How to convert liquid into powder

Liquid to Powder Conversion: Improving Efficiency and Performance

Anhydro MicraSpray 150 dryer by SPX

Jan 31, 2012

High yield is always an important factor in selecting the right drying process for converting liquids to powders – and the higher the cost of the product the more important it becomes. There are various methods by which to implement this process and the decision on which to use of course includes consideration of the capital and operational costs versus the savings gained by higher efficiencies.

The spray drying process is widely used across many different applications – chemicals, flavors, foods, and pharmaceuticals to name just a few. Spray dryers have many advantages and provide easy operation with continuous and rapid drying of a compound. Their simplicity does not require complicated automation systems and CIP is straightforward. They are known for their reliability, efficiency, and predictable scale-up.

The concept of using a spray dryer to convert fluids into dry powders is a simple one and has been utilized for many decades. The straightforward technique uses a heater with gas flowing through it (usually air) to dry the fluid. The thermal energy of the hot gas is consumed in evaporation so there is no heat damage to the product being treated. It is, therefore, very popular where the product may be sensitive to temperature changes and is widely used in the pharmaceutical and food industries.

Freeze drying, or lyophilization, is a typical technology choice to meet high-yield percentages, particularly of smaller particles in high-value areas such as pharmaceutical or biotechnology. However, this technology comes at a much higher cost and is a time consuming process, whereas a single spray dryer could replace six lyophilizers and maintain the same production capacity. A spray dryer installation is estimated to take 25% of the square footage of a lyophilizer, which requires significant additional machinery such as vacuum systems to support what is a quite complex process. The installed cost of a freeze-drying process compared to spray drying for the same production scale, is significantly higher. Therefore, a spray drying processor with a high yield at scale would offer numerous benefits with reduced costs and improved process efficiency.

Clearly the installed cost of a freeze-drying process compared to spray drying for the same production scale is significantly higher. So if a spray drying processor could bring a high enough yield at scale it would offer numerous benefits with reduced costs and improved process efficiency.

Instead of a cyclone for collecting powder, systems that use bag filters would, of course, also bring a high enough yield of product. Bag filters are not, however, suitable for use with all compounds. There can be issues with particles being retained within the bag for an undetermined amount of time and contamination of the product can occur with delamination of the filter media.

Spray dryers that use a cyclone to collect powder are a well-established technology and have predictable results as a process is scaled up in size. They offer precise control of all critical process parameters. This predictability and the simplicity of their operation also provides a high degree of user confidence and product consistency – perfect for applications in areas such as pharmaceutical that require validation. Historically, however, the yields have not been high for larger production capacities with particles in the range of less than 10 microns. The issue here is that the size of cyclone needed to gain the throughput is not ideal for the small particle sizes.

So, for an application where particle size is small, a bag filter is not suitable and high product value demands high product yields, freeze drying would seem to be the best option. If, however, the efficiencies of a spray dryer with a cyclone collection system to handle a higher production capacity could be vastly improved, it would remove a great deal of cost from the initial installation (capital cost) and significantly reduce ongoing operational overheads.

The solution is a relatively simple one: Instead of one larger cyclone, where there is potential for small particles to be carried through with the gas used to dry them, two smaller cyclones can be installed in parallel within the machine. Smooth, pharmaceutical-grade materials within the cyclones help with the execution of the process and the results are truly dramatic. The dual system provides a larger production capacity but with the collection performance levels of a much smaller system. Predictable performance and product consistency are maintained at the high levels expected from a spray dryer. Tests with a drying air rate of 150 kg/hr have shown a yield percentage in the high nineties for a particle size of about six microns.

High yield spray dryers bring an exciting alternative to expensive lyophilization techniques for many applications within the pharmaceutical and biotech industries. There are no requirements for vacuum systems and the installed and operational costs are greatly reduced. A single spray dryer could typically replace multiple freeze dryers to gain the same production capacity.

There are clear advantages to this dual cyclone spray dryer in the pharmaceutical industry where the operation also lends itself to straightforward validation of the system in line with FDA requirements. Its higher efficiencies, however, would be equally applicable to other application areas with higher cost products, for example flavors and fragrances, catalyst processing or high precision ceramics.

Robert Turok is technology manager, SPX Flow Technology Systems Inc. For more information, visit www.spxft.com.

TAGS: Optimization

United States - English

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How to make liquid from dry powder

Not all housewives trust the chemistry used in the production of powders for automatic machines. With a little effort, you can create with your own hands a much cheaper, but no less effective analogue of washing powder, which is safe for humans.

