Fluid Bed Granulator for Calcium Chloride Granules (CaCl₂)

Project Overview

The project involves the design, engineering, supply, installation, and commissioning of a Calcium Chloride Granulation Plant based on Fluid Bed Granulator (FBG) technology.
The system is designed to convert calcium chloride feed into uniform, free-flowing granules with controlled moisture and particle size.

The process utilizes a coal-fired indirect heating system to generate hot air for fluidization, ensuring high thermal efficiency while preventing any contamination of the product.

Scope of Supply

Fluid Bed Granulator with complete internals
Coal-fired indirect hot air generator
Heat exchanger for indirect heating
Feed preparation and dosing system
Granulation spray system
Product discharge and collection system
Air handling system (blower, ducting, dampers)
Dust collection system (cyclone / bag filter)
Control panel with automation and safety interlocks
Erection, commissioning, and performance testing

Process Description

Calcium chloride feed material is introduced into the Fluid Bed Granulator, where it is fluidized using heated air supplied from an indirect coal-fired hot air generator.

The hot air passes through a heat exchanger, ensuring that combustion gases do not come into contact with the process air. Controlled spraying promotes granule formation through agglomeration while moisture is simultaneously removed.

The granulated product is dried to the desired residual moisture level and discharged as uniform calcium chloride granules, suitable for storage, handling, and downstream applications.

PROCESS FLOW DIAGRAM FOR GRANULATION UNIT

PROCESS FLOW DIAGRAM FOR HOT AIR GENERATION UNIT

Calcium Chloride Granulation Process

(Liquid to Granules)

1. Feed Tank

Liquid calcium chloride solution is stored in the feed tank. An agitator ensures uniform concentration and prevents settling before processing.

2. Screw Pump (Metered Feed)

The liquid feed is transferred from the feed tank using a screw pump with variable frequency drive (VFD). This provides precise control of the feed rate into the granulation system.

3. Fluid Bed Granulator

The liquid calcium chloride is sprayed into the fluid bed granulator. Hot air enters from the bottom, fluidizing the particles.

Moisture evaporates rapidly
Solid calcium chloride deposits on seed particles
Granules grow in a controlled and uniform manner

4. Hot Air Generator & Air Filter

Ambient air is filtered and heated in the hot air generator. The heated air supplies the energy required for granulation and drying inside the fluid bed.

5. Rotary Sieve (Size Classification)

Granules exiting the fluid bed pass through a rotary sieve:

On-size granules continue forward
Oversized granules are separated for crushing
Undersized fines are recycled back into granulation

This ensures consistent product size.

6. Crusher (Oversize Recycling)

Oversized granules are reduced to the desired size in the crusher and recycled back into the system, improving yield and minimizing waste.

7. Bucket Elevator

Accepted granules are lifted using a bucket elevator and conveyed to the finished product section with minimal breakage and dust generation.

8. Finished Granules Collection

Uniform, free-flowing calcium chloride granules are collected and made ready for storage, packing, or further handling.

9. Cyclone Separator (Fine Recovery)

Process air carrying fine particles exits the granulator and enters the cyclone separator. Fine calcium chloride powder is recovered, and clean air moves to the next stage.

10. Venturi Scrubber – Stage 1

Air from the cyclone passes through a venturi scrubber, where water captures remaining fine dust particles.

11. Scrubber Tank – Stage 1

The dust-laden water is collected in the scrubber tank for separation and reuse or disposal as per process design.

12. Venturi Scrubber – Stage 2

A second venturi scrubber provides additional air cleaning to meet strict emission standards.

13. Scrubber Tank – Stage 2

Final particulate removal occurs here before clean air discharge.

14. Induced Draft Blower

The ID blower maintains negative pressure throughout the system, ensuring stable operation and controlled airflow.

15. Exhaust Stack

Cleaned air is safely discharged to the atmosphere in compliance with environmental regulations.

Final Product Outcome

The system converts liquid calcium chloride into uniform, low-dust granules with:

Controlled particle size
Low moisture content
High bulk density
Excellent handling and storage characteristics

Key Design Features

Fluid Bed Granulation for uniform particle growth
Indirect coal-based heating to maintain product purity
Optimized air distribution for stable fluidization
Controlled moisture removal to prevent lump formation
Energy-efficient thermal design
Robust construction for continuous industrial operation
Low maintenance and operator-friendly layout

Project Highlights

Proven Fluid Bed Granulator technology
Cost-effective coal-based heating solution
High-quality, dust-free granule production
Environmentally safer indirect heating system
Scalable design for future capacity expansion
Reliable operation with consistent product quality

Applications & Benefits of Calcium Chloride Granules

Applications:

Dust suppression on roads and mining areas
De-icing and anti-icing applications
Oil and gas drilling fluids
Construction industry (concrete acceleration)
Moisture control and desiccant applications
Industrial drying and chemical processing

Benefits:

Free-flowing, non-caking granules
Easy handling, storage, and transportation
High chemical purity and consistency
Rapid solubility and effective performance
Reduced material loss and dust generation