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Minerals, chemicals, metals

A great number of processes require at some stage a dryer, a calciner, a cooler, a mixer or a reactor. Ingetecsa can supply all the equipment for this. Equally important, most of these process steps we can simulate in our test centre.

We offer a comprehensive range of process equipment for your products. The design of each dryer, calciner, cooler, mixer, or reactor is around reliability, accessibility, and performance. Products we process vary as example from lithium to HDPE, from rare earth to PVC, from Melamine to sodium sulphate to zinc oxide. The feed stock can be anything such as a liquid, a sticky glue or a sub-micron powder.

A dryer, calciner, cooler, mixer or a reactor in a chemical factory

 

All equipment of INGETECSA is suitable for both indoor and outdoor installation. These can be fully washed down if desired. Furthermore, every unit normally operates under a light vacuum. Dust emissions stay at an absolute minimum by using for instance very high efficiency cyclones, bag house filters and water/gas scrubbers. Normally, all our equipment is used full continuously. Also, some of our units/processes allow a batch wise operation too. Where needed is our equipment explosion resistant. Accessibility and reliability are one of our key design factors.

We offer the following process steps:

  • Drying process
  • Calcining process, click here
  • Cooling process, click here
  • Solidification process, click here
  • Mixing processes / reaction process, click here

Go to our download section for downloading the brochures.

 

 


DRYING PROCESS

 

Products that are smaller than 5-6 mm:

These are best processed in the Spiral Flash Dryer. A highly thermal efficient, rapid drying technology that is static.
This technology is suitable for most granules.

  Static drying chamber, entirely pneumatic dispersion (unique)
  Offering longer drying times at lower product temperatures than conventional flash dryers
  Transporting capability at the same time, up to 200m
  Capable of processing reasonably sticky products
  Self supported technology, quick installation time

Some examples are lithium hydroxide/carbonate/sulphate, rare earth concentrate, sodium sulphate, sulphate of potash, zircon, titanium dioxide, ilmenite, graphite, calcium phosphates, kaolin, calcium phosphate/carbonate/fluoride/oxide/hydroxide.

Read more here.

 

 

Static Spiral Flash Technology for drying and for cooling

Products that are quite uniform in size
(in the range of ~0.3 – 3 mm) and that are brittle:

These are best processed in the Fluid Bed Dryer. By slowly removing the moisture from the core of the granule, possible particle damaged is minimised.

  Very gentle processing
  Longer drying times (several to many minutes)
  Drying and cooling in the same unit possible
  Entirely static drying process

Some examples are HDPE, NPK, salt, urea, polyesther, ammonium sulphate (AmSul).

Read more here.

 

 

Ingetecsa's static Fluidised Bed technology, very gentle product treatment, superior product quality, high reliability and uptime

When steam is available, free flowing products that can be heated up to around 100°C during drying:

These are best processed in the Rotary Tube Dryer.

  Most energy efficient
  Simple operation
  Ideal for medium to high throughputs
  Longer drying times (several to many minutes)
  Capable of processing toxic and reasonably sticky products
  Minimum process air flow and emission

Some examples are (poly)carbonates, phosphates, sulphates, HDPE, terephthalic acid (PTA/CTA/PIA), polyacetal, sludge, copper ore, iron ore, gypsum, ash, soda-ash.

Read more here.

 

 

When steam is available, pasty products that can be heated up to around 100°C during drying, or that require a low throughput:

These are best processed in the Paddle Dryer.

≡  Most energy efficient
≡  Ideal for low to medium throughput applications
≡  Longer drying times (several to many minutes)
≡  Capable of processing sticky, gluey and toxic products
≡  Vacuum possible
≡  Minimum process air flow and emission

Read more here.

Andritz Gouda paddle dryer / cooler

Larger particles that can be heated up indirectly by steam or hot water:

These are best processed in the Plate Dryer.

≡  Ideal for low throughput applications
≡  Capable of processing large particles and toxic products
≡  Vacuum possible
≡  Low process air flow and emission

Read more here.

Andritz Gouda plate dryer

CALCINING PROCESS

When it comes to calcination, there are several up-stream processes possible:

  • No pre drying
  • Pre drying in a Spiral Flash Dryer
  • Pre drying in a conventional Flash Dryer
  • Pre drying in a Rotary Drum Dryer, directly coupled to the Rotary Calciner

The ideal configuration depends on the pre drying process conditions: for example what temperatures are available from the calcine process, if direct contact with exhaust gasses is allowed, and the abrasiveness of the product.

Ingetecsa employs the indirect calcining technology.

