Homogeneous Granulation of Powder Systems
Typical applications for Freeze Granulation are homogeneous granulation and drying of engineering (advanced, fine, high-performance) ceramic powders; oxides (alumina (Al2O3), zirconia (ZrO2), silica (SiO2)), nitrides (silicon nitride (Si3N4)) and carbides (SiC) and also granulation of powders of metal oxides, plasma spraying, nanomaterials (nanopowders), diamonds (PCD/CBN inserts), LED Lighting, explosives/pyrotechnicals (igniters, delay elements) and drying of pharmaceuticals and drugs, and for drying of biomaterials like proteins, enzymes and fine chemicals.
- Freeze Granulation - for improved* granule properties compared with spray drying! (*Improved granule properties: Granules with no void formation, no migration of fine particles or binders, and no formation of hard dry shell).
- R&D-Labs working with powder processing: “Homogeneous granulation” – Homogeneous distribution of powder particles and binder mixtures for improved performance of the final products. Save time and money in lab-granulation (quick, no contamination, easy to clean) and last but not least – with Improved granule properties!
- Advanced ceramics and ceramic composites (Engineering ceramics): Homogeneous granulation of powder and binder mixtures.
- Metal Powders: Freeze granulation can also be used for granulation of metal powders in water. We have experience of processing of several different kind of metal powders with very good results. However, it is in general contract work connected to specific companies why we have not been able to publish data. A specific advantage with Freeze Granulation regarding metals is that water can be used in many cases as the freeze drying ensure very limited oxidation vs conventional spray drying in air.
- Ceramic electronic parts for ceramic capacitors with improved performance.
- Diamond tools (PCD/CBN inserts): Homogeneous powder-mixture/dispersion of diamond and ceramic particles with inorganic fillers and binders for improved cutting performance and tool life.
- Nanomaterials/Nanotechnology (Nanopowders): Freeze Granulation will give you a homogeneous distribution of the active component in different nanomaterials like nanocomposites with for example carbon nanotubes (fullerenes). It also offers you homogeneous mixtures of nano and micron powders and binders and it preserve the nano particle size in the granules also after drying – Only possible with Freeze Granulation! Nanopowders can be granulated and dried into a powder and then re-dispersed to nanopowders again avoiding agglomeration (aggregates) of nanoparticles, which is not possible with other granulation methods like spray drying.
- LED Lighting (Lighting): Freeze Granulation is today used for commercial production of homogeneous granules for the production of oxides used as a ceramic phosphor plate for white illumination in LED Lighting. By using Freeze Granulation of the powder and binder mixture, compared with spray drying, it is possible to manufacture a homogeneous phosphor plate with optimal properties for to generate a soft and warm white light from high power LEDs.
- Cathodes for lithium-ion batteries Homogeneous granulation of cathode materials for improved performance and lower costs.
- Catalysts: Homogeneous distribution of the active material in the particles and binder mixtures for improved performance.
- Pharmaceuticals and drugs (Pharma industry): Improved solubility (re-disperse) and low-temperature drying of pharmaceuticals and drugs.
- Biotechnology (Biotech industry): Improved solubility (re-disperse) and low-temperature drying of biomaterials like proteins, enzymes and fine chemicals.
- Explosives/pyrotechnicals (Mining industry): Homogeneous powder-mixtures for improved properties (igniters and delay elements in mining).
- Environmental and energy engineering (Greenhouse Gas Control Technologies): Oxygen-carrier particles for chemical-looping combustion (CLC) have been manufactured by freeze granulation for improved environmental combustion of coal and fuel gases (syngas). Freeze granulation ensures homogenous distribution of the porosity and of the active material in the particles (ex NiO) and, hence, provides reliable performance. This advantageous characteristic can be extended for use in production of all kinds of catalytic particles for various processes. See link for a paper on the application of Freeze Granulation in CLC: Prospects of Al2O3 and MgAl2O 4-supported CuO oxygen carriers in chemical-looping combustion (CLC) and chemical-looping with oxygen uncoupling (CLOU)
- Cryogenics (Cryochemical synthesis): Freeze Granulation is a commercial method for cryogenic processing (granulation) of chemicals and powder-based materials. A unique cryofixation of the material in the droplet give a homogeneous granule and result in improved properties in the final product.