Abstract: A method of wet granulation of fertilizer and other materials into granules. The method involves formation of the granule directly on the pan from the feedstock without intermediate steps or the use of seed materials. The result is a product having a completely uniform cross section. The feedstock is initially in the size distribution of -150 mesh with 90% or greater in the size range of 200 mesh. Moisture is maintained to facilitate a steady process without cycling. The method has the advantage of allowing granulation of materials either known to be hazardous or inherently difficult to granulate in a safe and expedient manner.

Abstract: An apparatus and method for uniform granulation is disclosed. The method involves the use of an initial feedstock having particle size of -150 mesh and 90% or greater particle size of 200 mesh. The feedstock may be contacted in a pan granulator which includes a minor amount of nucleating material of about -35 mesh. Binder is introduced into the pan granulator to progressively layer the feedstock material onto the nucleating to form a final product having a size distribution -8 mesh to +4 mesh. The method is designed to be interruptible and is particularly useful for forming granules having a plurality of layers of differing material. The method has marked improvement over the prior art methods since a particularly fine granule can be formed in a relatively expedient process to result in a granule having high commercial value and high break strength. These factors are achievable in addition to 100% product usage with no waste.

Abstract: Mechanically strong, water-disintegrable agglomerates for use as a soil conditioner produced from dust particles emitted from kilns during the manufacture of cement and a process for forming such agglomerates are disclosed. The process comprises combining cement kiln dust and a water-soluble binder to produce agglomerates which are then subjected to controlled drying such that the dried agglomerates having a size ranging from -7 to +8 Tyler Standard Sieve Series exhibit an average green crush strength of at least about 2 pounds (about 0.9 kg).

Abstract: A process for producing granules from a liquid composition which includes the steps of applying the liquid composition onto solid particles of the same composition circulating in the granulation zone of a granulator, thereby causing particles to grow, discharging a stream of grown particles from the granulation zone, cooling this stream in a cooler, and dividing the stream exiting the cooler, in a size-sorting apparatus, into three streams of grown particles based on size. The stream of desired-sized particles is withdrawn for future use or processing, the stream of undersized particles is returned to the granulation zone and the stream of oversized particles is sent to a size-reducing apparatus for crushing, with the resulting crushed particles recycled back to the cooler located downstream of the granulator and upstream of the size-sorting apparatus.

Abstract: A method of making a vegetation-friendly ice melting composition with sub-zero ice melting characteristics is described. The method of making the composition includes mixing from about 60-90 parts by weight non-fully hydrated ice melter, which is preferably calcium chloride with from about 10-40 parts by weight of fertilizer, which is preferably urea. The most preferred composition is about 70 parts by weight of calcium chloride and about 30 parts by weight urea. The calcium chloride and urea are preferably admixed first to coat the calcium chloride. To this mixture is added a measured amount of powdered non-fully hydrated calcium chloride as a solid coatant. The non-fully hydrated calcium chloride by hydration forms a coating around the ice melt base. The resultant mixture is discharged from the mixer, screened and packaged.

Abstract: This composition consists of a coated composition of solid ice melting agents, abrasives and absorbents. The coated composition employs a coating of calcium chloride.The method of making the composition, also part of the invention, includes placing a solid ice melting agent such as urea, potassium chloride, sodium chloride and abrasives such as sand, gravel, cinders, and absorbents (i.e. calcined diatomaceous earth) into a mechanical stirring device; and spraying a measured amount of adhering solution on to the medium. This adhering solution may be made up, but not limited to, plain water, solutions of organic or inorganic solids with ice melting properties, etc. To this mixture is added a measured amount of powdered non-fully hydrated calcium chloride as a solid coatant. The non-fully hydrated calcium chloride by hydration forms a coating around the ice melt base. The resultant mixture is discharged from the mixer, screened and packaged.

