Annexure 1

Technical specifications of Integrated Extruder and Spheronizer

1. Introduction:
Integrated Extruder-Spheronizer unit that can be used for making beads of various materials like
alumina, silica-alumina, silica, zeolites and their composites is to be supplied. The unit should
be a lab scale unit designed to provide smooth and reliable operations and supplied in ready to
use condition. The unit should also have all necessary safety features and corrosion resistant
internals for operation in both alkali and acid media.

2. Vendor’s Scope:
The following will be covered in vendor’s scope
a) Supply of ready to use Integrated Extruder-Spheronizer unit along with all necessary
accessories, connections, fittings, extruder dies, chequered plates etc required for smooth
operation of the unit
b) Installation and commissioning
c) Demonstration and training on the operation

3. Technical specification of Integrated Extruder-Spheronizer unit

The Integrated Extruder and Spheronizer should meet the following specifications:
1 Application The unit intends to be used for preparing beads of materials like alumina,
alumina silica, zeolites and their composites in different sizes. For this
purpose, the unit should be capable of extruding the powdered materials
in the form of extruders of appropriate size, followed by bead formation
using spheronizer to obtain spherical beads of appropriate size. The units
should have all necessary features to vary the extrusion and
spheronization conditions to obtain beads of appropriate size and desired
mechanical properties.
2 Capacity The unit should be a Laboratory scale design with features to operate the
extruder and spheronizer with throughput in the range 300-600g/h and
should be capable of working at a batch size of 150 - 350g.
3 Design Good manufacturing practice (GMP) designed Bench top Integrated unit,
with features for operating extruder and spheronizer independently.
4 Material of The equipment contact parts should be of SS 316 while the non-contact
construction parts should be alkali and acid resistant.
5 Feed The unit should be provided with a suitable hopper to introduce the
Section material manually along with adequate safety features like transparent or
SS sheet to cover the hopper for extruder and the drum of spheronizer.
 The section should be acid and alkali resistant and should be easy to
clean.
6 Screw Type Extruder should be single screw extruder with suitability to extrude
alumina, alumina silica, zeolites and their composites. It should be non-
corrosive in nature and should be designed to allow mixing of the
material to be extruded in the barrel and to continuously generate enough
pressure in the barrel for extrusion.
7 Extruder The extruder chamber should be jacketed and should be acid and alkali
chamber resistant and easy to clean.
8 Drive The drive unit for both extruder and spheronizer should be designed to
system operate for speed of 20 – 100 RPM and should provide optimal speed
consistency over the range of operating conditions. The motor should be
suitable for trouble free operations with adequate safety features like
adjustable over current limit switch. The motor should be of min 1HP.
9 Gear The system should be equipped with appropriate gearboxes and bearings
Assembly in order to provide variable screw rpm of suitable range for achieving the
desired throughputs. In extruder, the gear assembly should be able to
generate sufficient torque as required for smooth extrusion. The design
should have low noise operation.
9 Extruder The extruder should be provided with cone shaped dies or screens for
Die producing extrudates having diameters 0.6 mm, 0.8 mm, 1.0 mm, 1.2
mm, 1.5 mm & 2.0 mm. It should have features for quick disassembling,
cleaning and fitting of different screens/dies.
10 Spheronizer The size of the drum should be capable to meet desired capacities and
drum provided with chequered plates with vertical shaft having RPM of 200 -
1500. The drum should be fitted with chequered plate of sizes 1.0 mm,
2.0 mm, 3.2 mm & 6.5 mm, for varying size of the beads. The drum
should be acid and alkali resistant and should be easy to clean. The radial
clearance between the plate and the drum should be kept minimal to
reduce the powder leakage.
11 Chiller unit Suitable chiller unit is to be provided for maintaining the desired
temperature from 10C to 20C in the extruder chamber. Necessary
fixtures should be provided for connecting chiller with the jacketed
chamber. The chiller unit should have temperature stability of ±2C with
microprocessor control systems, digital display and features for setting
temperature. The MOC of the chiller should be SS 304 and refrigerant
piping should be made of Copper and provided with SS valves. The
condenser should be air cooled. The compressor should be suitable for
low noise operation.
12 Control Enclosed in a SS cabin having microprocessor controlled control panel
panel having on-off button, speed regulator, RPM indicator, emergency
shutdown
13 Safety All electrical components of the unit should be protected with IP 55
 Components enclosure
14 The vendor should give warranty for the instrument for minimum 12
Warranty
months after the installation.
Operating User / operational / service manual along with circuit and wiring
15 and Service diagram, layouts etc. should be provided with the instrument in hard
manuals copy.

