Micro-Structured Iron (III)-Hydroxide Agglomerates with High Porosity as Adsorbent

This study focusses on the production of micro-structured agglomerates with high porosity from iron (III)-hydroxide-containing materials as adsorbent. A fractal-like structure of the agglomerates was created through a two-stage agglomeration process. Developing porous structures was necessary to increase the adsorption capacity. Various materials were used for the agglomeration experiments: i) filter cake (dry matter content 23 to 27 wt.-%); ii) FerroSorp®DGµ, a product which is already being used commercially for various applications in water cleaning. These materials in the pristine state have different characteristics such as dry matter content and particle size distribution. The desired optimised agglomerates can be achieved with the help of additives or binders, respectively. Additionally, the agglomeration process parameters play a vital role. In order to produce agglomerates with high porosity, the process was carried out in two steps. Firstly, FerroSorp®DGµ (d90 < 30 µm) was agglomerated jointly with the aforementioned filter cake in an Eirich intensive mixer (particle size range 125 µm < d90 < 500 µm). The second agglomeration step post drying was carried out in a pelletisation disc or in an Eirich intensive mixer with the addition of polymeric binders (up to particle sizes ranging from 2 to 4 mm). Agglomerates were characterised both in short and long term loading tests using phosphate as model ion. Contact times were less than 10 min, similar to practical application in percolation columns, or more than 7 days, respectively. The results show that the agglomerates produced in the two-stage pelletisation process have more advantageous properties like better accessibility of the active sites obtained by specificly influencing the particle size distribution during the two-stage pelletisation process.