Process technologies for tomorrow.

SUPERABSORBENT POLYMERS Mixing & drying technologies.

PROCESS SOLUTIONS FOR SAP PRODUCTION

Combining continuous mixing and drying technologies.

Superabsorbent Polymers (SAP) are

polymers that can absorb and retain

extremely large volumes of liquid.

Amazingly, water absorbing polymers

(hydrogels) can absorb and retain up to 500

times their own weight in water.

Their absorbency is determined by the type

and ratio of cross-linking agents used to

make the gel. Low density cross-linked SAP

have a larger absorbent capacity, while the

higher cross-linked SAP have lower

absorbent capacity but form firmer gels.

Hosokawa Micron offer a range of

specialist powder analysis equipment along

with an extensive portfolio of laboratory

and pilot scale machines, suitable for

processing from a few kilos to a few grams,

and capable of processing materials in the

nano size fineness range.

TRY BEFORE YOU BUY

At Hosokawa Micron B.V. we have our own

testing and process development centre in

Doetinchem, the Netherlands. It offers unique

possibilities for testing your product to

determine the most efficient process, system

or plant prior to final design. We can provide

laboratory-level as well as production-sized

trials.

Whether you wish to test a single machine or a

complete powder processing system, the same

skilled and experienced staff are here to help

ensure that your requirements are met, and

that you are entirely satisfied with the results.

We offer process equipment and technologies

from individual units to large scale bespoke

system solutions..

TYPICAL APPLICATIONS INCLUDE:

Candles

Composites and laminates

Disposable hygiene products

Fire-retardant gel

Medical waste solidification

Motionless water beds

Surgical pads

Soil conditioners

Waste stabilization

Water-blocking applications in

electrical and optical cables

Wound dressing

02 | HOSOKAWA MICRON GROUP

FROM R&D TO

PRODUCTION SCALE

COMBINING MIXING WITH DRYING

The Flexomix mixer/agglomerator can be

used to add surface cross-linking agents to

SAP. It can be used to dose powder and liquid

in the correct proportions to create a

homogenous mixture and is self-cleaning

to avoid product build-up which can often

be a problem in SAP production.

The Flexomix is a unique vertical

continuous mixer and agglomerator,

developed to achieve a highly homogeneous

mixture of powders and liquids. It is unlike any

other continuous mixer with its vertical

cylindrical chamber and vertical rotating

shaft.

Flexomix mixer/agglomerator

Its high rotational speed and turbulent mixing

keep the mixer chamber clean; it provides

accurate dosing of both liquid and solid

components and is suitable for even the

stickiest of media.

After mixing, the product can be heat treated

using the Torusdisc continuous disc dryer.

The Torusdisc dryer gently moves the product

while the product is heated. In proportion to

its compact size, the Torusdisc dryer has a

very large heat coefficient and a very large

energy transfer area, making it well suited to

the heat treatment of SAPs.

The Torusdisc uses hot air or gas as a drying

medium in combination with a heating jacket

and heating rotor. The rotor consists of

special, heated discs within a cylindrical

jacketed housing. It is a low-speed, horizontal,

indirect dryer, suitable for heating and

cooling various types of product like filter

cakes, powders, viscous materials and

granules.

Torusdisc continuous dryer

It is a compact dryer that combines high heat

transfer rates ranging from 85 to 300 W/m²K

with high surface/volume ratios. Residence

times range from minutes to several hours,

making the Torusdisc more versatile than

almost any other indirect heat exchanger

available today.

GRINDING

Solution-based polymerization is one of

the methods for SAP manufacture. The

solution process uses a water based

monomer solution to produce a mass of

reactant polymerized gel.

The polymerization's own reaction energy

(exothermic) is used to drive much of the

process, helping reduce manufacturing

cost.

The reactant polymer gel is then chopped

to a size of approx. 3-5 cm and dried

typically in a belt dryer. After the drying

process it is pre-ground by means of a

Rotoplex cutting mill to 3-5 mm and

ground to its final granule size by roller

mills. Sieving machines are installed at the

roller mill outlet for the required top size

limitation. Oversize material is conveyed

back to the roller mill. The requested

particle size is in the range of 150-600 μm

and with maximum 3-5 % < 150 μm, which

results in a dust free and free flowing

product.

Any treatment to enhance performance

characteristics of the SAP is usually

accomplished after the final granule size is

created. For such surface modifications two

process are used, coating process with

liquid injection in intensive mixer (i.e.

Flexomix) and a following cross linking

process in a paddle dryer. The production

capacity of such a continuous process is in

the range of 2.5 to 3 t/h for each line.

Rotoplex cutting mill

HOSOKAWA MICRON GROUP | 03

Mixing, drying

HOSOKAWA MICRON B.V.

Team Chemicals, Minerals & Metals

Gildenstraat 26

7005 BL Doetinchem

Netherlands

tel. +31 314 373 460

cmm@hmbv.hosokawa.com

www.hosokawamicron.nl

PLENTY OF REASONS TO GIVE US A CALL

Combined advantage

The Hosokawa Group has

several technology centres,

each expert in one or more

specific powder processing

technologies. Combining

this knowledge gives you

the benefit of having just

one supplier and contact.

Vast experience

Hosokawa has decades of

experience in providing

solutions for super-

absorbent polymer (SAP)

processing. We have

references all over the

world, including the biggest

names in the industry.

R&D/test facilities

Hosokawa has extensive

research and test facilities

in Germany and the

Netherlands to perfectly

assist clients determining

what the best system

solution is for their specific

process or application.

Worldwide service

Hosokawa has a very

responsive and smoothly

operating service depart-

ment. Our Service Team

carries out repair and

maintenance services

onsite or in one of our

fully-equipped workshops.

More information

For detailed information and equipment and system specifications, please contact one of our offices below or visit us online.

HM

G.S

AP.E

NG

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3

Grinding

HOSOKAWA ALPINE A.G.

Food Division

Peter-Dörfler-Straße 13-25

86199 Augsburg

Germany

tel. +49 821 5906-402

food@alpine.hosokawa.com

www.hosokawa-alpine.com