Presentation Mse 260
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SPRAY DRYINGSPRAY DRYING,,
GEL CASTINGGEL CASTING,,HOT ISOSTATIC PRESSINGHOT ISOSTATIC PRESSING
; AND; ANDPOWDER INJECTION MOLDPOWDER INJECTION MOLD
RYAN D. CORPUZRYAN D. CORPUZ
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SPRAY DRYINGSPRAY DRYING
a very widely applied, technical method used to
dry aqueous or organic solutions, emulsions
etc., in industrial chemistry and food industry
the transformation of feed from a fluid state intoa dried particulate form by spraying the feed into
a hot drying medium
The mixture being sprayed can be a solvent, em
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The complete process of spray dryingThe complete process of spray drying
basically consists of a sequence of fourbasically consists of a sequence of four
processesprocesses::
Dispersion of the feed solution in sma
Mixing of spray and drying medium (ai
Open-cycle and closed cycle system Drying of spray (removal of moisture)
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Dispersion of the feed solution inDispersion of the feed solution in
small dropletssmall droplets
dispersion can be achieved with a pressurenozzle, a two fluid nozzle, a rotary disk atomiseror an ultrasonic nozzle.
different kinds of energy can be used to dispersethe liquid body into fine particles
atomiser type depends upon the nature andamount of feed and the desired characteristics
of the dried product The higher the energy for the dispersion, the
smaller is the generated droplets.
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Mixing of spray and drying medium (air)Mixing of spray and drying medium (air)
with heat and mass transferwith heat and mass transfer
The manner in which spray contacts the
drying air has great bearing on dried
product properties by influencing droplet
behaviour during drying.
mixing defines the method of spray drying
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MIXING IS ACHIEVED BY ANY OFMIXING IS ACHIEVED BY ANY OF
THE FOLLOWING:THE FOLLOWING:
Co-Current flow
Counter-Current flow
Combined Disk atomizer (rotary wheel)
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Co-Current flowCo-Current flow
The material is sprayed in the same
direction as the flow of hot air through the
apparatus
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Counter-Current flowCounter-Current flow
The material is sprayed in the opposite
direction of the flow of hot air
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CombinedCombined
The advantages of both spraying methods
mentioned earlier are combined.
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Disk atomizer (rotary wheel)Disk atomizer (rotary wheel)
The material to be sprayed flows onto a
rapidly rotating atomizing disk and isconverted to a fine mist.
The drying air flows in the same direction
CLOSE AND OPEN
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Open-cycle and closed cycleOpen-cycle and closed cycle
systemsystem
open-cycle system, air stream is heated
electrically or in a burner and after the
process exhausted to atmosphere
closed cycle system, the heating medium
is recycled and reused
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Drying of spray (removal ofDrying of spray (removal of
moisture)moisture)
As soon as droplets of the spray come intocontact with the drying air, evaporationtakes place from the saturated vapour film
which is quickly established at the dropletsurface.
Due to the high specific surface area andthe existing temperature and moisturegradients, an intense heat and masstransfer results in an efficient drying.
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Diagram of the dry air flowDiagram of the dry air flow
TO APPLICATION
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Diagram of the product flow andDiagram of the product flow and
spray nozzlespray nozzle
TO THE 4 PROCESS OF DRYING
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OVERVIEW OF APPLICATIONSOVERVIEW OF APPLICATIONS
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GELCAST
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GEL CASTINGGEL CASTING
is a forming process similar to slip casting
for making complex-shaped parts
produces large complex-shaped parts that
are strong enough to be machined before
firing
this process is simple, economical, and
uses conventional equipment
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A P P L I C A T I O N SA P P L I C A T I O N S
large, complex-shaped components
large components having simple shapes
prototypes custom manufacturing
adding features to a cast part that would
be too difficult or too costly to include inthe mold
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HOT ISOSTATIC PRESSINGHOT ISOSTATIC PRESSING
subjects a component to elevated
temperatures and pressures to eliminate
internal microshrinkage
a slow process and takes 6-24 hours for
completion
for low production volumes of costly alloys
and advanced composites
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sintering kineticssintering kinetics
where p is the porosity at time t, po is the
initial porosity, and k is a temperature-dependent hot-pressing constant, determined
from the analysis of experimental data
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APPLICATIONSAPPLICATIONS
densifying castings
diffusion bonding of dissimilar materials
component repair powder metal consolidation
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Powder Metal MarketPowder Metal Market
HIP technology is applied in four separate
areas:
Consolidation of powder metals (PM)
Creation of PM shapes
Production of near-net shapes
Cladding
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PIM
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APPLICATIONSAPPLICATIONS
PIM is especially competitive in the
production of small intricately shapedcomponents
silicon carbide turbochargers
radial rotors for heat engines alumina thread guides
rare earth magnet pole pieces for hard
disk drives and stainless steel gear wheels for electric
tooth brushes
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TTHANK YOU!!!HANK YOU!!!