Method of agglomerating powders

Claim 1

A method of agglomerating finely divided clays into pellets with a packing density greater than 60 lbs/ft 3 , said method comprising the steps of: (a) introducing finely divided clay having a moisture content of about 1.5 to 5% by weight into one end of a rotating cylindrical drum having an inlet end, an axis of rotation, and a discharge end and tumbling said material therein; (b) contacting said tumbling clay with a liquid wetting agent in said drum wherein said clay begins to curl back and tumble down the side of said rotating drum; (c) spraying said liquid wetting agent at said curl in the form of a spray having an angle that the spray makes with a vertical line through the axis of rotation of said drum in the range of 35° to 85° and a spray angle and an angle of inclination, as shown at (23) and (24) of FIGS. 6a and 6b respectively of said drawings, of about 30°; (d) continuing rotation of said drum at a speed below the critical speed RS c , defined by RS.sub.c = 76.6/√D wherein D is the diameter of the drum in feet, to form pellets having a size range exhibiting maximum effective packing density of from about 60 to 70 pounds per cubic foot; and (e) removing pellets that would pass through a tight-mesh screen from near the discharge end of said rotating drum and discharging said pellets into the incoming stream of finely divided clay at the inlet end of said rotating drum to provide seeds and nuclei for pellet initiation; (f) removing pellets that would not pass through a large-mesh screen from near the discharge end of said rotating drum, grinding said pellets, and discharging said pellets into the incoming stream of finely divided clay at the inlet end of said rotating drum to provide seeds and nuclei for pellet initiation; (g) discharging pellets from said drum that would pass through a large-mesh screen, but would not pass through a tight-mesh screen, such pellets having a packing density greater than 60 lbs/ft 3 , wherein the tight-mesh screen and the large-mesh screen are defined to produce a pelleted clay consisting of compacted pellets of varying sizes which efficiently utilize available voids in the arrangement of closely packed uniform spherical pellets comprising a gradation of pellets with from 25 to 55% of the pellets being retainable on a 5 mesh screen, from 30 to 55% of the pellets being retainable on a 10 mesh screen but capable of passing through a 5 mesh screen, from 5 to 25% of the pellets being retainable on a 20 mesh screen but capable of passing through a 10 mesh screen, 0.5 to 5% of the pellets being retainable on a 40 mesh screen but capable of passing through a 20 mesh screen, and less than 2% of the pellets capable of passing through a 40 mesh screen.

Claim 2

A method of agglomerating finely divided clays into pellets with a packing density greater than 60 lbs/ft 3 , said method comprising the steps of: (a) introducing finely divided clay having a moisture content of about 1.5 to 5% by weight into one end of a rotating cylindrical drum having an inlet end, an axis of rotation, and a discharge end and tumbling said material therein; (b) contacting said tumbling clay with a liquid wetting agent in said drum wherein said clay begins to curl back and tumble down the side of said rotating drum; (c) spraying said liquid wetting agent at said curl in the form of a spray having an angle that the spray makes with a vertical line through the axis of rotation of said drum in the range of 35° to 85° and a spray angle and an angle of inclination, as shown at (23) and (24) of FIGS. 6a and 6b respectively of said drawings, of about 30°; (d) continuing rotation of said drum at a speed below the critical speed RS c , defined by RS.sub.c = 76.6/√D wherein D is the diameter of the drum in feet, to form pellets having a size range exhibiting maximum effective packing density of from about 60 to 70 pounds per cubic foot; and (e) removing pellets that would pass through a tight-mesh screen from near the discharge end of said rotating drum and discharging said pellets into the incoming stream of finely divided clay at the inlet end of said rotating drum to provide seeds and nuclei for pellet initiation; (f) removing pellets that would not pass through a large-mesh screen from near the discharge end of said rotating drum, grinding said pellets, and discharging said pellets into the incoming stream of finely divided clay at the inlet end of said rotating drum to provide seeds and nuclei for pellet initiation; (g) discharging pellets from said drum that would pass through a large-mesh screen, but would not pass through a tight-mesh screen, such pellets having a packing density greater than 60 lbs/ft 3 , wherein the tight-mesh screen and the large-mesh screen are defined to produce a pelleted clay consisting of compacted pellets of varying sizes which efficiently utilize available voids in the arrangement of closely packed uniform spherical pellets comprising a gradation of pellets with from 25 to 55% of the pellets being retainable on a 5 mesh screen, from 30 to 55% of the pellets being retainable on a 10 mesh screen but capable of passing through a 5 mesh screen, from 5 to 25% of the pellets being retainable on a 20 mesh screen but capable of passing through a 10 mesh screen, 0.5 to 5% of the pellets being retainable on a 40 mesh screen but capable of passing through a 20 mesh screen, and less than 2% of the pellets capable of passing through a 40 mesh screen.