Granulation is the process of binding particles together to form larger granules. There are two main types: dry granulation which uses no liquid, and wet granulation which uses a liquid binding solution. Wet granulation methods include fluidized bed granulation where granulation and drying occur together, tumbling granulation using drums or pans where particles are set in motion by tumbling forces, and mixer-granulators which use high shear mixing to form agglomerates. Key steps in wet granulation are wetting, nucleation and binder distribution, consolidation and growth, and attrition and breakage. Granule size and properties depend on the specific granulation equipment used.

1. Granulation
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Presented by:
Syed Waqas Haider
Process Engineer

2. Definition
 Granulation is the process of collecting
particles together by creating bonds
between them. Bonds are formed by
compression or by using a binding agent
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3. Types of Granulation
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 Dry Granulation
without using a liquid solution
 Wet Granulation
addition of a liquid solution (with or without
binder)

4. Dry Granulation
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 Primary powder particles are aggregated under
high pressure
Roller
Compaction
• Powder is
squeezed between
two rollers to
produce sheet of
material
Slugging
• Large tablets
produce in heavy
duty tablet press
Dry
granulation

5. Wet Granulation
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 This class of process includes Fluid beds,
tumbling drums & pans, and mixer-granulators
Mechanism
 Wetting, nucleation and binder distribution
 Consolidation and growth
 Attrition and breakage

6. Fluidized bed Granulation
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 Granulation and drying in the
same equipment
 Granulation is controlled by
moisture content of the bed
 Too high moisture content will
defluidize the bed and in too
low moisture, no
agglomeration will occur
 Granules obtained are more
porous than those obtained
from shear mixers

7. Fluidized bed Granulator
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Spray Arrangements

8. Tumbling Granulation
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 Particles are set in motion by the tumbling action
caused by the balance between gravity and
centrifugal forces
 Includes discs, drums, pans and a range of
similar equipment

9. Characteristics of tumbling
granulators
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 Product granule size in the range of 2 to 20mm
 Not suitable for producing very small granules
 Good for producing high density balls or pallets
 Capable of handling very large throughputs
 Extensively used in mineral processing and
fertilizer granulation

10. Disc Granulator
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 Rotating disc with a rim to
hold the tumbling granules
 Powder feed continuously
fed to the disc, typically at
the edge of the rotating
granulator bed
 Liquid binder is added
through a series of single
fluid nozzles distributed
across the face of the bed

11. Drum granulator
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 Typically used for high capacity applications and
usually requires some type of recycle depending on
the product specification
 Granulation where the only feed or the majority of the
feed is a liquid or melt such as urea granulation
 Feeds may be either pre-moistened by mixers to form
granule nuclei or liquid may be sprayed onto the
tumbling bed via nozzles or distributor pipe system
 Scrapers are often but not always used to limit build
up on the drum wall

12. Drum Granulator
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13. Mixer-Granulator
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 The High Shear Mixer-Granulator is a multi-purpose
processor equally suitable for high speed dispersion
of dry powders, and aqueous or solvent granulations
 Melt Granulation: Melt agglomeration is a process
by which agglomeration is obtained through the
addition of either a molten binder liquid or a solid
binder which melts during the process
 Agglomerates are formed by agitation of the mixture
 The mechanism of melt granulation is similar to that
of wet granulation

14. Mixer-Granulator
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15. Double shaft paddle Mixer-Granulator
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 Dual counter-rotating shafts run the length of the device
 The paddles move material from the bottom of the trough,
up the middle, and back down the sides creating a
kneading and folding effect that intimately mixes the
material
 Typical Use: Mixing, conditioning, or agglomerating

16. 4/20/2014
Granulators in different Industries

17. References
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 The Science and Engineering of granulation-
(books.google.com)
 Granulation - (books.google.com)
 http://www.slideshare.net/NAMDEOSHINDE15/gran
ulation-ppt
 http://www.fertilizermachine.org/rotary-drum-
granulator.html
 http://www.slideshare.net/svpv14/characterization-of-
granules
 http://feeco.com/2013/12/27/choosing-industrial-
mixer-pin-mixers-paddle-mixers/
 http://www.scribd.com/doc/113643719/PPT-Wet-
Granulation