Gyrolite Calcium Silicate Powder Production via Spray Drying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gyrolite-type calcium silicate powders have small particle sizes and poor handleability due to their finely divided form, leading to issues with flowability and high powder scattering during filling, and attempts to increase particle size through granulation compromise oil absorption and strength.
Innovation Solution
A method involving the use of gypsum and a calcium compound in an aqueous solvent, followed by hydrothermal synthesis and spray-drying to produce gyrolite-type calcium silicate powder with large particle size, high oil absorption, and enhanced particle strength without the need for granulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional gyrolite-type calcium silicate powder is produced by hydrothermal treatment, then high oil absorption is achieved, but particle size remains small and handleability deteriorates
Solution Approach 1:
The patent applies preliminary action by conducting hydrothermal treatment before spray-drying to pre-form the gyrolite crystal structure with high oil absorption capacity. This preliminary crystallization ensures that the oil absorption properties are established before the particle size enlargement process, resolving the contradiction between maintaining high oil absorption and achieving large particle size for better handleability
Solution Approach 2:
The patent employs parameter changes by controlling the spray-drying conditions (inlet temperature, outlet temperature, feed rate) to transform the hydrothermally treated slurry into large-particle powder. By optimizing these parameters, the process achieves particle size enlargement while preserving the gyrolite crystal structure's oil absorption capacity, thus resolving the contradiction between particle size and oil absorption
2Ease of operation
If granulation is performed to increase particle size, then handleability improves, but particle strength decreases and disintegration occurs
Solution Approach 1:
The patent replaces the mechanical granulation process with a spray-drying process that uses fluid dynamics and rapid evaporation to form particles. This substitution eliminates the mechanical compression and tumbling that cause particle densification and strength loss, while still achieving large particle size and improved handleability through controlled droplet formation and drying
Solution Approach 2:
The patent utilizes phase transitions in the spray-drying process, where the slurry undergoes rapid evaporation of water from liquid to vapor phase, forming solid particles. This phase transition approach creates particles with porous structures that maintain strength while achieving large size, resolving the contradiction between particle size and particle strength
3Quantity of substance
If granulated material is produced with priority on oil absorption, then high oil absorption is achieved, but particle strength is insufficient and granules disintegrate
Solution Approach 1:
The patent applies preliminary action by completing the hydrothermal treatment to form gyrolite crystals with high oil absorption capacity before the spray-drying step. This ensures that the oil absorption properties are fully developed in the crystal structure before particle size enlargement, preventing disintegration while maintaining high oil absorption
Solution Approach 2:
The patent creates a composite structure where the gyrolite crystal framework provides both high oil absorption capacity and structural strength. The spray-drying process preserves this composite structure by forming particles that maintain the internal gyrolite morphology, thus achieving both high oil absorption and sufficient particle strength
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting powder exhibits excellent handleability, flowability, and maintains particle size with high oil absorption and strength, suitable for various applications including drug additives and cosmetics, reducing dusting and improving overall performance.
Implementation Method 1
subjecting an aqueous slurry containing the reaction product to a hydrothermal synthesis reaction to obtain gyrolite-type calcium silicate
Implementation Method 2
spray-drying a dispersion liquid containing the gyrolite-type calcium silicate to obtain a gyrolite-type calcium silicate powder
Data Source
Figure 1~3
Figure 4~6
AI summary
Provided is powdered gyrolite-type calcium silicate that has a relatively large particle size, yet is endowed with both a high oil absorption and a high particle strength. The powdered gyrolite-type calcium silicate has (1) an oil absorption of at least 2.8 mL/g, (2) an average particle diameter of at least 40 µm, and (3) in treatment where the gyrolite-type calcium silicate is charged into a laser diffraction-type particle size analyzer within the range of a diffraction volume of from 0.1 to 0.6 and circulated at a flow rate of 32.5 mL/s for 5 minutes, a percent change in average particle diameter following treatment with respect to average particle diameter before treatment of 15% or less.