Institute for Briquetting and Agglomeration

27th Biennial Conference - November 2001

Providence, RI

A COMPARISON OF LIQUID BINDERS FOR LIMESTONE

PELLETIZING
Jim Veverka
Project Engineer – Mars Mineral, Mars, PA

Robert Hinkle
Director of Agglomeration – Mars Mineral, Mars, PA

1. ABSTRACT

The Limestone pelletizing process is typically operated with a water/solids binder

mix as the binding agent. The binding agent is required to bond the dust particles and
allow handling of the pellets until they are applied to the soil without degradation or
breakdown.

The purpose of this study is to give some direct comparisons of usage rates and
physical properties for 11 binders used in a controlled test environment for 2 grades of
limestone fines. Some of the common binders used in the production of limestone
pellets are Lignosulfonates, Brewex, and Molasses. This study was performed using
different types of these binders (plus blends which may be candidates for use). During
the testing the binders were not identified by name or supplier and all results were
tabulated before revealing the type and source of binder.

Results of this study can be used to compare binder properties for selection of a
binder to meet requirements of individual limestone pelletizing operations. Results also
include properties of the finished pellets with respect to tested binders for pelletizing,
drying, sizing, abrasiveness, hardness, and strength.

2. BACKGROUND

The Limestone pelletizing process produces a dry chemical product available to

the general public in granular form for application on soil. Limestone pellets are typically
sold in 40# bags or in bulk to large users. Like any fertilizer product, limestone has the
following properties:
Non-hazardous (for environmental concerns)
Chemical Reactivity with water (for breakdown into the soil)
Soil additive (for pH control and improved plant growth)
 For optimum utilization of the limestone into the soil, the particle sizing should be
as small as possible. Fine particles, however, are difficult to handle and distribute and
are not user friendly. While ground lime does have the above properties, a “dust-free”
property is attractive to the end-user for spreading and handling reasons. Agglomeration
of fine limestone particles enables the limestone to be applied in pellet form which will
quickly breakdown for assimilation into the soil.

The mineral (rock) source and grinding specification are two important parameters in
the pelletizing process and can certainly affect the final product. After grinding, the
pelletizing process is further defined by 3 common equipment categories (in order of
material flow):
Pelletizing (with binder application)
Drying (with heat)
Screening

The type of binder affects the operation of each of the above processes and
associated equipment design as well as other process (handling) systems such as
recycling and dust collection. Most pellet production plants, however, may not be
familiar with binders until they begin operations. (Published data comparing binder
properties that would allow the best selection for a particular plant or material is not
readily accessible). Also, many binder suppliers may or may not have data comparisons
for their binder in relation to both types of limestone. The processing facility or plant
must consider all logistic parameters for binder usage (cost, handling, and supply
reliability) as well as usage rate and physical properties of the binder (odor, corrosion,
abrasion, and other binder properties). Cost, handling, and supply reliability are location
dependent and must be reviewed and selected by the plant or processor; they are not
addressed in this study.

To properly compare binders, a binder test should be run multiple times varying
the binder dilution rate and application rate each time and testing pellets after the run to
optimize pellet characteristics. Performing this test sequence would be cumbersome
and time consuming, thus preventing data in this paper from being easily presented.
This study tested each binder at approximately the same dry solids percentage in the
finished pellet to allow comparisons to other binders under the same conditions.

3. DESCRIPTION OF BINDERS

Binders and their properties have been previously described in detail in various
articles including previous Mars Mineral papers (see reference list). Below is a brief
description of general binder types:

Lignosulfonate – A cellulose-based organic component of trees that comes as a by-

product of the paper making industry. It is generated by a chemical pulping process and
is a non-toxic fluid with levels of dissolved and/or suspended solids. Lignins from the
sulfite pulping process are called Lignosulfonates and will dissolve in water. They are
used for their binding, dispersing, and emulsifying properties. Since the source of lignin
is trees, their physical properties will vary by the type of trees processed (i.e. hardwood,
softwood, etc.).

Brewex – An organic modified starch brewery by-product containing glucose, maltose,

and maltodextrin. It is an evaporative product derived from beer production residuals
containing the above carbohydrates, protein, and water.

Molasses – An organic by-product of cane or beet sugar refining. It is a residual heavy

syrup left after the crystallization process. Cane molasses is derived as a by-product
from fermentation industries (which use cane molasses) or from the production of
alcohol, yeast, citric acid or other fermentation products.

Blends - Blends of molasses, whey, and lignin are available and some have been
included in these tests.