Harm from household chemicals from the store

Manufacturers of washing powders claim that the harmful substances contained in their products are not dangerous to humans, since they are used in minimal quantities. However, during washing, harmful components combine with other ingredients of the product, which poses a significant threat to health.

Hazardous substances contained in washing powders penetrate the skin and suppress the immune system when left on clothes

The main hazardous substances contained in washing powder are surfactants and phosphates, and even after 10 rinses in hot water these substances still remain on the fibers of clothing. Surfactants are easily absorbed by the skin and may cause allergies. Phosphates are toxic and adversely affect the activity of the liver and kidneys, enhance the negative effects of surfactants, cause dermatosis and allergies. In addition to these harmful substances, the washing powder contains other components that are no less harmful to the human body. These include formaldehydes, optical brighteners, ammonium and others.

Important information: Scientists have found that surfactants, penetrating the skin into the human body, increase the risk of infertility several times.

The main distinguishing feature of handmade washing powders is the absence of harmful substances in their composition.

do not have an unpleasant chemical odor;
do not cause allergic reactions;
cope with washing no worse than store-bought powders;
are low cost;
can be used in automatic machines.

Homemade products do not lather well. This is an added bonus as foam can damage parts of automatic washing machines.

True, there are also negative aspects. Firstly, it takes some time to prepare the washing powder.

Secondly, most of these products contain soap, which leaves marks on clothes, but this problem can be easily dealt with by adding wine vinegar to the water when rinsing.

Third, homemade laundry detergent contains soda ash. The product can corrode the skin of the hands in case of direct contact, so it is recommended to use gloves.

Natural Home Laundry Detergent Recipes

There are several ways to make natural laundry detergent, and the ingredients do not differ much.

Dry powders

To prepare loose powder for washing cotton and linen fabrics, you will need:

laundry soap (72%) - 150 g;
baking soda - 500 g;
soda ash - 400 g;
salt - 2 tbsp. l.

Add a few drops of essential oil to scent your clothes.

It is advisable to use natural dark soap for the preparation of laundry detergent

Lightly dry the laundry soap and grind it on a grater, then add the rest of the ingredients to it and mix thoroughly. Essential oil should be added at the very end, then mix the mixture again.

To use the powder in an automatic machine, the soap must be rubbed finely, otherwise its grains may remain on clothes.

Important information: Cotton and linen are vegetable fibers, so the detergent used for them must be alkaline.

For silk or wool clothes, use the following recipe:

laundry soap - 150 g;
salt - 500 g;
citric acid - 3 tbsp. l.

Citric acid provides favorable conditions for washing wool and silk, and also gives freshness to things

Salt can be replaced with baking soda, but this recipe is not suitable for colored fabrics. The cooking process does not differ from the previous one: grind the soap on a grater, add salt, citric acid, mix the powder thoroughly and use as directed.

Salt retains color during washing, prevents things from shedding

To wash clothes made of artificial fabrics, prepare the following powder:

laundry soap - 150 g;
baking soda - 700 g;
soda ash - 200 g.

Grind laundry soap on a grater, mix it with the rest of the ingredients.

Detergent for artificial fibers replaces most of the soda ash with food

Washing powder prepared according to the following recipe is suitable for children's clothes:

laundry soap - 150 g;
baking soda - 500 g;
borax - 200 g;
tea tree essential oil - 5-7 drops.

Grate laundry soap, add baking soda and borax, mix thoroughly. At the end, drip the essential oil.

Borax (sodium tetraborate) has an antifungal and antibacterial effect, great for washing children's clothes

Dry mustard can be used as a washing powder - it is suitable for use in automatic machines, rids clothes of dirt and gives them freshness. If you need to remove a stubborn stain, first apply mustard to it and then add 50 g to the machine.

You can wash wool, children's things with mustard, but it is not recommended to use it for cotton.

Liquid Powder

To make liquid laundry detergent you will need the following ingredients:

laundry soap - 1 bar;
water - 20 liters;
borax - 0.5 cups;
soda ash - 1 cup;
essential oil - 30 drops.

Grate the laundry soap and transfer to a saucepan, then add enough water to completely cover the soap shavings. Place the saucepan over medium heat and cook the remedy until a homogeneous mass is obtained. Half fill the bucket with boiling water, add borax, soda and dissolved soap to it. Mix all the ingredients, fill the remaining volume of the bucket with water, cover and leave overnight. When the liquid powder has cooled, essential oil can be added to it.

