PRESENTATION OF SPRAY GRANULATION

1. Spray Granulator By :- Sasi Keerthi.G (CH05B037) T.Kenneth Winfred (CH05B015) S.Ramachandran (CH05B025) Virendra Kumar (CH05B047)

3. In a more broader way , Granulation methods can be classified as follows : Granulation Process Methodology Wet processes Pan granulation Spray drying High shear granulation (wet massing) Fluid bed spray granulation Dry processes Slugging Roller compaction

5. What is Spray Granulation? Spray Granulation occurs when a liquid solution is rapidly dried over an active ingredient. This newly encapsulated particle structure is harder and denser, yielding particle properties that are desirable in many applications. The newly formed particle can be sprayed again and again creating larger and larger spherical pellets that form in successive onion like layers.

6. In the granulation process, the particles are conveyed through the inner partition into the expansion chamber by the hot fluidizing air. Gravity overcomes the force of the fluidized air and the particles fall back into the outer partition. The pneumatic atomizing nozzle in the bottom center of the chamber introduces the coating solution. This nozzle sprays upward providing successive applications of coating to the product.

13. Different types of granulators Spray Granulator The powder to be granulated is suspended in the heated air of a fluid bed, and a liquid binder sprayed from nozzles positioned above High-shear Granulator The high-shear granulation process combines the active powder with a binder solution using a high-speed mixing blade and chopper.

15. Fluid Bed Spray Granulator Nowadays, spray granulation wherever used is mostly done in a fluid bed. Fluid bed granules are very homogeneous. All particles in the powder mix are sprayed evenly with liquid starting materials. The type of granulate (size, density, porosity) can be influenced over a wide range by the adjustment of various parameters.

16. The particle formation in fluidized bed granulation is influenced by numerous parameters 1. Moisture content in solids 2. Liquid spray flow rate 3. Airflow rates 4. Atomization pressure

17. Batch fluid bed For Granulation in batch mode, the dry starting product is placed in the product container. Here it is mixed vigorously in the heated gas stream, held in suspension and agglomerated/granulated by spraying with a suitable bonding material. The product is then dried to the required end moisture content with high heat and material transition coefficients. Principle: Batch fluid bed granulation, Top Spray Principle: Batch fluid bed granulation, Bottom Spray

18. Continuous fluid bed Continuous granulators are sub-divided into several granulation zones, which are operated at different speeds and temperatures, e.g. Granulation in the first and second sections, drying in the third and cooling at the end of the process chamber. Principle: Principle: Continuous fluid bed granulation, Continuous fluid bed granulation, Top Spray Bottom Spray

19. Case Study I Port Kembla Steelworks Problem – A significant amount of material is stored in the plant’s stockpile areas at any given time. In the Raw Materials area, approximately 1.2million tonnes of iron ore and other material is stored in the primary and secondary yards. These stockpiles have the potential to create dust emissions as fine particles of material are blown from the stockpiles into the air and out into the community. Analysis – Dust emissions can be avoided if the particles that reside on the surface were somehow made heavy or large. This was achieved by granulation.

20. Solution - The granulation process can be achieved by installing sprayers that spray water thereby increasing the size of fine particles (dust). The installed water spray granulator system effectively suppresses dust emissions from the stockpiles under most weather conditions. The spray system includes regular dampening of stockpiles and spraying. Conclusion – The problem of dust emission was solved to a great extent by the installation of the sprayers in the stockpile area of Port Kembla Steelworks

21. Bibliography http://www.glatt.com http://www.malvern.co.uk/ProcessEng/processes/granulation http://www.pro-c-ept.com http://www.google.com Thank you