≡  Very high thermal efficiency
≡  Temperatures up to ~850°C
≡  Low process air flow and emission

The picture shows a combination of a Rotary Calciner where the exhaust gasses are used for the pre drying stage in a Rotary Drum Dryer. The exhaust gasses are used to pre heat the inlet air to the high efficiency IR burners.

Read more here.

 

Ingetecsa's Rotary calciners excel in robustness, high efficiency and low maintenance

COOLING PROCESS

Ingetecsa has a cooling technology for almost every product and application.

Products that are free flowing and very fine:

These are best processed in the standard Flash Cooler.

  Particle sizes up to some 2 mm
  Quick cooling time (2-3 seconds)
  Transporting capability at the same time, up to 200m
  (Reasonably) sticky products can be processed also

Read more here.

Ingetecsa's Flash Dryer, offering optimised particle dispersion, aerodynamics, and possibility to dry at very high temperature

 

Products that are free flowing and coarser:

These are best processed in the Spiral Flash Cooler.

  Particle sizes up to some 5-6 mm
  Offering longer cooling time for coarser particles (5-10 seconds)
  Transporting capability at the same time, up to 200m
  (Reasonably) sticky products can be processed also
  Entirely static cooling process

Read more here.

Static Spiral Flash Technology for drying and for cooling

 

Products that are free flowing, quite uniform in size and brittle:

These are best processed in the Fluid Bed Cooler.

  Very gentle processing
  Longer cooling times (several to many minutes)
  Drying and cooling in the same unit possible
  Entirely static cooling process

Examples are HDPE, NPK, salt, urea, polyesther, ammonium sulphate (AmSul).

Read more here.

Ingetecsa's static Fluidised Bed Cooler for sugar

Products that are free flowing, and >2 mm

These can be processed in the Rotary Drum Cooler.

The Rotary Drum Cooler is most suitable for processes that have either very high flows or too great a range of particle sizes that can not be processed in other technologies. Fine particles are less suitable to process in this technology as these are blown out of the unit. Indirectly cooled Rotary Drum Coolers avoid this but are less efficient due to their low specific heat exchange surface.

  Longer cooling times (many minutes up to one hour)
  Robust technology
  Deals well with large variances in feed stock

Examples are aggregates, biomass, bio solids, chips, manure, shavings, sludge.

Read more here.

Ingetecsa's Rotary Drum Dryer used for a variety of different products

 

 

Products that are <5 mm and toxic or pasty or gluey

These can be best processed in the Paddle Cooler.

  Very suitable for gluey, sticky materials
  Longer cooling times (many minutes up to one hour)
  Indirect cooling, ideal for dangerous or sensitive products

Examples are granules, viscous products.

Read more here.

Andritz Gouda paddle dryer / cooler

 

Products that are very hot

The Multi Chamber Cooler is like no other technology capable of cooling very hot, irregularly shaped products. Many references are for product temperatures greater than 800°C.

  Very robust and highly reliable equipment
  Deals well with most process hiccups upstream
  Suitable for erosive and abrasive products

Typical products are foundry salts, zinc oxide, caustic soda, sodium chloride, potassium carbonate.

Read more here.

 

Ingetecsa's Multi Chamber Cooler, when robustness and reliability are most important

SOLIDIFICATION PROCESS

The Andritz-Gouda drum flaker has a unique place in our cooling program. A drum flaker solidifies molten products. Solidification of chemicals is normally for storage and transport. Most of the times these are intermediate products that require further processing at other facilities.

Segregated cooling water system
Suitable for toxic processes
Small footprint

Fatty acids are likely the most well known products that are solidified in the industry, but the range is basically endless. Stearic acid, sulphur, urea, soap, resin, maleic and phtalic anhydride, lactate, polyethylene glycols, are just a few of the products that are solidified on a drum flaker.

The different models of the drum flaker cater for the wide range of product viscosities, adhesion, and crystallization characteristics.

Read more here.

 

Flakes produced on the Andritz-Gouda drum flaker

MIXING AND REACTION PROCESS

The Ingetecsa mixer granulator is capable of blending and reacting chemicals under high demanding process conditions. The twin shafts can continuously mix and/or granulate solids with other solids, with liquids or with a slurry.

Very robust and highly reliable equipment
Designed to operate under very demanding conditions
Suitable for erosive and abrasive products

Also spraying a hydrochloric or sulphuric acid for example on a powder is possible. Often, these kind of processes are meant to start a chemical reaction. Toxic or corrosive vapours escape, products that can change in a gluey product mass, temperatures rise, and high product viscosities. The Ingetecsa mixer granulator is designed to deal with these demanding process conditions.

Read more here.