CHAPTER THREE

Agglomeration (Size enlargement)

 1. Agglomeration
 Size enlargement operations are used in the
materials processing industry with different aims,
such as:
 Improving handling and flow
 Reducing losses
 Producing specific shapes
 Boosting appearance and so on
 2. Why size enlargement?
 There are many reasons why to increase the
mean size of a product;
 There are many problems in the handling
of fine particles.
 To reduce dust hazard (explosion hazard
or health hazard)
 Increases bulk density for storage.
CONT….
 In many industries the raw materials are in the
form of powders;
 E.g in ceramics industry pressed particles
made of barium titanate and manganese-
zinc, nickel-zinc and barium ferrites are
initially fine powders.
 To provide a defined metered quantity of active
ingredient (e.g. pharmaceutical drug
formulations)
 To reduce the losses.
 3. Agglomeration Methods
 Agglomeration methods can be classified
into two groups:
 Tumble/growth agglomeration and
 Pressure agglomeration.
3.1. Tumbling agglomeration
 The mechanism of tumble/growth agglomeration
is;
 The overall growth process is complex
and involves both disintegration of
weaker bonds and
 Re-agglomeration by abrasion transfer
and coalescence of larger units.
 Coalescence occurs at the contact point when

impact a binding mechanism develops which is

stronger than the separating forces.
 CONT…
 For particles below 10μm approximately, the
natural attraction forces, such as;
 Molecular
 Magnetic and
 Electrostatic
 The above force become significantly larger than

the separation forces due to particle mass and

external influences.
 In tumbling agglomeration where no external

forces are applied.

 In such a way natural agglomeration occurs.
 CONT…
 Theparticles to be agglomerated the particle-
to-particle adhesion addition of binders, such
as water or other more viscous liquids,
depending on;
 The properties of particles being
agglomerated and
 The required strength of the
agglomerate structure.
 CONT…
 Kinetics of tumble/growth agglomeration: (a) nucleation, (b)
random coalescence (c) abrasion transfer and (d) crushing
and layering.
 CONT…
 The equipment needed for tumbling
agglomeration can be provided by;
 Inclined discs
 Rotating drums
 Powder mixer and
 Fluidized beds
 CONT…
 Thetumble/growth agglomeration post-treatment
can be through;
 Drying and heating
 Cooling
 Screening
 Adjustment of product characteristics by
crushing
 Rescreening
 Recirculation of undersize material
 CONT…
 The equipment used for tumble/growth
agglomeration are;
CONT…
3.2 Pressure agglomeration
(Compaction)
 In pressure agglomeration pressure forces act on a
confined mass of particulate solids, which is then
shaped and densified.
 Pressure agglomeration can be performed;
 Employing a low-pressure
 A medium-pressure or
 A high-pressure mode.
CONT…
 When utilizing low or medium-pressure
agglomeration;
 Relatively uniform agglomerates obtained.
 The porosity of the feed material is
changed but no change in particle size or
shape occurs.
 The agglomeration yield relatively
uniform agglomerates of elongated
spaghetti like or cylindrical shape.
 CONT…
 High-pressure agglomeration is characterized by;
 A large degree of densification.
 The products strength is high.
 To increase strength small amounts of
binders are used.
 Post-treatment methods are required.
 Produces pillow or almond like shapes.
 CONT…
 Pressure agglomeration can be carried out in
different types of equipment. Generally;
 A low and medium pressure agglomeration is
achieved in extruders including;
 The screen extruder
 The screw extruder and
 The intermeshing gears extruder.
 CONT…
 (a.1) screen extruder, (a.2) basket extruder, (a.3) cylindrical
die screw extruder (b.1) flat-die extruder (b.2) cylindrical
die extruder (b.3) intermeshing-gears extruder.
CONT…
A high-pressure agglomeration is performed in
presses such as;
 The punch and die press
 The compacting roller press and
 The briquetting roller press.
 CONT…
 Equipment used for high-pressure agglomeration:
(a) compacting roller press (b) briquetting roller press
 4. Applications
 In metallurgical processes, sintering is used for
obtaining agglomerates of different metallic minerals
such as aluminum, copper, iron, gold, and silver.
 Pertaining nonmetals, diverse products such as salt,

cement, asbestos, and ceramics are agglomerated.

 In the chemical industry, detergents, fertilizers,

oxides, sulfites, and other products are sort of

agglomerate or compact form.
 The pharmaceutical industry produces many and

diverse products as pellets, tablets, capsules, granules

and so on.
 CONT…
 Specific shapes of different by extrusion in
industries as grain processing and the polymers.
 In the food industry compacted in different shapes

and extrude.
 In the food industry, tumbling agglomeration is

used in the food processing to improve re-

constitutability of products flours, cocoa powder,
instant coffee, dried milk, sugar, sweeteners, fruit
beverages powders, instant soups and diverse
spices.
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