YC-018 Ceramic Spray Dryer

Ceramic Spray Dryer: The Complete Buying Guide

Ceramic powder is used in many industries for anti-corrosion, fireproof, high-temperature resistance purposes and as various industrial and civil coatings. Then, how can we get ceramic powder or ceramic particles with good fluidity in the laboratory?

Pilotech YC-018 ceramic spray dryer is the best choice for your laboratory when preparing ceramic powder.

Pilotech YC-018 ceramic spray dryer has a capacity of 4L/h, but it can also process a 100mL sample, so you won’t waste a large amount of samples.

Different ceramic particles have the best performance at different particle sizes, some at 1-10 microns, and some at 60-80 microns. Can any single laboratory spray dryer meet such different requirements? YC-018 ceramic spray dryer would be your best choice, it can be adjusted to produce ceramic particles varying from 1 to 100 microns in particle size, sometimes our customers get nanoparticles with YC-018 ceramic spray dryer equipment, so it can meet different requirements.

The temperature range of the Pilotech YC-018 ceramic spray dryer is very wide, with the inlet air temperature ranging from 110 °C to 350 °C, and the outlet temperature ranging from 60 °C to 200 °C.

Pilotech ceramic spray dryer is not only suitable for drying ceramics, but also very efficient for drying of Pharma such as Chinese herbal extracts and natural product extracts. No auxiliary materials are needed during the drying process to produce powders with good fluidity.

Pilotech YC-018 ceramic spray dryer can also be used in industrials like minerals, metals, food, pharmaceutical, energy, paper, biology, chemicals, and materials.

Energy utilization efficiency of the Pilotech YC-018 ceramic spray dryer is very high, capacity 4L/h machine consumes only 5.5kw power.

To limit the impact of noise on the laboratory environment, YC-018 ceramic spray dryer has been specially designed to reduce the noise to less than 60bd during operation.

Pilotech ceramic spray dryer currently has more than 3,500 customers’ worldwide, with very low repair rate and good user experience.

Pilotech YC-018 ceramic spray dryer has an English interface by default and can be customized for your language. And a tutorial video has been prepared for convenience of use.

If you’re looking for lab & pilot scale spray dryer manufacturer, then you’re in the right place, request a quick quote now.

Ceramic Spray Dryer: The Ultimate FAQ Guide

This comprehensive guide answers all questions you have been asking about ceramic spray dryer.

Whether you want to learn about the working components, working principle, classification, specification or quality standards – everything you’re looking for is in this guide.

Keep reading to learn more.

What is Ceramic Powder?

Ceramic powder is a material that you use to make ceramics.

The ceramic powder contains ceramic particles and additives that enhance how easily you will use the powder throughout fabricating components.

The ceramic powder comes in ranges such as:

• Aluminum nitride
• Alumina
• Zirconia powder
• Magnesia
• Boron nitride
• Zirconia powder fiber
• Boride or carbides

 Ceramic powder

Why do you need Ceramic Powder?

You will use a ceramic powder in many industries.

Here are some of the ways industries use ceramic powder:

• Anti-corrosion
• Industrial coatings
• Civil coatings
• Fireproof
• High-temperature resistance

What is a Ceramic Spray Dryer?

Ceramic spray dryer

A ceramic spray dryer is equipment that you will use to prepare ceramic powder.

You will use a ceramic spray dryer in the laboratory, and the pilot test uses various materials.

A ceramic spray dryer is suitable for:

• Chemicals
• Biology
• Pharmaceuticals
• Ceramics
• Battery materials
• Food

You can use ceramic spray dryer for heat-sensitive materials like:

• In the preparation of enzymes
• In the preparation of sugary substances such as traditional Chinese medicine juices.

A ceramic spray dryer is also non-sticky, and it has a high recovery rate.

It is also important to note that a ceramic spray dryer has a broad range of inlet air temperature between 105 °C and 300 °C.

What are the Parts of a Ceramic Spray Dryer?

 Parts of ceramic spray dryer

A ceramic spray dryer has several components.

These components work together to produce the best quality of the ceramic powder.

It is necessary to have some knowledge of how the parts of a ceramic spray dryer operate.

