Spray-Drying Agglomeration for Large Stable Particles
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Solution Overview
Problem
Current methods for producing large agglomerate particles in the food sector are expensive and limited in size, resulting in mechanically unstable particles that are prone to abrasion and dust formation, with low load capacities and poor solubility.
Innovation Solution
A spray-drying agglomeration process using a fluidized bed with a nozzle or atomizer construction at the bottom, which constantly circulates and collides particles with a binder liquid, producing large, stable, and low-dust agglomerate particles by enhancing adhesive surfaces and promoting particle collision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If spray-drying method is used to produce large particles, then high load capacity (up to 30%) is achieved, but particle size is limited to 70-100 μm
Solution Approach 1:
The process segments particle production into two distinct stages: first, spray-drying produces fine pulverulent particles with high load capacity; second, these particles are agglomerated in a fluidized bed to form larger particles. This segmentation allows each stage to optimize for its specific function, resolving the contradiction between load capacity and particle size.
Solution Approach 2:
The spray-dried pulverulent particles serve as an intermediary material between the spray-drying process and the final large particle product. These intermediate particles are then used as building blocks in the fluidized bed agglomeration process, enabling the transition from fine high-load particles to large stable particles.
2Length of moving object
If spray-bed drying is used to generate larger particles (up to 200 μm), then particle size is increased, but mechanical stability deteriorates causing great abrasion and dust formation
Solution Approach 1:
The spray-drying stage performs a preliminary action by producing fine particles with optimal properties (high load capacity, controlled morphology) before they enter the agglomeration stage. This preliminary structuring ensures that when particles are later agglomerated into larger sizes, they maintain mechanical stability because the fine particles form a solid core structure rather than loose aggregates.
Solution Approach 2:
The final large particles are composite structures formed by agglomerating multiple fine spray-dried particles together. This composite structure, held together by binder liquid, provides both the desired large size and improved mechanical stability, as the multiple fine particles create a interlocked core structure that resists abrasion better than particles formed by direct spray-bed drying.
3Length of moving object
If conventional methods are used to produce large agglomerate particles, then production cost increases, but particle size and load capacity are limited
Solution Approach 1:
The invention merges two existing processes (spray-drying and fluidized bed agglomeration) into an integrated system where the output of one process directly feeds the other. This combination allows the production of large particles at lower cost than conventional methods because it uses established, scalable technologies in sequence rather than requiring expensive specialized equipment or multiple separate processing steps.
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 process yields agglomerate particles larger than 200 μm with improved mechanical stability, low dust values, and high load capacities, ensuring better solubility and handling characteristics.
Implementation Method 1
a spray-drying segment (A) in the upper region of a chamber for drying feed liquid sprayed by a feed liquid atomizer (Z1)
Implementation Method 2
an integrated fluidized bed (B) in the spray-drying agglomeration device, which bed is situated 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
Implementation Method 3
the particles being constantly kept in motion and whirled up during production
Implementation Method 4
the circulation which constantly keeps the particles in motion allows a large probability of collision amongst the particles
Data Source
AI summary
The invention is in the technical field of particles; more particularly, the invention relates to large agglomerate particles obtainable by spray-drying agglomeration.