# US 2013/0153157 A1 · Spray-drying apparatus and methods of using the same

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- Number: US 2013/0153157 A1
- Document ID: US20130153157A1
- Status: Published application
- Kind: A1
- Application number: 13/820,483
- Filed: 2011-09-01
- Published: 2013-06-20
- Earliest claimed: 2010-09-03
- Assignees: Bend Research, Inc.
- Inventors: Daniel E. Dobry; James M. Mullin; Douglas L. Millard
- Web page: https://patentgrep.com/patent/US20130153157A1

## CPC

- B01D 1/20: Sprayers (in general B05B)
- A61K 9/16: Agglomerates; Granulates; Microbeadlets {; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction (A61K9/20 takes precedence if the final form is a tablet; microspheres with drug-free outer coating, microcapsules A61K9/50; mixture of different granules, microcapsules, (coated) microparticles A61K9/5084; nanoparticles A61K9/51)}
- A61K 9/1682: {Processes}
- A61K 31/137: Arylalkylamines, e.g. amphetamine, epinephrine, salbutamol, ephedrine {or methadone}
- A61K 38/22: Hormones (derived from pro-opiomelanocortin, pro-enkephalin or pro-dynorphin A61K38/33, e.g. corticotropin A61K38/35)
- A61K 38/28: Insulins
- B01D 1/18: to obtain dry solids (B01D1/24 takes precedence)
- B01J 2/04: in a gaseous medium {(if combined with suspending the material in a gas, e.g. fluidised beds B01J2/16)}
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- A61K: PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES (devices or methods specially adapted for bringing pharmaceutical products into particular physical or administering forms A61J3/00; chemical aspects of, or use of materials for deodorisation of air, for disinfection or sterilisation, or for bandages, dressings, absorbent pads or surgical articles A61L; soap compositions C11D)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

A spray-drying apparatus includes a drying chamber that has a first end, a second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis. A nozzle can be positioned at the first end of the drying chamber and be configured to atomize liquid and spray the atomized liquid into the interior of the drying chamber at a maximum spray pattern angle relative to the center axis. A ratio of the length between the first end and second end to a maximum width between opposing internal surfaces of the interior of the drying chamber can be at least 5 to 1.

## Claims

### Claim 1

A spray-drying apparatus comprising:
a drying-gas conduit;
a drying chamber having a first end, a second end, and at least one side wall extending between the first and second ends to define an interior of the drying chamber having a center axis; and
a nozzle positioned at the first end of the drying chamber, the nozzle being configured to atomize liquid and spray the atomized liquid into the interior of the drying chamber,
wherein the drying-gas conduit is in fluid communication with the drying chamber, and is configured to direct a flow of drying gas into the drying chamber, and
a ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 5 to 1, and
at least a portion of the at least one side wall that surrounds the nozzle at the first end of the drying chamber extends away from the center axis at a first angle relative to the center axis, the first angle being at least 5° but less than 45°.

### Claim 2 (depends on 1)

The apparatus of claim 1, wherein the:
drying gas enter enters the drying chamber in substantially parallel flow.

### Claim 3 (depends on 1)

The apparatus of claim 1, wherein a velocity vector of the drying gas entering the drying chamber averaged over the opposing internal surfaces of the interior of the drying chamber is essentially parallel to the center axis of the drying chamber and is substantially towards the second end of the drying chamber.

### Claim 4 (depends on 1)

The apparatus of claim 1, wherein any circulation cell near the first end of the drying chamber in the vicinity of the nozzle have diameters of less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber.

### Claim 5 (depends on 1)

The apparatus of claim 1, wherein a velocity vector of the drying gas entering the drying chamber averaged over the opposing internal surfaces of the interior of the drying chamber is essentially parallel to the center axis of the drying chamber and is substantially towards the second end of the drying chamber; and
any circulation cells near the first end of the drying chamber in the vicinity of the nozzle have diameters of less than 20% of the maximum width between opposing internal surfaces of the interior of the drying chamber.

### Claim 6 (depends on 1)

The apparatus of claim 1, wherein the drying gas forms drying gas streamlines at the first end of the drying chamber that are towards the second end of the drying chamber, and wherein the streamlines have vectors that are between the vector formed by the center axis of the drying chamber and the vector defined by the walls of the drying chamber.

### Claim 7 (depends on 1)

The apparatus of claim 1, wherein the walls of the drying gas conduit are generally parallel to the walls of the drying chamber.

### Claim 8 (depends on 1)

The apparatus of claim 1, wherein the ratio of the length between the first and second ends to a maximum width between opposing internal surfaces of the interior of the drying chamber is at least 6 to 1.

### Claim 9 (depends on 1)

The apparatus of claim 1, wherein a ratio of the maximum width to the width at the second end of the drying chamber interior is less than 3 to 1.

### Claim 10 (depends on 1)

The apparatus of claim 1, wherein the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 45°.

### Claim 11 (depends on 1)

The apparatus of any of claim 1, wherein the first angle is at least 5° but less than 30° relative to the center axis.

### Claim 12 (depends on 1)

The apparatus of claim 1, wherein the nozzle is configured to atomize a liquid into the drying chamber at a maximum spray pattern angle relative to the center axis of less than 30°.

### Claim at position 13

-15. (canceled)

### Claim 16 (depends on 1)

The apparatus of claim 1, wherein the at least one side wall of the drying chamber further comprises a second tapered portion at the second end, and the second tapered portion is narrowest at the second end and widest at a distance furthest from the second end.

### Claim 17 (depends on 16)

The apparatus of claim 16, wherein the at least one side wall of the drying chamber further comprises a cylindrical portion of generally constant width located between the first and second tapered portions.

### Claim 18 (depends on 1)

The apparatus of claim 1, wherein the at least one side wall of the drying chamber has a generally circular cross section at each point along the center axis between the first end and the second end.

### Claim 19 (depends on 1)

The apparatus of claim 1, wherein the atomized liquid comprises at least one active agent and at least one excipient.

### Claim at position 18

-22. (canceled)

### Claim 23 (depends on 1)

The apparatus of claim 1, wherein the first end of the drying chamber is located in the vicinity of an outlet in the nozzle.

### Claim 24 (depends on 1)

A method of spray drying using the apparatus of claim 1, comprising:
forming a plurality of droplets by atomizing a spray solution using a nozzle positioned at the first end of the drying chamber,
delivering the plurality of droplets into the drying chamber;
delivering drying gas into the drying chamber to at least partially dry the plurality of droplets to form a plurality of particles; and
directing the plurality of particles out of the drying chamber.

### Claim at position 21

-32. (canceled)