Efficient recovery of active pharmaceutical ingredients (APIs), chemical substances or food powders after drying applications such as spray and fluid bed drying is frequently a problem. The same problem occurs in many milling and micronization applications.
The preferred way to recover these sensitive products is with cyclone collectors due to their direct powder capture. Unlike bag filters or wet scrubbers, cyclones minimize filter or product contamination and product cross contamination and can easily handle a wide range of operating temperature, pressure and moisture conditions.
The current problem with cyclones is their low efficiency. And therefore, when necessary, cyclones have to be complemented with expensive specialized bag filters or wet scrubbers to increase yield or to avoid emissions to the atmosphere.
Client's needs include a high efficiency cyclone system that dramatically increases powder yield, is easy to clean and is efficient enough to comply with regulatory PM emission limits, thus avoiding the use of secondary filters.
Spray Drying | General Arrangement
Usual spray drying arrangements (single point, two point and closed cycle) include a high efficiency cyclone and a bag filter.
The cyclone serves the purpose of separating and collecting the dried powder originated in the spray-drying chamber. For some chemical powders, the fraction of product escaping to the bag filter is not considered as first grade product, and thus seen as losses. The main reasons for this are contamination with filter fibers, product cross contamination and risk of heat degradation.
For fine powders with a median diameter in volume (MVD) of less than 5 µm, losses due to low cyclone efficiency can rise to more than 25 %.
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Advanced Cyclone Systems, S.A. (ACS) is a company exclusively dedicated to the development and commercialization of high efficiency cyclone systems, worldwide.
The company works in a very close cooperation with its clients in order to design custom made cyclone systems that really solve their unmet needs.
ACS has grown to be a turnkey project provider in any part of the world, whenever cyclones are part of the solution.
· Particulate Matter (PM) Emission Control in boilers, furnaces and dryers and general dedusting;
· Product (powder) Recovery in the chemical, food and pharmaceutical industries.
In multiple industries stated below, products are manufactured in the powder form. Examples go from milk powders to pharmaceuticals and from fertilizers to nano-particles. The separation of these products from the air after processes such as drying or milling is unavoidable. Multiple industrial filtration systems can be used for that purpose.
Cyclones have the advantage of easily handling a wide range of operating temperatures, pressures and moisture conditions, unlike other dust collectors, e.g. bag filters. By its simple and aseptic design, without any moving parts, cyclones have very low maintenance costs and can be easily and effectively cleaned, minimizing bacteria contamination or product cross contamination.
ACS cyclones can be designed both to increase product yield and to comply with strict particle emission limits, frequently exempting the use of other filters downstream.