The influence stirrer-vessel configuration on the pelleting process can be quite significant. In fact, the realization of the pelleting technique is predicated upon the right choice of reactor geometry and mixer. The two reactors tested in the course of this investigation differs slightly in terms of their geometry while the stirrer configuration is similar. In spite of this, the results of this study show a certain degree of differences in terms of the power consumption, flow pattern and vortex structure. The choice of appropriate flocculant and dosage has a profound effect not only on the pelleting process but also the cost of pre-treatment. There are several operating parameters that influence the micro processes, a number of which were optimized for the reactor systems. The analysis of the nature and structure of the flow stream pattern has been performed using experimental technique (PIV). Process optimization has been shown to be a crucial step in the design and development of process equipment.