A Review on Recent Progress in Material Design Using Spray Drying Technology—An Experimental and Theoretical Study—

Abstract

Spray drying is a versatile and well-established technique used to produce materials with precisely controlled morphologies, enabling the generation of nanostructured particles with high surface area and purity, suitable for diverse applications. This review explores the optimization of spray drying parameters such as inlet temperature, air velocity, nozzle type, and precursor characteristics, which are critical for achieving desired particle characteristics such as size, shape, and morphology. The review discusses the broad industrial applications of spray drying, including the creation of pigments, catalysts, cosmetics, and drug delivery systems, and highlights various particle structure such as hollow, porous, and encapsulated particles, which offer specific benefits for different applications. Furthermore, it emphasizes the importance of integrating experimental and theoretical approaches, including computational fluid dynamics (CFD), to advance the understanding and optimization of the spray drying process. By providing review on the recent advancements and methods in spray drying technology, this paper offers valuable insight for researchers and professionals aiming to enhance material design and process efficiency for a range of industrial applications.