COMPACTED CALCIUM-BASED GRANULES

Abstract

The present disclosure is related to compacted calcium-based granules, in particular pellets, spheroidal/lens-shaped pellets, exhibiting specific chemical and physical properties and comprising a source of calcium and/or a source of magnesium, and optionally one or more additives. The present disclosure further relates to a method for the production of said pellets and to the use of said pellets in, for example, the steel industry, agriculture (in particular precision farming) and the glass industry.

Claims

1. Compacted spheroidal pellets, comprising: a calcium source and/or a magnesium source, said calcium source comprising at least CaO, said magnesium source comprising at least MgO; wherein the pellets comprise at least 60 wt % of said CaO and/or said MgO, based on a total weight of the pellets, wherein said pellets have: an average size lower than 10 mm, measured by sieve analysis, and a granule density equal to or higher than 1.60 g/cm.sup.3 measured by mercury picnometry.

2. The pellets according to claim 1, wherein the pellets have a particle size distribution after tablet breaking and prior to screening, having a D10/D90 ratio equal to or higher than 0.60, wherein the D10 value and the D90 value are obtained by means of sieve analysis.

3. The pellets according to claim 1, wherein the pellets have a mercury porosity equal to or lower than 0.3 cm.sup.3/g, measured by mercury intrusion on pores with a diameter larger than 7.5 nm.

4. The pellets according to claim 1, wherein the pellets have a load until rupture of at least 40 N, measured by compression testing until rupture.

5. The pellets according to claim 1, wherein the pellets have a neutralization value of at least 70 equivalent CaO according to EN12945.

6. The pellets according to claim 1, wherein said pellets have a dispersibility of at least 70% at 315 μm in water, according to the method defined in EN15704.

7. The pellets according to claim 6, wherein the pellets are uncoated pellets.

8. A process for manufacturing the compacted spheroidal pellets according to claim 1, wherein said process comprises at least the following process steps: providing a homogeneous powder comprising a calcium source and/or a magnesium source, the calcium source comprising at least CaO, the magnesium source comprising at least MgO, compacting the homogeneous powder between two rollers to form a compacted tablet, tablet breaking of the compact tablet into compacted spheroidal pellets, screening the compacted spheroidal pellets by sieving to separate undersized and oversized compacted spheroidal pellets from the pellets having a pre-selected pellet size, wherein a gap, being a distance between outer surfaces of the rollers, said outer surfaces facing each other, measured in a plane defined by the middle point of a cross-section of the two rollers and their central axis, is at least 0.1 mm, and wherein a force between the two rollers, measured at a position where the gap is measured, in the compacting step is between 25 kN and 75 kN, for a roller having a diameter between 250 mm and 1500 mm, and having a width between 40 mm and 1200 mm, meaning applying a pressure between 50 MPa and 500 MPa.

9. The process according to claim 8, wherein the homogeneous powder comprises an additive selected from the group consisting of a fertilizer, a nutrient, and a binding agent or lubricating agent.

10. The process according to claim 8, further comprising a mixing step prior to the compacting step.

11. The process according to claim 8, wherein the force between the two rollers in the compacting step is between 40 kN and 60 kN.

12. The process according to claim 8, wherein the process further comprises a post-treatment applied to the compacted spheroidal pellets after the step of sieving the pellets.

13. The process according to claim 8, wherein the process further comprises a step of recycling the undersized compacted spheroidal pellets and/or the oversized compacted spheroidal pellets.

14. A process for producing steel, the process comprising: forming slag during production of steel, wherein forming the slag includes using the pellets according to claim 1 as a slag forming material.

15. A process for producing glass, the process comprising: forming glass using the pellets according to claim 1 as a raw material.

16. The process of claim 15, wherein using the pellets comprises adding the pellets to control chemistry and viscosity of molten glass during manufacturing.

17. The compacted spheroidal pellets of claim 1, wherein the pellets comprise at least 70 wt % of said CaO and/or said MgO, based on the total weight of the pellets.

18. The compacted spheroidal pellets of claim 1, wherein the pellets have a granule density equal to or higher than 1.70 g/cm.sup.3, measured by mercury picnometry.

19. The pellets according to claim 3, wherein the pellets have a mercury porosity equal to or lower than 0.2 cm.sup.3/g.

20. The pellets according to claim 4, wherein the pellets have a load until rupture of at least 75 N.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] FIG. 1 relates to a schematic representation of a process according to the present disclosure.

[0052] FIG. 2 relates to another schematic representation of a process according to the present disclosure.

[0053] FIG. 3 shows a photo of spheroidal pellets according to the present disclosure, having an average size of 4 mm.

[0054] FIG. 4 shows a photo of spheroidal/lens-shaped pellets according to the present disclosure, having an average size of 5.5 mm.

[0055] FIG. 5 shows the cumulative particle size distribution (PSD) in graphical form for the examples according to the present disclosure and two comparative samples.

[0056] FIG. 6 shows the projection angle distribution for several examples.

