Abstract
A new spray-drying system has been designed to overcome the limitations caused by existing designs. A key feature of the approach has been the systematic use of Computational Fluid Dynamics (CFD) to guide innovation in the design process. An example of an innovation is the development of a box-shaped transitional feature between the bottom of the main drying chamber and the entrance to the secondary chamber. In physical experiments, the box design performed better in all three representative operating conditions, including the current conditions, a higher feed solids concentration (30% solids rather than 8.8%), and a higher inlet drying temperature (230 °C rather than 170 °C). The current conditions showed a 3% increase in yield (solids recovery) while the 30% feed condition improved the yield by 7.5%, and the higher temperature test increased the yield by 13.5%. Statistical analysis showed that there were significant reductions in the wall flux at the high solids feed concentration. The observed deposition in the box was primarily from the predicted particle impacts by an inertial deposition process on the base of the box, which underwent little degradation due to lower temperatures. There is therefore evidence that the box design is a better design alternative under all operating conditions compared with other traditional designs.
Highlights
Spray drying is a unit operation with an optimistic future, because it has been suggested [1]that spray drying for pharmaceutical products will increase by 17% between 2018 and 2028
That spray drying for pharmaceutical products will increase by 17% between 2018 and 2028
The continuous nature of spray drying has significant economic benefits, with the cost of spray drying being reported to be around one-sixth of that for freeze drying [4]
Summary
Spray drying is a unit operation with an optimistic future, because it has been suggested [1]. That spray drying for pharmaceutical products will increase by 17% between 2018 and 2028. Being a continuous and one-step drying and particle production process, it may be described as a robust technique that avoids a significant amount of manual handling, in contrast to freeze drying, which is a batch and manual process [2,3]. The continuous nature of spray drying has significant economic benefits, with the cost of spray drying being reported to be around one-sixth of that for freeze drying [4]. State that “Spray drying is the most popular and widely studied alternative to freeze drying because it is cost effective, readily available, easy to operate, and can be implemented for large-scale throughputs. Spray drying is 4 to 7 times cheaper and it is more energy efficient than freeze drying.” Santivarangkna, et al [5] state that the fixed costs involved in spray drying are 12% of those for freeze drying, and the manufacturing costs involved in spray drying are 20% of those for freeze drying
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