Slide 1: Challenges and Opportunities in Spray Drying
Challenges and Opportunities in Spray Drying PRESENTED BY: WILLIE HENDRICKSON CEO & FOUNDER Particle Processing Services Toll Manufacturing Research & Development Innovative Solutions
Slide 2: Presentation Outline
Presentation Outline • Overview of AVEKA • Spray Drying Process • Particle Formation and Types in Spray Drying • Spray Drying Applications • Economics of Spray Drying • Examples • Conclusions
Slide 3: AVEKA Group Overview
• Particle Technology Company focused on contract manufacturing • Spin-off of 3M in 1994 • Comprised of 5 separate companies AVEKA • ISO certifications / food-grade certifications Group Overview • Currently 200 employees
Slide 4: Spray Drying Definition and Product Form
Definition: Spray Drying • Drying of atomized droplets to form free-flowing Definition powder and Product Raw Material Characteristics Form • Raw materials can be solutions or slurries • Typically feed solutions/slurries are aqueous • Feed typically between 10-60% solids Powder Characteristics: • 5-
Slide 5: Spray Drying Uses and Industries
Spray Drying Uses and Industries Food Catalysts Pharmaceuticals Agriculture Chemicals Polymers Ceramics Animal Feed AVEKA
Slide 6: Spray Drying Equipment
Spray Drying Equipment Büchi Lab Dryer Box Dryer Production Bustle Dryer Niro Mobile Minor High Pressure Atomization Production Tower Dryer Niro Pilot Dryer
Slide 7: Atomization Methods
Atomization Methods Rotary Atomization (Rayleigh Breakup) Atomization and Drying Zones in a spray chamber Swirl Cone Atomization Single Fluid Atomization vs. Viscosity Ashgriz IFPRI Report FRR 96-05 2022
Slide 8: Product Form from Spray Drying
Product Form from Spray Drying Andrew Bayly IFPRI Review SAR 38-17 2015
Slide 9: Particle Formation Mechanism
Particle Formation Mechanism Bayly IFPRI Review 38-17 2015
Slide 10: Economics of Particle Processing
Economics of Particle Processing Spray Drying - an Illustrative Example Cost of Spray TheDrying Equipment: Economics of $30,000,000 Particle Processing • Process Parameters: • Input –Solids Spray Drying, an • DryingIllustrative Rate Example • Yields: 98-99% • Operating Income: $500-700/hour
Slide 11: Spray Drying Economics I
Spray Drying Economics I 4667 3000 Output 2000 kg/hr 1333 857 500 20.2 222 1 10 20 30 40 50 60 70 % Solids of Solution
Slide 12: Spray Drying Economics II
Spray Drying Economics II Assumptions • 19%, 20%, and 21% solids • 80%, 90%, and 95% Operational Time • 2000 kg/hr Water Evaporation Rate % Solids Dried Product 80% 90% 95% kg/hr (7008 hr/yr) (7884 hr/yr) (8322 hr/yr) 19 469 3,286,752 3,697,596 3,903,018 20 500 3,504,000 3,942,000 4,161,000 21 532 3
Slide 13: Spray Drying Economics III
Spray Drying Economics III Assumptions • 19%, 20%, and 21% solids • 80% Operational Time • 1900, 2000, 2100 kg/hr Water Evaporation Rate % Solids 1900 kg/hr 2000 kg/hr 2100 kg/hr kg/hr Product kg/hr Product kg/hr Product 19 446 469 499 20 475 500 525 21 505 532 558
Slide 14: Spray Drying Economics IV
Spray Drying Economics IV Assume the Yield is 98% Therefore, at 2000 kg/hr evaporation rate the actual output is 490 kg/hr not 500 kg/hr However, product typically has 8% retained water or an actual theoretical yield of 543 kg/hr (but the yield is calculated on 500 kg/hr not 543 kg/hr) Where is the
Slide 15: Economic Overview
Economic Overview CHALLENGES OPPORTUNITIES Water Evaporation Rate % Relative Humidity Preventative Maintenance % Solids on Solutions Atomization Assists Viscosity of Solution Yields Poor Collection Wall Sticking and Pneumatic Conveying Operation Time Cleaning Cycle Times Preventative Maintenance
Slide 16: The Examples…. Finally
The Examples…. Finally Effect of Dryer and Drying Conditions • Scaling up a new product Standard Drying • Yeast • Yeast cell wall • Aluminum sulfate/ Sodium Succinate • Vegetable Proteins Hard to process materials • Sodium Acetate When there are no explanations • Water, Ozone, Ions ❖ Statement of ne