Knowing such parts enable you to operate the machine with ease.

Besides, you will be able to conduct inspections.

In addition to the parts listed below, you also need other equipment like fans and cooling systems.

These adjoining parts will help you enhance the efficiency of the ceramic spray dryer.

Here are the parts of a ceramic spray dryer:

· Atomizer

The atomizer makes the evaporation process to be more effective.

Normally, the function of the atomizer is to change the liquid into tiny droplets.

Here, the tiny droplets assist in fabricating ceramic powder with the best and desirable properties.

Remember, the nozzles come in various designs.

The nozzle design influences the energy consumption that makes the droplets.

· Pneumatic Nozzles

This system uses high air velocity to atomize the liquid.

This leads to the formation of friction forces that break all the liquid into tiny droplets.

Pneumatic nozzles form droplets in two stages:

1. Stage one

In this stage, you will transform the liquid feed into rough droplets.

2. Stage two

In this stage, you are transforming the rough droplets into fine droplets.

The surface tension, viscosity, and the density of the air and feed determine the quality of the final product.

· Centrifugal Nozzles

Centrifugal nozzles make the liquid to move to the center of the rotary disk due to the centrifugal force.

The disk blades then deform the droplets.

It is important to note that the size of the particle is inversely related to the diameter of the centrifuge disk.

On the contrary, the velocity of the rotary directly relates to the surface tension, density, and viscosity of the product.

You can make high viscosity products with this system since it does not have problems related to clogging and fouling.

· Pressure Nozzles

The pressure nozzles transform the pressure of the liquid into the kinetic energy of the thin layers of flowing liquid.

The air friction effect together with the physical properties of the liquid makes the liquid layers separate.

Besides, the change in pressure affects the property of the nozzle and the feeding rate of the liquid.

The liquid feeding rate and its viscosity is in direct correlation with the mean size of the nozzle.

Applying pressure nozzles in ceramic spray dryers reduces sedimentation in the drying chamber.

Pressure nozzles also lead to the powder not having an irregular texture or a high bulk density.

· Heating System

The inlet air heating system has two design methods.

The two design methods are direct methods and indirect methods.

Direct Method

Air is in direct contact with a heating source in the direct heating system method.

The source of heat can be a flame.

Indirect Method

In this method, you are not heating the air directly by the heat exchanger.

The design parameters in the indirect heating system method include:

• The thermophysical properties of air
• The rate of the airflow
• The temperature of the airflow

· Drying Tower Chambers

Ceramic spray drying happens in the drying chamber.

In the drying tower chamber, you will remove moisture from the material by spraying it as tiny droplets.

The moisture evaporates as the droplets move by hot air circulation.

Besides, the moisture that evaporates exits from the drying tower chamber together with the air.

Also, the drying happens at a constant rate.

The size of the drying tower chamber depends on:

1. The feed rates
2. The type of atomizer
3. The type of distribution of the feed
4. The inlet hot air

· Recovery System

The hot air that exits the drying chamber contains some dry ceramic powder.

With this in mind, it is mandatory to separate the dry ceramic powder from the air.

You achieve this by using cyclonic separating systems that use centrifugal force.

The number and size of the cyclone influence the efficiency of dry ceramic powder separation.

How does a Ceramic Spray Dryer Work?

A ceramic spray dryer will dry atomized liquid to form a ceramic powder.

A ceramic spray dryer works in the following steps:

· Wetting Process

This is the very first step, to begin with when making ceramic powder.

All materials that make up ceramic powder is in liquid form.

The liquid state makes it possible for atomization to take place efficiently.

Some of the steps you are to do in the wet process involve:

1. Formulation or Dissolution

This step involves mixing all raw material that makes up a ceramic powder in a liquid form.

2. Evaporation or Concentration

In this stage, you are increasing the overall solid that results in a superior yield or the ceramic spray dryer.

3. Heating

The heating step helps to compensate for the increase in viscosity that happens due to concentration.

4. Pumping

All the mixed raw materials are called the slurry.

In the pumping step, you are pumping the slurry to the ceramic spray dryer at high pressure.

· Atomization Process

You are to atomize the liquid into small droplets to ensure it dries rapidly.

