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Specialist article
29.09.2023  |  1581x
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Wet agglomeration as alternative to spray agglomeration

In certain cases wet agglomeration combined with fluidised bed drying offers an energy-efficient alternative to spray and fluidised bed processes.
In particle agglomeration, spray and fluidised bed processes are common, but in certain cases wet agglomeration combined with fluidised bed drying offers an energy-efficient alternative. Water evaporation, an energy-intensive process, plays a central role in many process technologies. Therefore, it is essential to optimise the energy consumption in drying processes.

Among other things, the production of granulates such as detergents, instant powders, animal feed or building materials is often done by spray drying or fluidised bed processes. These processes are versatile, allowing mixing, drying, granulation, coating and agglomeration of particles to produce high-quality products. However, they are energy-intensive as large amounts of water have to be evaporated, which requires high amounts of heat.

inprotec operates plants for these processes and offers an alternative to spray agglomeration: the wet agglomerator. This features several advantages, including the ability to process viscous and sticky products, continuous operation without set-up times and a flexible inner wall that allows difficult materials to be processed.

The choice between spray dryers/ fluid bed processes and wet agglomeration depends on the product composition and desired properties. Powder agglomeration is a key step in combining fine powders into larger particles. Wet agglomeration achieves a better energy balance due to lower water requirements, lower drying temperatures and reduced air flows. It can be particularly suitable for temperature-sensitive products and consumes about a third less energy than spray dryers.

The choice between processes depends on product formulation and manufacturing requirements. Spray granulation is advantageous for liquid raw materials or ideal multi-component mix ratios, while wet agglomeration is worth considering for multi-component systems with high solids content or viscous liquid components.

In summary, customising processes and considering alternatives such as wet agglomeration is crucial to efficiently meet the challenges in particle agglomeration. As a contract manufacturer, inprotec offers the expertise to develop the best and most energy-efficient solution together with customers.

Summary:

  • Wet agglomeration as an energy-efficient alternative
  • Spray and fluidised bed dryers are versatile
  • Wet agglomerator suitable for temperature-sensitive products and multi-component systems.

Company information

inprotec GmbH
inprotec GmbH
inprotec was found in 1999 at the headquarters in Heitersheim. Today, the company engages around 260 employees at two sites (Heitersheim and Genthin) in Germany. The total capacity is over 150,000tons per year (8 production lines thereof 7 fluidized bed spray granulators and 1 classical spray drier). The customized granules and powders are developed and toll manufactured by using the fluidized-spray granulation technology and classical spray drying technology. The technologies are the basis for a multiplicity of process in the field of drying and particle forming like spray granulation, spray drying, spray chilling, spray agglomeration, fluid-bed drying, coating and matrix encapsulation. During this there is a combined treatment of solid components (powders, granules and bulk goods) and/ or liquids (aqueous solution, suspension, emulsions and melts) in one and more component system. As a competent and trustful partner with long experience in different industry sectors, we offer a full integrated tolling service from development in lab scale (0.1kg – 5kg) through scale-up trials in pilot scale (0.02tons - 5tons) to industrial production (20tons – 10,000 tons per campaign). The main industry sectors are washing and detergent industry, animal feed additives, building additives, cosmetic additives and specialities. The main industry sectors are washing and detergent industry, animal feed additives, building additives, cosmetic additives and specialties.
Last update: 22.11.2023

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