A common application of spray drying is the production of powders which are subsequently pressed and fired, where the unique properties of the spray dried product, i.e. narrow particle size distribution and spherical particle shape, result in good flow characteristics. Therefore, spray dryers have been widely used in the manufacture of ceramics such as carbides, nitrides and borides. Other applications include powders for plasma spraying and slip casting, and ferrites for magnetic toners.
However, for a spray drying application to be successful, it is important for the user to understand the drying process of the spray dryer. It is also important that the user selects the correct system based on the needs of the application.
The basic spray drying process consists of three processing steps:
1. Atomize the slurry into tiny droplets, which is done by a rotary or nozzle atomizer.
2. Mix the atomized spray with hot drying gas (usually air) and dry the individual droplets into solid particles. This is done in a drying chamber and it is important that the particles are dry (at least on the surface) before coming into contact with the inner surfaces of the drying chamber.
3. Recycle the dried product. This can be done partly from the bottom of the drying chamber and partly from a separation device for the used drying air.
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