Enlargement Processes

Spray drying – particle size is largely determined by the size of the droplet of liquid or suspension, which
may be controlled by a suitably designed spray nozzle. The aggregates of dried material are held
together as a result of the deposition of small amounts of solute on the surface of the particles.

Prilling - relatively coarse droplets are introduced into the top of a tall, narrow tower and allowed to fall
against an upward flow of air. This results in somewhat larger particles than those formed in spray
dryers.

Fluidised bed – the bed of solids is supported and mixed by fluidization gas, generally with
simultaneously drying. An atomised liquid or suspension is sprayed on to a bed of hot fluidised particles
and layers of solid build up to give enlarged particles the size of which is largely dependent on their
residence time, that is the time over which successive layers of solids are deposited.

Sprout bed – These are used, particularly with large particles. In this case, the rapid circulation within
the bed gives rise to a high level of inter-particle impacts.

Drum agglomerators – common in metallurgical and fertilizer industries and are primarily used for every
large throughput application. Particles are ‘tumbled’ in an open cylinder with roughened walls and
subjected to a combination of gravitational and centrifugal forces. In order to aid agglomeration, liquid
may be sprayed on to the surface of the bed or introduced through distribution pipes under the bed.

Pan agglomerators – In the pan agglomerator, a classifying action may be achieved which results in the
fines having a preferentially longer retention time. Larger, denser and stronger agglomerates are
produced as compared with those from the drum agglomerator.

Pug mills – impart a complex kneading action that is a combination of ribbing and shearing and mixing.

Extruder - High degrees of compaction are achieved, leading to the production of pellets with low
porosity with the result that less binder is required.

Elevated temperatures - with many materials, agglomeration may be achieved by heating as a result of
which softening occurs in the surface layers. For the formation of porous metal sheets and discs, high
temperatures are required.

Pressure compaction – If a material is subjected to very high compaction forces, it may be formed into
sheets, briquettes or tablets. In the tableting machines used for producing pills of pharmaceuticals, the
powder is compressed into dies, either with or without the addition of a binder.