[0057] FIG. 7 shows the average projection distance for different rotation speeds of the distribution disk of the projecting for several examples.

OVERVIEW OF THE REFERENCE NUMBERS USED IN THE DRAWINGS

[0058] 1 homogeneous powder [0059] 2 compactor [0060] 3 first roller [0061] 4 second roller [0062] 5 compacted tablet [0063] 6 tablet breaker [0064] 7 polishing drum [0065] 8 compacted spheroidal pellet [0066] 9 screener [0067] 10 pellet having a pre-selected pellet size [0068] 11 oversized pellet [0069] 12 undersized pellet [0070] 13 additive [0071] 14 post-treatment equipment [0072] 15 pellet after post-treatment [0073] 16 grinder [0074] 17 recycled powder particles [0075] 18 mixer [0076] 19 homogeneous powder [0077] 50 spheroidal pellet [0078] 51 first plate [0079] 52 second plate

DETAILED DESCRIPTION

[0080] The pellets of the present disclosure comprise at least a calcium source and/or a magnesium source. The calcium/magnesium source to be compacted may be a powder comprising particles having a D95 value of the particle size distribution (PSD) equal to or lower than the desired size of the resulting pellet, such as a D95 value equal to or lower than 50% of the desired D50 value of the pellets, wherein the particle size is measured by sieve analysis. For example, for compacted pellets according to the present disclosure having an average size of 4 mm (or D50 value), the calcium/magnesium source preferably is a powder comprising particles having a D95 value lower than 2 mm.

[0081] The D50 value and the D95 value of a compound comprising particle are calculated from the particle size distribution for that compound, e.g. the pellets or the powder, and in particular from the cumulative particle size distribution for that compound comprising particles. The D50, resp. D95 value is the size of the particles of the compound—i.e. pellets or powder comprising particles—for which 50%, resp. 95% of the compound's particles have a size equal to or lower than the D50, resp. D95 value. Other Dx values are calculated in the same way, wherein x is a value between 0 and 100, meaning that for a given Dx value x % of the particles (pellets, granules, powder particles) have a size equal to or lower than the Dx value.

[0082] For example, for particles or pellets having an average size (i.e. D50 value of the particle size distribution (PSD)) of 4 mm, a D10 value of 1 mm and a D90 value of 10 mm, this means that 10% of the particles or pellets have a size equal to or lower than 1 mm and 90% of the particles or pellets have a size equal to or lower than 10 mm. This means that 80% of the particles or pellets have a size higher than 1 mm and equal to or lower than 10 mm. The D10/D90 ratio is 0.10.

[0083] The particle size distribution is in the light of the present disclosure considered as a wide particle size distribution.

[0084] For example, for particles or pellets having an average size (i.e. D50 value of the particle size distribution (PSD)) of 4 mm, a D10 value of 3.6 mm and a D90 value of 4.8 mm, this means that 10% of the particles or pellets have a size equal to or lower than 3.6 mm and 90% of the particles or pellets have a size equal to or lower than 4.8 mm. This means that 80% of the particles or pellets have a size higher than 3.6 mm and equal to or lower than 4.8 mm. The D10/D90 ratio is 0.75. The particle size distribution is in the light of the present disclosure considered as a narrow particle size distribution.

[0085] Preferably, the calcium source comprises calcium oxide (CaO) as main component. The calcium source may further comprise calcium carbonate (CaCO.sub.3) and/or calcium hydroxide (Ca(OH).sub.2). The calcium source may further comprise dolime (CaO.MgO) and/or dolomite (CaMg(CO.sub.3).sub.2).

[0086] Preferably, the magnesium source comprises MgO as main component. The magnesium source may further comprise MgCO.sub.3 and/or Mg(OH).sub.2.

[0087] The pellets according to the first aspect of the present disclosure comprise at least 60 wt % of CaO and/or MgO, based on the total weight of the pellets. The pellets may comprise at least 65 wt % CaO and/or MgO, such as at least 70 wt %, 75 wt %, 80 wt %, 85 wt % or 90 wt % CaO and MgO. With “at least 60 wt % of CaO and/or MgO” it is meant in the light of the present disclosure “60 wt % CaO” or “60 wt % CaO and MgO”, wherein the weight of CaO and MgO is to be understood as the sum of the weight (or weight fraction) of CaO, the weight (or weight fraction) of MgO, and, when present, the weight (or weight fraction) of CaO.MgO.

[0088] The compacted spheroidal/lens-shaped pellets according to the first aspect of the present disclosure may further comprise one or more additives, such as a fertilizer, a nutrient, a lubricating agent and/or a binding agent. Said nutrient may be a micronutrient. Said fertilizer may be, without being limited thereto, ammonium nitrate (NH.sub.4NO.sup.3), urea. Said nutrient may be, without being limited thereto, potassium chloride (KCl). The binding or lubricating agent may be, without being limited thereto, PEG, calcium stearate (C.sub.36H.sub.70CaO.sub.4), magnesium stearate (C.sub.36H.sub.70MgO.sub.4), NaNO.sub.3, or a lignosulfonate, such as calcium lignosulfonate (C.sub.20H.sub.24CaO.sub.10S.sub.2). Preferably, the optional additive is free of water.

