The document discusses the pelletizing process which involves conditioning materials through mixing, forming pellets using a disc pelletizer or drum, and drying the pellets using a rotary or fluidized bed dryer. Pelletizing is used in various industries to process materials like dust, chemicals, limestone, coal, and minerals. Choosing the right binder and equipment is important for efficient pellet production.

1. Pelletizing Process
Experts in process design and material
processing for over 60 years.
A Look at the

2. Pelletizing is a non-pressure (tumble growth)
agglomeration method used throughout a
variety of industries to process all sorts of
materials.

3. Common pelletizing applications:

4. Common pelletizing applications:
• EAF Dust

5. Common pelletizing applications:
• EAF Dust
• Chemical Powders

6. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone

7. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone
• Gypsum

8. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone
• Gypsum
• Coal

9. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone
• Gypsum
• Coal
• Fly Ash

10. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone
• Gypsum
• Coal
• Fly Ash
• Minerals and Ores

11. Common pelletizing applications:
• EAF Dust
• Chemical Powders
• Limestone
• Gypsum
• Coal
• Fly Ash
• Minerals and Ores
• And more….

12. Pelletizing produces uniform, round pellets
through the use of either a disc pelletizer, or
agglomeration drum. Disc pelletizers are a
more common choice for the pelletizing
process, with agglomeration drums being
reserved for more specific applications
requiring a robust, high capacity solution.

13. What follows gives an overview of the disc
pelletizing process.

14. What follows gives an overview of the disc
pelletizing process.
In an application using an agglomeration
drum, the process would be similar, with only
the replacement of the disc with the drum.

15. Pre-Conditioning

16. Material fines are first conditioned in a pin or
paddle mixer. Not all processes utilize a
conditioning step, but in many cases, those
that do see many benefits from it, including
reduced binder costs, increased production,
and an improved product.

17. FEECO Pin Mixer

18. Conditioning a material helps to prepare
it for optimal pellet formation, and
ultimately creates a more refined
product.

19. Pelletization

20. Once material has been conditioned, it can be
fed to the disc pelletizer.

21. Once material has been conditioned, it can be
fed to the disc pelletizer.
For processes that do not utilize a conditioning
step, this is where the process begins.

22. Material fines and binder are fed onto
the rotating disc at a continuous rate. The
material fines become tacky through the
addition of the binder, allowing them to
pick up more fines as they tumble on the
disc, similar to rolling a snowball.

23. FEECO Disc Pelletizer

24. Once pellets have reached the desired
size, they exit the disc pelletizer, and are
most commonly carried via a conveyor
belt into a dryer to bring the pellets down
to the desired moisture level.

25. Drying

26. Drying essentially “cures” the pellets into their
final, hardened form, allowing them to be
durable enough to withstand further
handling, but still capable of breaking down
as needed.

27. Drying essentially “cures” the pellets into their
final, hardened form, allowing them to be
durable enough to withstand further
handling, but still capable of breaking down
as needed.
The drying step can be carried out using
either a fluid bed dryer, or a rotary dryer, with
rotary dryers being the more robust choice.

28. In a rotary dryer, pellets tumble through the
drum, with flights picking up the material
and showering it through a stream of hot air
or combustion gas.
This efficiently dries and hardens the pellets
into their final form.

29. FEECO Rotary Dryer
Dried pellets then typically go through a screening
process, where on-size pellets are separated out to
move on to packaging or transport, under-size
pellets are put back into the process as recycle,
and over-size pellets are broken down to be put
back into the process as recycle.

30. It is also sometimes desirable to cool pellets
prior to bagging or storage. In this case, a
rotary cooler is often used, offering the
same advantages as a rotary dryer. Again,
fluid bed coolers are also an option.

31. Simplified Pelletizing Diagram
1. Paddle/Pin Mixer
2. Disc Pelletizer
3. Liquid Spray System
4. Transfer Conveyor
5. Rotary Dryer
6. Vibrating Screen
7. Oversize Mill
8. Surge Hopper

32. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:

33. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation

34. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation
• Binder feed rate

35. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation
• Binder feed rate
• Material feed rate

36. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation
• Binder feed rate
• Material feed rate
• Material feed location

37. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation
• Binder feed rate
• Material feed rate
• Material feed location
• Pan speed

38. The process of pelletizing fines on a disc
pelletizer has been likened to a form of
art. Many variables affect the success of
the end product, and can be adjusted to
fine-tune end product characteristics:
• Binder formulation
• Binder feed rate
• Material feed rate
• Material feed location
• Pan speed
• Pan angle

39. Gypsum fines are fed into the pin mixer, with
the addition of a binder.
Pelletizing results in a durable pellet that can
withstand handling, but still break down
quickly under standard field conditions.

40. While there are many things to consider in a
pelletizing operation, two of the most
important factors are:

41. While there are many things to consider in a
pelletizing operation, two of the most
important factors are:
- Binder

42. While there are many things to consider in a
pelletizing operation, two of the most
important factors are:
- Binder
- Equipment

43. Binder

44. A binder aids in pellet formation and also
helps to achieve the desired end product
crush strength.

45. A binder aids in pellet formation and also
helps to achieve the desired end product
crush strength.
Consulting an agglomeration expert can
help in deciding which binder will best suit
your needs.

46. Equipment

47. Choosing quality equipment will go a long
way in providing for an efficient, long-lasting
operation that produces an optimum
product.

48. Choosing quality equipment will go a long
way in providing for an efficient, long-lasting
operation that produces an optimum
product.
Instead of a one-size-fits-all approach,
equipment should be designed around the
material’s unique characteristics for best
results.

49. Choosing quality equipment will not only
aid in process efficiency, but will also
typically require less maintenance and
down time, and will often result in
prolonged equipment life.

50. has been a leader in the agglomeration industry
since the 1950s, helping customers solve material
problems through process & product
development, feasibility testing, and high-quality,
custom agglomeration equipment.
FEECO

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