Intro to Micro-Pelletizing

Micro-pelletizing is a method of tumble growth agglomeration used to produce small agglomerates. This presentation goes over the basics of micro-pelletizing, including common applications, how it works, and the equipment used.

1. Micro-Pelletizing Experts in process design and material processing for over 60 years. Intro to

2. Micro-pelletizing is the process of agglomerating material fines into tiny pellets, or “micro-pellets.” This method is different from traditional pelletizing, in that it produces smaller pellets, around 20-60 mesh.

3. Micro-pelletizing can be carried out in either a pin mixer (sometimes referred to as conditioning), or a pin mixer/disc pelletizer setup. When only small pellets, or material conditioning is necessary, a pin mixer alone can provide sufficient results.  

4. Why Micro-Pelletize? Micro-pelletizing is used to process fine materials, allowing for easier handling and transportation, as well as improved end use.

5. Benefits of Micro-Pelletizing

6. Dust Reduction/Elimination The opportunity to significantly reduce or even eliminate dust is one of the most common reasons why someone might choose to micro-pelletize their material. Reducing dust is beneficial for many reasons:

7. It prevents material from becoming windblown, which is a common concern for materials that are to be landfilled, such as fly ash .

8. It creates a cleaner, safer processing environment: f ugitive dust can be harmful to workers, and can also clog up equipment, causing process upsets and damage.

9. It creates a cleaner, safer processing environment: f ugitive dust can be harmful to workers, and can also clog up equipment, causing process upsets and damage. Coal fines are particularly dangerous, because they are combustible when sufficiently aerated. For this reason, coal fines are commonly processed via micro-pelletizing.

10. Dust also results in the loss of raw material/product. The ability to prevent material or product lost as dust offers significant value.

11. Improved Handling and Transport A micro-pelletized material is significantly more easy to handle and transport without the loss of material than a dusty material.

12. Improved Application and Use Micro-pelletizing also offers the opportunity to improve product performance and application in a variety of ways :

13. Improved Application and Use Micro-pelletizing also offers the opportunity to improve product performance and application in a variety of ways:   More accurate application: micro -pellets move through spreading equipment much more easily.

14. More predictable results : micro -pellets won’t blow away like a dusty material would.

15. More predictable results : micro -pellets won’t blow away like a dusty material would. Faster product breakdown : smaller pellets break down faster than larger ones .

16. Reduced visibility – micro-pellets sink between grass blades, so they are not easily visible, an ideal characteristic for professional applications such as golf courses and lawns.

17. Micro-Pelletizing Applications

18. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include :

19. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs

20. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black

21. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black Coal Dust

22. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black Coal Dust Fly Ash

23. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black Coal Dust Fly Ash Specialty Powders

24. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black Coal Dust Fly Ash Specialty Powders Filter Media

25. As a process that can benefit nearly any material that comes in powder form, micro-pelletizing can be found in many industries. Some of the most common applications include : Pigments & Dyestuffs Carbon Black Coal Dust Fly Ash Specialty Powders Filter Media Catalysts

26. The Process

27. Pin mixers are the industry standard when it comes to micro-pelletizing. These industrial mixers are an ideal solution for mixing solid and liquid feed, as well as for agglomerating ultra-fine materials into small agglomerates. Pin mixers use a high-speed spinning action to densify and agglomerate material fines.  

28. FEECO Pin Mixer

29. While the pin mixer can be used in combination with a disc pelletizing unit, it is often used as a stand-alone agglomeration device to reliably produce micro-pellets in a continuous process setting.  

30. While the pin mixer can be used in combination with a disc pelletizing unit, it is often used as a stand-alone agglomeration device to reliably produce micro-pellets in a continuous process setting. A typical micro-pelletizing operation looks like this…  

31. Raw feed material and binder are fed at a continuous, specified rate into the pin mixer . The materials are thoroughly mixed , and begin to agglomerate, forming micro-pellets as the mixture moves down the length of the pin mixer . Pellets are discharged from the pin mixer.

32. At this point, the material could be fed onto a disc pelletizer to further grow and/or round the pellets.

33. FEECO Disc Pelletizer

34. FEECO Rotary Dryer If a disc pelletizer is not being used, micro-pellets are then typically carried from the pin mixer discharge via conveyor, to a rotary dryer. A rotary dryer reduces the moisture content of the pellets down to the required level.

35. Here, pellets tumble through the rotating drum, as flights pick up the pellets and drop them through the stream of combustion gas in order to maximize efficiency . Fluid bed dryers are an alternate choice for drying .

36. Here, pellets tumble through the rotating drum, as flights pick up the pellets and drop them through the stream of combustion gas in order to maximize efficiency . Fluid bed dryers are an alternate choice for drying .   Once dried, pellets are taken via conveyor to their next processing stop (screening), or to storage or bagging.

37.   Some processes utilize a cooling step prior to bagging or storage, in order to prevent caking issues during storage.  

38. Conclusion Micro-pelletizing offers a valuable solution to making powdered materials more easy to handle, transport, apply, and use.  

39. Conclusion Micro-pelletizing offers a valuable solution to making powdered materials more easy to handle, transport, apply, and use. Furthermore , when only rough agglomeration is desired, micro-pelletizing in a pin mixer alone offers a cost-effective alternative to a full-scale disc pelletizing or drum setup.  

40. 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

41. Want to learn more? Download our Agglomeration Handbook Agglomeration Handbook Intro to Agglomeration Processing Techniques Considerations in Agglomeration And more… Download Now