4. TEST SET-UP AND PROCEDURE

4.1 GENERAL

Test runs were conducted first with Dolomitic limestone using each of the 11
binders. Similar tests were then run with the Calcitic limestone dust using each of the 11
binders. The pelletizing tests were set up with the following process equipment in order
of material flow (See flowsheet FIG. 1 at end of this section):

Bag dumping – 50# bags of pulverized Dolomitic and Calcitic limestone dust were hand
dumped into a hopper above a screw feeder.

Feeding – Dumped material was processed through a volumetric screw feeder designed
to accurately feed material to the Pin Mixer.

Photo 1 – System Set-up Photo 2 – Feeding and Binder Tank

Pelletizing – Pelletizing was performed in 2 steps. The material is initially processed
through a Mars Mineral Pin Mixer where the majority of the binder is applied. (The Pin
Mixer sprays binder on the material, thoroughly wetting the particles, and partially
agglomerates the material to prepare it for final pelletizing.) The conditioned material
dropped onto a belt conveyor and transferred to a Mars Mineral Disc Pelletizer. (The
Disc Pelletizer compacts the material through tumble growth agglomeration.) Finished
pellets discharged onto a belt conveyor and into a storage drum. Wet pellets were
screened during each test run to determine when sampling could be done. The
acceptable size is considered to be passing through 4 mesh but retained on 20 mesh.

Pin Mixer - MM model 12D54L Pin Mixer Disc Pelletizer - MM model P30 Disc Pelletizer
Pin size – 5/8” dia Pan diameter – 3’
Pin clearance (off liner) – 3/16” Pan depth – 8”
Motor – 40 HP Motor – 1 HP
Rotor speed range – 560-1120 rpm Pan speed range – 12.5-37 rpm
Liner – Natural rubber Angle range (from horizontal) – 40-60 degrees

Binder application – Each binder tested was batch mixed with water to give a similar
application rate in lbs. of solids applied per lb. of dry lime processed. (All tests were set
up to add binder solids at 2% by wet pellet weight and assuming 8% moisture content in
pellets. The binder spray was increased or decreased until proper size pellets were
seen discharging from the Disc Pelletizer). The solution components were weighed to
make a 10 gallon batch and dumped in a 30 gallon polyethylene tank. The solution was
pumped through a centrifugal pump with a recirculation loop back into the tank (to
ensure sufficient mixing and to provide sufficient pressure (40 psi) for the pelletizer
sprays).

Samples from pelletizing (off the Disc Pelletizer discharge belt conveyor) were dried,
screened, and tested below.

Photo 3 – Disc Pelletizer Photo 4 – Pellet Discharge

Drying - Pellet samples were placed in a vibrating fluid bed with hot air blown through
the bed of pellets to heat the product, evaporate the water, and set the binder. Partially
dried samples were pulled from the pellet bed at 15, 30, 45, 60, and 75 seconds, and
moisture content was measured to determine a drying curve for the product.
Dryer – Carrier Batch Vibrating Fluid Bed System set up with vertical stroke
drive, 5 HP supply blower, 30 kw electric heater, and exhaust fan with cyclone.
Bed depth set by sample size on a 1 sq. ft. deck with insertion thermocouples
for air, product, and exhaust temperatures. Set-up parameters were for 25#
(wet) batch, 300 cfm air flow, 3/16” stroke, and 520-540 deg.F drying air
temperature.

Photo 5 - Batch Fluid Bed Dryer Photo 6 – Dryer Samples

4.2 DEFINITIONS OF SAMPLE TESTS

Bulk Density – Weight of material per cubic foot volume. Measured with scale and
graduated cylinder (1000 ml sample).

Drop Strength – 6 by 10 mesh pellet samples individually dropped from 18” height to
determine average number of drops the pellets can withstand before breaking apart.

Compression Test - Individual 6 by 10 mesh pellets put in a 50 # crush tester to

determine the average force in lbs. required to break pellet.

Attrition Test – Pellet sample screened to be 6 by 10 mesh then placed on a 20

mesh screen and agitated for 5 minutes. The fines that pass though the screen are
weighed and the value recorded is the “loss” amount as a % of the starting sample
weight.

Moisture Content – Wet pellet samples are put in a moisture balance which
measures starting “wet” weight, evaporates off moisture, and measures finished
 “dry” weight during a recorded time period. The % moisture is a “wet” weight = wt. of
water evaporated/wt. of wet product. (Moisture Balance – Mettler Instrument Corp., NJ model
LP-16/PM480 delta range - 320 deg. F - 50 gram sample size).

Particle Size – Pellet samples passed through 4, 6, 16, 20, 30, and 40 mesh screen
sizes in a mechanical shaker. Used US standard sieves on Ro-tap shaker (400 gram
sample).

