Agglomeration tanks are crucial components in industries such as fertilizers, food processing, chemicals, agrochemicals, and pharmaceuticals, where fine powders need to be converted into granules or slurry with improved flow, solubility, or reactivity. Fabricating an agglomeration tank requires close attention to process behavior, material compatibility, hygiene, and mechanical integrity.
Below are the essential guidelines to follow when fabricating a high-performance agglomeration tank.
1. Define Product Requirements and Process Conditions
Before fabrication, clearly define:
Material behavior: Is it abrasive, corrosive, heat-sensitive, or hygroscopic?
Target granule specs: Size, uniformity, binder ratio
Operation mode: Batch or continuous flow?
Understanding these factors ensures correct decisions around tank design, dimensions, and agitation strategy.
2. Select the Right Material of Construction (MOC)
Base material choices on chemical exposure and industry hygiene standards:
SS304 / SS316L: Ideal for food-grade or pharmaceutical applications
MS with epoxy/FRP lining: Suitable for neutral or basic chemical handling
Hastelloy, PTFE-lined, or glass-lined tanks: Required for highly corrosive environments
3. Design Efficient Agitation and Mixing Systems
Mixing quality directly impacts granulation outcomes. Optimize for:
Homogeneous blending of powders and liquids
Dead-zone prevention using baffles or custom geometry
Shear rate control via VFD-driven anchor, paddle, or helical agitators
4. Integrate an Accurate Binder Spray System
Ensure consistent binder distribution using:
High-precision nozzles for droplet control
Strategic nozzle placement (overhead or inline with agitation zone)
Automated binder dosing to improve repeatability and avoid over-saturation
5. Thermal Control (If Required)
Some agglomeration processes require temperature-sensitive environments:
Integrate jacketed walls or internal coils for heating or cooling
Choose steam, hot water, or glycol circulation based on your setup
Use temperature sensors for continuous monitoring
6. Maximize Hygiene and Cleaning Access
Especially important in food and pharma:
CIP/SIP-ready design for automated cleaning and sterilization
Flush-welded manways and spray balls
Avoid crevices and use sanitary fittings for bacteria-free operation
7. Include Smart Instrumentation and Controls
Enable process visibility and traceability with:
Level sensors, temperature and pH probes, and flow meters
PLC/SCADA integration for recipe control and alarms
HMI displays for real-time status and batch logging
8. Structural Design & Compliance
Choose the right geometry (conical bottom for discharge, cylindrical body for mixing)
Include baffles if needed to improve mixing turbulence
Comply with relevant industry codes: ASME, GMP, FDA, BIS, ATEX, or ISO
9. Safety and Operational Considerations
Install pressure release valves and emergency shutoffs for pressurized tanks
Use non-sparking materials in explosive or ATEX-rated zones
Ensure grounding and bonding for electrical safety in chemical environments