Optimization of product characteristics of porous carbon agglomerates using a design of experiments in fluidized bed agglomeration

Abstract

Spraying parameters during particle agglomeration processes can affect the agglomeration kinetics and particle growth. This study was conducted to better understand the influence of the spraying parameters in a fluidized bed wet agglomeration process, and the influence on the stability characteristics of carbon tablets. A formulation based on fine carbon and peroxide powder, as well as carboxymethyl cellulose as a binder, was used to produce agglomerates in a first production step. Thereafter in a second production step carbon tablets with a high porosity were molded for the customer goods industry. The optimization of the compressive strength of these carbon tablets was the goal of the trials. Carbon agglomerates were produced with a laboratory scale granulator called “ProCell” and were compressed with a five-cavity mechanical press. The screening of the agglomeration process parameters and their influence on the agglomerates quality, as well as the performance characteristics of the carbon tablets, were investigated using a multilevel factorial design. The experimental runs were done by varying atomized air pressure and feed rate of the fluid. This was determined by the design model. The findings of the statistical trials showed that low atomized air pressure and a low feed rate lead to a higher tablet compressive strength.