SPP 1423:  Process-Spray: Functionalised Solid Particles from Spray Processes - From Powder Property Demands to Tailored Spray Processes and Feed Control

• Subject Area: Thermal Engineering/Process Engineering
• Term: from 2009 to 2016
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 73857889

For the production of solid particles and powders the process industry increasingly employs atomisation and spray techniques. Knowledge of the fundamental principles and mechanisms of process integrated spray technologies is relatively coarse, therefore this joint Priority Programme has been initiated. The participating research groups are from engineering disciplines as process and particle technology, fluid mechanics and physical chemistry, pharmaceutical or metall-powder technics. The aimed gain of fundamental knowledge is intended to be used in technical applications of spray processes.
The research approach of the joint Priority Programme uses innovative methods and processes in atomisation and spray technology for the derivation of the description of transport- and transfer-processes in dense, concentrated multiphase systems for the generation of solid particles in sprays. Actual developments and achievements in process integrated measurements technologies for multiphase systems and processes in combination with advanced, recently developed modelling and simulation techniques allow the approach, analysis and description of the fundamental processes in atomisation and sprays.
These achievements in combination with the industrial demand for particles and powders having very specific properties (as composition, size and shape, flowability and others) necessitate a multi disciplinary cooperation for analysis and modelling of particle generation in spray processes. The atomisation liquids typically involved for particle production are complex multiphase rheological systems as e.g. a suspension or emulsion. These boundary conditions reflect the challenging research programme for establishing and development of specific spray processes for particle production, but also reflect the huge possibilities and potentials for the development of innovative and new powders. From the process to system configuration in this approach technical expertise for the development of tailor-made dispersed systems is expected.
In the frame of the Priority Programme finally a recursive design approach is expected to be derived, where from the user claimed particle properties the requirement profile for the disintegration and atomisation process as well as for the spray process is defined. The technical application of the derived findings in the form of realisation of adapted atomisation facilities and plants for spray made particles is the focus point of the research programme.

• DFG Programme: Priority Programmes
• International Connection: Switzerland

Projects

• An Imaging System for the Real-Time Process Analysis Based on the Simultaneous Acquisition of Characteristics in Spray Processes (Applicant Simon, Sven )
• Analysis of the formation mechanisms of PVP-drug-formulations generated by the supercritical antisolvent spray process (Applicants Bräuer, Andreas ;  Schlücker, Eberhard )
• Atomization of superheated liquids (Applicant Wirth, Karl-Ernst )
• Chaotic disintegration of complex liquid jets, with application to airblast atomization and spray drying (Applicant Roisman, Ilia )
• Coordination Funds (Applicant Fritsching, Udo )
• Design of functional particles by a spray method - from requirements on the powder characteristics towards a suitable spray process (Applicants Lamprecht, Alf ;  Sommerfeld, Martin )
• Development of correlations between process operation, granule structure and product properties - Influence of spray- and process parameters on internal structure and mechanical properties of ceramic granules (Applicant Fries, Manfred )
• Enhancing the performance of dry powder inhalates with any inhalable active pharmaceutical ingredient by using spray dried mannitol carrier particles with tailored surface roughness (Applicant Scherließ, Regina )
• Erzeugung von Kompositpartikel durch in situ-Injektion von Feststoffpartikeln während des Lamellenzerfalls (Applicant Uhlenwinkel, Volker )
• Experimental investigation and modelling of coalescence and agglomeration for spray drying of suspensions (Applicant Sommerfeld, Martin )
• Experimental investigations of the morphology and the morphology formation of levitated single-particles as a model system for reactive and non-reactive spray processes (Applicant Moritz, Hans-Ulrich )
• Gemisch- und Partikelbildung im überkritischen Antisolvent-Sprühverfahren (Applicant Kronenburg, Andreas )
• Hochparallele Erzeugung monodisperser Partikel mit mikrostrukturierten Multikanaldüsen (Applicant Ziegler, Christoph )
• Integral Process Modeling and Simulation of Spray Processes for Powder Production in the SPP "Process-Spray" (Applicant Fritsching, Udo )
• Interfacial engineering and its use in microencapsulation of lipophilic active ingredients by spray drying (Applicant Drusch, Stephan )
• Investigation of Elementary Processes in a Process-Spray at Non-Newtonian Droplets by means of Direct Numerical Simulations (Applicant Bothe, Dieter )
• Investigation on the Influence of the Velocity Distribution and the Turbulent Fluctuations at the Nozzle Exit on the Liquid Jet Breakup with Direct Numerical Simulation of Multiphase Flows (Applicant Weigand, Bernhard )
• Investigation on the usage of effervescent atomization for spraying and spray drying of complex rheological food liquids and on the resulting particle and product properties (Applicant Karbstein, Heike )
• Jet breakup and drop formation in the centrifugal field influenced by a gas flow - variation of geometric boundary conditions (Applicant Piesche, Manfred )
• Modeling of particle distribution and dispersion in spray and spray drying processes (Applicant Gutheil, Eva )
• Monitoring of drying processes to create functional particles with an inline-sensor (Applicant Ripperger, Siegfried )
• Morphology Evolution of Particles in Spray Processes (Applicant Nieken, Ulrich )
• Numerical simulation of monodisperse droplet generation in pneumatic extension nozzles (Applicant Turek, Stefan )
• Particle generation by spraying of gas containing polymer melts and polymer solutions (Applicant Petermann, Marcus )
• Process design of ultrasonic spray pyrolysis synthesis of RuO2/TiO2 nanoparticles for catalytic applications (Applicants Friedrich, Bernd ;  Schroeder, Michael )
• Process Technology of hot gas atomization process for rheological complex liquid feed for production of powders with given properties (Applicant Fritsching, Udo )
• Processing of microstructured solid particles based on simple or multiple emulsions by prilling - under consideration of their function preservation for encapsulation of functional components and controlled release (Applicant Windhab, Erich J. )
• Production of narrowly distributed particles by laminar rotary atomization. Experimental investigation and control of the aerodynamic interaction to the ambient gas (Applicant Walzel, Peter )
• Pulverisation of emulsions with supercritical CO2 (Applicant Weidner, Eckhard )
• Spray-polymerization (Applicant Peuker, Urs )

• Spokesperson: Professor Dr.-Ing. Udo Fritsching