Atomization increases the surface area, which makes the moisture leave the particles.

Atomization happens with the assistance of one or many nozzles.

There are a variety of nozzle designs present, and the one you choose depends on the material and the flow rate.

This ensures that you get the best outcome.

Some of the types of atomization nozzles include:

1. Pressure nozzles
2. Two-fluid nozzles
3. Rotary nozzles

· Contact Between the Liquid and Air

Drying takes place once the liquid droplets get in contact with dry air.

You are to heat the air before it enters the ceramic spray dryer drying chamber.

This will make it possible for the air to take up the moisture from the liquid droplets.

The hot dry air has low humidity and high temperature at the inlet.

On leaving the drying chamber, the hot air has a lower temperature and high humidity.

The hot air can come from the top [co-currently] of the drying chamber or the bottom [counter-current] of the drying chamber.

A majority of ceramic spray dryers use the co-current drying technique.

This is because the high-temperature air gets into contact with the first particles that have high humidity.

This prevents the ceramic powder particles from overheating.

· Drying Process

Once the particles are inside the drying chamber, the drying process starts.

The heat transfer that occurs between air and the particles will remove moisture.

You can conduct the drying process in three ways:

1. The Falling Rate

The capability of the liquid in the solid particles influences the drying.

Diffusion controls this process.

2. Bubble Formation

During the falling rate, the temperature of the particles will increase.

The liquid in the particle evaporates when the temperature gets higher than its boiling point.

A bubble, then forms when evaporation happens.

3. Constant Drying Rate

Liquid saturates the particles in this stage.

Mas transfer occurs rapidly when the surface of the particle is broader.

· Separation Process

You are to collect the dry ceramic powder in this step.

The separation of ceramic powder from air happens with the help of cyclones.

You can fix filters to the cyclone to increase the efficiency of the separation process.

Once in the cyclone, dry ceramic powder separates from the air.

The dry ceramic powder, then collects at the bottom of the ceramic spray dryer.

What are the Different Layouts of Ceramic Spray Dryer?

A ceramic spray dryer can come in different layouts.

Ceramic spray dryer

Some of the layouts include:

• Self-inertizing [semi-closed] layout
• Standard [semi-closed] layout
• Combination layout
• Open cycle layout
• Closed cycle layout
• Two-stage layout

What are the Advantages of a Ceramic Spray Dryer?

A ceramic spray dryer equipment has several advantages.

Here are some of the advantages of a ceramic spray dryer:

• You will use it to dry ceramics.
• The machine has a wide inlet and outlet air temperature.
• You can also use it to dry Pharma like Chinese herbal extracts as well as natural product extracts.
• You will not need any auxiliary materials during the drying process to produce good fluidity powders.
• You can use a ceramic spray dryer to produce particles of various sizes, shapes, and moisture content.
• A programmable logic controller enables you to operate a ceramic spray dryer.
• You can easily control the quality and property of the ceramic powder in the entire drying process.
• A ceramic spray dryer does not corrode easily, since the materials are of high quality.
• You can use a ceramic spray dryer for large production and small sample capacities.
• The ceramic spray dryer has different languages for ease of operation.
• You can use a ceramic spray dryer in industries like:

1. Energy
2. Paper
3. Biology
4. Metals
5. Food
6. Minerals
7. Pharmaceuticals

Are there Limitations of Ceramic Spray Dryer?

Even though a ceramic spray dryer is advantageous, it also comes with some limitations.

Some of the limitations of a ceramic spray dryer include:

• It consumes a lot of energy.
• The ceramic spray dryer produces a lot of noise.
• The machine is quite expensive.
• The machine is bulky.
• A ceramic spray dryer is not easy to clean after use.
• You cannot dry solid materials with a ceramic spray dryer.
• The machine will degrade or a fire may start when the dry ceramic powder deposits on the drying chamber.
• A ceramic spray dryer has low thermal efficiency meaning a lot of heat is lost.

Ceramic spray dryer system

How can you Increase Particle Size in Ceramic Spray Dryer?

Reconstitution behavior and flowability is one factor that affects the quality of the ceramic powder.

