Solutions spray drying

Gordon, M.S. Lord, J.D. Processes for Spray Drying Solutions of Hydrophobic Drugs and Compositions Thereof. US Patent 5,985,248, 1999. 

Corrigan DO, Healy AM, Corrigan OI. The effects of spray drying solutions of polyethylene glycol (PEG) and lactose/PEG on their physicochemical properties. Int J Pharm 2002 235(1-2) 193-205. 

Adsorption on carrier Spray drying Solution in oil, PG etc. Emulsion... 

Derivation Aluminum hydroxide is dissolved in formic acid and spray-dried. Solutions are also prepared by treating aluminum sulfate with formic acid, followed by lime. 

In spray-drying solutions the evaporation from the surface of the drops leads to initial deposition of solute at the surface before the interior of the drop reaches saturation. The rate of diffusion of solute back into the drop is slower than the flow of water from the interior to the surface, and the entire solute content accumulates at the surface. The final dry particles are often hollow, and the product from a spray dryer is quite porous. 

The factors which lengthen the pathway for diffusion not only slow the reaction, but also can lead to the formation of nonequilibrium intermediate phases. As an example, coarse particles of an equimolar mixture of BaC03 and Sn02 will lead to the initial formation of Ba2Sn04 rather than BaSn03. This aspect generally makes chemically prepared mixtures, for example, sol-gel, coprecipitation, and freeze- or spray-dried solution processes, more attractive as synthetic methods. 

Dry matter test conditions Spray-dried Solution... 

Product from melt or suspension treatment is obtained directly as emmb or powder. Polymer recovered from solution treatment is obtained by precipitative cooling or spray drying. Polymer with now stable end groups may be washed and dried to remove impurities, especially acids or their precursors, prior to finishing operations. 

In Du Pont patents (116) the catalyst is prepared by spray-drying a mixture of colloidal siUca or other carriers and Pt/Pd salts. Aqueous hydrogen peroxide solutions up to 20 wt % ate reported for reaction conditions of 10—17°C and 13.7 MPa (140 kg/cm ) with 60—70% of the hydrogen feed selectively forming hydrogen peroxide. 

Spray Drying. Spray-dry encapsulation processes (Fig. 7) consist of spraying an intimate mixture of core and shell material into a heated chamber where rapid desolvation occurs to thereby produce microcapsules (24,25). The first step in such processes is to form a concentrated solution of the carrier or shell material in the solvent from which spray drying is to be done. Any water- or solvent-soluble film-forming shell material can, in principle, be used. Water-soluble polymers such as gum arable, modified starch, and hydrolyzed gelatin are used most often. Solutions of these shell materials at 50 wt % soHds have sufficiently low viscosities that they stiU can be atomized without difficulty. It is not unusual to blend gum arable and modified starch with maltodextrins, sucrose, or sorbitol. 

The second step is to disperse the core material being encapsulated in the solution of shell material. The core material usually is a hydrophobic or water-knmiscible oil, although soHd powders have been encapsulated. A suitable emulsifier is used to aid formation of the dispersion or emulsion. In the case of oil core materials, the oil phase is typically reduced to a drop size of 1—3 p.m. Once a suitable dispersion or emulsion has been prepared, it is sprayed into a heated chamber. The small droplets produced have a high surface area and are rapidly converted by desolvation in the chamber to a fine powder. Residence time in the spray-drying chamber is 30 s or less. Inlet and outlet air temperatures are important process parameters as is relative humidity of the inlet air stream. 

Ultrafiltration. Membranes are used that are capable of selectively passing large molecules (>500 daltons). Pressures of 0.1—1.4 MPa (<200 psi) are exerted over the solution to overcome the osmotic pressure, while providing an adequate dow through the membrane for use. Ultrafiltration (qv) has been particulady successhil for the separation of whey from cheese. It separates protein from lactose and mineral salts, protein being the concentrate. Ultrafiltration is also used to obtain a protein-rich concentrate of skimmed milk from which cheese is made. The whey protein obtained by ultrafiltration is 50—80% protein which can be spray dried. 

Naphthalenesulfonic Acid. The sulfonation of naphthalene with excess 96 wt % sulfuric acid at < 80°C gives > 85 wt % 1-naphthalenesulfonic acid (a-acid) the balance is mainly the 2-isomer (P-acid). An older German commercial process is based on the reaction of naphthalene with 96 wt % sulfuric acid at 20—50°C (13). The product can be used unpurifted to make dyestuff intermediates by nitration or can be sulfonated further. The sodium salt of 1-naphthalenesulfonic acid is required, for example, for the conversion of 1-naphthalenol (1-naphthol) by caustic fusion. In this case, the excess sulfuric acid first is separated by the addition of lime and is filtered to remove the insoluble calcium sulfate the filtrate is treated with sodium carbonate to precipitate calcium carbonate and leave the sodium l-naphthalenesulfonate/7J(9-/4-J7 in solution. The dry salt then is recovered, typically, by spray-drying the solution. 

The ammonium perchlorate solution is spray-dried to the desired crystal size at air temperatures below 150°C and crystal temperatures of about 110°C. This procedure provides a pure product having a controlled grain size. Prior mechanical and thermal treatment affects the isothermal... 

The prepolymer is separated from the water by spray drying and then formed into cylindrical pellets of uniform size (159). At this point additives can be added to the porous pellets from solution or suspension. These pellets are then placed in a soHd-phase condensation reactor where they are heated to 260°C for up to 4 h under nitrogen, with a small amount of water added. The pressure is maintained close to atmospheric pressure. At the end, x > n. 

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. 

Poly(vinyl acetate) and its copolymers with ethylene are available as spray-dried emulsion soHds with average particle sizes of 2—20 p.m the product can be reconstituted to an emulsion by addition of water or it can be added directly to formulations, eg, concrete. The powders may be used to raise soHds of a lower soHds latex. Solutions of resin in methyl and ethyl alcohol at 2—50 wt % soHds are also available. 

Sodium borate solutions near the Na20 B202 ratio of maximum solubihty can be spray-dried to form an amorphous product with the approximate composition Na20 4B202 4H20 commonly referred to as sodium octaborate (64). This material dissolves rapidly in water without any decrease in temperature to form supersaturated solutions. Such solutions have found apphcation in treating ceUulosic materials to impart fire-retardant and decay-resistant properties (see Cellulose). 

Manufacturing Processing and Uses. In commercial production, aqueous urea solution is mixed with acetaldehyde in 1 1 molar ratios. An acid catalyst is introduced into the reaction mixture which is staged at various process temperatures. After neutralization with a base, the CDU is separated from the mother hquor by filtration or spray drying. 

Later it was found growing in South America where the Indians used the red dye from the seeds as a body paint. An extract of the seeds appears on the market as annatto. This extract is used in coloring butter, margarine, and cheese such as Leicester cheese. In Mexican and South American cuisine, it finds special use as a flavor and coloring matter. The seeds are sold under the name achiote in many Latin grocery stores and markets. Ann at o is available as an aqueous solution, as an oleaginous dispersion, and a spray-dried powder. 

In drying solutions or slurries of solutions, the location of the feed-injection nozzle (spray nozzle) has a great effecl on the size of particle formed in the bed. Also of importance are the operating temperature, relative humidity of the off gas, and gas velocity. Particle growth can occur as agglomeration or as an onion sldnuing. ... 

Spray-dried extract The solutions containing the drug extracts, which are sprayed through a nozzle, sink in the form of fine droplets in the current of warm air, losing their moisture and reaching the separator as dry and hollow pellets of extract which can be recognized with a hand lens. The spray-... 

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