[0089] The particle size distribution (PSD) is measured by means of sieve analysis. Sieve analysis is an analysis technique known in the field, and uses sieves with different mesh sizes to determine the weight fraction (in wt %) of the initial weight of the test sample that is passing the sieve with a given mesh size. Preferably, the sieving is performed by means of vibrating sieves, wherein the sieve vibrating is controlled by the equipment used. Alternatively, the sieving may be performed manually. Components of the test sample that pass a sieve with a certain mesh size have at least one dimension that is smaller than the mesh size of that particular sieve. The mesh sizes used in the sieve analysis will depend on the expected dimensions of the particles under investigation. It may be preferred to perform a first sieve analysis with a wide range of mesh sizes, for example going from 50 μm to 15 mm, to have an idea of the particle size range. A second sieve analysis may be carried out with sieves having a mesh size around the particle size range obtained in the first sieve analysis, to obtain a more detailed particle size distribution. The standard measurement procedure starts with the sieve with the largest mesh size and ends with the sieve with the smallest mesh size.

[0090] Preferably, the pellets of the present disclosure have a D10/D90 ratio equal to or higher than 0.60, for example equal to or higher than 0.65, 0.70, or 0.75.

[0091] The compacted spheroidal/lens-shaped pellets may have a shape ratio equal to or higher than 0.56, such as equal to or higher than 0.58, 0.60, 0.62 or 0.65. The shape ratio is in the light of the present disclosure defined as the ratio of the minimum dimension (preferably the thickness) to the maximum dimension (preferably the length) of a same pellet.

[0092] The density of granules can be defined in different ways. The bulk density is the density calculated from the weight of pellets that fills a given volume, for example 300 cm.sup.3. The bulk density is measured according to ASTM D5004, performing the measurement three times and calculating the average bulk density. The bulk density takes into account the interstices between the pellets in said volume filled with pellets, the volume of solid material of the pellets and the volume of the closed and open pores of the pellet. For example, when a volume of 300 cm.sup.3 is filled with 600 g of pellets, the bulk density is 2 g/cm.sup.3.

[0093] The granule density, also called the apparent particle density, is the mass of a particle or pellet divided by its apparent pellet or granule volume, i.e. the volume calculated from the outer dimensions of the pellet. The granule density takes into account the volume of solid material of the pellets and the volume of the closed and open pores of the pellet. The granule density is measured with a mercury picnometer. The granule density by means of mercury picnometry is measured on 0.3 g pellets according to the following procedure (source: catalogue of PMI—Porous Material Inc., and ‘Improved mercury picnometry for measuring accurate volumes of solid materials’, by S Yamagishi and Y Takahashi, published on IOPScience website): [0094] sample cell is weighed, [0095] sample is placed in the sample cell, cell and sample are weighed together. This gives accurately the weight of the sample, [0096] mercury is added to the cell until saturation at atmospheric pressure, [0097] the cell including the sample and the mercury is weighed, [0098] the granule density of the sample is computed from the known weights, the volume of the cell, the volume of mercury in the cell with and without the sample being present, and the density of the mercury.

[0099] The measurement is performed 3 times, and the average granule density is calculated.

[0100] The skeletal density of a granule is defined as the mass of discrete pieces of solid material divided by the sum of the volume of the solid material and the closed pores. The skeletal density is measured according to ASTM D3766, and takes into account the volume of solid material of the pellets and the volume of the closed pores of the pellet.

[0101] The true density of a granule is defined as the mass of a pellet divided by the volume of solid material, excluding the volume of the open and the closed pores.

[0102] In the light of the present disclosure, the granule density or apparent particle density is preferred. Preferably, the compacted pellets have a granule density, measured by means of mercury picnometry, equal to or higher than 1.60 g/cm.sup.3, such as equal to or higher than 1.70, 1.85, 2.00, 2.10, or 2.2 g/cm.sup.3. It is to be understood that the maximal granule density of the pellet is the density of the raw material's skeleton for a pellet having no pores. For example, when pure CaO is used to produce the compacted spheroidal/lens-shaped pellets, the maximal granule density would be from 3.2 g/cm.sup.3 to 3.3 g/cm.sup.3.

[0103] The granule density is a measurement for the degree of porosity of a pellet. The higher the granule density, the more compact the pellet is and the lower the degree of total porosity. In the light of the present disclosure, pores in the pellets having an equivalent pore size lower than 2 nm are classified as micropores, while pores with an equivalent pore size higher than 50 nm are classified as macropores, and pores with an equivalent pore size equal to or lower than 50 nm and equal to or higher than 2 nm are classified as mesopores. This division into micropores, mesopores and macropores is common general knowledge (source: Reporting Physisorption Data for Gas/Solid Systems, with Special Reference to the Determination of Surface Area and Porosity, Pure & Appl. Chem., Vol. 57, No. 4, pp. 603-619, 1985).