The morphology of the particles influences the properties of ceramic powder.

You can increase the particle size in a ceramic spray dryer by:

• Increasing the overall quantity of solids.
• Decreasing the pressure in the atomizers.
• Increasing the flow rate of the feedstock.

What should you Consider when Selecting Ceramic Spray Dryer Nozzle?

The spray nozzle is a vital part of a ceramic spray dryer.

The ceramic spray dryer nozzle affects the quality of the ceramic powder.

Some of the factors to consider when selecting a ceramic spray dryer nozzle include:

• The spray media flow rate.
• The density, particulate size, viscosity, and the solid content of the spray media.
• The size of the dryer, velocity, humidity, temperature, and pressure.
• The density and viscosity of the spray media.
• The applicable pressure drop is across the nozzle inlet and outlet.
• The materials that you require for construction for the corrosive environment.

 Spray dryer nozzle

What are the Classifications of Ceramic Spray Dryer?

There are various classifications of ceramic spray dryers.

The economic and commercial agenda influence the design of ceramic spray dryers.

The structural design of ceramic spray dryers depends on the stage number[s], the cycle type, and the flow rate.

· Cycle Types

When you consider the cycle types, you can classify ceramic spray dryers into a closed cycle and open cycle.

Open Cycle Ceramic Spray Dryer

In an open cycle ceramic spray dryer, you first start by applying the drying air.

After applying the drying air in the drying process, you will clean the air in the drying chamber.

You will use a secondary separator to dry the air before releasing it into the environment.

Since you will release the air into the environment, an open cycle has less energy efficiency compared to a closed cycle dryer.

Closed Cycle Ceramic Spray Dryer

In a closed cycle ceramic spray dryer, you also start by applying the dry air.

Once you apply it in the drying process, you will clean the air, dry the air, and then recycle it into the drying chamber.

Closes cycle ceramic spray dryers have a high energy efficiency compared to open cycle ceramic spray dryers.

· The Stage Number[s]

You can also classify ceramic spray dryers into multi-stage dryers and single-stage dryers.

Single-stage Ceramic Dryer

This is the most common and simple type of ceramic spray dryer.

In a single-stage ceramic dryer, you reduce the moisture content to about 2-5% by weight.

A single-stage ceramic dryer has a low heat efficiency when you compare it to a multi-stage ceramic dryer.

Multi-stage Ceramic Dryer

In a multi-stage ceramic dryer, the moisture content of the product that leaves the drying chamber is about 5-10%.

A multi-stage ceramic spray dryer allows the use of low temperatures in the drying chamber.

The low temperature is a perfect choice when you are drying heat-sensitive items.

A multi-stage ceramic dryer has a high heat efficiency when you compare it to a single-stage ceramic dryer.

· Flow Types

When considering the flow types, you can classify ceramic spray dryers into:

Counter-current Dryer

In a counter-current dryer, the air and the product flow towards each other.

At the top, you will find the atomizer and at the bottom is where the air enters,

With this in mind, the dry particles get in contact with the hottest air.

Counter-current ceramic dryers will offer you a faster evaporation rate and high energy efficiency compared to co-current dryers.

Co-current Dryer

In a co-current dryer, the product and airflow come from the same direction.

This makes the hottest air to get into contact with the droplets when they have the most moisture content.

Mixed Flow Dryer

In this type, the ceramic spray dryer ruses both co-current and counter-current flow to dry ceramic.

What Parameters Influence the Quality of Product in Ceramic Spray Dryer?

Several factors influence the properties of the ceramic powder.

Some of the parameters that influence the quality product in a ceramic spray dryer include:

Ceramic spray dryer system

Feed Viscosity

You will use a lot of atomization energy when you increase the feed viscosity.

This increase in force overcomes the huge forces of the viscous solution.

This results in a large droplet size since little energy is left for the fission of droplets.

Atomization Pressure

When you use nozzle atomizers, atomization will happen under pressure.

The pressure that you apply influences the size of the droplet.

In some feed solution and atomizers available, an increase in pressure reduces the size of the droplets.

Inlet Temperature

The inlet temperature is the dry gas temperature before it enters the drying chamber.

