling jacket, as the case may be horizontal or ploughshare mixers, for instance for briquetting of some minerals with molasses ; these mixers can also be equipped with heating or cooling jacket, as the case may be. PROCESS According fo the material, the main stages of the process can be as follows @ Product preparation unit screening-erushing, drying, sieving). * Dosing and mixing of product with binder # Briquetting emit * Pos! treatment of the briquettes (air or oven dying, curing, polymerization, aging) BRIQUETTING UNIT WITH BINDER AND FURNACE f i, ~40°C and +1000% 50 kg/h to 100 T/h and for produc's The capacity of a briqueting line can range from ‘ : is wilh a temperature range belween eo w esFields of application + Chemicals dium corborole,socum ctleride, sodium sulphte, sodium tat, ‘ammonium chloride, ion sulphate, calcium cherie, foundry odes.) « Ferlizers PK, NPK, potossum chloride, ‘potassium sulphate, ammonium sulphate, polos nile, phosphate, potash slog, + Pharmaceuticals fantibios, . + Detergents « Antcxidans «Polymers * Coal or charcoal for production of ectvaed carbon Oxides raium oxide, chromium oxide, ion oxide, zinc oxide, .) * Minerals (ime, dolomie, magesi,..) © Pont pigments * Nickel ore dust + Cloy «Dred sewage sudge * Catalysts Granulation by compaction is a dry process iransforming powdess Info granules of various shapes and dimensions. Gonerally, there is no need of @ binder for compactiongranulation of powders and the bonding of particles is ensured by the mechanical pressure exerted on the product being compacted. The compacts produced at low or high pressure are in fake form of variable thickness (up to 30 mn PROCESS According to the material and the end-product ‘equited, the main stages of the process con be as followsCo E S S * A preparation unit for powders (scree soa crushing, drying, sieving) A weighing and mixing unt of the components A. compaction unit transforming the powders info flakes * A granulatiomscreening unit converting the flokes inio granules of the requited size. * And for some plants and in particular for the production of compacted ferillzers, a sav anemns finishing unt with polishing and coating of granules for improved appearance, Sao | reduced amount of residual fines and NPK FERTILIZER GRANULATION BY easier storage. ‘COMPACTING UNIT own os cue The capacity of such a line can range from 50 kg/h to 50 T/h of granules and for products with a temperature up to 200°C, and over. — = ‘ap POLISHING DRUM if GRANULATION BY COMPACTING UNIT FOR THE CHEMICALSP R © From a long experience of design and construction of double rol! presses, SAHUT-CONREUR has developed a roller press specifically adapted for grinding. This machine can crush marerials of variable size range. The material fed between the rollers is ground and comes out as friable flakes. Compared with iraditional techniques, the use of this process means : * energy savings up to 30 & for some materials ; * throughput increases of crushed end- product from 30 to 100 % when the process is fitted into an existing grinding civevit. The roller press can be installed either in a new plant or an existing one. Compared with the double roll press presented on pages 4 and 5, the following adaptations have been made on the roller press FEED SYSTEM It is equipped with @ hopper fitted with inclined flaps. The manval or automatic adjustment of these flaps enables one to control the flow of material above the rollers. 0Cc E Ss = ROLLERS Forged steel monobloe rollers with an abrasion resistant. working surface (deposit of a baselayer and chevron or straight seams) are usually supplied but other technological solutions (surfaced tyres, bimetal tyres and segments) implemented according fo siveness of the feed material ROLLER DRIVE When high installed, one output gearbox fitted with infernal gear couplings which can ower presses h roller is driven withstand misalignement. In particular cases high torque, restricted space, | other drive systems [planetary gear-box, hydraulic motor) can be used. CONTROL - AUTOMATION Two means of conirol can be installed on the press her control of power consumed by the roller drive by positioning of the feed flaps © or control of roller gap by positioning of the feed flaps iMicro-Compactor SAHUFCONREUR has developed a range of micro- compactors for laboratory use, Research ond Development centers and the pharmaceutical incsty 05 well This equipment enables to make briquetting and compaction granulation feasabilty studies on a wide variety of preducts in very small quantiies (about 0,25 liter for one test, a few kg/h in continuous use) Another advantage of this equipmant is thot the pieces in contact with the product can be easily and rapidly dismantled, cleaned and reassembled These microcompactors are available in 2 versions = the type PBI, made of 2 fixed rolls in translaiory movement and without any hydraulic system =the type MPT, including a fixed rail, a mobile roll in ranslaiory movement and a hydraulic system. lified Press For simple opplications such as charcoal briqueting or the agglomeration of some chemicals or fozen food, SAHURCONREUR has designed several models of simplted presses, in particular without hydraulic system and with both rolls five inthe press frame.Pharma Compactor The PHARMA compactors improve and simplify the dry process granulation for a fair number of applications. bis particularly tue when some powders have to be densified or when their compactabiliy or lowabilty needs improving. This compactor also enables fo stabilize mixtures of powders and ensures an easier packaging, handling, storage and/or transport of powders. SAHUFCONREUR has developped a range of compactors specifically adapied fo the requirements of the pharmaceutical industy : online production without dust generation, “production area” fully isolated from the drive system, quick change over of paris in the production area and easy cleaning of these parts, a design and @ constriction