[0104] Preferably, the pellets have a mercury porosity, measured on pores with a diameter larger than 7.5 nm, equal to or lower than 0.3 cm.sup.3/g, such as equal to or lower than 0.28, 0.25, 0.22, 0.20, or 0.19 cm.sup.3/g.

[0105] The mercury porosity is measured by mercury porosimetry, preferably mercury intrusion, and is expressed as the pore volume of the pellet that is filled with mercury during the test per gram of pellet (V.sub.Hg in cm.sup.3/g), for pores with a diameter larger than 7.5 nm. The test is performed on a mass of 0.3 g pellets. Mercury, a non-wetting liquid, is forced to enter the pores at a set pressure. The measurement is performed in a pressure range between 0.012 MPa and 200 MPa, starting with the lowest pressures. For low pressures, an equipment Porosimeter Pascal 140 (supplier: Thermo Scientific) is used, for high pressures, an equipment Porosimeter Pascal 240 (supplier: Thermo Scientific) is used.

[0106] Preferably, the compacted pellets have a load until rupture of at least 30 N, such as at least 40 N, such as at least 50 N, 60 N or at least 75 N. Preferably, the compacted pellets have a compressive strength, as measured by compression testing until rupture, of at least 1.8 N/mm.sup.2, such as at least 2.0 N/mm.sup.2 or 4.0 N/mm.sup.2. The inventors have discovered that pellets having a load until rupture of at least 40 N and/or a compressive strength of at least 1.8 N/mm.sup.2 provide sufficient mechanical strength to withstand handling, transport and distribution with a highly reduced degree of damaged pellets.

[0107] The load until rupture, and corresponding compressive strength, is measured by means of compression testing, in particular crush testing, until rupture, using a high quality digital particle strength tester YHKC-2A. A spheroidal/lens-shaped pellet is placed on a first plate with its two largest dimensions (preferably length and width) parallel to the plane of the first plate and its third dimension (preferably the thickness) perpendicular to the plane of the first plate. The first plate is positioned parallel to the plane of the floor. Another plate, parallel to said first plate, is pressed onto the pellet with a predetermined force. The applied force is increased until fraction or rupture of the pellet occurs. The load until rupture is defined as the force applied by the test equipment to the pellet under testing at the moment of rupture of the pellet.

[0108] The compressive strength of the pellet in term of pressure (N/mm.sup.2) is defined as the maximal force applied by the second plate to the pellet until fraction or rupture of the pellet divided by the average projected surface of the tested pellet. The average projected surface is calculated according to formula (I), wherein x and y are the two largest dimensions of the pellet, i.e. the dimensions that are positioned parallel to the plane of the first plate upon testing (preferably length and width).

[00001]$\begin{array}{cc}\mathrm{Average}\mathrm{projected}\mathrm{surface}=\pi *\frac{x}{2}*\frac{y}{2}& \left(I\right)\end{array}$

[0109] The compressive strength in the present disclosure is measured on pellets having an average dimension between the lowest dimension that provides pellets that are not fractured, and the highest dimension that provides single pellets. For example, for pellets having an average diameter (i.e. D50 value of the particle size distribution (PSD)) around 4 mm, the compressive strength is tested on pellets having dimensions between 3 and 5 mm. For pellets having an average diameter (i.e. D50 value) around 5.5 mm, the compressive strength is tested on pellets having dimensions between 5 mm and 6 mm. This ensures measurement on well-shaped pellets and allows comparison of the compressive strength values (in N/mm.sup.2) and of the load until rupture (in N). The compressive strength and the load until rupture is the average value of the compressive strength and the load until rupture of 15 to 30 pellets, preferably 15 to 20 pellets, more preferably 20 to 30 pellets, taken at random from a batch of pellets and tested individually.

[0110] The inventors have discovered that compacted pellets having a spheroidal/lens-shaped shape may even further reduce the risk of clogging and of blockage of the equipment. Spheroidal/lens-shaped pellets have a reduced number of sharp edges compared to pellets having random shapes. Said sharp edges may break off during handling of said pellets. A reduced number of sharp edges may reduce the quantity of powder and particles having undersized dimensions, and may thus reduce said clogging.

[0111] Preferably, in particular for use in soil conditioning (e.g. soil liming), the pellets have a neutralization value of at least 70 equivalent CaO according to EN12945, for example at least 75 equivalent CaO, 80 equivalent CaO, 85 equivalent CaO, 90 equivalent CaO, or 95 equivalent CaO.

[0112] Preferably, in particular for use in soil conditioning, the pellets, for example uncoated pellets (i.e. pellets without any additional coating), have a dispersibility of at least 70% at 315 μm in water, such as at least 75%, 80%, 85%, 87%, 90%, 92%, or 95% at 315 μm in water. The dispersibility is measured on the pellets of the present disclosure using the method defined in the standard EN15704, adapted to be applied for oxide-based products instead of carbonate products.