Abstract: This composition consists of a coated composition of solid ice melting agents, abrasives and absorbents. The coated composition employs a coating of calcium chloride.The method of making the composition, also part of the invention, includes placing a solid ice melting agent such as urea, potassium chloride, sodium chloride and abrasives such as sand, gravel, cinders, and absorbents (i.e. calcined diatomaceous earth) into a mechanical stirring device; and spraying a measured amount of adhering solution on to the medium. This adhering solution may be made up, but not limited to, plain water, solutions of organic or inorganic solids with ice melting properties, etc. To this mixture is added a measured amount of powdered non-fully hydrated calcium chloride as a solid coatant. The non-fully hydrated calcium chloride by hydration forms a coating around the ice melt base. The resultant mixture is discharged from the mixer, screened and packaged.

Abstract: Glass microfibers having diameters of less than one micron are useful in engineered plastics to achieve very smooth surfaces and thermal stability in composite parts. As made, glass microfibers are very bulky and intertwined making it impossible to meter and feed the material using conventional equipment. The processes used for chopping and milling coarser glass fibers to prepare them for engineered plastic composites are unsatisfactory for glass microfibers for various reasons. It has been discovered that flowable glass microfiber agglomerate products can be made by processing the microfiber in a muller mill or in a self impact mill.

Abstract: The specification describes a process for pelletising particles of an alkali metal ferrite with an aqueous binder such as a black liquor derived from pulping wood chips. The particles are ground and fed to a microgranulator in measured quantities together with measured quantities of aqueous binder. The particles are ground such that they have an even size distribution about a mean in the range from 25 to 50 microns. The particles are mixed with the binder in the microgranulator to form microgranules which are fed to a pelletising pan. The temperature of the microgranules on the pelletising pan is controlled by cooling either or both the alkali metal ferrite or aqueous binder prior to measuring them into the microgranulator. A pan temperature of less than 70.degree. C. is disclosed.

Abstract: Industrial materials can be efficiently pan granulated by grinding the material to 95% minus 150 mesh, feeding this to a pan in conjunction with 1 to 15% seed materials and applying binder solution such that the free moisture content of the green ball is between 8-13% by weight of the feedstock. The granules build up on the seed to a desired size range, say -5 to +8 mesh, in an onion skin manner. Product is sent preferably to a fluid bed dryer for drying. The productivity and classification is very high with yields up to 95% for two mesh size ranges, such as -5 to +8 mesh.

Abstract: A method for preparing granulated alkaline earth metal carbonate, especially barium carbonate and strontium carbonate, by adding a binding agent and optionally water, and granulating the carbonate material by the action of mechanical forces or by accretional granulation in, for example, a flash reactor, with simultaneous drying, and thereafter optionally subjecting the granules to a high-temperature treatment, in which method the material to be granulated and the granulated material do not come in contact with inorganic refractory material either during the granulation or during any subsequent high-temperature treatment.

Abstract: Ammonium carbamate, in solution with urea, water and ammonia and under high temperature and pressure is cooled to below its crystallization temperature while being subjected to an elevated pressure. The crystallized substance formed is then dried, crushed, and pelletized with the aid of a binding agent to produce pellets having substantial strength and stability, and having particular utility as a deicer for roadways.

Abstract: Whiskers having a diameter of 0.1-10 .mu.m and a length of 5-200 .mu.m are pelletized and granulated into agglomerates which have a size of 0.1-10 mm and a bulk density of 0.2-1.0 kg/liter.To pelletize, powders of whiskers are moistened with water while mixing to form primary aggregates. Then, the powders and the primary aggregates are subjected to a rolling movement to cause the primary aggregates to grow into secondary aggregates having desired size distribution. Finally, the secondary aggregates are dried to obtain pelletized or granulated agglomerates of whiskers.Handling of whiskers is facilitated because the agglomerates are less bulky and less likely to fly up in the air. When blended into molding materials for fiber reinforcement, however, the agglomerates are readily disintegrated back into separated individual fibers to provide homogeneous dispersion.

