Pellets granulated to about 1-5 mm using an intensive blender are a common process in various industries such as ceramics, masonry, glass, metallurgy, refractories, chemicals, fertilizers, fly ash, carbon black, metal powders, zirconium oxide, pharmaceuticals, etc. Intensive blenders are very efficient in this regard because they combine mixing, agglomeration, and granulation into a single step. Here is an overview of the process and key considerations:Process Overview

1. Feed Preparation Ensure that the powders are properly prepared (e.g., dried, sieved, or pre-mixed) to achieve homogeneity. Add binders or liquid additives (if required) to promote particle formation.

2. Mixing and Agglomeration: The high-speed rotating blades or paddles of an intensive blender create shear and impact forces that cause powder particles to collide and adhere. A liquid binder (e.g., water, solvent, or polymer solution) can be sprayed into the blender to promote agglomeration.

3. Particle Growth: As the blender continues to operate, the particles grow into larger agglomerates.Control the process to achieve the desired particle size (1~5 mm).

4. Discharge: Once the granules have reached the target size, they are discharged from the mixer.Depending on the application, the granules may be further dried, sieved or cured.

4. Process parameters: Mixing speed: Adjust the rotor speed to control the granule size and density. Mixing time: Optimize the duration to achieve the desired granule size (~5 mm). Temperature: Control the temperature if heat-sensitive materials are involved.

5. Particle size control: Monitor the granule size during processing. Sieving or screening is used after discharge to separate oversized or undersized granules.

Advantages of using an intensive mixer

Efficiency: Mixing and granulation are done in one step. Homogeneity: Produces consistent granule size and density.

Flexibility: Suitable for a wide range of materials and applications.

Scalability: Can be scaled up for industrial production. By optimizing the process parameters and equipment settings, you can efficiently produce granules of about 5 mm using an intensive mixer.

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