[0113] A further important characteristic of products used for soil conditioning (e.g. soil liming) is the handling performance and the dispersion performance to the field. An improved handling performance may ensure an easier filling of equipment and transportation of the pellets from the equipment reservoir to the distribution part of the equipment, e.g. a distribution disk that is rotating, with a reduction in loss of material due to crushing and breaking. An improved dispersion performance allows to spread the required quantity of product in a precise way, reducing the quantity of pellets needed for sufficient liming products, e.g. deacidifying products, per unit of soil surface area. The dispersion performance can be characterized by, amongst others, the projection distance and the projection angle, in particular the projection angle distribution.

[0114] The average projection distance is the weighted average of the projection distance distribution. The projection distance distribution provides the weight fraction of the total captured mass of pellets per projection distance, and is measured as explained below by using compartments of 0.5 m.

[0115] The maximal projection distance is the maximal distance to which the pellets are dispersed upon testing as explained below, and is a value for a set projection angle, since the projection angle is a set value in the test method.

[0116] The projection angle and the projection distance are measured using a method and equipment as described in NBN EN 13739-1:2011 and NBN EN 13739-2:2011.

[0117] The equipment used for the measurement of the projection angle is a lab-scale version of a fertilizer and nutrient distribution equipment (supplier: Irstea) onto which a collector is placed. The collector is divided in compartments of each 15°, as measured from the middle point of the equipment in an angular direction. 1 kg to 2 kg of pellets are fed to the distribution equipment, which supplies the pellets to the distribution disk under a fixed angle and at a constant flow. The distribution disk rotates at a preset velocity. In the light of the present disclosure, the rotational speed of the distribution disk is varied between 600 rpm and 1000 rpm. Such a rotational speed represents a real rotational speed used in agriculture on large-scale devices, in particular for precision farming. The collector collects the projected, dispersed pellets and provides information on the weight fraction of the total captured mass that is projected at each angle.

[0118] A narrower projection angle distribution indicates a more precise orientation of the pellets upon dispersion. A lower average projection angle indicates a lower loss of energy in the distribution equipment, in particular in the rotating distribution disk of the distribution equipment, and a lower energy loss indicates a more efficient dispersion or projection of the pellets to the field's surface area.

[0119] The projection distance is measured by means of an equipment that is a lab-scale version of a fertilizer and nutrient distribution equipment (supplier: Irstea, equipment described in for example EP 1 610 112 B1) onto which a collector is placed. The collector extends in a radial direction from the middle point of the equipment, and is divided in compartments of 0.5 m long. The projection angle for the test is determined and set in the equipment. 1 kg to 2 kg of pellets are fed to the distribution equipment, which supplies the pellets to the distribution disk under the set projection angle and at a constant flow. The distribution disk rotates at a preset velocity. In the light of the present disclosure, the rotational speed of the distribution disk is varied between 600 rpm and 1000 rpm. The collector collects the dispersed pellets and provides information on the weight fraction of the total captured mass that is projected in radial direction, under the set projection angle, at each compartment of the collector. These weight fractions provide the projection distance distribution at the set projection angle, and allow to calculate the average projection distance.

[0120] By repeating the projection angle measurement for every projection angle, a 3D-representation of the dispersion of the pellets can be obtained, presenting in the X-Y-plane the surface area covered in angular and radial direction, and on the Z-axis the weight fraction of the total captured mass at each point in the X-Y-plane. Alternatively, a 3D-representation can be obtained by extrapolating the projection distance data obtained for a single, set, projection angle, wherein the extrapolation is performed using a model. The 3D-representation of the pellet dispersion visualizes the dispersion of the pellets as measured by using a combination of projection angle measurement and projection distance measurement. The 3D-representation can also be presented in 2D, using a color scale to present the data of the Z-axis (weight fractions).

[0121] A large (maximal) projection distance allows also to supply pellets to a larger width of the field upon a single passage of the distribution equipment. For example, for a projection distance of 10 m, a width of 20 m is covered in a single passage, i.e. 10 m at both sides of the distribution equipment, in particular at both sides of the center of the rotating disk of the distribution equipment. An improved projection distance of 20 m allows to cover a width of 40 m in a single passage, i.e. 20 m at both sides of the distribution equipment, in particular the center of the rotating disk of the distribution equipment. Hence, the number of passages needed to disperse the required quantity of pellets to the field may be reduced.

[0122] Preferably, the pellets have an average projection distance of at least 15 m for rotation speeds of the distribution disk between 600 rpm and 1000 rpm, such as at least 16 m or 17 m. Preferably, the pellets have an average projection distance of at least 15 m, such as 16 m or 17 m, for a distribution disk rotation speed of 600 rpm. Preferably, the pellets have an average projection distance of at least 16 m, such as 18 m or 20 m, fora distribution disk rotation speed of 800 rpm. Preferably, the pellets have an average projection distance of at least 18 m, such as 20 m or 22 m, for a distribution disk rotation speed of 1000 rpm.

