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Volume 13
Issue 6
10.3390/pr13061643
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

The Impact of the Feed Rate and the Binder Concentration on the Morphology of Spray-Dried Alumina–Polymer Nanocomposites

by
Rahul Mitra
1,*,
Lukas Fuchs
2,
Orkun Furat
2,
Yannik Sinnwell
3,
Sergiy Antonyuk
3,
Volker Schmidt
2 and
Urs Alexander Peuker
1
1
Institute of Mechanical Process Engineering and Minerals Processing, TU Bergakademie Freiberg, Agricolastr. 1, 09599 Freiberg, Saxony, Germany
2
Institute of Stochastics, Ulm University, Helmholtzstr. 18, 89069 Ulm, Baden-Württemberg, Germany
3
Institute of Particle Process Engineering, University of Kaiserslautern-Landau (RPTU), Gottlieb-Daimler-Strasse 74, 67663 Kaiserslautern, Rhineland-Palatinate, Germany
*
Author to whom correspondence should be addressed.
Processes 2025, 13(6), 1643; https://doi.org/10.3390/pr13061643
Submission received: 28 April 2025 / Revised: 18 May 2025 / Accepted: 20 May 2025 / Published: 23 May 2025
(This article belongs to the Section Materials Processes)
Versions Notes

Abstract

Spray-drying is a flexible method for creating fine porous composites with controlled size and morphology. This study investigates how the morphology and porosity of the spray-dried powder of nano-alumina and polyvinylpyrrolidone (PVP-30) granules are affected by both the feed rate and the binder concentration. Droplet size and velocity distributions, measured with a HiWatch system, showed that higher feed rates produce larger droplets with faster velocities, therefore affecting the final morphology of the dried product. The morphology of the dried granules was analyzed using inline SOPAT imaging. While mercury intrusion porosimetry quantified the nano-pore volume and nano-pore size of the granules, offline scanning electron microscopy (SEM) was also used to characterize the morphology of the dried product. The findings show that, while raising the binder concentration produces a more compact morphology with a lower nano-pore volume, higher feed rates produce larger granules with a larger nano-pore volume. This study offers fundamental insights that can support the future development of control strategies for optimizing the production of spray-dried porous alumina–polymer nanocomposites by means of knowledge about the relationship between these process parameters and product qualities.
Keywords: spray-drying; optimization; process–product relationship; polymer composite; particle technology; image processing; parametric stochastic modeling spray-drying; optimization; process–product relationship; polymer composite; particle technology; image processing; parametric stochastic modeling

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MDPI and ACS Style

Mitra, R.; Fuchs, L.; Furat, O.; Sinnwell, Y.; Antonyuk, S.; Schmidt, V.; Peuker, U.A. The Impact of the Feed Rate and the Binder Concentration on the Morphology of Spray-Dried Alumina–Polymer Nanocomposites. Processes 2025, 13, 1643. https://doi.org/10.3390/pr13061643

AMA Style

Mitra R, Fuchs L, Furat O, Sinnwell Y, Antonyuk S, Schmidt V, Peuker UA. The Impact of the Feed Rate and the Binder Concentration on the Morphology of Spray-Dried Alumina–Polymer Nanocomposites. Processes. 2025; 13(6):1643. https://doi.org/10.3390/pr13061643

Chicago/Turabian Style

Mitra, Rahul, Lukas Fuchs, Orkun Furat, Yannik Sinnwell, Sergiy Antonyuk, Volker Schmidt, and Urs Alexander Peuker. 2025. "The Impact of the Feed Rate and the Binder Concentration on the Morphology of Spray-Dried Alumina–Polymer Nanocomposites" Processes 13, no. 6: 1643. https://doi.org/10.3390/pr13061643

APA Style

Mitra, R., Fuchs, L., Furat, O., Sinnwell, Y., Antonyuk, S., Schmidt, V., & Peuker, U. A. (2025). The Impact of the Feed Rate and the Binder Concentration on the Morphology of Spray-Dried Alumina–Polymer Nanocomposites. Processes, 13(6), 1643. https://doi.org/10.3390/pr13061643

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