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Equipment List

Calcination and Sintering Equipment

New Emission Control System Ready for Operation

Responding to demand from various industries for processing materials that emit nitrogen oxide (NOx), Powder Processing and Technology (PPT) has added advanced emission control capability to support its growing client base. The Tri-Mer emissions control unit, based on catalytic ceramic filters, is state-of-the-art technology for processes that emit NOx. The unit has been fully commissioned and has demonstrated the ability to handle NOx emissions in the range of two to fifty pounds per hour with NOx destruction efficiency adjustable up to 95%. The Tri-Mer unit also captures particulate - PM10, PM2.5, and submicron PM - to over 99% efficiency. The system can be modified to handle SOx, HCl and VOC's and PPT will add those capabilities as clients' requirements dictate. Thermal processing equipment with emission control noted with "ECS".

      Indirect Fired Calciners #2 and #6 (Gas Fired)

      • Temperature capability of 1100°C (2025°F)
      • Inconel 601 Tube; 1 m (39") Ø x 10 m (33') (L) with 7 m (23') heating zone
      • Tube RPM of 0.75 ~ 6
      • 3 individually controlled temperature zones
      • Powder and pellet feed capability
      • ~ 550 Kg/hr (~ 1,200 lbs/hr) throughput
      • Can be retrofitted to run nitrogen atmosphere
      • 2 units are available
      • Manufactured by Riedhammer
      • #6 is ECS capable

      Direct Fired Calciner #5 (Gas Fired)

      • Temperature capability of 1425°C (2600°F)
      • Refractory brick lined tube; 1.12 m (44") Ø x 12 m (40') (L)
      • Tube RPM of 0.50 ~ 6
      • Slurry or pellet feed capability
      • ~ 680 Kg/hr (~ 1,500 lbs/hr) throughput
      • Manufactured by Bartlett-Snow
     

      Indirect Fired Calciner #7 (Electric Fired)

      • Temperature capability of 1110°C (2025°F)
      • Inconel 601 Tube; 36 cm (14") Ø x 8 m (26') (L) with 4.5 m (15') heating zone
      • Tube RPM of 0.75 ~ 6
      • 4 individually controlled temperature zones
      • Powder or pellet feed capability
      • ~ 70 Kg/hr (~ 150 lbs/hr) throughput
      • Manufactured by Riedhammer
      • Nitrogen Atmospheric Control Capability
      • ECS capability (soon)

      Indirect Fired Calciner #8 (Gas Fired)

      • Temperature capability of 1100°C (2010°F)
      • HT Alloy Tube; 0.6 m (24") Ø x 7.3 m (24') (L) with 5.5 m (18') heating zone
      • Tube RPM of 0.75 ~ 6
      • 3 individually controlled temperature zones
      • Powder feed capability
      • ~ 250 Kg/hr (~ 550 lbs/hr) throughput

    Indirect Fired Calciners #9 and #10 (Electric Fired)

    • Temperature capability of 1100°C (2010°F)
    • HT Alloy Tube; 0.6 m (24") Ø x 10 m (33') (L) with 7.3 m (24') heating zone
    • Tube RPM of 0.75 ~ 6
    • 3 individually controlled temperature zones
    • Powder feed capability
    • ~ 250 Kg/hr (~ 550 lbs/hr) throughput
    • 2 units are available
    • Nitrogen Atmospheric Control Capability (#10)

    Calcining / Sintering Tunnel Kilns (Electric)

    • Temperature capability of 1480°C (2700°F)
    • Powder, pellet and pressed compact materials
    • Material loaded into refractory saggers on kiln cars
    • Load capacity: 3.5 liter (9" x 8.5" x 2.75")/sagger x 40 or 48 saggers/car (37 cars in kiln)
    • Push intervals of 45 minutes to 3 hours
    • 2 units have nitrogen atmosphere capability
    • Manufactured by Harper

    Calcining / Sintering Tunnel Kiln (Electric)

    • Temperature capability of 1480°C (2700°F)
    • Powder, pellet and pressed compact materials
    • Material loaded into refractory saggers on kiln cars
    • Load capacity: 3.5 liter (9" x 8.5" x 2.75")/sagger x 40 or 48 saggers/car (34 cars in kiln)
    • Push intervals of 45 minute to 3 hours
    • Manufactured by Harper

    Calcining / Sintering Shuttle Kiln (Electric)

