Forming, and spraying

Forming operations are described from both a chemical and ceramic engineering perspective, with emphasis on design of structures with desired mass transfer and strength characteristics. Specific forming methods that are discussed include extrusion, bead forming and spray-drying. Newer forms will also be introduced. 

Two basic methods are used for the appHcation of protective coatings to metal containers, ie, roUer coating and spraying. RoUer coating is used if physical contact is possible, eg, coating of metal in sheet and coil form. Spraying techniques are used if physical contact is not possible, eg, to coat the inside surface of two-piece drawn and ironed can bodies (see Coating processes). 

Reaction times can be as short as 10 minutes in a continuous flow reactor (1). In a typical batch cycle, the slurry is heated to the reaction temperature and held for up to 24 hours, although hold times can be less than an hour for many processes. After reaction is complete, the material is cooled, either by batch cooling or by pumping the product slurry through a double-pipe heat exchanger. Once the temperature is reduced below approximately 100°C, the slurry can be released through a pressure letdown system to ambient pressure. The product is then recovered by filtration (qv). A series of wash steps may be required to remove any salts that are formed as by-products. The clean filter cake is then dried in a tray or tunnel dryer or reslurried with water and spray dried. 

Products. Damping treatments are available from many manufacturers in sheet form, as tapes for adhering to a surface, and in bulk form for spraying or troweling onto a surface. Laminated glass is available from many glass suppHers (see Laminated materials, glass). 

Waferboard, a more recent wood constmction product, competes more with plywood than particle board. Waferboard and strand board are bonded with soHd, rather than Hquid, phenoHc resins. Both pulverized and spray-dried, rapid-curing resins have been successfully appHed. Wafers are dried, dusted with powdered resin and wax, and formed on a caul plate. A top caul plate is added and the wafers are bonded in a press at ca 180°C for 5—10 min. Physical properties such as flexural strength, modulus, and internal bond are similar to those of a plywood of equivalent thickness. 

Hand Lay-Up and Spray-Up. In hand lay-up, fiber reinforcements in mat or woven form are placed on the mold surface and then saturated with a Hquid polymer, typicaHy a polyester resin, that has been chemically activated to polymerize (cure) without the addition of heat. Multiple pHes of reinforcement and multiple cure steps aHow very heavy waH thicknesses to be achieved. 

Fig. 13. Scanning election micrograph of polyacrylonitrile fibrils formed by spraying a 0.05 wt % polyacrylonitrile in dimetbylform amide solution into CO2 through a 50-//m inner diameter, 18-cm-long no22le at a temperature of 40°C, density of 0.66 g/mL, and solution flow rate of 0.36 ml,/min (118).

Because of the multiple conjugated olefinic stmcture in the molecule, pure crystalline carotenoids are very sensitive to light and air and must be stored in sealed containers under vacuum or inert gas to prevent degradation. Thus, commercial utilization as food colorings was initially limited however, stable forms were developed and marketed as emulsions, oil solutions and suspensions, and spray-dried forms. 

In the human market, oral and parenteral dosage forms are prepared from the crystal. However, because of the extremely high potency, more dilute (0.1—10%) forms are avabable. These include dilutions with mannitol, triturations on dicalcium phosphate or resins, and spray-dried forms. Prices for these forms are driven by that of the crystal, which in early 1996 was ca 9.50/gram (95). Prices for the vitamin have risen during the first half of the 1990s. However, Htde growth in price beyond inflation is anticipated. 

Types of air strippers include packed towers, tray towers, and spray towers. Packed towers are packed or filled with small forms made of polyethylene [9002-88-4] stainless steel, poly(vinyl chloride) (PVC) [9002-86-2] or ceramic that provide large surface area to volume ratios which increase transfer rates into the air stream. Packed towers operate in countercurrent mode, that is, the aqueous stream enters at the top of the tower while air is blown in from the bottom. An example of this type of unit is shown in Figure 1. Channeling or short circuiting of the aqueous stream is minimized by... 

Amino Resins. Amino resins (qv) include both urea- and melamine—formaldehyde condensation products. They are thermosets prepared similarly by the reaction of the amino groups in urea [57-13-6] or melamine [108-78-1] with formaldehyde to form the corresponding methylol derivatives, which are soluble in water or ethanol. To form plywood, particle board, and other wood products for adhesive or bonding purposes, a Hquid resin is mixed with some acid catalyst and sprayed on the boards or granules, then cured and cross-linked under heat and pressure. 

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