Our dedicated portfolio of hard carbide (HC) closed-cycle spray drying plants for processing hard metal powders is available in a range of sizes and capacities. Built for spray drying solvent-based feeds in oxygen-free, inert gas environments, GEA HC closed-cycle plants are supplied with an integrated PLC-based safety monitoring, alarm and control platform, and highly automated, purpose-designed clean-in-place (CIP) systems with solvent recovery.
Global partner for hard metals spray drying
Tungsten carbide powders and similar materials used to produce cutting and mining tools are dense, abrasive, and typically processed using organic solvents and inert gas (e.g. nitrogen). Issues including nozzle clogging and inconsistencies in powder properties, together with the safety and environmental considerations associated with using flammable solvents combustible powders, mean that spray drying carbides and other hard metals poses significant challenges for manufacturers.
With more than 140 installations worldwide GEA is the proven spray drying partner for the world’s leading hard metal producers. Our HC closed-cycle spray dryers are designed specifically to solve the challenges associated with processing these high value materials. Hard metals are typically processed at the small industrial scale, so we can supply compact, fully featured plants with capacities of 60-600 kg/h product. All of our closed-cycle spray dryers for hard metal powders are supplied as packaged units.
Spray drying hard metals is commonly carried out in closed-cycle systems and inert gas environments to reduce explosion risk, product oxidation and solvent emissions. Backed by decades of process experience and spray drying expertise, we understand the unique demands of carbide powder manufacture, from powder binder and solvent temperature limitations, to real-time plant safety monitoring and control, solvent recovery and recycling.
Safe, closed-cycle spray drying for solvent-based feeds
We take a safety by design approach to spray dryer development, so all GEA HC closed-cycle spray drying plants for hard metals are designed to meet the ATEX directive. Our systems are supplied with a dedicated, integrated control platform that monitors plant operation in real time and keeps your process within safe limits.
Integrated system for plant monitoring and safety
The integrated control platform connects to the spray dryer’s safety sensors and interlocks for process temperature, pressure, oxygen, and solvent vapor. Automated warning alarms and potentially plant shut down are triggered in the event that safety limits are breached.
Built around a user-friendly PC/PLC with monitor, and recipe management, the control station allows operators to adjust and monitor plant operation, in real time.
High batch flexibility with fast, highly automated CIP
Hard metal powders are also commonly processed in small batches through short campaigns that may involve frequent powder grade changes, and a dryer run of just a few hours. Thorough, fast and safe cleaning between batches is really important to help maintain plant agility and safety, and to prevent unnecessary downtime and stoppage. We’ve developed highly automated solvent-based CIP systems that are purpose-designed to help ensure safe, effective and fast cleaning for these closed-cycle, solvent-based spray dryers.
CIP solvent recovery is performed in a combined scrubber-condenser unit, which ensures efficient solvent reuse, and supports environmental compliance. The plant is supplied with two tanks for solvent recovery, enabling sedimentation of powder and recirculation of CIP liquid. This helps to reduce solvent waste and overall costs.
The thorough high-pressure cleaning cycle is set up by the operator via the PLC, and is continually under spray dryer control system oversight, to help ensure safe cleaning and to monitor solvent temperature, pressure and time for each cleaning cycle step. Importantly, GEA CIP technology for our HC closed-cycle spray dryers requires only minimal manual intervention, which supports faster cleaning and turnaround. A cleaning cycle might be completed in just one hour, significantly reducing system downtime compared with manual cleaning.This all helps to maximize plant availability, free up operators for other tasks, and reduce the risk of manual errors.
Spray dryer features for top performance
Hard metal particles are high density, and GEA HC closed-cycle spray dryers are commonly configured using a fountain-spray nozzle, which atomizes from the bottom of the spray drying chamber upwards. This increases particle residence time in the dryer and helps to ensure thorough, uniform drying as the particles fall back down, even for these high-density powders. We can also supply counter-current nozzles.
The plants are designed so that operators can swap out atomization nozzles and add or remove nozzle inserts with minimal disruption. While the plant is in “idle” mode operators can pressure-neutralize just the section of the plant containing the nozzle components. This section can then be opened safely so that the nozzle lance can be mounted/dismounted, without compromising the nitrogen- and solvent-filled closed cycle system.
Compliant plant layouts for hard metals spray drying
Importantly, critical plant systems, including oil heaters that supply heat for the spray dryer heat exchanger, as well as the solvent-recovery tanks, and the electrical and control systems, are housed in dedicated safe rooms that are separate to the spray dryer room. Our experts can provide you with layout guidance, complete engineering support, and regional know-how to help ensure compliance with relevant manufacturing and safety regulations.
Test spray drying plants before you invest
Here at GEA we like to share our expertise and know-how with our customers. At our spray drying center of excellence GEA experts can work with you to carry out feasibility and stability testing of your processes and products on pilot-scale closed-cycle systems. Mirroring production performance on commercial HC closed-cycle spray dryers, the pilot scale setup allows you to validate process parameters and ensure that the final process and equipment configuration will consistently and efficiently generate high yields of powders with the expected particle size distribution, particle shape and density.
A complete spray dryer support package
Our experts will help you throughout presale system design and configuration, supply, installation and start-up of your GEA HC closed-cycle spray drying plant. As well as offering layout, safety and integration support, we can tailor a spare parts, service and support package covering ongoing maintenance, upgrades and troubleshooting, not just while you get up and running, but for the whole life cycle of your plant.
Want to find out more? Contact us and let’s get talking.
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