Cacl2 granules are made using cacl2 solution by using following steps:  

1. Hot air is generated by using fuel either by using indirect heating technology or direct  heating technology.  

2. Either granules already produced or sand particles of 2 to 4 mm size are fed in a fluidised  bed dryer  

3. The fluidised bed has a specific perforated plate which has guided holes or particular size to  enable good fluidisation of particles in fluidised bed once hot air is purged 

 4. Hot air is purged from bottom of guided hole perforated plate initiating fluidisation. 

 5. Cacl2 liquor is sprayed over the fluidising bed of granules while granules are in fluidisation  state.  

6. The liquid spray forms layer over granules and its size increases. The coated liquid gets dryed  due to hot air coming from below the bed while fluidisation is happening.  

7. As the calc2 quantity increases in fluidised bed, the granules start overflowing from the exit  of the fluid bed unit through a rotary air lock valve.  

8. The granules at the outlet of fbd are in a range which contains smaller size particles too  

9. The product at FBD outlet goes to a sifter which separates the fine particles from required  particle size granules.  

10. The smaller granules separated by sifter are recycled to the FBD so that they pass through  the coating and drying cycles again and become larger as product. 

11. The larger granules are taken to a fluid bed calciner. Here the product is heated above  calcinations temperature so that bound moisture is removed thus increasing purity of  product granules.  

12. The hot product granules are taken in to cooler so that granules are cooled.  

13. Cooled granules are taken into silo for storage and further packing.  

14. The hot air after fluidisation is passed through a cyclone separator. Cyclone separator  removes fine particles from exhaust air. Exhaust air is passed to scrubber.  

15. The fine particles removed at cyclone are further recycled to FBD for passing through the  coating and drying process so that larger particles are generated.  

16. The exhaust air is treated by using cacl2 liquor so that the exhaust air temperature drops  and also the scrubbing takes place partly. This also transfers heat from exhaust gases to the  calc2 liquor and also partly evaporation takes place increasing its solid content.  

17. The exhaust air which is passes through first scrubber then goes to second scrubber. In this  scrubber, either fresh water or low density cacl liquor is sprayed on to exhaust air so that it  is properly scrubbed.  

18. Clean air is then passed to atmosphere.  

19. The entire process is controlled by using PLC based control system.