Process technology – crucial for outstanding powders and bulk solids

Process plants

Every day, powders and bulk solids are used in countless products, such as construction materials, plastics, paints, fertilizers, and many others. Process-treated bulk solids are an essential component of numerous materials and are crucial for product quality. To ensure this quality, process technology processes must meet numerous parameters, such as exact particle sizes, particle densities, and residual moisture content (dry substance).

We contribute our expertise and our technologies to ensure that your powders and bulk solids are processed with the best possible quality and process efficiency. Grenzebach works with a holistic approach. We keep different bulk material properties and reaction behaviors in mind.

Our experts have in-depth knowledge of diverse powders and bulk solids used in industry. We support our customers from planning and design to commissioning and maintenance.

Application-oriented process knowledge

Process technology knowledge in chemistry

Chemistry:

For processing chemical solids, Grenzebach supplies application-oriented technology for fine grinding, cooling, compacting and drying.

Process technology knowledge in stones and soils

Stones and soils:

Limestone, quartz or kaolin – Grenzebach offers solutions for crushing, classifying and compacting various mineral materials.

Process technology knowledge in paints and coatings

Paints and coatings:

Processing pigments – a core process in the production of paints and coatings. Here, Grenzebach contributes its expertise in drying and compacting pigments.

Process technology knowledge in recycling

Recycling:

It is becoming more and more important to tap secondary raw material sources. Process engineering components from Grenzebach can make the recycling of raw materials a reality. Together with our scientific partner, the Clausthal University of Technology, we are working intensively to tap the potential of recycling in practice.

Process technology knowledge in special products

Special products:

Special products need special technologies. Cold grinding or grinding coating, gentle deaeration, gentle drying or iron-free grinding – your task is our motivation.

Our experience – your success

Our solutions and services incorporate 130 years of experience in the efficient processing of raw materials, dating back to Babcock BSH. Combined with the process and technology knowledge gained in Grenzebach’s 60 years, this means we can apply extensive know-how to your process technology solutions. Our experience guarantees your success.

Customized mechanical process technology
Optimal mechanical process technology

Grinding, classifying, compacting

Mechanical Process Technology

Coarse crushing or finest powder grinding? Compacting bulk solids to the highest degree? Classifying bulk materials according to their particle size? Whatever your task, Grenzebach will support you in selecting the optimum process technology. With our proven technologies, we will equip you with a tailor-made mechanical process engineering system.

Whirlwind mill: Grinding soft to medium-hard bulk materials
Fine grinding through whirlwind mill

Whirlwind mill: Grinding soft to medium-hard bulk materials

Grenzebach’s whirlwind mill ensures excellent results in the field of fine and ultra-fine grinding of soft to medium-hard bulk materials (up to Mohs hardness 5). The whirlwind mill can produce very fine powder qualities with narrow particle size distribution and excellent upper particle size limitation.

Sample applications:

  • Limestone
  • Cellulose insulation
  • Gypsum
  • Pigments
  • Salts of various origins
Whirlwind Mill
Vibration tube mill: Grinding medium-hard and hard products
Grinding through vibration tube mill

Vibration tube mill: Grinding medium-hard and hard products

Grenzebach’s vibrating tube mills are the solution for grinding medium-hard to hard, abrasive products. For example, they can grind slags, ashes or fireclay and operate according to the vibromill principle. In this process, Grenzebach’s vibration tube mill achieves consistently high throughput rates with low energy consumption.

Sample applications:

  • Ashes
  • Slags
  • Quartz
  • Fireclay
Jet Airstream Sifter: Separating fine, medium and coarse material
Separating through jet airstream sifter

Jet Airstream Sifter: Separating fine, medium and coarse material

With the Grenzebach Jet Airstream Sifter, powders from all areas of solids processing technology can be separated into three fractions – fine, medium and coarse material – in just one step. The Jet Airstream Sifter is suitable for sifting bulk materials and for separating fines without spattering.

Sample applications:

  • Titan slag
  • Quartz
  • Aluminum oxide
  • Pigments
  • Limestone
    VACUPRESS: Compacting fine-grained bulk materials
    Compacting through Vacupress

    VACUPRESS: Compacting fine-grained bulk materials

    In Grenzebach’s VACUPRESS, bulk materials with a particle size smaller than 40 µm and a bulk density smaller than 750 kg/m³ can be compacted. The VACUPRESS can therefore be used as a deaeration and compaction unit upstream of packing equipment. It provides clear practical benefits: reduced dust generation during dosing and improved handling properties. The VACUPRESS also offers advantages as a pre-compaction device upstream of granulators.

    Sample applications:

    • Silica
    • Carbon black
    • Magnesium hydroxide
    • Aluminum oxide
    • Pigments
    VACUPRESS
    Sustainable thermal process technology
    Optimal thermal process technology

    Heating, cooling and drying

    Thermal process technology

    Heating and cooling of fine-grained bulk materials: this is what Grenzebach’s thermal process solutions can deal with. By optimally controlling the temperatures in the individual processes, they make thermal separation processes such as absorption or calcination possible. We make efficient, economical use of the waste heat generated from thermal processes: the heat is recycled and used to temper the bulk materials. This saves resources and improves your carbon footprint!

