Fertilizer Industry:
Fertiliser industry does make use of fluidization phenomenon in many processes. One
of the most important process is Fluidized Bed Granulation.
Fluidized bed granulation is a very common technique in fertilizer industry, used for
producing granular fertilizers with desirable characteristics such as controlled release,
uniform particle size distribution and enhanced handling of properties. The process
goes as follows:
o The feedstock for the process is the raw materials for fertiliser production are
prepared and often mixed to achieve the desired nutrient composition
o This prepared feedstock is entered into the fluidised bed granulator. The
fluidised bed granulator consists of a vessel that is equipped with a distributor
plate at the bottom to evenly distribute a fluidising gas such as air. The
distributor plate supports bed of solid particles typically inert materials such as
silica or alumina.
o A stream of the fluidising gas is passed through the distributor plate at a
controlled flow rate which causes the inert particles present at the distributor
plate to become suspended and behave like a fluid. This creates a fluidised bed
within the granulator.
o A liquid binder solution often containing water or combination of water and
binding agents is sprayed into the fluidised bed using high pressure
automation nozzles. The binder solution coats the individual particles of feed
promoting adhesion and agglomeration.
o When the liquid binder comes into contact with the feed particles in the
fluidised bed it forms bridges between the particles leading to the formation of
granules through a process of wet agglomeration.
A visual representation of fluidized bed granulator is shown below:
Food Industry:
The two main common techniques in food industry involving the fluidization process
are fluidised bed drying and fluidised bed coating. These techniques are also used in
other chemical industries such as Fertiliser industry.
In Fluidised Bed Drying, there are multiple processes that take place to ensure
efficient drying. The process is as follows:
o The fluidized bed drying process in the food industry starts by deep
preparation of food product that is to be dried according to the specific
requirements. Many pre-processing steps such as washing, slicing, cutting, etc
may be used for the preparation. The prepared food product is then entered
into the fluidised bed dryer.
o The dryer consists of a chamber or vessel equipped with the distributor plate at
the bottom which supports a bed of inert particles such as sand, etc.
o As the food product enters the dryer, a stream of heated air or gas passes
through the distributor plate and into the bed of inert particles. This air flow
creates a fluidised state within the bed, causing the inert particles to behave
like a fluid. The food product becomes suspended within the fluidised bed.
o As the fluidised bed of particles circulates around the food product, heat is
transferred from the hot air or gas to the surface of the food. This heat causes
moisture within the food to evaporate, leading to drying.
o The moisture laden air or gas leave the fluidised bed dryer through the exhaust
vents or ducts carrying away the evaporated moisture from the food product.
The diagram below shows a fluidized bed dryer:
The other common technique used in the food industry involving fluidization
phenomenon the fluidised bed coating.
In the Fluidized Bed Coating, a coating solution or suspension is prepared by
dissolving or suspending coating materials such as sugars, starches, oils, waxes,
vitamins, flavours, colorants, etc depending on the desired properties of the coated
product.
The food product to be coated is placed in a fluidised bed coating system which
typically consists of a chamber equipped with a porous plate or distributor at the
bottom. This distributor distributes air or another gas evenly throughout the bed,
creating a fluidised state in which the food particles become suspended. These
suspended food particles start to behave like a fluid.
The prepared coating solution is then sprayed on to the fluidised food particles using
spray nozzles or automizers Positioned above the bed.
The following is a schematic diagram of a fluidized bed coating system:
