Product (Client): A leading German MNC based in Bangalore specializing in high-quality ceramics manufacturing.
Timeline: The plant has been operating at full capacity for over 1 year.
Status of the Plant: The plant is functioning efficiently and consistently, meeting the client’s critical specifications.
Plant Capacity: The installed spray dryer handles 102 kg/hr of water evaporation, processing high solid-content slurry (~70%).
Project/Equipment (Shachi):
Spray Dryer with Open Cycle Rotary Atomizer
Summary of the Project:
The project involved designing and commissioning a spray dryer for ceramic applications, focusing on producing high-quality alumina ceramics. The goal was to achieve specific particle size distribution with precise moisture content in the final product while handling high solid-content slurry feeds.
Challenges in the Project:
- Particle Size Requirement: The client needed a specific particle size for the ceramics.
- High Solid Content Feed: Managing slurry feeds with over 70% solid content posed significant challenges in terms of drying efficiency.
- Atomization: Achieving the required atomization was critical due to the high viscosity of the slurry.
- Moisture Control: Maintaining moisture content below 0.1% in the final product was another key challenge.
- Loss of Ignition: To meet the quality standards of the ceramic materials, the client required precise control over the loss of ignition (LOI).
- Bulk Density: Achieving the correct bulk density of the final product was essential to ensure consistency and quality in ceramic production.
Solutions by Shachi:
- Customized Design: Shachi engineered a bespoke spray dryer with a specialized feed and pumping system capable of handling high-solid content slurries.
- Rotary Atomizer: A high-speed rotary atomizer was imported from Italy, designed specifically for this application, ensuring precise atomization without the need for oil lubrication.
- Moisture Control: Shachi employed advanced moisture control through optimized plant mass balance and temperature management, ensuring consistent moisture levels below 0.1%.
- Oil-Free Operation: The atomizer design was customized to ensure oil-free functioning, eliminating the need for lubrication oil while meeting strict client standards.
Looking for customized drying solutions that ensure precise particle size and moisture control?
Contact Shachi Engineering today!
Additional Points:
- The plant’s performance has been consistent, operating at full capacity for the last year.
- Shachi’s collaboration with European partners ensured the integration of top-tier rotary atomizers, contributing to the plant’s success.