Instructions for use

More natural dry powder should be poured into the automatic machine than the store-bought product. For 5 kg of laundry, an incomplete glass of dry detergent is required. You can do this: fold the gauze in two layers, pour the powder on it, collect the gauze in a bag, tie a loose knot and put it together with the laundry. During the washing process, it will untie, and the product will be evenly distributed over the drum of the washing machine. When using liquid detergent, half a glass is enough for 6 kg of laundry. But the use of a home remedy does not affect the washing mode, so choose the same mode as usual.

If the soap is ground on a coarse grater, the powder should be added not to a special compartment, but to the linen.

Natural washing powder is easy to make, and you don't have to spend a lot of money on ingredients. A home remedy erases no worse than a store-bought one, and its safety is an indisputable plus.

Harm from household chemicals from the store

Remaining on clothes, dangerous substances that are part of washing powders penetrate the skin and suppress the immune system

The main hazardous ingredients found in washing powder are surfactants and phosphates, and even after 10 rinses in hot water, these substances still remain on the fibers of clothing. Surfactants are easily absorbed by the skin and may cause allergies. Phosphates are toxic and adversely affect the activity of the liver and kidneys, enhance the negative effects of surfactants, cause dermatosis and allergies. In addition to these harmful substances, the washing powder contains other components that are no less harmful to the human body. These include formaldehydes, optical brighteners, ammonium and others.

Important information: Scientists have found that surfactants, penetrating the skin into the human body, increase the risk of infertility several times.

The main distinguishing feature of handmade washing powders is the absence of harmful substances in their composition.

do not have an unpleasant chemical odor;
do not cause allergic reactions;
cope with washing no worse than store-bought powders;
are low cost;
can be used in automatic machines.

Homemade products do not lather well. This is an added bonus as foam can damage parts of automatic washing machines.

True, there are also negative aspects. Firstly, it takes some time to prepare the washing powder.

Secondly, most of these products contain soap, which leaves marks on clothes, but this problem can be easily dealt with by adding wine vinegar to the water when rinsing.

Third, homemade laundry detergent contains soda ash. The product can corrode the skin of the hands in case of direct contact, so it is recommended to use gloves.

Natural Home Laundry Detergent Recipes

There are several ways to make natural laundry detergent, and the ingredients do not differ much.

Dry powders

To prepare loose powder for washing cotton and linen fabrics, you will need:

laundry soap (72%) - 150 g;
baking soda - 500 g;
soda ash - 400 g;
salt - 2 tbsp. l.

Add a few drops of essential oil to scent your clothes.

It is advisable to use natural dark soap for the preparation of laundry detergent

Lightly dry the laundry soap and grind it on a grater, then add the rest of the ingredients to it and mix thoroughly. Essential oil should be added at the very end, then mix the mixture again.

To use the powder in an automatic machine, the soap must be rubbed finely, otherwise its grains may remain on clothes.

Important information: Cotton and linen are vegetable fibers, so the detergent used for them must be alkaline.

For silk or wool clothes, use the following recipe:

laundry soap - 150 g;
salt - 500 g;
citric acid - 3 tbsp. l.

Citric acid provides favorable conditions for washing wool and silk, and also gives freshness to things

Salt retains color during washing, prevents things from shedding

To wash clothes made of artificial fabrics, prepare the following powder:

laundry soap - 150 g;
baking soda - 700 g;
soda ash - 200 g.

Grind laundry soap on a grater, mix it with the rest of the ingredients.

Detergent for artificial fibers replaces most of the soda ash with food

Washing powder prepared according to the following recipe is suitable for children's clothes:

laundry soap - 150 g;
baking soda - 500 g;
borax - 200 g;
tea tree essential oil - 5-7 drops.

Grate laundry soap, add baking soda and borax, mix thoroughly. At the end, drip the essential oil.

Borax (sodium tetraborate) has an antifungal and antibacterial effect, great for washing children's clothes

You can wash wool, children's things with mustard, but it is not recommended to use it for cotton.

Liquid Powder

To make liquid laundry detergent you will need the following ingredients:

laundry soap - 1 bar;
water - 20 liters;
borax - 0. 5 cups;
soda ash - 1 cup;
essential oil - 30 drops.

Instructions for use

If the soap is ground on a coarse grater, the powder should be added not to a special compartment, but to the linen.

Natural washing powder is easy to make, and you don't have to spend a lot of money on ingredients. A home remedy erases no worse than a store-bought one, and its safety is an indisputable plus.

Everyone knows about the dangers of classic washing powder. They are hazardous to health and often cause allergies, pollute the environment and spoil the appearance of fabrics.