A high inlet temperature enables the moisture to evaporate rapidly.

It is important to note that a high inlet temperature impacts the wet-bulb temperature of the surrounding air.

It is important to balance it according to the property of the feedstock.

Feed Flow Rate

You will pump the feedstock into the atomizer at a sustainable rate.

When you maintain a constant atomization pressure, you increase the size of the droplets by increasing the rate of feed flow.

This is true since the nozzle has the same amount of energy.

The atomizer uses this same energy to atomize the high volume of feed.

This means you are minimizing the fission of droplets hence reducing its size.

Feed Surface Tension

Atomization will occur when you disrupt the surface tension of the feed.

With this in mind, it is correct to say that you will hinder atomization since the feedstock has high surface tension.

It is thus important to emulsify and homogenize feedstock before you start the ceramic drying process.

This will reduce the surface tension of the feedstock.

Drying Gas Flow Rate

The dry gas flow rate is the drying gas that enters the drying chamber per unit time.

A high gas flow rate increases the movement of the particles inside the chamber.

This minimizes the interaction time of the air and droplet.

The flow rate of the drying gas needs to be low enough.

This enables the ceramic powder to be completely dry.

The rate should also be suitable to facilitate the separation process.

Outlet Temperature

This is the air that gets in contact with the ceramic particles before going to the collection station.

The heat exchange inside the drying chamber influences the outlet air temperature.

Generally, the outlet temperature is higher due to the heat exchange.

In the counter-current ceramic dryers, the outlet temperature is lower than the ceramic powder.

Residence Time within the Drying Chamber

Residence time is the period the droplets spend in the drying chamber.

Residence time has to be adequate to ensure complete drying of ceramic powder.

What are the Types of Ceramics you can make from a Ceramic Spray Dryer?

You can use ceramic powder from ceramic spray dryers to make a variety of ceramics.

Some of the types of ceramics you can make include:

· Porcelain

Example uses include pottery, electrical insulator, etc.

· Earthenware

Example uses include tiles and pottery.

· Bone China

Example uses include tableware and ornamentals.

· Glass-ceramics

Example uses include cookware, medical devices, cooktops, bakeware, etc.

· Stoneware

Example uses include pottery and tiles.

· Carbon

Example uses include aviation, sporting goods, etc.

· Fired Bricks

Example uses include fireplaces, chimneys, walls, landscapes, etc.

· Silicon Carbide

Example uses include furnaces, heating elements, abrasives, brake disks, cutting tools, etc.

· Silicone

Example uses include solar panels, semiconductors, integrated circuits, etc.

· Tungsten Carbide

Tungsten carbide contains tungsten and carbon in equal parts.

Examples include cutting tools, sports, and industrial equipment, etc.

· Titanium Carbide

Example uses include tool bits, watch mechanisms, heat shields, machine parts, etc.

· Boron Carbide

Boron carbide is a hard ceramic resistant to heat, chemicals, and ionizing radiation.

Example uses include nozzles, abrasives, locks, brake linings, and neutron absorbers.

· Barium Titanate

Example uses include capacitors, microphones, sensors, transducers, etc.

· Bioceramics

Biometrics are ceramics that you can safely use inside the human body.

Example uses include bone plates, screws, artificial hip, etc.

· Ceramic Foam

Foam is any material that has pockets of liquid or gas.

Ceramic foams are strong and lightweight.

Example uses include thermal and acoustic insulations, etc.

· Ceramic Matrix Composites

This is a composite material that has ceramic fibers ingrained in a ceramic matrix.

Example uses include brake disks, machine parts, turbines, furnaces, etc.

· Ferrite

Ferrites are made by heating iron oxide with other metals such as nickel, zinc, or barium.

Example uses include; inductors, transformers, speakers, refrigerator magnets, etc.

What are the Convectional Atomizers used on a Ceramic Spray Dryer?

The convectional atomizers hat a ceramic spray dryer uses include:

Rotary Atomizers

Rotary atomizers have a horizontal disc or wheel.

The feedstock directs to the center of this atomizer.

A centrifugal force makes the feed spread to the periphery hence forming spray droplets.