    Rotary kiln: High temperature for calcining, roasting and reacting.
    Process technology rotary kiln

    Rotary kiln: High temperature for calcining, roasting and reacting.

    Rotary kilns from Grenzebach can be used in various process steps for processing temperatures of up to 1600 °C. This rotary kiln is characterized by a simple, robust design, high operational reliability, large throughput capacities and the ability to handle fluctuating feed quantities.

    Sample applications:

    • Petroleum coke
    • Quartz
    • STPP
    • Titanium dioxide
    • Iron oxide
    • Activated carbon
    • Catalysts
    Rotary heat exchangers: Cooling and energy recovery
    Energy recovery rotary heat exchangers

    Rotary heat exchangers: Cooling and energy recovery

    With Grenzebach’s indirect air-cooled rotary tube coolers, you can recover energy from heated solids after high-temperature processes – a clear contribution to energy-efficient process technology. This rotary tube heat exchanger ensures efficient energy recovery with simultaneous cooling of the bulk materials, especially when it is combined with rotary kilns. Savings for you and a plus for the climate!

    Sample applications:

    • Gypsum
    • STPP
    • Sodium carbonate
    Moving Bed heat exchangers: Gentle product cooling and heating
    Process technology moving bed heat exchangers

    Moving Bed heat exchangers: Gentle product cooling and heating

    Grenzebach’s moving bed heat exchangers enable particularly gentle heating or cooling of fine-grained, free-flowing products. The heat exchanger, which is indirectly water-cooled or steam-heated, can handle large product mass flows. The moving bed heat exchanger can also be designed for food processing and can handle product temperatures of up to 1200 °C.

    Sample application:

    • Quartz
    • STPP
    • FCC catalyst
    • Soda ash
    • Fertilizer
    Turbine dryer: Drying sensitive bulk materials
    Process technology turbine dryer

    Turbine dryer: Drying sensitive bulk materials

    The Grenzebach turbine dryer is the perfect solution for continuous drying of sensitive powder, crumbs, pastes, and flaky or lumpy products. In this process, the particles are rearranged slowly and gently, with virtually no abrasion and with minimal dust generation.

    Sample applications:

    • Calcium carbonate
    • Calcium phosphates
    • Pumice gravel
    • Bentonite
    • Titanium oxide
    Sectional coolers: Cooling high-temperature bulk materials
    Process technology sectional coolers

    Sectional coolers: Cooling high-temperature bulk materials

    Grenzebach’s sectional coolers are indirectly water-cooled rotary tubes for cooling high-temperature bulk materials with material temperatures of up to 1,400 °C. The Grenzebach sectional cooler is suitable for very fine particles and for solids interspersed with coarser particles or agglomerates. Treatment of reactive products is also possible.

    Sample applications:

    • Petroleum coke
    • Zinc oxide
    • Magnesite causter
    • Molybdenum oxide
    • STPP
    • Catalysts
    Process technology project management

    Exploiting potential with optimum process engineering

    Project management to ensure your success

    Ensuring high product quality, being able to deliver continuously, and meeting customer needs with maximum process efficiency: these are the requirements that unite companies in numerous industries dealing with powders and bulk solids. The Grenzebach team is your reliable partner.

    To ensure that you achieve the best possible results over your plant’s entire life cycle, we get involved in working together at an early stage. At the planning phase, we analyze the material properties of your bulk solids in our own laboratory in Bad Hersfeld. Based on the knowledge we gain, we create your tailor-made solution for process engineering.

    You may also have questions about tomorrow and the day after: How can materials be processed in a more product-friendly way? How can process plants work even more energy-efficiently? Grenzebach’s experts can provide answers for process optimization here, too.

    Analysis service and feasibility tests

    • Analysis of bulk material properties, such as material characteristics, bulk density, particle size and other parameters
    • Feasibility test under realistic conditions in Grenzebach’s technical center
    • Preliminary test for special requirements; integrated into your research and development

    Layout and integration into your process environment

    • Defining parameters and designing the equipment accordingly.
    • Scaling of the equipment
    • 3D scanning of your operating environment
    • Technical solutions for integration of upstream and downstream process steps

    Commissioning and assembly

    • Worldwide assembly and commissioning by Grenzebach experts on site
    • Training and instruction of your employees
    Kiln and drum measurement

    Kiln and drum measurement

    Is everything operating perfectly? Grenzebach checks the condition of your rotary kilns, drums, dryers, coolers, sectional and tubular coolers, and calciners, applying extensive measuring and analysis methods. Our special measuring equipment and our trained engineers enable us to take measurements both during hot operation and during a plant shutdown. We present the results to you directly on site and are happy to advise you on the planning of preventive maintenance.

    Kiln and drum measurement

    Contact

    Your contact person: Michael Meyer

    From special solutions for processing your products to questions about existing plants: feel free to contact us with your process engineering concerns!

    Michael Meyer Grenzebach