Spray Drying Nozzle Tip Cooling via Gas Deflector
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Solution Overview
Problem
Existing spray-drying technologies face challenges in preventing overheating of the spray nozzle tip and denaturation of heat-sensitive substances like proteins during the drying process, leading to reduced potency and potential blockage due to the lack of effective cooling mechanisms for the nozzle tip.
Innovation Solution
A spray-drying apparatus equipped with a drying gas deflector that deflects the flow of drying gas away from the spray nozzle tip, preventing overheating and maintaining the integrity of heat-sensitive substances by minimizing direct exposure to hot gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a drying gas conduit is used to provide hot drying gas to dry spray particles, then drying efficiency is improved, but the spray nozzle tip overheats causing denaturation of heat-sensitive substances
Solution Approach 1:
A cooling gas conduit is introduced as an intermediary element between the drying gas conduit and the spray nozzle tip. The cooling gas flows through this intermediate conduit to protect the spray nozzle tip from direct exposure to hot drying gas, thereby preventing overheating while maintaining drying efficiency in the drying chamber.
Solution Approach 2:
The gas flow system is segmented into separate cooling gas and drying gas pathways. The cooling gas conduit and drying gas conduit are distinct, allowing independent control of cooling and drying functions. This segmentation enables the cooling gas to protect the nozzle tip while the drying gas efficiently dries the spray particles in the chamber.
2Speed
If high temperature drying gas is used to dry spray particles rapidly, then drying speed is improved, but proteins and heat-sensitive substances undergo denaturation and loss of potency
Solution Approach 1:
The cooling gas acts as a protective intermediary that creates a thermal barrier around the spray nozzle tip and liquid flow path. This allows high-temperature drying gas to be used in the drying chamber for rapid drying, while the cooling gas prevents direct thermal exposure to the heat-sensitive liquid and proteins during atomization.
Solution Approach 2:
Different temperature zones are created: a cool zone around the spray nozzle tip and liquid conduit where the cooling gas flows to protect heat-sensitive substances, and a hot zone in the drying chamber where high-temperature drying gas rapidly dries the spray particles. This local differentiation of thermal conditions resolves the contradiction between drying speed and substance integrity.
3Productivity
If the spray nozzle tip is exposed to hot drying gas, then drying of spray particles is efficient, but sedimentation and blockage of the spray nozzle tip occur
Solution Approach 1:
The cooling gas conduit serves as a protective intermediary that prevents direct contact between hot drying gas and the spray nozzle tip. This thermal protection eliminates the cause of sedimentation and blockage, ensuring reliable operation while maintaining drying efficiency through the separate drying gas pathway.
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 use of a drying gas deflector effectively reduces the temperature around the spray nozzle tip, preventing denaturation of proteins and maintaining their potency, while also preventing blockages and ensuring a consistent spray pattern with high yield of dry powder.
Implementation Method 1
a drying gas deflector (40) positioned so as to deflect a flow of drying gas away from the spray nozzle tip
Implementation Method 2
by two-fluid nozzle atomization, wherein spray is created by combination of a liquid flow and a gas flow
Implementation Method 3
drying of the spray in a hot gas (e.g. air) flow provided by a drying gas conduit. The spray particles rapidly dry yielding a powder
Implementation Method 4
The powder produced is separated from the drying gas by a cyclone unit (30)
Data Source
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AI summary
Provided is a spray drying apparatus comprising a spray nozzle comprising a spray nozzle tip at the distal end of the spray nozzle, a liquid conduit for guiding a liquid to be spray-dried out through the spray nozzle tip, an atomizing component for producing a spray of droplets from the liquid exiting the spray nozzle; a drying gas conduit comprising an outlet for directing a drying gas to dry the spray of droplets; and a drying gas deflector positioned so as to deflect a flow of the drying gas away from the spray nozzle tip.