Briquetting with binders

Many binders have been proposed and used to produce hard coal briquettes. A review of binders published in 1969 by Waters3 is shown in Appendix 1. The properties required of a binder are:

(a) Produces a strong briquette.

(b) Produces a waterproof briquette.

(c) Does not detract from the quality of the coal.

(d) Does not interfere with the use of the coal.

(e) Is environmentally acceptable.

(f) Is economically viable.

The binders enjoying most success in the production of hard coal briquettes have been:

Pitch

Bitumen

Lignosulphonates

Molasses

Starch

Pitch is highly carcinogenic and has largely been replaced by Bitumen.

Lignosulphonate, although at one time extensively used, is being replaced by Molasses as a result of environmental concern.

Molasses is modified for use as a binder by the addition of either lime or Phosphoric Acid.

Starch, Molasses and Lignosulphonates must be treated at 200 to 300 degrees centigrade to develop the required strength and weather resistance.

All of the binders are expensive and are difficult to justify economically for use in South Africa.

Newly developed resin binders are showing promise. These are cold curing binders, often supplied in two parts, which when mixed together set chemically to form a strong weatherproof briquette. Anthracite briquettes are being made in this manner in the U.K. and sold under the name of Thermac. The cold curing binder is supplied by Du Pont and is a by-product from their nylon plant at Wilton, Middlesborough.

Almost all binders used commercially require that the total moisture of the feed is reduced to in the order of 10% in order to produce an acceptable briquette.

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History of roller press

The first successful roller press was designed in Belgium by Louiseau in response for the need for a small briquette that could be transported over long distances. Roller presses are machines that achieve compaction of particulate matter by squeezing the material between two counter rotating rollers. Pockets formed in the working faces of the rollers form egg or pillow shaped briquettes that weigh in the order of 45 g each. Presses with capacities from 25 to 100 ton per hour can be constructed. Little has changed in the basic design of the presses, major improvements being in the way in which the pressure is applied to the rolls, the materials of construction to improve life and the ease of changing rolls and general maintenance.

Roller presses can also be used with fluted rolls to produce sheets of material that can then be broken up and screened to give a granular product. The granular material would be suitable for mixing with power station feedstock and would solve the handling and moisture problems associated with fine coal.

Briquettes can be produced with the aid of binders or by the use of pressure only either at low temperature or at a temperature where the coal is in the plastic state. The introduction of the Clean Air Act in the U.K. in 1956 saw an increase in high temperature briquetting to produce smokeless fuels from bituminous coals. The advent of cheap North Sea natural gas saw the closure of these processes. Cheap gas and oil has caused a reduction of coal briquette production in most countries although development of briquetting technique has continued as a result of the need to agglomerate many other materials. Improvement in plant throughput has been achieved in a variety of industries by agglomerating the raw feed to the process. Notable uses have been in glass production, iron smelting, zinc refining and the fertilizer industry.

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Why do you need briquetting machine?

What’s the application of briquetting machine in industry?

1.  Control dust pollution

2.  Reduce volume for less storage space

3.  Add density for materials that go back to the metallurgy furnace secondly.

4.  Recovery the materials that are seen as waste

5.  Obtain products of uniform size and weight

6.  Improve the flowability of the powders, thus preventing problems of feeding, dosage or package.

Engaged in this area for many years, we are provider for briquetting solution.

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Wearing parts of briquetting machine - the roller

Working under high pressure, abrasive environment, the roller of briquetting machine is the most wearing part. The service life is of great importance to the economic profit.

The material of roller is an important factor. What we use is two kinds of alloy steel, 65Mn and 9Cr2Mo (for special purpose, stainless steel is also available). Generally, roller of 65Mn could serve about 6-10 months, while roller of 9Cr2Mo could serve about 12-15 months. Of course, service life also depends on the working hours and the materials you feed into the machine.

Even of the same alloy steel, rollers processed by different thermal treatment show different performance. Our roller would undergo several processes in sequence, annealing to reinforce the tenacity for further machining, quenching to improve the hardness after machining, aging treatment of 6-12 months to eliminate the internal stress. For some extremely abrasive materials, carburization of the roller surface is necessary. The thickness of 2-3mm would extend the service life a lot.

What can you conclude now? Obviously, we are an engaged, serious manufacturer of briquetting machine, briquetting press, roller press. If you need briquetting production line or briquetting plant, come to us for the professional solution.

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How to choose suitable binder?

How to choose suitable binder?

Briquetting machine is applicable for various powders in waste & by-product, mineral & ore, chemical industry, such as mill scale, steelwork sludge, iron concentrate, sponge iron, magnetite, chrome ore fines, ferrosilicon powder, coal powder, caustic soda, quicklime or burnt lime, etc.

For most occasions, binder is used. Also, there are many different types of binder, which could be categorized into four groups based on mechanism:

1.   Van-der-waals force

2.   Mechanical linkage

3.   Forging

4.   Plasticization under pressure

Facing so many binders, which one is suitable for your material? Engaged in briquetting, HJ Machinery could give you the best professional advice. Both the type of binder and percentage are important.