Slide 17: Scaling up a new spray dried material
Scaling up a The Result – particle size too small in new spray first lab test and in pilot test dried material Lab Dryer 19 µm Statement of challenge • Polymer for Ag applications Pilot Dryer 45 µm • Replicate current material • Particle size • Flowability Competitor Sample 68 µm
Slide 18: Scaling-up New Material
Scaling-up New Material Explanations and Expectations for Scaling-up 1) Smaller droplets in Lab Dryer 19 µm smaller dryer 2) Peclet Number higher in larger dryer – hollow particles to produce larger particle 3) Production dryer is an agglomerating dryer Pilot Dryer 45 µm Competitor Product 68 µm
Slide 19: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • Proof of concept Process scale-up is always complete with a challenge with multiple adjustments to be made options to consider in final scale-up
Slide 20: Spray Drying Spherical Powder
Spray Drying The Result Spay drying after bead milling produced the desired material Spherical Powder Starting Material Mean PSD = 11.7 µm Statement of challenge Spray Drying produced correct size, but not desired sphericity Milled Material Mean PSD = 1.9 µm
Slide 21: Spray Drying Milled Starting Material
Spray Drying Milled Starting Material SEM (5000x) of spray-dried silica without (left) and with (right) prior bead milling
Slide 22: Drying of Vegetable Protein
The Result Drying of • PSD varies due to vegetable source, but structure is similar Vegetable Protein Statement of challenge Spray dry vegetable protein • Protein 1 64 µm Protein 1 Protein 2 • Protein 2 92 µm • Protein 3 55 µm Protein 3
Slide 23: Spray Drying of yeast
Results Spray ◦ Deactivated yeast dries to make small particle dependent on yeast source Drying of yeast materials Statement of challenge • Why do different yeast sources provide different results during drying? • Particle shape • Flowability
Slide 24: What Is Happening? The Reality
WHAT IS HAPPENING? THE REALITY • Dried deactivated yeast • The resulting particle has varying amounts of has different strengths lysed cells and extract due to the binder – during drying (particle limiting attrition and flow and binder) issues
Slide 25: SEM of Spray Dried Yeasts
SEM of Spray Dried Yeasts
Slide 26: Spray Drying and Crystallization
Spray Drying and Crystallization NaCl (Vehring 2008) Statement of challenge • Dry sodium succinate to stable product Sodium Succinate After Drying Upon Exposure to Humid Air
Slide 27: Hard to Dry Materials
Product drying is dependent on: Hard to Dry ◦ Neutralization pH (higher better) Materials ◦ Atmospheric RH (lower better) ◦ Addition of dry air in pneumatic conveying Product stability after drying is dependent on: Statement of challenge o Storage temperature and RH during drying • Dry a material th
Slide 28: SEM Analysis of Sodium Acetate
SEM Analysis of Sodium Acetate Prepared at: Low pH High pH Sample 1 - High pH Sample 2 - Low pH
Slide 29: When All Else Fails – Blame Water Vapor, Ozone, Atmospheric Ions
When All Else Fails – Blame Water Vapor, Ozone, Atmospheric Ions
Slide 30: Plasma Cutters, Spray Dryers and Metal Detectors
Plasma Cutters, Spray Dryers and Metal Detectors While spray drying in plant, plasma cutting was being done in same building 100 meters away and behind 3 doors. Powder set off metal detector during and after plasma cutting.
Slide 31: Plasma Cutters, Spray Dryers and Metal Detectors
Plasma Cutters, Spray Dryers and Metal Detectors No Metal Contamination was found by ICP analysis Charge contamination is known to trigger metal detector Charge did not dissipate after 3 months What is happening?
Slide 32: Summary
Summary • Spray Drying can be straight forward but: Value Added Product ➢ Particle shape and size will vary and can Partnerships affect your final product ➢ Economy of drying is sensitive to yields and feed % solids Full Scale Manufacturing • Process conditions and materials are critical • Be prepar