Methods and apparatus for producing granular compositions

Abstract

Methods for producing granular compositions comprise the steps of preparing a viscous liquid mixture, forming a plurality of ligaments from the viscous liquid mixture, cutting the ligaments with one or more liquid jet streams to form pieces, and drying the pieces to form the granular compositions. Apparatus for producing a granular compositions comprise a viscous liquid composition supply, a ligament forming device in fluid communication with a viscous liquid composition supply, one or more liquid jet nozzles adjacent an outlet of a ligament forming device, and a dryer.

What is claimed is:  
     
         1 . A method for producing a granular composition comprising the steps of: 
 a) providing a viscous liquid mixture;    b) forming a plurality of ligaments from the viscous liquid mixture;    c) cutting the ligaments with one or more liquid jet streams to form pieces; and    d) drying the pieces to form the granular composition.    
     
     
         2 . The method of  claim 1 , wherein the step of forming a plurality of ligaments comprises extruding the viscous liquid mixture.  
     
     
         3 . The method of  claim 1 , wherein the viscous liquid mixture comprises a slurry.  
     
     
         4 . The method of  claim 1 , wherein the viscous liquid mixture comprises a paste.  
     
     
         5 . The method of  claim 1 , wherein the liquid jet streams move in a linear motion.  
     
     
         6 . The method of  claim 1 , wherein the liquid jet nozzles have a diameter of from about 0.002 inch to about 0.2 inch.  
     
     
         7 . The method of  claim 1 , wherein the liquid jet nozzles have a diameter of from about 0.002 inch to about 0.004 inch.  
     
     
         8 . The method of  claim 1 , wherein the liquid jet nozzles expel liquid at a pressure of from about 100 psi to about 55,000 psi.  
     
     
         9 . The method of  claim 1 , wherein the liquid jet nozzles expel liquid at a pressure of from about 500 psi to about 20,000 psi.  
     
     
         10 . The method of  claim 1 , wherein the liquid jet nozzles expel liquid at a pressure of from about 10,000 psi to about 20,000 psi.  
     
     
         11 . The method of  claim 1 , wherein the step of forming a plurality of ligaments comprises extruding the slurry through an orifice plate having one or more holes.  
     
     
         12 . The method of  claim 11 , wherein the holes in the orifice plate have a diameter of from about 0.001 inch to about 0.1 inch.  
     
     
         13 . The method of  claim 11 , wherein the holes in the orifice plate have a diameter of from about 0.01 inch to about 0.05 inch.  
     
     
         14 . The method of  claim 11 , wherein the holes in the orifice plate have a diameter of from about 0.0125 inch to about 0.02 inch.  
     
     
         15 . The method of  claim 1 , wherein the viscous liquid composition comprises from about 20 to about 80 weight percent solids.  
     
     
         16 . The method of  claim 1 , wherein the viscous liquid composition comprises from about 55 to about 70 weight percent solids.  
     
     
         17 . An apparatus for producing a granular composition comprising: 
 a) a viscous liquid composition supply;    b) a ligament forming device in fluid communication with the viscous liquid composition supply;    c) one or more liquid jet nozzles adjacent an outlet of the ligament forming device; and    d) a dryer.    
     
     
         18 . The apparatus of  claim 17 , wherein each liquid jet nozzle has a diameter of from about 0.002 inches to about 0.2 inch.  
     
     
         19 . The apparatus of  claim 17 , wherein the ligament forming device comprises an orifice plate having one or more holes.  
     
     
         20 . The apparatus of  claim 19 , wherein the holes in the orifice plate have a diameter of from about 0.001 inch to about 0.1 inch.  
     
     
         21 . The apparatus of  claim 19 , wherein the orifice plate has a diameter of from about 3 inches to about 50 inches.  
     
     
         22 . The apparatus of  claim 19 , wherein the holes in the orifice plate has a diameter of from about 0.01 inch to about 0.05 inch.  
     
     
         23 . The apparatus of  claim 19 , wherein the liquid jet nozzles expel liquid at a pressure of from about 100 psi to about 55,000 psi.  
     
     
         24 . The apparatus of  claim 19 , wherein the liquid jet nozzles expel liquid at a pressure of from about 10,000 psi to about 20,000 psi.  
     
     
         25 . A method for producing a granular composition comprising the steps of: 
 a) producing a viscous liquid mixture;    b) forming a plurality of ligaments from the viscous liquid mixture;    c) cutting the ligaments with one or more liquid jet streams to form pieces; and    d) solidifying the pieces to form the granular composition.