Abstract: A method of forming a deicer composition. The deicer composition comprises of a mixture of halide salts of alkali and alkaline earth metals which are then pan agglomerated to form a low bulk density easily dissolvable but free flowing agglomerate composition.

Abstract: Whiskers having a diameter of 0.1-10 .mu.m and a length of 5-200 .mu.m are pelletized and granulated into agglomerates which have a size of 0.1-10 mm and a bulk density of 0.2-1.0 kg/liter.To pelletize, powders of whiskers are moistened with water while mixing to form primary aggregates. Then, the powders and the primary aggregates are subjected to a rolling movement to cause the primary aggregates to grow into secondary aggregates having desired size distribution. Finally, the secondary aggregates are dried to obtain pelletized or granulated agglomerates of whiskers.Handling of whiskers is facilitated because the agglomerates are less bulky and less likely to fly up in the air. When blended into molding materials for fiber reinforcement, however, the agglomerates are readily disintegrated back into separated individual fibers to provide homogeneous dispersion.

Abstract: A process for producing spherical pellets from stack gas desulfurization residue filter cake. The process includes mixing dry fly ash with a filter cake in a mixer and discharging the blend onto a shallow pan disc pelletizer where pellets are produced. Additional fly ash produces pellets in a reroll ring. Instead of fly ash, cement kiln dust, portland cement, lime kiln dust or lime is utilized.

Abstract: A process for producing spherical pellets from wet coal silt or also known as filter cake. The process involves mixing dry ash with the filter cake in a mixer. The blend thereof is discharged into a shallow pan disc pelletizer to produce pellets which are then coated in a reroll ring surrounding the disc pelletizer with more fly ash.

Abstract: A pelletized ferrous sulfate monohydrate (FeSO.sub.4 .multidot.H.sub.2 O) product and method for the manufacture thereof. Hard, spherical ferrous sulfate monohydrate pellets are manufactured by combining ferrous sulfate monohydrate powder with an aqueous solution of ammonium sulfate (NH.sub.4).sub.2 SO.sub.4 having a preferred concentration of about 1-40% by weight ammonium sulfate. Mixture of these components occurs in a conventional pelletizing apparatus (e.g. a disc pelletizer) which produces individual pellets from the components. The pellets are then heated in order to remove excess water therefrom. The foregoing process enables durable pellets to be made without substantial hydration of the ferrous sulfate monohydrate. The pellets are spherical, have a size of about -6+20 U.S. standard mesh, and have not less than about 25% by weight soluble Fe.

Abstract: A process for the production of silica-bound zeolite granulates is disclosed, wherein zeolite to be formed into a granulate is mixed with silica sol. The process is carried out by adding aqueous alkali metal silicate to the silica sol immediately before the silica sol is mixed with the solid zeolite to be granulated. By the described process, granulates of various grain sizes can be obtained, and the resultant granulates can have a narrow grain size distribution.

Abstract: The invention is a process for manufacturing an iodophor filler for a lavatory cleaning cake. The process involves mixing in a dry-mixer means or "Turbulizer" a dry filler composition. The dry filler composition contains an adsorbent and the dry-mixer means provides a uniform turbulent flow of the dry filler composition as the composition passes through the dry-mixer means. The method then involves wetting the dry filler composition with a liquid iodophor while the composition is in the uniform turbulent flow. Agglomerating of the wetted filler composition then occurs within a controlled residence time of the wetted filler composition in the dry-mixer means whereby the iodophor is substantially, uniformly distributed throughout the dry filler composition. The dry filler composition, desirably, includes both a dry adsorbent and a dry absorbent. This invention includes the product of the process.

Abstract: A method for forming strong and durable pellets from dust collected from stack gases. The dust includes CaSO.sub.3, CaSO.sub.4 and unreacted CaD. A portion of water required for total hydration with the dust is blended in a mixer. The moistened powder is stored in a conditioning container wherein the moistened powder is chemically reacted and heated to form a hydroxide with the oxides in the powder. Water is added to the hydrates and the wetted hydrates are subjected to an intense second mixing. The wetted hydrates are then pelletized in a pelletizer.