Hydraulic Nozzle Atomizers

It is also called a one-fluid nozzle.

You direct the feed through a pipe that narrows in diameter.

This makes the fluid come out at high pressure to form droplets.

Pneumatic Nozzle Atomizers

It is also known as a multi-fluid nozzle.

Two nozzles aid in the atomization process.

You will feed the feedstock a well as the compressed atomizing medium.

What is Atomization in a Ceramic Spray Dryer?

Atomization is an integral part of a ceramic spray dryer.

Atomization is the process where the liquid feedstock is converted to tiny droplets using an atomizer.

Atomization determines the quality, viscosity, and particle size of the ceramic powder.

The moisture if the droplets evaporate in the drying chamber to become individual ceramic powder in the drying stage.

What are the Common Atomization Techniques in Ceramic Spray Dryer?

These are the atomization techniques in a ceramic spray dryer:

Two-fluid Nozzle Atomization

In this technique, you are creating spray by contacting the feed and the compressed gas.

The contact can happen inside or outside the nozzle.

With this technique, you create a broader particle size distribution.

Two-fluid atomization is the least energy-efficient technique.

Centrifugal Atomization

In this technique, you are creating a spray by passing the fluid through a rotating disk.

You will produce a broader particle size distribution with this technique.

You also require a high inlet gas velocity to control the wall buildup.

Pressure Nozzle Atomization

In this technique, you will force fluid through an orifice.

This atomization technique is the most energy-efficient.

You can achieve the narrowest particle size distribution with a pressure nozzle atomization technique.

What is the Price of a Ceramic Spray Dryer?

The price of a ceramic spray dryer varies a lot depending on the material, size, and capacity.

The one you will buy depends on your production needs and your budget.

The price can range from 1,000 US Dollars to 1,000,000 US Dollars.

How does Freeze Granulation compare to Spray Drying?

Freeze granulation is more expensive compared to spray drying.

Freeze granulation is suitable for small to medium size batches where granule quality is high.

Spray drying is suitable for large scale processing even though you can use it for small samples.

Freeze granulation applies a two-step process; spray freezing and freeze-drying.

Freeze granulation applies low temperatures while spray drying uses high temperatures.

How do you Maintain Ceramic Spray Dryer?

You are to maintain a ceramic spray dryer to ensure it works well at all times.

You are to replace nozzles that have clogs.

You are to replace or repair any faulty or broken parts.

You are to use recommended parts when replacing worn-out or damaged parts.

How do you conduct Factory Acceptance Tests (FAT) on ceramic spray dryers?

You are to conduct a factory assessment test [FAT] on a ceramic spray dryer to ensure it is working well.

It also ensures that the machine meets the design and operational specifications.

The following are the steps on how to conduct a factory assessment test [FAT]:

· Preparation Stage

The manufacturer of the ceramic spray dryer presents the FAT procedure to the client.

Besides, the client then reviews and approves it.

The manufacturer then tests the equipment once the client approves the FAT procedure.

· Documentation Stage

The manufacturer gathers and reviews many documentations during the FAT procedure.

Furthermore, the manufacturer will provide these documents before, during, and after the FAT procedure.

· Testing Stage

In this stage, you will test all parts of the ceramic spray dryer.

This ensures that each component is in the best working condition and meets the required standards.

What is the Quality Standards Ceramic Spray Dryer Machine Must Conform to?

Spray dryer machine

A ceramic spray dryer has to conform to quality standards for health and safety reasons.

A ceramic spray dryer machine must conform to the following standards:

• Food and Drug Administration [FDA] Quality Standard

FDA ensures the machine is fit to meet the necessary health standards.

• Current Good Manufacturing Practices [cGMP] Quality Standard

This quality standard ensures the ceramic spray dryer uses the best design and working principles.

• International Organization for Standardization [ISO]

ISO ensures the machine works in the best way possible.

• CE Quality Standard

All companies worldwide accept this quality standard.

CE Quality Standard applies to European Economic Areas.

As you can see, there are many factors to consider before buying ceramic spray dryer machine.

The best part – this guide has outlined everything you need to know.

In case you have any questions or inquiries, feel free to contact Pilotech team.