The customer was looking for a way to create ceramic particles for a specialty application. Particle morphology was important: particles could not be hollow, broken or irregularly shaped. A narrow particle size distribution was required to achieve the desired powder flow properties. In addition, the mechanical strength of particle had to be high enough to withstand basic handling, but low enough to allow for quick dispersion when exposed to a solvent.
AVEKA spray dried the ceramic with a surfactant and binder. After conducting many trials, AVEKA successfully produced a highly-engineered, dispersible particle with the desired particle morphology. To optimize particle shape and size, AVEKA varied feed formulation, liquid atomization, feed rates and dryer temperatures.