Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Spray drying the precision particle under the virtual magnifying glass

06.05.2015

Spray drying is a common manufacturing process, used in the production of ceramic granulate for technical components or dental prostheses as well as dissolvable medicinal substances, food additives and in the processing of milk into powder. Using computer simulation methodology developed by scientists at the Fraunhofer Institute for Mechanics of Materials IWM, a more comprehensible understanding can now be gained of the behavior of particles in solvent during the spray drying process. This allows powder and granulate manufacturers to specifically adjust the properties of their products while reducing waste.

Previously, it was unusual for granule and powder producers to use granulation simulations to improve their products. For new product development or process optimization, manufacturers relied on trial and error.


Spray dried granules: Depending on the choice of process and suspension parameters, the simulation can generate dense (left) or porous or hollow (right) granulate.

© Fraunhofer Institute for Mechanics of Materials IWM

Spray drying is, however, influenced by many process parameters as well as the material behavior of the fluid and dissolved particles. Experts at the Fraunhofer IWM have now developed a new simulation method: coupled particle flow simulation shows the interaction between the particles and suspension. "The flow of the various particle sizes as well as their location in the liquid are incorporated“, explains Fraunhofer IWM simulation expert Thomas Breinlinger.

"For example, we can detect if there is an increase of smaller particles outside while the larger particles are more likely to be found inside or how they move in the liquid throughout the process.“ This new numerical simulation model combines long-established Fraunhofer IWM particle flow simulations, i.e., CFD (Computational Fluid Dynamics) and DEM (Discrete Element Method).

The spray drying simulation technology is already successfully being deployed with ceramic granules, but can also be implemented for powder and granulate in the pharmaceutical, biotechnology, nanotechnology and food industries. Additionally, manufacturers of drying systems benefit from the simulation by gaining a better grasp of the origin and structure of the granular materials.

Increased economic efficiency through simulations and modeling

Using the new simulation method, granulate manufacturers better understand how their product is created and what most affects granule quality. As a result, it becomes clear which of the modeled flow parameters are actually relevant for improving product quality or to aid in the resolution of specific problems.

By providing the possibility for targeted granulate and powder manufacturers to produce a special morphology, the process simulation and modeling can also aid in the reduction of development costs. In a project sponsored by the DFG (German Research Foundation), scientists at the Fraunhofer IWM have conducted simulations on various ceramic suspensions to discover their specific differences regarding the resulting granules.

"We have combined several primary particles in the suspension to be represented by a single particle in our simulation," states Breinlinger, who goes on to say that the particles in the simulation have been slightly enlarged, to facilitate better and more predictable calculations and descriptions. "Depending on whether the primary particles in the suspension have agglomerated rather than dispersed, the particles in the simulation maintain different properties, which aid in mapping the interaction of the primary particles," he explains.

This means that the influence of the interaction of microscopically small primary particles on the formation of granular materials can be directly described, without the need for further simulations. As a basis for his work, the Fraunhofer scientists rely on their many years of experience in materials modeling and simulation, in particle flow simulation, in the development of simulation codes and corresponding methods, as well as on the profound understanding of materials and material systems established at the Fraunhofer IWM.

Implementing the simulation to the technical process of spray drying

The materials specialists are now seeking an industrial partner with whom they can conduct and refine spray drying process simulations. Currently under consideration is the energy potential between particles in an approximated form as well as the calculation of a "smeared" suspension behavior. In the future they plan still further in-depth simulations of these parameters so as to validate concrete applications. "The tool already works very well and we look forward to continuing to refine and implement it for large scale commercial use" concludes Breinlinger.

Weitere Informationen:

http://www.en.iwm.fraunhofer.de/press-events-publications/details/id/1011/ - Press release online -
http://www.en.iwm.fraunhofer.de/business-units/manufacturing-processes/powder-te... - Fraunhofer IWM: Powder Technology, Fluid Dynamics -

Thomas Götz | Fraunhofer-Institut für Werkstoffmechanik IWM

Further reports about: Fluid IWM drying explains glass granular materials granule granules materials powder

More articles from Process Engineering:

nachricht New technology for ultra-smooth polymer films
28.06.2018 | Fraunhofer-Institut für Organische Elektronik, Elektronenstrahl- und Plasmatechnik FEP

nachricht Diamond watch components
18.06.2018 | Schweizerischer Nationalfonds SNF

All articles from Process Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: First evidence on the source of extragalactic particles

For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.

To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...

Im Focus: Magnetic vortices: Two independent magnetic skyrmion phases discovered in a single material

For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.

Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...

Im Focus: Breaking the bond: To take part or not?

Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.

A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...

Im Focus: New 2D Spectroscopy Methods

Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.

"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....

Im Focus: Chemical reactions in the light of ultrashort X-ray pulses from free-electron lasers

Ultra-short, high-intensity X-ray flashes open the door to the foundations of chemical reactions. Free-electron lasers generate these kinds of pulses, but there is a catch: the pulses vary in duration and energy. An international research team has now presented a solution: Using a ring of 16 detectors and a circularly polarized laser beam, they can determine both factors with attosecond accuracy.

Free-electron lasers (FELs) generate extremely short and intense X-ray flashes. Researchers can use these flashes to resolve structures with diameters on the...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Leading experts in Diabetes, Metabolism and Biomedical Engineering discuss Precision Medicine

13.07.2018 | Event News

Conference on Laser Polishing – LaP: Fine Tuning for Surfaces

12.07.2018 | Event News

11th European Wood-based Panel Symposium 2018: Meeting point for the wood-based materials industry

03.07.2018 | Event News

 
Latest News

Microscopic trampoline may help create networks of quantum computers

17.07.2018 | Information Technology

In borophene, boundaries are no barrier

17.07.2018 | Materials Sciences

The role of Sodium for the Enhancement of Solar Cells

17.07.2018 | Power and Electrical Engineering

VideoLinks
Science & Research
Overview of more VideoLinks >>>