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Spray drying new technologies

Auto-PSD-Control System

By measuring particle size distribution in real time, you can see various changes in the process. Even if raw materials, recipes and operating conditions are already fixed, the quality of the spray dried powder changes constantly during the process. This means that the fixed atomizer rotating speed may not achieve a stable particle size distribution. With our new technology, you can control not only the rotating speed but also the particle size distribution.

Understand the real process

“Insitec” is a Malvern’s real time particle size distribution measurement system. The system can monitor flowing particle in real time with high accuracy in the process.

Recognize and control automatically (Patent pending)

The spray dried powder is composed of various sized granules. Therefore, the size of granules is referred as “distribution”. Spray drying process is one of the most ideal processes that can create granules with a sharp particle size distribution. However, conditions of feeding liquid material, process gas and inlet/outlet temperatures are not precisely consistent in the process. Therefore, it is important to stabilize the final dried product by measuring and controlling particle size distribution at the manufacturing process in real time.

 

 

Coanda Effect Disc (Patent pending)

In centrifugal atomization, the liquid material is fed and the droplets are atomized toward horizontal direction by centrifugal force. In general, it is necessary to design a drying chamber bigger in order to prevent adhesions of undried material droplets on the inner wall. To solve this issue, we developed a brand new type of disc shapes named Coanda Effect Disc (the coanda effect is the tendency of a fluid to keep attaching to a convex surface). With this phenomenon, sprayed droplets go downwards and can be taken more fall-down time inside the chamber. This allows to enhance the drying efficiency and reduce the material adhension loss compared to the process operation by conventional disc, and can even design a drying chamber size smaller without sacrificing the production yield rate.

 

 

Swirl Flow Classifier (Patent pending)

By dual collection method which is generally used for inorganic materials such as fine ceramics, granulated powder which has a large particle size and is excellent in fluidity is collected from the drying chamber, and fines are collected from the cyclone. Granules collected by the cyclone may be broken in to fines due to the friction impact on the inner cyclone wall, and therefore are often returned to raw materials. To increase the collection yield from the drying chamber we developed the swirl flow classifier at the inlet of the cyclone. By attaching the classifier, it is possible to improve the collection efficiency from the drying chamber.

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