[0123] The applicants have surprisingly discovered that for the pellets of the present disclosure, an increased average projection distance is obtained compared to state of the art products. The applicants have further discovered that the dispersion has an improved homogeneity compared to state of the art products. Hence, the number of passages needed to cover uniformly a field is reduced. Distribution at the same speed in combination with a reduced number of field passages reduces the total time needed to distribute the required quantities of pellets to a field, which clearly is an economical advantage. Further, these improvements are realized when using standard precision farming equipment, excluding the need for specialized equipment.

[0124] Alternatively, when the dispersion of the pellets to the field requires maintaining a preset projection distance that is also used to disperse other products to the field, and/or that is limited by the field's geometry, orientation, and slope, and this requires a preset projection distance lower than the (maximal) projection distance obtainable for a preset rotational speed of the rotating disk of the distribution equipment, the rotational speed of the rotating distribution disk can be reduced. A reduced rotation speed of the distribution disk may reduce the impact force on the pellets, resulting in reduced damage to the pellets upon feeding to the distribution disk. The pellets according to the present disclosure reach surprisingly improved (average) projection distances that are similar to those of fertilizers and nutrients, contrary to products of the state of the art.

[0125] FIG. 1 and FIG. 2 show a schematical representation of a process for manufacturing pellets according to the present disclosure. The process is a substantially dry process, i.e. a process wherein substantially no water and/or substantially no liquid, for example a solvent, is used.

[0126] According to FIG. 1, a homogeneous powder 1 is provided, comprising a calcium source and/or a magnesium source, the calcium source comprising at least CaO, the magnesium source comprising at least MgO. The homogeneous powder may also comprise one or more additives. Preferably, the homogeneous powder 1 is homogeneous to the naked eye. The powder 1 is supplied to a compactor 2 comprising at least a first roller 3 and a second roller 4. The powder 1 is compacted between the rollers 3 and 4 into a compacted tablet 5. Preferably the rollers 3, 4 have a parallel position into the compactor 2 and a predefined gap between the rollers 3, 4.

[0127] Preferably, one of the rollers 3 has a fixed position, in particular the axis of the roller 3 has a fixed position. Preferably, the other roller 4 has a movable position, in particular the axis of the roller 4 has a movable position, to allow provision of a constant compacting pressure. Advantageously, the compactor 2 further comprises a feed system to provide a flow of powder to the rollers 3, 4. The quality and uniformity of the tablets obtained in the compacting step depends at least on the provision of a steady flow of powder to the rollers 3, 4.

[0128] The feed system may be fitted with one or more conical screws. The rotational screw speed may be variable. Preferably, the screws squash out any air, i.e. air voids, from the powder feed, and perform a pre-compacting step on the powder before the compacting step by the rollers 3, 4. Preferably, one or both rollers 3, 4 have an embossed surface. Preferably, the embossed surface comprises a plurality of cavities. When one or both rollers 3, 4 comprise a plurality of cavities, the resulting tablet will have respectively one or two, parallel, surface sides comprising bumps. The powder 1 may be preheated prior to the compacting step, e.g. between room temperature and 140° C.

[0129] Preferably, the force between the rollers 3, 4, measured at the position where the gap is measured, is between 25 kN and 75 kN, preferably between 40 kN and 60 kN, for a roller having a diameter between 250 mm and 1500 mm, preferably between 400 mm and 600 mm, and having a width between 40 mm and 1200 mm, preferably between 145 mm and 500 mm. Preferably, the pressure between the rollers 3, 4, measured at the position where the gap is measured, is between 50 MPa and 500 MPa, such as between 75 MPa and 400 MPa, preferably between 100 MPa and 300 MPa. The rotational speed of the rollers is between 1 rpm and 50 rpm, preferably between 2 rpm and 35 rpm, more preferably between 3 rpm and 20 rpm. The rotation speed of the rollers is preferably adapted to the mass flow rate of the powder.

[0130] The duration of the compacting step may be in the range of seconds, from example between 0.5 seconds and 60 seconds. Preferably, the duration of the compacting step is less than 60 seconds, such as less than 50, 40, 30, 20, 10, or 5 seconds.

[0131] The compacted tablet 5 leaves the compactor 2 by means of gravity. This means that for a given granule density the tablet 5 must have certain minimal dimensions for easy exit from between the rollers 3, 4 of the compactor 2. The higher the granule density, the smaller the compacted tablet 5 may be.