Today, the traditional powder is being replaced by safer products with a gentle, gentle effect. These are eco-friendly phosphate-free powders and liquid washing gels containing natural ingredients.

However, natural eco-friendly products are quite expensive, so many people think about making and using home remedies instead of purchased household chemicals. In this article, we will look at how to make laundry detergent at home for a washing machine.

Harmful washing powder

Washing powders are made from surface-active substances (surfactants), phosphates, fragrances, fragrances, dyes and other harmful aggressive additives. In addition, they form powdered lime.

This composition and this action cause skin irritation and contribute to the occurrence of an allergic reaction. Especially these funds are dangerous for young children. Read more about the symptoms of a laundry detergent allergy here.

Even after ten rinses, the surfactant is not completely washed out and remains in the fibers of the fabric. These substances from clothes penetrate the body through the skin, reduce immunity, increase the risk of allergies and even infertility. Phosphates release toxins, which negatively affects the functioning of the kidneys and liver.

After washing with household detergents, soap marks and stains often remain on things. In addition, over time, the condition of clothes and linen deteriorates.

Pellets appear on the surface of the material, things wear out, lose their shape, color and quality. This is especially true for delicate fabrics, including natural silk, wool, satin and lace.

Household detergents are very harmful to the environment and the environment, as the components in the composition of such products do not decompose and are not destroyed. To reduce the harm and danger of a bulk product, you can switch to safe and environmentally friendly phosphate-free powders or liquid laundry gels.

However, a more affordable and economical option would be to make your own home laundry detergent.

Home laundry products: pros and cons

Homemade powder does not contain harmful and toxic substances, does not have a negative impact on human health and the environment. Such compounds will not cause allergies and skin irritation, do not have an unpleasant sharp chemical odor.

They are also available and inexpensive. And since this product is difficult to foam, it is perfect for washing in an automatic machine.

Among the minuses, it can be noted that you need to prepare such a tool yourself. And that takes time and effort. In addition, sometimes it's just too lazy to do it.

Homemade powder does not always remove old stains and difficult stains effectively. In this case, you will have to resort to the use of more effective chemistry.

Laundry soap, which is part of the household powder, leaves soap stains and marks on clothes. However, this problem is easily solved by adding wine vinegar to the rinse. In addition, the alkali in the composition of laundry soap and mustard powder can ruin the operation of the washing machine.

Soap solution settles in the drum, tank, drain and filters. Therefore, so that the machine does not break down, you need to regularly clean the equipment. Be sure to add soda to the product, as it reduces the amount of soap suds.

If you are using soda ash powder, you will need to wear rubber gloves when washing, as the soda will corrode the skin. Next, we offer recipes that will help you prepare your own laundry detergent for an automatic machine.

How to make liquid laundry detergent

Laundry, tar or antibacterial soap - 1 bar;
Borax - 100 ml;
Soda ash - 200 ml;
Water - 20 liters;
30 drops of any essential oil.

Liquid agent acts more gently, retains the structure and softness of tissues. Rub the soap on a grater and pour half the volume of water. Put to boil over medium heat and leave until a homogeneous mass is formed.

Then add the rest of the water, soda and borax. Heat to a uniform state, constantly mixing the composition. Then cover the resulting solution with a lid and leave overnight.

When the product has cooled, add the essential oil, mix and pour into containers. Close the container with a tight lid and place in a cool dark place. In a detergent for washing colored things, along with borax and soda, add a tablespoon of fine edible salt. It will keep the color of the products.

How to make children's homemade powder

When washing children's clothes, approach the most carefully and carefully, as children are most susceptible to allergic and other negative reactions. To prepare baby powder, take 150 grams of laundry soap, 200 grams of borax and 0.5 kg of baking soda.

Borax effectively kills bacteria, disinfects things and has an antifungal effect. Grind the soap on a grater, add borax and soda, mix. At the end, you can add 5-7 drops of tea tree essential oil.

Dry mustard can also be used as baby powder. To remove stubborn stains, sprinkle mustard on the stained area and pour 50 grams into the washing machine.

Mustard powder effectively removes dirt, freshens clothes and is mildly gentle. Therefore, it is suitable for washing children's clothes, wool and silk. But mustard is not recommended for linen and cotton!

Dry detergent for natural fabrics

Laundry detergent made from laundry soap and soda is a classic way to make homemade laundry detergent for cotton and linen. The alkaline composition will optimally cope with pollution on natural fabrics. In addition, it is great for bleaching things.

To prepare the product, take 500 grams of baking soda, 400 grams of soda, 150 grams of laundry soap and two tablespoons.