Wrong type of binder wouldn’t give you satisfied result. And inappropriate percentage has bad influence on the strength.

Too less binder results in briquetting failure, too much binder brings more impurity which reduces the strength.

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Binder or not?

Binder works as additives to hold the particles together during briquetting process. With binder coated evenly on the surface, powder could adhere to each other. Many different units come as one strong briquette. So, binder helps a lot for the briquetting machine to achieve the best performance. For wet powder briquetting, the moisture content is controlled around 12-15%. Sometimes, drying process is recommended to reduce moisture. After then, briquette strength comes to its highest level.

However, for some materials, binder is not allowed. Why? Some process has strict control on the impurity. It is binder, meanwhile, also impurity. What should we do for such occasion? Dry powder briquetting machine could solve this problem. Featured with high pressure, hydraulic system of dry powder briquetting machine compresses powder heavily. Van Der Waals force between molecules keep them together, rather than binder adhesion.

These two processes are of different mechanism.

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Screw feeder of briquetting machine helps a lot for some materials that need high pressure

Screw feeder of briquette machine helps a lot for some materials that need high pressure

Screw feeder equipped on the briquette machine is not necessary for every material.

For some bulk materials such as quick lime, no additive is allowed. It is difficult to make quick lime into briquettes. So, additional pressure is required. This is where screw feeder shows its function.

While counter-rotating rollers are horizontal, screw feeder is vertical. With auger pushes material into the gap between rollers, screw feeder presses burnt lime heavily.

Thus, solid briquettes are formed.

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The application of FGD gypsum briquettes

The application of FGD gypsum briquettes

In coal-fired power plant, flue gas which contains sulfur oxides is air pollutant resulting in acid rain. People handle this problem by burnt lime powder. Thus, FGD gypsum is formed which could be used as retarder in cement industry. This is an innovation for the waste recycling.

Gypsum briquette machine is necessary for the utilization. Different from other materials, in the gypsum briquetting, no additive is needed.

Core part of gypsum briquetting plant is the two counter-rotating rollers. When materials come down to the gap between rollers, pressure grows heavier and heavier. Solid gypsum briquettes are formed.

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The application of sponge iron briquette machine in steel industry

The application of sponge iron briquette machine in steel industry

DRI (sponge iron) is made from high grade iron ore in a low temperature environment by reduction reaction. Stable composition, little impurity, low carbon content, sponge iron is mainly used as raw material in electric furnace for steel making. Also, it could be used as coolant in converter or metallurgy powder after twice reduction.

In recently year, steel and iron products are treading towards smaller in size, upgrading in function, so non-metallic materials and non-ferrous metal content increases. This results in the decreasing quality of waste steel. As waste steel comes from different materials, chemical composition varies greatly and is hard to control. This brings difficulty for electric furnace steel making. If certain ratio sponge iron is  mixed (30%-50%) with waste steel as diluent, it will not only increase the uniformity of steel, but also improve the physical property. So, DRI is not just substitute of waste steel, also raw materials for making high quality steel.

As a test on 3TPH electric furnace shows, if sponge iron is mixed, per ton of furnace burden saves electricity 27%, time 28%, oxygen consumption 22%, physical property improves significantly. This increases capacity of electric furnace and reduces energy consumption and cost.

However, sponge iron need to be fed into furnace in briquettes, in either ball shape or cylinder shape. Sponge iron briquette machine is what we supply. If you are interested, please visit my homepage on Linkedin.

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What’s the advantages of hydraulic briquette press over mechanical briquette press?

What’s the advantages of hydraulic briquette press over mechanical briquette press?

hydraulic briquette machine

1.  Usually, hydraulic briquette press is equipped with screw feeder that ensures raw material comes into roller constantly and uniformly. It is driven by electromagnetic speed-adjustable motor, belt pulley and worm reducer. Due to the constant torque of electromagnetic speed-adjustable motor, when the quantity of material that is fed into matches with the quality that machine need, briquettes quality is stable.

2.  When the material is overfed, piston rod of hydraulic cylinder is overloaded. Hydraulic pump will stop at such a situation, overflow valve is opened to get oil back, energy accumulator has a buffer action on the pressure. The displacement of piston rod widens the space between the rollers. Hydraulic pressure system return to normal.

3.  Driving system includes motor, triangle belt, reducer, counter-rotating gear, roller. The machine is powered by electromagnetic motor. By the transmission of belt pulley, gear reducer, coupler, power is transmitted to the driving roller. Counter-rotating gear ensures the synchronized operation of driving and driven rollers. Hydraulic protection device pumps high pressure oil into cylinder, piston makes displacement on the shaft direction. The front end of piston rod is connected with shaft bearing to meet the pressure requirement.

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What factors have impact on the capacity of roller briquette press?

What factors have impact on the capacity of roller briquette press?

Capacity of a machine is an important economic factor. When roller briquette press is processing a certain material, the capacity varies. 

What will influence the capacity?

1.  Specific gravity of the material

2.  Property of material

3.  Diameter and width of the roller

4.  Rotation speed of the roller

5.  Pockets on the surface of tires.

Do you have any idea? Let’s discuss.

For more info, please visit roller press.

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