An agglomeration tank is a specialized vessel used to blend fine powders with liquid binders to create uniform granules or slurries. Its performance depends on several critical components, each designed to support effective mixing, uniformity, and process control.
1. Tank Body / Vessel
Purpose: The primary containment where the agglomeration or wet granulation process occurs.
Construction Materials:
Stainless Steel (SS304/SS316): Corrosion-resistant and ideal for hygienic applications.
Mild Steel with Epoxy Coating: Cost-effective for less aggressive chemicals.
PTFE-lined tanks: Suitable for corrosive media in chemical formulations.
Design Options:
Cylindrical or Dished-End: Enhance material flow and reduce dead zones.
Conical Bottom Tanks: Improve discharge efficiency, especially for slurries.
2. Agitator or Mixing System
Purpose: Achieves homogenous mixing by uniformly dispersing binder into the powder matrix.
Mixer Types:
Anchor Mixers: Handle high-viscosity systems or thixotropic slurries.
Helical / Paddle Agitators: Great for medium-viscosity blends.
High-Shear Impellers: Ideal for rapid dispersion and powder wetting.
Drive System:
Gear or direct drive motors with variable speed controls to adapt to different formulations.
3. Binder Spray or Injection System
Purpose: Delivers liquid binder or additives into the mixing zone with precision.
Key Elements:
Spray Nozzles: Fine atomization ensures uniform binder distribution.
Flow Meters & Pumps: Maintain consistent binder flow rates.
Automation Control Units: Time and dose binder delivery based on batch needs.
Application Insight:
A uniform binder spray pattern minimizes clumping and promotes controlled granule growth.
4. Temperature Control Jacket
Purpose: Regulates tank temperature to meet formulation needs.
Common Systems:
Steam Heating for viscous slurries
Chilled Water Jackets for heat-sensitive ingredients
Hot Oil Circulation for high-temperature processes
5. Inlets and Outlets
Powder Inlet Hopper: For feeding solid ingredients.
Binder Inlet Port: For injecting liquid binders.
Discharge Port / Valve: Usually conical or bottom-mounted for smooth discharge of granules or slurry.
Manways and Access Ports: For maintenance, inspection, and cleaning.
6. Instrumentation and Control Systems
Sensors and Meters:
- Temperature sensors
- pH meters (for chemical compatibility)
- Load cells (for weight-based control)
- Flow meters (for binder dosing)
Control Panel:
Manual or PLC-based automation for managing agitator speed, binder injection, batch timing, and safety alarms.
7. Safety & Sealing Features
Sealed Lids / Covers: Prevent contamination and vapor escape.
Pressure Relief Valves: Important for closed systems.
Vent Ports or Fume Extractors: Especially critical when working with volatile compounds.
8. Internal Baffles
Purpose: Disrupt rotational flow, enhancing turbulence and mixing.
Use Case: Especially helpful in large-scale systems or those using viscous liquids.