Process

Agglomeration in Process Engineering

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In process engineering, agglomeration generally means enlarging particles. It is also called grain enlargement or granulation. It requires many contact points between the primary particles and adhesive forces at these points. In principle, all solids can be agglomerated if they are fine enough.

Easier storageLarger particles are easier to handle.
Less dustBetter flowability and mixability.
Stable emulsionsWhere clumping is a problem, homogenisation helps.

Agglomeration techniques

The process works with or without binders, with binders being more common. There are three main techniques:

Pelleting

Plastic waste, for example, is turned into granules with high bulk density. Friction plasticises them below the melting point.

Sintering

Fine-grained solids are heated below their melting temperature. The particles bond at their contact points by diffusion, see sintering.

Flocculation

Solid particles in liquids join to form larger particles. This makes filtration easier.

Wanted or unwanted?

Unwanted in emulsions

Emulsions need droplets that are as small as possible. Flocculation of the droplets is a precursor to coalescence and phase separation. Therefore, homogenisation reduces the particle size and ensures a stable emulsion.

Wanted for powders and suspensions

Granulated instant powders such as milk, coffee or cocoa powder create less dust and dissolve faster. In pharmacy, granulation improves the flowability and tabletability of powder blends. In water treatment, targeted flocculation makes solids easier to separate.

What matters in agglomeration

  • The solids must come into contact and be able to bond
  • After that, no forces should act on the agglomerates so that they do not break apart
  • In emulsions, on the other hand, suitable shear prevents the droplets from clumping

Other processes

AgitationMixingDispersionSolid-liquid mixingHomogenisationEmulsificationSuspensionAerationDeaeration
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Frequently Asked Questions about agglomeration

What does agglomeration mean?

Agglomeration is the enlargement of particles by clustering, also called grain enlargement or granulation. It requires many contact points and adhesive forces between the primary particles.

Which agglomeration techniques exist?

For example pelleting, flocculation and sintering – with or without binders, binders being predominant.

When is agglomeration desirable?

For example to improve flowability, storability and miscibility, reduce dust, make instant powders (e.g. milk or cocoa powder) dissolve better, granulate powders for tableting or separate solids from suspensions by flocculation.

Why is agglomeration undesirable in emulsions?

It is a precursor to phase separation. Homogenization reduces particle size and stabilizes the emulsion.