SPRAY DRYING,

GEL CASTING,
HOT ISOSTATIC PRESSING
; AND
POWDER INJECTION MOLDIN
RYAN D. CORPUZ
 SPRAY 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 into
a dried particulate form by spraying the feed into
a hot drying medium
• The mixture being sprayed can be a solvent, emulsio
 The complete process of spray drying
basically consists of a sequence of four
processes:
• Dispersion of the feed solution in small dr
• Mixing of spray and drying medium (air) w
• Open-cycle and closed cycle system
• Drying of spray (removal of moisture)
Dispersion of the feed solution in
small droplets
• dispersion can be achieved with a pressure
nozzle, a two fluid nozzle, a rotary disk atomiser
or an ultrasonic nozzle.
• different kinds of energy can be used to disperse
the liquid body into fine particles
• atomiser type depends upon the nature and
amount of feed and the desired characteristics
of the dried product
• The higher the energy for the dispersion, the
smaller is the generated droplets.
Mixing of spray and drying medium (air)
with 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
MIXING IS ACHIEVED BY ANY OF
THE FOLLOWING:
• Co-Current flow
• Counter-Current flow
• Combined
• Disk atomizer (rotary wheel)
 Co-Current flow
• The material is sprayed in the same
direction as the flow of hot air through the
apparatus
 Counter-Current flow
• The material is sprayed in the opposite
direction of the flow of hot air
 Combined
• The advantages of both spraying methods
mentioned earlier are combined.
 Disk atomizer (rotary wheel)
• The material to be sprayed flows onto a
rapidly rotating atomizing disk and is
converted to a fine mist.
• The drying air flows in the same direction

CLOSE AND OPEN

 Open-cycle and closed cycle
system
• 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
 Drying of spray (removal of
moisture)
• As soon as droplets of the spray come into
contact with the drying air, evaporation
takes place from the saturated vapour film
which is quickly established at the droplet
surface.
• Due to the high specific surface area and
the existing temperature and moisture
gradients, an intense heat and mass
transfer results in an efficient drying.
Diagram of the dry air flow

TO APPLICATION
Diagram of the product flow and
spray nozzle

TO THE 4 PROCESS OF DRYING

OVERVIEW OF APPLICATIONS
GELCAST
 GEL 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
 APPLICATIONS

• 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 in
the mold
 HOT 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
sintering 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
 APPLICATIONS

• densifying castings
• diffusion bonding of dissimilar materials
• component repair
• powder metal consolidation
 Powder 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
PIM
 Powder Injection-Molding (PIM)

• is an efficient method for the high volume

production of shaped components from
powders
• a derivative of polymer injection moulding
and uses much of the same technology,
along with batch sintering processes used
in powder metallurgy and ceramic
processing
 APPLICATIONS
PIM is especially competitive in the
production of small intricately shaped
components
• 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
THANK YOU!!!