Pelletizing Disc Scarabaeus®

HAVER ENGINEERING GmbH
Associated-Institute of TU Bergakademie Freiberg
THE SCARABAEUS®
Sustainability in processing of
fertilizers, industry minerals and recycling of remnants
Dr.-Ing. Jan Lampke
08.10.2020

Experience in Pelletizing of Iron Ores
The Principle of Roll Mill to produce sand flour
2

Agglomeration
Press agglomeration Sintering Granulation

Growth agglomeration process
Background
Nucleation and
compaction
Layering Coalescence Abrasion transfer

Growth agglomeration process
Background

Agglomeration
Tailor-made product properties
 Improved storage and transport properties
 Defined particle size and shape
 Production of narrow particle size distributions
 Avoidance of segregation effect
 Adjustment of porosity or density
 Improvement of flowability
 Increased market value
6

Segregation effect
Lack of Segregation in Pelletizing Drum

Segregation effect

Laboratory

HAVER ENGINEERING GmbHSource: https://www.evenses.de/

Pelletizing disc
D
α
mH2O
m
H
n
D
α
mH2O
m
H
n

organic Binders vs. Bentonite
Source: https://www.formel1.de/
Source: https://www.mercedes-benz-trucks.com
Source: https://www.skoda-motorsport.com

Pelletizing disc - Basics

KGV - Harzmetall
0
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90
100
0 5 10 15 20
Pelletgröße in mm
Volumenanteilin%
Probe 1 - Zeitpunkt 2
grainsizedistribution[%]
grain size [mm]
KGV - Harzmetall
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0 5 10 15 20
Pelletgröße in mm
Volumenanteilin%
Sample 1
Sample 2

Measuring of Pellet strength

Measuring of Drop Number

Process Know-how

 Carbon black
 Ash
 Metal oxides
 Sewage sludge
 Potassium
chloride
 Mineral fertilizer
 Limestone
 Remnants of Cat.
II / III
 SAP
 Dolomite
 Graphite
 Cement
 Rock salt
 Hydrated lime
 Glass batch
 Iron ore
 Gold ore
 Zinc dust
 Molybdenum
trioxide
 Design and
construction
Aggregates Fertilizer Metals Recycling
Machinery and
plant engineering

Need for Fertilizers
20
Fertilizers
Crop
protection
Maschinery
Miscellaneou
s
Seeds
OPERATING RESOURCES IN
AGRICULTURE

The law of the minimum
Source: Landi
21
The law of the minimum
Every organism can only use its genetic potential to the extent
that the smallest available resource allows.
Justus von Liebig, 1855
Limestones (CaCO3) are used as a fertilizer

Limestones act as Soil improvers
Source: Rheinkalk KDI
pH-
value
Utilisation rate of the used substances
(pH 7,0 = 100 %)
Nitrogen Potassium Phosphate
7,0 100 100 100
6 89 100 52
5,5 77 77 48
5 43 53 31
4,5 30 33 23
22
Soil liming at Canterbury Agriculture Collage 1949
Source: Wikipedia
1) Improved soil structure by limestone addition
2) Improved ultilization of macronutriens by variation of ph-value

Fertilizers - Liming
Type Content Description
Carbonic lime 80 … 95 % CaCO3; MgO3 Almost insoluble in H2O, conversion to Ca(HCO3)2 therefore slow effect
Quick lime 70 … 95 % CaO Conversion with H2O to Ca(OH)2 for fast de-acidification, expensive
Hydrated lime 60 … 70 % CaO; MgO Similar to quicklime more expensive than carbonic lime
Mixed lime 60 … 65 % CaO Mixture of the three above mentioned fast and lasting effect
Slag lime
47 % CaO; 32 % SiO2;
7 … 10 % MgO
Slow effect
Converter lime 40 … 50 % CaO Similair to slag lime
Residual lime 30 … 40 % CaO Observe dusts, sludges, residues of AT pollutants (Pb, Cd, Ni, Hg, Tl; ...)
Carbocalk 45 % CaCO3 Clarification of sugar beet raw juice with Ca(OH)2 - like carbonic lime
23

Fertilizers - Pelletizing
Raw material
1 Material bunker 5 Dryer / cooler
2 Mixer 6 Screening
3 Binder Stock 7 Crusher / Recycling
4 The SCARABAEUS
Product
26

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 The Scarabaeus® pelletizing disc with precise production for
significantly tighter pellet size distribution.
 The Scarabaeus® pelletizing disc gives the operators a full
range of influencing parameters by the machine itself.
 Desired pellet quality could be achieved by changes of
machine parameters, no longer only by addition of more and
more binders and additives.

28
Configuration example:
HAVER Pelletizing disc
 The Scarabaeus® SC4200
 Limestones 16 t/h in Europe

29
Configuration example:
HAVER Pelletizing disc
 The Scarabaeus® SC4200
 Blended Fertilizer 15 t/h in Australia

Drum vs. Disc
Drum Disc
Product fraction 1 to 7 mm 1 to 7 mm
Max. yield of production 60 wt.-% 80 wt-%
Total capacity 7.7 tph 15 tph
Production capacity 4.6 tph 12 tph
30

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Pelletizing of Steelworks Remnants

Diameter: 4200 mm
Revolution speed: 0 – 20 rpm
Inclination: 40 – 65 °
Installed power: 60 kW
Weight: 12 t
Max. throughput: 20 t/h (zinc dust)
Technical data:
 Adjustment of inclination
 Autogenous wear protection
 Bottom and side wall scraper
 Flexible water spray system
 Central lubrication system
 Dust cover
Pelletising of Steelworks RemnantsPelletizing of Steelworks Remnants

Diameter: 2200 mm
Revolution speed: 0 – 38 rpm
Inclination: 40 – 65 °
Installed power: 11 kW
Weight: 2.7 t
Max. throughput: 5 t/h
Technical data:
 Adjustment of inclination
 Autogenous wear protection
 Bottom and side wall scraper
 Flexible water spray system
 Central lubrication system
 Dust cover
Pelletising of Steelworks RemnantsPelletizing of Steelworks Remnants

Pelletizing of mineral fines
0
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90
100
0,1 1 10 100 1000
Q3vonxinV%
x in μm
Quarzsand
Granodiorit
Kalksteinfüller
Zement
zerkl. Quarzsand
Maximilian Pohl, Bachelor thesis, TU Bergakademie Freiberg, 2019
Silica sand
Granodiorite
Limestone filler
Cement
grinded
silica sand

Mixture of different materials
Growth agglomeration in pelletizing disc

HAVER Engineering GmbH
Our process know-how – proofed experience – in laboratory and production!
Scale-upPilot study
 Development and Optimization of processes, machines and plants
 Objective of HAVER Engineering is to meet your technical requirements and economic benefits
 Observing whole pelletizing process
 Raw materials preparation, binders and additives
 Chemical analysis
 Tailor-made processes creating production process that saves energy and resources!
Feasibility study
46

Associated Institute of TU Bergakademie Freiberg
Halsbrücker Str. 34
09599 Freiberg
www.haverengineering.de
www.haverniagara.de/pelletizing
Tel. 0049 3731 419700
Dr.-Ing. Jan Lampke
J.Lampke@haverengineering.de
Tel. 0049 151 151 958 17
Contact us!

Pelletizing Disc Scarabaeus®

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Pelletizing Disc Scarabaeus®