according fo the Good Manufacturing Practices (GMP). The operating conditions are monitored by (gap, strength) sensors. All the elements ore contolled by a drive and control system for aviomation and ‘monitoring of he process as well as logging of data {batch reports) received by a computor BCrushing/Grant The range of crushing//granulation equipment developed by SAHUTCONREUR fs specially adapted to the requirements of fhe compaction granelation systems These machines are selected according fo the physical properties of the product (hardness, abrasiveness,..), the final size range and the shape of granules required for the marketable product. The yield of 2 compoctiongranulation unit (ratio of the quantity of granules 10 the quantiy of flakes prodiiced by the compactor is essential: from the compacted flakes, the maximum amount of granules of the right size has 0 be produced while kaping the amount of fines fo @ minimum ; these fines wall be recycled back fo the compactor T-CONREUR can propose 7 types of granulators/crushers : the flake-breaker : it consists of wo rotors fitted with toothed discs rotating ab the same speed and in reverse direction : the flakes produced by the compactor run through the toothed discs and ‘are reduced in size. the hammer-mill : it consists of 0 ‘ctor fited with mobile hommers and o screen installed under the rotor ; the rotor speed and scroen hole size are determined! by the product to process ond the end size range required. the oscillating or continuous rotor granulator : the granvlator is equipped with o roior fited with several arms ; the product is crushed when running through the screen installed under the rotor. cSEquipment the knife crusher ir consists of two rotors, the working surface of which is machined fo obtain either vertical knives or horizontal knives, The product ‘unning through the rotors fs crushed by the knives. The size range of the crushed material between 2 and 20 mm) is conditioned by the gap between rotors and the distance between knives. the smooth roll crusher it is well adapted for finer particle size ange with an average diameter between 0.3 and 2 mm. With this crusher, the size ‘ange can be perlecty targeted while reaching crushing yields vastly superior to the usual yields for such a fine paricle size range. the single-deck grid granulator itis equipped with a rotor fited with several blades and a perforated grid is placed under the rotor; the rotor rotating at low speed forces the product through the perforations. Thanks to this grinding technique, e granules have a rounder shape. Besides, the crushing/granulation yield is higher than the one obtained with the hammer The single-deck grie! grenulotor will be installed as primary or secondary granulator the double-deck grid granulator it includes a primary granulator and two secondary granvlators. Taking the throughput of the grid of the secondary granulator into he flow of product from the primerry granviator is distributed among both secondary granvlators mounted in poral The aperture of the grid of the secondary granulators can correspond fo the upper size requested forthe marketable granules : in that case, the upper cloth can be removed and the circulating load in the haralling equipment reduced.SAHUT-CONREUR : the Company Pilot plant Customers are fee to use the SAHUFCONREUR pilot facilities in Ralimes for any feasibly testing on brquetng, granulation by compacting or grinding of procs The test lab 1s equipped wth * 0 lab press for feasibly tests on small quanites of product Pharma compactor a granulation by campacting unit for pharmaceuticals and chemicals (throughput capacity yp to 50 kg/h) #2 granulation by compacting uri fhroughpur capacity up to 500 ka/b) idistiascale press throughput capacty up to 9 1/h) * industial scale press throughput copacty up to T.5i/h) {ris aso equipped wth a whole range of machines used inthe briqueting, compactongrarulation and grinding processes hye; mixes, granulaters ond screens The required testing devices are available fo quant the quality of he fished prodkcts Wih all hese equipments, all saps of briqueting, granulation by compacting, or grinding procasses can be reprechica, Production plant The continuous production plant in Raismes is maintained for the production of batches of briqueties or granules {up 10 a few hundred tonnes) for tasing of indusral processas or for potent The plant is ako available for telfprodvcton. Engineering and design department The design of the plants and keyequipment (press, mer, casher, granulo, ..] 1s computer assisted and the process contol and automatic conta (PD) ae ao provided by tis department. The software used {with bridging with other Z sofware) permits the exchange of compuier fies (cravings and data sheos} Workshop Equipped with specific machinory for the manufacture of presses and ancillary equipment, the workshop meets the reliability and quali standards of production and provides «fil autonomy to SAHUFCONREUR.Services provided by SAHUT-CONREUR # Test runs and feasibility studies af the pilot plant * Custommadle production of beiches at the production plant. © Rental of complete units for compaction-granulation of chemicals or pharmaceutical proolucts for testing or for small site procluctions © Rental of industrial scale presses and crushers/granulators for industrial site testing) @ Basic and detail engineering of briquetting and compaction-granulation units @ Design and manufacture of the keyequipment of thase units (press, mixer, crusher, granulator,...). # Technical assistance for mounting and commissioning of the units © Training of operators. # Supply of spare parts * Modernization of existing plants and equipment. # Adaptation of SAHUPCONRELR technology fo equipment manufactured by other makers. SAHUT-CONREUR 700, rue Corbeau - 59590 RAISMES - B.P. 49 - FRANCE Tél, 33.(0]3.27.46.90.44 - Fax 33.(0}3.27.29.97.65 - Email : sahutconreur@wanodoo fr hitp:// www. sahutconreur.com