Drying / Cooling
These are the most frequent applications of large fluid bed systems. Different process systems are applied depending upon product, volatiles, operational safety and environmental requirements.
Open system
Featuring atmospheric air in a once-through system where water is to be removed. Normally a push-pull system is used to balance the pressure to be slightly negative in the free board of the fluid bed. Depending upon the product and available heat source, direct or indirect heating may be applied. The exhaust air is cleaned by e.g. bag filter, cyclone with or without wet scrubber.
In cases where products pose a dust explosion risk, open cycle systems feature pressure shock resistant components or alternatively semi-closed cycle, self-inertizing layouts can be considered.
Closed cycle system
Featuring drying in an inert gas atmosphere (usually nitrogen) recycling within the system. It must be used for drying feedstocks containing organic volatiles or where the product must not contact oxygen during drying.Closed cycle systems are gastight, and addition of inert gas is controlled by monitoring the oxygen content of the drying gas and the system pressure, which is kept positive. The evaporated volatiles are recovered in a condenser.
Agglomeration / Granulation
Fluid bed processing requires that the solids are in particulate form prior to entering the fluid bed. In the special case of fluid bed spray granulation, particles are built up in the fluid bed by spraying a liquid into the fluidized layer particles. Particulate solids ideal for fluid bed processing may be formed in an independent process step such as crystallization, coagulation, or polymerization, followed by mechanical dewatering. Particles may also be formed by spray drying. In other cases dry or wet solid particles may have to undergo a degree of agglomeration or granulation prior to entering the fluid bed.
Rewet agglomeration system
In the rewet agglomeration system, a fine powder is conveyed to an agglomeration chamber where the powder is dispersed in air and contacted with a spray of liquid. Moist, porous agglomerates are formed and subsequently dried under lenient fluidization conditions in a Vibro-Fluidizer®. After cooling, the powder is discharged, classified, and fines recycled for further agglomeration together with fines from the exhaust air dust collector. Rewet agglomeration systems are typically used for food products like coffee, cocoa-sugar, where instant properties and coarse particles are required.
| Survey of agglomeration and granulation processes using fluid bed technology | ||
| Feed material | Particle formation | Drying |
| Fine, dry powder | Rewet agglomeration | Fluid Bed Drying |
| Friable wet cake | Milling | |
| Liquid | Fluid bed spray granulation | |
Batch Fluid Bed Systems
Batch fluid bed processing allows several process steps (mixing, agglomerating, drying and cooling) to be carried out in a single unit. The batch process assures uniformity of all product within a batch and allows every unit of final product to be traced to a given batch run.
Batch
Niro supply a full range of customized batch fluid bed systems for food ingredients, chemical and pharmaceutical applications. Systems are available in various sizes, from laboratory and pilot-scale to large production units. Our batch fluid bed technology is developed by our sister-company Aeromatic-Fielder (located in Switzerland and UK) and it:
enables control bulk density
improves dispersibility
reduces dust
provides timed release of active ingredients
enables tablet compression
Processors known as:
Agglomeration
Coating
Drying
Granulation
All fluid bed systems can be pre-assembled in modules or skids to provide rapid on-site start-up.
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