Abrasion Test – The purpose of this test was to obtain relative comparison of the
pellet samples to determine abrasive differences caused by the binder. (Similar to
ASTM Specification #G65 – Standard Test Method for Measuring Abrasion using the
Dry Sand/Rubber Wheel test.) 10 # pellet samples were screened to –4 mesh and
then passed between a rubber wheel and a metal specimen. The rubber wheel was
rotated through a mechanical drive. The pellets were forced between the metal
specimen and wheel with a counterweight. The metal specimen was weighed before
and after the test run to determine mass loss from abrasion. For these tests,
aluminum was used as the metal specimen material.

Solubility – A small sample of dry pellets put in a container with water to confirm their
ability to break down and dissolve.

4.4 SET-UP PARAMETERS

4.4.1 Set-up Parameters for Binder Dilution

Binder # - Type % Solids Density (#/gal) Dilution rate pH – raw pH – diluted

(assumed) (assumed) (%binder/ binder binder
%water) (measured) (measured)
1 – Lignin 52.0 10.5 38/62 2.0 2.2
2 – Lignin 57.4 10.9 35/65 3.7 4.2
3 – Lignin 34.8 9.8 42/58 9.5 9.5
4 – Lignin 53.4 10.6 38/62 2.9 3.1
5 – Lignin 50 9.9 40/60 6.3 6.3
6 – Lignin 54 10.4 37/63 3.1 3.6
7 – Brewex 50 10.0 40/60 4.8 5.0
8 – Molasses 60 10.5 33/67 9.5 8.7
9 – Molasses 73 11.7 27/73 5.6 5.7
10 – Mosasses/Whey 63 10.8 32/68 5.1 5.1
11 – Lignin blend 52 10.6 38/62 4.0 4.3

Note: % solids and density based upon binder vendor supplied data.
4.4.2 Set-up Parameters for Pelletizing

Target run time 30 minutes (Adjusted as needed during test run)

Target moisture content 8% (Adjusted as needed during test run)
Target binder application 2% solids (Affected by % moisture applied)
Feed rate 725 lbs/hr
Pin Mixer speed 850 rpm
Disc angle 54 degrees (Adjusted as needed during test run)
Disc speed 20 rpm (Adjusted as needed during test run)

4.5 APPLICATION OF SAMPLE TESTS

Wet samples were tested for bulk density (lbs/cf), drop strength, compression
strength, and attrition loss.
Wet samples were dried in a moisture balance to determine moisture content (%
water of wet weight) and drying time (for comparison of drying rate).
Wet samples were dried in a fluid bed dryer to determine drying characteristics.
Dry samples were tested for bulk density (lbs/cf), drop strength, compression
strength, attrition loss, sieve analysis, abrasion, and solubility.
6. TEST SUMMARY

6.1. RESULTS BY TESTING PARAMETER

Listed below are conclusions as interpreted by the test run data previously
shown. In general, all of these binders may be suitable for limestone pelletizing with
adjustments to binder solids application rate by varying the concentration (dilution).

6.1.1. Pelletizing/Moisture/Sizing – Pelletizing was rated as either “good, fair, or poor”

depending upon level of ease/difficulty and time to produce proper sized pellets.

Using the time required to produce and maintain pellets in the required size range,
the Dolomitic test runs were “easier” to pelletize.
Calcium based Lignins produced stronger pellets for Dolomitic lime, and Sodium
based Lignins produced stronger pellets for Calcitic lime.
All Dolomitic test runs pelletized at a lower moisture content than the Calcitic test
runs – a conclusion from this is that the binder dose may have to be higher for
Dolomitic lime applications, in direct comparison to Calcitic lime applications, to
maintain the same % solids applied to the pellets. However, satisfactory pellet
strengths were achieved in most cases and the tests proved that a 2 % application
rate is sufficient for some binders.
Although the Calcitic limestone required more moisture to pelletize, and therefore
more binder solids applied, it was evident that the binder applied (app. 2 %) was not
sufficient for proper pellet bonding.

6.1.2. Drying – Binders were ranked for total change in moisture over the sampling
times (which produced drying curves). Final moisture content is also important, but it
depends upon the starting moisture which varied for each test. The pellet temperatures
(when measured at the sample times) did vary for the different binders suggesting that
the binder affects the specific heat of the material. The Dolomitic lime pellets seemed to
have steeper drying curves than the same binders with the Calcitic lime pellets.

6.1.3. Drop Strengths - All dry samples averaged 50 + pellet drops. All green samples
varied as shown on the Test Run Data. Drops were higher for most binders with the
Dolomitic lime.