    • Temperature capability of 1340°C (2445°F)
    • Powder, pellet and pressed compact materials
    • Material loaded into refractory saggers or on refractory shelves
    • Load capacity: 3.5 liter (9" x 8.5" x 2.75")/sagger, ~ 784 saggers/load
    • Working dimensions: 5 m³ (38" (W) x 144" (L) x 56" (H)) with 2 cars
    • Nitrogen atmosphere capability
    • Manufactured by Nabertherm
      Spray Drying Equipment

    20' Niro Spray Dryer

    • Slurry feed to nozzles or wheel atomizer
    • 1 ~ 5 nozzles capability of maximum 1,000 psi pump pressure
      • ~ 680 Kg/hr (~ 1,500 lbs/hr) throughput
      • Median granule size of 80 ~ 140 microns
    • Wheel atomization capability of maximum 12,500 wheel RPM
      • ~ 1,350 Kg/hr (~ 3,000 lbs/hr) throughput
      • Median granule size of 60 ~ 120 microns

    18' Niro Spray Dryer

    • Slurry feed to nozzles or wheel atomizer
    • 1 ~ 5 nozzles capability of maximum 1,000 psi pump pressure
      • ~ 630 Kg/hr (~ 1,400 lbs/hr) throughput
      • Median granule size of 80 ~ 150 microns
    • Wheel atomization capability of maximum 12,500 wheel RPM
      • ~ 900 Kg/hr (~ 2,000 lbs/hr) throughput
      • Median granule size of 60 ~ 120 microns

    16' Niro Spray Dryer

    • Slurry feed to wheel atomizer
    • Wheel atomization capability of maximum 14,000 wheel RPM
      • ~ 900 Kg/hr (~ 2,000 lbs/hr) throughput
      • Median granule size of 60 ~ 120 microns.

    9' 6" Anhydro Spray Dryer

    • Slurry feed to nozzle
    • 1 nozzle capability of maximum 700 psi pump pressure
      • ~ 230 Kg/hr (~ 500 lbs/hr) throughput
      • Median granule size of 80 ~ 150 microns.

    13' 6" Anhydro Spray Dryer

    • Wheel atomization capability of maximum 18,000 wheel RPM
      • ~ 200 Kg/hr (~ 440 lbs/hr) throughput
      • Median granule size of 30 ~ 80 microns

    11' Anhydro Spray Dryer

    • Wheel atomization capability of maximum 20,000 wheel RPM
    • ~ 150 Kg/hr (~ 330 lbs/hr) throughput
    • Median granule size of 30 ~ 80 microns

Grinding Equipment

    Ceramic Ball Mills

    • High Alumina spherical grinding media
    • Six 5' x 6' Ceramic Mills

    Steel Ball Mills

    • Hardened C-Steel spherical grinding media
    • Two 3' x 3' Steel Mills
    • One 3½' x 4' Steel Mill
    • One 4' x 5' Steel Mill
    • Seven 5' x 6' Steel Mills
    • One 8' x 10' Steel Mill

    Attrition Mills (Union Process Q-50)

    • Recirculating batch attrition
    • Used for fine grinding
    • Chrome Steel spherical grinding media
    • Load capacity of 1,000 ~ 3,000 Kg (2,000 ~ 7,000 lbs) solids
    • 2,000 liter (500 gallon) Holding Tank for continuous attrition
    • 2 Attritors are available
 

    Dry Grinding Mill (Palla Rod Mill)

    • Particle size reduction capability down to 1 micron
    • ~ 1,000 Kg/hr (~ 2,000 lbs/hr) throughput

    Hammer Mill (Prater Mill)

    • De-agglomeration
    • ~ 500 Kg/hr (~ 1,000 lbs/hr) throughput

    Hammer Mill (Jacobson Mill)

    • De-agglomeration to finer particles used after Prater milling
    • ~ 500 Kg/hr (~ 1,000 lbs/hr) throughput

    Vibratory Mills (Sweco Vibratory Mills)

    • Cylindrical shaped steel grinding media
    • ~ 250 Kg (~ 550 lbs) load capacity

Mixing/Pelletizing

    Eirich R-15 Mixer/Pelletizer

    • Pellet size of 5 ~ 10 mm
    • 550 Kg/hr (1,200 lbs/hr) throughput
    • Calcination option of pellets/powder through Indirect Calciner
    • Packaging capabilities to barrels or bulk bags

    Eirich R-12 Mixer/Pelletizer

    • Pellet size of 5 ~ 10 mm
    • 270 Kg/hr (600 lbs/hr) throughput
    • Calcination option of pellets/powder through Indirect Calciner
    • Packaging capabilities to barrels or bulk bags
 

