In cold briquetting process, many industries face a frustrating problem: briquettes that break easily during drying, storage, transportation, or use. Broken briquettes not only increase rework rates and production costs but also disrupt downstream processes and negatively impact customer satisfaction.
While equipment and operating parameters are often blamed, the real root cause often lies in the raw materials. In many cases, the majority of cold briquetting failures can be traced back to raw material problems. Without addressing these issues at the source, even the most advanced machines or binders cannot achieve stable, high-quality briquettes.
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This article draws on Jianjie Group’s practical field insights to briefly introduce eight common raw material issues that can cause cold briquettes to break or become brittle. We hope it will help you better understand these challenges and take steps toward improving the stability and quality of your briquetting process.
Why Raw Materials Are the Key to Affect Briquettes Quality
Cold briquetting is a typical powder agglomeration process. Through external pressure and the role of binder, fine powders are compacted into stable, high-strength briquettes without thermal treatment.
If the raw material has defects, the internal structure of the briquette becomes unstable, resulting in low strength, cracks during drying, and high breakage rates during storage or transportation.
Raw Material Pile
For example, in steel plant, if EAF dust or mill scale contains excessive fine particles or moisture fluctuations, the resulting briquettes may crumble during handling or disintegrate in the furnace. This not only disrupts production process but also increases recycling costs and material losses.
Addressing these raw material challenges at the source ensures reliable briquette performance and more efficient recycling or smelting operations.
8 Critical Raw Material Problems That Lead to Briquettes Breakage
Over years of on-site investigations and production analysis, it has been found that most cases of briquette breakage are closely linked to raw material characteristics rather than equipment or binder performance.
The following eight raw material issues are the most common root causes of poor briquette strength and durability. By understanding how these problems arise and affect the briquetting process, producers can take targeted actions to improve briquettes stability and reduce breakage rates.
1. Uneven or Excessively Fine Particle Size
Raw materials with poorly graded or overly fine particles struggle to form a stable internal structure. Freshly pressed briquettes may appear smooth, but as drying progresses, uneven shrinkage occurs due to high porosity, leading to cracks and easy breakage during handling or transport.
2. Unstable Moisture Content
Moisture fluctuations, whether from inconsistent raw material storage, transport, or absorption, directly affect briquetting and drying. Excess moisture causes warping and cracking during drying, while too little prevents full binder activation, resulting in weakly bonded particles and poorly formed briquettes.
3. High Impurity Levels
염소(Cl), 황(S), 인(P), 아연(Zn), 납(Pb) 등의 불순물을 함유한 원료는 표면 결함 및 내부 약점을 유발할 수 있습니다. 고온 환경에서 이러한 불순물은 기화되거나 반응하여 구조적 무결성을 손상시키고 환경 규제 준수 위험을 증가시킬 수 있습니다.
4. 화학적 조성의 불일치
주요 화학 성분의 배치별 변동으로 인해 브리켓의 강도와 크기가 예측 불가능해집니다. 이로 인해 공장에서는 장비나 결합제 비율을 자주 조정해야 할 수 있으며, 표준화된 생산이 어려워지고 운영 신뢰성이 저하됩니다.
5. 기름 또는 유기 오염 물질의 존재
일부 원료, 특히 산업 부산물에는 입자 표면을 코팅하는 오일이나 기타 유기 잔류물이 포함되어 있습니다. 이로 인해 결합제의 접착력이 약해져 압축력이 약한 브리켓이 생성되고, 특히 고온 조건에서 균열이 발생하기 쉽습니다.
6. 바인더와의 호환성이 떨어짐
원료 표면의 특정 특성, 예를 들어 높은 오일 함량, 왁스 함유 또는 반응성 불순물은 결합제 성능에 영향을 미칠 수 있습니다. 결합제 투입량을 신중하게 최적화하더라도 이러한 원료는 여전히 깨지기 쉬운 브리켓을 생성할 수 있습니다. 이는 원료의 특성에 잘 맞는 결합제를 선택하는 것이 중요하다는 점을 강조합니다.
7. 불안정한 공급 및 취급 조건
공급업체 변동, 자재 품질의 불일치, 보관 또는 운송상의 문제는 수분 변동이나 오염과 같은 다른 원자재 문제를 악화시킬 수 있습니다. 불안정한 공급망은 배치별 품질 편차 및 생산 차질 위험을 증가시킵니다.
8. 높은 산화칼슘(CaO) 함량
Materials with elevated CaO levels are highly hygroscopic. When exposed to moisture, CaO expands, causing internal stresses that lead to self-cracking, surface bulging, or powdering.
This reduces storage stability and overall briquette yield. If left unaddressed, excessive CaO content significantly lowers production yield and increases material waste.
젠지에 바인더 솔루션 및 고품질 브리켓 생산을 위한 서비스 지원
원자재 관련 문제는 종종 복잡하며 생산 현장에서 완전히 해결할 수 없는 경우가 많지만, 적절한 기술적 접근 방식을 통해 브리켓 성형에 미치는 부정적인 영향을 크게 줄일 수 있습니다.
Jianjie focuses on providing high-performance 맞춤형 바인더다양한 종류의 원료에 맞춰 설계되었으며, 생산자가 냉간 성형 공정을 안정화하고 전반적인 제품 품질을 향상시킬 수 있도록 전문적인 지원 서비스를 제공합니다.
Jianjie 연탄 바인더
Jianjie가 할 수 있는 방법 돕다 브리켓 성능 향상
맞춤형 바인더 배합
고함량 아연 전기로 분진 또는 유분 오염 분말과 같은 특정 원료 문제를 해결하기 위해 맞춤 설계된 바인더.
Dynamic Recipe Guidance
Recommendations for adjusting binder ratios in response to fluctuations in raw material composition, ensuring more consistent performance.
Improved Particle Bonding
High-activity binders that enhance adhesion in ultra-fine or high-porosity materials, helping to offset structural weaknesses.
Moisture Tolerance Enhancement
Binders formulated to remain effective within a wider moisture range, reducing the risk of cracking caused by uneven water content.
Technical Consulting and Support
On-site guidance to help plants optimize handling practices, stabilize supply chains, and standardize quality control procedures.
By combining targeted binder solutions with process expertise, Jianjie assists customers in minimizing the effects of raw material variability, resulting in stronger, more durable briquettes and more reliable furnace performance.
Collaborative Approaches to Improve Briquettes Quality
Briquettes breakage usually results from several raw material issues interacting with each other. While these challenges cannot always be completely eliminated, they can be effectively managed through careful monitoring and process adjustments.
Jianjie Group supports customers with high-performance binders and on-site technical guidance that integrate with existing production processes to enhance briquette strength and reduce breakage rates.
Reach out to Jianjie for professional binder solutions and technical support to address your raw material challenges, enhance briquette strength, and reduce breakage in your cold briquetting process.