6.1.4. Crush Strength – Using an acceptable level of 4.0 # crush, some binders
exceeded and some failed at 2 % concentration. Crush strengths were generally greater
for most binders with Dolomitic lime than those of Calcitic lime.

6.1.5. Attrition Loss – All dry Dolomitic tests had attrition losses less than 0.6 %. All dry
Calcitic tests had attrition losses less than 1.7 % with the exception of binder #8. All wet
Dolomitic tests had attrition losses less than 1.4 %, while all wet Calcitic tests had
attrition losses much higher (this is confirmed by the fact that more fines were captured
in the dryer exhaust cyclone for the Calcitic tests).
6.1.6 Pellet sizing - As noted above, it was easier for the pellets to form in the required
size range for all the binders tested with the Dolomitic lime.

6.1.7. Abrasiveness – All Dolomitic lime samples were tested as well as 3 calcitic lime
samples (1 with Lignin binder, 1 with Molasses binder, and 1 with Brewex binder) for
comparison. The Dolomitic samples had a much higher abrasion rate on the metal
specimen. No other correlations comparing binders could be made.

6.1.8. Solubility – All samples were tested, and they dissolved in water.

6.2. Ranking of Binders

The 3 “best” binders are ranked below in relation to testing parameter. Due to the
minute differences in some of the measured parameters and associated inaccuracies of
measurements in the tests, we have taken only the top three from the test run data.

Testing Parameter Best 3 – Best 3 -

Dolomitic Calcitic
6.2.1 Ease of pelletizing 6,2,11 1,7,10
LO moisture content 6,9,5 1,11,8
6.2.2 Drying (% moisture dried) 2,4,3 7,2,8
6.2.3 HI wet drop strength 5,4,7 1,3,7
6.2.4 HI dry crush strength 5,6,8 1,3,9
6.2.5 LO wet attrition loss 4,3,2 1,11,2
6.2.6 Sizing – % 4 by 20 mesh 2,6,7 7,1,2
6.2.7 Abrasiveness 4,8,5 ---

From this table we suggest that binder #6 and #2 (both Calcium based Lignins) were
the best overall for the Dolomitic Test Runs. Binder #1 and binder #7 were the best
overall for the Calcitic Test Runs.

Note: While we did not measure for hygroscopic (absorption of moisture into the pellet)
parameters, some pellet strengths did seem to weaken after exposure to air – binders
8,9, and 10 (which are all Molasses based) had much lower crush strengths when re-
tested.

6.3. SYSTEM DESIGN AND BINDER SELECTION

The pelletizing process is an operator dependent process as reflected by the fact

that pellets are determined “acceptable” when their size is in the desired range.
Downstream sampling after drying will determine pellet characteristics and whether or
not the pellet meets strength, size, and efficiency criteria. In full scale pelletizing
systems, the only control data the operator has for monitoring the pellet size range
(efficiency) is to monitor product weight after screening in comparison to feed rate to
determine efficiency. Off-size material must be handled through a recycle material
handling system or disposed. Strength can only be tested by manual sampling
(although examination of the product as discharged into bags or out of storage bin will
indicate product degradation from handling). In designing pelletizing equipment and
systems, Mars Mineral recommends including automation of the equipment to allow the
operator to make changes in the control set-up and to reduce the number of variables in
the system operation including:
Feedrate control
Product weight measurement
Binder dilution and spray flow control
Drying temperature and air flow control

This paper is not designed to examine all binders used in the agglomeration process.
Certainly other dry and wet binding agents are used for various materials throughout the
industry, but the ones tested here seem to be most applicable to limestone pelletizing.

The binder selection relates to long term operating costs of a limestone pelletizing
system. Capital costs for purchasing binders may be compared for a site specific plant,
but costing data has not been included in this study because operating costs can offset
capital costs.

The following considerations are location/operation dependent:

Location of the plant in relation to the binder source location (which affects shipping
costs)
Consumption level (gal/day) or bulk usage costs
Environmental controls (odor, spill clean-up, corrosiveness)

The following considerations are binder dependent:

Application rate (% binder solids to # dry pellet)
Drying characteristics (fuel costs)
Abrasive wear to equipment (maintenance costs)
Pellet properties – strength, sizing, etc.