4. Other terms and conditions

The offers of the parties in addition should also meet the following requirements:

 Two sets of operation and service manuals should be provided along with the system
along with required tool kit.
 Party should give detailed specification of their design of the equipment and mention the
features of the equipment for meeting the requirements along with necessary drawings.
Relevant technical literature for various components and system should be enclosed with
the offer.
 The make and technical specifications of various individual components employed for
fabricating the system should be given in detail.
 Party has to provide the unit in a ready to use condition complete with all the necessary
components.
 Party to provide all consumable required for the smooth operation of the unit for at least
one year
 Party to agree to provide all the spares of the unit for its smooth operation subsequent to
commissioning at site.
 Party to provide the user’s list and their contact addresses of users of the similar units in
India/abroad
 Pre-installation requirement should be indicated in advance and the party should also
mention the scope of installation and commissioning of the system at the user’s
laboratory.
 The unit will be treated as accepted only after installation, commissioning and
demonstration of the performance as per specification with consistent results.
 Compliance Sheet for Technical specifications of Integrated Extruder - Spheronizer

S.No Category Details Vendor Proposed

Model Compliance to
Technical Specification
1 Application The unit intends to be used for preparing beads of
materials like alumina, alumina silica, zeolites and
their composites in different sizes. For this
purpose, the unit should be capable of extruding
the powdered materials in the form of extruders of
appropriate size, followed by bead formation
using spheronizer to obtain spherical beads of
appropriate size. The units should have all
necessary features to vary the extrusion and
spheronization conditions to obtain beads of
appropriate size and desired mechanical
properties.
2 Capacity The unit should be a Laboratory scale design with
features to operate the extruder and spheronizer
with throughput in the range 300-600g/h and
should be capable of working at a batch size of
150 - 350g.
3 Design Good manufacturing practice (GMP) designed
Bench top Integrated unit, with features for
operating extruder and spheronizer independently.
4 Material of The equipment contact parts should be of SS 316
construction while the non-contact parts should be alkali and
acid resistant.
5 Feed Section The unit should be provided with a suitable
hopper to introduce the material manually along
with adequate safety features like transparent or
SS sheet to cover the hopper for extruder and the
drum of spheronizer. The section should be acid
and alkali resistant and should be easy to clean.
6 Screw Type Extruder should be single screw extruder with
suitability to extrude alumina, alumina silica,
zeolites and their composites. It should be non-
corrosive in nature and should be designed to
allow mixing of the material to be extruded in the
barrel and to continuously generate enough
pressure in the barrel for extrusion.
7 Extruder The extruder chamber should be jacketed and
chamber should be acid and alkali resistant and easy to
clean.
8 Drive system The drive unit for both extruder and spheronizer
should be designed to operate for speed of 20 –
100 RPM and should provide optimal speed
 consistency over the range of operating
conditions. The motor should be suitable for
trouble free operations with adequate safety
features like adjustable over current limit switch.
The motor should be of min 1HP.
9 Gear The system should be equipped with appropriate
Assembly gearboxes and bearings in order to provide
variable screw rpm of suitable range for achieving
the desired throughputs. In extruder, the gear
assembly should be able to generate sufficient
torque as required for smooth extrusion. The
design should have low noise operation.
9 Extruder Die The extruder should be provided with cone
shaped dies or screens for producing extrudates
having diameters 0.6 mm, 0.8 mm, 1.0 mm, 1.2
mm, 1.5 mm & 2.0 mm. It should have features
for quick disassembling, cleaning and fitting of
different screens/dies.
10 Spheronizer The size of the drum should be capable to meet
drum desired capacities and provided with chequered
plates with vertical shaft having RPM of 200 -
1500. The drum should be fitted with chequered
plate of sizes 1.0 mm, 2.0 mm, 3.2 mm & 6.5 mm,
for varying size of the beads. The drum should be
acid and alkali resistant and should be easy to
clean. The radial clearance between the plate and
the drum should be kept minimal to reduce the
powder leakage.
11 Chiller unit Suitable chiller unit is to be provided for
maintaining the desired temperature from 10C to
20C in the extruder chamber. Necessary fixtures
should be provided for connecting chiller with the
jacketed chamber. The chiller unit should have
temperature stability of ±2C with microprocessor
control systems, digital display and features for
setting temperature. The MOC of the chiller
should be SS 304 and refrigerant piping should be
made of Copper and provided with SS valves. The
condenser should be air cooled. The compressor
should be suitable for low noise operation.
12 Control panel Enclosed in a SS cabin having microprocessor
controlled control panel having on-off button,
speed regulator, RPM indicator, emergency
shutdown
13 Safety All electrical components of the unit should be
Components protected with IP 55 enclosure
14 Warranty The vendor should give warranty for the
 instrument for minimum 12 months after the
installation.
Operating User / operational / service manual along with
15 and Service circuit and wiring diagram, layouts etc. should be
manuals provided with the instrument in hard copy
 Two sets of operation and service manuals
should be provided along with the system
along with required tool kit.
 Party should give detailed specification of
their design of the equipment and mention the
features of the equipment for meeting the
requirements along with necessary drawings.
Relevant technical literature for various
components and system should be enclosed
with the offer.
 The make and technical specifications of
various individual components employed for
fabricating the system should be given in
detail.
 Party has to provide the unit in a ready to use
condition complete with all the necessary
Other terms components.
16 and  Party to provide all consumable required for
conditions the smooth operation of the unit for at least
one year
 Party to agree to provide all the spares of the
unit for its smooth operation subsequent to
commissioning at site.
 Party to provide the user’s list and their
contact addresses of users of the similar units
in India/abroad
 Pre-installation requirement should be
indicated in advance and the party should also
mention the scope of installation and
commissioning of the system at the user’s
laboratory.
 The unit will be treated as accepted only after
installation, commissioning and
demonstration of the performance as per
specification with consistent results.

17 Installation and commissioning

Demonstration and training on the operation
18

Seal & Sign