[0132] The compacted tablet 5 is then transported into a tablet breaker 6 for the tablet breaking (separation) of the compacted tablet 5 into compacted spheroidal/lens-shaped pellets. The tablet breaking separates the individual spheroidal/lens-shaped pellets from the compacted tablets 5 between the tablet's bumps, said bumps formed by the embossed surface of one or both rollers 3, 4 of the compactor 2. The smaller the bumps, and thus the resulting spheroidal/lens-shaped pellets 8, are, the more difficult it is to control the tablet breaking to avoid damage to the pellets. Damage results in broken pellets, the pellets consequently having undersized dimensions. The smaller the bumps, the more difficult it is to avoid insufficient tablet breaking as well, which results in pellets with oversized dimensions. The compacted spheroidal/lens-shaped pellets are then fed to a polishing drum 7. The polishing drum 7 is a concentric or coaxial double drum where the internal drum is perforated so that smaller pellets can pass. Remaining inside the inner drum, the compacted pellets are polished by the rotation movement to eliminate sharp edges and irregular dimensions of the compacted pellets, to obtain compacted spheroidal/lens-shaped pellets 8.

[0133] Contrary to production methods of the state of the art, the inventors are able to obtain a very high yield in the tablet breaking step and the subsequent polishing step, leading to pellets having a narrow particle size distribution and a reduced amount of pellets having out-of-range dimensions. FIG. 3 and FIG. 4 show compacted spheroidal/lens-shaped pellets 8 after the tablet breaking step and the polishing step, having resp. an average size of 4 mm and 5.5 mm.

[0134] The compacted pellets 8 are then transported to a screener 9, for example a sieve or a set of sieves, for screening to separate the undersized pellets 12 and the oversized pellets 11 from the pellets 10 having a pre-selected pellet size. For example in the present disclosure to produce granule with a D50 around 3.5 mm, it is found that pellets having a size lower than 2 mm may be considered undersized, and are often broken pellets. These undersized particles may also comprise small quantities of dust and powder formed during the separation and the polishing steps. In the present disclosure, pellets having a size higher than 6 mm may be considered oversized, because they often show burrs, rough edges, and/or aggregates of two or more pellets still attached to each other.

[0135] Optionally, as shown in FIG. 2, the pellets 10 may receive a post-treatment in a post-treatment equipment 14. Said post treatment may be a coating step or a surface treatment such as, without being limited thereto, a Corona treatment, a plasma treatment, at atmospheric pressure or low pressure, a spray coating, a dip coating. Said post-treatment may be performed in a tumbler, e.g. a rotary drum, wherein the pellets are rotated. Alternatively, said post treatment may be performed such that the pellets are spread on a horizontal surface, such as a conveyor belt or a tray. Said post treatment may be a continuous process step. Alternatively, said post treatment may be a batch process step.

[0136] When the post-treatment is a coating, said coating may delay the absorption of water and/or moisture by the pellets, and/or to delay the reaction of the pellets with moisture and/or water. Additionally or alternatively, the coating may decrease the amount of dust generation as well. The coating may have one or more of the following functions, without being limited thereto: delaying the absorption of moisture from the atmosphere without negatively affecting the sensitivity to water in the midterm, improving the stability of the pellets, coloring the pellets (the coating being a dye or a colorant), providing a fertilizer and/or a macronutrient, enhancing the visual aspect of the pellet, for example the degree of shiny appearance.

[0137] When said post treatment is a surface treatment, said surface treatment may be a process to enhance or reduce the surface tension of the pellets for a limited duration of minutes, days, weeks, up to months.

[0138] The pellets 15 after the optional post-treatment are then packed for storage and shipment.

[0139] The process according to the present disclosure may further comprise a step of recycling the undersized 12 and/or oversized 11 compacted pellets. The recycling step may comprise the grinding of pellets 11, 12 in a grinder 16 into recycled powder particles 17, which may be reused in the production process. Upon reuse of the recycled powder particles 17, the powder 1, the recycled powder 17 and/or optionally an additive 13 may be mixed in a mixer 18 to obtain a homogeneous powder 19 that is then fed to the compactor 2.

EXAMPLES

[0140] Table 1 represents the relevant test data for four examples according to the present disclosure, as well as for two comparative examples. All samples are made starting from a powder having the same composition, comprising a calcium/magnesium source comprising primarily CaO and a limited amount of a magnesium source comprising primarily MgO. The particles in the powder mixture have a D95 equal to or lower than 2 mm.

[0141] The examples according to the present disclosure are produced by compacting the powder 1 at a pressure between the rollers 3, 4 of the compactor 2 between 40 kN and 60 kN, followed by separating the obtained tablets 5 in a tablet breaker 6, polishing the pellets in a polishing drum 7 followed by screening the compacted spheroidal/lens-shaped pellets 8 in a screener 9. The tablet breaker is typically a flake breaker made of two rotary shafts equipped with pins.

[0142] Samples 1 and 2 are both pellets having an average size (D50 value of the PSD) of approximately 4 mm, wherein Sample 2 comprises calcium stearate (CaSt—0.15 wt %) as additive to the powder.

[0143] Samples 3 and 4 are both pellets having an average size of approximately 5.5 mm (D50 value of the PSD), wherein Sample 4 comprises calcium stearate (CaSt—0.15 wt %) as additive to the powder.

