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Updated: Jul 18, 2025

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Driving Spray Drying towards Better Yield: Tackling a Problem That Sticks Around.

Pavithra Sundararajan1, Justin Moser2, Lisa Williams3

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|August 26, 2023
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Summary
This summary is machine-generated.

Spray drying yield loss in consecutive batches is caused by powder accumulation on chamber walls. Addressing surface roughness, gas flow variations, and thermal degradation of deposited powder during shutdowns mitigates this issue, improving process efficiency.

Keywords:
glass transition temperatureprocess product and performancesorption kineticsstart-up and shutdown operationwall deposition

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Area of Science:

  • Chemical Engineering
  • Materials Science

Background:

  • Powder deposition on spray dryer walls is a known issue affecting yield and process continuity.
  • Existing research focuses on factors influencing deposition extent and rate in chemical and food industries.

Purpose of the Study:

  • Investigate an atypical spray drying yield loss occurring in consecutive batches.
  • Identify key mechanisms responsible for yield reduction in repeated spray drying cycles.

Main Methods:

  • Analyzed the interplay between process parameters, material properties, and equipment.
  • Examined factors including inner wall surface roughness and gas flow variations.
  • Assessed the impact of start-up/shutdown parameters on deposited powder's thermal properties.

Main Results:

  • Identified specific mechanisms causing yield loss in subsequent batches.
  • Found that surface roughness, gas flow changes, and thermal exposure of deposited powder contribute to increased wall accumulation.
  • Demonstrated that correcting these factors mitigates yield reduction.

Conclusions:

  • Atypical yield loss in spray drying is linked to cumulative effects of wall deposition over batches.
  • Surface characteristics, process dynamics, and thermal history of deposited material are critical.
  • Process optimization by addressing identified factors significantly improves spray drying efficiency and yield consistency.