A 48-inch (1220 mm) diameter Circular Fluid Bed Dryer equipped with an integral Circular Vibratory Screener quadrupled production of a proprietary granular chemical product while improving uniformity.

Granules are Pre-Screened, Dried, Re-Screened
The product is comprised of a granular carrier material, a filler material and an active ingredient. The granular carrier is screened into a narrow size range using a 48-inch (1220 mm) diameter, two-deck Kason Vibroscreen^® circular vibratory screener, after which the filler material and active ingredient are added, and the batch undergoes a proprietary conversion process.

A 48-inch (1220 mm) diameter Circular Fluid Bed Dryer reduces moisture content of the converted material to less than 1.0 percent at 120°F (49°C), after which it is discharged into an integral 48-inch (1220 mm) diameter, two-deck Vibroscreen separator that removes (oversize) agglomerates and (undersize) fines, and discharges
into storage containers at a rate of 2000 lb/h (907 kg/h).

Rectangular Fluid Bed Dryers Considered
The company’s engineering manager says he considered a rectangular fluidized bed dryer but found it cumbersome and costly. “Rectangular fluidized beds,” he explains, “work fine but are twice as large as a circular unit, requiring massive infrastructure and ancillary equipment, and they require higher airflow, consuming more energy.

“We were impressed with the circulating unit’s small footprint, fluidizing action, speed of drying, and modularity—you can move it without difficulty. We also had operating experience and a comfort level with circular vibratory screeners that look and function similar to a circular fluidized bed dryer,” he says.

Operation of the Circular Fluid Bed Dryer/Screener
Converted material from storage containers is fed into the top inlet of the dryer by a bucket elevator. In the fluid bed chamber, the material vibrates on a circular screen within a rising column of 120°F (49°C) air created by an upstream heater/ blower ducted into the bottom of the chamber. The continuous air flow, and vibration induced by two vibratory motors and spring suspension, separate and fluidize individual particles, maximizing surface area and drying efficiency. The vibratory action also causes material to travel from the center of the screen to a discharge spout at the screen's periphery in controlled spiral pathways on a first-in-first-out basis, ultimately discharging dried material into the top-center inlet of the circular vibratory screener.

An imbalanced-weight gyratory motor positioned beneath the chamber of the screener vibrates two screening decks. Oversize particles travel from the center of the screen to a spout at the screen's periphery where they are discharged for reprocessing.

On-size and undersized particles pass rapidly through the top screen onto a bowl-shaped feed tray that directs the material to the center of the lower screen. On-size particles are discharged through a spout at the screen's periphery, while undersize material passes through the lower screen onto an integral metal chute that discharges it for reprocessing.

Analysis of Separated Material
Since any increase in the ratio of active ingredient to carrier and filler increases the occurrence of aggolmeration, the company monitors the ratio of agglomerates to on-size material to detect whether any process variation has affected distribution of the active ingredient.

Because the drying-screening portion of the overall process operates off-line, it is also utilized to dry raw materials containing excess moisture, and to dry other bulk products manufactured by the company. In anticipation of wide-ranging drying applications, the system was engineered to operate at temperatures higher than those required to dry the proprietary chemical.