[0144] The comparative examples are produced from pebbles coming from the kiln, followed by a screening step to separate undersized and oversized pellets from pellets having a pre-selected size. The pre-selected size is from 2 mm to 8 mm for Sample A and from 2 mm to 4 mm for Sample B. The pellets of Samples A and B do not comprise calcium stearate (CaSt) as additive.

[0145] The particle size distribution reported in Table 1 is measured by sieve analysis after the screening step. FIG. 5 shows the cumulative particle size distribution (PSD) in graphical form. The D10 and D90 value are calculated from the cumulative PSD. All samples 1 to 4, according to the present disclosure, have a D10/D90 ratio that is at least 0.73, while the D10/D90 ratio of the comparative samples A and B is lower than 0.60. The samples according to the present disclosure have thus a significantly narrower PSD.

[0146] It is further clear from Table 1 that the load until rupture is for all four samples of the present disclosure at least 80 N, up to even 110 N, while the load until rupture of the comparative samples is at most 27.5 N. The compressive strength, measured by compression testing until rupture, is for all four samples of the present disclosure at least 1.87 N/mm.sup.2, up to even 6.26 N/mm.sup.2, while the compressive strength of the comparative samples is at most 1.74 N/mm.sup.2, and goes as low as 0.62 N/mm.sup.2.

[0147] FIG. 6 shows the projection angle distribution for Sample 2 according to the present disclosure, reference Samples A and B of Table 1, spherical NH.sub.4NO.sub.3 (fertilizer) and non-spherical potassium chloride (KCl) (nutrient). The projection angle distribution is measured and calculated according to the test set-up and the procedure as explained above. The rotational speed or velocity at which the test is performed is 810 rpm. It is clear from FIG. 6 that the pellets of the present disclosure (Sample 2) show a narrower angle distribution than sample A, the nutrient and the fertilizer. For Sample 2 almost 100% of the pellets is distributed at a projection angle between −100° and 0° (a range of 100°), whereas for sample A the distribution is between −90° and 30° (a range of 120°).

[0148] FIG. 7 shows the average projection distance for Sample 2 according to the present disclosure, reference Samples A and B of Table 1, spherical NH.sub.4NO.sub.3 (fertilizer) and non-spherical potassium chloride (KCl) (nutrient). The projection distance is measured as explained above, for rotation speeds of the distribution disk from 600 rpm up to 1000 rpm.

[0149] It is clear from FIG. 7 that the pellets of the present disclosure (Sample 2) show significantly larger average projection distances than the pellets of the comparative examples (Samples A and B) and the nutrient KCl, and are the only calcium-based pellets having average projection distances in the range of—and even higher than—the spherical fertilizer NH.sub.4NO.sub.3. At 600 rpm, the average distribution distance of Sample 2 is 60% higher than that of Sample A, 32.50% higher than that of Sample B, and 47% higher than that of KCl. The average projection distance increases with the rotation speed of the distribution disk.

TABLE-US-00001 TABLE 1 Pellets of Present Disclosure Sample 1 Sample 2 Sample 3 Sample 4 Comparative samples Characteristic Unit 4 mm 4 mm CaSt 5 mm 5 mm CaSt Sample A Sample B Additive — CaStearate — CaStearate — — Granule density (Hg picnometry) g/cm.sup.3 1.971 2.22 1.70 1.60 1.52 1.58 Load until rupture N 80 100 100 110 27.5 27.5 Compressive strength N/mm.sup.2 5.07 6.26 1.87 2.18 0.62 1.74 Mercury porosity (V.sub.Hg intrusion) cm.sup.3/g 0.174 0.189 0.190 0.190 0.322 0.300 PSD after screening 0 μm wt % passing the 0 0 0 0 0 0 (Sieve analysis) 500 μm sieve with mesh 2.93 1.0 2.56 3.86 2.93 1.86 1000 μm width × μm 3.27 1.1 2.73 4.17 3.25 1.90 2000 μm 3.82 1.3 3.19 4.59 4.12 2.81 3150 μm 10.82 3.9 3.48 4.92 28.80 64.97 4000 μm 98.74 93.5 3.75 5.01 54.66 99.73 5000 μm 100.00 100.00 16.08 6.04 78.00 100.00 6300 μm 100.00 100.00 95.11 95.87 90.31 100.00 8000 μm 100.00 100.00 100.00 100.00 98.08 100.00 10000 μm 100.00 100.00 100.00 100.00 100.00 100.00 D10 (Calculated from Sieve analysis) mm 3.01 3.21 4.51 5.06 2.27 2.13 D50 (Calculated from Sieve analysis) mm 3.53 3.59 5.56 5.64 3.85 2.87 D90 (Calculated from Sieve analysis) mm 3.92 3.97 6.22 6.22 6.27 3.76 D10/D90 ratio No unit 0.77 0.81 0.73 0.81 0.36 0.57 Shape ratio (d.sub.min/d.sub.max) No unit 0.66 0.66 0.56 0.61 0.55 0.54