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.
