Spray-Dried Agglomerate Production via Integrated Fluidized Bed
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Solution Overview
Problem
Existing methods for producing large agglomerate particles in the food sector, such as spray drying and spray-bed drying, result in mechanically unstable particles that are prone to abrasion and dust formation, limiting their size to around 200 μm and making them unsuitable for high-load applications.
Innovation Solution
A device incorporating a spray-drying segment and an integrated fluidized bed with a nozzle or atomizer construction at the bottom, where binder liquids are sprayed to promote agglomeration, allowing for the production of stable agglomerate particles larger than 200 μm by enhancing particle collision and adhesive contact areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If spray-bed drying is used to generate larger particles, then particle size can be increased beyond 100 μm, but the particles become mechanically unstable and suffer great abrasion
Solution Approach 1:
The device segments the particle production process into two distinct stages: spray-drying segment for initial particle formation and fluidized bed segment for controlled agglomeration. This segmentation allows each stage to optimize for its specific function, producing mechanically stable large particles
Solution Approach 2:
A binder liquid is introduced as an intermediary substance in the fluidized bed to facilitate controlled agglomeration of spray-dried particles. The binder acts as a mediating agent that binds particles together through adhesive forces, creating mechanically stable large agglomerates rather than relying on mechanical instability
2Quantity of substance
If spray drying is used to produce particles, then high load of dried particles up to 30% can be achieved, but the particle size is limited to 70-100 μm
Solution Approach 1:
The device merges spray-drying technology with fluidized bed technology in an integrated system. The spray-drying segment produces high-load particles, while the integrated fluidized bed segment enables subsequent agglomeration to larger sizes, combining the advantages of both methods
Solution Approach 2:
The spray-drying segment performs preliminary particle formation with high active substance load before the fluidized bed agglomeration stage. This preliminary action ensures that particles entering the agglomeration stage already have the desired high load, which is then maintained during size enlargement
3Volume of moving object
If large particles greater than 200 μm are produced by conventional methods, then particle size requirement is met, but production cost increases or load decreases to about 6%
Solution Approach 1:
The integrated device performs multiple functions in sequence: spray-drying for particle formation, fluidization for particle suspension and mixing, and agglomeration for size enlargement. This multi-functionality allows a single device to produce large high-load particles without requiring separate expensive processes
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 device produces large, stable agglomerate particles with improved mechanical stability and low dust values, capable of carrying high loads of active substances like flavorings, and maintains their stability during use, with particle sizes up to 1000 μm or more.
Implementation Method 1
a spray-drying segment (A) in the upper region of a chamber for drying feed liquid particles sprayed by a feed liquid atomizer (Z1)
Implementation Method 2
the particles being constantly kept in motion and whirled up during production... spraying the binder liquid... promotes agglomeration... enhancing particle collision and adhesive contact areas
Implementation Method 3
an integrated fluidized bed (B) in the lower region of a chamber, in which region the powder of the spray-drying segment from step (i) is sprayed with a binder liquid by means of a nozzle or atomizer construction (Z2) mounted at the bottom of the fluidized bed, the particles being constantly kept in motion and whirled up during production
Data Source
AI summary
The invention is in the field of devices for producing particles, in particular large agglomerate particles.