Abstract: An apparatus including an evaporator, a pre-crystallizer, a spray dryer and a fluid bed for drying whey and a rotating disc having a cone-shaped upper surface is provided for receiving partially dried whey from the spray dryer and delivering the whey to the fluid bed while permitting crystallization of the whey as it rests on the surface of the disc.

Abstract: An improved process for economically and effectively granulating solid, finely-divided, particulate feedstock comprising phosphogypsum, limestone, or mixtures comprising sulfogypsum, natural or mineral gypsum, or mixtures thereof and limestone and having from about 80 to 95 percent by weight of such sulfogypsum/mineral gypsum to effect products which exhibit excellent physical and chemical properties relative to dustiness, storage, handling, and perhaps most importantly, aqueous media-induced rapidity of reversion to a mesh-size distribution of particles substantially similar to the initial size distribution of said feedstock, which improved process involves introducing such relatively finely-divided feedstock, together with material comprising recycle thereof into a suitable agglomeration device, such as a rotary drum, and therein effecting agglomeration/granulation of such feedstock in the presence of aqueous media, the improvement comprising the utilization, in combination with said aqueous media, of relat

Abstract: Magnesia pellets are formed from finely-divided, highly reactive, lightburned magnesia (MgO) particles by granulating such powders in conventional equipment using either an organic liquid or an organic liquid-binder mixture. The organic liquid may be an alcohol or a ketone the alkyl groups of which, independently, can have from 1 to 4 carbon atoms. Magnesium chloride and water are among disclosed binders which may be used in combination with said organic liquid. The organic liquid should be more than about 80% of any admixtures with water.

Abstract: A free-flowing granulate of a powder-form or fine-grained component and a liquid component; the granulate containing at least 20% by weight of the liquid component, is prepared by moving the powder-form or fine-grained component in a mixer-granulator, adding the liquid component while mixing until a moist granulate having a particle size of at most 1.5 mm is obtained, subsequently coarsening the granulate thus obtained with an increase in temperature to a particle size of from 0.4 to 4 mm and optionally coating this coarse granulate with another powder-form and/or fine-grained component at 60.degree. to 90.degree. C. The optionally coated granulate is converted by lowering the treatment temperature into a dry-looking, free-flowing, coarse-grained product, which if desired, may be coated with another powder-form and/or fine-grained material. Despite the high percentage of a liquid component, the granulate thus obtained appears as a dry granulate and is free-flowing.

Abstract: In a process for making ferrous sulphate in granule form, ferrous sulphate heptahydrate is mixed with fine-grain brown coal or lignite having a low water content, in such an amount that the resulting mixture is pourable.

Abstract: A method of producing agglomerates from a fine iron ore or the like having a wide particle size distribution. A solid fuel is added to the fine ore and the material is formed into pellets or briquettes of a two-layer structure comprising a core portion and a shell portion having different solid fuel contents, and the pellets or briquettes are charged onto a grate of a travelling grate-type furnace including an updraft drying zone, a downdraft drying zone, an ignition zone and a suction burning zone in such a manner that the charge having a higher solid fuel content forms a grate upper layer portion and the charge having a lower solid fuel content forms a grate lower layer portion, thereby firing the pellets or briquettes by the furnace.

Abstract: Ammonium sulfate in dissolved form is dried in a gas current to obtain the ammonium sulfate in finely divided form. Thereafter the ammonium sulfate is quickly placed into a pelletizing device, subjected to a fine water spray, pelletized to substantially uniform grain size, and dried if necessary and/or desired.

Abstract: A detector for thermoluminescence dosimetry (TELDE.TM.) based on an ionic compound is shaped as a pellet. The pellet is composed of a plurality of single-crystal particles bonded together by molecular forces. A method for manufacturing such a detector is carried out by melting a powdered ionic compound in vacuum and then slowly cooling it whereby a pellet is formed.

