Drum granulation of NPK fertilizers

Nitrate-based NPK fertilizer was granulated in a bench scale drum granulation unit. The initial fertilizer possessed a particle size distribution similar to those in industrial granulation units. In this work, three factors are identified affecting the degree of fertilizer granulation, these are solution to solid phase ratio, the binder viscosity and the optimal rotation speed of the drum. Experimental results indicate that a critical solution to solid phase ratio is required for an increase in granulation in terms of mass median diameter. The saturated solution viscosity in this system was measured and correlated well to binder viscosity granulation theory with the critical Stokes number calculated at 700. The optimum rotation speed for flighted and unflighted drums correlated with the Froude number relationship for full scale granulation units. (C) 2000 Elsevier Science S.A. All rights reserved.

Effect of batch size on mechanical properties of granules in high shear granulation

The flow patterns in a high shear granulator depend on the fill volume. For example, DEM simulations reported by Terashita et al. [1] show that fill volume affects the velocities and kinetic energies of the particles. It also influences the granule size distribution [2]. Here the effects on the properties of the granule are described. The total mass of the granulate material was varied without changing the other variables such as impeller speed, granulation time and liquid to solid ratio. The resulting mechanical properties, such as strength, yield stress and Young's modulus, of the granules were measured. For the materials studied in the current work, increasing the fill factor (batch size) increased the values of these material parameters. This could be explained by the relative increase in the number and intensity of collisions between the particles, when the size of a batch was increased, leading to smaller porosities. (c) 2010 Elsevier B.V. All rights reserved.

The effect of the binder size and viscosity on agglomerate growth in fluidised hot melt granulation

Fluidised hot melt granulation (FHMG) is a novel granulation technique for processing pharmaceutical powders. Several process and formulation parameters have been shown to significantly influence granulation characteristics within FHMG. In this study we have investigated the effect of the binder properties (binder particle size and binder viscosity) on agglomerate growth mechanisms within FHMG. Low-melting point co-polymers of polyoxyethylene–polyoxypropylene (Lutrol® F68 Poloxamer 188 and Lutrol® F127 Poloxamer 407) were used as meltable binders for FHMG, while standard ballotini beads were used as model fillers for this process. Standard sieve analysis was used to determine the size distribution of granules whereas we utilised fluorescence microscopy to investigate the distribution of binder within granules. This provided further insight into the growth mechanisms during FHMG. Binder particle size and viscosity were found to affect the onset time of granulation. Agglomerate growth achieved equilibrium within short time-scales and was shown to proceed by two competing processes, breakage of formed granules and re-agglomeration of fractured granules. Breakage was affected by the initial material properties (binder size and viscosity). When using binder with a small particle size (<250 µm), agglomerate growth via a distribution mechanism dominated. Increasing the binder particle size shifted the granulation mechanism such that agglomerates were formed predominantly via immersion. A critical ratio between binder diameter and filler has been calculated and this value may be useful for predicting or controlling granulation growth processes.

Optimisation of high shear granulation of multicomponent fertiliser using response surface methodology

This work describes a novel method of producing multicomponent fertiliser granules using high shear granulation. The granulation process was optimised using the response surface methodology technique. The variables used in the optimisation process include granulation time, batch size, impeller speed and binder concentration. Granulation time, binder concentration and interaction between the batch size and granulation time were found to be the main factors affecting the granule median size. The product yield is mainly influenced by granulation time and binder concentration. The interaction between the impeller speed and batch size also have a significant influence on the product yield. Product yield (2-4 mm) of approximately 60% could be obtained with high sphericity and granule strength (> 0.5 MPa). A low product recycle ratio of about 2:3 can be obtained at the optimised process conditions, compared to typical recycle rations of 6:1 which are obtained in typical fertiliser plants. © 2012 Elsevier B.V. All rights reserved.

Alternative method for producing organic fertiliser from anaerobic digestion liquor and limestone powder:High Shear wet granulation

Generally, the solid and liquid fractions (digestate) from Anaerobic Digestion (AD) energy production are considered as waste. This has a negative impact on the sustainability of AD processes because of the financial outlay required to treat digestate before being discharged into municipal water treatment plants or natural water bodies. The main aim of this research was to investigate feasibility of producing an organic fertiliser using anaerobic digestate and limestone powders as the raw materials employing a high shear granulation process. Two-level factorial experimental design was used to determine the influence of granulation process variables on, the strength, resistance to attrition and yield of the granules. It was concluded from the study that it is technically feasible to produce organic fertiliser granules of acceptable strength and product yield. Increasing the liquid-to-solid ratio during granulation leads to increased granule strength and better product yield. Although the strength of the granules produced was lower than typical strength of commercial synthetic fertiliser granules (about 5 to 7. MPa), this could be improved by mixing the digestate with a polymeric binder or coating the particles post granulation. © 2012 Elsevier B.V.

The variability in nutrient composition of Anaerobic Digestate granules produced from high shear granulation

This study investigates the production of organic fertilizer using Anaerobic Digestate (as a nutrient source) and limestone powder as the raw materials. A two-level factorial experimental design was used to determine the influence of process variables on the nutrient homogeneity within the granules. Increasing the liquid-to-solid ratio during granulation resulted in increased granule nutrient homogeneity. Increasing the processing time and the impeller speed were also found to increase the nutrient homogeneity. In terms of nutrients release into deionized water, the granules effectively released both potassium and phosphate into solution. © 2012 Elsevier Ltd.