#Industry News
User Success Story: Sharply Improving the Yield Rate of Spray Dry Particle Size Distribution by Reviewing the Pump Selection
Improving granulation problems during spray drying with Smoothflow Pumps
Processing Molding Manufacturer, Company H
Production Engineering Department
Company H, which mainly processes fine ceramics which are used in various fields such as semiconductors, industrial machinery and medical care, had problems with granulation during spray drying.
Problem:
・The particle size distribution was broad and the yield rate was deteriorating.
Ceramics are produced by high heat treatments with high purity inorganic materials or inorganic compounds as raw materials. In particular, fine ceramics are manufactured with high precision under strict control. In company H, which processes fine ceramics, the spray drying method is used for granulation of the fine ceramics.
If the ceramics are molded in a state in which the particle diameter is not uniform, the density of the molded product also becomes uneven, so Company H casts ceramics only with particles with a very sharp particle size distribution. However, in their current granulation process, the number of particles that had to be removed during the particle size classification process was large and the yield rate was very bad.
Mr. T of the Production Engineering Department decided to review the granulation process. “In the past, we used a peristaltic pump to supply the raw materials stock solution. I had an air chamber installed in the system, but since the pulsation was not completely eliminated, the particle size distribution became broad. The yield rate was bad and productivity did not improve, so we decided to start reviewing the pumps.”
Problem Points:
・Want to narrow down the particle size distribution of the spray dry process
・Want to improve the yield rate and production efficiency.
Solution:
・In order to solve this problem, we reviewed all of the equipment in the process line.
While reviewing the selection of the peristaltic pump, Mr. T started to collect information on different kind of pumps. “During that time, I just happened to come across Tacmina’s homepage and I was interested in the Smoothflow pumps that was being introduced for spray dry applications, so I decided to inquire about it.”
Tacmina’s salesperson in charge of Mr. T’s inquiry visited his factory and confirmed the situation of the site and equipment. In addition to the air chamber not being able to completely eliminate the pulsation of the peristaltic pump and fluctuations of the supply amount of the raw materials stock solution, other potential causes to the non-uniform particle size distribution were identified. First, there was a possibility that some of the raw materials solution was staying in the air chamber and density unevenness began to occur. Second, there was potential that the raw materials tank in the previous process was not being stirred sufficiently.
・Drastically improved yield rate
Using the advice provided by Tacmina, Mr. T improved the potential problem points that were pointed out.
Also, by deciding to use a Smoothflow Pump, the pulsation disappeared and the supply amount of the raw material stock solution became stable. Also, since there is no need to use an air chamber with a Smoothflow Pump, he no longer had to worry about concentration unevenness due to raw materials retention in the air chamber.
“As a result of reviewing the granulation process, we were able to vastly sharpen the particle size distribution and increase the yield rate. Also, all of the monitoring and adjustments to the flow rate which we had to do up until now became unnecessary so burden on the workers as well as labor costs were reduced.”
Solution Points:
・By improving the pumps and peripheral equipment, they were able to improve and sharpen the particle size distribution.
・Since there is no need to monitor or adjust the flow rate, the burden on the operators was greatly reduced.