Abstract: Synthetic absorbent granules of calcium sulfate dihydrate are manufactured by a process which utilizes a commercial type of dry powdered gypsum plaster or calcium sulfate hemihydrate, mixes the plaster with water in an inclined rotating disc machine to cause hydration to occur, and wherein the plaster is formed and grown into balls or granules of a generally predetermined size and discharged from the disc when reaching such size. The ball forming operation is started in the disc with seed material in the form of balls of a size corresponding generally to the balls to be manufactured by the process. Water spray is applied to the seed material in the rotating disc and a uniform pattern of movement of such material with a well defined eye is developed. When this occurs, generally the water is turned off.

Abstract: A method and apparatus are provided for controlling the amount of dry particulate matter and liquid added to a rotary pelletizer. A transducer placed within the pelletizer senses a characteristic of the mixed material in the pelletizer. This characteristic may be, for example, the level of the batch or the size of the pellets. The transducer signal is then conditioned to provide a signal level corresponding to a desired characteristic level and which varies about that level corresponding for example to the variations of pellet size about a desired size. That signal is added to a second signal representing the actual liquid flow into the pelletizer or added to a second signal representing actual dry particulate flow into the pelletizer and modulates that respective flow to maintain the input of either the dry or the liquid material into the pelletizer as necessary. Additionally, a set point signal can be provided as a constant signal representing desired dry particulate in flow or liquid in flow.

Abstract: A process for the manufacture of a free flowing granular dishwasher detergent having enhanced chlorine stability over extended periods of shelf life is disclosed. The process comprises mixing in a ventilated vessel, a dry mixture of sodium tripolyphosphate and chlorinated trisodium phosphate. The ratio of the volume of the dry mixture and the volume of the vessel is between about 1:25 and 1:8. An aqueous solution of silicate is sprayed onto the dry mixture to form an agglomerate during hydration of the sodium tripolyphosphate. The formed agglomerate is sprayed with a nonionic surfactant. The treated agglomerate is coated with a silicate. The coated agglomerate is mixed in the vessel while being discharged from the vessel. The silicate coated agglomerate inhibits chlorine loss from the dishwasher detergent over extended periods.

Abstract: A strategically located series of spaced apart classifiers set at varying depths within a pelletizer pan operated to classify the forming pellets and also impart controlled energy into the forming pellets producing pellets of improved quality. Controlled classifying of the forming pellets stabilizes pellet output. With a stabilized pellet output obtained the need for driving the pellet pan with a variable speed device can be eliminated since pan rotation can be maintained at a constant speed.

Abstract: The invention provides an improved pan granulation process for the production of low-water or substantially anhydrous nitrogenous compounds. Hot nitrogenous melt and cooled particulate solids are fed to a rotating pan to form a cresent-shaped bed of rolling or tumbling particles, the thickness or depth of the bed increasing in the direction towards the periphery of the pan and its overflow sector, i.e. position 2 o'clock to position 6 o'clock when the pan surface is regarded as a clock face and the rotation of the pan is counter-clockwise. The cooled solid particles are fed to the pan at a point where the depth of existing material is small, desirably substantially zero, preferably in position 7 to 8 o'clock, if need be by feeding the particles through a tube or the like which extends into the tumbling material on the pan to the proximity of the surface of the pan itself. Subsequently, the cooled particles will then be covered by and with warmer particles tumbling over them.

Abstract: A process for granulating finely divided particulate sulfate or chloride salts of potassium to produce therefrom agricultural products having exceptionally satisfactory physical and chemical properties in regard to bulk blending with other fertilizer blend materials and also in regard to storage and handling properties. The instant methods involve introducing fine-sized, particulate feedstock together with recycle material into a conventional granulator and granulating the solids with use of a water solution comprised of the potassium salt to be granulated and portions of lignosulfonate, which solution has been found to bind the solids material together in a manner and form highly desirable. Drying of the resulting granulation material is required. Nominal grades of the sulfate and chloride granular products are about 47 and 57 percent by weight K.sub.2 O equivalent, respectively.