Selecting an appropriate binder to prepare alumina granules via spray freeze granulation drying

Spray freeze granulation drying (SFGD) is a granulation technique, involving the freezing of sprayed droplets, followed by freeze drying. This technique affords soft granules, which is advantageous for producing sintered bodies with few defects. However, non-spherical and/or hard granules are sometimes formed by SFGD, and the sintered body fabricated from such granules shows reduced density and strength. The formation of such non -spherical and/or hard granules is expected to be avoided by selecting an appropriate binder. Therefore, in this study, four types of binders (water-soluble acrylic polymer, acrylic emulsion, and poly vinyl alcohol with low and high degree of polymerization) were tested to produce alumina granules via SFGD. The shapes and properties of the granules, as well as densities and strength of the sintered bodies, were evaluated. By choosing a suitable binder, the formation of non-spherical granules can be significantly reduced, and soft granules are obtained. These leads to a sintered body with high density and high strength. The acrylic emulsion binder was found to be the best performing binder among the four binders.