Pelletizing System – Cost/Usage Calculation for Binder Application

Assume cost of binder @ $50/ton, density @ 10.0 #/gal, and 50 % solids in solution
($ 50/ton) x (1 ton/2000#) / (10 #/gal) = $ 0.25 /gal

Assume binder application rate @ 2 % solids/ton moisture in pellets @ 8 %

(0.02) x (2000#/ton) = 40 # dry binder solids/ton pellets
(40#/ton) / (0.50) % solids = 80 # liquid binder/ton pellets
(80#/ton) / (10.0#/gal) = 8 gal liquid binder /ton pellets

(8 gal liquid binder/ton) x ($0.25/gal) = $2.00/ton of dry lime (binder cost)

Dilution rate required for above = 37% binder to 63 % water
7. MATERIAL DATA

7.1 BINDER IDENTIFICATION

Binder # Name Description Source

1 Norlig 12 Sodium Lignosulfonate Lignotech USA, Inc.
(Hardwood) 100 Grand Ave.
Rothschild, WI 54474
715-355-3628
2 Norlig A Calcium Lignosulfonate Lignotech USA, Inc.
(Hardwood)
3 D-1262 Developmental Sodium Lignin Lignotech USA, Inc.
(Softwood)
4 D-1736 Desugared Calcium Lignotech USA, Inc.
Lignosulfonate (Hardwood)
5 Lignin Ammonium Lignon Sulfonate
6 Lignin Calcium Lignin Westway Trading Corporation
6816 West 156th St.
Oak Forest, IL 60452
708-802-8944
7 Brewex Brewers Condensed Solubles Developing Environmental Resources
P.O. Box 194
Elkhorn, WI 53121
414-249-1750
8 Big Chief De-Sugarized Beet Molasses Westway Trading Corporation

9 Wes Las 79.5 79.5 Brix Cane Molasses* Westway Trading Corporation

10 Mol-Whey 63 Cane Molasses/Condensed Westway Trading Corporation

Whey Mix*
11 Cane-Lignin Westway Trading Corporation
Water Blend
* with 1/2% sulfuric acid as preservative

7.2 BINDER PHYSICAL DATA (from vendor supplied information)

Binder name PH % solids Density (lbs/gal) Viscosity (cps)

1 Norlig 12 2.0 52.0 10.48 75 @ 77 deg F
2 Norlig A 3.6 57.4 10.87 350 @ 77 deg. F
3 D-1262 9.2 34.8 9.81 170 @ 77 deg. F
4 D-1736 2.6 53.4 10.58 150 @ 77 deg. F
5 Lignin 5.2-6.5 50 (varies) 9.9 1500 @ 80 deg. F
6 Lignin 3-4 54 10.4 150 @ 70 deg. F
7 Brewex 3.5 50 10.0 250 @ 80 deg F
8 Big Chief 60 min 10.5 150 @ 70 deg. F
9 Wes Las 79.5 5.7 73 11.7 Up to 3500 cps
10 Mol-Whey 63 63 10.8 200 @ 70 deg. F
11 Cane Lignin Water Blend 52 10.6 300 @ 70 deg. F
7.3 DOLOMITIC LIMESTONE - Cemex (Southdown) Yardright Dolomitic pulverized
limestone

Sieve Analysis
Chemical – CaCO3 and MgCO3 1.9 % retained on 45 mesh screen
Material source – Raymond mill 7.1 % retained on 80 mesh screen
Calcium Carbonate equivalent (CCE) = 93 % 14.1 % retained on 120 mesh screen
Effective Neutralizing value (ENV) = 84 % 49.9 % retained on 200 mesh screen
Moisture content – 0.1 % 21.2 % retained on 325 mesh screen
Bulk density – 83-110 #/cf 5.8 % retained in pan

7.4 CALCITIC LIMESTONE - Cemex (Southdown) Thomasville, PA #3.5 HI-Calcitic

pulverized limestone

Sieve Analysis
Chemical – CaCO3 1.0 % retained on 45 mesh screen
Material source – Hammermill 13.2 % retained on 80 mesh screen
Calcium Carbonate equivalent (CCE) = 98.9% 11.1 % retained on 120 mesh screen
Effective Neutralizing value (ENV) = 93.0 % 37.6 % retained on 200 mesh screen
Moisture content – 0.01 % 26.5 % retained on 325 mesh screen
Bulk density – 91-112 #/cf 10.6 % retained in pan

REFERENCES
IBA 1993 Pelletizing Limestone Fines - A Study of the Benefits of Pelletized
Limestone Fines in the Commercial and Agricultural Market
IBA 1991 Of Beer, Leather, and Beets – A Study of Alternative Binders in Agitation
Pelletizing

CONTRIBUTORS
Mars Mineral would like to thank the following contributors who assisted with developing
this study:

Cemex (Southdown) For supply of Lime material

Carrier Vibrating Equipment For supply of pellet dryer
Lignotech USA For supply of binder
Westway Trading Company For supply of binder
Developing Environmental Resources For supply of binder