Struggling with the handling of fine dust or waste powder?
As global awareness of a sustainable society grows, environmental regulations are becoming more stringent.
The proper treatment and recycling of such materials generated during manufacturing processes have become urgent challenges across industries.
Solution Proposals / Processing Example for Improving Handling Properties and Resource Recovery through Granulation of Dust
The Eirich Intensive Mixer is a high-speed mixer and granulator capable of handling complex powder processing tasks such as mixing, granulation, kneading, and coating—all in one machine (one-pot process). It also has a proven track record in dust processing.
This report will focus specifically on examples of the granulation process.
Challenges and Advantages Expected from Granulation Process
| Challenges Addressed by Granulation | Advantages of Granulation |
|---|---|
| Poor working conditions caused by dust scattering and airborne particulates | Improved workplace safety by reducing dust scattering |
| Storage and transportation issues due to moisture absorption and agglomeration | Enhanced storage and transportation efficiency through better flowability |
| Leaching of harmful substances and associated environmental risks | Suppression of leaching through surface coating and additive use |
| Recovery of valuable materials | Promotion of valuable material recovery and reuse through proper downstream treatment |
| Difficulty in recycling and reusing materials in powder form | Promotion of resource recovery and reuse by improving handling properties |
| Increased disposal and processing costs | Lower disposal costs through volume reduction and reuse |
Our Technical Center also offers consultations on sample production using actual powders and assessments of process suitability and feasibility. Please feel free to contact us.
Powders Before Processing
In this case, Kanto Loam fired product powder is used as a sample for the granulation process.
In practice, fine dust powders present many physical challenges, such as dust scattering, poor flowability, and difficulties in storage and feeding.
Additionally, variations in raw material properties and moisture content fluctuations pose significant challenges, making the development of a stable process a technical challenge.
After processing (1-3mm granules)
Challenges: Preventing dust scattering, improving handling properties
We added a binder (water) to the test powder and produced 1–3 mm granules, suitable for feeding into subsequent processes and preventing scattering.
The intensive mixer stands out for enabling complex processes such as mixing and granulation with a single unit, while also allowing operating conditions to be easily adjusted via the touch panel.
After processing (3-6mm granules)
Challenges: Adjustment of particle size, improvement of handling properties, and enhancement of storability
We added additional binder to the granulated 1–3 mm particles and produced 3–6 mm granules with excellent handling and storage properties.
Operating conditions can be easily adjusted via the touch panel, allowing particle size and granule strength (or granule hardness) to be flexibly tailored for different applications.
You can try the performance of our equipment at our Technical Center using our test machines.
Reusing Steelmaking Dust Through Granulation Processing
Challenge: Reuse of by-products
With the Eirich mixing system, residues like dusts and sludges from sinter plants, blast furnaces, cast shops, BOF plants and electric arc furnaces are effectively prepared.
By using the Intensive Mixer, processes that previously required multiple steps can be carried out in a single operation.This not only reduces the amount of equipment required and the use of additives, but also contributes to resource recovery from waste and the efficient utilization of by-products.
Recommended Products
Eirich Intensive Mixer is a high-speed mixer and granulator designed for a wide range of processing tasks involving raw materials, mixtures, and compounds.Optimal material processing is achieved by selecting the appropriate mixing tool shape and rotation speed according to the application.
By adjusting the operating conditions, a single machine can handle multiple processes such as mixing, granulation, kneading, and slurry preparation.The mixer features a jacketed mixing pan for both cooling and heating, and offers a wide range of customizable options to accommodate various processes.
Advantages of the Eirich mixing principles
- Eccentrically positioned rotor tool (mixing tool)
The rotor tool shape, rotation direction, and speed range can be selected to suit the application. - Tool Set (scrapers)
It scrapes off raw materials adhering to the inner wall and bottom of the mixing pan, while simultaneously promoting efficient material transfer to the rotor tool. - Mixing Pan (mixing vessel)
Through rotation, all raw materials in the mixing pan are continuously supplied to the rotor tool.
Unique Mechanisms
- Short mixing time and high homogeneity
- Capable of processing raw materials with varying specific gravities
- The rotating mixing pan promotes material movement and reduces residue.
- By selecting the rotor tool shape and adjusting the mixing pan speed, the system can handle complex material processing
- Process integration enables compact and energy-efficient production systems
- Setting optimal operating parameters ensures consistent and reproducible material processing
Below is an overview of the equipment best suited for the process introduced above, along with the test machines currently available at our Technical Center.If you would like more information, please feel free to contact us via the inquiry form.
Eirich Intensive Mixer
| Type | Capacity (L) | Operation Data Log | Cooling Jacket Availability | Test Unit Availability |
|---|---|---|---|---|
| EL1 | 1 | 〇 | × | 〇 |
| EL5 Profi Plus | 5 | 〇 | 〇 | 〇 |
| EL10 Profi Plus | 10 | 〇 | 〇 | × |
| R05T | 40 | 〇 | Operation | 〇 |
| RV12W | 400 | 〇 | Operation | 〇 |
Click here for product details.
Test Unit Availability
here
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If you would like more information, please feel free to contact us via
the inquiry form
.
