Station Three of our virtual Showcase introduces an ideal piece of equipment used for pelletizing powder materials – the disc pelletizer, also known as pan granulator or pan pelletizer. We demonstrated a small-scale version for our Showcase, replicating the same techniques used in larger machines. With the North American fertilizer market valued at US$60B, the growth potential for this technology can be easily envisioned.
Fine grinding increases the surface area of mineral fertilizers, which in turn increases their bioavailability. However, spreading fine powders on agricultural fields results in windborne material loss (and often, unhappy neighbours!) By turning the powders into granules or pellets, a disc pelletizer transforms regenerative fertilizers into products that are easier to package, handle and broadcast.
The pelleting process is aided by gravity. Material is rotated on a slanted disc, and its incline can be adjusted for processing materials at different speeds. When the disc rotates around the central axis and a liquid binder is applied, the balled material rolls down the bottom of the disc, and the micronized powder coalesces onto the wet surface creating a prill. As this disc continues to rotate, the prills grow as more powder agglomerates on them. When the particles reach their desired size, they are ejected from the disc via centrifugal force.
The disc pelletizer allows for the mixing of powders to form pelletized prills for the fertilizer industry. This machine permits the monitoring and adjusting of particle sizes which is essential in the constantly evolving demands of the market.
Almost any combination of fine powders can be used with liquid binding agents, aided by the specialized blending technology shown in Station Two. This broadens our production possibilities as multiple ingredient blends can be formulated to exact customer specifications. Not only are disc pelletizers important in fertilizer production, but they are also used in concrete and metallurgical applications.
As announced through our Investor Update July 5, this summer Progressive Planet will take delivery of a large-scale pelletizer with a 5-meter disc. Once in place, this pelletizer will produce up to 14 tonnes per hour of finished product, and our output will be ramped up to commercial levels.