    Wet Mixer #1

    • Slurry mixing of powders and liquids via Cowles or RotoSolver Shear Mixer
    • 1,000 Kg/hr (2,200 lbs/hr) solids throughput
    • Currently used to feed Spray Dryer
    • Wet calcination option of slurry through Direct Gas Fired Calciner

    Wet Mixer #2

    • Slurry mixing of powders and liquids via Cowles or RotoSolver Shear Mixer
    • 1,000 Kg/hr (2,200 lbs/hr) solids throughput
    • Currently used to feed Spray Dryer

    Intensive Mixer - Henschel Mixer, 250 liter (60 gallons) capacity

Powder Classification Equipment

    48" Sweco Screeners (single and double deck)

    • 150 ~ 700 Kg/hr (300 ~ 1,500 lbs/hr) throughput
    • 4 US Mesh through 325 US Mesh screening capability

    30" Sweco Screeners (single deck)

    • 50 ~ 700 Kg/hr (100 ~ 1,500 lbs/hr) throughput
    • 4 US Mesh through 325 US Mesh screening capability

    Magnetic Separator

    • Magnetic separation of powders or slurry
    • ~ 450 Kg/hr (~ 1,000 lbs/hr) throughput

Dry Blending Equipment

    Double Cone Blender

    • 4.4 m³ (155 ft³) load capacity
    • 1 MT (2,200 lbs) super sacks packaging capability
    • 2 units are available

    V-Blender

    • 1.4 m³ (50 ft³) load capacity

    Nauta Blender

    • 3.2 m³ (113 ft³) load capacity

    Nauta Blender

    • 1.4 m³ (50 ft³) load capacity

    Ribbon Blender

    • 3.6 m³ (127 ft³) load capacity

Alternative Drying Equipment

Pan Drying Ovens

  • Various sized Blue M Ovens

Innovative Materials Center (IMC) Equipment

    Batching and Blending Equipment

    • Mixer / Pelletizer (Eirich R-7); 50 Kg load capacity
    • Intensive Mixer (Pappenmeier); 5 Kg load capacity
    • Intensive Mixer (Henschel); 250 liter (60 gallons) capacity
    • V-Blender; Ribbon Blender; Drum Blender; Double Cone Blender
    • Shear Mixer; Cowels Mixer and Rotosolver

    Calcining and Sintering Equipment

    • Electric Fired Rotary Calciner (Bartlett-Snow) capable to 1110°C
      • Inconel 601 tube of 20 cm Ø x 2.7 m (L)
      • 3 ~ 6 Kg/hr throughput
    • Electric Fired Rotary Calciner (Riedhammer) capable to 1110°C
      • Inconel 601 tube of 36 cm Ø x 8 m (L) with 4.5 m heat zone
      • 30 ~ 70 Kg/hr throughput
    • Electric Elevator Kilns (Harper) capable to 1370°C
      • Nitrogen atmosphere capability; 2 units are available
      • Maximum loading 48 (3.5 liter) saggers
    • Electric Shuttle Kiln (Nabertherm) capable to 1340°C
      • 38" (W) x 144" (L) x 56" (H) working dimension;
      • Maximum loading 546 (3.5 liter) saggers
    • Temperature Gradient Furnaces; 2 units are available

    Grinding Equipment

    • Batch Attritor (Union Process S-1) with YTZ balls; 4 Kg capacity
    • Recirculating Attritor (Union Process Q-6) with YTZ balls connected with a 300 liter (80 gallons) Slurry Holding Tank
    • Steel Jar Mills and Ceramic Jar Mills with Roller
    • Steel Ball Mill (2' x 2½') with Hardened C-Steel grinding media
    • Steel Ball Mill (3' x 3') with Hardened C-Steel grinding media
    • Ceramic Ball Mill (1,000 liter) with high Alumina grinding media
    • Dry Mills - Hammer Mill; Prater Mill; Sweco Vibratory Mill

    Spray Drying Equipment

    • Bowen Nozzle Tower™ Dryer; ~ 5 Kg/hr throughput
    • 9'6" Anhydro Spray Dryer - Nozzle Dryer 80 - 150 microns Dv50

    Complement Equipment

    • Blue M Ovens
    • De-lumper for breaking up agglomerates
    • 24", 30", and 42" Sweco multiple deck Screeners
    • Magnetic Separator

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