It is better to use natural dark laundry soap 72%, which is dried and ground on a grater to the state of chips. Rub the soap as finely as possible, otherwise the grains will settle and remain on things.

Then mix the components. If desired, you can add a few drops of any essential oil. This will give the linen and clothes a pleasant aroma after washing. Add the oil at the very end and mix the ingredients again.

Dry powder for silk and wool

In addition to dry mustard, for silk, wool and other delicate fabrics, a laundry detergent recipe that includes laundry soap, table salt and citric acid is suitable. Citric acid will soften and refresh things. It prevents deformation of the material and has a gentle effect.

Salt keeps garments from shedding. When washing white clothes, salt can be replaced with baking soda. But such a composition is categorically not suitable for colored linen!

For preparation, take 150 grams of soap, three tablespoons of acid and 0.5 kg of salt. Grind soap. With the resulting soap shavings, mix citric acid and salt or soda. Household powder for delicate things is ready!

Dry powder for synthetics and artificial fabrics

Soap and soda ash are suitable for synthetics and artificial materials. To prepare the powder, you will need 150 grams of laundry soap, 200 grams of soda ash and 700 grams of food. Rub the soap on a grater and mix with soda.

For light stains, make a solution of borax and baking soda. It will take two hundred grams of each component. Mix the substances and use as directed. To get the most benefit from home remedies, follow the guidelines for using homemade powder.

How to use homemade powder

Keep the mixture in a cool, dark place in a plastic or glass container. Be sure to close the lid tightly. Before washing, take 30-40 grams of powder for two kilograms of laundry. The product is poured into a glass and filled with hot water to the brim. Mix the ingredients and pour into the powder compartment.

If the soap is too coarse, add the detergent directly to the laundry in the drum. To do this, pour the powder into gauze, laid in two layers. Tie in a loose knot and put in the drum with things. It is desirable to wash at a temperature of 40-60 degrees. In hotter or colder water, the components may not work.

For rinsing, add wine vinegar to the conditioner compartment. It will soften water and fabrics, give things softness and a fresh scent. Pour 40 grams of vinegar per two kilograms of laundry.

Note that experts do not advise using only homemade powders, since such compositions do not cope with washing completely and often cannot remove stubborn old stains or serious dirt. In addition, they are not suitable for shedding clothes and are not always effective for colored fabrics.

For effective, safe and economical washing, it is best to alternate between store-bought and homemade products. And how to choose the right washing powder, read the link https://vsepodomu.ru/stirka/kak-vybrat-poroshok/.

Dry water will help fight global warming

Chemists have long known this substance, but now a unique substance called "dry water" has become of general interest as a means of combating climate change. The scientists note that in addition to various uses of this substance to protect the environment, dry water can also be used to absorb carbon dioxide, one of the greenhouse gases that cause global warming.

Dry water looks like fine white sand, which is not surprising since it is the smallest water droplets in a water-repellent shell of silicon, which is part of ordinary beach sand.

The shell prevents water molecules from reuniting and turning back into liquid. And the resulting fine powder can interact with gases, forming useful chemical compounds - hydrates. According to University of Liverpool scientist Ben Carter, the production of dry water is a simple and short process: “By mixing silicon and water at high speed, you can get dry water powder in just 90 seconds".

Dry water is not a new invention. Patented in 1968, this substance was initially popular due to its great potential for the cosmetics industry. However, in recent years, Carter and his colleagues have focused on more important uses for its unique properties, starting with its ability to interact with methane. With dry water, Carter says scientists hope to one day develop a safer way to store methane fuel for natural gas vehicles.

“Methane hydrate was our primary goal, as an improved system for storing and transporting methane as a natural gas is key to developing alternative fuels. We went further and proved that carbon dioxide hydrate can be created in the same way. Using dry water will store three times as much carbon dioxide as using gravity water,” says Carter.

In addition, according to the scientist, due to the ability of dry water to absorb large amounts of carbon dioxide, the use of hydrates can be an effective method of reducing greenhouse gases in the atmosphere. According to Ben Carter, experiments have shown that dry water can be made more recyclable by adding a gelling agent when preparing the mixture: "Gel is more durable than powder, and thus dry water can be used many times."

Chemists also propose the use of dry water in the production of food products and their individual components, as well as other consumer goods. Laboratory tests have shown that this can significantly speed up the catalytic reactions in the production of such products and make chemical processing more energy efficient and less harmful to the environment. The scientists also believe that dry water could be used to improve the way in which potentially dangerous liquids are stored and transported, by turning them into a dry powder.