Control of the radial distribution of chemical components in spray-dried crystalline microparticles

The process of particle formation from evaporating droplets containing more than one solute was studied. Two-component microparticles were produced using a piezoceramic dispenser with an inner diameter of 30 µm. Initial droplets had a diameter in the range of 70–85 µm and contained sodium nitrate and potassium nitrate in different molar ratios of 30:70, 50:50, and 70:30, corresponding to weight ratios of 26.5:73.5, 45.7:54.3, and 66.2:33.8, in the form of aqueous solutions with initial concentrations of 1 or 10 mg/ml. The monodisperse droplets were dried in a dry laminar gas flow with temperatures of 50°C or 100°C. Different initial conditions affected the particle formation process and the particle morphology. The diameter of the final dried microparticles ranged from 4 to 10 µm. Their density varied from 1250 to 1950 mg/ml. The formulation and process conditions determined the distribution of chemical components in the dried microparticles, especially their surface composition as determined by energy-dispersive X-ray spectroscopy. The distribution of the chemical components was theoretically explained using characteristic times for the crystallization kinetics of the drying process. It was shown that the solute that reached supersaturation first formed most of the outer shell of the microparticles.