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 Harder 3D-printed tools – Researchers from Dresden introduce new process for hardmetal industry
11.10.2018 | Fraunhofer-Institut für Keramische Technologien und Systeme IKTS

nachricht Flying High with VCSEL Heating
04.10.2018 | Fraunhofer-Institut für Lasertechnik ILT

All articles from Process Engineering >>>

The most recent press releases about innovation >>>

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

Im Focus: Nonstop Tranport of Cargo in Nanomachines

Max Planck researchers revel the nano-structure of molecular trains and the reason for smooth transport in cellular antennas.

Moving around, sensing the extracellular environment, and signaling to other cells are important for a cell to function properly. Responsible for those tasks...

Im Focus: UNH scientists help provide first-ever views of elusive energy explosion

Researchers at the University of New Hampshire have captured a difficult-to-view singular event involving "magnetic reconnection"--the process by which sparse particles and energy around Earth collide producing a quick but mighty explosion--in the Earth's magnetotail, the magnetic environment that trails behind the planet.

Magnetic reconnection has remained a bit of a mystery to scientists. They know it exists and have documented the effects that the energy explosions can...

Im Focus: A Chip with Blood Vessels

Biochips have been developed at TU Wien (Vienna), on which tissue can be produced and examined. This allows supplying the tissue with different substances in a very controlled way.

Cultivating human cells in the Petri dish is not a big challenge today. Producing artificial tissue, however, permeated by fine blood vessels, is a much more...

Im Focus: A Leap Into Quantum Technology

Faster and secure data communication: This is the goal of a new joint project involving physicists from the University of Würzburg. The German Federal Ministry of Education and Research funds the project with 14.8 million euro.

In our digital world data security and secure communication are becoming more and more important. Quantum communication is a promising approach to achieve...

Im Focus: Research icebreaker Polarstern begins the Antarctic season

What does it look like below the ice shelf of the calved massive iceberg A68?

On Saturday, 10 November 2018, the research icebreaker Polarstern will leave its homeport of Bremerhaven, bound for Cape Town, South Africa.

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Optical Coherence Tomography: German-Japanese Research Alliance hosted Medical Imaging Conference

19.11.2018 | Event News

“3rd Conference on Laser Polishing – LaP 2018” Attracts International Experts and Users

09.11.2018 | Event News

On the brain’s ability to find the right direction

06.11.2018 | Event News

 
Latest News

Nonstop Tranport of Cargo in Nanomachines

20.11.2018 | Life Sciences

Researchers find social cultures in chimpanzees

20.11.2018 | Life Sciences

When AI and optoelectronics meet: Researchers take control of light properties

20.11.2018 | Physics and Astronomy

VideoLinks
Science & Research
Overview of more VideoLinks >>>