Micro Mist Spray Dryer
Four-fluid nozzle Micro Mist Spray Dryer (MMSD)
Micro Mist Spray Dryer
Single micron range has been achieved since it was not possible in conventional spray dryer.
Particle size distribution
Particle size distribution of primary particle before spray drying
Particle size distribution after spray drying by MMSD
Click to enlarge
Click to enlarge
Particle size distribution after spray drying by micro mist spray dryer
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Micro Mist Spray Dryer | Spray dryer |
Atomization Methods |
Four-fluid nozzle | Two-fluid nozzle Rotary atomizer *Need high speed rotation, and there is not past results. |
Atomizing Small Amount |
One nozzle | One nozzle |
Atomizing in High-volume Fine Powder Production |
One nozzle | Multiple nozzles |
Scale up |
Easy to scale up using parameter test by a laboratory unit. | There are some problems such as gas-flow turbulence and droplet collision with multiple nozzles, so consideration should be made in many aspects. |
Drying Efficiency |
Drying efficiency is high due to 180° hollow cone and there is no unevenness in hot air contact. | Drying efficiency is not good due to full cone that has forwardness and takes a lot of time to contact the hot air. |
System Size |
Drying chamber is smaller since the drying efficiency is high compared to the general spray drying. | Drying chamber will be bigger. |
Continuous Operation |
Long time operation without nozzle clogging | Likely to cloggy the inside of nozzles. |
Compressed Air Volume |
In the case that the liquid processing rate is same, the air flow rate is less than the total of multiple nozzle. | Large |
Operating Performance |
Easy to control with a touch panel. | Complex due to control many nozzles and liquid sending pumps. |
Maintenance |
Easy to maintain. | Hard to maintain due to many nozzles and pumps. |
Initial Cost |
Make the size smaller, can suppress a cost. | In the case of scale-up, likely to increase in cost. |
Running Cost |
Electrical energy consumption of compressor will be 20% to 50% less. | Electrical energy of compressor is huge. |
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Micro Mist Spray Dryer | Other method |
Few Microns Fine Powder Manufacturing Process |
Powder can be attained directly from the liquid. | In the case of slurry, condensation will be necessary if the solution is a type that attains powder by disintegrating/pulverizing the liquid after dehydrating at the filter press and drying by shelf drying. |
System Configuration |
1 unit | Several units |
Research Development |
Powder can be attained easily. | Takes time |
Operating System |
Long time continuous operation. | Batch operation |
Closed Loop |
Possible | Difficult |
Classifying Operation |
Not necessary | Sometimes necessary |
Productivity |
Operating time is short for production amount and high productivity can be attained if the liquid concentration rises. Have great collection efficiency. | In case of long operating time. Low collection rate because of the adherence and flying apart at each device. |
Operating Performance |
Simple | Operating knowledge is necessary for each device and washing and assembling is complex and difficult. |
Maintainability |
Simple Nozzle is the only spare parts item that is necessary. |
Maintenance knowledge and spare parts item is necessary for each device. |
Sanitary Property |
High | Low |
Initial Cost |
Comparing the total cost, it is about the same, or even cheaper. | It can be either expensive or cheap depending on the device selection & combinatio? and system integration complexity. |
Running Cost |
Manpower is not needed much, electrical energy of compressor is big. | Manpower can be needed much depending on the material flow between devices. |
Contamination |
Never | High chance of contamination |
Fluid Property |
Possible on both solution and slurry. Slurry initial particles better to be below 1 to 2 µm. |
Difficult in solution, and increasing concentration will be necessary. |
Product Property |
Spherical form Porous, low density |
Formation is instable. High density |
Quality control of the product |
Easy to control since the factor is less. | Quality control is necessary on each device and the factor will be a lot. |
Residual moisture of the product |
Almost every powders can observe the standard. | Sometimes final drying might be necessary. |
Thermal denatured |
Instant drying at low temperature below boiling point is possible. | Exposure time at drying heat temperature is long. |